Sany Src45 Manual

Quality Changes the World
Container Reach Stacker
Safety, Operation & Maintenance Manual

Safety, Operation & Maintenance Manual - September 2014 I


Safety, Operation & Maintenance Manual
WARNING
Read and follow the safety precautions and instructions in this manual and on
the machine labels. Failure to do so can cause serious injury, death or property
damage. Keep this manual along with the machine for reading and future reference.
II Safety, Operation & Maintenance Manual - September 2014

Address: SANY Industry Town, Changsha Economic &

Technical Development Zone,
Hunan, China 410100
Tel: 0086-0731-84031711
Fax: 0086-0731-84031999-654
E-mail: crd@SANY.com.cn
Service hotline: 4006 098 318
© 2014 by Sany Group. All rights reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as described
herein. All information included within this publication was accurate at the time of
publication. Product improvements, revisions, etc., may result in differences between
your machine and what is presented here. Sany Group assumes no liability. For more
information, contact Sany Group.
Safety, Operation & Maintenance Manual - September 2014 III
SPECIFIC DECLARATION
SANY container reach stacker 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 reach
stackers correctly. SANY expressly bears no liability for any consequences due to the violation of
following rules:
• The personnel should observe the information on this manual.
• It is 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,
observe 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 Safety, Operation & Maintenance Manual,
can they operate and maintain the container reach stacker.
• Ensure the operation and maintenance personnel are qualified and know their related
responsibilities.
• Periodically check related personnel's safety consciousness during working.
• If any failure which would lead to 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.
• Ensure timely maintenance and repair on this machine.
• Carefully plan the use of this machine.
IV Safety, Operation & Maintenance Manual - September 2014

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 Safety, 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.
Safety, Operation & Maintenance Manual - September 2014 V

VI Safety, Operation & Maintenance Manual - September 2014

Container Reach Stacker Table of Contents
Table of Contents
1. Introduction
1.1 Overview�� 1-3
1.2 Application Range�� 1-5
1.2.1 Intended use�� 1-5
1.2.2 Unintended use�� 1-6
1.3 CE Authorization��1-7
1.4 Your Documentation Package�� 1-8
1.4.1 CD system requirements�� 1-8
1.4.2 Recommendations on using the documentation�� 1-9
1.4.3 Documentation storage��1-10
1.4.4 Manual organization��1-10
1.5 Terminology��1-12
1.6 Machine Information��1-14
1.6.1 Machine nameplate��1-14
1.6.2 Engine nameplate��1-14
1.6.2.1 VOLVO engine nameplate��1-14
1.6.2.2 CUMMINS engine nameplate��1-15
1.6.2.3 YUCHAI engine nameplate��1-15
1.6.3 Spreader nameplate��1-16
1.6.3.1 SANY spreader nameplate��1-16
1.6.3.2 ELME spreader nameplate��1-16
1.6.3.3 BROMMA spreader nameplate��1-17
1.6.4 Transmission case nameplate��1-18
1.6.4.1 DANA transmission case nameplate��1-18
1.6.4.2 ZF transmission case nameplate��1-18
1.7 Running in a New Machine ��1-19
1.8 Machine Serial No. and Agent Info.�� 1-20
1.9 Correction Request Form��1-21
1.10 Contact Information�� 1-22
2. Safety
2.1 Safety Information�� 2-4
Safety, Operation & Maintenance Manual - September 2014 I

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

2.1.2 Examples of using signal words �� 2-5
2.1.3 Other signal words�� 2-5
2.1.4 Safety labels�� 2-6
2.2 Machine Labels��2-7
2.2.1 Safety labels - location�� 2-8
2.2.2 Safety labels - content�� 2-9
2.3 General Precautions��2-16
2.3.1 Basic safety instructions��2-16
2.3.2 Personal protective equipment��2-17
2.3.3 Never operate while in bad health�� 2-20
2.3.4 No passenger in the cab�� 2-20
2.3.5 Hand signals��2-21
2.3.6 Preparing safety items��2-24
2.3.7 Checking safety equipment��2-24
2.3.8 Precautions in high voltage areas��2-25
2.3.9 Precautions in thunderstroke��2-28
2.3.10 Precautions in wind��2-28
2.3.11 Abnormal cases�� 2-29
2.3.12 Unauthorized modification�� 2-30
2.4 Safety During Operation��2-31
2.4.1 Work area safety��2-31
2.4.1.1 Work area requirements��2-31
2.4.1.2 Work area indications��2-31
2.4.2 Checks before operation�� 2-32
2.4.3 Keeping machine clean�� 2-35
2.4.4 Mounting and dismounting the machine safely�� 2-35
2.4.5 Start-up safety �� 2-37
2.4.5.1 Inside the operator cab�� 2-37
2.4.5.2 Adjusting the seat�� 2-37
2.4.5.3 Checking the seat belt�� 2-38
2.4.5.4 Machine starting precautions�� 2-38
2.4.5.5 Jump-start the engine, precautions�� 2-40
2.4.5.6 In cold weather��2-41
2.4.5.7 After starting the engine��2-41
2.4.6 Precautions for safe operation�� 2-42
II Safety, Operation & Maintenance Manual - September 2014

2.4.6.1 Ensuring good view �� 2-42

2.4.6.2 Safety rules for traveling�� 2-42
2.4.6.3 Precautions while operating on slopes�� 2-44
2.4.6.4 Avoiding injury from reversing �� 2-44
2.4.6.5 Preventing control failure�� 2-45
2.4.6.6 Never hoist the load except container�� 2-46
2.4.6.7 Never hoist the load over others’ head�� 2-46
2.4.6.8 Never stand under the load�� 2-46
2.4.6.9 Precautions for operating emergency stop button�� 2-47
2.4.6.10 Precautions for operating safety bypass switch�� 2-47
2.4.7 Parking the machine securely�� 2-48
2.4.7.1 Parking requirements�� 2-48
2.4.7.2 Turning off the engine �� 2-49
2.5 Safety During Maintenance�� 2-50
2.5.1 Preparation for the work area�� 2-50
2.5.2 Warning label is important��2-51
2.5.3 Lockout/tagout procedures��2-51
2.5.4 Self-preparation before maintenance�� 2-52
2.5.5 Using tools correctly �� 2-52
2.5.6 Regular replacement of safety-related parts�� 2-52
2.5.7 Removing attachments carefully�� 2-53
2.5.8 Adding fluids to the machine�� 2-53
2.5.9 Towing or lifting the machine�� 2-54
2.5.10 Keep clear of moving machinery�� 2-55
2.5.11 Preventing hydraulic hazards �� 2-56
2.5.11.1 Checking rubber hose regularly�� 2-56
2.5.11.2 Releasing the pressure before maintenance�� 2-57
2.5.11.3 Replacing rubber hose regularly�� 2-58
2.5.11.4 Prevent heating near the hydraulic pipeline�� 2-59
2.5.11.5 Filling accumulator�� 2-59
2.5.11.6 Selecting oils and fuel�� 2-60
2.5.11.7 Handling hydraulic oil �� 2-60
2.5.12 Preventing burn and scald�� 2-61
2.5.12.1 Burn by high temperature liquid�� 2-61
2.5.12.2 Chemical burn�� 2-62
2.5.13 Preventing fire and explosion�� 2-64
Safety, Operation & Maintenance Manual - September 2014 III

2.5.13.1 Handling inflammables safely�� 2-64

2.5.13.2 Removing inflammables�� 2-64
2.5.13.3 Checking oil leakage�� 2-65
2.5.13.4 Checking short circuit�� 2-65
2.5.13.5 Checking ignition key�� 2-66
2.5.13.6 Preventing battery explosion�� 2-66
2.5.13.7 Evacuating from the machine�� 2-67
2.5.14 Preventing poisoning and asphyxiation�� 2-69
2.5.14.1 Handling chemicals safely�� 2-69
2.5.14.2 Preventing poisoning by paint �� 2-69
2.5.14.3 Preventing poisoning by off-gas��2-70
2.5.15 Preventing dust hazard��2-71
2.5.16 Working under machine��2-72
2.5.17 Precautions in welding��2-72
2.5.18 Safe maintenance of air conditioning system��2-73
2.5.19 Precautions in maintaining the engine�� 2-74
2.5.20 High voltage precautions��2-75
2.5.21 Precautions after maintenance��2-75
2.5.22 Handling waste properly��2-75
2.6 Tag��2-77
3. System Functions
3.1 Main Components of Machine�� 3-4
3.1.1 Power driving system�� 3-6
3.1.1.1 Engine�� 3-7
3.1.1.2 Torque converter – gearbox�� 3-8
3.1.1.3 Transmission shaft�� 3-8
3.1.1.4 Drive axle�� 3-9
3.1.1.5 Tyre��3-10
3.1.2 Steering system�� 3-11
3.1.3 Main frame system��3-12
3.1.4 Boom system��3-13
3.1.5 Spreader system��3-14
3.1.6 Hydraulic system��3-16
3.1.7 Electrical system��3-16
3.2 Cab Control System ��3-17
IV Safety, Operation & Maintenance Manual - September 2014

3.2.1 Steering controller��3-18

3.2.1.1 Steering wheel panel��3-18
3.2.1.2 Gear selector�� 3-22
3.2.1.3 Direction indication controller�� 3-23
3.2.1.4 Adjusting the angle of steering controller �� 3-27
3.2.2 Pedal�� 3-27
3.2.3 Joystick�� 3-28
3.2.4 Right operation panel�� 3-29
3.2.4.1 Ignition switch�� 3-30
3.2.4.2 Emergency retraction / lowering switch�� 3-31
3.2.4.3 Emergency stop switch�� 3-32
3.2.4.4 Safety bypass switch�� 3-32
3.2.4.5 Cab moving switch�� 3-34
3.2.4.6 Counterweight moving switch (optional)�� 3-34
3.2.4.7 Parking switch�� 3-35
3.2.4.8 Fuel heating switch (optional)�� 3-35
3.2.4.9 Hydraulic oil preheating switch (optional)�� 3-35
3.2.5 Front operation panel�� 3-36
3.2.5.1 Spreader light switch�� 3-36
3.2.5.2 Boom light switch�� 3-37
3.2.5.3 Rear light switch�� 3-37
3.2.5.4 Front wiper switch�� 3-38
3.2.5.5 Top wiper switch�� 3-39
3.2.5.6 Rear wiper switch�� 3-39
3.3 Display�� 3-41
3.3.1 Menu introduction�� 3-42
3.3.2 Introduction and operation of display area�� 3-43
3.3.2.1 Start menu�� 3-43
3.3.2.2 Main menu�� 3-43
3.3.2.3 Engine information menu�� 3-46
3.3.2.4 Hydraulic system menu�� 3-47
3.3.2.5 Gearbox information menu�� 3-47
3.3.2.6 Fault alarming menu�� 3-48
3.3.2.7 Digital input menu�� 3-49
3.3.2.8 Digital output menu�� 3-49
3.3.2.9 Analogy input menu�� 3-53
Safety, Operation & Maintenance Manual - September 2014 V

3.3.2.10 Analogy output menu�� 3-53

3.3.2.11 Setting menu�� 3-53
3.4 Air Conditioning System�� 3-55
3.4.1 Control panel�� 3-55
3.4.1.1 Power switch�� 3-56
3.4.1.2 Fan speed switch�� 3-56
3.4.1.3 Temperature or Paging switch�� 3-57
3.4.1.4 Mode switch�� 3-57
3.4.1.5 Fresh air switch�� 3-58
3.4.2 Operation�� 3-59
3.4.3 Precautions�� 3-60
3.4.4 Troubleshooting�� 3-61
3.5 Electric Control Cabinet�� 3-62
3.6 Fuse�� 3-64
3.7 Fire Extinguisher�� 3-65
4. Operation
4.1 Before the Starting of Engine�� 4-4
4.1.1.1 Wiper water tank, checking�� 4-4
4.1.1.2 Expansion water tank, checking�� 4-4
4.1.1.3 Engine oil level, checking�� 4-6
4.1.1.4 Gearbox oil level, checking�� 4-7
4.1.1.5 Hydraulic oil level, checking�� 4-7
4.1.1.6 Fuel tank, checking�� 4-9
4.1.1.7 Brake oil tank, checking��4-10
4.1.1.8 Tyres, checking��4-10
4.1.1.9 Electrical components, checking�� 4-11
4.1.1.10 Working light, checking��4-12
4.1.1.11 Horn, checking��4-12
4.1.2 Adjustment before operation��4-13
4.1.2.1 Seat, adjusting��4-13
4.1.2.2 Rearview mirror, adjusting��4-15
4.1.2.3 Safety belt, adjusting��4-16
4.2 Starting the Machine��4-17
4.2.1 Start in normal weather��4-17
VI Safety, Operation & Maintenance Manual - September 2014

4.2.2 Start in cold weather�� 4-20

4.2.3 Start with booster batteries or starting generators�� 4-21
4.3 Stopping the Machine�� 4-23
4.4 Driving�� 4-25
4.4.1 How to drive�� 4-25
4.4.2 Driving forward�� 4-26
4.4.3 Driving backward�� 4-27
4.4.4 Turning around�� 4-27
4.4.5 Parking�� 4-28
4.5 Load Handling �� 4-29
4.5.1 Joystick�� 4-29
4.5.2 Boom, operation�� 4-31
4.5.3 Spreader, operation�� 4-36
4.5.4 Hook, operation�� 4-39
4.5.5 Load capacity diagram�� 4-40
4.5.5.1 Load capacity diagram of C-type container reach stackers�� 4-41
4.5.5.2 Load capacity diagram of SRSC1009-6E empty container reach stacker
�� 4-42
4.5.5.3 Load capacity diagram of SRSC4545C heavyweight container reach
stacker�� 4-43
4.5.5.4 Load capacity diagram of SRSC4535 heavyweight container reach stacker
�� 4-44
4.5.5.5 Load capacity diagram of SRSC4540H2-70 heavyweight container reach
stacker�� 4-45
4.5.5.6 Load capacity diagram of SRSC3515-3 lightweight container reach stacker
�� 4-46
4.5.6 Picking up a container from the stack�� 4-47
4.5.7 Depositing a container on the stack�� 4-50
4.6 Transportation and Assembly�� 4-52
4.6.1 Guidelines�� 4-52
4.6.2 Packing, requirements �� 4-53
4.6.3 Transportation�� 4-54
4.6.3.1 Transporting by platform lorry�� 4-54
4.6.3.2 Transporting by container�� 4-54
4.6.3.3 Detailed caution in unloading�� 4-54
4.6.3.4 Unloading the machine�� 4-55
Safety, Operation & Maintenance Manual - September 2014 VII

4.6.3.5 Loading the machine�� 4-58

4.6.4 Assembly and disassembly preparations�� 4-59
4.6.4.1 Safety precautions�� 4-60
4.6.4.2 Requirements for crew members �� 4-61
4.6.4.3 Tools for assembly and disassembly�� 4-61
4.6.4.4 Assembly alerts of the components �� 4-62
4.6.4.5 Hoisting points of parts�� 4-62
4.6.5 Assembly�� 4-65
4.6.5.1 Prepare the work area �� 4-65
4.6.5.2 Rear counterweight, installation�� 4-66
4.6.5.3 Sliding counterweight, installation�� 4-67
4.6.5.4 Pitching cylinder, installation��4-70
4.6.5.5 Boom, installation��4-72
4.6.5.6 Spreader, installation�� 4-81
4.6.5.7 Lights, installation�� 4-83
4.6.5.8 Final check�� 4-86
4.6.6 Disassembly�� 4-87
4.6.6.1 Prepare the work area�� 4-87
4.6.6.2 Lights, removal�� 4-88
4.6.6.3 Spreader, removal�� 4-90
4.6.6.4 Boom, removal�� 4-92
4.6.6.5 Pitching cylinder, removal��4-101
4.6.6.6 Sliding counterweight, removal��4-103
4.6.6.7 Rear counterweight, removal��4-104
5. Maintenance
5.1 Scheduled Maintenance, General Information �� 5-7
5.2 General Tightening Torques ��5-11
5.3 Recommended Fuel, Coolant and Lubricant��5-12
5.3.1 Specification��5-12
5.3.2 Capacity of the tanks��5-13
5.3.2.1 C-type / SRSC4535 container reach stackers��5-13
5.3.2.2 SRSC4545C container reach stacker��5-13
5.3.2.3 SRSC3515-3 container reach stacker��5-14
5.3.2.4 SRSC1009-6E container reach stacker��5-14
5.3.3 Application principle ��5-14
VIII Safety, Operation & Maintenance Manual - September 2014

5.3.4 Hydraulic oil, description��5-16

5.3.5 Quality of hydraulic oil, check��5-17
5.4 Lubricating Points��5-18
5.4.1 Lubricant��5-18
5.4.2 Lubricating points of whole machine��5-19
5.4.3 Lubricating points of engine and gearbox�� 5-21
5.4.4 Lubricating points of drive axle�� 5-22
5.5 Scheduled Maintenance�� 5-23
5.5.1 Maintenance every day�� 5-23
5.5.2 Maintenance every 50 hours�� 5-24
5.5.6 Maintenance 1500 hours�� 5-28
5.6 Engine�� 5-30
5.6.1 General engine inspection �� 5-30
5.6.2 Charge air pipe, checking�� 5-31
5.6.3 Drive belt, checking�� 5-31
5.6.4 Generator belt, replacing �� 5-32
5.6.5 Drive belt, replacing �� 5-33
5.6.6 Air filter, checking / changing�� 5-34
5.6.7 Air filter, cleaning�� 5-35
5.6.8 Lubrication system�� 5-36
5.6.8.1 Engine oil, changing �� 5-36
5.6.8.2 Oil filter / Bypass filter, changing �� 5-37
5.6.9 Cooling system�� 5-38
5.6.9.1 Coolant, mixing�� 5-39
5.6.9.2 Water quality�� 5-40
5.6.9.3 Coolant level, checking�� 5-40
5.6.9.4 Coolant, filling�� 5-41
5.6.9.5 Coolant, draining�� 5-42
5.6.9.6 Coolant filter, changing�� 5-43
5.6.9.7 Radiator, cleaning�� 5-43
5.6.9.8 Radiator fan, checking�� 5-44
Safety, Operation & Maintenance Manual - September 2014 IX

5.6.9.9 Fan hub, checking�� 5-44

5.6.9.10 Cooling system, cleaning�� 5-45
5.6.10 Fuel system�� 5-47
5.6.10.1 Fuel filter, replacing �� 5-47
5.6.10.2 Diesel filter, changing �� 5-48
5.6.10.3 Oil-water separator with water monitor, replacing�� 5-48
5.6.10.4 Oil-water separator, draining�� 5-49
5.6.10.5 Fuel system, bleeding �� 5-50
5.6.11 Inlet system, checking leakage �� 5-51
5.6.12 Attaching bolts of engine seat, checking �� 5-52
5.6.13 Shock absorber, checking�� 5-52
5.6.14 Turbocharger and blast pipe, checking�� 5-53
5.7 Transmission�� 5-54
5.7.1 Gearbox, function description�� 5-54
5.7.2 Attaching bolts of transmission shaft, checking�� 5-54
5.7.3 Speed sensor, checking�� 5-55
5.7.4 Attaching bolts and fixed seat, checking�� 5-55
5.7.5 Transmission shaft, lubricating�� 5-56
5.7.6 Gearbox oil, changing�� 5-57
5.7.7 Gearbox oil level, checking�� 5-58
5.7.8 Gearbox oil filter, changing�� 5-58
5.8 Drive Axle�� 5-59
5.8.1 Attaching bolts of drive axle to the frame, checking�� 5-59
5.8.2 Attaching bolts of drive axle to the transmission shaft, checking�� 5-59
5.8.3 Oil leakage of drive axle and brake components, checking�� 5-59
5.8.4 Drive axle oil, changing�� 5-60
5.8.5 Breather connector, cleaning�� 5-61
5.8.6 Brake pedal, checking and adjusting�� 5-62
5.8.7 Parking brake pads, changing�� 5-62
5.8.8 Brake oil filter, changing�� 5-63
5.9 Steering Axle�� 5-64
5.9.1 Daily check�� 5-64
5.9.2 Steering axle, lubricating�� 5-65
5.9.3 Steering knuckle, maintaining�� 5-65
5.9.4 Steering axle cradle, checking�� 5-66
5.9.5 Steering pressure, checking�� 5-66
X Safety, Operation & Maintenance Manual - September 2014

5.10 Tyres and rims�� 5-67

5.10.1 Tyre, description�� 5-67
5.10.2 Tyre, inflating�� 5-69
5.10.3 Tyres, checking��5-70
5.10.4 Wheel rim, description��5-70
5.10.5 Rim, checking��5-71
5.10.6 Wheel rim, installing and removing��5-73
5.10.6.1 Wheel rim, installing��5-73
5.10.6.2 Wheel rim, removing�� 5-74
5.10.7 Tyre, removing and installing (drive axle)��5-75
5.10.7.1 Tyre of drive axle, removing��5-75
5.10.7.2 Tyre of dirve axle, installing��5-76
5.10.8 Tyre, removing and installing (steering axle)��5-77
5.10.8.1 Tyre of steering axle, removing��5-77
5.10.8.2 Tyre of steering axle, installing��5-78
5.11 Boom��5-79
5.11.1 Basic boom, checking�� 5-80
5.11.2 Sliding blocks, checking��5-81
5.11.3 Sliding blocks of the fixed arm, replacing�� 5-82
5.11.4 Sliding blocks of the telescopic arm, replacing�� 5-82
5.11.5 Pitching cylinder, checking�� 5-83
5.12 Spreader�� 5-84
5.12.1 SANY / ELME spreader�� 5-84
5.12.1.1 Twistlock, checking�� 5-84
5.12.1.2 Twistlock, lubricating�� 5-85
5.12.1.3 Sensor / Indicator of twistlock, checking�� 5-85
5.12.1.4 Fixed bolts of spreader rotating gearbox, checking�� 5-86
5.12.1.5 Sliding blocks of spreader, checking�� 5-86
5.12.2 BROMMA spreader�� 5-88
5.12.2.1 General precautions�� 5-90
5.12.2.2 After 50 hours�� 5-90
5.12.2.3 After 250 hours��5-91
5.12.2.4 After 500 hours��5-91
5.12.2.5 After 1000 hours��5-91
5.12.2.6 After 2000 hours�� 5-92
5.12.2.7 After 4000 hours�� 5-92
Safety, Operation & Maintenance Manual - September 2014 XI

5.12.2.8 After 8000 hours�� 5-92

5.13.1 General recommendations �� 5-93
5.13.2 Air conditioning, checking / performance test�� 5-94
5.13.3 Refrigerant quantity, checking �� 5-95
5.13.4 Refrigerant, filling�� 5-96
5.13.5 Cleanness of heat-exchanger plate in evaporator and condenser, checking 5-97
5.13.6 Leakage or lack of oil in condenser, checking�� 5-97
5.13.7 Radiator, cleaning�� 5-98
5.13.8 Maintenance table for air conditioner�� 5-98
5.14 Hydraulic System��5-100
5.14.1 Hydraulic oil level, checking��5-100
5.14.2 Hydraulic oil filter, changing��5-100
5.14.3 Hydraulic oil, changing��5-101
5.14.4 Oil return filter element, replacing��5-102
5.14.5 Hydraulic oil tank, cleaning��5-103
5.14.6 Parking brake unit, checking and adjusting��5-104
5.14.7 Accumulator��5-105
5.14.7.1 Brake system accumulator, checking��5-105
5.14.7.2 Accumulators, charging with nitrogen gas��5-106
5.14.8 Hydraulic oil circuit, checking��5-108
5.15 Electrical System��5-109
5.15.1 Battery�� 5-110
5.15.1.1 Battery, cleaning�� 5-110
5.15.1.2 Electrolyte, filling�� 5-111
5.15.1.3 Battery, checking�� 5-112
5.15.1.4 Battery, charging�� 5-112
5.15.1.5 Battery, using�� 5-114
5.15.1.6 Battery cables, checking�� 5-115
5.15.1.7 Battery, scheduled maintenance �� 5-116
5.15.2 Fuses, changing�� 5-116
5.15.3 All working lights and indicators, checking �� 5-117
5.15.4 Wiper, adjusting�� 5-117
5.15.5 Wiper, replacing�� 5-118
5.16 Maintenance Record List�� 5-119
XII Safety, Operation & Maintenance Manual - September 2014

6. Troubleshooting
6.1 Precautions�� 6-2
6.2 Troubleshooting Procedures�� 6-3
6.3 Common Troubleshooting Methods�� 6-5
6.3.1 Troubleshooting the engine system�� 6-5
6.3.2 Troubleshooting the transmission system�� 6-8
6.3.2.1 Overview�� 6-8
6.3.2.2 Troubleshooting procedures�� 6-9
6.3.2.3 Troubleshooting table��6-11
6.3.3 Troubleshooting the drive axle and brake system��6-12
6.3.4 Troubleshooting the steering system��6-13
6.3.5 Troubleshooting the spreader system��6-13
6.3.6 Troubleshooting the mast system��6-15
6.3.7 Troubleshooting the air conditioning system��6-16
6.3.8 Troubleshooting the hydraulic system��6-17
6.3.9 Troubleshooting the electrical system��6-18
6.3.9.1 Troubleshooting the cable harness��6-19
6.3.9.2 Troubleshooting table�� 6-20
6.4 Engine Error Codes �� 6-27
6.4.1 VOLVO engine error codes�� 6-27
6.4.2 CUMMINS engine error codes�� 6-36
6.4.3 YUCHAI engine error codes�� 6-42
6.5 Machine Error Codes �� 6-47
7. Specifications
7.1 Technical Specifications��7-2
7.1.1 Basic parameters��7-2
7.1.2 Technical parameters��7-8
7.1.3 Power system configuration�� 7-10
7.2 Unit Conversion�� 7-13
7.2.1 Unit abbreviation explanation�� 7-13
7.2.2 Conversion table, SI units �� 7-14
7.2.3 Conversion table, length�� 7-15
7.2.4 Conversion table, area �� 7-15
7.2.5 Conversion table, volume�� 7-15
7.2.6 Conversion table, weight �� 7-16
Safety, Operation & Maintenance Manual - September 2014 XIII

7.2.7 Conversion table, pressure�� 7-16

7.2.8 Conversion table, temperature��7-16
8. Optional Parts
8.1 Fire Detection and Alarm System / Automatic Extinguishing Device�� 8-3
8.1.1 Fire detection and alarm system�� 8-4
8.1.1.1 Product features�� 8-4
8.1.1.2 Application site and environmental conditions�� 8-5
8.1.1.3 Technical features�� 8-5
8.1.1.4 Function description�� 8-6
8.1.1.5 Precautions�� 8-8
8.1.1.6 Troubleshooting�� 8-9
8.1.1.7 Maintenance and repair�� 8-9
8.1.2 Automatic fire extinguishing device ��8-11
8.1.2.1 Precautions��8-11
8.1.2.2 Technical parameters��8-12
8.1.3 Electrical diagrams��8-13
8.2 Loudspeaker and Controller Kit��8-16
8.2.1 Control panel��8-16
8.2.2 Operations��8-16
8.2.3 Electrical wiring diagram��8-17
8.2.4 Precautions��8-18
8.3 Engine Idle Protection Function��8-18
8.4 Engine Preheating Protection Function��8-19
8.5 Engine Hour Calculator��8-19
8.6 Twistlock Calculator��8-19
8.7 Reversing Radar Display�� 8-20
8.8 Radio�� 8-20
8.8.2 Mute (Silence)�� 8-22
8.8.3 Sound�� 8-22
8.8.4 Audio setting�� 8-22
8.8.5 Radio�� 8-23
8.8.6 Radio troubleshooting�� 8-25
8.9 CCTV System�� 8-26
8.9.1 Safety precautions�� 8-26
XIV Safety, Operation & Maintenance Manual - September 2014

8.9.2 Major parts�� 8-27

8.9.3 Installation�� 8-28
8.9.4 Vehicle DVR�� 8-29
8.9.4.1 Physical interfaces�� 8-29
8.9.4.2 Shift switch�� 8-30
8.9.4.3 Disassembly of hard disk�� 8-30
8.9.5 Troubleshooting the CCTV system�� 8-32
8.9.6 Wiring diagram�� 8-33
8.10 Flowmeter�� 8-34
9. Schematics
9.1 Symbol Explanation�� 9-2
9.2 Hydraulic Schematic Diagrams�� 9-3
9.2.1 C-type / SRSC4535 / SRSC4535C / SRSC4535C1 container reach stackers� 9-4
9.2.2 SRSC4545C container reach stackers�� 9-5
9.2.3 SRSC3515-3 container reach stackers�� 9-6
9.2.4 SRSC1009-6E container reach stackers�� 9-7
9.3 Electrical Schematic Diagrams�� 9-8
9.3.1 C-type container reach stacker�� 9-8
9.3.2 Empty container reach stacker�� 9-23
9.4 Schematic Diagrams of Spreader System�� 9-36
9.4.1 Hydraulic schematic diagram of spreader system�� 9-37
9.4.1.1 SDJ450 Spreader�� 9-37
9.4.1.2 SJD450F-R3 / SDJE100-R1 Spreader�� 9-38
9.4.1.3 SJD450E-R1 / SJD450F-R1 Spreader�� 9-39
9.4.1.4 ELME817 Spreader�� 9-40
9.4.1.5 BROMMA RSX40 Spreader�� 9-41
9.4.2 Electrical schematic diagram of spreader system�� 9-42
9.4.2.1 SDJ450 Spreader�� 9-42
9.4.2.2 SDJ450F-R1 Spreader�� 9-44
9.4.2.3 SDJ450E-R1 Spreader�� 9-46
9.4.2.4 SDJ450F-R3 Spreader�� 9-48
9.4.2.5 SJE100-R1 Spreader�� 9-50
9.4.2.6 ELME817 Spreader�� 9-52
9.4.2.7 BROMMA RSX40 Spreader�� 9-54
Safety, Operation & Maintenance Manual - September 2014 XV

Container Reach Stacker Introduction
Introduction
1. Introduction
1.1 Overview�� 1-3
1.2 Application Range�� 1-5
1.2.1 Intended use�� 1-5
1.2.2 Unintended use�� 1-6
1.3 CE Authorization��1-7
1.4 Your Documentation Package�� 1-8
1.4.1 CD system requirements�� 1-8
1.4.2 Recommendations on using the documentation�� 1-9
1.4.3 Documentation storage��1-10
1.4.4 Manual organization��1-10
1.5 Terminology��1-12
1.6 Machine Information��1-14
1.6.1 Machine nameplate��1-14
1.6.2 Engine nameplate��1-14
1.6.2.1 VOLVO engine nameplate��1-14
1.6.2.2 CUMMINS engine nameplate��1-15
1.6.2.3 YUCHAI engine nameplate��1-15
1.6.3 Spreader nameplate��1-16
1.6.3.1 SANY spreader nameplate��1-16
1.6.3.2 ELME spreader nameplate��1-16
1.6.3.3 BROMMA spreader nameplate��1-17
1.6.4 Transmission case nameplate��1-18
1.6.4.1 DANA transmission case nameplate��1-18
1.6.4.2 ZF transmission case nameplate��1-18
Safety, Operation & Maintenance Manual - September 2014 1-1

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

1.8 Machine Serial No. and Distributor Info.�� 1-20
1.9 Correction Request Form��1-21
1.10 Contact Information�� 1-22
1-2 Safety, Operation & Maintenance Manual - September 2014

1. INTRODUCTION
Thank you heartily for choosing
our SRSC45C30 / SRSC45C30-6 /
SRSC45C1 /SRSC45C2 / SRSC45C5 /
SRSC45C7 / SRSC45C22 / SRSC45C23 /
SRSC45C31 /SRSC45C32 / SRSC4535 /
SRSC4535C / SRSC4535C1 / SRSC4545C
/ SRSC4540H2-70 / SRSC1009-6E /
SRSC3515-3 Container Reach Stacker. We
are commited to provide you with superior
machine and heartful after-sales service.
1.1 Overview
This Safety, Operation & Maintenance Manual
is a guide for you to handle this machine
correctly. It provides technique and safety
information necessar y for operation and
maintenance of this machine. Please make
sure to read every parts of this manual in
detail.
WARNING
WARNING
Before starting operation and maintenance,

personnel shall observe the following
items:
• Only the qualified and experienced
operators with official license
(according to the local laws) are
allowed to operate this machine.
• Always operate your machine according
to national, provincial, prefectural and
municipal laws and regulations.
• Read and understand the whole
manual.
• Read and understand safety notices in
this manual and safety labels on the
machine.
• Do not operate this machine under any
circumstances or in a manner that is
prohibited in this manual.
Failure to do this would result in personal
injuries or possibly death.

Information, specifications, and illustrations

in this publication are on the basis of the
latest available information. 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
without 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 this machine. If
the machine is sold to a third party, give
this manual to the new owner.
• SANY products are in line with all
specif ic ations and standards of the
customer’s country. If the machine is
purc hased f rom anot her c ount r y o r
someone of a third countr y, it might
lack of some safety devices or technical
requirements necessary for using in your
country.
• In case you question whether the machine
is in accordance with the specifications
and standards of your country, please
contact SANY authorized distributors
before operating the machine.

1.2 Application Range
1.2.1 Intended use
Container reach stacker is a type of auxiliary

equipment for transferring, lifting and stacking
containers mainly on ports, quaysides, and
yards .
• At the small ports and quaysides, container

reach stacker, which is the main machine
for container operations there, is less
expensive and more flexible compared
with gantry cranes and portal cranes. Fig. 1-1 Container Reach Stacker
• At the railway and highway transfer

stations, container reach stacker, with
its advantages of f lexible operation,
high ef ficiency and high use ratio of
storage yard, is the main machine for
transportation there.
Container reach stackers are applicable for

the operation of 20 and 40 feet international
st a n da r d c o nt ai n e r s. W i t h a n o pt i o n a l
spreader, except the containers mentioned
above, containers of 30 and 35 feet can be
handled. Never hoist and transport the load
heavier than the max. lifting capacity of this
machine. (For detailed information, see: “Load
capacity diagram” on page 4-49.)
The rules for intended and approved uses

of this machine must be followed under all Fig. 1-2 Standard Container
circumstances by the responsible persons,
especially by the operator and ser vic e
personnel.
The user, and not SANY, is responsible for any

danger arising from applications not authorized
by the manufacturer.

Machines covered by this manual are used for

various operations under normal conditions.
If you are unsure about the safety of some
procedures, please contact SANY directly.
1.2.2 Unintended 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 hurting yourself and other personnel.
Improper uses include:

• Transpor ting people outside the cab.
Inside the cab, there is only one seat for
the operator. No additional people may be
transported;
• Tr a n s p o r t i n g p e o p l e i n s i d e o r o n
containers;
• Applying load to or on the machine;
• Using c ables, chains or other items
attached to the boom to transport or lift
objects;
• Pulling or pushing vehicles, trailers or
containers;
• Operating, driving and crossing on roads;
• Starting, retracting and operating in areas
with risks of explosion;
• Overloading the machine beyond its max.
lifting capacity listed in the load capacity
diagram on page 4-49;
• 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 misusing it might impair the machine’s
performance, or result in potential hazard.
Improper operation may cause personal injury
or damage. SANY assumes no liability for
such losses.
1.3 CE Authorization
All machines and equipment (some equipment

installed on the machines or installed with used
spare parts are exclusive) manufactured by
SANY Port Machinery Company are labeled
with CE, which certifies their conformity to the
European Union machine safety instructions.
Fig. 1-3 CE Label

1.4 Your Documentation Package
Several documentations will be packed for you

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

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

1.4.2 Recommendations on using the

documentation
• This documentation applies only to this

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

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

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

updated year of this edition

1.4.3 Documentation storage
• Always keep this manual in the operator

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

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

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

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

1.5 Terminology
Table 1-1 Terminology

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

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

1.6 Machine Information

Please inform SANY authorized distributors of the following information when ordering
replacement parts or requiring assistance for your equipment.
1.6.1 Machine nameplate
Fig. 1-4 Machine Nameplate
1.6.2 Engine nameplate

1.6.2.1 VOLVO engine nameplate
Manufacturer AB VOL VO PENT A
Engine Type TWD1240VE Engine Power 256kW/210 0
Assembly Date 08-1 1 Certificate No. CNFCG2096608000 4
Power Range Emission Level Phase II
THIS ENGINE CONFORMS TO SA TGE II OF CHINA NON ROAD MOBILE MACHINE RY

DIRECTIVE CHIN A STANDARD GB200891-200 7
Fig. 1-5 VOLVO Engine Nameplate

1.6.2.2 CUMMINS engine nameplate
Fig. 1-6 CUMMINS Engine Nameplate
1.6.2.3 YUCHAI engine nameplate
Development code
Displacement code
Power code
Serial Code
Code of cylinder amount
Enterprise Code
Fig. 1-7 YUCHAI Engine Nameplate

1.6.3 Spreader nameplate
1.6.3.1 SANY spreader nameplate
Fig. 1-8 SANY Spreader Nameplate
1.6.3.2 ELME spreader nameplate
Type Year
Cap Weight
Voltage Ser.No.
Elme Spreader AB
P O Box 174 S-343 33 AL MHULT
Phone +46 475 558 90 Fax +46 478 558 99
www.elme.com Made in Sweden
Fig. 1-9 ELME Spreader Nameplate

1.6.3.3 BROMMA spreader nameplate
Spreader type RSX40

Serial No: 12810-12815
General Assy No: 1031900
Container Range 20´and 40´
Fig. 1-10 BROMMA Spreader Nameplate

1.6.4 Transmission case nameplate
1.6.4.1 DANA transmission case nameplate
SPICER OFF-HIGHWAY
BRUGES
BELGIUM
MODEL XX.XXXXXXXX-XXX
SERIAL XXXXXXXXXX XX/XX
Fig. 1-11 DANA Transmission Case Nameplate
1.6.4.2 ZF transmission case nameplate
ZAHNRADFABRIK PASSAU
G.m.b.H.
MADE IN GERMANY
TYPE / SERIAL NO.
PARTS LIST NO. TOTAL RATIO
OPERATING PRESS. (bar)
TORQUE CONVERTER
PARTS LIST NO. TYPE
OEL-LEVEL
CHECK AT IDLING SPEED
USE OIL ONLY ACCORDING TO

ZF SPEC. TE-ML 03
Fig. 1-12 ZF Transmission Case Nameplate

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

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

1.8 Machine Serial No. and

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

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

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

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

1.10 Contact Information
Address: SANY Industry Town, Changsha Economic & Technical Development Zone, Hunan,
China 410100
Tel: 0086-0731-84031711
Fax: 0086-0731-84031999-654
E-mail: crd@SANY.com.cn

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Container Reach Stacker Safety
Safety
2. Safety
2.1 Safety Information�� 2-4
2.1.1 Signal words�� 2-4
2.1.2 Examples of using signal words �� 2-5
2.1.3 Other signal words�� 2-5
2.1.4 Safety labels�� 2-6
2.2 Machine Labels��2-7
2.2.1 Safety labels - location�� 2-8
2.2.2 Safety labels - content�� 2-9
2.3 General Precautions��2-16
2.3.1 Basic safety instructions��2-16
2.3.2 Personal protective equipment��2-17
2.3.3 Never operate while in bad health�� 2-20
2.3.4 No passenger in the cab�� 2-20
2.3.5 Hand signals��2-21
2.3.6 Preparing safety items��2-24
2.3.7 Checking safety equipment��2-24
2.3.8 Precautions in high voltage areas��2-25
2.3.9 Precautions in thunderstroke��2-28
2.3.10 Precautions in wind��2-28
2.3.11 Abnormal cases�� 2-29
2.3.12 Unauthorized modification�� 2-30
2.4 Safety During Operation��2-31
2.4.1 Work area safety��2-31
2.4.1.1 Work area requirements��2-31

Safety Container Reach Stacker
2.4.1.2 Work area indications�� 2-31

2.4.3 Keeping machine clean�� 2-35
2.4.4 Mounting and dismounting the machine safely�� 2-35
2.4.5 Start-up safety �� 2-37
2.4.5.1 Inside the operator cab�� 2-37
2.4.5.2 Adjusting the seat�� 2-37
2.4.5.3 Checking the seat belt�� 2-38
2.4.5.4 Machine starting precautions�� 2-38
2.4.5.5 Jump-start the engine, precautions�� 2-40
2.4.5.6 In cold weather�� 2-41
2.4.5.7 After starting the engine�� 2-41
2.4.6 Precautions for safe operation�� 2-42
2.4.6.1 Ensuring good view �� 2-42
2.4.6.2 Safety rules for traveling�� 2-42
2.4.6.3 Precautions while operating on slopes�� 2-44
2.4.6.4 Avoiding injury from reversing �� 2-44
2.4.6.5 Preventing control failure�� 2-45
2.4.6.6 Never hoist the load except container�� 2-46
2.4.6.7 Never hoist the load over others’ head�� 2-46
2.4.6.8 Never stand under the load�� 2-46
2.4.6.9 Precautions for operating emergency stop button�� 2-47
2.4.6.10 Precautions for operating safety bypass switch�� 2-47
2.4.7 Parking the machine securely�� 2-48
2.4.7.1 Parking requirements�� 2-48
2.4.7.2 Turning off the engine �� 2-49
2.5 Safety During Maintenance�� 2-50
2.5.1 Preparation for the work area�� 2-50
2.5.2 Warning label is important�� 2-51
2.5.3 Lockout/tagout procedures�� 2-51
2.5.4 Self-preparation before maintenance�� 2-52
2.5.5 Using tools correctly �� 2-52
2.5.6 Regular replacement of safety-related parts�� 2-52
2.5.7 Removing attachments carefully�� 2-53
2.5.8 Adding fluids to the machine�� 2-53
2.5.9 Towing or lifting the machine�� 2-54

2.5.10 Keep clear of moving machinery�� 2-55

2.5.11 Preventing hydraulic hazards �� 2-56
2.5.11.1 Checking rubber hose regularly�� 2-56
2.5.11.2 Releasing the pressure before maintenance�� 2-57
2.5.11.3 Replacing rubber hose regularly�� 2-58
2.5.11.4 Prevent heating near the hydraulic pipeline�� 2-59
2.5.11.5 Filling accumulator�� 2-59
2.5.11.6 Selecting oils and fuel�� 2-60
2.5.11.7 Handling hydraulic oil �� 2-60
2.5.12 Preventing burn and scald�� 2-61
2.5.12.1 Burn by high temperature liquid�� 2-61
2.5.12.2 Chemical burn�� 2-62
2.5.13 Preventing fire and explosion�� 2-64
2.5.13.1 Handling inflammables safely�� 2-64
2.5.13.2 Removing inflammables�� 2-64
2.5.13.3 Checking oil leakage�� 2-65
2.5.13.4 Checking short circuit�� 2-65
2.5.13.5 Checking ignition key�� 2-66
2.5.13.6 Preventing battery explosion�� 2-66
2.5.13.7 Evacuating from the machine�� 2-67
2.5.14 Preventing poisoning and asphyxiation�� 2-69
2.5.14.1 Handling chemicals safely�� 2-69
2.5.14.2 Preventing poisoning by paint �� 2-69
2.5.14.3 Preventing poisoning by off-gas�� 2-70
2.5.15 Preventing dust hazard��2-71
2.5.16 Working under machine�� 2-72
2.5.17 Precautions in welding�� 2-72
2.5.18 Safe maintenance of air conditioning system�� 2-73
2.5.19 Precautions in maintaining the engine��2-74
2.5.20 High voltage precautions�� 2-75
2.5.21 Precautions after maintenance�� 2-75
2.5.22 Handling waste properly�� 2-75
2.6 Tag�� 2-77

2. SAFETY
2.1 Safety Information
This manual has provided 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 adhere to the safety
rules and suggestions in this manual. Take
positive actions to reduce the risk of personal
injur y or death, the damage of machine
caused by improper service, and the risk of
unsafe factors, to the minimum.
2.1.1 Signal words

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

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

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

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

This hazard alert symbol appears

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

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

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

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

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

2.1.4 Safety labels

Safety labels, fixed on the machine, are used
to warn the operator or maintenance personnel
of potential dangers.
a. Safety label example 1
WARNING
Keep clear of moving machinery

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

2.2 Machine Labels

The operator and all other personnel involved
with this machine must be aware of the label
contents and locations.
• All safety, alert and warning labels must

be in place and always clean, undamaged,
covered or removed.
• 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. Never modify
or change existing label information unless
authorized by your SANY distributors.
• When replacing labels, be sure that they
are placed in the proper locations.
NOTE:
SANY cannot accept any liability for damage/
injury as a result of the user’s failure to order
replacement labels in due time.

2.2.1 Safety labels - location
6 16
3 2
8
4
5
6 15
7
8
9
10
11
12
13
14
1
16 15
2
5
19
6
17 21
14 18
20
20
Fig. 2-3 Safety Labels of Whole Machine

2.2.2 Safety labels - content
1. Label, stand is clear in moving
Never stand in places where there is a label

as shown in the right figure.
For its location on machine, see position 1 in

Fig. 2-3.
Fig. 2-4 Stand is Clear in Moving
2. Label, no climbing
Never climb on the place glued with this no

climbing label.
For its location on machine, see position 2 in NO CLIMBING

Fig. 2-3.
Fig. 2-5 No Climbing
3. Warning label, against scald injury
Do not touch parts of high temperature to

avoid scald injuries.

Fig. 2-3.
Fig. 2-6 Against Scald Injury

4. Warning label, caution for the cable
There are cables near the position of this label.

Pay attention not to be hurt by the cables.

Fig. 2-3.
Fig. 2-7 Cautious for Cables
5. Warning label, no jumping
Do not jump out of the machine, or injuries

may occur.

Fig. 2-3.
Fig. 2-8 No Jumping
6. Warning label, anti-crushing
Death or serious injury may occur if you are

WARNING
crushed by the machine. Do not go nearby or
stay there.
Crush Hazard
For its location on machine, see position 6 in Death or serious injury can occur
Fig. 2-3.
Fig. 2-9 Anti-crushing

7. Warning label, no passing through
Passing through is forbidden where there is a

label as shown in the right figure.

Fig. 2-3.
Fig. 2-10 No Passing Through
8. Warning label, no entrance
Unauthorized persons are not allowed to enter

where the right label is glued.

Fig. 2-3.
Fig. 2-11 No Entrance
9. Warning label, fire is forbidden
D o n o t s m o ke o r u s e a ny o p e n f i r e s .
Otherwise, fire disaster or explosion may
occur.

Fig. 2-3.
Fig. 2-12 Fire is Forbidden

10. Warning label, anti-clamping
Mind for the danger of being clamped.

Fig. 2-3.
Fig. 2-13 Anti-clamping
11. Label, power switch
This label indicates the correct turning

directions for opening or closing the power
supply.

Fig. 2-3.
Fig. 2-14 Power Switch
12. Warning label, no touching
Do not touch the place where there is a label

as shown in the right figure. Otherwise, injury
may occur.

Fig. 2-3.
Fig. 2-15 No Touching

13. Warning label, avoid electricity attack
Do not touch the place glued with this warning

label. This may lead to personal injuries
caused by electricity attack or sudden stop of
machine.

Fig. 2-3.
Fig. 2-16 Avoid Electricity Attack
14. Warning label, no opening
Never open! Injury can occur.

Fig. 2-3.
Fig. 2-17 No Opening
15. Warning label, spreader
Never stay around the spreader. There is a

danger of being hit by it.
For its location of on machine, see position 15

in Fig. 2-3.
Fig. 2-18 Keep Away From the Spreader

16. Warning label, caution for hanged objects
Keep away from the machine in the operation

process and be cautious about the hanged
objects.

Fig. 2-3.
Fig. 2-19 Caution for Hanged Objects
17. Warning label, tyre
Pay par ticular at tention when inf lating,

maintaining and repairing the tyres.

Fig. 2-3.
Fig. 2-20 Tyre Precautions
18. Label, mind your head
Mind your head not to be hit.

Fig. 2-3.
Be sure not to
be hitted
Fig. 2-21 Mind Your Head

19. Warning label, avoid falling
Make sure not to fall down from the machine.

Fig. 2-3.
Fig. 2-22 Avoid Falling
20. Warning label, no staying
Please keep away from the machine with a

distance of at least 8m.
WARNING

Staying at least 8m (26f t)clear
Fig. 2-3.
8m(26ft) from the rear of the machine
Fig. 2-23 No Staying
21. Warning label, keep clear of moving

machinery
Keep clear of moving machinery. Death or WARNING

serious injury can occur.
For its location on machine, see position 21 in Keep clear of moving machinery
Death or serious injury can occur
Fig. 2-3.
Fig. 2-24 Keep Clear of Moving Machinery

2.3 General Precautions
WARNING
WARNING
Neglect by maintenance or on-site

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

are allowed to operate and maintain this
machine.
• A lways keep the machine in nor mal
condition.
• The safety information in this manual
does not substitute for any rules or laws in
your country. Know the local safety rules
or laws. Make sure that those equipment
fitted to your machine abide by these rules
or laws.
WARNING
WARNING
Read and follow all safety precautions

before operating or maintaining this
machine. Failure to do so could result
in equipment damage, serious injury or
possibly death.

2.3.2 Personal protective equipment
Protective equipment ensures only the proper

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

operating, maintaining, or repairing the
machine. Take protective tools necessary for
tasks.
Fig. 2-25 Protective Equipment
CAUTION
CAUTION
Operator and maintenance personnel are

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

Protective equipment should contain:
• Safety Helmets:
Safety helmets can protect head from harms.
B e s u r e t o we a r s a f et y h e l m et s w h i l e
operating, maintaining, repairing the machine.
Fig. 2-26 Safety Helmet
• Safety Shoes
Safety shoes can decrease the foot injuries
caused by following reasons:
1. hit hard objects
2. step on sharp objects
3. heavy objects fall down
Be sure to wear safety shoes while operating,

maintaining, repairing the machine.
Fig. 2-27 Safety Shoes
• Safety Goggles and Mask
Safety goggles can protect eyes from harms.
Put on safety goggles while hammering or

grinding the par ts. Other wise, splashing
objects such as dust, sand or metal scraps
may get personnel seriously injured.
Hold a protective mask in hand while welding.
Fig. 2-28 Safety Goggle

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

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

tested and protects personnel against the
proper noise level.
Fig. 2-29 Ear-muffle
• Dustproof Mouth-muffle
Please put on a dustproof mouth-muffle while

welding or working in the area surrounded with
harmful gases or dusts.
Fig. 2-30 Dustproof Mouth-muffle
• Protective Gloves
Protective gloves can prevent you from hand

injuries. Make sure to put on protective gloves
under below circumstances:
• during the repair:
• when handling over-heated, over-cold,
corrosive, wood materials;
• when handling steel wires or metals with
sharp angle.
• when the environment temperature is
relatively low;
Fig. 2-31 Protective Glove
• when using vibrating tools for a long time.

• Protective Clothes
Be sure to wear protective clothes while

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

pant legs, etc, since the unqualified garments
may hook up the control lever or protrusion of
machine and thus lead to personal injuries.
Clothes should be in good condition and Fig. 2-32 Protective Clothes

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

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

allowed to stay in the cab. Passengers may
block the operator’s sight, which can result in
an unsafe situation.
Fig. 2-33 No Passenger

2.3.5 Hand signals
DANGER
DANGER
Operation without signals and instructions

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

the operator and the signalman is a must for
safe and proficient machine operation. Both
personnel must know proper hand signals for
each movement of the machine or load.
RAISE LOAD
With forearm vertical and index finger pointing
up, move the hand in a small horizontal circle.
RAISE
LOAD
Fig. 2-34
LOWER LOAD
With arm extended downward and index finger
pointing down, move hand in a small horizontal
circle.
LOWER
LOAD
Fig. 2-35

RAISE LOAD SLOWLY

Use one hand pointing upward to give a motion
signal and place the other hand motionless
above the hand giving the motion signal.
RAISE
LOAD
SLOWLY
Fig. 2-36
LOWER LOAD SLOWLY

Use one hand pointing downward to give
a motion signal and place the other hand
motionless below the hand giving the motion
signal.
LOWER
LOAD
SLOWLY
Fig. 2-37
NORMAL STOP
Use one hand starting at the waist and move it
outward.
STOP
Fig. 2-38

EMERGENCY STOP
Use both hands starting at the waist and move
them outward.
EMERGENCY
STOP
Fig. 2-39
Tips for safe signaling
• A new container reach stacker operator
or signalman should brief each other to
assure that each understands the other.
• Never begin operations until all signals are
clearly understood. If non-standard signals
are to be used, be sure that the operator
and signalman agree on them before
operations.
• If communication with the signalman is
obstructed in any way, all movements
of the machine must be stopped until
communications are restored.
• Obey a signal to stop from anyone.
• There should be only one designated
personnel at a time giving machine signals.
• An operator should move loads only based
on signals from a designated signalman
who wears distinctive clothing.
• The signalman must have a clear view of
the load and machine at all times.
• The signalman must keep all personnel
outside the container reach stacker’s
operating area. Any requests or questions
should only be addressed to the
signalman.
• The signalman should never direct a load
over a person.

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

precautions:
• Fire extinguisher and first aid kit should be
available nearby.
• Read and understand the instruction
label glued to fire extinguisher. Use fire
extinguisher correctly. Fig. 2-40 Safety Items
• Do regular inspection and maintenance
to ensure proper func tioning of f ire
extinguisher at any time.
• Check the f irst aid kit regularly and
replenish it when necessary.
• Make emergency scheme to deal with fire
and accidents.
CAUTION
CAUTION
Fireman should put on a fire-fighting

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

To protect you and others around you, your
machine may be fitted with the following safety
equipment. Ensure that each item is securely
in place and in operating condition.
• Guard against fallen objects
• Handrail
• Lights
• Safety labels Fig. 2-41 Check Safety Signs
• Horn
• Reversing alarm buzzer
• Rearview mirrors
• Fire extinguisher
• First aid kit
• Wipers
Be sure that the above devices are available
for operation. Never remove or disconnect any
safety devices.

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

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

maintained whatever the voltage is. During
operation no part of the load, machine or Fig. 2-42 Electricity Attack
additional equipment employed should violate
this limit. If you have any doubt, contact your
local Electrical Power Utility Company FIRST!
DANGER
DANGER
• NEVER operate the machine under

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

To address these risks:

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

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

If the equipment or any of its components

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

2.3.9 Precautions in thunderstroke
If the thunderstroke occurs, operator and

ot her s around t here may be c aught in
danger. Some parts of the machine would be
damaged.
• Make sure to stop operating if there is the
possibility of thunderstroke.
• Lower the load to ground and stop the
engine.
• Leave the machine and hide yourself in the
secure area. Fig. 2-43 Thunderstroke
• After the thunderstroke, check each parts
of the machine before re-operating it. If
any abnormalities found, contact the local
SANY distributors to maintain and fix it.
Check the abnormalities:

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

that may be lifted by a container reach stacker.
Wind forces act differently on the machine,
depending upon the direction from which the
wind is blowing.
SANY recommends that operation of this

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

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

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

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

2.3.12 Unauthorized modification
• Installation of optional parts or attachments

may involve safety or law issues. 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 work
devic es may result in the danger of
crashing the cab or other components
of machine. Before operating the work
devices that you are not familiar with,
check the possibility of collision and
operate carefully.

2.4 Safety During Operation
2.4.1 Work area safety
When working on port, wharf, freight station

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

substantially f irm, smooth, level and
prepared ground.
• There is a possibility of tipping when the
machine works on wharf or yard with poor
road conditions, leading to serious injury
or death. It is essential to check the road
condition in advance to avoid accidents.
• Make a work plan and select a machine
that is suitable for such work or site.
• When working on a narrow site, try to
Fig. 2-44 Do not Work on Uneven Ground
operate the machine in a small working
radius, and assign a signalman when
necessary.
• Pay special attention to avoid slipping
when working on frozen ground.
• It is forbidden to perform any operations
on uneven road or muddy road. Drive the
machine only on even and firm road.
• Reinforce the ground prior to work when
the ground is too loose or soft.
2.4.1.2 Work area indications
Do not start working before the area has

been indicated by a “blue flag” or some other
recognizable indications.
Fig. 2-45 Indicate the Work Area

2.4.2 Checks before operation
Check the machine carefully before starting it

everyday or per shift:
• Check whether the air pressure in tyre

is abnormal. The normal tyre pressure
should be 0.95-1.05 MPa.
Fig. 2-46 Check Tyre Pressure
• Check whether the attaching bolts of tyre,

driving axle, transmission shaft, mast and
frame are loose.
Fig. 2-47 Check Attaching Bolts

• Check whether the lubrication points of
connecting shaft of boom pitching cylinder
and boom telescopic cylinder, steering
cylinder and its connecting plate, hinge
point of spreader cylinder, and sliding
blocks are adequately lubricated.
Fig. 2-48 Check Lubrication Points

• Check if the hydraulic pipes are damaged

or leaking, and whether the electric wirings
are tightened.
Fig. 2-49 Check Hydraulic Pipe
• Check whether the engine oil level, fuel

level, hydraulic oil level and expansion
water level are appropriate.
Fig. 2-50 Check Oil Level
• Check whether the t wistlocks are

abnormal, such as looseness, deformation,
crack etc.
Fig. 2-51 Check Twistlock

• Check the conditions of engine filters (air

filter, fuel filter, diesel filter), fuel pipeline,
etc.
Fig. 2-52 Check Filters
• Check whether all limit switches work

normally.
• Check whether there is any alarm.

ALARM MESSAGE 1
01.FuelLevel_L 11.Hyd_OilTemp_H
02.Engine_OilPress_L 12.Front_Lean_Protect
03.Engine_Tem_H 13.Load_too_Back
04.Engine_Coolant_L 14.Lock_Unlock_Err
05.Battery_Voltage_Err 15.Loaded_too_High
06.Gearbox_Temp_H 16.Loaded_Overspeeded
07.Gearbox_OilPre_L 17.Safety_Bypass
08.BrakeOil_Temp_H 18.CANBus_Err
09.BrakeOil_Pre_L 19.Not_Safe
10.SystemOil_H 20.Weight_Over_45t
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Fig. 2-53 Check Alarm Message

2.4.3 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 of oil, grass, snow,
ice or mud, which can cause slippary or
fall. Remove all mud, oils or any debris
from the soles of your shoes before
climbing the steps to the operator cab.
• Never use caustic soaps, high-pressure
water or steam cleaners to clean the
electrical system, for these could damage
the system or cause intermittent system
failures.
Fig. 2-54 Avoid Cleaning the Electrical System

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

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

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

immediately. Tighten the loose bolts.

• Always maintain both feet and one hand or
one foot and both hands with the handrails,
steps, walkway and platforms to ensure
that you can support yourself properly.
• Wear shoes with a highly slip-resistant sole
material. Clean any mud or debris from
shoes before entering the container reach
stacker cab or climbing onto the container
reach stacker superstructure.
• Do not mount or dismount the machine
when you are carrying tools or supplies.
Fig. 2-55 Mount the Machine
• Never leave tools or similar objects on the
machine walkway or service areas. These
could drop and get caught in the machine
operating systems.
• Do not mount the engine hood, cover,
covering parts or counterweight without
the antislip sticker.
• Do not step on surfaces of the container
reach stacker that are not approved or
suitable for walking and working. You could
lose your balance, slip and fall from the
machine.
• Never exit or enter the container reach
stacker cab or deck by any other means
than the access system’s provided steps
and grab handles.
• Never modify container reach stacker’s
access system in any way that has not Fig. 2-56 Avoid Slipping
been evaluated and approved by SANY.
WARNING
WARNING
• Always face to the machine when

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

2.4.5 Start-up safety
2.4.5.1 Inside the operator cab
Once inside the operator cab, observe the

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

to operator fatigue and operating mistake.
Therefore, operators should obser ve the
following:
• Seat in a comfortable position before
operating the machine.
• Adjust the seat and console so that you
can easily access all controls from a
seated position and be sure that your
vision is clear in all directions as viewed Fig. 2-57 Adjust the seat
from the seated position.

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

be injured or thrown out of the cab, or crushed
by the tipping machine. Operators should
observe the following:
• Before operating, carefully check the
strap, buckle and fastener of the seat belt.
If any abrasion or damages are found,
replace the seat belt or its components
immediately.
• When the machine is traveling, always
Fig. 2-58 Check the Seat Belt
sit in the seat and fasten the seat belt to
minimize the probability of injury resulted
from unexpected accident.
• To reduce the danger, it is preferred to
replace the seat belt every three years.
2.4.5.4 Machine starting precautions
DANGER
DANGER
Prior to operation, be sure that you can

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

machine, see “Starting the Machine” on
page 4-17 for instructions.

WARNING
WARNING
Never start the container reach stacker

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

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

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

must be carried out according to instruction of
the operation section (For detailed information:
see: “Star t with booster bat teries or
starting generators” on page 4-21). Improper
operation can lead to battery explosion and
machine out of control, hence personal injury
and death.
• Never use jumper cable to star t the

engine without permission. Contact SANY
authorized distributor when necessary.
• Two personnel should work together to
start engine with jumper cable (One is
seated in the operator's seat and another
handles the battery).
• Wear goggles and rubber gloves before
starting the engine with jumper cable.
• When jumper cable is used to connect a
normal machine with a faulty machine,
ignition switch of both machines should be
turned to position O.
• Never use a welder or equipment with a 2
1
higher voltage system to jump-start the
machine, because it may damage the
machine’s electrical system or cause an
unexpected explosion or fire. Always jump-
start the engine with equal voltages.
• When connecting jumper cable, connect
the positive (+) (position 1 in Fig. 2-59)
first. When disconnecting jumper cable, 1
disconnect the grounding or negative (-) 2
(position in Fig. 2-59) first.

• Prevent the clips of jumper cable from
touching each other or the machine when
removing the jumper cable.
Fig. 2-59 Booster Battery

2.4.5.6 In cold weather
Cold weather operation requires additional

caution:
• Check operating procedures in this manual
or the engine manual for cold weather
starting. (For detailed information: see:
“Start in cold weather” on page 4-20).
• Do not touch metal surfaces that could
cause you to be frozen by them.
• Keep the container reach stacker clear of
all ice and snow.
• Allow time for the hydraulic oil to warm up.
• Park the container reach stacker 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.
2.4.5.7 After starting the engine
Run the enigne idly for 3-5 minutes after

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

2.4.6 Precautions for safe operation
2.4.6.1 Ensuring good view
Observe the following items when operating or

driving the machine in a place without a clear
view.
• Check rearview mirrors, remove debris
and adjust the view every time before
operation.
• Pr i o r to o p e r at i o n, b e su r e t h at a l l
personnel understand the signals and
gestures.
Fig. 2-60 Ensure Good View
• Turn on working lights and headlights of
the machine while working in a darkened
area. Set up auxiliary 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 bad view, a signalman
should be available if necessary. Operator
shall especially pay attention to the marks
and follow the instructions of signalman.
2.4.6.2 Safety rules for traveling
• Do not operate machine over the max

acceptable load or performance parameter.
• When traveling or operating, keep a safe
distance from people, building or other
machines so as to avoid collision.
• Speed must be adjusted according to
personnel, visibility, surface and load of
the site.
• When traveling on a road, contact the
related depar tments and follow their
instructions.
• When traveling on rough ground, move 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 br idge or
building, check first its structural strength
to see whether it could support the weight
of machine.
• Operate slowly when you are working in
a tunnel, under bridge or power cables or
under where working height is limited. Pay
special attention to not damage anything
with work equipment.
• Under all circumstances, the machine must
be operated at a speed which enables it to
be brought to a stop in a safe manner.
NOTICE
NOTICE
Slow down the machine before changing

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

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

possibly death.

2.4.6.3 Precautions while operating on

slopes
When operating on slopes, obser ve the

following rules:
1. The machine must move up and down
slopes slowly.
2. Do not turn the machine on slopes, nor
drive across slopes.
3. The load must fac e uphill when the
machine is driving up or down gradients of Fig. 2-61 Operate on Slope
over 10%.
2.4.6.4 Avoiding injury from reversing
In the reversing process, personnel around the

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

• Look around to make sure that nobody is
standing around the machine before the
reversing operation. Keep the traveling
alarm device in working status. Always
keep alert whether someone goes into the Fig. 2-62 Avoid Injury from Reversing
work area.
• Keep the windows, rearview mirrors and
lights clean and undamaged.
• Before moving the machine, warn others
with horn or other signals.
• In the reversing process, if your sight is
blocked, assign a signalman. Always keep
the signalman within your visual field.
• The machine can’t be moved before that
both signalman and operator understand
the meaning of all flags, signals and
marks.
• Avoid sudden acceleration or braking
in reversing process. In addition, the
driver should adjust the speed properly
in reversing process to avoid slippage or Fig. 2-63 Avoid Injury from Reversing
tipping.

2.4.6.5 Preventing control failure
Injury may be resulted from control failure. In

order to avoid control failure, you should:
• Do not lif t a container whose weight

exceeds the max. load capacity of the
machine.
• Make the unloaded engine run idle for 3~5
minutes to make it cool down. Then shut
down the engine and pull the ignition key
out.
• Park the machine on a horizontal ground Fig. 2-64 Signalman
rather than on a slope. Maintain a proper
distance from other machines.
Operation on a slope has tipping hazard,

which can result in serious injury or death. In
case the machine is to tip, never try to jump
out of the machine. Otherwise, serious or fatal
crush damage can occur. The tipping speed
of machine is much higher than your jumping
speed.
Fig. 2-65 Go to Hospital
In case of tipping accidents, always stay in the

cab holding tightly the steering wheel. Never
try to jump out of the cab.
Fig. 2-66 Never Jump Down

2.4.6.6 Never hoist the load except

container
Container reach stacker is forbidden to hoist

any load except for containers. For instance,
never tighten a sling on spreader to lifting other
load. Otherwise, personnel may be seriously
injured.
SANY number
Fig. 2-67
2.4.6.7 Never hoist the load over others’

head
The load hoisted over others’ head may fall

down and result in personal injuries.
Never hoist the load over others’ head.
Besides, do not let any personnel stand under
the load.
Fig. 2-68
2.4.6.8 Never stand under the load
Personnel under the load may be seriously

hurt if the load falls down. Do not let any
personnel stand under the load.
Fig. 2-69

2.4.6.9 Precautions for operating

emergency stop button
The emergency stop button can be also used

to brake the machine in emergency cases.
However it can only be used when the brake
system fails in a really prompt circumstance.
NOTE:
It is forbidden to use the emergency stop
button when the brake pedal is still working
normally or in not really emergent cases.
Fig. 2-70 Emergency Stop Button

If the emergency stop button has been used
for two times, replace the brake lining block
immediately. Be sure to readjust it for a good
parking brake effect if the parking brake has
been separated from the machine.
2.4.6.10 Precautions for operating safety

bypass switch
OPERATING RULES OF SAFETY BYPASS

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

be kept by a special technician. Only in
special cases can it be used after approval
by the principals of relevant departments.
• When using this function, note to find out
the condition of work area to ensure the
safe operation. Fig. 2-71 Safety Bypass Switch
• SANY will take no responsibilities for any
accidents caused by improper operation of
the safety bypass function.

2.4.7 Parking the machine securely
2.4.7.1 Parking requirements
After work, always park the machine in a safe

area away from tracks and truck lanes.
Fig. 2-72 Safe Area to Park the Machine
The ground on which the machine is parked

or traveling must have sufficient carrying
capacity. It should be hard and horizontal with
even supporting distribution.
Fig. 2-73 Park Ground
It is not allowed to park the machine on uneven

and loose ground.
Fig. 2-74 Avoid Parking on Uneven Ground

If the machine is parked on a slope, wedge its

front and rear wheels with blocks to prevent
sliding.
Fig. 2-75 Caution for Parking on Slope
2.4.7.2 Turning off the engine
Before maintaining the machine:

E A B
1. Park the machine on solid and even
horizontal ground.
P
2. Retract the spreader and lower it to its
lowest position.
3. Turn the gear selector to neutral gear.
Run engine idle for 3 - 5 minutes to cool it
down.
4. Turn the ignition key to ON position (B
in Fig. 2-76). Move the joystick forward,
back ward, lef t ward and right ward Fig. 2-76 Ignition Switch
respectively t wo or three times to
depressurize the hydraulic system.
5. Turn the key to OFF position (A in Fig. 2-76)
to stop the engine.
6. Turn the key to E position as shown in Fig.
2-76. And remove it from the switch.
7. Close all the doors and windows in cab.
8. Dismount the machine safely. Never
jump out of it. For detailed information,
see: “Mounting and dismounting the
machine safely” on page 2-35.
9. Put blocks under the wheel to avoid the
machine from moving.
Fig. 2-77 Secure the Wheel

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

below rules should be followed:
• Only approved and qualified personnel can
conduct the maintenance or repair.
• Comprehend fully all the maintenance
information covered in this manual prior to
maintenance.
Fig. 2-78 Read the Manual
• Maintenance personnel shall be physically
suited for this work, especially his health
and eyesight.
• Do not spray water or steam in the cab.
• N e v e r a d d l u b r i c a n t s o r p e r f o r m
maintenanc e when your mac hine is
moving.
• Keep your hands, feet and clothing away
from rotating parts.
2.5.1 Preparation for the work area
Before maintenance, you should:

• Choose a clean and even area with
enough space, light, fine 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 hammer or other tools in work
area. Fig. 2-79 Prepare for the Work Area

2.5.2 Warning label is important
If others have started the engine or operated

the joystick during the maintenance, serious
ac cidents would happen. Before any
maintenance work on the machine, be sure to:
• Set the WARNING LABEL of “Shut down!
Under maintenance!” on the steering wheel
SHUT DOWN
UNDER MAINTENANCE
or ignition switch.
• If necessary, place a warning label around
the machine.
Fig. 2-80 Warning Label
2.5.3 Lockout/tagout procedures
The following steps shall be followed in

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

affected by the repair or maintenance of
the machine.
2. Secure the machine in a safe position.
3. Identify, remove or disconnect all power
or energy sources and be sure to install a Fig. 2-81 Lock
lockout / tagout device on them.
4. Attach the warning lable to the machine.
5. If the ser vice personnel is issued a
lock and key, he/she shall not share the
lock or key with other personnel until all
maintenance procedures are complete
and the machine is ready to put back into
service.
6. Be sure all personnel involved in the
maintenance have installed their own locks
on the power source before performing.
Each one who completes his/her work
must remove his/her own lock and not
access the machine further.

2.5.4 Self-preparation before

maintenance
For detailed information, see: “Personal

protective equipment” on page 2-17.
Fig. 2-82 Protective Equipment
2.5.5 Using tools correctly
• Only use appropriate tools in a correct

way. Using damaged, inferior, defective,
temporary tools or misusing the tools
would result in serious accidents.
• Keep your tools clean. And take inventory
of the tools you were using to confirm no
tools were left in the machine when the job Fig. 2-83 Tools
is complete.
• Always put shop tools back in their proper
storage location when finished.
2.5.6 Regular replacement of safety-

related parts
For the consideration of operating the machine

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

2.5.7 Removing attachments carefully
• If removing large and heavy attachments,

always be sure to use the correct lifting
equipment rated for the capacity of the
load you will be lifting.
• After the attachment or part has been
removed, store it where it cannot fall or
move. Always be sure that the attachment
is stable on a solid surface and clear of all
walkways or fire exits.
• W h e n i nst a l li n g a n d u s i n g o pt i o n a l Fig. 2-84 Crushed by Removed Attachments
attachments, read and follow Chapter 8 for
the instructions.
• Do not use attachments that are not
authorized by SANY. Use of unauthorized
attachments could result in dangers and
adversely affect proper operation and
useful life of the machine. Any injuries,
accidents, product failures resulting from
the use of unauthorized attachments will
not be the responsibility of SANY.
2.5.8 Adding fluids to the machine
Before adding fluids, shut down the engine

and allow the systems to cool to outdoor
ambient temperature before removing any
caps. Failure to do so may result in serious
burns or a sudden loss of fluid. Read and
understand the following:
• Refueling the machine could pose some
hazards.
• Grease, fuel, oil or coolant spills pose a Fig. 2-85 Refueling
hazard if not cleaned up immediately.
• When refueling or adding any fluids to
the machine, be sure you are in a well-
ventilated area.
• Never smoke or allow open flames near
you while you are refueling the machine.
• Never mix gasoline with diesel or fuel.

Gasoline is extremely flammable and could

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

during operation, always be aware that
these systems are under high pressure and
hot. Otherwise, you may be hurt.
2.5.9 Towing or lifting the machine
Serious injury or death could result if an

in o p er at i ve mac hine i s towe d o r li f te d
incorrectly or if there is a mistake in the
selection of cables or towing locations. Adhere
to the following:
• Use only the designated lift points to lift
the machine and designated tow points to
tow the machine. Be sure that the lift and
tow points are undamaged and in good
working order.
• Always tow or lift in the direction indicated
by the label. If the label is missing or Fig. 2-86 Hoisting Point
damaged, contact your SANY distributors
for the proper procedures.
• Always wear leather gloves when handling
cables.
• During the towing operation, never stand
between the towing machine and the
machine being towed.
• Never tow a machine on a slope.
• Never use towing equipment that is
damaged, stretched or overstressed.
CAUTION
CAUTION
Only tow or lift the machine after you

have confirmed that nobody is around the
machine. Otherwise, they could be hurt.

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

WARNING
crushed by moving parts of this container
reach stacker.
Keep clear of moving machinery
Barricade the entire area where the container Death or serious injury can occur
r e ac h st ac ke r i s wo r k in g an d ke e p a l l
unnecessary personnel out of the work area.
Never allow anyone to stand or work near the

container reach stacker while the machine is
Fig. 2-87 Keep Clear of Moving Machinery
in operation.

2.5.11 Preventing hydraulic hazards
2.5.11.1 Checking rubber hose regularly
CAUTION
CAUTION
Contact with coolant of high temperature

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

• Check whether the joint of oil hose is
damaged.
Fig. 2-88 Check the Rubber Hose
• Check whether the housing of oil hose is
worn out.
• Check whether the external surface of oil
hose expands.
• Check whether the oil hose is bent or
flatted.
• Check whether the external bracket of oil
hose is lost.
WARNING
WARNING
In case of any damage on the rubber hose,

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

2.5.11.2 Releasing the pressure before

maintenance
1. Park the machine.

2. Retract the spreader and lower it to its
lowest position.
3. Stop the engine.
4. Release the pressure in hydraulic system.
5. Turn the ignition key to ON position (B in
Fig. 2-89). A B
If there is pressure in the hydraulic system,
a clear sound of “hiss-hiss” would be P
heard.
Then start the pitching, telescoping and
side-shif ting function of spreader for
several times.
Turn the ignition key to OFF position (A in
Fig. 2-89).
Turn off the main power. Fig. 2-89 Ignition Key
• Open the pressure-releasing valve on the

accumulator charging valve to release the
pressure in brake system.
Fig. 2-90 Release the Brake Pressure

2.5.11.3 Replacing rubber hose regularly
Due to aging, fatigue and wearing, rubber

h o se c o nt aining f lammab l e li qui d may
rupture under high pressure. Its aging and
wearing degree can’t be judged only by visual
inspection.
Failure to replace the rubber hose regularly

can result in accidents such as fire disaster,
Fig. 2-91 Replace the Rubber Hose
splashed liquid onto skin, or fallen work device
on personnel, etc. These could lead to serious
burn, necrosis or other injuries or death.
Fig. 2-92 Avoid Hydraulic Injury 1
Fig. 2-93 Avoid Hydraulic Injury 2

2.5.11.4 Prevent heating near the hydraulic

pipeline
Heating near the hydraulic pipeline can

generate flammable spray, which can result
in serious burn to you and personnel around.
Therefore, personnel should follow below
rules:
• Avoid heating pipes or hoses conveying
flammable liquid:
• Do not perform welding or air-cutting on Fig. 2-94 Do not Heat near the Hydraulic Pipe
the pipe or hose conveying flammable
liquid.
• Before welding or air-cutting the pipeline,
clear off the flammable liquid thoroughly
with nonf lammable solvent. Set a
temporary fireproof shield to protect the
hose or other materials.
2.5.11.5 Filling accumulator
The system consists of brake accumulator and

control accumulator, whose pressures before
using should be up to 100 bar and 25 bar
respectively by filling with nitrogen gas.
The accumulator is f illed with nitrogen.

Improper operation will lead to explosion
causing machine damage and personal injury.
Pay attention to the following items when
dealing with accumulators: Fig. 2-95 Caution for Filling Accumulator
• Do not dismantle the accumulator.
• Keep the accumulator away from fire.
• D o n o t d r i l l h o l e s o n o r w e l d t h e
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.

2.5.11.6 Selecting oils and fuel
Pay attention to the following items when

selecting oils and fuel:
• Select the allowable highest viscosity
at the corresponding temperature when
starting the machine.
• For the machine already run for a long
time, select the lubrication oil with higher
viscosity on its final drive to try to keep the
thickest oil film.
• The fuel may become frozen and starting
the engine becomes dif f icult in cold
weather. Therefore, fuel should be selected
according to the weather and temperature.
• Use the antifreeze specified by SANY. It
is forbidden to fill tap water or coolant of
other brands without permission.
• Use the hydraulic oil specified by SANY.
It is forbidden 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. Otherwise,
the machine may be unable to start or may
act suddenly, causing serious accidents.
2.5.11.7 Handling hydraulic oil
Hydraulic oil contains harmful and toxic

substances. When handling the waste oil,
observe the following to protect personal
safety:
• Do not touch hydraulic oil for a long time.
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 forbidden to wash the contaminated

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

the reach of children. It is forbidden to
store the lubrication oil in an uncovered
or unmarked vessel. Or possible injuries
would happen.
2.5.12 Preventing burn and scald
2.5.12.1 Burn by high temperature liquid
Hot water and steam exist in the hot water pipe

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: Fig. 2-96 Caution for Burn
• Do not open the radiator cover before the
engine cools down.
• Turn the cover slowly when opening it.
Remove the cover after the pressure has
fully released.
• Start the check or maintenance after the
oil and parts cool down.

In case of burn or scald:

• Wrap the injured with wet carpet; make
him/her roll on the ground.
• Do not try to tear off the substances like
fiber attached on the skin.
• In case of scald by liquid, take off the wet
clothes immediately. Special attention must
be paid when taking off the clothes.
• The wound should be wrapped or bound
with protective bandage.
• If serious, go to the hospital immediately.
2.5.12.2 Chemical burn
Some oil seals and repair kits used on the

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

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

used at a temperature exceeds 300˚C, the
following measures should be taken:
• Wear thick rubber gloves and special
protective glasses; then, remove the parts
and put them into plastic bags.
• Wash the burnt part with 10% Ca (OH)2
solution (limewater) or other alkaline
solution. Wash away the residues attached

on the metal surface. Then, wash this part

again with the mixture of fresh water and
detergent.
• Place all residues into a proper container.
Dispose them in a proper method
according to the local laws and regulations.
In case of burn caused by battery electrolyte,

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

lubrication oil and diesel, the following
measures should be taken:
1. Wash the eyes with fresh water for at least
20 min. Keep the eyes open to wash the
eyeballs with fresh water. Roll the eyeballs
towards different directions.
2. Consult the doctor immediately.
Fig. 2-97 Go to Hospital

2.5.13 Preventing fire and explosion
2.5.13.1 Handling inflammables safely
If the inflammables are ignited, explosion or

fire may occur. Pay attention to below items:
• Handle the fuel carefully, because it is a
highly flammable substance.
• Never fill the fuel to the machine while
smoking, or near the naked f ire and
sparkle.
• Shut down the engine before refilling fuel.
• Always fill the fuel at outdoors. Fig. 2-98 Avoid Fire
• Store the flammable liquid (all fuels, most
lubricants and some coolants) in a place
far away from fire hazard.
• Do not burn or puncture the pressure
container.
• Do not store oily cloth. They can be ignited
or combusting spontaneously.
2.5.13.2 Removing inflammables
Splashed fuel, oil, waste, grease, scrap,

accumulated coal dust and other inflammables
can result in fire.
Check and clean the machine ever yday.

Re m ove t h e s p l a s h e d o r a c c u m u l ate d
inflammables immediately to prevent fire.
Fig. 2-99 Remove Inflammable

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

result in fire. Personnel should observe the
following regulations to prevent fire:
• Check whether the clamp is lost or loose.
• Check whether the hose is twisted.
• Check whether the hose and pipeline rub
each other.
• Check whether the oil cooler is damaged .
• Check whether the flange bolt of oil cooler
Fig. 2-100 Check Oil Leakage
is loose.
• Tighten, repair or replac e all loose,
damaged or lost clamps, pipelines, hoses,
oil coolers, or flange bolts.
• Do not bend or strike high pressure
pipelines.
• Do not install any bent or damaged
pipelines, tubes, or hoses.
2.5.13.4 Checking short circuit
Short circuit can result in fire. Pay attention to

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

2.5.13.5 Checking ignition key
If the engine is not shut down when the P

machine is on fire, the fire would spread
and it will become difficult to put out the fire.
Therefore, you should:
• Check the function of ignition key before
operating the machine everyday.
• Start the engine and make it run at an idle
speed.
• Turn the key switch to OFF position (see Fig. 2-101 OFF Position
the arrow in Fig. 2-101) to confirm whether
the engine shuts down.
• In case of any abnormality, make sure to
fix it before operating the machine.
2.5.13.6 Preventing battery explosion
Battery electrolyte contains corrosive sulfuric

ac i d w hi c h may c reate f lammab l e an d
explosive hydrogen. Improper operation would
result in personal injury or fire accident. Be
sure to follow below regulations:
• Keep the battery away from children.
• Do not smoke near the battery.
• Avoid open fires and kindling materials
while charging or using the battery.
Fig. 2-102 Battery Explosion
• Never put the battery under sunshine in
hot seasons.
• Avoid battery terminals to contact with
tools and other metal objects.
• Switch the ignition key to OFF position (see
the arrow in Fig. 2-101) 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 wires.
Connect plus-cable (red) first and then
minus-cable (black). Make sure that all the
Fig. 2-103 Cables

terminals are firmly fixed.

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

fire
If the engine is not stopped when the fire

disaster happens, the fire would become
i nte n s e a n d t hu s o b st r u c t t h e r e s c u e.
Therefore, be sure to check the function
of ignition key before running the machine
everyday.
Fig. 2-104 Evacuate
If it is permitted to fight the fires preliminarily,
you may pull out the fire as long as you are
able to evade the danger anytime.

In case of fire, you must:

• switch the ignition key to OFF position (see
the arrow in Fig. 2-101) and make sure that
the engine is stopped. Evacuate from the
machine.
• call the fire agency.
• if time permits, put the gear selector to
neutral position and press brake button to
keep it in the “P” position.
• if time permits, use the fire extinguisher.
2. Emergency evacuation
In case that distorted windows and doors

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

breaking the windows. Otherwise, you may
get hurt.
Fig. 2-105 Emergency Hammer
1. Open the front window to evacuate from
the machine in special cases.
2. An emergency hammer is equipped at the
right of rear cab. If the front window cannot
be opened, break the window to pieces
with this emergency hammer immediately.
And then retreat the machine from the
front window.
3. If it is impossible to evacuate from the front
window, break the back window to pieces
with this emergency hammer. And then
retreat the machine from the back window.
NOTE:
There is an emergency exit label glued to the
back window.
4. When both front and back windows cannot

be used to evacuate, open the top window Fig. 2-106 Emergency Exit Label
and retreat the machine.

2.5.14 Preventing poisoning and

asphyxiation
2.5.14.1 Handling chemicals safely
Direct contact with harmful chemicals can

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

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

before welding or heating.
• Remove the paint at outdoor s or in
Fig. 2-107 Respirator
ventilated place.
• If sand paper and grinding wheel are used
to remove the paint, prevent inhaling dust
by wearing a qualified respirator.
• If solvent or paint remover is used, wash

away the paint remover with soap and

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

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

is started or operated in an enclosed
environment. Fig. 2-108 Avoid Poisoning by Off-gas
• If a person is poisoned by off-gas in the
enclosed environment, open the doors
and windows first to reduce the level of
harmful gases before conducting the first
aid treatment.
• Put the poisoned person to a ventilated
place or outdoors. If the poisoned person
is unconscious, make him/her lie sideways.

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

lung if inhaled. If there is a danger of inhaling
the dust when operating on the work area,
always observe the following:
• If there is possibly asbestos dust or similar
dust in the air, always operate the machine
from an upwind position. All personnel
should use qualified respirators.
• Spray water to keep down the dust when
cleaning. Do not use compressed air for
cleaning.
• Always obser ve the national or local
rules and regulations for work site and
environmental standards.
Fig. 2-109 Avoid Poisoning by Dust
NOTE:
SANY machines do not contain asbestos, but
there is a possibility that fake or aftermarket
parts may contain asbestos.
Always use genuine SANY replacement parts.

2.5.16 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 per form maintenance or repair
under the machine before the machine is
firmly supported by blocks or supports.
• Always use blocks or supports that are
strong enough to support the machine or
work equipment. Never use slag bricks, Fig. 2-110 Work under Machine
empty tyres or stands to suppor t the
machine. These things may collapse under
continuing load. Never use a single jack to
support the machine.
2.5.17 Precautions in welding
DANGER
DANGER
Never weld directly on the machine.

Failure to do so may lead to personal injury
even death.
Fire or electricity attack may occur if the

weld is performed incorrectly. Observe the
following:
• O n l y q u a l i f i e d w e l d e r w i t h p r o p e r
e qui p m e nt i s a p p r ove d to we l d t h e
machine.
• Welding must be performed in correct
procedures to prevent damaging the
P
electronic control device and bearing.
• Before welding on the machine or engine
equipped with electronic control device,
you should turn the ignition key to OFF
position first. And then remove the positive
and negative cables of the battery.
• Prevent wire harness from contacting with
the scrap and splashed objects generated
in the welding process. Fig. 2-111 OFF Position

Follow standard procedures in welding:

1. Clamp the parts to be welded with ground
clip of the welding machine.
2. Make the clip as close as possible to the
welding point, ensuring that current from
the ground wire to the parts will not pass
any bearing.
3. This c ould reduc e the possibilit y of
damaging the parts such as transmission
bearing, hydraulic parts, electrical parts,
other mechanic parts.
2.5.18 Safe maintenance of air

conditioning system
Make sure to observe below items:

• Keep fire source away when servicing air
conditioning system.
• In maintenance of air conditioning system,
observe the instructions on refrigerant
vessel and use it correctly. The type of
refrigerant is R134a. Other refrigerants are
not allowed for use, which may damage
the air conditioning system otherwise.
• Avoid refrigerants from getting into eyes or
splashing onto skin.
• Refrigerant R134a would highly create the
greenhouse effect. 1kg emission of R134a
(af ter t wenty years) equals to 3400g
emission of CO2. Obey local material
disposal regulations of refrigerants. Never
discharge refrigerant directly into the air.
DANGER
DANGER
Refrigerant R134a is a harmless gas under

room temperature. It will change into highly
toxic gas when burning. Handle it properly
to prevent personal injury even death.

2.5.19 Precautions in maintaining the

engine
To prevent injury, no maintenance shall be

carried out when the engine is running. If
maintenance has to be done on a running
engine, there should be at least two personnel
handling the maintenance according to the
following rules:
• One person should always be seated in
operator’s seat and ready to shut down
the engine at any time. All personnel must Fig. 2-112 Caution for Fan
keep in touch.
• Always lock the machine and fix its wheels
with wedges to prevent it from moving or
operating.
• Never enter into the movable places of
machine and 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, people may get caught by
them when staying close.
Fig. 2-113 Be Clamped by the Rotating Parts
• Do not leave or insert any tools or other

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

of the control levers must be used, send
signal to others and warn them to move
quickly to a safe area.
Fig. 2-114 Parts Flying to Hurt Personnel

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

shut down, high voltage can occur in fuel
injector and engine controller. Personnel
should observe the following to prevent the
danger of electricity attack:
• Do not touch the fuel injector or the engine
controller that might cause electrocution.
• Contact SANY authorized distributors if
you have to access the fuel injector or the
engine controller. Fig. 2-115 Caution for High Voltage
2.5.21 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 the leakage
of hydraulic system. Check whether all
liquid levels are normal.
• Operate all control devices to be sure of
their proper functioning. Make road test if
necessary.
2.5.22 Handling waste properly
The potential harmful substances used in

this machine include oil, fuel, coolant, brake
fluid, filter and battery etc. Improper disposal
of waste can impair the environment and
ecosystem. Therefore, pay attention to the
below items:
• Always abide by the national or local
regulations, rules and environmental
standards. Do not pour the waste liquid on Fig. 2-116 Disposal of Waste

the ground, in the sewer or into any water

source.
• Consult the local environmental protection
organization or recovery center for the
correct method of recovering or handling
the waste.
• Use the leakage-proof container when
draining the liquid. Do not use food or
beverage container, which might mislead
somebody to drink accidentally.
• Leakage of refrigerant into the air can
damage the atmosphere. For detailed
information, see: “Safe maintenance of
air conditioning system” on page 2-73.
NOTE:
The following substances and liquids must
be delivered to authoritative waste treatment
facility for disposal:
• Starter battery
• Waste lubricating oil
• Lubricating grease
• Mixture of water and anti-freezing fluid
• Filter element
• Waste tyre
• Other auxiliaries (such as grease or oily
Fig. 2-117 Do not Drop Waste Randomly
duster cloth etc.).
NOTICE
NOTICE
Pay attention to the following items to

prevent the environmental problems:
• Strictly observe laws and regulations of
the region/country where the machine
is located. Any actions that violates
these laws and regulations will be
punished.
• It is forbidden to drop and drain the
waste product, waste oil and relevant
washing goods without permission. The
waste should be handled following the
local laws and regulations.

2.6 Tag
SANY cannot predict every circumstance that

might involve a potential hazard in operation or
maintenance. The safety chapter in this manual
you just finished reading may not include
every possibly dangerous circumstance. But
the safety measures and regulations you have
understood would help you to make positive
judgments when encountering danger.
Our aim is to help you get into the habit of safe

operation and to make you a better operator of
container reach stacker.
Safety is your career and responsibility.

Wish you work pleasantly!

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Container Reach Stacker System Functions
System Functions
3. System Functions
3.1 Main Components of Machine�� 3-4
3.1.1 Power driving system�� 3-6
3.1.1.1 Engine�� 3-7
3.1.1.2 Torque converter – gearbox�� 3-8
3.1.1.3 Transmission shaft�� 3-8
3.1.1.4 Drive axle�� 3-9
3.1.1.5 Tyre��3-10
3.1.2 Steering system��3-11
3.1.3 Main frame system��3-12
3.1.4 Boom system��3-13
3.1.5 Spreader system��3-14
3.1.6 Hydraulic system��3-16
3.1.7 Electrical system��3-16
3.2 Cab Control System ��3-17
3.2.1 Steering controller��3-18
3.2.1.1 Steering wheel panel��3-18
3.2.1.2 Gear selector�� 3-22
3.2.1.3 Direction indication controller�� 3-23
3.2.1.4 Adjusting the angle of steering controller �� 3-27
3.2.2 Pedal�� 3-27
3.2.3 Joystick�� 3-28
3.2.4 Right operation panel�� 3-29
3.2.4.1 Ignition switch�� 3-30
3.2.4.2 Emergency retraction / lowering switch�� 3-31

System Functions Container Reach Stacker
3.2.4.3 Emergency stop switch�� 3-32

3.2.4.4 Safety bypass switch�� 3-32
3.2.4.5 Cab moving switch�� 3-34
3.2.4.6 Counterweight moving switch (optional)�� 3-34
3.2.4.7 Parking switch�� 3-35
3.2.4.8 Fuel heating switch (optional)�� 3-35
3.2.4.9 Hydraulic oil preheating switch (optional)�� 3-35
3.2.5 Front operation panel�� 3-36
3.2.5.1 Spreader light switch�� 3-36
3.2.5.2 Boom light switch�� 3-37
3.2.5.3 Rear light switch�� 3-37
3.2.5.4 Front wiper switch�� 3-38
3.2.5.5 Top wiper switch�� 3-39
3.2.5.6 Rear wiper switch�� 3-39
3.3 Display�� 3-41
3.3.1 Menu introduction�� 3-42
3.3.2 Introduction and operation of display area��3-43
3.3.2.1 Start menu��3-43
3.3.2.2 Main menu��3-43
3.3.2.3 Engine information menu��3-46
3.3.2.4 Hydraulic system menu�� 3-47
3.3.2.5 Gearbox information menu�� 3-47
3.3.2.6 Fault alarming menu��3-48
3.3.2.7 Digital input menu��3-49
3.3.2.8 Digital output menu��3-49
3.3.2.9 Analogy input menu��3-53
3.3.2.10 Analogy output menu��3-53
3.3.2.11 Setting menu�� 3-53
3.4.1.1 Power switch��3-56
3.4.1.2 Fan speed switch��3-56
3.4.1.3 Temperature or Paging switch�� 3-57
3.4.1.4 Mode switch�� 3-57
3.4.1.5 Fresh air switch�� 3-58
3.4.2 Operation�� 3-59

3.4.3 Precautions�� 3-60

3.4.4 Troubleshooting�� 3-61
3.5 Electric Control Cabinet�� 3-62
3.6 Fuse�� 3-64
3.7 Fire Extinguisher�� 3-65

3. SYSTEM FUNCTIONS
3.1 Main Components of Machine
Container reach stacker is composed of driving

system (1), steering axle (2), frame assembly
(3), boom assembly (4), spreader assembly
(5), cab assembly (6), hydraulic system (7),
electrical system (8), and lubrication system (9),
etc. Refer to Fig. 3-1.
4
7
5
3
9
1
Fig. 3-1 Main Components of Container Reach Stacker

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

3.1.1 Power driving system
Power driving system of container reach

stacker is composed of engine, transmission
case (including hydraulic torque converter),
transmission shaft, drive axle and tyres, as
shown in Fig. 3-2.
1
2
1. Engine 4. Drive axle

2. Transmission case 5. Tyre
3. Transmission shaft
Fig. 3-2 Power Driving System

3.1.1.1 Engine
Engine is the power source of the whole

machine.
This device is composed of air inlet system,

air outlet system, fuel system, cooling system,
electrical system, engine body and engine
support, etc. See Fig. 3-3.
2 3 4 5
1. Electrical system 4. Air inlet system

2. Lubrication system 5. Air outlet system
3. Fuel system 6. Radiating system
Fig. 3-3 Engine

3.1.1.2 Torque converter – gearbox
Torque converter, locating between engine and

gearbox, mainly flexibly transmits and adds
torque. Gearbox mainly functions to transmit
torque for driving and braking the machine.
1
O n S A N Y c o nt ai n e r r e ac h st ac ke r, a n
American DANA Clark transmission assembly
is used. It is composed of hydraulic torque
2
converter (1) and gearbox (2), whose structure
can refer to Fig. 3-4.
Fig. 3-4 Transmission Case
3.1.1.3 Transmission shaft
Tr a n s m i s s i o n s h a f t l o c a t e s b e t w e e n 1
1
transmission c ase and dr ive a xle. It is
connected with universal couplings at both
ends. Transmission shaft transmits the output
power of gearbox to drive axle, enabling the
forward and backward movements of whole
machine.
2
1. Universal joint
2. Transmission shaft
Fig. 3-5 Transmission Shaft

3.1.1.4 Drive axle
On SANY container reach stacker, a German

Kessler drive axle is adopted as shown in Fig.
3-6.
Drive axle is composed of main reducer,

differential mechanism, half axis, hub reducer,
disc traveling brake, parking brake and shell
body, etc.
6
4 5
3
1- 2
1-2. Main reducer and differential 5. Traveling brake

3. Parking brake 6. Hub reducer
4. Half axis (in the shell body)
Fig. 3-6 Drive Axle

3.1.1.5 Tyre
This machine adopts inner tube inflating tyre

specific for port engineering machinery. The 6
general type is 18.00-25 40PR (1.0 MPa) with
thickening thread E-4B (4J) to add abrasive 5
persistence, whose rim is spokeless heavy 4
rim. There are four tyres on the front axle, and
two on rear axle, each one able to bear 25t of
static load.
Our reach stacker applies five- element-

type wheel rim with no spoke. Wheel rim is
composed of wheel rim body, retainer ring, 3
seat ring, and lock ring.
2
NOTE:
Tyre specification of special reach stackers: 1
Empty container handler (SRSC1009-6E):
14.00-24-28PR
Lightweight container handler (SRSC3515-3): 1. Retainer ring
16.00-25-32PR-E-3J 2. Wheel rim
Heavyweight container handler (SRSC4545C): 3. Tyre
21.00-35-36PR 4. Retainer ring
5. Seat ring
6. Lock ring
Fig. 3-7 Wheel Rim

3.1.2 Steering system
Steering system is composed of steering axle

beam (1), rotating shaft (2), steering hydraulic
cylinder (3), connecting rod (4), interlocking
mechanism (5), steering knuckle(6), etc. as
shown in Fig. 3-8.
3 4
5
6 1
RS-1406027-1
Fig. 3-8 Steering System of Container Reach Stacker, Empty Container Reach Stacker and Light
3 4
5
1
6
Fig. 3-9 Steering System of Heavy Container Reach Stacker

3.1.3 Main frame system
Main frame assembly is a major par t of

container reach stacker. It is composed of
frame, cab side-turning mechanism, front
and rear mudguard, counterweights, handrail
and the interfaces of other assemblies, etc as
shown in Fig. 3-10.
1. Staircase 4. Cab mounting support

2. Rear counterweight 5. Cover plate assembly
3. Upper counterweight
Fig. 3-10 Frame Assembly

3.1.4 Boom system
B o o m sy s t e m o f t h i s r e a c h s t a c ke r i s
composed of basic arm (1), pitching cylinder
(2), drag chain (3), telescopic cylinder (4),
sliding block (5), telescopic arm (6), etc.
4 1 2 3 5 6
Fig. 3-11 Boom

3.1.5 Spreader system
Spreader system is composed of telescopic

cylinder (1), telesc opic beam assembly
(2), twistlock mechanism (3), cross beam
assembly (4), rotating mechanism (5), etc.
2 4
3
RS-1406030-1
Fig. 3-12 Standard Spreader
5
4
2
3
Fig. 3-13 H-type Spreader

5
4
2
3
RS-1406031-1
Fig. 3-14 F-type Spreader

3.1.6 Hydraulic system
Hydraulic system of container reach stacker

consists of two parts: braking/steering
hydraulic system and working hydraulic
system. Four gear pumps, which are installed
on the power take-off mouth of hydraulic
torque converter, are driven by the engine to
realize below functions:
• Steer and brake the whole machine while

it is traveling
• Side-shift, extend, retract, lock and unlock
the spreader
3.1.7 Electrical system

Panel button External Display
sensor
Electrical system of this machine consists of
the following sections: traveling control circuit,
driving control circuit, boom control circuit, Controller
Engine commu-
nication interface
spreader control circuit, regular control circuit.
Refer to Fig. 3-12 for the structure of the
electrical system. Switch valve, relay,
indication light, alarm
A mature CAN bus telecommunication system

is adopted in this electrical control system to Fig. 3-15 Basic Structure of Electric Control
communicate among controller, display and System
diesel engine controller. Controller monitors
the system real-time when the system is
running. Display only shows the data without
any control functions. The running parameters
of engine can be sent to display and controller
through the communication interface.

3.2 Cab Control System
NOTE:
To operate correctly and safely, it is significant
to fully comprehend the methods to operate
the control devices and the meaning of display
items.
Cab control system is composed of steering

controller (1), brake pedal (2), accelerator
pedal (3), joystick (4), right operation panel
(5), front operation panel (6), display (7), air
conditioner panel (8) and so on. See Fig. 3-16.
8 7
6 4
2 3
Fig. 3-16 Control Device

3.2.1 Steering controller
Steering controller is composed of steering

wheel panel (1), gear selector (2), direction
7 3
indication controller (3), steering column (4),
steering wheel angle adjusting handle (5), 2
steering column angle adjusting pedal (6) and
steering wheel (7). See Fig. 3-17. 1
Fig. 3-17 Steering Controller
3.2.1.1 Steering wheel panel
There are four indicator lights and two switches

on the steering wheel panel, including left
steering indicator light (1), fault indicator light
(2), parking indicator light (3), right steering
indicator light (4), warning light switch (5) and
headlight switch (6). See Fig. 3-18.
Fig. 3-18 Steering Wheel Panel

Left steering indicator light (1 in Fig. 3-18)
This left steering indicator light would

blink if the left steering light is turned
on.
Fault indicator light (2 in Fig. 3-18)
This fault indicator light would blink to

alert the operator if there is any fault of
the machine.
Parking indicator light (3 in Fig. 3-18)
This parking indicator light would blink

if the parking brake is engaged.
Right steering indicator light (4 in Fig. 3-18)
This right steering indicator light would

blink if the right steering light is turned
on.

Warning light switch (5 in Fig. 3-18)
This switch is used to turn on or off the

warning light.
Fig. 3-19 Warning Light Switch
Press down the warning light switch. The

warning light on the boom and warning
indicator light in the cab will begin blinking.
Fig. 3-20 Warning Light
Press down the warning light switch. The

width lights, fitted on the flank of front and rear
mudguards, will light up.
Fig. 3-21 Width Light

Headlight switch (6 in Fig. 3-18)

headlight.
Fig. 3-22 Headlight Switch
Headlight is located in the center front of main

frame.
Fig. 3-23 Standard Headlight
RS-1407028-1
Fig. 3-24 Optional Headlight

3.2.1.2 Gear selector
Gear selector (2 in Fig. 3-17) can be flipped

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

1
selector in the direction of arrow):
3
• F: Forward gear (flip forward) 1
2
• N: Neutral gear (in the middle) 3
• R: Reverse gear (flip backward)
Fig. 3-25 Flipping Forward
1
2
3
1
2
3
1
2
3
Fig. 3-26 Flipping
The rear light illuminates when gear selector is

placed at the R mark. And the reversing alarm
will soon make a sound.
1
2
3
1
2
3
Fig. 3-27 Flipping Backward

Gear selector can also be rotated towards 3

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

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

the engine can be started.
Fig. 3-28 Rotating
• In switching over between the forward
and reverse positions, stop the machine
completely to avoid overload on the
gearbox or transmission system.
3.2.1.3 Direction indication controller
Direction indication controller (3 in Fig. 3-17)

can be flipped upward, downward, forward or
backward.
• Flipping it forward or backward is to turn
on or off the left / right steering indicator
lights.
• Flipping it upward or downward is to turn
on or off the distant or nearby light.
Left / right steering
Steering light is used to warn the nearby

personnel that the machine is about to change
its driving direction.
Steering indicator lights are used to remind

the driver whether the steering light turns on
normally.
Fig. 3-29 Flipping Forward/backward

Push the direction indication controller forward.

The left steering light on front mudguard and
the left steering indicator light in cab will begin
blinking.
Fig. 3-30 Left Steering Indicator Light
Push the direction indic ation c ontroller

backward. The right steering light on front
mudguard and the right steering indicator light
in cab will begin blinking.
Fig. 3-31 Right Steering Indicator Light
Front steering lights are fitted together with

headlights.
Fig. 3-32 Front Steering Light

Rear steering lights, located at the end of main

frame, are fitted together with tail lights.
Fig. 3-33 Tail Light
Switchover of headlight beam
Flip the direction indication controller up and

down, and the switchover between distant and
nearby beam of headlights can be realized.
NOTE:
Some machines do not have the nearby or
distant beam. Filpping the controller up and
down cannot switch between the distant and
nearby beam of headlights.
Fig. 3-34 Flipping Upward/downward
• Flip t he c o nt r o ll e r upwar d, an d t h e
headlight blinks.
• Remain the controller at middle, and the
headlight emits nearby beam.
• Flip the controller downward, and the
headlight emits distant beam.
Fig. 3-35 Headlight

Horn switch
Horn switches are located at the ends of

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

continuously.
Fig. 3-36 Horn Switch
Washer switch
Direction indication controller is equipped with

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

right figure, water would be sprayed out.
• Hold this switch, and water would be
sprayed out continuously.
• Release it. The switch will automatically
retur n to its original plac e and stop Fig. 3-37 Washer Switch
spraying out water.
The controller can be rotated to four positions,

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

3.2.1.4 Adjusting the angle of steering

controller
The angle of steering wheel and steering

column can be adjusted to a desire angle.
Steering wheel angle adjusting handle (1)

1. Loosen the handle.
2. Adjust the steering wheel to a desired
position.
3. Tighten up the handle after the adjustment.
1
Steering column angle adjusting pedal (2)
1. Step on the pedal.
2. Adjust the steering column to a desired
2
position.
3. Release the pedal.
Fig. 3-38 Adjustment Handle and Pedal
3.2.2 Pedal
Brake pedal (3)

Brake pedal is used to slow down the machine
speed.
Accelerator pedal (4)

Accelerator pedal is used to speed up the
machine speed.
3 4
Fig. 3-39 Washer Switch

3.2.3 Joystick
2
3
Joystick is located at the right of cab seat. It 6
can be swayed in different directions to control
telescopic and pitching of the boom. Six 1 4
buttons at its front are to control rotating, side-
7
shifting, locking and unlocking of the spreader.
5
Two buttons at its back are handle enable 8
switch and vertically lifting/lowering enable
switch.
1. Spreader locking
2. Spreader unlocking
3. Spreader rotating anti-clockwise
With the rocker switch of handle enable (9 in
4. Spreader rotating clockwise
Fig. 3-41) pressed down, the joystick can be
5. Spreader side-shifting leftward
switched and thus realize the singal operation
6. Spreader side-shifting rightward
of boom to total four directions without
7. Vertically lifting/lowering enable
pressing the handle enable button (8 in Fig.
8. Handle enable
3-40).
Fig. 3-40 Joystick
NOTE:
To avoid misoperation, the driver should switch
off the button (9 in Fig. 3-41) before leaving
the cab.
When a combination operation is needed,

push the joystick directly.
NOTE:
React rate of all operations (except vertical
operation) is directly related to the joystick
angle. When the joystick remains at its neutral
position, all operations will be ceased.

3.2.4 Right operation panel

5
Right operation panel is composed of the 6
following switches (see Fig. 3-41): 7
8
9
1. Ignition key switch 11
2. Safety bypass switch 12
3. Buzzer
13
14
4. Emergency stop switch 2
4
5. Cab moving switch
6. Boom emergency retraction switch
7. Counterweight moving switch 10
8. Boom emergency lowering switch 1
9. Handle enable switch 3
10. Spreader 40 feet switch
11. Spreader 20 feet switch
12. Moving enable switch
13. Alarm resetting switch
14. Parking switch
Fig. 3-41 Right Operation panel

3.2.4.1 Ignition switch

E A B
Ignition switch (position 1 in Fig. 3-41) is used C
to start or stop the engine. P
D
A: OFF position
The key can be plugged in or pulled out. Turn
off all the electrical equipment.
B: ON position
The key stays at position B during engine
operation.
Fig. 3-42 Ignition Switch
C: HEAT position
This is the position to preheat the engine.
Plug in the key. Turn it clockwise to position C
and keep it there to preheat the engine.
NOTE:
Some engines have the function of preheating
automatically.
D: START position
This is the position to start the engine.
Plug in the key. Turn it clockwise to position D
and keep it there to start the engine.
Loosen the key after the engine is started, and
it will automatically return to position B.
E: PARK position
The key can be plugged in or pulled out.
When the key is at position E, the engine is
stopped.
NOTICE
NOTICE
Stopping engine not at idle speed would

shorten the service life of engine. Unless
in emergency, never stop the machine
urgently when the engine is running at high
speed. Otherwise, machine faults such
as wear crack on cylinder cover, burnt
bearings of turbocharger and so on may
occur.

3.2.4.2 Emergency retraction / lowering

switch
Buzzer would begin alarming to alert the

operator of current danger if the torque
percentage is larger than a certain value (90%)
in boom operation. Thus, be sure to operate
joystick to retract the boom as soon as
possible. After the danger is eliminated, press
down the reset button (13 in Fig. 3-41) to
cancel the alarm. If the safety value decreases
further due to the mis-operation or inertia until
the torque percentage is larger than another
value (100%), the program would lock the
boom operation of pitching and extension
(except for the retraction). Fig. 3-43 Boom Emergency Retraction
In some emergency cases, press down the

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

boom, the system program will give alarm
and lock the current operation if the forward-
overturning sensor is triggered to send tilting
signal. The boom then can only be retracted. Fig. 3-44 Boom Emergency Lowering
NOTE:
If the controller fails to work normally, it will
reset automatically 3 seconds after its power
supply is disconnected as long as the danger
is eliminated.

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

operation panel. Press down this switch, and
the engine is stopped. The entire electrical
system has no power and all actions stop.
After the fault is eliminated, turn the switch in
the arrow direction as shown in Fig. 3-45 to
cancel the emergency stop. Parking brake can
be used for emergency brake.
This switch can be also used to brake the

machine in emergency cases. However it
can only be used when the brake system
fails in a really prompt circumstance. When Fig. 3-45 Emergency Stop Switch
driving this reach stacker, it is forbidden to use
this emergency stop switch when the brake
pedal is still working normally or in not really
emergent cases.
3.2.4.4 Safety bypass switch
When the working system can’t work normally

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

OPERATING STEPS OF SAFETY BYPASS:

2
1. Confirm that this protection can’t be
canceled without using the safety bypass
function.
2. Before using the safety bypass function,
make sure the machine is in the safe
status.
3. Insert the key into the safety bypass switch
(2).
3
4. Turn the key clockwise to activate the
safety bypass function. Meanwhile, the
buzzer (3) near the safety bypass key
would begin to make alarm and the screen
would display “Safety Bypass Switch Fig. 3-46 Safety Bypass Button
Activated”. The protection is canceled.
5. When safety bypass switch is turned on,
the operator can only control the joystick
to lift / lower the boom and to side-shift /
rotate / telescope the spreader after the
machine is confirmed to be in the safe
status. When the machine is unloaded,
the safety bypass enables the locking and
unlocking of speader if the mechanical
lock pin of spreader twistlock mechanism
is released.
6. When the reach stacker is adjusted to the
normal status, make sure to proceed with
the next operation after this safety bypass
function is canceled, the fault indicator
light stops giving alarm and the “Safety
Bypass Function Activated” displayed on
the screen disappears.
7. After the operation, take away the key
and pass it to the special personnel for
keeping.
Fig. 3-47 Fault Indicator Light

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

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

engaged, the cab would not move even if the
cab moving switch (2) is pressed down.
Fig. 3-48 Cab Moving Enable Button
3.2.4.6 Counterweight moving switch

(optional)
After the moving enable switch (position 1

in Fig. 3-48) is engaged, the counterweight
would move forward when the counterweight 3
moving switch (3) is pressed forward, and
move backward when this switch is pressed
backward. The moving stops as soon as the
switch (3) is released. When the counterweight
reaches its limit positions, it will not move any
more even if the switch (3) is pressed down.
When the moving enable switch (1) is not

engaged, the counterweight would not move
even if the counterweight moving switch (3) is
pressed down.
Fig. 3-49 Counterweight Moving Button

3.2.4.7 Parking switch

parking brake.
Fig. 3-50 Parking Brake Switch

Press the parking brake switch, and the
parking indicator light will be turned on.
The machine will give off an alarm when the

driver leaves the seat without pressing down
this parking brake switch.
Fig. 3-51 Parking Indicator Light
3.2.4.8 Fuel heating switch (optional)
Press the fuel heating switch (1) when the fuel

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

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

when the temperature of hydraulic oil is too
low, and the hydraulic oil would be preheated.
Fig. 3-52 Heating Switches (Optional)

3.2.5 Front operation panel
The switches on front operation panel consist

of three working light switches including
spreader light switch (1), boom light switch (2),
rear light switch (3) and three wiper switches
including front wiper switch (4), top wiper
switch (5), and rear wiper switch (6). See Fig.
3-53.
The three working light switches can be used

together as a combination light. Fig. 3-53 Front Operation Panel
3.2.5.1 Spreader light switch

spreader light.
Fig. 3-54 Spreader Light Switch
There is respectively one spreader light at

both ends of spreader telescopic beam.
Fig. 3-55 Spreader Light

3.2.5.2 Boom light switch

boom light.
Fig. 3-56 Boom Light Switch
There are respectively two boom lights at both

sides of the middle of boom.
Fig. 3-57 Boom Light
3.2.5.3 Rear light switch

rear light.
Fig. 3-58 Rear Light Switch

There are respectively two rear lights at both

sides near the end of boom telescopic cylinder.
Fig. 3-59 Rear Light
3.2.5.4 Front wiper switch

front wiper.
Fig. 3-60 Front Wiper Switch
The front wiper is located at the front of cab.
Fig. 3-61 Front Wiper

3.2.5.5 Top wiper switch

top wiper.
Fig. 3-62 Top Wiper Switch
The top wiper is located at the top of cab.
Fig. 3-63 Top Wiper
3.2.5.6 Rear wiper switch

rear wiper.
Fig. 3-64 Rear Wiper Switch

The rear wiper is located at the back of cab.
Fig. 3-65 Rear Wiper

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

function display area (2), operation buttons F1-
F6 (3), and frequency adjustment button (4).
See Fig. 3-66.
10 15 10 20 48
5 20 5 25 2 10
0 25 0 30 0 12
x100rpm x10°c
F N R 1 2 Auto
G Y R
1
Gear %2.1f t
Load:%s %
0 1.1 %2.2f m
0.60 .9
%2.2f °
%s
%s.%%s.%s s. %s
HOME ENGINE HYDRAULIC GEARBOX ALARM INFO 2
4 F1
ESC F2 F3 F4 F5 F6 3
Fig. 3-66 Display

3.3.1 Menu introduction
Menu display area (position 1 in Fig. 3-66)

10 15 10 20 48
5 20 5 25 2 10
This area displays system parameters and 0 25 0 30 0 12
fault information. When a fault occurs, main x100rpm x10°c
menu will display the real-time information F N R 1 2 Auto

G Y R
about this fault.
Gear %2.1f t
Load:%s %
0 1.1 %2.2f m
0.60 .9
%2.2f °
%s
%s.%%s.%s s. %s
HOME ENGINE HYDRAULIC GEARBOX ALARM INFO
Fig. 3-67 Menu Display Area
Function display area (position 2 in Fig. 3-66)

Operation buttons (position 3 in Fig. 3-66)

The functions of 6 buttons from F1 to F6 are
corresponded to the indications on function
display area.
By pressing relevant buttons, the desired F1

ESC F2 F3 F4 F5 F6
menu can be displayed.
Fig. 3-68 Operation Buttons
Frequency adjustment button (position 4 in

Fig. 3-66)
Switch the frequency adjustment button to a

certain value, then press the button down to Return Adjust
confirm the selection. Press the button again
to confirm after that all the items are set. F1
ESC F2
Fig. 3-69 Frequency Adjustment Button

3.3.2 Introduction and operation of

display area
3.3.2.1 Start menu
When the ignition key is turned to position O,

the screen would display start menu as shown
in the right figure.
Fig. 3-70 Start Menu
10 15 10 20 4 8
3.3.2.2 Main menu 5 20 5 25 2 10
0 25 0 30 0 12
x100rpm x10°c
About 2 seconds after the star t menu is F N R 1 2 Auto
displayed, menu 2 will be shown automatically G Y R
as Fig. 3-71 under normal circumstances. Or Gear %2.1f t

you can press F1 directly to enter main menu. Load:%s %
0 1.1 %2.2f m
0.6 0.9
Main menu displays engine rotate speed, %2.2f °
%s
vehicle speed, engine water temperature, %s. %s.%s %s. %s
t r ave l i n g g e a r, s p r e a d e r l i g h t , t o r q u e HOME ENGINE HYDRAULIC GEARBOX ALARM INFO
percentage, alarm, container weight, boom Fig. 3-71 Main Menu

length, boom angle, and timing information.
NOTE:
The control unit monitors the preheating
situation of engine real time. Once the
preheating system is detected to be working
over 20 seconds, it would alarm for “Pre_
Heat_Err”. In this case, make sure to stop
the machine and turn of f the electricit y
immediately to check the engine preheating
system.

Below are the explanations of information

shown on main menu.
1. Engine rotate speed

The left instrument in Fig. 3-72 indicates the
actual rotate speed of engine.
Displayed speed on instrument alters within 5
10 15
5
10 20
2
48
20 25 10
the range of 0-25. It signifies the rotate speed 0 25 0 30 0 12
of 0-2500 rpm/min. x100rpm x10°c
2. Vehicle speed
The middle instrument in Fig. 3-72 indicates Fig. 3-72 Instruments
the actual traveling speed of machine.
Displayed speed on instrument alters within
the range of 0-30. It signifies the vehicle speed
of 0-3000 km/h.
3. Engine water temperature

The right instrument in Fig. 3-72 indicates the
real-time water temperature of engine.
Displayed temperature on instrument alters
within the range of 0 -12. It signifies the
temperature of 0-120°C.
4. Traveling gear
• F, N and R signify respectively forward,
neutral and reverse.
• 1, 2 and Auto signify the gear positions at
F N R 1 2 Auto
gear selector. With gear selector rotated to
1, the □ under 1 on screen changes into ■
and the machine travels at 1st gear. With
gear selector rotated to 2, the □ under 2 Gear
on screen changes into ■ and the machine
travels at 2nd gear. With gear selector Fig. 3-73 Gear Information
rotated to 3, the □ under Auto on screen
changes into ■ and the machine travels at
1st - 4th gear automatically.
• Gear signifies the actual traveling gear.
Gear 4 means that the actual traveling
gear is 4th gear. Similarly, Gear 1 means
that the actual traveling gear is 1st gear.
• When the machine stops, gear information
on screen would disappear. Fig. 3-74 Gear Positions

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

signify the conditions of spreader twistlocks.
G Y R
• G (green) indicates the locking condition;
• Y (yellow) indicates the seating condition; Fig. 3-75 Spreader Indicator Lights
• R (red) indicates the unlocking condition.
6. Torque percentage
Torque percentage is aimed at protecting the

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

load 0 1.1
• To r qu e p e r c e nt a g e > 9 0%: a l a r m f o r
0.60 .9
dangerous working condition
• Torque percentage=100%: impossible to
extend and lower the boom
Fig. 3-76 Torque Percentage
7. Alarm information
The alarm information consists of the code

and content of current fault.
The detailed alarm information can be referred 01 Fuel level _ L

to “Fault alarming menu” on page 3-48.
Fig. 3-77 Alarm

8. Load weight, boom length, boom angle
• Load weight: the weight is shown as 0

when the machine is unloaded. And it will
change according to the weight of load. %2.1f t
• Boom length: the retracted or extended
length of boom %2.2f m
• Boom angle: the angle is shown as 0
degree when the spreader is lowered to its %2.2f °
lowest position. And it will change along
with the lifting of boom.
Fig. 3-78 Load & Boom Information
9. Timing information
This area displays the current time.
The time information can be adjusted on

“Setting menu” on page 3-53.
2012.03.01 15:01
Fig. 3-79 Time Information
3.3.2.3 Engine information menu
Press F2 to enter engine information menu. %s °C RPM %s
%s bar Engine %s H
indicates the engine water temperature
indicates the engine oil pressure %2.1f L Engine SPN %s
indicates the fuel level
%s V
indicates the system voltage
indicates the engine rotate speed
Fig. 3-80 Engine Information Menu
indicates the engine working hours
indicates the engine SPN code

3.3.2.4 Hydraulic system menu

L %2.1 Mpa %s m
Press F3 to enter hydraulic system menu.
R %2.1 Mpa %2.1f °

Hydraulic parameters:
Foc-Distance %s cm
L indicates the pressure of left lifting O %2.1 Mpa Weight_Fix %2.1f t
cylinder non-rod chamber Load %s %

Count_Box %s
R indicates the pressure of right lifting System %2.1 Mpa Count_Lock %s
cylinder non-rod chamber
O indicates the pressure of lifting
cylinder rod chamber Fig. 3-81 Hydraulic System Menu
Machine parameters:
indicates the boom length
indicates the boom angle
Foc-Distance indicates the outreach of

boom
Weight_Fix indicates the load weight
(fixed point)
Load indicates the torque percentage
Count_Box indicates the counting of
container
Count_Lock indicates the counting of twist-
lock
3.3.2.5 Gearbox information menu %s Km/h F/N/R
Press F4 to enter gearbox information menu. %s rpm Manual
Gearbox parameters:
%2.1f bar Gear
indicates the driving speed
%s °C
indicates the gearbox rotate speed
indicates the gearbox oil pressure
indicates the gearbox oil temperature
Fig. 3-82 Gearbox Information Menu

Traveling gear information:
indicates respectively forward, neu-

tral, and reverse gear
indicates respectively 1st gear, 2nd
gear, and auto gear
indicates the actual traveling gear
3.3.2.6 Fault alarming menu ALARM MESSAGE 1

01.FuelLevel_L 11.Hyd_OilTemp_H
Press F5 to enter fault alarming menu. 02.Engine_OilPress_L 12.Front_Lean_Protect
03.Engine_Tem_H 13.Load_too_Back
In alarming, the □ on the right changes into ■. 04.Engine_Coolant_L 14.Lock_Unlock_Err
05.Battery_Voltage_Err 15.Loaded_too_High
06.Gearbox_Temp_H 16.Loaded_Overspeeded
The overall alarm list is as shown in Fig. 3-83 07.Gearbox_OilPre_L 17.Safety_Bypass
and Fig. 3-84. 08.BrakeOil_Temp_H 18.CANBus_Err
09.BrakeOil_Pre_L 19.Not_Safe
10.SystemOil_H 20.Weight_Over_45t
Fig. 3-83 Fault Alarming Menu 1
NOTE: ALARM MESSAGE 2

If the □ on the right of “21. Engine_flame
21.EngineOil_Flameout 31.Down_Valve_Err
out” turns into ■, alarm of displayed on this
22.Gearbox_slip 32.Speed_Sensor_Err
menu, be sure to check the engine oil at 23.Len_Angle_Error 33.SPN_Alarm
once to eliminate the fault. At this time, the 24.Oilpre_L_Sensor_Err 34.GPS_CAN_Alarm
engine cannot be started again in 10 minutes. 25.Oilpre_R_Sensor_Err
For protection of the engine, it can only be 26.Oilpre_O_Sensor_Err
27.Ctr_Filter_Blocking
restarted 10 mins after the failure is eliminated.
28.Hyd_Filter_Blocking
29.Brake_Filter_Blocking
30.Foot_Switch_Error
Fig. 3-84 Fault Alarming Menu 2

3.3.2.7 Digital input menu Digital Input

Backword MoveV H
Press F6 to enter digital input menu. And then Forword AlarmReset
Shift signal1 Spreader Locked
by pressing F1-F6 accordingly, the screen Shift signal2 On Location
displays respectively main menu, digital input, Gear Auto BrakeOil Tem H
FootBrake BrakeOil Pre L
digital output, analogy input, analogy output, HandBrake Hyd OilTemp H
and setting menus. Spreader Move Front Lean Protect
Engine Coolantlevel L Hyd filter blocking
Safe bypass Brake filter blocking
When a certain signal is “1” (real), the □ on the Engine Start Ctrl filter blocking
Engine Preheat Spreader Unlocked
right of the words changes into ■. ArmMove Enable
HOME DI DO AI AO SET
Explanations of the words on the left of Fig. Fig. 3-85 Digital Input Menu
3-81 are listed in sequence as below:
Reverse gear, forward gear, 1st gear, 2nd
gear, auto gear, service brake, parking brake,
spreader movements, low level of engine
coolant, safety bypass, engine starting, engine
preheating, handle enable.
Explanations of the words on the right of Fig.

Vertical movement, alarm resetting, spreader
locked, spreader seated, high temperature
of brake oil, low pressure of brake oil,
high temperature of hydraulic oil, forward
overturning protection, clogged hydraulic oil
filter, clogged brake oil filter, clogged control oil
filter, spreader unlocked.
Digital Output
3.3.2.8 Digital output menu
Press F3 on the digital input menu to enter

EmergBrake En ArmTens HSpd Valve
digital output menu. Gearbox valve F ArmLift HSpd Valve
Gearbox valve R Alarm Light Voice
Gearbox valve 1 Arm Down Valve
When a certain signal is “1” (real), the □ on the Gearbox valve 2 Auto Lock output
right of the words changes into ■. Gearbox valve 3 Safe Bypass output
Fig. 3-86 Digital Output Menu

Explanations of the words on the left of Fig.

High-speed parking chain, forward solenoid
valve, backward solenoid valve, gear solenoid
valve 1, gear solenoid valve 2, gear solenoid
valve 3.
Explanations of the words on the right of Fig.

Boom quickly extension solenoid valve,
pitching cylinder quickly lifting solenoid valve,
malfunction light alarming, boom lowering
emergency valve, automatic locking output,
safety bypass output.
Examples of digital output menu:
1. When the vehicle speed is larger than 12

km/h, the 1st frame on the left of digital EmergBrake En
output menu becomes black as shown in Gearbox valve F
Fig. 3-87. Gearbox valve R
Gearbox valve 1
Gearbox valve 2
Gearbox valve 3
Fig. 3-87 Digital Output Menu Example 1
2. When the actual traveling gear is displayed

as Gear 1 on main menu, the 2nd, 4th,
5th, 6th frames on the left of digital output
EmergBrake En
menu become black as shown in Fig. 3-88.
Gearbox valve F
Gearbox valve R
Gearbox valve 1
Gearbox valve 2
Gearbox valve 3


as Gear 2 on main menu, the 2nd, 5th, 6th
frames on the left of digital output menu
become black as shown in Fig. 3-89. EmergBrake En
Gearbox valve F
Gearbox valve R
Gearbox valve 1
Gearbox valve 2
Gearbox valve 3

as Gear 3 on main menu, the 2nd, 6th
frames on the left of digital output menu
become black as shown in Fig. 3-90. EmergBrake En
Gearbox valve F
Gearbox valve R
Gearbox valve 1
Gearbox valve 2
Gearbox valve 3

as Gear 4 on main menu, the 2nd frame
on the left of digital output menu becomes
EmergBrake En
black as shown in Fig. 3-91.
Gearbox valve F
Gearbox valve R
Gearbox valve 1
Gearbox valve 2
Gearbox valve 3

6. When the machine is unloaded and the

boom length is larger than 8.9m, turn the
joystick rightwards, and the 1st frame on
the right of digital output menu becomes ArmTens HSpd Valve
black as shown in Fig. 3-92. ArmLift HSpd Valve
Alarm Light Voice
Arm Down Valve
Auto Lock output
Safe Bypass output
7. The 2nd frame on the right of digital output

menu becomes black as shown in Fig.
3-93.
• if the joystick is pulled upward when the ArmTens HSpd Valve
machine is unloaded and the boom length ArmLift HSpd Valve
is less than 14m. Alarm Light Voice
• if the joystick is pulled upward when the Arm Down Valve
machine is little loaded (load weight less Auto Lock output
than 15t) and 5 seconds after the spreader Safe Bypass output
leaves the seated position.
8. The 4th frame on the right of digital output

menu becomes black as shown in Fig.
3-94.
• if the joystick is pushed downward. ArmTens HSpd Valve
ArmLift HSpd Valve
• if the joystick is released after pulling it
Alarm Light Voice
upward when the machine is little loaded
Arm Down Valve
(load weight less than 15t) or unloaded.
Auto Lock output
Safe Bypass output

3.3.2.9 Analogy input menu

Analogy Input
Gearbox Pressure %s Arm Length %s
analogy input menu. Gearbox Temp %s OilPreIN Left %s
Speed of Gearbox %s OilPreOut Left %s
Speed of Engine %s OilPreIN Right %s
The framework on the right of words is the Analn Joy FB %s Battery Voltage %s
relevant data display area. Analn Joy LR %s FuelLevel %s
Arm Angle %s System Pressure %s
Foot Throttle %s
Fig. 3-95 Analogy Input Menu
3.3.2.10 Analogy output menu

Analogy Output
analogy output menu. Boom Out %s
Boom In %s
Boom Up %s
4 output status of PWM valve: Boom Down %s
• The valve opening is 0 when the value is
1526.
• The smaller the value is, the larger the
valve opening becomes.
• When the joystick is pushed and pulled to HOME DI DO AI AO SET
its limit positions, the accordant value is
around 762. Fig. 3-96 Analogy Output Menu
3.3.2.11 Setting menu

Screen Setting
Press F6 on the digital input menu to enter F3
setting menu. And then by pressing F1-F6
accordingly, the screen displays respectively F4
main menu, idle protection menu, display Spreader prevent

luminance setting, display contrast degree
F5:Save energy enable
setting, energy-saving mode setting and
automatic lock setting menus. F6:Auto lock enable
F2:Idle Protect
indicates the luminance of display
Return Adjust Bright Contrast save ener Auto lock
indicates the contrast degree of display
Fig. 3-97 Setting Menu

Press F2 for 3 sec onds to set the idle

protection function of engine (optional). The
corresponding indicator light on this menu
would illuminate if the function is activated.
By pressing F2 repeatedly for 3 seconds, this
function can be canceled.
• Starting idle protection: within 60 seconds
after the engine is started, there is no
response from throttle and the engine
keeps running at idle. After 60 seconds,
it is able to operate the machine normally
and there is no limitation to the throttle.
The screen displays “Idle_Protect”.
• Running idle protection: when the engine
is running at high speed, switching ignition
key to P position cannot stop the engine
immediately. This protection allows a few
seconds for the engine to run idle before
stopping.
NOTE:
• High speed: engine rotate speed exceeds
1500 rpm.
• Idle speed: engine rotate speed exceeds
800 rpm.
NOTE:
The emergency stop button is effective even if
the idle protection function is activated.
Press F5 for 3 seconds to set the energy

saving mode. The corresponding indicator
light on this menu would illuminate if this mode
is activated. By pressing F5 repeatedly for 3
seconds, this function can be canceled.
Press F6 for 3 seconds to set the

automatic locking function of spreader. The
corresponding indicator light on this menu
would illuminate if this function is activated.
By pressing F6 repeatedly for 3 seconds, this
function can be canceled.

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

2. Fan speed switch 6. Temperature down or Page down switch
3. Power switch 7. LCD display
4. Temperature up or Page up switch
Fig. 3-98 Control Panel

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

the functions of air conditioner (refrigeration,
dehumanization, ventilation, heating).
• Press the power switch when the fan is

working to start the air conditioner, and
the indicator light above this switch would
illuminate. Press it again to stop the air
conditioner, and the indicator light would
go out.
Fig. 3-99 Power Switch
• Air conditioner cannot function while the
fan is turned off (no indication of fresh air
mode on the display).
3.4.1.2 Fan speed switch
This switch is used to adjust the air volume by

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

volume increases gradually.
• Press this switch when the system reaches
its highest air volume, and the air volume
would return to its original condition. Fig. 3-100 Fan Speed Switch
• Air volume automatically transits among
the gears during the automatic operation
of air conditioner.
Indications of air volume on display screen:

• A: it indicates low air volume
• B: it indicates medium air volume A B C
• C: it indicates high air volume
Fig. 3-101 Air Volume Indication

3.4.1.3 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
Fig. 3-102 Temperature or Paging Switch
temperature.
• No operation for 5 seconds, temperature
returns to the original display condition.
• The temperature is generally set at 25°C
(77°F).
Table 3-2 Temperature Reference
Display Temperature (℃ ) Set Temperature (℃ )

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

among refrigeration, dehumanization,
ventilation and heating.
indicates that air conditioner is in

refrigeration mode.

ventilation mode.
indicates that air conditioner is in Fig. 3-103 Mode Switch

heating mode.

dehumidification mode.

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

among fresh air, ozone sterilization, and
automation. Press this switch, and above
modes circulate in proper sequence.

fresh air mode.

Fig. 3-104 Fresh Air Switch
ozone sterilization mode.

automation mode.
NOTE:
• Mode, Fresh Air, Set and Fan Speed have
the memory function after power-off.
• Memory function after power-off means
that the operation mode, the fresh air
status, the set temperature, and the fan
speed when the controller is turned on this
time remain the same condition as that
before the system is powered off last time.
• Condenser starts within 30 seconds after
the fan begins working.

3.4.2 Operation
Press power switch after the starting

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

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

would blink all the time. Then the idling
lifter would start to work if the engine is Fig. 3-105 Mode Switch
equipped with idling lifting device.
2. Press or one time to raise or
reduce 1℃ of the set temperature. The set

temperature can be adjusted between 16℃
to 32 ℃ . Generally, human body could
adapt to the temperature between 22℃ to
28 ℃ . As soon as the cab temperature is
lower than the set value, the sensor would
send signals to controller. And the air
conditioner will stop refrigerating.
Fig. 3-106 Temperature or Paging Switch

3. Press to adjust the air volume.
Fig. 3-107 Fan Speed Switch
3.4.3 Precautions
1. As an electric c omponent, once the

c ont roller 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 splashing 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 pressure light up.
4. Close windows, doors and ventilation
devices (except fresh air device) during the
operation of air conditioner.
5. Do not close all the air outlets. Keep at
least one thirds of air outlets open.

NOTICE
NOTICE
Turning on air conditioner before the

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

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

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

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. Electrical diagnosis
requires professional techniques and must
be conducted by a qualified and specific
personnel. When important parts like a breaker
or a relay are damaged, please refer to the
Parts Book and find out the relative material
code, then purchase them from SANY.
1. Breaker 3. Intermediate relay

2. Fuse protector 4. Switching board
Fig. 3-108 Cab Electric Control Cabinet

2 1
4 3
5 6
1. Controller 4. Breaker
2. Intermediate relay 5. Switching board
3. Fuse protector 6. Large current relay
Fig. 3-109 Frame Electric Control Cabinet

3.6 Fuse
Fuses are located in the electric control

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

of each fuse.
Table 3-5 Specifications of the Fuse
Code Fuse Function

FU0 5A GPS
FU1 10A Engine
FU2 5A Taillight
FU3 10A Rear light
FU4 10A Front wiper
FU5 5A Top wiper
FU6 5A Rear wiper
FU7 10A Signal system
FU8 5A Parking brake switch
FU9 10A Auxiliary electrical equipment control
FU10 5A Boom light switch
FU11 5A Alarm light switch
FU12 10A Spreader light switch
FU13 10A Spreader power supply
FU14 5A Spreader movement control
FU15 10A Controller power supply 1
FU16 10A Controller power supply 2
FU17 20A Sensor power supply
FU18 10A Emergency switch
FU19 10A Backup
FU20 10A Backup
Fuse 8JS 711 684-002 5A
Fuse 8JS 711 686-002 10A
Fuse 8JS 711 688-003 15A
Fuse 8JS 711 687-004 20A

3.7 Fire Extinguisher
There are totally two fire extinguishers in the

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

the following items:
NOTE: Fig. 3-110 Fire Extinguisher

• Make sure to put fire extinguishers in
cab and read carefully the instructions.
Understand its usage under emergent
circumstances.
• Check the fire extinguisher at regular
intervals. Be sure that the fire extinguisher
is in the guarantee period.
• If the f ire ex tinguisher exc eeds the
guarantee period, you must change it in
time.

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GE
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A
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P
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K
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N
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A
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L
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Container Reach Stacker Operation
Operation
4. Operation
4.1 Before the Starting of Engine�� 4-4
4.1.1.1 Wiper water tank, checking�� 4-4
4.1.1.2 Expansion water tank, checking�� 4-4
4.1.1.3 Engine oil level, checking�� 4-6
4.1.1.4 Gearbox oil level, checking�� 4-7
4.1.1.5 Hydraulic oil level, checking�� 4-7
4.1.1.6 Fuel tank, checking�� 4-9
4.1.1.7 Brake oil tank, checking��4-10
4.1.1.8 Tyres, checking��4-10
4.1.1.9 Electrical components, checking��4-11
4.1.1.10 Working light, checking��4-12
4.1.1.11 Horn, checking��4-12
4.1.2 Adjustment before operation��4-13
4.1.2.1 Seat, adjusting��4-13
4.1.2.2 Rearview mirror, adjusting��4-15
4.1.2.3 Safety belt, adjusting��4-16
4.2 Starting the Machine��4-17
4.2.1 Start in normal weather��4-17
4.2.2 Start in cold weather�� 4-20
4.2.3 Start with booster batteries or starting generators�� 4-21
4.3 Stopping the Machine�� 4-23
4.4 Driving�� 4-25
4.4.1 How to drive�� 4-25

Operation Container Reach Stacker
4.4.2 Driving forward�� 4-26

4.4.3 Driving backward�� 4-27
4.4.4 Turning around�� 4-27
4.4.5 Parking�� 4-28
4.5 Load Handling �� 4-29
4.5.1 Joystick�� 4-29
4.5.2 Boom, operation�� 4-31
4.5.3 Spreader, operation�� 4-36
4.5.4 Hook, operation�� 4-39
4.5.5 Load capacity diagram�� 4-40
4.5.5.1 Load capacity diagram of C-type container reach stackers�� 4-41
4.5.5.2 Load capacity diagram of SRSC1009-6E empty container reach stacker
�� 4-42
4.5.5.3 Load capacity diagram of SRSC4545C heavyweight container reach
stacker�� 4-43
4.5.5.4 Load capacity diagram of SRSC4535 heavyweight container reach stacker
�� 4-44
4.5.5.5 Load capacity diagram of SRSC4540H2-70 heavyweight container reach
stacker�� 4-45
4.5.5.6 Load capacity diagram of SRSC3515-3 lightweight container reach stacker
�� 4-46
4.5.6 Picking up a container from the stack�� 4-47
4.5.7 Depositing a container on the stack�� 4-50
4.6 Transportation and Assembly�� 4-52
4.6.1 Guidelines�� 4-52
4.6.2 Packing, requirements �� 4-53
4.6.3 Transportation�� 4-54
4.6.3.1 Transporting by platform lorry�� 4-54
4.6.3.2 Transporting by container�� 4-54
4.6.3.3 Detailed caution in unloading�� 4-54
4.6.3.4 Unloading the machine�� 4-55
4.6.3.5 Loading the machine�� 4-58
4.6.4 Assembly and disassembly preparations�� 4-59
4.6.4.1 Safety precautions�� 4-60
4.6.4.2 Requirements for crew members �� 4-61
4.6.4.3 Tools for assembly and disassembly�� 4-61

4.6.4.4 Assembly alerts of the components �� 4-62

4.6.4.5 Hoisting points of parts�� 4-62
4.6.5 Assembly�� 4-65
4.6.5.1 Prepare the work area �� 4-65
4.6.5.2 Rear counterweight, installation�� 4-66
4.6.5.3 Sliding counterweight, installation�� 4-67
4.6.5.4 Pitching cylinder, installation��4-70
4.6.5.5 Boom, installation��4-72
4.6.5.6 Spreader, installation�� 4-81
4.6.5.7 Lights, installation�� 4-83
4.6.5.8 Final check�� 4-86
4.6.6 Disassembly�� 4-87
4.6.6.1 Prepare the work area�� 4-87
4.6.6.2 Lights, removal�� 4-88
4.6.6.3 Spreader, removal�� 4-90
4.6.6.4 Boom, removal�� 4-92
4.6.6.5 Pitching cylinder, removal��4-101
4.6.6.6 Sliding counterweight, removal��4-103
4.6.6.7 Rear counterweight, removal��4-104

4. OPERATION
4.1 Before the Starting of Engine
4.1.1 Checks before operation
Every time before starting the machine or

changing shift, the driver should check wiper
water tank, expansion water tank, engine
oil level, gearbox oil level, hydraulic oil level,
fuel level, brake oil level, tyre, electrical
components, working lights, and horn to
ensure that the machine is in good condition
and ready for operation.
4.1.1.1 Wiper water tank, checking
The wiper water tank is located behind the

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

driver’s cab, is directly connected to the engine
radiator.
This tank is made of transparent plastic,

making it convenient to read its water level.
The water level in this tank indicates the
amount of coolant in the radiator.
Never start the machine when the coolant is

insufficient.

CAUTION
CAUTION
Never open the tank cap (1) when the

engine is running and touch it within 10
minutes after the engine is turned off.
Coolant temperature and the pressure 1
in tank are still high even if the engine is
stopped. Removing the cap to check the
coolant level at this moment may lead to
personal scald.
Therefore, firstly 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. Fig. 4-2 Expansion Water Tank
Steps to fill coolant into expansion tank:

1. C o olant level should be maint ained
between the MAX and MIN markings on
tank when the engine is operating. If the
coolant level is below the MIN marking, it
is time to fill in coolant through the filling
port (1) until it reaches the MAX marking.
Tighten up the cap after filling in coolant.
2. If the tank is empty, the coolant may be
leaking. Check the coolant pipelines for
leakage. If yes, fix the trouble immediately
Top up the tank if the coolant level is low.
3. Clean the expansion tank when the tank is
too dirty to see the level.
REMARK:
Tank capacity: 35 - 50L
For detailed information, see: “Capacity of
the tanks” on page 5-13.

4.1.1.3 Engine oil level, checking
WARNING
WARNING
Parts and oil remaining high temperature

after the engine is stopped would result
in serious burn. Make sure to conduct
this operation after the oil temperature is
reduced.
2
Steps to check engine oil level:

Fig. 4-3 Check Engine Oil Level
1. Open the engine bonnet.
2. Take the dipstick 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 L H
the H and L markings. If it is below the L
marking, fill in oil through the filling port (2).
Fig. 4-4 Level Markings
5. If it is above the H marking, open the oil
drainage plug (see the arrow in Fig. 4-5)
in the bottom of engine oil tank and drain
the redundant oil. Tighten up the plug and
recheck the oil level.
NOTE:
• At least 15 minutes are needed for oil to
flow into the engine before rechecking the
oil level.
• If the machine is sloping, keep it horizontal
before the check. Fig. 4-5 Oil Drainage Plug
6. If the oil level is proper, tighten up the cap

of filling port and close the engine bonnet.
REMARK:

4.1.1.4 Gearbox oil level, checking
Steps to check gearbox oil level:
1. Start the machine. Run the engine at idle

after it is preheated. Open the gearbox
bonnet.
2. Open the cap of filling port (3). Take the

3
dipstick out and wipe away the oil on it.
3. Plug the whole dipstick in oil tank and then Fig. 4-6 Check Gearbox Oil Level
take it out.
4. The oil level must be maintained between

marking, fill in oil through the filling port.
L H
REMARK:
the tanks” on page 5-13. Fig. 4-7 Oil Dipstick
4.1.1.5 Hydraulic oil level, checking
WARNING
WARNING
Parts and oil remaining high temperature

after the engine is stopped would result
in serious burn. Make sure to conduct
this operation after the oil temperature is
reduced.
Rotate slowly the cap of filling port to
release the inner pressure when removing
it.
Avoid welding near the hydraulic oil tank.

1. Retract and lower the boom completely.

2. Turn off the engine.
3. Switch the joystick towards each direction
to release the hydraulic pressure 15 H
seconds after turning off the engine.
Fig. 4-8 Oil Level Marking

4. The oil level must be maintained between
marking, fill oil through the filling port (4).
4
NOTICE
NOTICE
Do not exceed the H marking when filling

in the oil. Too much hydraulic oil will
splash and damage the hydraulic devices.
Fig. 4-9 Oil Filling Port of Hydraulic Oil Tank
NOTE:
Shut down the engine immediately when
the oil level is above the H marking. Put a
container under the draining hole in the bottom
of hydraulic oil tank to receive the oil. Then
drain out the redundant oil from draining hole.
REMARK:

4.1.1.6 Fuel tank, checking
WARNING
WARNING
Do not splash or outflow the fuel. Failure

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

check the fuel level shown on display (5).
After the check, turn the switch back to %s °C RPM %s
position O. %s bar Engine %s H
5 %2.1f L Engine SPN %s
%s V
Fig. 4-10 Display Menu
2. If the fuel level is low, release the cap of

filling port (see Fig. 4-11) on fuel tank, and
fill in fuel through the filling port until oil
floater reaches its highest point.
REMARK:
Fig. 4-11 Oil Filling Port of Fuel Tank

4.1.1.7 Brake oil tank, checking
The level in brake oil tank can be indicated by

level-temperature indicator mounted on the
tank. The oil level must be maintained between
the H and L markings. You can also check the
quality of brake oil by its color. When the oil
level is lower than the L marking, refill the tank
up to the H marking. Change the oil when it is
necessary.
Fig. 4-12 Brake Oil Tank

REMARK:
4.1.1.8 Tyres, checking
2
Carry out a visual inspection of the tyre. Make
sure that the rim and hub cover (1) are not
deformed, both sides of the tyres (2) and the
wheel tread (3) are not damaged. In case
of faults, the tyre will have to be carefully 3
inspected by the maintenance personnel
before being used.
Fig. 4-13 Check Points of Tyre
Tyre pressure should be 0.95-1.05 Mpa.
DANGER
DANGER
A splashed lock ring or exploding tyre can

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

allowed to serve the tyres. Failure to do
this could result in serious injury or death.
Fig. 4-14 Tyre Explosion

4.1.1.9 Electrical components, checking
Check the following electrical components:

• Check if the fuses are damaged, or
conformed to the subscribed volume.
• Check if there is a sign of open circuit or
short circuit in cables, and if the cover of
cables is damaged.
• Check if the terminals are loose. If yes,
tighten them up.
• Besides, pay particular attention to the
cables when checking the battery, engine,
start motor, and alternator. Be sure to
check if there are flammable materials
accumulated around the battery. If yes,
clear them away immediately.
NOTE:
• If the fuses are burnt out frequently or there
is a sign of short circuit in cables, please
contact SANY authorized distributors to
find out the reasons and repair it.
• Keep the upper surface of battery clean
and check the air vent on battery cover. If it
is jammed by dirt or dust, wash the battery
cover and clean the air vent.

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

light switch.
• Check if the working light can be turned on
normally.
• Check if there are dirt or damage of the
working light.
• Check whether the working light is on.
• If the working light is off, maybe the bulb is
burnt out or the electricity is disconnected. Fig. 4-15 Working Light
Please contact SANY authorized
distributors to repair it.
4.1.1.11 Horn, checking
Start the machine. And press down the horn

switch.
• Check whether the horn can alarm.
• Check whether the horn sound is normal.
• If the horn does not alarm or the horn
sound is abnormal, please contact SANY
authorized distributors to repair it.
Fig. 4-16 Horn

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

then loosen it to get it locked.
Distance: 120mm
2
3
4
4
5
4
6
Fig. 4-17 Headrest

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

of armrest is increased; Turn it anticlockwise,
and the height is decreased.
2
Angle range: -50°to 50°
Fig. 4-18 Handle to Adjust the Armrest

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

firstly pull the handle (3) upward and tilt the
backrest to a desired position, then loosen the
handle to get the backrest locked properly.
3
Angle range: 75°to 140°
Fig. 4-19 Handle to Adjust the Backrest
4. Adjustment of safety belt
For detailed information, see: “Safety belt,

adjusting“ on page 4-16.
5. Adjustment of suspension
Turn the handle (5) to left, and the suspension

becomes hard to accommodate the drivers of
large weight.
Turn this handle to right, and the suspension
becomes soft to accommodate the drivers of
5
small weight.
Weight range: 50 to 130 KG
Fig. 4-20 Handle to Adjust the Suspension
6. Adjustment of seat height
The first hearing of “snip-snap” after the

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

Fig. 4-21 Adjust the Seat Height

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

operation.
Failure to do this may hurt yourself or

others due to the blocked view.
Adjust the rearview mirrors to make the driver

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

1
1. Rotate the rearview mirror to a proper
angle.
2. If the mirror cannot move smoothly while
the angle is being adjusted, loosen the
fixing bolts of mirror and the bolts in fixing
lever of mirror.
3. Take the view of machine’s profile in mirror
Fig. 4-22 Rearview Mirror
as the standard while adjusting the angle
of rearview mirror.

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

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

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

1. Press down the button (5) on shackle (4).
2. Pull out the lock tongue (3) from the
Fig. 4-23 Safety Belt
shackle (4).
3. Safety belt will automatically roll back to
the intertwist device (1).
4. Hold the safety belt clamp (2) and Make
the safety belt roll back slowly to intertwist
device (1).

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

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

circuit switch and turn it clockwise.
Fig. 4-24 Main Power Key

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

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

1
2
I II
0
3
P
4-26) to electrify the entire system.
III
Fig. 4-25 Gear Selector
4. Turn the key to start position (III) and hold
for 3-5 seconds until the engine is started
successfully.
P
NOTICE
NOTICE
Do not operate the start motor for longer

than 15 seconds. In case of start failure,
wait fore 10 seconds between one start
attempt and another.
After the start failure, the start motor
would be damaged if you turn the ignition
key before the engine stops. Fig. 4-26 Ignition Switch
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 trouble before starting it again, so as to
avoid damaging the engine.
In order to protect the battery, an interval

of 1-2 minutes should be kept between two
starts. Only start the engine after the system
is powered on and the start menu displays.

NOTE:
• When the temperature of engine is low, do
not run it at a high speed.
• Before the temperature of engine rises
to 6 0˚C, do not r un it by ac cidental 60°c
acceleration or at full load.
0°c
- 5°c
Fig. 4-27 Temperature Gauge
The following conditions must be met to start

the engine.
• Observe if there is any alarm information %s °C RPM %s
showing on the display. If there is, correct
%s bar Engine %s H
and clear the fault accordingly.
• Check if relevant parameters on Engine
Information Menu conform to their %2.1f L Engine SPN %s
standards.
• Put the gear selector in the neutral %s V
position.
• Release the emergency stop button. HOME ENGINE HYDRAULIC GEARBOX ALARM INFO
• S te p o n t h e ac c e l e r ato r p e da l w i t h
observation on the parameters of the Fig. 4-28 Engine Information Menu
engine.
CAUTION
CAUTION
Emission of the diesel engine contains

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

4.2.2 Start in cold weather
NOTE:
When the temperature is below 50°F (10°C),
special care should be taken to start the
engine. A start in cold weather may require
some assistant devices, but the operations in 35°c
the driver’s cab are identical to a normal start.
0°c
- 5°c
For maximum engine protection and easier
start at low temperature, observe the following
precautions:
• Keep the batteries fully charged.
• Keep the fuel clean and free of water. Fig. 4-29 Temperature Gauge
• Use lubricating oil with correct viscosity for
the ambient temperature range where the
engine has to be operated.
A hydraulic oil heater should be used when

the machine is operating in cold environment
(temperature below 0˚C). A preheating light
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 another start. If the
engine continuously fails to start for several
times, do not start it again before finding out
the reason and solving the trouble. Besides,
ask the maintenance personnel to check the
air intake preheating system.

4.2.3 Start with booster batteries or

starting generators
WARNING
WARNING
Booster batteries should only be

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

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

end and with the positive (+) terminal of the
battery on machine at the other end.
• b. Connect another jumper cable with the
negative (-) terminal of the booster battery
and with the grounding connector (the one
away from the battery) on the machine
frame at the other end. Fig. 4-30 Booster Battery
3. Start the engine in a normal manner.
4. After the engine has been started, first
disconnect the negative (-) jumper cable
from the frame, then remove the positive (+)
jumper cable.
NOTE:
Never try to start the machine by towing or
pushing it.

WARNING
WARNING
Batteries produce explosive gases when

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

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

4.3 Stopping the Machine
1. Release the accelerator pedal (3) to slow

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

the gearbox and the transmission shaft.
WARNING
WARNING
When the machine is loaded with extended 2 3

boom, do not brake it suddenly. If not
Fig. 4-31 Brake Pedal
avoided, this could result in injur y or
possibly death.
3. When the machine is totally still, press

down the parking switch (4), and the
parking indicator light (5) would illuminate. 4
Fig. 4-32 Parking Switch
Fig. 4-33 Parking Indicator Light

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

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

1
minutes if it has been run constantly with
3
loads. 1
1 2
3
1
2
3
Fig. 4-34 Gear Selector
6. Turn the ignition key to position P in order

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

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

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

suspended. It could inadvertently lower,
possibly causing serious injury or death.
Fig. 4-36 Main Power Supply Switch

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

with the functional features, load limits and
safety rules of the machine are allowed to
operate this machine.
F
1
2
N
1. Adjust the operator’s seat to a comfortable 3
R
and suitable position.
2. Run the engine idle and select driving
direction and traveling gear with the gear 1 3
selector (1).
3. Release the parking brake (2), and step on
the accelerator pedal (3).
Fig. 4-37 Driving
4. Before changing the gear, release the
accelerator pedal first, and then speed up
normally after the desired gear has been
applied.
5. Keep stepping on the accelerator pedal 2
when driving.
WARNING
WARNING
NEVER drive the machine when there is a

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

or possibly death. Fig. 4-38 Parking Switch
SPEED
• Adjust the speed according to personnel,
visibility, surface and load of the work area.
• Special care must be taken on wet and
slippery surfaces, such as snow or ice.
• Under all circumstances, the machine
must be operated at a speed that enables
it to be stopped in a safe manner.

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

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

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

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

2. Release the parking switch (see Fig. 4-38).
3. Step on the accelerator pedal (3) slowly so
that the machine starts gently.
NOTE:
When accelerating up a hill, do not release the
brake pedal (4) until the machine has sufficient
pulling power.
4 3
Fig. 4-39 Driving Forward

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

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

no personnel stays near the machine. If
not avoided, this could result in injury or
3
possibly death.
Fig. 4-40 Driving Backward
4.4.4 Turning around
With the help of a hydraulic assistant system,

the machine is characterized by a relatively
small turning torque.
To minimize unnecessary tyre wear, do not
turn around the machine when it is still.
Do not continue turning the steering wheel
when it is reaching its turning limit. Otherwise,
steering components may be overheated.
WARNING
WARNING
To maintain machine stability and prevent Fig. 4-41 Turning Around

possible tipping, do not turn around the
machine abruptly, especially:
• when the machine is traveling at a high
speed;
• with spreader elevated higher than its
mid-point;
• on uneven ground.
If not avoided, these could result in injury
or possibly death.

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

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

the parking brake switch, the machine would
give off an alarm. Fig. 4-42 Parking
NOTE:
T h e p a r k i n g sy s te m i s l o c ate d o n t h e
transmission shaft. Switch on the parking
brake, and the transmission shaft will be
locked. Do not use the parking brake to brake
the machine unless in emergency.

4.5 Load Handling
4.5.1 Joystick
Joystick is located at the right of the cab

seat. It can be swayed in different directions
to control the telescoping and pitching of
boom. Six buttons in its front are to control
rotating, side-shifting, locking and unlocking of
spreader. Two buttons at its back are handle
enable switch and vertically lifting/lowering
enable switch.

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

2. Spreader 3. Spreader rotating 4. Spreader rotating 5. Spreader
1. Spreader locking
unlocking anti-clockwise clockwise shifting leftward
6. Spreader shifting 7. Vertically lifting /
8. Handle enable
rightward lowering enable
12. Boom
10. Boom emergency 11. Counterweight
9. Cab shifting emergency 13. Handle enable
retraction shifting (optional)
lowering
17. Alarm resetting 18. Fuel heating
14. Spreader 40 feet 15. Spreader 20 feet 16. Shifting enable
button switch (optional)
20. Fire detection
19. Hydraulic oil heating
alarm switch 21. Parking switch
switch (optional)
(optional)
24. Safety bypass 25. Emergency stop
22. Ignition key switch 23. Buzzer
switch switch
Fig. 4-43 Joystick

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

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

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

table. Fig. 4-44 Enable Buttons
Table 4-1
Key Function Category

Vertically shifting
A Inching button
enable switch
Handle enable
B Inching button
switch
Handle enable Two-position rocker
F
switch switch

Boom, lifting:
1. Press down button B and hold it.
2. Pull the hydraulic joystick backward.
Fig. 4-45 Boom Lifting
Boom, lowering:
2. Push the hydraulic joystick forward.
Fig. 4-46 Boom Lowering

Boom, extension:
2. Turn the hydraulic joystick rightward.
Fig. 4-47 Boom Extension
Boom, retraction:
2. Turn the hydraulic joystick leftward.
Fig. 4-48 Boom Retraction

Boom, lifting vertically:

1. Press down button A and hold it.
2. Pull the hydraulic joystick backward.
Fig. 4-49 Boom Lifting Vertically
Boom, lowering vertically:

1. Press down button A and hold it.
2. Push the hydraulic joystick forward.
Fig. 4-50 Boom Lowering Vertically

Vertically lifting/lowering the boom can only

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

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

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

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

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

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

twistlock is LOCKED;
When light B turns yellow, it indicates that the
crown bar is SEATED;
A B C
When light C turns red, it indicates that the
twistlock is UNLOCKED. Fig. 4-51 Spreader Light
Spreader, locking:
1. When the spreader is seated, light B would

turn yellow.
2. If the operator has set up the automatic
locking program, the controller would
send a locking signal and thus realize the
automatic locking of spreader. Then, light
A would turn green.
3. If the operator has not set up the automatic
locking program, spreader would be locked
and light A would turn green after the
locking button on joystick is pressed down. Fig. 4-52 Spreader Locking Button
Spreader, unlocking:
1. When the spreader is seated, press down

the unlocking button and handle enable
switch to unlock the spreader.
2. Then light C turns red and light A goes out.
WARNING
WARNING
NEVER try to press the spreader unlocking

button when the load is suspended, or the
load may fall down accidently. If not avoid-
ed, this could result in injury or possibly
Fig. 4-53 Spreader Unlocking Button
death.

Spreader, side-shifting (leftward):

When the spreader is not seated, press down
the side-shifting button (left), and the spreader
would shift leftward.
Fig. 4-54 Spreader Side-shifting Leftward
Spreader, side-shifting (rightward):

When the spreader is not seated, press
down the side-shifting button (right), and the
spreader would shift rightward.
Fig. 4-66 Spreader Side-shifting Rightward

Spreader, rotating (anti-clockwise)

Press down the spreader anti-clockwise
rotating button, and the spreader would rotate
anti-clockwise.
Fig. 4-56 Spreader Rotating Anti-clockwise
Spreader, rotating (clockwise)

Press down the spreader clockwise rotating
but ton, and t he spreader would rot ate
clockwise.
Fig. 4-57 Spreader Rotating Clockwise

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

loading bulk.
Observe the following rules when operating

the hooks:
• Make sure to connect ropes and tooling of
sufficient load capacity to the hooks.
• All the four hooks should be used at the
same time.
• Retract the spreader to be 20ft before
loading. Fig. 4-58
• The four ropes should be of the same
length.
The angle between the rope and the normal of

spreader corner parts is α.
• Angle range: 0°≤ α ≤ 30°
• Max. spreader load G should not exceed
the curve in right figure when α is different.
For example: G should be less than 20T
when α is 30°.
Fig. 4-59
Spreader tooling should be adopted to hoist

load by hooks. The size of tooling is as below:
• A≤5560 mm
• B≤2260mm
• 1≤ A/B ≤2.5
Fig. 4-60

4.5.5 Load capacity diagram
WARNING
WARNING
Overload is absolutely forbidden during

the operations, for it could result in injury
or possibly death.
This reach stacker is only used to lift
20′ and 40′ containers. If not otherwise
indicated, lifting other containers could
result in injury or possibly death.
Pay attention to stack and pick up containers

according to the load capacity diagram.
Unit of the unmarked sizes in the diagram is

mm.

4.5.5.1 Load capacity diagram of C-type

container reach stackers
6000
Fig. 4-61 Load Capacity Diagram

4.5.5.2 Load capacity diagram of

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


SRSC4545C heavyweight container reach
stacker
13600
2100
3900 8000
6400


SRSC4535 heavyweight container reach
stacker
15100
1965
3815 6500
6315


SRSC4540H2-70 heavyweight container
reach stacker


SRSC3515-3 lightweight container reach
stacker
9200
1965 5500
3815

4.5.6 Picking up a container from the

stack
WARNING
WARNING
Overload is absolutely forbidden during

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

2. Carefully move the machine so that the
container is centered to it.
3. Lift the spreader until it is right ahead of
the container.
NOTE:
The right light (red) is light, indicating that the
spreader is unlocked.
Fig. 4-67
4. Drive the machine forward as close to the
stack as possible.
5. Apply the parking brake if desired, or stop
the machine by stepping on the brake ped-
al.
6. Adjust the position of spreader by side-
shifting and rotating it, making the twist-
locks align with the four holes at the con-
tainer corners.
NOTE:
The right light (red) is light, indicating that the
spreader is unlocked.
Fig. 4-68

7. Put the spreader on the container.

NOTE:
The middle light (yellow) is light, indicating that
all four corners are correctly aligned.
Fig. 4-69
8. Press the spreader unlocking button to

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

Fig. 4-70
moment! Otherwise the container could be
locked loosely and fall, possibly causing
personal injuries.
9. Ready to lift the container.

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

dle light (yellow) goes out and the twistlock
function is interrupted.
11. Lift the container only as much as needed
to ensure that its clearance from the lower
container (A) is approx. 20 to 40 cm.
12. Reverse the machine carefully to a position
where the lifted container is away from the
lower container. Reverse it only as much
as needed to ensure that the clearance
between the stack and the lifted container
(B) is less than 20 to 40cm. Then stop the
machine.
Fig. 4-71
13. Retract the boom as much as possible.
Then the lifted container will be lowered.
The system would alarm and interrupt the
retraction of the boom when it is too far
back.
14. Be sure to keep a certain distance from
the stack in front while retracting the boom,
because the container would move for-
ward horizontailly at the same time when it
is lowered vertically.
15. Continue retracting the boom and lowering

the container until the safe traveling posi-
tion is reached.
16. Retract the boom all the way back.
17. Lower the container as much as possible
without obstructing the visibility (not below
C).
Fig. 4-72

18. Center the container by moving the

spreader horizontally until the container is
right ahead of the machine.
19. Drive the machine with a suspended con-
tainer away from the stack carefully and
slowly.
Fig. 4-73
4.5.7 Depositing a container on the

stack
1. Approach to the stack.

2. Carefully move the machine so that the
container is centered to the machine.
3. Lift the container until it is right above the
stack.
4. Drive the machine forward as close to the
stack as possible.
5. Apply the parking brake if desired, or stop
the machine by stepping on the brake ped-
al.
Fig. 4-74

6. Center the container over the stack by

side-shifting and rotating the spreader.
7. Lower the container onto the stack.
Fig. 4-75
8. The middle light (yellow) illuminates when

the spreader is seated.
9. Then it is able to unlock the spreader.
10. The left light (green) goes out when the
twistlocks begin unlocking.
11. The right light (red) only lights up when the
twistlocks are fully unlocked.
12. Remove the spreader from the container.
And the machine can now begin picking up
or stacking a new container.
Fig. 4-76
WARNING
WARNING
Never lift the spreader during the locking

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

4.6 Transportation and Assembly
4.6.1 Guidelines
Container reach stacker is a special kind of

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

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

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

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

4.6.2 Packing, requirements
Observe the following rules when packing the

parts of machine:
1. Block the disassembled hoses and valve
connectors with plugs.
2. Plug all the connectors of main oil hoses.
3. Fix all the hydraulic hoses and electrical
cables on the main body after bunching
them, and pack the fixing position with
cotton for protection.
4. All the exposed axles, shaft pins and
mounting holes must be spread with
grease and sealed with oilpaper;
5. Pack the lights with foam, tie them with
tapes and put them in the wooden case.
6. Fix the valve block of pitching cylinder in
the wooden case. Apply the company’s
standard case. Dimension: 900×500×600.
Delivery lists are attached inside and
outside the case.
7. Pack all the parts neatly and tightly.

4.6.3 Transportation
4.6.3.1 Transporting by platform lorry
If the machine is to be transferred to a nearby

yard by road, it can be disassembled into
several parts and bound to 3 platform trailers
of 30T for transpor tation. Weight of the
parts should not exceed load capacity of the
platform lorry. Binding positions should be
protected to avoid paint damage.
4.6.3.2 Transporting by container
If the machine is to be transferred to a distant

place by sea, totally three containers should
be prepared. Encase the main body in a frame
container. Besides, load the boom, pitching
cylinder, and rear counterweight in a 40 feet
standard container, and the spreader, sliding
counterweight, other small parts in another 40
feet standard container. All the parts should be
fixed in the containers to avoid moving.
4.6.3.3 Detailed caution in unloading
• Sort out the delivery items according to the

delivery list.
• Special attention is needed for fixing
devices of parts before unloading the
machine.
• Shackles and slings must be fastened.
• Components should be lifted slowly and
steadily to a proper height.
• Package cases should be transferred as
whole to prevent spare parts from being
damaged and missing.

4.6.3.4 Unloading the machine
Transport the containers encasing various

components of the reach stacker to a specified
site, and unload it.
1. Open the container door to check the

position and package of each part.
Fig. 4-77
2. Move the accessory case out with a heavy
forklift and put it in a place convenient for
refetching.
Fig. 4-78
3. Use slings to connect hoisting points

of the sliding counter weight with the
heavy forklift. Move the truck to drag the
counterweight out. Put a cushion wood at
the entry of the container to prevent it from
falling suddenly.
Fig. 4-79

4. After dragging the sliding counterweight

to a certain position, lift and move it to a
proper place for mounting later.
Fig. 4-80
5. Use slings to connect the spreader tooling

with the heavy forklift. Move the truck to
drag the tooling out. Put a cushion wood at
falling suddenly.
Fig. 4-81
6. After dragging the spreader to a certain

position, lift and move it to a proper place
for mounting later.
Fig. 4-82

7. Use slings to connect hoisting points of the

rear counterweight and the heavy forklift.
Move the truck to drag the counterweight
out. Put a cushion wood at the entry of
the container to prevent it from falling
suddenly.
Fig. 4-83
8. After dragging the counter weight to a

certain position, lift and move it to a proper
place for mounting later.
Fig. 4-84
9. Use slings to connect the boom tooling

and the heavy forklift. Move the truck to
drag the tooling out. Put a cushion wood at
falling suddenly.
Fig. 4-85

10. After dragging the boom and pitching

cylinder to a certain position, lift and move
the pitching cylinder to a proper place for
mounting later.
Fig. 4-86
11. Disassemble the bolts on the boom tooling,

and move the boom out from the tooling to
a proper place for mounting later.
Fig. 4-87
12. Lift the main body with a crane of 50T, and

put it in a proper place.
Fig. 4-88
4.6.3.5 Loading the machine
The process of loading the machine reverses

that of unloading it. (For detailed information,
see: “Unloading the machine” on page 4-63).
Pay particular attention when loading the
machine.

4.6.4 Assembly and disassembly

preparations
This manual provides information needed

for the safe assembly and disassembly of
container reach stacker. All personnel involved
in this operation must abide by all safety
instructions set forth by SANY.
Major parts in below figure will be assembled

and disassembled:
5
2
1. Rear counterweight 4. Boom

2. Sliding counterweight 5. Spreader
3. Pitching cylinder 6. Lights
Fig. 4-89

4.6.4.1 Safety precautions
Always obey the following rules in order

to avo i d e q ui p m e nt d a m a g e, p ote nt i a l
injury or possible death when assembling,
disassembling and operating this container
reach stacker:
• Only trained personnel shall per form

assembly / disassembly on container reach
stacker.
• All the operations must be well planned
in advance and carefully conducted in
the same order explained in this chapter
(unless otherwise described).
• The operator and super visor of this
machine have the responsibility to ensure
that the auxiliar y loading / unloading
devices (ropes, hook rings or slings) have
sufficient load-bearing capacity.
• All fasteners must meet the proper torque
specification. The plugs of electrical
system must be clean, dry, and free of any
oil.
• Always beware of the stability of this
machine. Always keep it even and on solid
ground. Avoid serious crushing injury by
warning all personnel to stand clear of the
machine.
• Never c limb on the c ont ainer reac h
stacker’s railing or boom. If the access
is required, use a ladder to reach the
location. If the location is out of your reach,
an approved OSHA lifting device must be
used. Wear a safety harness to avoid a
falling hazard and observe all applicable
safety regulations.
• O nly w hen t he mac hine is prop er ly
attached to the assembled / disassembled
component can an installation procedure
be deemed as completed. Before the
completion, no personnel shall enter the
area exposed to a potential risk of a falling
load.

4.6.4.2 Requirements for crew members
• When working near moving parts, the

o p e r a t o r, a s s e m b l y p e r s o n n e l a n d
supervisor must take preventive measures
to avoid accidents or injury.
• The assembly / disassembly personnel
must maintain communication at all times
with the operator of lifting device. For
detailed information, see: “Hand signals”
on page 2-20.
• All crew members must leave the area of
reach stacker before the counterweights,
boom or spreader are lifted or lowered.
• Unauthorized personnel are prohibited
from approaching the assembly /
disassembly area of reach stacker.
4.6.4.3 Tools for assembly and disassembly
Following tools are needed for the assembly

and disassembly of reach stacker:
• A mobile crane of 50t.

• A forklif t of 12t with trailing plate or
platform.
• An elevator
• Four slings of 15t, four slings of 3t and four
shackles of 15t (or above).
• One chain hoist of 3t.
• Several safety belts and helmets, oil barrel,
cloth and accessories.

4.6.4.4 Assembly alerts of the components
• Check each component for damage before

assembling.
• All the major components are equipped
with designated hoisting points which must
be used in the assembly procedures. If
no hoisting point is indicated, nylon slings
must be used especially on the boom
and spreader. Always use protective pads
(such as rubber or wood) when using steel
cables or chains.
• After finishing the assembly, verify that all
procedures have been completed.
NOTICE
NOTICE
The hoisting of components demands

special care to avoid damage to
components and to the reach stacker.
There are hoisting lugs on each component
which can maintain the load balance and
prevent damage in the process.
4.6.4.5 Hoisting points of parts
Label, hoisting point:

Please choose suitable hoisting points before
using a hoisting equipment.
NOTE:
It is the container reach stacker owner’s
responsibility to ensure all hoisting chain
cables, hangers and hook blocks are in safe
condition and with sufficient capacity rating to Fig. 4-90 Hoisting Point Label
hoist the attached load.

1. Hoisting points of main body
There are 4 hoisting points on the main body,

each two at both sides of machine (position 1
and position 2 in Fig. 4-91).
2
1
Fig. 4-91 Hoisting Points of Main Body
1 2 3 4
2. Hoisting points of cab
There are 4 hoisting points on the cab, all at

the top of cab (position 1, 2, 3, 4 in Fig. 4-92).
Fig. 4-92 Hoisting Points of Cab

3. Hoisting points of boom

There are 6 hoisting points on the boom, each
three at both sides of boom (position 1, 2 and
3 in Fig. 4-93).
2
3
Fig. 4-93 Hoisting Points of Boom
4. Hoisting points of spreader

There are 4 hoisting points on the spreader;
each two at both sides of spreader (position 1
and position 2 in Fig. 4-94).
1
2
Fig. 4-94 Hoisting Points of Spreader

4.6.5 Assembly
4.6.5.1 Prepare the work area
1. Choose a work area with enough space

around the c ont ainer reac h st ac ker
for components, auxiliary cranes and
scaffolding / work platforms.
NOTE:
The work area must be large enough to
contain the machine body, cylinders, boom,
spreader, boxes of smaller parts and the lifting
equipment.
2. Lift the main body of container reach

stacker to a designated work area, and get
ready to begin the assembly process.
3. The container reach stacker must keep

horizontal and level.
WARNING
WARNING
Do not move the container reach stacker

onto a surface or area that has not been
approved for the machine. The container
reach stacker is heavy and could possibly
break the soft ground, causing damage to
the machine. This could result in injury or
possibly death.

4.6.5.2 Rear counterweight, installation
1. C l e a r t h e a r e a b e h i n d w h e r e t h e
counterweight will be installed (1).
Fig. 4-95
2. Prepare the following parts for assembly:
• position 2: Rear counterweight
• position 3: Shims
• position 4: Hardware 2
NOTE:
The rear counterweight weighs 5.7 ton.
WARNING
WARNING
3
Use an appropriate lifting device. Failure to
follow this warning could result in serious 4
injuries or death.
Fig. 4-96
3. Lift the rear counterweight (2) into place

and line up the assembly holes.
WARNING
WARNING
Do not stand or place arms between the

rear counterweight and the reach stacker
when lining up the assembly holes. Failure
to follow this warning could result in
serious injuries or death.
2
Fig. 4-97

4. Install the shims (3) and hardware (4) with

a torque of 1600 +10 Nm.
NOTE: 5
Make sure the shims are lined up evenly with
the frame (5).
Fig. 4-98
4.6.5.3 Sliding counterweight, installation
1. Prepare the following parts for assembly:
• position 1: Sliding counterweight

• position 3: Large locking plate
• position 4: Small locking plate 1
• position 5: Hardware
NOTE:
The sliding counterweight weighs 14.6 ton.
WARNING
WARNING
4 3 2 5
Use an appropriate lifting device. Failure to Fig. 4-99
follow this warning could result in serious
injuries or death.

2. Cut and remove the wire (6) holding the

sliding cylinder (7) in place.
Fig. 4-100
3. Clean the protective grease off the sliding

surfaces (8).
Fig. 4-101
4. Lift the sliding counterweight (1) into place.
WARNING
WARNING
Do not stand or place ar ms bet ween

the sliding counterweight and the reach 1
stacker when lining up the assembly holes.
Failure to follow this warning could result
in serious injuries or death.
Fig. 4-102

5. Set the large locking plate (9) on top of the

sliding cylinder in preparation for installing
the underside of sliding counterweight.
Fig. 4-103
6. Place the shims (10) on top of the large

locking plate (9) and hold them in position.
10
7. Install the hardware with a torque of 1600
9
+10 Nm.
8. Install the small locking plate and the

hardware with a torque of 1600 +10 Nm.
Fig. 4-104
9. Put the sliding cylinder bracket (11) in place

and install the hardware (12).
12
10. Repeat steps 5-9 on the other side.
11
Fig. 4-105

4.6.5.4 Pitching cylinder, installation
1. Remove the cover (1) from both sides in

preparation to put the pitching cylinder in
place.
NOTE:
The pitching cylinder weighs 1.2 ton.
1
WARNING
WARNING

injuries or death.
Fig. 4-106
2. Lower the pitching cylinder (2) in place.
2
WARNING
WARNING
Do not place fingers between the cylinder

and the reach stacker when lining up the
assembly holes. Failure to follow this
warning could result injuries.
Fig. 4-107
3. Install the locking pin (3).
Fig. 4-108

4. Set the locking pin (3) completely in place

and install the hardware (4).
Fig. 4-109
5. Fasten a support (5) to hold the pitching

cylinder in place.
WARNING
WARNING 5
Use an appropriate suppor t method.

Failure to follow this warning could result
in serious injuries or death.
Fig. 4-110
Fig. 4-111

4.6.5.5 Boom, installation
WARNING
WARNING
Use appropriate man-lift or ladder, safety

harness and other safety gear. Failure to
injury or death.
Rear Support
1. Lift the boom (1) to be above the rear

support (2).
NOTE: 1
The boom weighs 17.3 ton.
WARNING
WARNING
2
injuries or death.
Fig. 4-112
2. Lower the boom onto the rear support (2).
WARNING
WARNING
Do not place fingers between the boom

2
Fig. 4-113

3. Line the holes (3) up to receive the locking

pins.
Fig. 4-114
4. Install the locking pin (4) on each side,

move it all the way in, and install the
hardware through holes (5).
Fig. 4-115
Lift Cylinder Support
1. Lower the boom onto the pitching cylinder

(1).
2. Install the gasket (2) on both sides of the

pitching cylinder. 2
WARNING
WARNING

and the reach stacker when lining up the 1
warning could result injuries. Fig. 4-116

3. Install the locking pin (3) and hardware (4).
4. Repeat steps 1 and 2 on the other side.
3 4
Fig. 4-117
Lift Cylinder Hydraulics
1. Obtain the valve block (1), short hose (2)

and long hose (3) for each cylinder (4).
4
5
1
3
Fig. 4-118

2. Remove the end cap from the hose (5)

and allow the hydraulic oil to drain into a
container.
5
Fig. 4-119
3. Remove the protective plate (6).
Fig. 4-120
4. Install the valve block (1) and tighten the

mounting hardware (7).
Fig. 4-121

5. Inst all the hose (5) and tighten the

mounting hardware.
Fig. 4-122
6. Remove the protective plates (8).
Fig. 4-123

7. Remove the protective cap (9).
NOTE:
Place a container under the fittings to collect
the hydraulic oil.
Fig. 4-124
8. Connect the long hose (3) to the outside

fitting (10).
10
Fig. 4-125

9. Connect the long hose (3) to the valve

block (1).
Fig. 4-126
10. Install the short hose (2) to the inside fitting

(11) and valve block (1).
11
Fig. 4-127

11. Install the electrical connectors (12, 13).
12
13
Fig. 4-128
12. Install the cover (14).
14
Fig. 4-129

Left Side Boom Hoses
1. Connect the bottom hose (1).
NOTE:
Place a container under the hose ends to
collect the hydraulic oil.
Fig. 4-130
2. Connect the hydraulic hoses (1, 2, 3, 4).
NOTE: 6
Place a container under fittings to collect the 5
hydraulic oil.
3. Connect the lubrication hoses (5, 6).
4
34
2 1
Fig. 4-131
Right Side Boom Hoses and Cables
1. Connect the hydraulic hoses (1, 2, 3).
NOTE:
Place a container under the hose ends to 1
2. Connect the electric cables (4, 5). 2
4 3
5
Fig. 4-132

3. Connect the lubrication hose (6).
Fig. 4-133
4.6.5.6 Spreader, installation
WARNING
WARNING

injury or death.
4
1. Prepare to lift the spreader (1) into place at
the boom head (4).
NOTE:
The spreader weighs 7.8 ton.
WARNING
WARNING
1
follow this warning could result in serious 9
injuries or death.
Fig. 4-134
NOTE:
After the spreader is attached to the boom
and all hoses are connected, use the controls
in the cab to release the transport frame (9).

2. Use the pins (2, 3) and attaching hardware

to fasten the spreader (1) in place.
3
Fig. 4-135
3. Connect the hydraulic hoses (5, 6, 7)

between the spreader and the boom head.
55
6
7
Fig. 4-136

4. Connect the electrical cable (8) between

the spreader and the boom head.
Fig. 4-137
5. Support the spreader transport frame (9)

to prevent it from dropping to the ground.
6. Unlock the spreader transport frame (9)

from the spreader.
92
Fig. 4-138
4.6.5.7 Lights, installation
1. Prepare each light for installation.
Fig. 4-139

2. Install the lights (1) on both sides of the

sliding counterweight.
Fig. 4-140
3. Install the lights (2) on both of the boom

supports.
Fig. 4-141

4. Install the lights (3) on the underside of the

boom.
Fig. 4-142
5. Install the lights (4) in the front of the reach

stacker.
Fig. 4-143

4.6.5.8 Final check
WARNING
WARNING

injury or death.
Before the reach stacker is put into operation,

the following items must be checked. Refer
to this manual for the correct operating
procedures.
• Lights
• Boom
• Spreader
Fig. 4-144
• Sliding counterweight
• Fluid levels
• Grease
• Torques

4.6.6 Disassembly
4.6.6.1 Prepare the work area
1. Drive the container reach stacker to a

designated work area ready to begin the
disassembly process.
2. Keep the machine level and on solid
surface.
NOTE:
The container reach stacker weighs 74 ton.
NOTE:
The work area must be large enough to contain
the container reach stacker, lifting cylinder,
boom, spreader, counterweights, cases of
smaller parts and the lifting equipment for the
disassembly process outlined in this section of
the manual.
WARNING
WARNING
Do not move the container reach stacker

onto a surface or area that has not been
approved for the machine. The container
reach stacker is heavy and could possibly
break the soft ground, causing damage to
the machine. This could result in injury or
possibly death.

4.6.6.2 Lights, removal
1. Remove the lights (1) from both sides of

the sliding counterweight.
Fig. 4-145
2. Remove the lights (2) from both of the

boom supports.
Fig. 4-146

3. Remove the lights (3) from the underside

of the boom.
Fig. 4-147
4. Remove the lights (4) from the front of the

reach stacker.
Fig. 4-148

4.6.6.3 Spreader, removal
WARNING
WARNING

injury or death.
1. Lock the spreader transport frame (9) to

the spreader.
2. Support the spreader transport frame (9)

to prevent it from dropping to the ground.
92
Fig. 4-149
3. Disconnect the electrical cable (8) between

the spreader and the boom head.
Fig. 4-150

4. Disconnect the hydraulic hoses (5, 6, 7)

between the spreader and the boom head.
55
6
7
Fig. 4-151
5. Loosen the pins (2, 3) and the attaching

hardware on the spreader (1).
3
Fig. 4-152

6. Separate the spreader from the boom.
7. Lift the spreader (1) into place away from

the boom head (4).
NOTE:
The spreader weighs 7.8 ton. 4
WARNING
WARNING

injuries or death.
Fig. 4-153
4.6.6.4 Boom, removal
WARNING
WARNING

injury or death.
Left Side Boom Hoses

1. Disconnect the lubrication hoses (5, 6).
6
NOTE:
5
Place a container under the hose ends to
2. Disconnect the hydraulic hoses (1, 2, 3, 4).
NOTE:
Place a container under fittings to collect the 4
34
hydraulic oil. 2 1
Fig. 4-154

3. Disconnect the bottom hose (1).
Fig. 4-155
Right Side Boom Hoses
1. Disconnect the lubrication hose (6).
Fig. 4-156

2. Disconnect the electric cables (4, 5).
3. Disconnect the hydraulic hoses (1, 2, 3).
NOTE:
Place a container under the hose ends to 1
4 3
5
Fig. 4-157
Lift Cylinder Hydraulics
1. Remove the cover (14).
14
Fig. 4-158

2. Remove the electrical connectors (12, 13).
12
13
Fig. 4-159
3. Remove the short hose (2) from the inside

fitting (11) and valve block (1).
11
Fig. 4-160

4. Remove the long hose (3) from the valve

block (1).
Fig. 4-161
5. Remove the long hose (3) from the outside

fitting (10).
10
Fig. 4-162

6. Install the protective cap (9).
NOTE:
Place a container under the fittings to collect
the hydraulic oil.
Fig. 4-163
7. Install the protective plates (8).
8. Remove the hose (5) and loosen the Fig. 4-164

mounting hardware.
Fig. 4-165

9. Remove the valve block (1) and loosen the

mounting hardware (7).
Fig. 4-166
10. Install the protective plate (6).
Fig. 4-167
11. Install the end cap to the hose (5) and

allow the hydraulic oil to drain into a
container.
5
Fig. 4-168

12. Collect the valve block (1), short hose (2)

and long hose (3) for each cylinder (4).
4
13. Repeat steps 1-12 for the other side. 5
1
3
Fig. 4-169
Lift Cylinder Support
1. Remove the locking pin (3) and hardware

(4).
3 4
Fig. 4-170

2. Remove the gasket (2) on both sides of the

pitching cylinder.
WARNING
WARNING
2
1
Fig. 4-171
3. Lift the boom away from the pitching
cylinder (1).
4. Repeat steps 1 and 2 on the other side.
Rear Support
1. Remove the locking pin (4) on each side,

move it all the way out, and remove the
hardware from holes (5).
Fig. 4-172

2. Lif t the boom (1) away from the rear

support (2).
NOTE:
The boom weighs 17.3 ton. 1
WARNING
WARNING
Use an appropriate lifting device. Failure to 2

injuries or death.
Fig. 4-173
4.6.6.5 Pitching cylinder, removal
1. Release the support (5) which holds the

pitching cylinder in place.
Fig. 4-174

2. Remove the hardware (4).
3. Remove the locking pin (3).
WARNING
WARNING

Fig. 4-175
4. Lift the pitching cylinder (2) up.
NOTE:
The pitching cylinder weighs 1.2 ton. 2
WARNING
WARNING

injuries or death.
Fig. 4-176
5. Install the cover (1) to both sides of reach

stacker.
Fig. 4-177

4.6.6.6 Sliding counterweight, removal
1. Remove the hardware (12) and put the

sliding cylinder bracket (11) in place.
12
11
Fig. 4-178
2. Remove the small locking plate and the

hardware.
10
3. Remove the hardware.
9
4. Remove the shims (10) from the top of
large locking plate (9).
5. Remove the large locking plate (9) from

the top of sliding cylinder.
Fig. 4-179
6. Lift the sliding counterweight (1) away.
NOTE:
The sliding counterweight weighs 14.6 ton.
WARNING
WARNING 1
injuries or death.
Fig. 4-180

7. C o l l e c t t h e f o l l o w i n g p a r t s a f t e r
disassembly:
• position 1: Sliding counterweight

• position 2: Shims 1
• position 3: Large locking plate
• position 4: Small locking plate
4 3 2 5
Fig. 4-181
4.6.6.7 Rear counterweight, removal
1. Remove the shims (3) and hardware (4).
Fig. 4-182

2. Lift the rear counterweight (2) away.
NOTE:
The rear counterweight weighs 5.7 ton.
WARNING
WARNING

injuries or death.
Fig. 4-183
3. Collect the following parts for assembly:
• position 2: Rear counterweight

2
Fig. 4-184

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A
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P
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K
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N
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A
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L
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B
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Container Reach Stacker Maintenance
Maintenance
5. Maintenance
5.1 Scheduled Maintenance, General Information �� 5-7
5.2 General Tightening Torques ��5-11
5.3 Recommended Fuel, Coolant and Lubricant��5-12
5.3.1 Specification��5-12
5.3.2 Capacity of the tanks��5-13
5.3.2.1 C-type / SRSC4535 container reach stackers��5-13
5.3.2.2 SRSC4545C container reach stacker��5-13
5.3.2.3 SRSC3515-3 container reach stacker��5-14
5.3.2.4 SRSC1009-6E container reach stacker��5-14
5.3.3 Application principle ��5-14
5.3.4 Hydraulic oil, description��5-16
5.3.5 Quality of hydraulic oil, check��5-17
5.4 Lubricating Points��5-18
5.4.1 Lubricant��5-18
5.4.2 Lubricating points of whole machine��5-19
5.4.3 Lubricating points of engine and gearbox�� 5-21
5.4.4 Lubricating points of drive axle�� 5-22
5.5 Scheduled Maintenance�� 5-23
5.5.1 Maintenance every day�� 5-23

Maintenance Container Reach Stacker

5.6 Engine�� 5-30
5.6.1 General engine inspection �� 5-30
5.6.2 Charge air pipe, checking�� 5-31
5.6.3 Drive belt, checking�� 5-31
5.6.4 Generator belt, replacing �� 5-32
5.6.5 Drive belt, replacing �� 5-33
5.6.6 Air filter, checking / changing�� 5-34
5.6.7 Air filter, cleaning�� 5-35
5.6.8 Lubrication system�� 5-36
5.6.8.1 Engine oil, changing �� 5-36
5.6.8.2 Oil filter / Bypass filter, changing �� 5-37
5.6.9 Cooling system�� 5-38
5.6.9.1 Coolant, mixing�� 5-39
5.6.9.2 Water quality�� 5-40
5.6.9.3 Coolant level, checking�� 5-40
5.6.9.4 Coolant, filling�� 5-41
5.6.9.5 Coolant, draining�� 5-42
5.6.9.6 Coolant filter, changing�� 5-43
5.6.9.7 Radiator, cleaning�� 5-43
5.6.9.8 Radiator fan, checking�� 5-44
5.6.9.9 Fan hub, checking�� 5-44
5.6.9.10 Cooling system, cleaning�� 5-45
5.6.10 Fuel system�� 5-47
5.6.10.1 Fuel filter, replacing �� 5-47
5.6.10.2 Diesel filter, changing �� 5-48
5.6.10.3 Oil-water separator with water monitor, replacing�� 5-48
5.6.10.4 Oil-water separator, draining�� 5-49
5.6.10.5 Fuel system, bleeding �� 5-50
5.6.11 Inlet system, checking leakage �� 5-51
5.6.12 Attaching bolts of engine seat, checking �� 5-52
5.6.13 Shock absorber, checking�� 5-52
5.6.14 Turbocharger and blast pipe, checking�� 5-53
5.7 Transmission�� 5-54
5.7.1 Gearbox, function description�� 5-54

5.7.2 Attaching bolts of transmission shaft, checking��5-54

5.7.3 Speed sensor, checking��5-55
5.7.4 Attaching bolts and fixed seat, checking��5-55
5.7.5 Transmission shaft, lubricating��5-56
5.7.6 Gearbox oil, changing��5-57
5.7.7 Gearbox oil level, checking��5-58
5.7.8 Gearbox oil filter, changing��5-58
5.8 Drive Axle��5-59
5.8.1 Attaching bolts of drive axle to the frame, checking��5-59
5.8.2 Attaching bolts of drive axle to the transmission shaft, checking��5-59
5.8.3 Oil leakage of drive axle and brake components, checking��5-59
5.8.4 Drive axle oil, changing��5-60
5.8.5 Breather connector, cleaning��5-61
5.8.6 Brake pedal, checking and adjusting��5-62
5.8.7 Parking brake pads, changing��5-62
5.8.8 Brake oil filter, changing��5-63
5.9 Steering Axle��5-64
5.9.1 Daily check��5-64
5.9.2 Steering axle, lubricating��5-65
5.9.3 Steering knuckle, maintaining��5-65
5.9.4 Steering axle cradle, checking��5-66
5.9.5 Steering pressure, checking��5-66
5.10 Tyres and rims��5-67
5.10.1 Tyre, description��5-67
5.10.2 Tyre, inflating��5-69
5.10.3 Tyres, checking�� 5-70
5.10.4 Wheel rim, description�� 5-70
5.10.5 Rim, checking�� 5-71
5.10.6 Wheel rim, installing and removing�� 5-73
5.10.6.1 Wheel rim, installing�� 5-73
5.10.6.2 Wheel rim, removing�� 5-74
5.10.7 Tyre, removing and installing (drive axle)�� 5-75
5.10.7.1 Tyre of drive axle, removing�� 5-75
5.10.7.2 Tyre of dirve axle, installing�� 5-76
5.10.8 Tyre, removing and installing (steering axle)�� 5-77
5.10.8.1 Tyre of steering axle, removing�� 5-77

5.10.8.2 Tyre of steering axle, installing��5-78

5.11 Boom�� 5-79
5.11.1 Basic boom, checking�� 5-80
5.11.2 Sliding blocks, checking�� 5-81
5.11.3 Sliding blocks of the fixed arm, replacing�� 5-82
5.11.4 Sliding blocks of the telescopic arm, replacing�� 5-82
5.11.5 Pitching cylinder, checking�� 5-83
5.12 Spreader�� 5-84
5.12.1 SANY / ELME spreader�� 5-84
5.12.1.1 Twistlock, checking�� 5-84
5.12.1.2 Twistlock, lubricating�� 5-85
5.12.1.3 Sensor / Indicator of twistlock, checking�� 5-85
5.12.1.4 Fixed bolts of spreader rotating gearbox, checking�� 5-86
5.12.1.5 Sliding blocks of spreader, checking�� 5-86
5.12.2 BROMMA spreader�� 5-88
5.12.2.1 General precautions�� 5-90
5.12.2.2 After 50 hours�� 5-90
5.12.2.3 After 250 hours�� 5-91
5.12.2.4 After 500 hours�� 5-91
5.12.2.5 After 1000 hours�� 5-91
5.12.2.6 After 2000 hours�� 5-92
5.12.2.7 After 4000 hours�� 5-92
5.12.2.8 After 8000 hours�� 5-92
5.13.1 General recommendations �� 5-93
5.13.2 Air conditioning, checking / performance test�� 5-94
5.13.3 Refrigerant quantity, checking �� 5-95
5.13.4 Refrigerant, filling�� 5-96
5.13.5 Cleanness of heat-exchanger plate in evaporator and condenser, checking 5-97
5.13.6 Leakage or lack of oil in condenser, checking�� 5-97
5.13.7 Radiator, cleaning�� 5-98
5.13.8 Maintenance table for air conditioner�� 5-98
5.14 Hydraulic System��5-100
5.14.1 Hydraulic oil level, checking��5-100
5.14.2 Hydraulic oil filter, changing��5-100
5.14.3 Hydraulic oil, changing��5-101

5.14.4 Oil return filter element, replacing��5-102

5.14.5 Hydraulic oil tank, cleaning��5-103
5.14.6 Parking brake unit, checking and adjusting��5-104
5.14.7 Accumulator��5-105
5.14.7.1 Brake system accumulator, checking��5-105
5.14.7.2 Accumulators, charging with nitrogen gas��5-106
5.14.8 Hydraulic oil circuit, checking��5-108
5.15 Electrical System��5-109
5.15.1 Battery�� 5-110
5.15.1.1 Battery, cleaning�� 5-110
5.15.1.2 Electrolyte, filling�� 5-111
5.15.1.3 Battery, checking�� 5-112
5.15.1.4 Battery, charging�� 5-112
5.15.1.5 Battery, using�� 5-114
5.15.1.6 Battery cables, checking�� 5-115
5.15.1.7 Battery, scheduled maintenance �� 5-116
5.15.2 Fuses, changing��5-116
5.15.3 All working lights and indicators, checking �� 5-117
5.15.4 Wiper, adjusting�� 5-117
5.15.5 Wiper, replacing�� 5-118
5.16 Maintenance Record List�� 5-119

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

5. MAINTENANCE
5.1 Scheduled Maintenance,

General Information
Do not perform any maintenance or repair not

authorized in Safety, Operation & Maintenance
Manual of this machine. Always obser ve
and follow all safety precautions and use the
proper tools when performing 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 required maintenance schedule listed in
this manual.
GENUINE SANY QUICK-WEAR PART

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

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

Use automotive windshield washer fluid only.
Do not mix impurities 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 filters for
signs of metal particles and impurities. Re-
port to the man in charge if any abnormality is
found in the filter or oil.

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

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

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

checking the machine or changing oils.

• Frequently clean the radiator fins and other
heat-exchanger parts to avoid clogging.
• Clean or replace the fuel filter and air filter
frequently.
• Check and clean any electrical
components especially the start 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 other components.
INSTALLATION OF HYDRAULIC TUBE

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

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

CLEANING PARTS OF THE MACHINE

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

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

stopped)
• Be sure you have completed all the steps
in the maintenance or repair of the machine
you have worked on.
• Check if ever y item is examined and
maintained correctly.
• Check if some 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 General Tightening Torques
CAUTION
CAUTION
If the nuts, bolts or other parts are not

tightened to regulated torques, loose or
damaged parts would result in machine
malfunction or operation failures.
Pay particular attention when tightening
parts.
Before starting the machine, please carefully

check critical bolts for tightness. Loose bolt
has a great possibility to result in dramatic
vibration of the machine, component damage
or weakened function of bolts, etc.
Periodical check can avoid unexpected results.
The following bolts must be checked:
Table 5-1 Recommended Tightening Torque of Bolts on Main Components
Bolt Recommended tightening torque(N·m)

Attaching bolts of engine 830
Attaching bolts of transmission case 210
Bolts coupling engine and transmission case 72
Bolts coupling transmission shaft and drive axle 65
Attaching bolts of drive axle 1600
Attaching bolts of steering cylinder 475±10
Attaching bolts of upper and lower counterweights 1600±10
Nuts of drive axle pressure plate 450
Nuts of steering axle pressure plate 550

5.3 Recommended Fuel, Coolant

and Lubricant
5.3.1 Specification
Fuel, hydraulic oil, and coolant recommend

by SANY in this manual must be used. The
quality and quantities of all functional liquids
should be periodically checked. Only when
their quality and quantities are up to standard
can the machine be started to work.
Table 5-2 Oil Specifications
Filling Position Type of Oil Name of Oil

Antiwear hydraulic oil Azolla 68 (Hot )
Hydraulic oil tank Hydraulic oil Antiwear hydraulic oil ZS 46 (Summer)
Antiwear hydraulic oil VG32T (Winter)
GL-5 80W/90
Drive axle
Gear oil GL-5 85W/140 (≥30°C)
Spreader reducer GL-5 80W/90
Brake oil tank Brake oil Hydraulic oil ZS 46 (94%) + additive LZ9990A (6%)
CH-4 (or CI-4) 10W-30
Torque converter Transmission Oil
Transmission oil DEXRON-III
Engine oil CH-4 (or CI-4) 15W-40
Coolant VOLVO VCS coolant (yellow)
Engine
Light diesel 0# (Summer)
Diesel
Light diesel -20# (Winter)
Lubrication Grease 2# or General lithium-based grease
NOTE:
Oils produced by different manufacturers
have different properties. So use the oils
recommended by SANY.
Be sure to drain out all the remained oil in tank
before filling in new oils.

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

reference.
Oil level indicator is installed on the side of oil
tank for oil level checking.
5.3.2.1 C-type / SRSC4535 container reach

stackers
Table 5-3 Oil Capacity Table
Items Capacities (unit: L)

Hydraulic oil tank 1200
Fuel tank 650
Brake oil tank 220
Engine oil 40
Engine coolant 50
Gearbox and torque converter 65
Main reducer of drive axle 73.5
Hub reducer 2 X 11
5.3.2.2 SRSC4545C container reach stacker


Fuel tank 740
Brake oil tank 250
Engine oil 40
Engine coolant 50
Main reducer of drive axle 37.9
Hub reducer 2 X 12.4

5.3.2.3 SRSC3515-3 container reach

stacker

Fuel tank 500
Brake oil tank 220
Engine oil 30
Engine coolant 35
Main reducer of drive axle 55
5.3.2.4 SRSC1009-6E container reach

stacker

Fuel tank 510
Brake oil tank 220
Engine oil 30
Engine coolant 45
Main reducer of drive axle 55
5.3.3 Application principle
The application temperature of brake oil and

hydraulic oil should be not higher than 80ºC.
NOTICE
NOTICE
Never replace oil with that of other types,

or machine damage could be resulted.
NOTE:
Be sure to warm up the machine when the
ambient temperature is lower than 0ºC.

Change intervals:
• The brake oil should be changed after 50
hours of running-in for the first time. After
500 hours, it should be changed again and
then every 1000 hours.
• The hydraulic oil should be changed after
50 hours of running-in and then every
2000 hours.
Their applications should comply with the

following principles:
Germany, Sweden, American, Australia,

etc.
• Diesel: -35# diesel
• Engine oil: CH-4 10W-30
• Gearbox oil: Donax TD 5W-30
• Drive axle oil: Spirax A GL-5 80W/90
• Brake oil: hydraulic oil 32T# + additive
LZ9990A, confected by 5.8%~6.5%
• Hydraulic oil: hydraulic oil 32T#
Southeast Asian, Brazil, New Zealand, etc.

• Diesel: 0# diesel
• Engine oil: CH-4 (or CI-4) 15W-40
• Brake oil: hydraulic oil ZS 46 + additive
• Hydraulic oil: hydraulic oil Azolla 68 or ZS
46
Torrid Zone such as Africa, the Mid East,

etc.
• Diesel: 0# diesel
• Engine oil: CH-4 (or CI-4) 15W-40
(≥30°C)
• Brake oil: hydraulic oil ZS 46 + additive
• Hydraulic oil: hydraulic oil Azolla 68

Cold area (ambient temperature is lower

than -25ºC), Russia, Canada
• Diesel: -50# diesel or -30# diesel mixed
with kerosene of good quality
• Engine oil: CH-4 10W-30
• Brake oil: hydraulic oil 32T# + additive
• Hydraulic oil: hydraulic oil 32T#
5.3.4 Hydraulic oil, description
Hydraulic oil, a vital part of hydraulic system,

is used to realize the transition and control of
power. It is rust-proof and anti-corrosive, able
to lubricate and cool the system.
The cleanness of hydraulic oil can influence
the performance of hydraulic system and
service life of hydraulic components. Besides,
it directly determines whether the hydraulic
system would work normally.
This mac hine adopts VG 4 6T anti - wear
hydraulic oil. Check the hydraulic oil in tank
every half year with the means of visual
inspection and oil analysis.
The malfunction of hydraulic system is mainly
due to the bad management of hydraulic
oil. Therefore, make sure to improve the
management of hydraulic oil:
• Do not mix 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 dismantled.

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

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

quality on the spot:
Table 5-7 Evaluation Method of Oil Quality
Color Odor Pollution Status Measures

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

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

5.4 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 wearing. Lubricant is an absolutely
necessary lubricating material for the normal
operation of engine.
This machine should adopt EP2 grease. Never

use lubricants not specified by SANY.
Application method of lubricants (grease):

Please c lean 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
on it and apply grease on the contact surface
of sliding block.

5.4.2 Lubricating points of whole

machine
The movable connecting shafts, boom and

spreader are key positions to be lubricated.
Refer to below figure and table for details.
Fig. 5-1 Lubricating Points for Whole Machine

Table 5-8 Lubricating Points of Whole Machine (Corresponded to Fig. 5-1)
No. Position Number Oil brand Oil change intervals

1 Steering axle 13
Lower hinge supporting point of
2 2
pitching cylinder
3 Lubricating pump 4
4 Lubricating block of telescopic boom 14
5 Telescopic surface of spreader 6
6 Hinge of spreader and boom 2
7 Damping cylinder lug of spreader 4
Grease EP2 60 h or weekly
8 Side-shifting cylinder lug of spreader 4
9 Side-shifting surface of spreader 4
10 Telescopic cylinder lug of spreader 4
11 Twistlock of spreader 8
Upper rotary platform slewing bearing
12 4
of spreader
13 Transmission shaft 3
14 Parking brake 1
CG-4 15W40 (>-10℃ )
15 Diesel engine 1 250 h
CG-4 15W30 (<-10℃ )
16 Brake oil tank 1 Donax TD5W-30 1000 h or 1year
17 Hub reducer of drive axle 2 VG150 (>0℃ ) 1000 h or 1year
18 Differential of drive axle 1 VG150 (>0℃ ) 1000 h or 1year
VG32T (<0℃ )
19 Hydraulic tank 1 VG46 (0℃ -30℃ ) 2000 h or 1year
VG68 (>30℃ )
20 Torque converter 1 Donax TD 5W-30 2000 h or 1year
VCS coolant (specific for
21 Engine radiator 1 VOLVO) 1 year
Anti-freezing fluid

5.4.3 Lubricating points of engine and gearbox
2 1
4 3
5 6 7 8
1. Engine oil dipstick 5. Fuel filter

2. Engine oil filler opening 6. Gearbox oil
3. Engine oil filter 7. Gearbox oil dipstick
4. Coolant filter 8. Gearbox oil filter
Fig. 5-2 Lubricating Points for Engine and Gearbox

5.4.4 Lubricating points of drive axle
A
X X
B B
X X
10
A B X–X 5 6
1
4
2
3 8 7
1. Differential oil inlet / Oil level detection opening 6. Brake pressure-measuring point
2. Planet gear oil inlet / Oil level detection opening 7. Oil outlet of wet-type disc brake
3. Oil outlet 8. Cooling oil outlet
4. Cooling oil inlet 9. Brake hydraulic pressure inlet
5. Ventilation hole of wet-type disc brake 10. Differential oil outlet
Fig. 5-3 Lubricating Points for Drive Axle

5.5 Scheduled Maintenance
5.5.1 Maintenance every day

Table 5-9
System Maintenance Item Reference
Check the drive belt. See “Drive belt, checking” on page 5-31
See “Air filter, checking / changing” on
Check the air filter indicator.
page 5-34
Check the oil-water separator. null
Engine See “Coolant level, checking” on page
Check the coolant level.
5-40
Check the engine oil level. null
See “Radiator fan, checking” on page
Check the engine radiator fan.
5-44
See “Gearbox oil level, checking” on
Check the gearbox oil level.
page 5-58
Check the gearbox for oil leakage. null
Gearbox Check the attaching bolts of transmission See “Attaching bolts of transmission
shaft. shaft, checking” on page 5-54
Check if the attaching bolts and fixed seat is See “Attaching bolts and fixed seat,
loosened. checking” on page 5-55
Steering
Check and tighten the hub bolts. null
Axle
Check the basic boom. See “Basic boom, checking” on page 5-80
See “Sliding blocks, checking” on page
Load Check and lubricate sliding blocks of boom.
5-81
Handling
See “Pitching cylinder, checking” on
Equipment Check the pitching cylinder.
page 5-83
Check the twistlock. See “Twistlock, checking” on page 5-84
Hydraulic Check the hydraulic oil for leakage. null
System Check the hydraulic pipes and connectors. null
Check if all the working lights and indicator See “All working lights and indicators,
Electrical
lights are working normally. checking” on page 5-117
System
Clean the battery. null
Check the tyre pressure. null
Others
Fill in lubricants. null

5.5.2 Maintenance every 50 hours
Table 5-10

See “Oil-water separator, draining” on
Engine Drain the water in oil-water separator
page 5-49
Check the drive axle and brake components See “Oil leakage of drive axle and brake
for oil leakage. components, checking” on page 5-59
Drive Axle
See “Breather connector, cleaning” on
Clean the breather connector.
page 5-61
See “Steering axle, lubricating” on page
Steering Axle Lubricate the steering axle.
5-65
Check the fixed bolts of spreader rotating See “Fixed bolts of spreader rotating
gearbox. gearbox, checking” on page 5-86
Lubricate the bearing of lifting cylinder. null
Load Handling
Lubricate the sliding blocks of boom. null
System
Lubricate the bearings of side -shif ting
null
cylinder.
Lubricate the bearings of telescopic cylinder. null
S e e “A i r c o n d i t i o n i n g , c h e c k i n g /
Check the performance of air conditioner.
performance test” on page 5-94
See “Refrigerant quantity, checking” on
Check the quantity of refrigerant.
page 5-95
See “Leakage or lack of oil in condenser,
Check the air condenser for oil leakge.
checking” on page 5-97
Check the pipeline. null
Air
Check the cables. null
Conditioning
Check if the fixing bolts of air compressor
System null
are tightened.
Check if the fixing bolts of air conditioner are
null
tightened.
See “Cleanness of heat-exchanger plate
Check the cleanness of heat-exchanger
in evaporator and condenser, checking”
plate.
on page 5-97
Check the filter screen of evaporator. null

Table 5-11
Clean the surface of engine. null

Clean the air filter. See “Air filter, cleaning” on page 5-35
Check the inlet system and outlet system See “Inlet system, checking leakage” on page
for air leakage. 5-51
Replace the engine oil. See “Engine oil, changing” on page 5-36
Engine
See “Oil filter / Bypass filter, changing” on
Replace the engine oil filter.
page 5-37
Replace the coolant filter. See “Coolant filter, changing” on page 5-43
Replace the fuel filter. See “Fuel filter, replacing” on page 5-47
Change the diesel filter See “Diesel filter, changing” on page 5-48
Check the attaching bolts of drive axle to See “Attaching bolts of drive axle to frame,
frame. checking” on page 5-59
Check the attaching bolts of drive axle to S e e “A t t a c h i n g b o l t s o f d r i ve a x l e t o
Drive Axle
transmission shaft. transmission shaft, checking” on page 5-59
See “Brake pedal, checking and adjusting”
Check and adjust the brake pedal.
on page 5-62
Check if the steering shaft is worn. null
See “Steering knuckle, maintaining” on page
Check the steering knuckle.
Steering Axle 5-65
See “Steering pressure, checking” on page
Check the steering pressure.
5-66
See “Sensor / Indicator of twistlock,
Check the sensor/indicator of twistlock.
Load checking” on page 5-85
Handling Lubricate the twistlock. See “Twistlock, lubricating” on page 5-85
System See “Sliding blocks of spreader, checking”
Check the sliding blocks of spreader.
on page 5-86
Air Fill the refrigerant. See “Refrigerant, filling” on page 5-96
Conditioning
Clean the radiator. See “Radiator, cleaning” on page 5-98
System
Hydraulic See “Hydraulic oil level, checking” on page
Check the hydraulic oil level.
System 5-100
Clean and tighten the wiring posts. null
Check the cables for tightness. null
Check the movements of emergency stop
Electrical null
device.
System
Check the electrolyte level. null
Check the battery for charging. See “Battery, charging” on page 5-112
Check and adjust the wiper. See “Wiper, adjusting” on page 5-117


Check if the lubrication system is working
Others null
normally.
Table 5-12
Check the charge-air pipes. See “Charge air pipes, checking” on page 5-31
Replace the generator belt. See “Generator belt, replacing” on page 5-32
Replace the drive belt. See “Drive belt, replacing” on page 5-33
Clean the radiator. See “Radiator, cleaning” on page 5-43
See “Oil-water separator with water monitor,
Replace the oil-water separator.
replacing” on page 5-48
Clean the ventilation pipe of crankcase. null
Engine
Replace the air filter. null
Bleed the fuel system. See “Fuel system, bleeding” on page 5-50
Check if the fixed bolts of engine seat is See “Attaching bolts of engine seat, checking”
loosened. on page 5-53
Adjust the valve. null
See “Turbocharger and blast pipe, checking”
Check the turbocharger.
on page 5-53
Replace the gearbox oil filter. See “Gearbox oil filter, changing” on page 5-58
Check the speed sensor. See “Speed sensor, checking” on page 5-55
Gearbox
Check and lubricate the transmission See “Transmission shaft, lubricating” on page
shaft. 5-56
Change the drive axle oil. See “Drive axle oil, changing” on page 5-60
Drive Axle
Replace the brake oil filter. See “Brake oil filter, changing” on page 5-63
Check and tighten the bolts. null
Check the steering axle components. null
Steering Axle
See “Steering axle cradle, checking” on page
Check the steering axle cradle.
5-66
Inflate the tyre. See “Tyre, inflating” on page 5-69
Tyre System
Check the rim. See “Rim, checking” on page 5-71


Check the oil pipes and suppor ting
null
bracket.
See “Hydraulic oil filter, changing” on page
Hydraulic Replace the hydraulic oil filter.
5-100
System
Replace the brake oil filter and brake oil. See “Brake oil filter, changing” on page 5-63
See “Oil return filter element, replacing” on
Replace the oil return filter element.
page 5-102
Check the harness of cab steering
null
mechanism for abnormality.
Electrical Check and fill the electrolyte. See “Electrolyte, filling” on page 5-111
System
Check the cables. See “Battery cables, checking” on page 5-115
Replace the fuses. See “Fuses, changing” on page 5-116
Table 5-13
Replace the gearbox oil. See “Gearbox oil, changing” on page 5-57
Gearbox
Check the manual brake function. null
Change the parking brake pads. See “Parking brake pads, changing” on page 5-62
Drive axle
Check the differential oil. null
Others Clean the whole machine. null

5.5.6 Maintenance 1500 hours
Table 5-14

Check and repair the oil injection nozzle. null
Check and set the charger. null
Engine
Check and set the supercharger. null
Check and adjust the valve opening. null
See “ B r a ke sys t e m a c c u m ul a t o r,
Check the accumulator.
Hydraulic
Check the volume and pressure of hydraulic motor. null
System
See “Hydraulic oil circuit, checking”
Check the hydraulic oil circuit.
on page 5-108
Check the overload control system and adjust it if
Others null
necessary.
Table 5-15

Gearbox Test the gearbox oil. null
See “Hydraulic oil tank, cleaning” on page
Clean the oil tank.
Hydraulic 5-103
System Test the pressure of hydraulic system. null
Replace the hydraulic oil. See “Hydraulic oil, changing” on page 5-101
Electrical
Replace the wiper. See “Wiper, replacing” on page 5-118
System
Clean fuel tank of possible impurities null
Others
Test the pressure of brake system. null

Table 5-16
Clean and adjust the fuel injection pump. null

Clean and adjust the engine fuel injector. null
Check the water pump. null
See “Coolant, filling” on page 5-41 and
Replace the coolant.
“Coolant, draining” on page 5-42
Engine See “Radiator fan, checking” on page
Check the radiator fan.
5-44
Check the fan hub. See “Fan hub, checking” on page 5-44
See “Cooling system, cleaning” on
Clean the cooling system.
page 5-45
See “Shock absorber, checking” on
Check the shock absorber.
page 5-52
See “Wheel rim, installing and
Replace the wheel rim.
removing” on page 5-73
Tyre See “Tyre, removing and installing
Replace the tyre of drive axle.
System (drive axle)” on page 5-75
See “Tyre, removing and installing
Replace the tyre of steering axle.
(steering axle)” on page 5-77
Load
Handling Replace the twistlock. null
System

5.6 Engine
WARNING
WARNING
Always observe the following items to

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

engine compartment a ”visual” inspection
before starting the engine and after operation
when the engine has stopped. This will help
you to quickly realize if something unusual has
happened or is happening.
Check especially carefully for oil, fuel and
coolant leakage, loose screws, worn or loose
drive belts, loose connections or damaged
hoses and wires. The inspection only takes Fig. 5-4 Check Oil Leakage
a few minutes but can mean that serious
service interruptions and costly repairs can be
avoided.
DANGER
DANGER
If you discover a leakage of oil, fuel or

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

5.6.2 Charge air pipe, checking
Inspect the condition of the charge air pipe,

pipe connections and clamps for cracks and
other damages. Change them if necessary.
NOTE:
Tighten the clamps with a torque of 9 ±2 Nm.
Fig. 5-5 Charge Air Pipe
5.6.3 Drive belt, checking
Check and adjustment should be done when

the drive belts are warm.
It should be able to press in the drive belt to

generator for 3-4 mm between the drive belt
pulleys.
3-4mm
The alternator belts and drive belts have
automatic belt tensioners and do not need to
be adjusted. Check the condition of drive belts. Fig. 5-6 Check Belt Tightness
Change them if necessary, refer to “Drive
belt, replacing” on page 5-33.

5.6.4 Generator belt, replacing TAD

3
NOTE: 1
Always replace a transmission belt that seems
worn or is cracked.
1. Switch the main power off and make sure

that the engine has no electrical power. 2
2. Remove the protective grill and the outer
fan ring from around the cooling fan.
3. Remove the protective guards from around
the drive belts.
4. Loosen the inner retaining screw (1) a
couple of turns.
5. Loosen the lock screws (2) so that the Fig. 5 -7 Replace Generator Belt (VOLVO
tightening screws (3) can turn freely. engine)
6. Loosen the tightening screws and remove
the drive belts.
7. Mount the new drive belt and tighten it with
the tightening screws. The play should be
3 mm for new belts and 3-4 mm for old
belts. The play is measured where the
drive belts are at their longest between
pulleys. Tighten the inner retaining screw
and the lock screws.
NOTE:
When the belt’s tensioning mechanism is
tightened, additional tension is applied to the
belt.
8. Replace the protective guards around the

drive belts.
9. Replace the protective grill and the outer
fan ring around the cooling fan.
10. Start the engine and do a functional check.

5.6.5 Drive belt, replacing
1. Disconnect the main power and check

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

5.6.6 Air filter, checking / changing
The engine is equipped with a electronic air

filter indicator. When the indicator (2) turns
red as a warning of pressure drop, the filter
element must be checked and possibly
changed. Reset the indicator after replacing
the filter element.
NOTE:
In continuous operation, the filter should be
checked every 8 hours.
1
2
The air filter element should be replaced
because: Fig. 5-9 Air Filter
• Unclean air filter element would prevent air
from flowing into the combustion chamber,
thus resulting in incomplete combustion.
• For the max. power of engine, sufficient air
is required to support the combustion.
• When the filtration performance of air filter
element is bad, impurities would enter
into the combustion chamber and result
in abnormal abrasion of inner parts of
cylinder.
Replace the safety filter element (1) in the

following situations:
• The main filter element has been replaced
for 5 times;
• Main indicator is still red after the main
filter element is replaced;
• The main filter element has been used for
more than 1 year.

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

air.
2. Pressurize the air to 3 Bar. Put the nozzle
at 5 cm around the filter element and start Fig. 5-10 Cleaning Air Filter
to clean it from the inner to the outer.
3. Never knock the filter element with the
hard surface of nozzle.
NOTE:
Never clean the filter element for more than 6
times. If yes, replace it.

5.6.8 Lubrication system
The oil change intervals can vary between 50

to 600 hours depending on the oil grade and
fuel sulfur content.
NOTE:
The oil change intervals shall never exceed a
period of 12 months.
5.6.8.1 Engine oil, changing
Keep an eye on the engine oil volume while

filling the oil. High engine oil level will cause
foam, decreasing the lubrication effect. And
low level means that engine oil is insufficient
for running through the whole lubrication
system.
CAUTION
CAUTION
Hot oil can cause severe burns.

Oil should be changed while the engine is
warm.
1. Connect the drain hose to the oil bilge Fig. 5-11 Change Engine Oil
pump and make sure that there would be
no leakage.
2. Pump out the oil (or remove the drain plug
and drain the oil).
NOTE:
Collect all the used oil and deliver it to a used
oil collection facility.
3. Remove the drain hose (or replace the

drain plug).
4. Fill with new oil. As to the volume of oil to
be filled, refer to “Capacity of the tanks”
on page 5-13.
Fig. 5-12 Drain Plug

5.6.8.2 Oil filter / Bypass filter, changing
CAUTION
CAUTION
Hot oil can cause severe burns.
1. Clean the oil filter housing.

2. Remove the oil filter (1) with appropriate
filter wrenches.
3. Clean the sealing surface on the filter
Fig. 5-13 Oil Filter (VOLVO engine TAD720VE)
housing, making sure that no gasket
residue remains.
4. Spread a thin layer of engine oil on the
new filter’s sealing rings.
5. Install the new oil filter. The two full-flow
filters should be tightened 1/ 2 to 3 /4 turn
following seal contact. The bypass filter
should be tightened 3/4 to 1 turn following
seal contact.
6. Fill with oil, start the engine and operate it
for 20-30 seconds.
7. Shut down the engine, check the oil level 1
and fill with oil as needed (Tank capacity:
30 - 40L. For detailed information, see:
“Capacity of the tanks” on page 5-13.).
8. Check the seals around the oil filter. Fig. 5-14 Oil Filter (VOLVO engine TAD750VE)
Pay attention to the following points when

replacing the engine oil filter:
Table 5-17 Engine oil Pollution Phenomena
No. Phenomena Causes

Raise of engine Water or coolant enters
1
oil level into the lubricating system
Metal particle in Serious damage of the
2
engine oil shell surface
The piston ring is worn,
Dramatic engine oil enters into 1
3 decrease of combustion chamber and Fig. 5-15 Oil Filter (CUMMINS engine)
engine oil engine oil leaks from the
connection and edge.

5.6.9 Cooling system
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 of fers 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.

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

and ecologically damaging. Shall not be
consumed!
Glycol is flammable.
Ethylene glycol should not be mixed with
other types of glycol.
Mix: Fig. 5-16 Mix Coolant

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

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

Total hardness .................................... < 9.5° dH
Chloride ............................................... < 40 ppm
Sulfate ............................................... < 100 ppm
pH value ................................................. 5.5-9
Silica (acc. to ASTM D859) ..... < 20 mg SiO2/l
Iron (acc. to ASTM D1068) ........... < 0.10 ppm
Manganese (acc. to ASTM D858) ...... < 0.05
ppm
Conductivity (acc. to ASTM D1125) ....< 500
Fig. 5-17 Water
μS/cm
Organic content, CODMn (acc. ISO8467) ......
< 15 mg KMnO4/l
5.6.9.3 Coolant level, checking
CAUTION
CAUTION
1
Do not open the coolant filler cap (1) when
the engine is warm. Steam or hot coolant
can squirt out as pressure is released.
NOTE:
Only open the filler cap (1). Do not open the
pressure cap. Fig. 5-18 Check Coolant Level
The coolant level should be above the MIN

mark. Add coolant as needed according to the
description in “Coolant, filling” on page 5-41.

5.6.9.4 Coolant, filling
1. Coolant level should be between the MAX

and MIN markings on coolant tank when 1
the engine is operating. If the coolant level
is below the MIN marking, it is time to fill
coolant into radiator and cooling water into
the auxiliary water tank.
2. Check the coolant level. If it is too low,
fill the coolant through the filler (1) until it
reaches the MAX marking.
3. Tighten up the cap after filling the coolant.
4. If the tank is empty, coolant leakage Fig. 5-19 Filler
maybe occur. Fix the trouble immediately
after examination. If no problem exists,
check the coolant level in radiator. Fill the
tank if the coolant level is low.
5. Clean the expansion tank when the tank is
too dirty to see the level.
REMARK:
CAUTION
CAUTION
Do not open the radiator cap, unless it is

necessary. Do not fill coolant through the
radiator cap.
After the engine is closed, coolant

temperature and the pressure in radiator
are high. Removing the radiator cap to
check the coolant level at this moment may
lead to personnel scald. Therefore, firstly
loosen the radiator cap 1/4 turn to check
whether the expansion tank is under high
pressure. If yes, open the radiator cap after
the pressure is lowered.

5.6.9.5 Coolant, draining
1. Remove the filler cap (1). 1

2. Open all drain plugs. Drain the coolant
from the radiator and engine cylinder by
using the drain hose. The drain nipples are
situated under the radiator on the right side
of engine cylinder.
3. Check that all coolant drains out. Deposits
may be found inside the drain plug / tap,
and need to be cleared away. There is
otherwise a risk that coolant could remain Fig. 5-20 Filler Cap
and cause frost damage. Check whether
the installation has any further taps or
plugs at the lowest points of the cooling
water pipes.
4. Shut any taps and check that the spring-
loaded c over s on the nipples c lose
completely. Install the rubber plugs.
CAUTION
CAUTION
Stop the engine before draining the cooling

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

5.6.9.6 Coolant filter, changing
1. Turn the tap (1) 90°C to stop the flow

through the coolant filter.
2. Remove the coolant filter with a suitable
extractor. Make sure that no residue from
the old seal remains in the housing.
3. Spread a thin layer of engine oil on the
new coolant filter seal. Screw down the
coolant filter by hand until the seal comes
into contact with the mating surface of filter
bracket. Then tighten the coolant filter a
further ½ turn.
4. Turn the tap 90°C to release the flow
through the coolant filter again.
5. Start the engine and perform a leakage
check.
6. Turn off the engine and check the coolant
level. For detailed information, see:
“Coolant, filling” on page 5-41.
Fig. 5-21 Coolant Filter

5.6.9.7 Radiator, cleaning
Clear away the impurities on the surface of

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

impurities:
1. Remove the radiator cover.
2. Wipe away all the dirt and dust on the
radiator fins.
3. Clean the radiator with special detergent.
4. Check the radiator fins and rubber sealing
parts for damage. If necessary, replace it.
NOTICE
NOTICE Fig. 5-22 Radiator
Never flush the radiator with high-pressure

water. Or the radiator may be damaged.

5.6.9.8 Radiator fan, checking
CAUTION
CAUTION
• Do not start the engine by dragging or

prizing the radiator fan.
• Do not rotate the curve shaft when
working on the radiator fan.
• Do not bend the fan blades.
1
D amaged or bent fan blades can n o t
function normally, even resulting in
personal injuries or property loss.
1. Check the radiator fan everyday.

2. Check if the fan blade (1) is cracked, if the 2
bolts (2) are loose, and if the blade is bent
or loosened.
3. Check the fan and make sure that it is
firmly mounted.
4. If necessary, tighten up the bolts (2). Fig. 5-23 Radiator Fan
5.6.9.9 Fan hub, checking
1. Machine in service position.

2. Remove the drive belt.
3. Check if the fan hub is cracked or rotating
freely.
NOTE:
The fan hub must rotate without wobbling or
excessive length clearance.
4. Seal the fan hub with grease.

Fig. 5-24 Fan Hub
Fan hub length clearance: MAX. 0.15 mm

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

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

information, see: “Coolant, draining” on
page 5-42.
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.
2. Put a hose into the expansion t ank

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 -20 %
mixture of concentrated coolant. Use only
SANY recommended concentrated coolant
mixed with clean water.
NOTE:
It is extremely important that the correct
concentration and volume of coolant is put
in the system. Mix them in a separate clean
vessel before filling the cooling system. Make
sure that the liquids mix.

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

operation.
6. F l u s h t h e sy s t e m i m m e d i a t e l y a n d
thoroughly with clean hot water to prevent
dirt from settling in the inner areas. Flush
until the water that runs out is completely
clean. Make sure that any heater controls
are set to full heating during emptying.
7. If contamination should still be left after
a long period of flushing, you can do a
clean-out with radiator cleaner, followed
by finishing-off with neutralizer. Otherwise,
continue as in item 8 below.
8. When the cooling system is completely
free from contamination, close the drain
taps and plugs.
9. Fill up with SANY recommended coolant,
following the instructions in the chapters
entitled “Coolant, mixing” on page 5-39
and “Coolant, filling” on page 5-41.

5.6.10 Fuel system
5.6.10.1 Fuel filter, replacing
Fuel filter mainly plays the role of filtrating the

fuel. When the filter is clogged, fuel would be
blocked out of the system, highly reducing the
oil supply and engine power. Therefore, it is
important to change the fuel filter in time.
WARNING
WARNING
To avoid the risk of fire due to spilled fuel F i g . 5 - 2 5 Fu e l F i l t e r ( V O LV O e n g i n e

on hot surfaces, please change the fuel TAD720VE)
filter when the engine is cold.
1. Remove the filter.

2. Spread a thin layer of oil on the gaskets of
the new filter.
3. Screw down the filter by hand until the
gaskets just contact the mating surface.
4. Then tighten a further half turn, no more.
NOTICE
NOTICE
Tightening the filter too much would lead

to the deformation of thread or the damage
of filter sealing parts.
F i g . 5 - 2 6 Fu e l F i l t e r ( VO LVO e n g i n e
TAD750VE)
5. Vent the fuel system.
6. Hand the old filter in to an authorized
waste processing facility for destruction.
7. Start the engine and make sure that no
leakage occurs.
1
NOTICE
NOTICE
Do not fill the new fuel filter with fuel

before assembly. There is a risk that
contamination could get into the system 2
and cause malfunctions or damage. 1. Sealing ring 2. Fuel filter
Fig. 5-27 Fuel Filter (CUMMINS engine)

5.6.10.2 Diesel filter, changing
NOTE:
Clogged and unclean filter may prevent diesel
from normally entering into the oil injection
system, which means that the diesel in fire
chamber cannot atomize well. Consequently,
the ef f iciency of engine is about to be
influenced.
1. Clean the area around the diesel filter.

2. Loosen the filter with a suitable filter
remover. Then remove it by hand.
3. Lubricate the seal with diesel and install
the new diesel filter.
4. Screw the filter onto the filter bracket by Fig. 5-28 Diesel Filter (VOLVO engine)
hand until the rubber seal just contacts the
mating surface. Then tighten a further half
turn, no more.
5.6.10.3 Oil-water separator with water

monitor, replacing
1. Clean the area around the separator. 1

2. Disconnect the water monitor (1).
3. Drain the oil-water separator.
4. Use an appropriate filter wrench to remove
the separator.
5. Clean the separator’s sealing surface on
the filter housing.
6. Spread a thin layer of oil on the sealing
ring and mount the new oil-water separator
according to the instructions on the
separator.
7. Connect the water monitor.
8. Start the engine and check for leaks. Fig. 5-29 Water Monitor (VOLVO engine)
NOTE:
If you are not going to change the entire filter
unit with water separator, please move the
water monitor to the new fuel filter.

5.6.10.4 Oil-water separator, draining
NOTE:
Wait a few hours after the engine has been
turned off before draining the separator.
Place a container under the water separator to
receive the condensation water and fuel.
1. Open the drain nipple in the bottom of the

water separator and let the condensation
water run out.
2. Close the drain nipple (2) when water-free
fuel flows out.
3. Start the engine and let the fuel fill the 2
water separator. Let the engine run idle for
10 minutes to discharge the air from the Fig. 5-30 Drain Nipple (VOLVO engine)
fuel system.
4. Shut down the engine and check for leaks.
Fig. 5-31 Drain Nipple (CUMMINS engine)

5.6.10.5 Fuel system, bleeding
1. Clean around the air bleed nipples on the

cylinder head and the fuel filter bracket.
2. Bleed the fuel system at the fuel filter.
C onnec t a transparent plastic hose
1
bet ween the bleed nipple (1) and a
collection vessel.
3. Open the bleed nipple on the fuel filter
bracket.
4. Pump with the hand pump until air-free fuel
flows out. Close the bleed nipple while the
fuel is no longer flowing out.
5. R e m o v e t h e h o s e a n d r e p l a c e t h e
protective cap on the bleed nipples.
Fig. 5-32 Bleed Nipple on Filter
6. Move the hose to the cylinder head’s bleed

nipple (2) and bleed in the same manner
as with the fuel filter bracket. 2
7. Run the engine at a higher idle speed
for approx. 10 minutes to discharge any
remaining air from the system.
8. Conduct the leakage and functional check.
Fig. 5-33 Bleed Nipple on Cylinder Head
NOTE:
No additional bleeding is required when
changing the fuel filter.

5.6.11 Inlet system, checking leakage
1. Check every week that if there is ruptured

pipe or damaged / loose clamp in the inlet
pipeline.
2. If necessary, replace the damaged pipe
and tighten the loose clamp to ensure that
the inlet system is not leaking.
Torque: 8 N.m
3. Check if the inlet pipeline is corroded,
because it would lead to the corrosive
materials and dirt into inlet system.
Fig. 5-34 Inlet Pipe
4. Dismantle if necessary and clean the inlet
pipeline.
Noise can be created due to the air leakage of

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

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

the engine to avoid impurities and scraps
into engine. If the inlet pipe is damaged or
loose, infiltrated air would enter into the
engine and lead to early wear or failure of
engine.

5.6.12 Attaching bolts of engine seat,

checking
Before star ting the engine, check if the
attaching bolts of engine seat are loosened.
• Check attaching bolt 1

Torque: 68 N.m
Torque: 195 N.m
Torque: 100 N.m
Fig. 5-35 Attaching Bolts
5.6.13 Shock absorber, checking
Functions of shock absorber:

• Fix the engine on the frame
• Reduce the shock when the engine is
started, running and stopped.
NOTICE
NOTICE
Silicone oil in the shock absorber would

turn solid if it is used for a long time. Thus
the ineffectiveness of the shock absorber
Fig. 5-36 Shock Absorber
would occur, and result in serious engine
fault or transmission malfunction.
• Check whether the silicone oil in shock

absorber is lacked.
• Check if the shock absorber is shaking.
• Check the depth of shock absorber.
• Check if the cover plate of shock absorber
is deformed.

5.6.14 Turbocharger and blast pipe,

checking
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 shall lead to the
entrance of fuel into the air-intake system of
turbocharger and engine.
Fig. 5-37
Turbocharger, checking:
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
Check the turbocharger every 6000 hours:

1. Remove the inlet and outlet pipe, and then
check the turbocharger.
2. Check if there are any damage or rupture
in the air compressor or turbine blades.
3. Check if the rotating shaft of turbocharger
can rotate freely.
4. If any problem occurs, please contact
SANY to repair it.

5.7 Transmission
5.7.1 Gearbox, function description

Gearbox converts the engine power to drive
axle via the propeller shaft and also the power
to drive hydraulic oil pumps for hydraulic
system and brake system.
The gearbox is fully automatic with torque

converter. It has four forward gears and four
reverse gears.
NOTICE
NOTICE
High modulation (that is, soft operation /

intensive slipping between gear positions)
results in high gearbox wear and high oil
temperature.
NOTE:
• The sensor for oil temperature generates
a warning when the oil gets warmer than
100 °C.
• If the oil temperature sensor indicates 125
°C, the gearbox declutches.
5.7.2 Attaching bolts of transmission

shaft, checking
Loose bolts will easily rupture under load and

vibration. Fixed bolts of transmission shaft
should be checked carefully before torque
force is transmitted.
1. Check if the attaching bolts of transmission

shaft are loose; (see Fig. 5-38)
Fig. 5-38 Attaching Bolts of Transmission
Shaft

2. Check if the universal joint bearing is

damaged; (see Fig. 5-39)
3. Tighten the loose bolts of transmission

shaft with a torque of 75 N.m.
Fig. 5-39 Universal Joint
5.7.3 Speed sensor, checking
Speed sensor is located at the connecting

parts between gearbox and transmission shaft
(4). Check if the speed sensor (3) or its bearing
is damaged to ensure that speed signals of the
machine can be transmitted to relative control
system exactly. Thus, steering can be carried 3
4
out only in low speed, and transmission device
can be protected.
Fig. 5-40 Speed Sensor

5.7.4 Attaching bolts and fixed seat,
checking
Functions of fixed seat and damping pad:

• Fix the transmission on the frame;
• Reduce the shock in the start, operation,
and stop of transmission.
Check:
• if damage exists on fixed seat (2) and 2
damping pad (1);
1
• if bolts are loosened.
Fig. 5-41 Attaching Bolts and Fixed Seat

5.7.5 Transmission shaft, lubricating
1. Inject the grease into lubrication points (see

arrow in Fig. 5-42) with manual lubrication
gun (not with high pressure lubrication
gun).
2. S to p inj e c t ing grease i f t he gre as e
squeezes out.
Fig. 5-42
NOTE:
Manually lubricate the transmission shaft
even if the machine is equipped with a central
lubrication system.
DANGER
DANGER
Always turn off the engine before operating

the transmission shaft.
Never touch the running transmission
shaft, or serious injuries even death would
happen.
Fig. 5-43

5.7.6 Gearbox oil, changing
1. Let the engine run idle.

2. Check the gearbox oil level. For detailed
information, see: “Gearbox oil level,
checking” on page 5-58. If necessary, fill
gearbox oil through the oil filler (1).
NOTE:
Wipe off the dipstick before checking.
The oil dipstick is long. Use gloves.
NOTE:
Make sure that the drain plug’s washer seal is 1
also removed.
NOTE:
Fig. 5-44 Change Gearbox Oil 1
Place a container under the drain plug to
receive the drained oil.
3. Remove the drain plug (2) for gearbox oil

and let the oil drain into the container.
4. Check the gearbox oil prefilter (3). If
the filter core is damaged, replace it
immediately.
5. When the gearbox oil has drained, fit the
drain plug (2). Make sure that the washer
for the oil plug is included.
3
6. Remove the gearbox dipstick and fill new
gearbox oil through the dipstick’s hole to
the making for low level on the dipstick. 2
7. Turn on the main electric power and start
the engine. Let the engine run idle for at Fig. 5-45 Change Gearbox Oil 2
least two minutes.
8. Check the gearbox oil level with the engine
running at idle and top up to the marking
for low level.
9. Check the drain plug’s sealing.
10. Operate and warm up the gearbox until the
operating menu shows oil temperatures
between 60-65 ℃ .
11. Let the engine run idle. Check the gearbox
oil level.

5.7.7 Gearbox oil level, checking
The oil level must be maintained between the

H and L markings. The oil level should be at
the H marking.
1. Check the oil level with the engine at
idle, gearbox in neutral position and at
operating temperature (approx. 60-65 °C).
2. Fill gearbox oil if needed. (Tank capacity:
45 - 65L. For detailed information, see:
“Capacity of the tanks” on page 5-13.)
3. I t i s r e c o m m e n d e d t h a t t h e o i l b e
Fig. 5-46 Check Gearbox Oil Level
filled when the gearbox is at operating
temperature. Fill----wait a moment----
check the dipstick.
NOTICE
NOTICE
Work carefully when filling gearbox oil

to prevent other fluids or particles from
contaminating the oil, which means risk of
gearbox damage.
5.7.8 Gearbox oil filter, changing

NOTE:
The gearbox does not need to be emptied of
oil before the filter is changed.
If the gearbox oil is to be changed, change the
gearbox 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 gearbox oil.
4. Install the new filter on the gearbox.
Tighten to contact and then another 2 / 3
turn. Fig. 5-47 Gearbox Oil Filter
5. Turn on the main electric power and start
the engine. Let the engine run at idle.
6. Check the gearbox oil filter’s sealing.
7. Check the gearbox oil level, see “Gearbox
oil level, checking” on page 5-58.

5.8 Drive Axle
5.8.1 Attaching bolts of drive axle to the

frame, checking
Check the drive axle’s attachment to the frame

so that there is no corrosion of structural
elements (e.g. attaching bolts).
• Loose bolts tend to rupture while machine
is overloading and vibrating.
• Ruptured attaching bolts would lead to 2
serious damage to machine, or even 1
personal injuries.
• Tighten the attaching bolts (2) with 1600 Fig. 5-48 Attaching Bolts of Drive Axle to the
N.m (oiled bolt). Frame
5.8.2 Attaching bolts of drive axle to the

transmission shaft, checking
Tighten the attaching bolt (3) with 65 N.m (oiled

bolt).
Fig. 5-49 Attaching Bolts of Drive Axle to the

Transmission Shaft
5.8.3 Oil leakage of drive axle and brake
components, checking
Check the oil-immersion disc brake and its

connecting pipe, parking brake system and its
connecting pipe, reducer, driving wheel and
driving axle for oil leakage.

5.8.4 Drive axle oil, changing
NOTICE
NOTICE
1
Dirt and impurities in the drive axle oil can
cause breakdown. Pay particular attention
to cleanliness when working on the drive
axle.
1. Place the machine in position so that the

2
hub’s drain plug (2) is at the lowest point
vertically.
NOTE:
This applies to both drive wheels.
• Wheel 1: move forward or backward to Fig. 5-50 Filler Plug and Drain Plug
obtain the correct position.
• Wheel 2: lift the wheel from the ground
(raise the machine under the drive axle)
and rotate the wheel into the correct
position.
2. Place a drainage receptacle at every hub.

Place a piece of sheet metal or similar in
the wheel to lead the oil to the receptacle.
3. Remove the hubs’ drain plugs on both
sides. Also remove the hub lever and filter
plugs to facilitate draining. Both sides shall
be drained separately.
4. Remove the differential’s drain plug. Also
remove the differential lever and filter plugs
to facilitate draining.
5. Clean the drive axle’s breather while the oil
is draining.
6. Install the drain 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 (1) on
the differential.
9. Fill oil in the differential until the oil is

flushed with the filter and lever holes.

10. Install the lever and filter plug on the
differential.
11. Turn on the main electric power.
12. Check the sealing and the oil level in the
drive axle after a short test-drive.
NOTE:
Make sure that the seals are in place.
NOTE:
The oil is very viscous and filling should be
slow. Level check should be done in stages so
that the oil has time to distribute itself.
5.8.5 Breather connector, cleaning
Clean the breather connector to release steam

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. 5-51 Breather Connector

5.8.6 Brake pedal, checking and

adjusting
1. Clean the floor around brake pedal and

check that nothing blocks the movement of
brake pedal.
2. Check that the brake pedal springs back
adequately and that the clearance between
brake pedal and brake valve is 1-1.5 mm. If
needed, adjust the stop bolt of brake pedal
to correct the clearance.
3. Check that the pedal’s travel is smooth.
Fig. 5-52 Brake Hinge
4. G r e a s e t h e p e d a l h i n g e s w i t h E P 2
universal grease.
5. Check that the rubber on the pedal is intact
and that the tread pattern isn’t worn out.
Change it if needed.
5.8.7 Parking brake pads, changing

2. Remove the cover from the brake caliper.
3. Loosen the lock nut.
4. Loosen the adjusting screw so that the
brake pads become loose.
5. Remove the split pin and loosen the nut
on the attaching bolt holding the parking
brake caliper.
6. Pull out the attaching bolt so that the brake
pads can be twisted out and removed.
Fig. 5-53 Parking Brake Pads
NOTE:
The bolt does not have to be removed.
7. Remove the parking brake pads.

8. Clean the brake disc with methylated spirit.
9. Fit the new parking brake pads.
10. Press back the attaching bolt.
11. Fit the nut and fit a new split pin.
12. Adjust the parking brake.

5.8.8 Brake oil filter, changing
NOTE:
The filter protects the brake system from
impurities. It is ver y impor tant that new
impurities do not enter the brake system when
changing the filter.

2. Depressurize the hydraulic and brake
system.
Fig. 5-54 Brake Oil Filter
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
since the oil drains slowly.
4. Remove the filter holder.
NOTE:
The filter holder is heavy. Loosen it carefully.
5. Remove the filter insert.
NOTE:
Note the position of O-rings.
6. Clean the filter holder.

7. Fit the O-rings on the filter cartridge and
filter holder. Lubricate the O-rings with
hydraulic oil.
8. Fit the new filter insert to the filter bracket.
9. Fit the filter holder 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
holder does not leak.

5.9 Steering Axle
5.9.1 Daily check
3 4
5
6 1
1. Steering axle beam 4. Connecting rod

2. Rotating shaft 5. Interlocking mechanism
3. Steering cylinder 6. Steering knuckle
Fig. 5-55 Main Components of Steering Axle
1. Check the wearing condition of rotating shaft (2). Inject grease onto it every 50 hours.
2. Check steering cylinder (3) for leakage. Check piston rod for deformation. Replace or repair
parts with damage.
3. Check whether the connecting rod (4) is damaged out of long-time run. Replace it
immediately when damage occurs.
4. Check whether the steering joints of interlocking mechanism (5) can rotate smoothly. Inject
grease onto the connecting pin shafts at both ends every 50 hours.
5. If the machine has driven for a long distance with insufficient tyre pressure, stop the machine
immediately, and dismantle tyres, wheel rings. Then check if the steering knuckle (6) is
damaged.

5.9.2 Steering axle, lubricating
1. Clean the grease nipple.

2. Use the grease gun to inject grease into
the nipple until remained grease is drained
away.
3. Clear the redundant grease. Lubricate
the lubrication points after scraping the
remained grease on sliding surface.
4. Smear grease on the lubrication point.
Fig. 5-56 Lubricate Steering Axle
5.9.3 Steering knuckle, maintaining
1. Remove the wheel ring cover.

2. Check the steering knuckle (position 6
in Fig. 5-55) for deformation, fatigue and
damage as early as possible; replace it
with a new one if there is damage.
3. If the wheel ring bearing is loosened,
adjust the nut of wheel ring to adjust
its clearance. Take proper pre-screw
measure, to prevent other components
from speeding up damage.
Fig. 5-57 Steering Knuckle
4. Inject grease through the grease nozzle
to lubricate the rotating shaft (position 2 in
Fig. 5-55) until it is hard to inject further.

5.9.4 Steering axle cradle, checking

2. Check that the bushings in the suspension
are intact.
3. Measure the distance between the frame
and the steering axle cradle. Note down
the measurement.
4. L i f t t h e m a c h i n e u n d e r t h e r e a r
counterweight.
NOTE:
Do not lift under the steering axle. Fig. 5-58 Take the Measurement
5. Re-measure the distance between the

frame and the steering axle cradle. Note
the measurement.
6. Calculate the difference between the two
measurements. The difference may not be
more than 3 mm.
5.9.5 Steering pressure, checking
1. Operate and warm up the machine so

that the oil in the brake system reaches
operating temperature (at least 50°C).
3. Connect a pressure gauge (0-25 MPa) to
the measuring outlet on the hydraulic oil
pump for steering and load handling.
4. Start the engine and increase engine
speed to approx. 1200 rpm.
5. Turn the steering wheel fully and read
pump pressure during the steering wheel
movement. Compare this to the steering
pressure on the hydraulic plate.
6. Turn the ignition key to position 0 and turn
off the main electric power.
7. Remove the pressure gauge and fit the
protective cap on the measuring outlet.

5.10 Tyres and rims
As a significant component of wheel vehicles,

technologies of tyre decide the performances
of traction, transition, smoothness, safety,
comfor t, and economy. Do remember to
maintain and change the tyre according to this
technical guide.
WARNING
WARNING
Mounting and changing of tyre for reach

stacker is extremely dangerous. At least
two professional operators are needed,
and high alert is required during the work.
Failure to do this could result in injury or

possibly death.
5.10.1 Tyre, description
Tyres are the points of contact between the

machine and the ground, and they absorb
unevennesses and provide suspension.
Generally, specification of tyres in C and F type
container reach stacker is 18.00-25-40PR-E-
4J.
NOTE:
Tyre specification of special reach stackers:
Fig. 5-59 Tyre
Empty container handler (SRSC1009-6E):
14.00-24-28PR
Lightweight container handler (SRSC3515-3):
16.00-25-32PR-E-3J
Heavyweight container handler (SRSC4545C):
21.00-35-36PR

CAUTION
CAUTION
Type of the tyre should be the same or

have the same performance with the
original tyre. Unmatched tyre and wheel
rim will cause further damage to the tyre
lip, or explosion of the tyre and personal
injuries.
NOTE:
Tyres on the same axle should be of the same
brand, type, structure, and use. The wearing
extent of tyres should be the same to ensure
the identical outer radius. Tyre should be
replaced when the tread at 1/4 of the tyre edge
is worn to a depth of 2-3 mm.
NOTE:
Before starting the machine, check if crack,
corrosion, over-wearing or uneven wearing
exists on the tyre surface. Replace tyres that
are seriously worn in time. Check and clean
impurities such as glass in the tyre. Check
the air pressure of tyre, and charge air in
time when the pressure is low, because low
pressure reduces stability and load capacity of
the overall machine.
DANGER
DANGER
Stop the machine when the tyre

temperature is too high. Park the machine
at a cool place to let itself cool down.
Never discharge the air to release pressure
or splash water on the tyre to cool it down,
for these would cause tyre explosion and
personal injuries.
Replace the tyre timely when it reaches it

wearing limit. Otherwise, tyre explosion
and personal injuries or even death can
occur.

5.10.2 Tyre, inflating
Always follow the instructions for inflating tyres

to avoid the risk of accidents.
• Only use approved rim components.
• If the tyre has been completely deflated,
the tyre must be dismantled and the rim
checked for damage.
• Never install rim components by striking
with a hammer during inflating. Never
strike fully or partly inflated tyres or rim
assemblies.
Fig. 5-60 Inflate the Tyre
• Never inflate tyres before all parts are in
place.
• Wheels shall be inflated on the machine
or in a protective device, designed and
dimensioned so that it can handle or
dissipate a shoc k wave from a t yre
explosion as well as catch the ejected
parts.
• Do not exceed prescribed tyre pressure
that is to be checked at ambient
temperature.
• Never stand directly opposite the tyre
when deflating or inflating. The lock ring
and retainer ring may release and shoot off
when the pressure changes.
• Check that all parts are in place when the
tyre pressure is 0.95-1.05 Mpa.
Steps to inflate the tyre:

1. Make sure that the lock ring and retainer
ring are in the correct position before
inflating.
2. Connect the compressor with the air valve
of tyre.
3. Stand to the side of the tyre while the
inflation is in progress.
4. Inflate the tyre to the prescribed level of
0.95-1.05 Mpa.
Other inflation pressure may apply when
changing tyre or rim version, contact SANY.

5.10.3 Tyres, checking
• Check for uneven and fast wearing which

is caused by mechanical problems such as
uneven brake action. Make sure that such
malfunctions are handled immediately.
• Remove penetrating objects such as
crushed glass, wood pieces, metal fillings,
etc.
If the tyre is damaged, dismantle the wheel

and change the tyre in time.
If the tyres have no defects, check and tighten

the wheel nuts with a torque of 650 N.m (oiled
bolt).
5.10.4 Wheel rim, description
Wheel rim cooperates directly with hub, and

its dimensions must be the same to that of the 6
hub. Only use the wheel rim that is approved
by SANY. 5
4
Our reach stacker applies five-element-type
wheel rim with no spoke. The wheel rim is
composed of wheel rim body, retainer ring,
seat ring, and lock ring.
1. Retainer ring 4. Retainer ring

2. Wheel rim 5. Seat ring
3. Tyre 6. Lock ring
Fig. 5-61 Wheel Rim

5.10.5 Rim, checking
Perform the following checks to minimize the

risk of accidents for all split rims.
• Always use the correct tyre dimension and
design corresponding to the manufacturer’s
rim type and dimension. Oversize tyres
may not be used.
• Replace all damaged, worn or corroded
rims or mounting parts.
• Check the rim in connection with tyre
change or once a year.
1. Dismantle the rim.

2. Carefully clean the outside of the rim edge
with a steel brush.
3. Measure the wearing 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 A
exceeds 0.5 mm, scrap the rim, lock ring
and the tapered rim course and replace Max 0.5 mm
them with new parts when necessary.
Fig. 5-62 Measure Wear

4. Check the rim’s diameter.
• Measure the rim edge’s circumference (O)
with a measuring tape and calculate the
diameter (D). (D=O/3.14)
• Compare the value of the diameter with
the specified min. measurement. If the D
O
diameter is smaller, the rim, lock ring and
the tapered rim course be discarded and
replaced with new parts.
O. Circumference D. Diameter
Fig. 5-63

5. Check for damage in the areas with high

stress concentration. Checking is done in
two steps:
• The magnetic particle method is used to
determine if there’s a crack or not, and
where it is.
• Confirmed cracks are investigated further
with penetrating fluid.
• Typical rim damages are circumference
cracks, corrosive damage, rust, warping
and wear.

5.10.6 Wheel rim, installing and

removing
5.10.6.1 Wheel rim, installing 6
5
1. Follow the procedures indicated by the
arrowhead in Fig. 5-64 to mount the tyre. 4
2. L ay t h e w h e e l r i m (2) ve r t i c a l l y o n
the ground with a 100 mm high block
underlaying. Put the retainer ring (1) in
wheel rim. Then mount valve core and
ensure that it is closely connected with
wheel rim.
3. Put the tyre (3) in wheel rim with a lifting 3
device such as a traveling vehicle. Put an
O-ring in the wheel rim. Put the retainer
ring (4) inside the tyre, and knock the seat 2
ring (5) into space between wheel rim and
1
retainer ring. Then knock the lock ring (6)
into space between wheel rim and shelter
ring, and lock the tyre ring.
Fig. 5-64 Wheel Rim
NOTE:
When knocking the seat ring (5) and lock ring
(6), equalize the force around the ring rather
than knock only at one place. Check if retainer
ring seat laps over with the whole 45° surface
of lock ring. If not, mount the rim again.
WARNING
WARNING
• If any crack or deformation exists in

relative parts of wheel rim, replace the
part immediately.
• Welding cannot be used as repair if the
wheel rim is damaged.
Failure to follow the above instructions

5.10.6.2 Wheel rim, removing
CAUTION
CAUTION
Be sure to work according to the correct 1

sequences while installing or removing the
tyre from wheel or rim. If the sequence is
wrong, the tyre may rupture and thus lead
to personal injury.
2
NOTE:
If the personnel has insufficient experience, or
the appropriate tools for work are not enough,
do not install or remove the tyre. Under such
circumstances, contact the authorized and
professional personnel related to tyres to deal
with the tyre.
3
Wheels can be disassembled horizontally and

vertically. Before disassembly, take down the
valve core and let all the air out.
1. Take down the tyre ring on the side of

wheel rim gutter with proper tools. Be
careful not to damage the tyre ring (1).
2. Take down the lock ring with proper tools 4
(2).
3. Take down the O-ring and diacard it (3).
4. Take down the seat ring of tyre ring (4).
5. Take down the rim from wheel rim seat.
Loosen the rear tyre ring and take down
the shoe from wheel rim (5).
Fig. 5-65 Remove the Wheel Rim

5.10.7 Tyre, removing and installing

(drive axle)
Most pressure of the machine is loaded on

drive axle, and the pressure may increase
under different working conditions. When the
machine is lifting containers, drive axle loads
almost whole weight of the machine.
WARNING
WARNING
Discharge the air before replacing tyre. If

the valve core is blocked, use a saw blade
to saw a notch with a depth of about 1/3 of
the diameter.
In replacing, always lay blocks under
the steering axle before lifting the drive
axle, otherwise personal injuries would
be caused by unexpected move of the
machine.
Failure to follow this could result in injury
or possibly death.
5.10.7.1 Tyre of drive axle, removing
1. Lay two jacks of 20t under the drive axle.

They should be placed symmetrically
around the centerline of frame, with their
centers 1.6m away from each other. After
all the positions have been checked to be
right, lift the drive axle until the tyres are
50mm clear from the ground.
2. Screw out the air valve cover and turn it
round. Insert the cover in the air valve and
turn it for 2-3 circles after it sticks to the
valve core. Then discharge air of the inner Fig. 5-66 Drive Axle Tyre
and outer tyres.
3. Loose all nuts symmetrically.
4. Ta k e d o w n a l l n u t s e x c e p t t h r e e
proportionally spaced ones.

5. Support the outer tyre with a forklift or

other reliable lifting devices.
6. Take down the rest three nuts and displace
the outer tyre (1). 1
7. Take down the spacer ring (3) between 3
tyres.
2
8. Displace inner tyre (5) safely with a forklift
or other lifting device.
4
5
Fig. 5-67
5.10.7.2 Tyre of dirve axle, installing
1. Remove the dust and impurities on hub

surface and in inner ring of wheel rim.
2. Mount the inner tyre (5) to drive axle with a
forklift or other lifting devices, with the lock
ring outwardly.
3. Mount the spacer ring (3).
4. Mount the outer tyre (1) to drive axle with a
ring inwardly.
5. Mount the open end thimble (4).
6. Mount the pressure plate (2) symmetrically
and tighten the nuts with a torque of 430 -
460 N.m.
7. Turn the tyre for several circles and ensure
that swing range at the max. radius do not
exceed 3 mm.
8. Char g e t h e t y re w it h a p re s sure of
0.95~1.05MPa.
9. During 200 hours after the machine is
started for the first time or the new tyre is
replaced, be sure to pre-tighten the hub
screw every 50 hours.

5.10.8 Tyre, removing and installing

(steering axle)
WARNING
WARNING
Discharge the tyre before replacing. Failure

to follow this could result in injury or pos-
sibly death.
NOTE:
If the valve core is blocked, use a saw blade
to saw a notch with a depth of about 1/3 of the
diameter.
5.10.8.1 Tyre of steering axle, removing

1. Lay two jacks of 20t under the drive axle.
They should be placed symmetrically
around the centerline of frame, with their
centers 1.4m away from each other. After
all the positions have been checked to be
right, lift the drive axle until the tyres are
50mm clear from the ground.
2. Tu r n t h e t y r e s to m a ke n oz z l e j et s
upwards. Discharge the tyres.
3. Take down nuts of short pressure plate
interlacedly and symmetrically, and take
out the short pressure plate.
4. Loosen the nuts of long pressure plate for
2-3 circles with a torque spanner.
5. Check if crack exists in wheel rim, shelter
ring, or lock ring. Fig. 5-68 Remove the Steering Axle Tyre
6. Lift the tyre with a forklift or other lifting
device.
7. Take d ow n t h e l o n g p r e s sur e p l ate
symmetrically.
8. Displace tyres with a forklift or other lifting
device.
NOTE:
If serious crack exists in shelter ring or lock
ring, first knock the wheel rim to discharge
force of the cracked shelter ring or lock ring
under the retaining of long pressure plate, then
take down the long pressure plate.

5.10.8.2 Tyre of steering axle, installing
1. Remove the dust and impurities on hub

surface and in inner ring of wheel rim.
2. Mount the tyre to steering axle with a
ring outwardly.
3. M o u n t t h e l o n g p r e s s u r e p l a t e
symmetrically and tighten the nuts with a
torque of 550 N.m. (The tightening torque
for SRSC1009-6E is 600 N.m.)
4. M o u n t t h e s h o r t p r e s s u r e p l a t e
symmetrically in group and tighten the nuts Fig. 5-69 Steering Axle Tyre
with a torque of 550 N.m. (The tightening
torque for SRSC1009-6E is 600 N.m.)
5. Turn the tyre for several circles and ensure
that swing range at the max. radius do not
exceed 3mm.
6. Char g e t h e t y re w it h a p re s sure of
0.95~1.05MPa.
7. Within 200 hours after the initial operation
or tyre replacement, the nuts of hub should
be tightened once per 50 hours.
NOTE:
A group consists of a long pressure plate and
two short pressure plates.

5.11 Boom
Boom system of reach stacker is composed of

basic arm (1), pitching cylinder (2), drag chain
(3), telescopic cylinder (4), sliding block (5),
telescopic arm (6), etc.
4 1 2 3 5 6
Fig. 5-70 Boom
Its function is to adjust the pitching angle of

boom by telescoping pitching cylinder, and to
adjust the extending length of telescopic boom
by telescoping oil cylinder, so as to realize
the lifting operation for container at different
positions through combination of both above
actions.

5.11.1 Basic boom, checking
Check if the fixed seat and pin shaft on

basic boom are loose or worn
The fixed seat and pin shaft on the basic

boom are the main components coupling the
frame and spreader. The structure and welding
of fixed seat, pin shaft, pin-hole bearing and
attaching bolts should be periodically checked.
If needed, conduct dye check.
Fig. 5-71 Check of Boom
Visually check for crack
Boom is an important element to directly lift

the container. The stability of its structure
directly influences the reliability and safety of
this machine. Frequently check the important
components to find the crack on spreader
timely and take appropriate actions. By doing
this, the further abrasion can be avoided.
Fig. 5-72 Crack of Boom

5.11.2 Sliding blocks, checking
1. Fully retract the boom and lower it to its

lowest position.
2. C h e c k t h e c l e a r a n c e b e t w e e n t h e
telescopic arm and sliding block.
• The normal clearance is 1mm.
• When needed, adjust it with gaskets.
3. Check the abrasion of upper and lower

sliding blocks at fixed arm.
• The max. clearance is 3mm. The min.
thickness of sliding plates is 15mm.
• Adjust the clearance with gaskets. If
needed, replace it with a new sliding block.
Fig. 5-73 Sliding Block
4. Check the abrasion of side -mounted
sliding block at the fixed arm of boom.
• The min. thickness of sliding plate is
25mm.
• Adjust the clearance, and if needed,
replace it with a new sliding plate.
5. Check the abrasion of side -mounted

sliding blocks and bottom sliding blocks at
telescopic arm.
• The min. thickness of sliding blocks is
25mm.
• When needed, replace it with a new sliding
plate.

5.11.3 Sliding blocks of the fixed arm,

replacing
Replace every 1500 work hours, proceeding

as follows (see Fig. 5-74):
1. Rest the arm with spreader on a container,

without raising the load.
2. Loosen the screws (1 and 2) and remove
the sliding block support (3).
4
3. Loosen the lock nuts (4) and remove the
worn sliding blocks.
4. Before fitting the new sliding block, make
sure there is no dirt in the housing that 1
could impair the perfect alignment of the 2
3
sliding block itself.
5. Correctly position the sliding block and Fig. 5-74 Sliding Block of Fixed Arm
tighten the screws.
5.11.4 Sliding blocks of the telescopic

arm, replacing
Replace every 1500 work hours, proceeding

as follows (see Fig. 5-75):
1. Rest the arm with spreader on a container,

without raising the load.
2. Loosen the screws (1 and 2) and remove
the sliding block support (3).
3. Loosen the lock nuts (4) and remove the
worn sliding blocks.
4. Before fitting the new sliding block, make
sure there is no dirt in the housing that
could impair the perfect alignment of the
sliding block itself.
5. Correctly position the sliding block and
tighten the screws.
6. The wearing of side sliding blocks (5)
is less than that of the upper and lower
sliding blocks. It is nonetheless best to
replace them.

7. After replacement, grease the sliding

blocks as previously described, pull out the
arm and apply a slight film of grease on the
surfaces indicated in the illustration below.
4
3
1
5 2
3
Fig. 5-75 Sliding Block of Telescopic Arm
5.11.5 Pitching cylinder, checking
Check the attaching seat and pin shaft on the

pitching cylinder.
Check the adjacent area of fixed seat for
crack. If needed, conduct dye check.
Refer to Fig. 5-76.
Fig. 5-76 Pitching Cylinder

5.12 Spreader
5.12.1 SANY / ELME spreader
2 1 5
4
3
1. Slewing table assembly 4. Side-shifting mechanism

2. Cross beam assembly 5. Hydraulic system
3. Twistlock mechanism
Fig. 5-77 Spreader
5.12.1.1 Twistlock, checking
• Check if the twistlock (1) is damaged.

Replace it when needed.
• Check if the coupling rod (2) of twistlock is
located correctly and stably.
• Check if all sensors are tightened. Adjust
the tightness when needed.
2
1
Fig. 5-78 Twistlock and Coupling Rod

5.12.1.2 Twistlock, lubricating
Spreader is an impor tant par t for lif ting

containers. Lubricating the twistlock can
reduce its wearing and extend its service life.
Fill lubricants in oil filler (3) every 200 hours.
If the twistlock is seriously worn, i.e. horizontal

cross section dimension is less than 25mm,
replace the t wistlock; it also should be 3
replaced after being used for more than 5000
hours.
Fig. 5-79 Oil Filler of Twistlock
NOTE:
It is very important to check the twistlocks and
related components, as they can facilitate the
lifting of container.
5.12.1.3 Sensor / Indicator of twistlock,

checking
Check:
• if the sensor (4) and its wiring are good.
• if all sensors (4) are tightened properly or
damaged.
• if the clearance between sensor and 4
sliding block is normal.
• if the indicator can work normally.
Fig. 5-80 Twistlock Sensor

5.12.1.4 Fixed bolts of spreader rotating

gearbox, checking
To avoid the rupture of loose bolts, damage of

components and unmanagement of spreader
rotation, make sure to check the par ts
fastened by fixed bolts at regular intervals.
Components of rotating motor are composed

of hydraulic motor, disc brake and planet gear.
They are all connected by fixed bolts.
Fig. 5-81 Fixed Bolts of Spreader
Hydraulic motor, above the disc brake,
provides power for rotating. Disc brake is used
to avoid accidental rotation. Release the brake
while the hydraulic motor is rotating, and the
planet gear of spreader is driven to rotate.
Thus strengthen the output of motor and disc
brake.
5.12.1.5 Sliding blocks of spreader,

checking
There are t wo types of sliding block on

spreader: side-shifting sliding block and
telescopic sliding block of 20/40 feet, both
of which can bear and guide related sliding
elements.
1. Side-shifting sliding blocks 1
Lubricating
When the surface of sliding block has little 2
sliding effect, be sure to smear grease on
the surface in time. No need to consider the 3
lubrication interval.
Replacing
Replace the sliding block if its worn depth
exceeds 3mm. Follow the below steps: Fig. 5-82 Side-shifting Sliding Block

1. Screw out the bolts (2) at both ends.

Remove the end baffle (3).
2. Install a new sliding block (1). Adjust the
clearance between horizontal sliding block
and main tube of spreader to 2mm by
adding or reducing the adjusting gaskets
or pads.
3. Reinstall the end baffle and tighten the
bolts with a torque of 90 N.m. Spread anti-
loosing glue on the bolt before installing it.
4. Smear lubricants on the surface of sliding
block.
5. If all the bolts are loosened, replace them
immediately. Spread anti-loosing glue on
them and re-tighten them with a torque of
560 N.m.
2. Telescopic sliding blocks
Lubricating 3
When the surface of sliding block has little

sliding effect, be sure to smear grease on
the surface in time. No need to consider the
lubrication interval.
Replacing
Replace the sliding block if its worn depth
exceeds 3mm. Follow the below steps:
1. Screw out the bolts (3) at both ends.
Remove the end baffle (2).
2. Install a new sliding block (1) or lower 2 1 4
sliding block (4). Adjust the clearance
between horizontal sliding block and main Fig. 5-83 Telescopic Sliding Block
tube of spreader to 2mm by adding or
reducing the adjusting gaskets or pads.
3. Reinstall the end baffle and tighten the
bolts with a torque of 70 N.m. Spread anti-
loosing glue on the bolt before installing it.
4. Smear lubricants on the surface of sliding
block.

5.12.2 BROMMA spreader
1. Slewing table assembly 4. Hydraulic system

2. Cross beam assembly 5. Telescopic mechanism
3. Twistlock mechanism
Fig. 5-84 Spreader

WARNING
WARNING
If the spreader is not used and / or

maintained in strict accordance with these
operating and maintenance instructions,
SANY cannot guarantee the safety or
reliability of this equipment.
• DO NOT crawl beneath a spreader bar

for maintenance, repair or adjustment.
Never put any body extremity beneath
the spreader bar.
• The RSX40 has a risk of crushing
between the telescoping units and the
main frame.
• M A I N TA I N a d j u s t m e n t f o r a l l
components.
• KEEP CLEAR of all moving parts such
as linkage and aligning arms.
• DO NOT connect or disconnect
electrical connectors while power is on.
• DO NOT tamper with hydraulic pressure
settings once adjusted by qualified
personnel.
• MAINTAIN all electrical and hydraulic
components for proper adjustments.
• Always drain the pressure from the
accumulators before any work on the
hydraulic system.
• Avoid prolonged skin contact with
hydraulic oil. Health hazard! Use
protective gloves.

5.12.2.1 General precautions
To ensure the safe and reliable spreader

operation it is important to perform regular
maintenance procedures.
The service intervals specified are for normal

operation where moderate temperature,
humidity and atmospheric conditions prevail.
In areas of extreme conditions, the service
periods and lubrication specifications should
be altered to meet existing conditions.
WARNING
WARNING
HAZARD! Always park the reach stacker

in service position and turn off the engine
during service work. Only exception is
when service work requires engine power.
Failure to do so could result in serious
injuries or possibly death.
Service position:
• Machine with fully retracted and lowered
boom
• Machine parked, that is, applied parking
brake.
• Engine off.
• Main electric power turned off with the
battery disconnected.
5.12.2.2 After 50 hours
1. Check that all hydraulic mountings are

tight.
2. Check and adjust the chain tension
extension.

Remove old grease and lubricate all sliding

surfaces.

2
1
1. Inspect the spreader for visible damage.
2. Twistlock: Check the nut and the floating
mechanism and ensure that all par ts
are properly tightened. Check that the
twistlock pin can be moved easily and that
it indicates the correct position.
3. Check that all hydraulic mountings are
tight.
4. Check the hydraulic oil level in reach
stacker.
5. Retighten all screws (Only the first 500 h
service).
3
1. M8 screw 3. Twistlock pin
2. Nut
Fig. 5-85
1. Perform the service points as in sections

above.
2. If the adjustment of twistlock is needed:
• Remove the M8 screw from the top of
twistlock.
• To lower the twistlock, loosen the twistlock
nut slightly.
• To raise the twistlock, tighten the nut.
• The distance between the top of twistlock
head and the bottom of guide block: 1 -2
Fig. 5-86 1-2mm Distance
mm
• Rec hec k the f loating mec hanism of
twistlock.
• Reinstall the M8 screw.
3. Lubricate and check the various lubricating
points.

4. Inspect all hoses, hose clips and hose

connections.
5. Defective hydraulic hoses and connections
may cause personal injury if jets of liquid
escape under high pressure.
6. Check that all electr ic c onnections,
sensors, cabling and other electrical
equipment are undamaged and properly
tightened.
7. Check that all sliding plates are fixed in
their positions.

above.
2. Re-tighten all screws on the gearbox and
motor.
3. Check all sensors. Clean and retighten
them.

above.
2. Dismantle all twistlocks and check for
cracks and wear.
3. Check the telescopic chain. Tighten if it
can be moved more than ± 8 mm in the
horizontal direction.
1. Perform the service points in sections

above.
2. The t wistlock pins and the spherical
washers shall be replaced.

5.13 Air Conditioning System
5.13.1 General recommendations

Authorization is required to perform repairs on
the climate control unit.
• If there is a rupture in the cooling coils or a
leakage on the attachment – immediately
switch off the unit.
• It is dangerous to allow refrigerants to
come in contact with skin or eyes.
• Never release refrigerant in a closed rum;
the gas can cause asphyxiation in, for
example, pits.
• Never weld on, or in the vicinity of, a
closed cooling system.
• Drain the refrigerant during repairs on the
air conditioning.
• Work may only be per formed on the
ref r i g e r ant c irc uit by an ac c r e dite d
company.
WARNING
WARNING
Electric fans can injure hands.

Risk of personal injury.
Avoid placing hands near the cooling fans
when the engine is running.

5.13.2 Air conditioning, checking /

performance test
NOTICE
NOTICE
If the pressure in the refrigerant circuit

b e c o m e s t o o l o w, t h e l o w - p r e s s u r e
monitor power supply to the compressor’s
magnetic clutch would break down, which
causes the air conditioning unit to stop
functioning.
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. C h e c k t h a t t h e r e i s n o l e a k a g e o f
refrigerant. Leaking often causes oil and
gas to form a dusty and dirty stain.
5. Start the engine and turn on the cooling
function set to maximum cooling. With
EEC: Choose Cool mode with temperature
on minimum.
Let the engine run at at least 1500 r/min.
(At temperatures below approx. 0 °C, the
cooling function will not start due to low
pressure in the system.)
6. Set the fan to intermediate speed.

7. After running for 10 minutes, check that

there are no bubbles visible in the receiver
dryer’s sight glass. (Bubbles should occur
only when the compressor starts and
stops.)
8. Place a thermometer at the exhaust
nozzle nearest the evaporator. After 5-10
minutes, the temperature should be under
10 °C. (Deviations in the measurement
result can occur if the performance test is
conducted when the ambient temperature
is under approx. 18 °C.) If bubbles occur,
subsequent filling should be done by an
expert.
5.13.3 Refrigerant quantity, checking
Check the refrigerant condition from the 1

o b s e r va t i o n w i n d o w (1) o n c o n d e n s e r
refrigerant container (2) when the engine is sufficient injection
running at high speed and air conditioner is
refrigerating powerfully.
2
Sight glass inspection
insufficient injuection
2. Start the engine and let it run idle.
3. Switch on the air conditioning with max. Fig. 5-87 Check Refrigerant Quantity
cooling and fan.
4. Check that a few bubbles are visible in the
sight glass on the receiver dryer.
5. Bubbles in the glass means that the
quantity of refrigerant is incorrect or that
the condenser is defective, clogged by e.g.
dust, or that the ambient temperature is
very high.
It is the easiest way to detect bubbles by

examing the sight glass while the compressor
is being star ted. Visible bubbles should
not normally be noticeable when the air
conditioning system is in operation. Bubbles

can occur if the system contains the incorrect

quantity of refrigerant, in connection with the
compressor stopping and starting, and if the
condenser is defective or at very high ambient
temperatures.
NOTE:
Reliable checking of refrigerant quantity
through the sight glass can only be made
when the ambient temperature is above
approx. 15 °C.
5.13.4 Refrigerant, filling
The type of refrigerants should be up to the

requirements of air conditioning system.
Choose the refrigerant of genuine quality.
Check the system for leakage.

1. Fill 150cc of cooling lubricants. Make sure
that no water or oil dirt enters into the
system.
2. Vacuumize the system for no less than 40
minutes.
3. Fill the refrigerants according to the
specified quantity of system. Too much or
too little refrigerants would influence the
cooling effect.
4. Check the tightness of system and if the
system 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
installed properly for use.

5.13.5 Cleanness of heat-exchanger

plate in evaporator and condenser,
checking
Clean the evaporator and condenser at least

one time every year by below two means:
• Use high-pressure hydraulic gun and
detergent to clean the outer surface of
condenser and evaporator core.
• Use high-pressure pneumatic gun to
clean the outer surface of condenser and
evaporator core.
Fig. 5-88 Evaporator
NOTE:
High-pressure hydraulic gun and pneumatic
gun should be adjusted pressure 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 dilution because the
fins are covered with lots of dust and dirt.
5.13.6 Leakage or lack of oil in

condenser, checking
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.
Obser ve the flatness of refrigerant oil in

condenser through the observation window:
check oil level 10-15 minutes after starting the
condenser. The condenser can be installed
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.

5.13.7 Radiator, cleaning
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.
NOTICE
NOTICE
Never flush the radiator with high-pressure

water. Or, the radiator may be damaged.
5.13.8 Maintenance table for air conditioner
Table 5-18 Maintenance Table for Air Conditioner
Maintenance
Item Condition Requirements
interval
Before / after Make sure that 2 /3 of air outlets are opened and well
Air outlet Everyday the start of ventilated when the air conditioner is running. Check
engine whether the air volume of two sides are proximal.
Clean the air return grid filter screen (sponge block)
Air return grid Before the start
Every week with clean water. Clean in advance the machine
filter screen of engine
running in areas surrounded by lots of dust.
Clean the filter screen of evaporator core with clean
Filter screen of Before the start
Every month water. Clean in advance the machine running in areas
evaporator core of engine
surrounded by lots of dust.
Check whether the condensed water is drained
from the condenser water pipe one hour after the air
Condenser water After the start of
Everyday conditioner has started. The volume of drained water
pipe engine
is relatively high at the south or inshore areas of high
humidity or in the rainy season.
Before the start Check the tightness and abrasion condition of belt.
Every week
Transmission of engine Adjust or change it if necessary. Impose vertically the
belt Before the start pressure of 10Kg (approx. 98 N) on the belt between
Everyday
of engine the two belt wheels with thumb.

Maintenance
Item Condition Requirements
interval
Check the oil quantity of compressor. The flatness
of compressor cooling oil can be seen from the
observation window. Compressor oil should exceed
4
/ 5 of the total oil quantity 30 minutes after the air
Before / after
Oil quantity of Everyday or conditioner is stopped and be within the range of 1/4 to
the start of 3
compressor every week /4 when the air conditioner is running.
engine
If the oil is less than the above standard in the 250
hours of running-in period, change the felt and fill
cooling oil; if the oil is less than the above standard
after the running-in period, replace the shaft seal.
Chec k t he nosie of c lutc h bear ing before t he
Before / after
Electromagnetic electrification. Check after the electrification whether
Everyday the start of
clutch the electromagnetic clutch can occlude and separate
engine
quickly and whether it is slippy.
Before the start Check if the bolts on fixing bracket of compressor are
Every year
of engine loose.
If the compressor will be unused for a long time, run it
once for several minutes every week. Check if all parts
Compressor
After the start of are functioning normally. (If the compressor cannot be
Every week
engine started due to low temperature, you can warm up the
machine by opening the warm wind firstly and then run
the air conditioner.)
After the start of Check if there is abnormal noises while the blower is
Blower Every year
engine running.
Change it. (Note: If the test paper does not turn yellow
After the start of
Dryer Every year and the system is refrigerating normally, there is no
engine
need to change the dryer.
Plug-in parts, Before the start Check whether the wires of compressor clutch and
Every month
terminals of engine terminals of generator are loose.
Check whether the main fuse of power supply, blower
Before the start
Fuse Every month fuse, and inserting fuse are normal. Check whether
of engine
two ends of fuse and fixed bolts of seat are loose.

5.14 Hydraulic System
5.14.1 Hydraulic oil level, checking
NOTE:
The oil level is checked with the boom lowered
and the spreader retracted completely.

2. Check the oil level in the hydraulic tank.
The oil level should be visible from the
level glass. Top up with oil when needed.
REMARK:
Tank capacity: 845 - 1270L Fig. 5-89 Hydraulic Oil Level
NOTICE
NOTICE
Do not overfill!
Leakage and environmental damage!
5.14.2 Hydraulic oil filter, changing
NOTICE
NOTICE
Ensure cleanliness around the filter and

filling point when working on the hydraulic
tank.
Dirt particle may cause machine damage.

1. Turn off the engine and main electric

power.
2. Remove the cover plate (1) over the
hydraulic oil filter.
3. Lift up the filter unit and place it in a
receptacle. Let the hydraulic oil drain.
4. Part the filter unit and remove the filter
element. Dispose the filter element as
environmentally hazardous waste. Note
the positions of these parts.
5. Clean the filter holder’s parts.
6. Fit the new filter and assemble the filter
unit.
7. Install the filter unit and the cover. Tighten
the screws crosswise.
8. Check the oil level with dipstick (2) in the
hydraulic oil tank. The oil level shall be
at the top of the level glass. Top up as
needed.
Fig. 5-90 Hydraulic Oil Tank
5.14.3 Hydraulic oil, changing
NOTICE
NOTICE
Ensure cleanliness around the filter and

filling point when working on the hydraulic
tank.
Dirt particle may cause machine damage.
1. Turn off the engine and main electric

power.
2. Remove the filter cap and pump out the
hydraulic oil in a receptacle.
3. When most of the oils have been pumped
out, place a receptacle under the hydraulic
oil tank’s drain plug (position 3 in Fig. 5-90)
and drain out the hydraulic oil.
4. Fit the drain plug when the oil has been
drained completely.

NOTE:
Make sure that the seal washer is installed as
well.
5. If necessary, change the filter before filling

the tank with oil, see “Hydraulic oil filter,
changing” on page 5-100.
6. Fill new hydraulic oil through the filler hole
on the filter’s cover. Then the oil can be
filtrated and the hydraulic system can be
protected from impurities.
NOTICE
NOTICE
Do not overfill!
Leakage and environmental damage!
5.14.4 Oil return filter element, replacing
The oil return filter element is located at the

oil outlet of hydraulic oil tank. Blocked filter
element will influence the flow of oil, resulting
in high pressure at the oil outlet of pump and
thus the explosion of oil pipe.
Steps to replace the filter element:

1. Dismantle the hydraulic oil return filter from
the hydraulic oil tank.
2. Loosen the fixed screws in the filter.
3. Take out the filter element.
4. Replace a new filter element.
WARNING
WARNING
Hot, pressurized oil!

Personal injury, burn injury!
Always depressurize the hydraulic system
before operation. Avoid skin contact with
the oil, and use protective gloves.
Failure to follow the above instructions

5.14.5 Hydraulic oil tank, cleaning

This mac hine adopts VG 4 6T anti - wear
hydraulic oil. Be sure to clean the oil tank
every half year.
The steps of cleaning oil tank are as follows:

1. Remove the oil drainage 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.) and paste.
4. After the tank is cleaned, install the cover
of cleaning hole.
5. Open the air filter cover on the tank. Fill
filtrated hydraulic oil into the tank until the
oil reaches the “H” marking as shown on
dipstick.

5.14.6 Parking brake unit, checking and

adjusting
WARNING
WARNING
The machine may start to roll.

Risk of crushing!
Block the wheels so that the machine
cannot start to roll when the parking brake
is released.
Fig. 5-91 Parking Brake Unit

1. Start the engine and run up hydraulic
pressure until the accumulators are fully
charged and the accumulator charging
valve switches to cooling.
2. Turn off the engine and turn the ignition
switch to position I.
3. Release the parking brake.
4. Check that the parking brake caliper can
move on the bracket.
5. Check that the brake disc is clean from oil
and dirt.
6. Remove the cover from the brake caliper.
Check that there is no oil inside the cover.
7. Loosen the lock nut.
8. Adjust the adjustment screw so that the
brakes are applied.
9. Turn back the adjusting screw so that the
clearance between pad and disc becomes
0.5±0.1 mm.
10. Tighten the lock nut.
NOTE:
To avoid turning the adjustment screw as well,
the lock nut must be held still when tightening
it.
11. Refit the cover on the caliper.

12. Check the function of parking brake.

5.14.7 Accumulator
There are two accumulators in the hydraulic

system: Brake System Accumulator, and
Control System Accumulator.
Usually the pressure of c ontrol system

accumulator conforms to the requirements of
control system.
WARNING
WARNING
• Hydraulic oil-way remains pressurizing.

Do not stand opposite 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.
Failure to follow above items may lead to
serious personal injuries or even death.
5.14.7.1 Brake system accumulator,

checking
The accumulator is f illed with nitrogen.

Improper operations would lead to explosion
causing machine damage and personal
injuries. Pay attention to the following items
when dealing with accumulators:

1. Start the engine (position 1 in Fig. 5-92);

let it run until the accumulator is fully 2
pressurized.
P
2. Stop the engine, and turn the ignition key
1
to position 2 in Fig. 5-92. Step on the brake
pedal (position 3 in Fig. 5-93) to its bottom
and hold it there for a certain interval, then
repeat this operation several times.

3. Make sure that at least 20 brakes can be
realized before the alarm light turns on.
4. S t a r t t h e e n g i n e t o p r e s s u r i z e t h e
accumulator, and then repeat step 2
several times.
NOTE:
If the brake cannot function normally for 20
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 3
as possible. The accumulator should be filled
again. Fig. 5-93 Brake Pedal
5.14.7.2 Accumulators, charging with

nitrogen gas
T h e a c c u m u l a t o r s h ave a l r e a d y b e e n
precharged with nitrogen gas before the
installation.
NOTE:
• As the precharging pressure changes
along with the temperature, recheck the
accumulator pressure approx. 2 minutes
af ter charging. Correct the possible
deviation of pressure.
• Tighten the accumulator pressure tighten-

ing screw to 25 N.m, and c lose the

nitrogen exhaust valve. Open the bleed
valve of charging device to discharge the
gas. Remove the charging device, and
check the tightening valve for tightness
with, for example, soap liquid. Repair it if
air leakage occurs.
• Seal the tightening screw with sealing
lacquer. The pressure accumulator is now
ready to be installed.
Steps to charge the accumulator:

1. M easure t he hydr aulic ac c umulato r
before charging to confirm that there is no
pressure in the system.
2. Precharge the accumulator with a special
charging device and check its pressure.
3. Remove the cap and clear away the
sealing lacquer around.
4. Clean the sealing surface and external
thread at the accumulator opening.
5. Loosen the tightening screw just a little
with a hexagon spanner.
6. C o n n e c t t h e c h a r g i n g d e v i c e t o Fig. 5-94 Charging Device
accumulator and the hose to a nitrogen
gas bottle.
7. Make sure that the O –ring is properly
positioned between the charging device
and accumulator sealing surface.
8. Open the accumulator pressure tightening
screw with a square spanner and auxiliary
tools of charging device until it is just
enough to see the readings on pressure
gauge.
NOTE:
If the precharging pressure is too high, please
open the bleed valve of charging device to
reduce the pressure. Note that the bleed valve
must be closed to check the correct reading.

5.14.8 Hydraulic oil circuit, checking
By observing and touching, check if there

are loose bolts or oil leakage at the installed
position of hydraulic oil circuit. If yes, contact
SANY authorized distributors to replace the
parts.
Fig. 5-95 Hydraulic Oil Hose

5.15 Electrical System
The nominal voltage of electrical system is 24

VDC.
The whole electrical system adopts only
one type of conductor, while the electrical
frame acts as the other conductor. For the
convenience of detecting failures, all wires are
numbered according to the markings specified
in the circuit diagrams.
SAFETY
T h e i nsul at i o n m ate r i a l o ut s i d e of t h e
conductor is oil resistant. However, please
avoid the contact of lead with oils or other
solvent fluids. Make sure that the insulation
layer of the lead close to the engine and other
hot surfaces is not damaged. If necessary,
replace the lead.
WARNING
WARNING
Risk of short-circuit and fire!

The burnt-out of a fuse always indicates a
fault in the electric system. Eliminate the
fault prior to fitting a new fuse.
Failure to follow the above instruction

5.15.1 Battery
WARNING
WARNING
Risk of fire and explosion! Avoid contact

with flames or sparks.
Never confound 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 Fig. 5-96 Precautions for Battery
water immediately. If electrolyte has gotten
into eyes, rinse with water and contact a
doctor immediately.
5.15.1.1 Battery, cleaning
Keep the battery clean and dry. Dirt and

oxidated materials on battery and battery
connector may cause electrical 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 and vaseline. Fig. 5-97 Clean the Battery

5.15.1.2 Electrolyte, filling
Check if the filler plug is blocked, and check

the electrolyte level at any time. Fill in purified
water when the electrolyte reaches the lowest
level. Make sure to charge the battery out of
electricity in time.
The electrolyte level should be 5-10 mm (0.2-

0.4”) above the electrode plate. If not, add
distilled water. Then run the engine idle for at
least 30 minutes to charge the battery.
Fig. 5-98 Fill the Electrolyte
1. Make sure that the adhesive sticker on

filler plug is removed.
2. Fill the qualified electrolyte in all the cells
of battery until the electrolyte reaches the
highest level.
3. Tighten up the filler plug.
4. Clean the surface of battery and mount
it on the machine. When installing the
battery, smear a little vaseline on the end
pole firstly to avoid corrosion.
5. Connect firmly the anode of battery with
that of generator, and the cathode of
battery with that of generator. Do not knock
the end pole.
6. Fix the battery up after connecting it with
the generator.
NOTE:
Make sure to follow all the instructions for
batteries free of maintenance.

5.15.1.3 Battery, checking
CAUTION
CAUTION
Battery electrolyte is very caustic. Avoid

any contact with battery electrolyte.
• If electrolyte comes into contact with
clothing, skin or eyes, flush the areas
immediately with water.
• In case of eye contact, rinse with plenty
of water and see a doctor at once!
The battery is fitted in the battery compartment

at the left side of machine.
• Check the battery for cracks in the casings,
and leaked electrolyte.
• Remove any corrosion on battery terminals
and check the connections for tightness.
• Tighten up the terminals and coat with
non-acidic grease.
5.15.1.4 Battery, charging
DANGER
DANGER
Danger of explosion!
Hydrogen would be released when the
battery is being charged. If the hydrogen
mixes with air, explosive gas would be
created.
Short circuit, flame or sparks shall result in
severe explosion. Keep ventilated.
Fig. 5-99 Charge the Battery

1. The current and time for charging the
battery can be referred to below table:
Table 5-19 Battery Charging Current & Time

Charging the new battery
Model
Current (A) Time (H)
6-QA-180 18 6-10

Charging the battery daily

Model
Current (A) Time (H)
according to the
6-QA-180 18
battery status
NOTE:
The accurate charging time can vary a lot
according to the battery status. (The voltage
should be above 12.56V and the specific
gravit y of elec t ro ly te should be ab ove
1.28+0.05)
2. Charge the battery in a well ventilated

place with the temperature of 10-30°C.
If the temperature of electrolyte exceeds
45°C, reduce the current value by half
f irstly 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
phenomenon would appear:
• T h e vo l t a g e o f a n o d e a n d c a t h o d e
exceeds 12.56V (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 phenomenon
appear can reckon that the battery is fully
charged.

5.15.1.5 Battery, using
1. Check regularly the electrolyte level every

week. If it is lowered, fill in adequately
purified water (Avoid filling mineral water,
tap water, etc.). Do not fill any sulfuric
fluid or other fluids, as well as avoiding
impurities into the battery. Clean water
drips on the battery cover after filling water.
Keep the surface of battery dry.
NOTICE
NOTICE
Prevent the electrolyte level from

descending to expose the pole group.
Otherwise, the battery would be damaged.
2. Battery should be charged under below

circumstances:
• If the battery on machine will not be used
for a long time (more than half month),
you should 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
NOTICE
the light is gloomy.
3. Check the charging voltage of engine

every month and control it in the regulated
range.
4. Keep the surface of battery clean and dry.

If there is dust and acid on the surface,
wipe it away with cloth soaked with soda
water immediately. And then wash it with
clean water. Check whether the battery is
clean every half month .

5. Clean the exhaust bolt with distilled water

frequently. Keep it well ventilated.
6. 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.
7. 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 acidating.
5.15.1.6 Battery cables, checking
WARNING
WARNING
Check that the battery cables are correctly

clamped and free from damage.
Fire hazard! Risk of serious injury!
Repair or replace damaged clamps and
check that no machine parts wear or chafe
against battery cables. Replace damaged
battery cables.
The following battery cables must be checked

for clamping, risk of chaf ing and c able
damages. Rectify incorrect clamping and risks
of chafing. Replace battery cables that show
signs of damage.
• Plus-cable between battery and battery
disconnector
• Plus-cable between battery and star t
motor
• Plus- c able bet ween star t motor and
alternator
• Plus-cable between battery disconnector
and main fuses
• Plus- c able bet ween 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

5.15.1.7 Battery, scheduled maintenance
Table 5-20 Scheduled Maintenance of Battery
Items Standards Schedule

Tighten the positive and negative binding post
Check if the binding post is
of battery at regular intervals to avoid loosening. per week
loose
Smear adequate vaseline to avoid corrosion.
Check if the fastening iron Check if the screws at two ends of the iron plate
per 15 days
plate is loose fixing the battery are loose.
Clean the dirt away from the battery surface. Use
Check if the battery surface is
distilled water to clean the exhaust bolt. Keep the per 15 days
clean
battery ventilated.
Add electrolyte to meet the max. marking. Fill
Check the electrolyte per week
electrolyte when it is below the min. marking.
Stop the machine immediately when the battery
Check the voltage alarms for difficult start or low voltage. And everyday
charge it.
Turn off the main power if the battery is unused
Maintenance for long-time
for over half month. Charge the battery every per month
unused
month.
Deposit the battery alone. Keep ventilated and
Check the battery storage avoid sunshine. Charge immediately as soon as per 60 days
the opening voltage is less than 12.55 V.
5.15.2 Fuses, changing
WARNING
WARNING
Risk of cable damage and fire in cable

harnesses! Always use fuses with the
correct ampere rating.
1. Turn off the main power supply (battery

disconnector).
2. Remove the cover from the fuse holder.
3. Check if the fuse is intact, and change it if
needed.

5.15.3 All working lights and indicators,

checking
Check whether working lights 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. 5-100 Working Light
5.15.4 Wiper, adjusting
1. Adjust the angle of wiper blade by hand to

vary its covering range.
1
2. If there is dust on the wiper blade, lift the
blade up and clean it, then place it back
to its original position so as to reduce the
wiping resistance.
3. Adjust the tightness of fixed screws (1) to
make the motor run the wiper blade easily.
4. If there is damage on the wiper blade,
loosen the screw, dismantle the old wiper
blade from the arm, and replace it with a Fig. 5-101 Fixed Screw of Wiper
new blade.

5.15.5 Wiper, replacing
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.
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
Nm.
3. When tightening, fix the wiper arm to make
it bear the torque pressure. Do not let the
torque transfer to the motor, or it would be
damaged.

5.16 Maintenance Record List
Machine
Model
Serial No.
Table 5-21
Finished Maintenance
Working Maintenance
Strategies Working hours Signature
hours Date
50
250
500
750
1000
1250
1500
1750
2000
2250
2500
2750
3000
3250
3500
3750
4000
4250
4500
4750

Finished Maintenance
Working Maintenance
Strategies Working hours Signature
hours Date
5000
5250
5500
5750
6000
6250
6500
6750
7000
7250
7500
7750
8000
8250
8500
8750
9000
9250
9500
9750
10000

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L
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B
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GE
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Container Reach Stacker Troubleshooting
Troubleshooting
6. Troubleshooting
6.1 Precautions�� 6-2
6.2 Troubleshooting Procedures�� 6-3
6.3 Common Troubleshooting Methods�� 6-5
6.3.1 Troubleshooting the engine system�� 6-5
6.3.2 Troubleshooting the transmission system�� 6-8
6.3.2.1 Overview�� 6-8
6.3.2.2 Troubleshooting procedures�� 6-9
6.3.2.3 Troubleshooting table��6-11
6.3.3 Troubleshooting the drive axle and brake system��6-12
6.3.4 Troubleshooting the steering system��6-13
6.3.5 Troubleshooting the spreader system��6-13
6.3.6 Troubleshooting the mast system��6-15
6.3.7 Troubleshooting the air conditioning system��6-16
6.3.8 Troubleshooting the hydraulic system��6-17
6.3.9 Troubleshooting the electrical system��6-18
6.3.9.1 Troubleshooting the cable harness��6-19
6.3.9.2 Troubleshooting table�� 6-20
6.4 Engine Error Codes �� 6-27
6.4.1 VOLVO engine error codes�� 6-27
6.4.2 CUMMINS engine error codes�� 6-36
6.4.3 YUCHAI engine error codes�� 6-42
6.5 Machine Error Codes �� 6-47

Troubleshooting Container Reach Stacker
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 maintenance, 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
corresponding sollution:
1. Read this manual in detail to get a general

knowledge about related system and its
operating principle as well as the structure,
function and technical specification of
system components .
2. Consult the driver

Before checking, you should consult relevant
personnel (the driver) for all the failure details.
• The current operation condition of the
machine (Does the machine operate
properly)
• When is the failure found and what is the
machine working at that time
• The failure development. Does the failure
get worse or occur for the priority time
• What other failures did the machine have
before
For example, which components have
been repaired or replaced
• What have been done and what was the
result after the failure occurred
• Can the failure be repeated
3. Check before starting

• Before per forming trouble diagnosis,
check the running record and operation
maintenance record for any irregular or
improper operation or maintenance.
• Check if any par t 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 connecting 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
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 required 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 Common Troubleshooting

Methods
6.3.1 Troubleshooting the engine

system
Table 6-1
Failure Symptom Possible Causes Suggested Actions Reference

Too low temperature
Completely preheat the
Insufficient preheating time of -
engine.
engine
Blocked air filter or air intake Check the air intake system
Hard to start the -
pipe of engine for blockage.
engine see “Fuel system”
Fault in oil way of fuel system Check the fuel system.
on page 5-47
Malfunction of thermostat Check the thermostat. -
Insufficient starting voltage Check the voltage of battery. -
The EDC fuel control unit has
The engine is runaway Check the fuel control unit. -
fault
The corrugated pipes
have cracks and air The quality of pipe itself Replace it. -
leakage
The rotate speed of The EDC fuel control unit has
Check the fuel control unit. -
engine is not stable fault
No oil in tank Check if fuel is used up. -
Check if fuel oil way is
Engine stops Blockage in oil pipe -
blocked.
unexpectedly
Check if air enters into the oil
Air entering in oil pipe -
pipe.
see “Coolant level,
Insufficient coolant in water Check if the coolant of water
checking” on page
tank tank is sufficient.
5-40
Temperature of water Malfunction of thermostat Check the thermostat. -
in engine is too high see “Drive belt,
Check if the fan belt is
The fan belt is loose checking” on page
loosened.
5-31
The water pump is damaged Check water pump. -
There is oil in water The engine oil cooler is Check if engine oil cooler is
-
but no water in oil damaged damaged. If yes, replace it.


The quality of cover itself Replace the cover. -
T he cy linder c over see “Coolant level,
Check if the coolant is
has crack Insufficient coolant checking” on page
sufficient.
5-40
The lubrication oil The cylinder cover or cylinder Check if cylinder cover or
-
level in oil pan rises body has crack cylinder body has crack.
unexpectedly and The water defender of cylinder Check if the water defender
-
water enters oil liner is damaged of cylinder liner is damaged.
The oil level is too low Refill the lubrication oil. -
see “Oil filter /
Bypass filter,
The oil filter is blocked Replace the filter.
Lubrication oil chaging” on page
pressure is too low 5-37
see “Engine oil,
The lubrication oil is too thin Replace the lubrication oil. changing” on page
5-36
The water tank has refer to “Shop
The water tank is damaged Replace it.
leakage Manual”
The engine oil radiator The engine oil radiator is refer to “Shop
Replace it.
has leakage (gearbox) damaged Manual”
Check if the fuel oil way is
The oil supply is insufficient -
unblocked.
The diesel quality cannot meet
Use accepted fuel. -
The power of engine requirements
is not sufficient see “Turbocharger
Check if the air intake pipe is and blast pipe,
The air intake pipe is damaged
unblocked. checking” on page
5-53
The speed of engine
Check if the fuel oil way is
is automatically The oil supply is not smooth. -
unblocked.
decreased
The pre-filter and filter The diesel is too dirt Chang the diesel. -
elements for engine
The diesel tank is unclean Clean oil tank. -
diesel are blocked
The exhaust pipe is damaged Replace the pipe.
The exhaust pipe of
The joint of exhaust pipe is
engine has leakage Tighten the joint. -
loosened
see “Drive belt,
The engine fan belt is The quality of belt itself Replace belt. replacing” on page
broken 5-33
The belt is too tight Adjust the tension of belt. -


The wear clearance between
The engine has blue valve and valve sleeve Replace the valve. -
smoke becomes large
The oil scraper is damaged Replace oil scraper. -
It is hard to speed up The EDC fuel control unit has
Check EDC fuel control unit. -
the engine fault
The engine
The seal of supercharge is
supercharger has oil Replace the seal. -
damaged
leakage
The indication of fuel The fuel gauge or oil level Check the fuel gauge and oil
-
gauge is incorrect sensor is damaged level sensor.
The oil seal at the
front end of engine The quality of seal itself Replace it. -
crankshaft

6.3.2 Troubleshooting the transmission

system
6.3.2.1 Overview
When troubleshooting a “ transmission”

problem, it should be kept in mind that the
transmission is only the central unit of a
group of related power-train components.
Proper operation of the transmission depends
on the condition and correct functioning of
other components of the group. Therefore,
to properly diagnose a suspected problem in
the transmission, it is necessary to consider
the transmission fluid, charging pump, torque
converter, transmission assembly, oil cooler,
f ilter, connecting hosees, and controls,
including the engine, as a complete system.
Torque converter transmission troubles fall

into three general categories: mechanical,
hydraulic and electrical problems. In addition
to the mechanical and electrical components,
all of which must be in the proper condition
a n d f u n c t i o n i n g c o r r e c t l y, t h e c o r r e c t
functioning of the hydraulic circuit is most
important. Transmission fluid is the “life blood”
of the transmission. It must be supplied in an
adequate quantity and delivered to the system
at the correct pressures to ensure converter
operation, to engage and hold the clutches
from slipping, and to cool and lubricate the
working components.

6.3.2.2 Troubleshooting procedures
Step 1: Stall test

Use a stall test to 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 for ward (or
reverse, as applicable) gear.
3. Select the highest speed.
4. With the engine running, slowly increase
engine speed to approx. 1/ 2 throttle and
hold until transmission (converter outlet) oil
temperature reaches the operating range.
NOTICE
NOTICE
Do not operate the converter at stall

condition longer than 30 seconds at
one time, shift to neutral for 15 seconds
and repeat the procedure until desired
temperature is reached. Excessive
temperature (120°C/250°F maximum)
will cause damage to the transmission
clutches, fluid, converter, and seals.
Step 2: Transmission pressure checks

Transmission problems can be isolated by
the use of pressure tests. When the stall test
indicates slipping clutches, measure clutch
pack pressure to determine if the slippage
is due to low pressure or clutch plate friction
material failure.
In addition, converter charging pressure and
transmission lubrication pressure may also be
measured.

Step 3: Mechanical and electrical checks:

Prior to checking any part of the system for
hydraulic function (pressure testing), make the
following mechanical and electrical checks:
• Check the parking brake for correct
adjustment.
• Be sure all lever linkage is properly
connected and adjusted in each segment
and at all connecting points.
• The controls are actuated electrically.
Check the wiring and electrical
components.
• B e sure t hat all c omp onent s of t he
cooling system are in good condition and
operating correctly. The radiator must be
clean to maintain the proper cooling and
operating temperatures for the engine
and transmission. Air clean the radiator, if
necessary.
• The engine must be operating correctly.
Be sure that it is correctly tuned and
adjusted to the correct idle and max. no-
load governed speed specifications.
Step 4: Hydraulic check
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 operating at stall RPM.

6.3.2.3 Troubleshooting table

Table 6-2

Low oil pressure see "Gearbox oil
Check the oil level. level, checking"
Insufficient oil
on page 5-58
Slipping of clutch
Damage of prefill pump Check the prefill pump. -
Invalid of the clutch abrasion refer to “Shop
Replace the clutch pump.
sheet Manual”
see "Gearbox oil
Low or high oil level Check the level of lubrication oil. level, checking"
on page 5-58
Damage of prefill pump Check the prefill pump. -
High oil temperature The torque converter works Avoid torque converter to work too
-
too long in low efficient area long in low efficient area.
Step the clutch in braking and
The clutch does not release
check if the clutch switch is -
in long time braking
inoperative.
Abnormal meshing of gear Check the meshing of gear. -
Too much noise Abrasion or damage of Replace the damaged or abraded
-
bearing bearing.
see "Gearbox oil
Low oil level Check the oil level. level, checking"
Inadequate oil on page 5-58
pressure displayed Damage of prefill pump Check the prefill pump. -
by oil pressure Damage of the clutch Check the presssure-adjusting
-
gauge pressure-adjusting valve valve.
Damage of the clutch oil-
Replace the damaged sealing part. -
sealing part
Check the signal of control unit of
-
gearbox.
The gearbox can Fault in control unit of
Check if the solenoid coil of
not switch gears gearbox -
gearbox solenoid valve is burnt out.
Check if the valve core is blocked. -
The gear cannot be
shifted manually
The contact is inoperative Check the contact. -
Disorder of control
lever
see "Attaching
The vibration and bolts of
The attaching screw is
noise in cab are Tighten the loosened screw. transmission
loosened
large shaft, checking"
on page 5-54

6.3.3 Troubleshooting the drive axle

and brake system
Table 6-3

Oil pressure of braking system see “Oil leakage
is low Check if the brake oil has of drive axle
The force of service Braking oil way has air leakage. and brake
brake is not sufficient components,
The brake components are checking” on page
Check the brake components.
worn out 5-59
Check if the fan of cooling
The oil temperature of braking system can rotate or fan flanks refer to “Shop
Too much noise
system is high are damaged. Replace it if Manual”
necessary.
Adjust the distance of brake
Failure of brake valve -
valve.
Check the clearance of brake
Failure of brake -
sheet.
Failure of pressure relay Clean or replace it. -
Without service brake see “Brake system
or the service brake accumulator,
Failure of accumulator Check the accumulator.
functions bad checking” on page
5-105
refer to “Shop
Failure of gear pump Replace it.
Manual”
refer to “Shop
Failure of brake valve group Clean or replace it.
Manual”
Failure of parking brake Clean the parking brake. -
Clean the solenoid valve or
Without parking brake Failure of solenoid valve -
replace it.
or the parking brake
High oil return back pressure Check the oil return pipe. -
functions bad
refer to “Shop
Failure of brake valve Clean or replace it.
Manual”

6.3.4 Troubleshooting the steering

system
Table 6-4

refer to “Shop
Insufficient fuel supply Check the system pressure.
Manual”
Failure of hydraulic steering
Clean and replace it. -
Ineffective or gear
impossibble to steer Serious leakage of steering
Replace the sealing parts. -
cylinder
Damping hole of flow amplifier
Clean it. -
is clogged
6.3.5 Troubleshooting the spreader

system
Table 6-5

Damaged overflow valve or relief Replace the overflow valve or
-
valve relief valve.
No pressure in the
Valve core is blocked Clean it. -
system
Check the oil pump feedback
No output of oil pump -
oil circuit.
Electrical failure Replace the circuit. -
Without movement Solenoid valve is damaged Replace the solenoid valve. -
The valve core is blocked Clean the valve core. -
Wearing connection caused by
Check and recover the fault. -
wiring fault
The corresponding solenoid valve
Clean the solenoid valve. -
Only a few is clamped
of spreader The coil of solenoid valve is
Replace the coil. -
movements are damaged
effective The controller of spreader is Replace the spreader refer to “Shop
damaged controller. Manual”
Check and repair it. Replace
Fault in button of joystick -
the joystick if necessary


see “Fuses,
The power supply fuse of spreader
Replace the fuse. changing” on
control device is burnt out
page 5-116
The hoses of general oil supplying
Inspect and recover it. -
No movement of valve have some malfunction
the spreader Check and resume it. Replace
General oil supplying valve has
the general oil supplying valve -
some malfunction
if necessary.
refer to “Shop
Spreader controller is damaged Replace it.
Manual”
The yellow indicator Wrong induction distance of
Adjust the distance. -
light blinks or seated sensor
illuminates all the Seated sensor is damaged Replace the sensor. -
time when the
The yellow indicator light is refer to “Shop
spreader is not Replace the indicator light.
damaged Manual”
seated
The red indicator Wrong induction distance of
light does not blink unlocked sensor
or illuminate when Unlocked sensor is damaged Replace the sensor. -
the spreader is refer to “Shop
The red indicator light is damaged Replace the indicator light.
unlocked Manual”
The green indicator Wrong induction distance of
light does not blink locked sensor
or illuminate when Locked sensor is damaged Replace the sensor. -
the spreader is The green indicator light is refer to “Shop
Replace the indicator light.
locked damaged Manual”

6.3.6 Troubleshooting the boom system
Table 6-6

Boom shakes while
Clogged solenoid valve Clean it. -
being retracted
Leakage of telescopic and Check and replace the sealing
-
Boom retracts or pitching cylinder parts.
lowers automatically Malfunction of self-locking
Check it. -
function of logic valve
Check, adjust the pressure
Low oil pressure -
No pitching or valve in pump and main valve.
telescopic movements Malfunction of logic valve Check it. -
of boom Only one movement of Check the electrification
-
differential solenoid valve situation of the valve.
Low oil level Fill oil into the tank. -
Boom is not extended Too large protecting distance
Reduce the distance. -
completely of telescopic cylinder
Insufficient system pressure Increase the pressure. -
The fuse of boom control see “Fuses,
return circuit power supply is Replace the fuse. changing” on
burnt out page 5-116
see
No movement of boom "Troubleshooting
Circuit failure Check and recover the circuit. the cable
harness" on page
6-20
Safe protection Check it. -
Too much interference signal Check and adjust it. -
Signal line of joystick is
Check the joystick. -
Boom movement is damaged
refer to “Shop
out of control The joystick is damaged Replace it.
Manual”
Electric proportional valve is
Replace it. -
damaged
The ignition switch is turned off Turn on the ignition switch. -
The boom cannot be Failure of emergency lowering Check and repair the valve. -
solenoid valve
lowered in emergency
The connector is loose or the
Check the connector and wire. -
wire is dropped

6.3.7 Troubleshooting the air

conditioning system
Table 6-7
Failure
Possible Causes Suggested Actions Reference
Symptom
Cab temperature is lower
Set a lower temperature. -
than the set temperature
Turn on the refrigeration mode
Temperature highly changes
after the temperature is getting -
during one day
higher.
Belt is loose Tighten the belt. -
Check if the inserting fuse in
see “Fuses, changing”
electric cabinet is burnt out. If
on page 5-116
yes, change the fuse.
Fuse of condenser burns out Check if the fuse is fixed. -
No refrigeration Check if the plug-in part of
effect controller and condenser coil -
has good contact effect.
Plug-in part of condenser
Insert the plug-in part again. -
clutch coil is loose
Coil is too tight or plug-in part
Fix the coil terminals. -
has poor contact effect
Turn off the refrigeration mode. -
see “Leakage or lack
Check the condenser for
Refrigerant is leaking of oil in condenser,
leakage.
Inform SANY to deal with it. -
Most of the air outlets are Adjust the cab temperature.
-
Poor blocked Open all the air outlets.
refrigeration Bad sealing effect of cab Close all the windows and doors. -
effect see “Refrigerant,
Refrigerant is not enough Fill in refrigerant.
filling” on page 5-96
Check the output, grounding and
Connecting wire to engine is
connecting wire of conditioner. -
loose or ruptured
Small air Connect the wire again.
volume or no see “Fuses, changing”
Fuse is burnt out Change the fuse.
air on page 5-116
Speed governing resistance
Inform SANY to deal with it. -
of evaporator is damaged
Few wind and
the refrigeration
Filter is dirty Clean the filter. -
effect becomes
poor

6.3.8 Troubleshooting the hydraulic system
Table 6-8
Failure
Symptom
refer to “Shop
Failure of cooler Replace it.
Manual”
Air-cooled hydraulic motor of cooling refer to “Shop
Replace the hydraulic motor.
circuit is damaged Manual”
High oil Oil supply of loop feed pump is not Replace the back pressure
-
temperature enough spring.
Inter drainage of reversing valve is
Replace the reversing valve. -
serious
Low flow of cooler Clean the cooler. -
Outer radiator fins are too dirty Wash the outer radiator fins. -
Use the hydraulic oil of substandard
see "Hydraulic oil,
quality
Replace the hydraulic oil. changing" on page
Use the hydraulic oil of substandard
5-101
viscosity
Long-term use of hydraulic oil
Periodical filtration. -
without filtrating or replacing it
see "Oil return filter
Hydraulic oil is The constant entrance of dust, sand Replace the filter core
element, replacing"
polluted and and other debris periodically.
on page 5-102
deteriorated
High temperature; oxidation
see "Hydraulic oil,
metamorphism
Replace the hydraulic oil. changing" on page
Enter with water and air, as a result
5-101
of cavitation, erosion, etc.
see "Hydraulic oil
Clogged filter Clean it or replace it. filter, changing" on
page 5-100
Leakage of Damaged or distorted sealing parts Replace the sealing parts. -
hydraulic oil Joints and pipelines are lossened Tighten the loose parts. -
see “Fuses,
The fuse of cooling system is burnt Replace the fuse. changing” on page
The hydraulic
5-116
or brake
The temperature switch is damaged Replace the switch. -
cooling system
The contact of relay controlling the
cannot cool Replace the contact. -
cooling system is fused
automatically
Failure of cooler solenoid valve Replace it. -
Failure of radiating motor Replace it. -

6.3.9 Troubleshooting the electrical

system
The causes for faults in electrical control

system are generally complicated. The real
causes for faults should be diagnosed only
based on careful obser vation, research,
experiments and rich practical experiences.
When the causes are diagnosed, eliminate
them in sequence from easy to difficult.

6.3.9.1 Troubleshooting the cable harness
NOTE:
Perform troubleshooting for all cables in the
same way to avoid damage to control units,
components or measuring equipment.
1. Study the circuit diagram in question.

Check where the suspected cable is
connected and if so where it is spliced.
2. Turn off the main electric power.
3. Unplug the connector at the control unit or
component in question.
4. Check if there is open circuit.
NOTE:
Some components cannot be checked without
power supply to the components. In such an
event, proceed to point 5.
• a. M easure the resist anc e bet ween

connections for the component in the
c onnec tor at the c ontrol unit or the
component in question.
• b. The resistance must correspond with
the component. Otherwise there may be
an open circuit or short circuit in cable
harness and / or the component.
5. Check if there is short circuit to frame:

• a. Unplug the connector at both the control
unit and the component in question.
• b. Measure the resistance of one lead at
a time. Measure between the lead and a
frame-connected part of the machine.
• c. The multi-meter should show endless
resistance.

6.3.9.2 Troubleshooting table
Table 6-9
Failure
Symptom
see
"Troubleshooting
Open circuit or short circuit Check and recover it.
the cable harness"
on page 6-19
Non-operation of
Rusty of magnet Scrub the magnet. -
magnetic valve
Replace the spool or seal
Spool abrasion or seal-ring aging -
ring.
Severe oil carbon pollution in the valve Scrub the magnet. -
Failure of deflection spring Replace the spring. -
Air ejection from
Failure of magnetic valve Replace the valve. -
magnetic valve
see
"Troubleshooting
Open circuit Check and recover it.
Water level the cable harness"
switch alarms for on page 6-19
full tank Fault of structure of water level switch Replace the switch. -
The water level switch is reversely
Reinstall the switch. -
installed
see
"Troubleshooting
Open circuit Check and recover it.
No indication of the cable harness"
fuel level on page 6-19
Reverse connection of power line and
Reconnect the lines. -
signal line
Line abrasion, there is contact
Inaccuracy
resistance between signal line and Check and recover it. -
of fuel level
power line
indication
Failure of sensor Replace the sensor. -
see
Non-operation "Troubleshooting
Failure of circuit Check and recover it.
of temperature the cable harness"
switch on page 6-19
Switch damaged Replace the switch. -
Big error of Adjusted value of temperature switch
Replace it. -
temperature is inaccurate
switch The temperature switch is ineffective Check and recover it. -


see
"Troubleshooting
Non-operation of Failure of circuit Check and recover it. the cable
pressure switch harness" on page
6-19
Switch damaged Replace the switch.
Adjusted value of pressure switch
Big error of pressure Readjust it. -
is inaccurate
switch
The pressure switch is ineffective Replace it. -
see
"Troubleshooting
Open circuit Check and recover it. the cable
No signal of pressure
harness" on page
sensor
6-19
Reverse connection of signal line
Reconnect the lines. -
and power line
Line abrasion: there is contact
resistance between signal line and
Big error of pressure Check and recover it. -
its housing, or power line and its
sensor signal
housing
The sensor is ineffective Replace it. -
Incorrect signal of
throttle. Start the engine
and run it at its max. Reverse connection of power line
Check and recover it. -
speed. Step on the of pedal and ground wire
throttle, but the rotate
speed decreases
The rocker switch is damaged Replace it. -
see
No operation of rocker "Troubleshooting
switch The lead is peeled Check and recover it. the cable
harness" on page
6-19
The bulb is damaged Replace the bulb. -
see
"Troubleshooting
No indicator light
Failure of circuit Check and recover it. the cable
harness" on page
6-19


The contact spring is too soft Adjust the elasticity of spring. -
The connection iron
The bottom plate is eneven Remove the protruding part. -
of contactor does
The connection iron or
not fall when the Recover it to be flexible. -
mechanical part is clamped
power is off
The contacts are fused together Replace the contact. -
The contact of
cotactor does not
The contact spring is too soft Adjust the elasticity of spring. -
close fully when the
power is on
Its load exceeds the max. Find out the reason and eliminate
-
volume the failure.
Contact of relay is The contact moves too much Replace the contact. -
heated The contact is serious burnt Replace the contact. -
The contact pressure is
Replace the contact. -
inadequate
The contact is covered with Find out the reason and eliminate
-
dust, dirt or is burnt out the failure.
Pool contact of relay
Adjust the elasticity of spring.
The contact spring is too soft -
Replace it as necessary.
The contact is not qualified Replace the contacts. -
There is sparkle on Adjust the elasticity of spring.
The contact spring is too soft -
the contact when Replace it as necessary.
the relay is closed The contact is burnt, poor
Replace it. -
contact
Pool connection of armature
Clean the connection surface. -
Abnormal noise of and iron core
DC contactor Large pressure of contact Replace the contact spring and
-
pressure contactor if necessary.
Battery switch The contacts are fused together Replace the contacts or switch. -
cannot be
The mechanical part is clamped Repair it to make it flexible. -
disconnected
see
"Troubleshooting
N on - operation of Open circuit Check and recover it. the cable
preheater harness" on page
6-19
Heater damaged Replace it. -


see
"Troubleshooting
Short circuit of horn power wire
The horn alarms all Check and recover it. the cable
and control power line
the time when the harness" on page
power is on 6-19
The contact of relay controlling the
Replace the relay. -
horn is fused
The contact head is loose Retighten the contact. -
see “Fuses,
The fuse of control circuit is burnt
out
Press down the wiper page 5-116
The zero wire is not connected in
button, but the wiper Re-connect the zero wire. -
the control circuit
motor is not started
Check the relay, and
The start relay is damaged -
replace it as necessary.
Check the button, and
The wiper button is ineffective -
see
"Troubleshooting
Sound & light alarm The lead is peeled or open circuit Check and recover it. the cable
does not work harness" on page
6-19
The alarm is damaged Replace it. -
see
"Troubleshooting
Open circuit Check and recover it. the cable
harness" on page
6-19
see “Fuses,
The fuse of power supply is burnt
Non-operation of out
page 5-116
display when the
see
system is electrified
"Troubleshooting
Failure of circuit Check and recover it. the cable
harness" on page
6-19
Check and recover the
Endless loop of program -
program.
The controller is damaged Replace the controller. -


The contact head is loose Retighten the contact. -
see “Fuses,
The fuse of control circuit is burnt
out
page 5-116
Rotate the ignition
The gear selector is not at neutral Rotate the gear selector to
switch, but the engine -
is not started position neutral position.
Check the relay, and
The start relay is damaged -
Check the switch, and
The ignition switch is ineffective -
Find out the reason and
Pool contact of ignition switch -
eliminate the failure.
see “Fuses,
Rotate the ignition The fuse of control circuit is burnt Replace the fuse body after
changing” on
switch, but the out inspection.
page 5-116
start relay and start The lead and contact head are Find out the reason and
-
contractor do not work loose, pool contact eliminate the failure.
The contact head of relay or
Find out the reason and
contactor is loose, the loop is -
eliminate the failure.
ineffective
The brake pedal is blocked and Make the pedal to move
-
unable to be stepped to its bottom.smoothly.
Engine speed cannot
Make the output signal to
reach to the rated Incorrect throttle output signal -
be 1.6-3.8V.
speed
The connector is loose or the wire Check the connector and
-
is dropped wire.
After the engine The brake pedal is blocked and Make the pedal to move
is started, and the -
unable to be stepped to its bottom. smoothly.
gear is selected, the
machine cannot move There is parking signal Press down the parking
-
with the gear signal button.
see
"Troubleshooting
Failure of the ground wire Check and recover it. the cable
The travelling speed
harness" on page
is not displayed and
6-19
the machine can only
The speed sensor is damaged Replace it. -
travel at 1st gear
Replace the channel, or
The circuit board is damaged if necessary, replace the -
frequency divider.


Reverse connection of rod
and rodless chamber pressure Reconnect them. -
Inaccurate sensors
measurement of Pressure sensor is damaged Replace it. -
weight The connector is loose or the
wire is dropped
Uneven road Make the road even. -
W r o n g a l a r m o f Wrong distance of proximity Adjust the distance. -
switch
forward over-turning
Proximity switch is damaged Replace it. -
protection
The connector is loose or the
wire is dropped
Cab cannot be Solenoid valve is damaged Check the solenoid valve. -
moved The connector is loose or the
wire is dropped
Counterweight Solenoid valve is damaged Check the solenoid valve. -
cannot be moved The connector is loose or the
wire is dropped
The menus cannot Too much redundancy data Refresh the page. -
be displayed The screen is disturbed by Eliminate the interference
-
normally with magnetism source.
distorted figures The screen is damaged Replace the screen. -
see
"Troubleshooting
Bus failure Check and recover the wire. the cable
harness" on page
6-19
The data displayed
Bus terminal resistance is
on the screen is Replace the resistance. -
damaged
abnormal
see
"Troubleshooting
The lead is peeled Check and recover the wire. the cable
harness" on page
6-19


see “Fuses,
out
page 5-116
Failure of controller Check it. -
Failure of program -
No operation of program.
controller Controller damaged Replace the controller. -
see
"Troubleshooting
Failure of input or output circuit Check the circuit. the cable
harness" on page
6-19
see “Fuses,
No operation of out
page 5-116
extended block
Failure of extended block -
communication circuit.
Communication fault Check if the circuit is
Failure of the communication
between engine and disconnected or if there is -
circuit
controler water in circuit.
Communication fault Check if the circuit is
between controller disconnected or if there is -
circuit
and I/O water in circuit.
Check if the circuit is
disconnected or if there is -
circuit
Communication fault water in circuit.
between controller Check if the terminal resistant
and display is burnt or poorly connected.
Failure of terminal resistant -
Check if the terminal resistant
is on its plug.
Check if the circuit is
disconnected or if there is -
circuit
Communication fault water in circuit.
between controller Check if the terminal resistant
and length & angle is burnt or poorly connected.
sensor Failure of terminal resistant Check if the terminal resistant -
is in its plug, or replace the
sensor.

6.4 Engine Error Codes
6.4.1 VOLVO engine error codes
For the detailed information, see: “VOLVO

ENGINE MANUAL”.
Table 6-10 Engine Error Codes

Code SPN
Description Possible Causes Failure Symptom Suggested Actions
No. Code
1.1 No faults
2.1 97 Water in fuel Water in fuel None Empty the primary fuel filter
1. Check the coolant level.
2.2 111 Coolant level Low coolant level Engine stopped 2. Check the function of coolant
level monitor.
1. Check that the coolant level
1. Short circuit to
Coolant level sensor cable is not damaged.
2.3 111 positive (+) None
sensor 2. Check the function of coolant
2. Fault in sensor
level sensor.
1. Check that the sensor
1. No signal connector is correctly installed.
2. Abnormal 2. Check that the engine speed
Engine is very
frequency sensor cable is not damaged.
Flywheel difficult to start and
2.4 637 3. “Intermittent” 3. Check that the engine speed
speed sensor runs roughly when it
signal from the sensor is correctly installed in
starts.
sensor the flywheel housing.
4. Fault in sensor 4. Check the function of engine
speed sensor.
1. Check that the engine speed
sensor connector is correctly
installed.
Engine takes
1. No signal 2. Check that the engine speed
Camshaft longer to start than
2. Abnormal sensor cable is not damaged.
2.5 636 drive speed normal. Engine
frequency 3. Check that the engine speed
sensor runs normally when
3. Fault in sensor sensor is correctly installed in
running.
the upper timing gear cover.
4. Check the function of engine
speed sensor.
After the engine has stopped,
Engine speed too
2.6 190 Engine speed None look for the reason for the high
high
speed.

Code SPN
No. Code
1. Engine goes to
idle 1. Check that the potentiometer
2. If you release the has been connected correctly.
Speed
1. Shorted to positive accelerator first and 2. Check that the cable harness
potentiometer
2.8 608 (+) or negative (-) then press it down to the potentiometer has not
connected to
2. Fault in sensor again, the engine been damaged.
CIU
can be forced to 3. Check the potentiometer
run using the idle function.
contact.
1. Check the indicator cables for
1. Short circuit breaks and short circuits.
Indicator for
2.9 97 2. Open circuit None 2. Check the function of
water in fuel
3. Fault in indicator indicator. Change it as
necessary
1. Short circuit 1. Check that the oil pressure
Oil pressure to positive (+) or sensor cable is not damaged.
3.1 100 None
sensor negative (ground) (–) 2. Check that the oil pressure
2. Open circuit sensor is correctly connected.
1. Check that the boost
temperature sensor connector is
correctly installed.
2. Check that the boost
1. Short circuit
Boost temperature sensor cable is not
to positive (+) or
3.2 105 temperature None damaged.
negative (ground) (–)
sensor 3. Check that the boost
2. Open circuit
temperature sensor is correctly
installed.
4. Check the function of boost
temperature sensor.
1. Check that the coolant
temperature sensor connector is
correctly installed.
2. Check that the coolant
1. Short circuit
Coolant Preheating is also temperature sensor cable
to positive (+) or
3.3 110 temperature activated when the is not damaged.
negative (ground) (–)
sensor engine is hot. 3. Check that the coolant
2. Open circuit.
temperature sensor is correctly
installed.
4. Check the function of coolant
temperature sensor.

Code SPN
No. Code
1. Check that the boost pressure
installed.
1. Short circuit Engine smokes
Boost 2. Check that the boost pressure
to positive (+) or more than normally
3.4 106 pressure sensor cable is not damaged.
negative (ground) (–) during acceleration /
sensor 3. Check that the boost pressure
2. Open circuit load increase.
sensor is correctly installed.
4. Check the function of boost
pressure sensor.
Engine control
module reduces
1. Check the function of
engine power
turbocharger compressor.
Boost Boost pressure too (unless the
3.5 106 2. Check the function of boost
pressure high protection has been
pressure sensor.
shut off with the
3. Check fuel volume / injector.
VODIA diagnostic
tool).
1. Check that the fuel pressure
installed.
1. Short circuit
Fuel pressure to positive (+) or
3.6 94 None sensor cable is not damaged.
sensor negative (ground) (–)
2. Open circuit
sensor is correctly installed.
4. Check fuel pressure sensor
function.
1. Check that the cable harness
1. Short circuit to the oil temperature sensor
Oil
to positive (+) or has not been damaged.
3.7 175 temperature None
negative (ground) (–) 2. Check that the oil temperature
sensor
2. Open circuit sensor has been connected
correctly.
1. Check if it is possible to
increase pressure with the hand
3.8 94 Fuel pressure Low supply pressure None pump.
2. Check the fuel filter.
3. Check the fuel pre-filter.
1. Faulty alternator
Battery Check the supply voltage from
3.9 158 2. Faulty battery, None
voltage, EMS the control unit.
battery cables

Code SPN
No. Code
1. The engine 1. Check that connections to
1. Short circuit
cannot be started. the ignition key have not been
Start output to positive (+) or
2. The engine starts damaged.
4.6 677 / Start motor negative (–)
immediately when 2. Check that the cable harness
relay 2. Activated for too
the ignition is turned to the ignition key has not been
long
on. damaged.
1. Short circuit to Engine can only be
520 Stop input Check that the starter switch
4.8 negative (-) stopped with the
195 EMS connections are not damaged.
2. Open circuit auxiliary stop.
1. The engine 1. Check that connections to
1. Short circuit to cannot be started. the ignition key have not been
520 Starter input negative (-) 2. The engine starts damaged.
5.2
194 CIU 2. Activated for too immediately when 2. Check that the cable harness
long the ignition is turned to the ignition key has not been
on. damaged.
1. Engine can only
be stopped with the
auxiliary stop.
2. Engine stops. A
1. Short circuit to
fault is displayed for 1. Check that the starter switch
negative (-)
Stop input 40 seconds and the connections are not damaged.
5.3 970 2. Open circuit
CIU engine can not be 2. Check that the ignition switch
3. Activated for too
started during this cable is not damaged.
long
time. When a fault
is active, the engine
can be started but
not stopped.
1. Preheating can
1. Short circuit
not be activated. 1. Check that the relay input
Preheating to positive (+) or
5.4 626 2. Preheating cable is not damaged.
relay negative (ground) (–)
relay is constantly 2. Check the function of relay.
2. Open circuit
connected.
5.7. 98 Oil level Oil level is too low Warning indication Check the oil level.
1. Warning
indication.
2. The engine
1. Check the oil level.
control module
Oil Oil temperature is 2. Check the oil temperature.
5.8 175 limits engine output
temperature too high 3. Check the function of oil
(unless protection
temperature sensor.
has been turned off
with the diagnosis
tool VODIA).

Code SPN
No. Code
1. Short circuit
to the oil level sensor has not
Oil level to positive (+) or
5.9 98 None been damaged.
2. Check the function of oil level
2. Open circuit
sensor.
2. Check the intercooler
Engine control
(cleanliness).
module reduces
3. Check if there is air in the
engine power
cooling system.
Coolant Coolant temperature (unless the
6.1 110 4. Check the pressure cap on
temperature is too high protection has been
the expansion tank.
shut off with the
5. Check the function of coolant
VODIA diagnostic
temperature sensor.
tool).
thermostat.
Engine control
module reduces
2. Check the intercooler
engine power
(cleanliness).
Boost Boost temperature is (unless the
6.2 105 3. Check boost temperature
temperature too high protection has been
sensor the function of.
shut off with the
VODIA diagnostic
thermostat.
tool).
1. Check that the 8-pin
connector is not damaged.
Data link Instruments and
Faulty data link 2. Check that the cables
6.4 639 (CAN), warning lights stop
(CAN), CIU between the CIU and the engine
CIU working.
management unit are not
damaged.
Internal fault in
control module.
Engine not
2. Check that the cables
operating: engine
between the CIU and the engine
2017 / PSID Data link (CAN), can not be started.
6.5 639 management unit are not
201 EMS 2 Engine operating:
damaged.
engine idles and can
3. Check that sleeves 11 and 12
only be stopped with
in the connector on the CIU are
the auxiliary stop
not damaged.
(AUX-stop).

Code SPN
No. Code
Engine control 1. Check the oil level.
module reduces 2. Check that the air filters are
engine power not blocked.
Oil pressure is too (unless the 3. Check system pressure
6.6 100 Oil pressure
low protection has been valves and safety valves in the
shut off with the oil system.
VODIA diagnostic 4. Check the function of oil
tool). pressure sensor.
Engine stopped. The
Check that the oil pressure in
520 Piston cooling Piston cooling fault is de-activated
6.7 the engine exceeds 175 kPa
192 pressure pressure is too low at engine speed
(25.4 psi).
below 1000 rpm.
1. Check that the piston cooling
pressure sensor contact is
1. Short circuit correctly installed.
Piston cooling
520 to positive (+) or 2. Check that the cable harness
6.8 pressure None
192 negative (ground) (–) to the piston cooling pressure
sensor
2. Open circuit sensor has not been damaged.
3. Check the function of piston
cooling pressure sensor.
1. Short circuit to 1. Check the supply voltage
negative (-) from the control unit.
Battery Problems in engine
6.9 158 2. Faulty alternator 2. Check the battery.
voltage, CIU starting.
3. Faulty battery or 3. Check the alternator.
battery cables 4. Check the 8-pin contact.
1. Check that the injector cables
are not damaged.
1. Engine runs on 5
1. Electrical fault 2. Check that the injector
cylinders.
Injector, 2. Faulty connections are not damaged.
7.1 651 2. Abnormal sound.
cylinder #1 compression or 3. Check fuel supply pressure.
3. Reduced
injector 4. Check the valve clearance.
performance.
5. Do a compression test and
check cylinder #1.
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #2.

Code SPN
No. Code
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #3.
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #4.
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #5.
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #6.
Crankcase The engine is 1. Check whether the crankcase
ventilation shut down (if the ventilation is blocked.
Crankcase ventilation
7.7 153 pressure protection has not 2. Check whether cylinder liner,
pressure too high
(TAD950- been shut off by the piston or piston rings
952VE) parameter tool). are worn or damaged.

Code SPN
No. Code
1. Check that the crankcase
ventilation pressure
sensor contact is correctly
Crankcase
installed.
ventilation 1. Short circuit
pressure to positive (+) or
7.8 153 None to the crankcase
ventilation pressure sensor has
(TAD950- 2. Open circuit
not been damaged.
952VE)
crankcase ventilation pressure
sensor.
1. Fault in cable
Internal EGR harness (boost Engine control 1. Check the cable harness
8.5 2791 (TAD950- pressure sensor) module reduces (boost pressure sensor).
952VE) 2. Mechanical fault engine power. 2. Check the IEGR.
on the IEGR
1. Faulty values in oil
pressure and boost
pressure sensors.
2. Fault for oil 1. Check that the cable harness
620/ pressure and boost to oil pressure and boost
1079/ Power supply 1. Shortcut pressure sensor. pressure sensor has not been
9.3
1080 to sensor 2. Fault in sensor 3. Low engine damaged.
output. 2. Check the oil pressure and
4. The instrument boost pressure sensors.
displays zero oil
pressure and boost
pressure.
Faulty data 2. Check that the cables
9.2 608 Faulty data link None.
link (J1587) between the CIU/DCU and the
engine management unit are not
damaged.

Code SPN
No. Code
1. Faulty values in oil
pressure and boost
pressure sensors.
2. Fault for oil 1. Check that the cable harness
pressure and boost to oil pressure and boost
620/ Power supply 1. Shortcut pressure sensor. pressure sensor has not been
9.3
1079 to sensor 2. Fault in sensor 3. Low engine damaged.
output. 2. Check the oil pressure and
4. The instrument boost pressure sensors.
displays zero oil
pressure and boost
pressure.
Data set 1. Internal fault in 1. Re-program the control
memory control module Engine does not module.
9.8 630
EEPROM, 2. Programming start. 2. If the fault remains, change
CIU faulty the control module.
1. Faulty EEPROM, 1. CIU returns to
CIU factory setting.
Fault in
2. Faulty flash 2. Engine goes to 1. Re-program the unit.
9.8 629 control unit,
memory, CIU idle. 2. Change the CIU unit.
CIU
3. Fault in control 3. Engine can not be
module, CIU started.
Memory fault in
Engine might not
9.9 639 Memory fault engine management Re-program the unit.
start.
system
Data set 1. Internal fault in 1. Re-program the control
memory control module Engine does not module.
9.9 630
EEPROM, 2. Programming start. 2. If the fault remains, change
EMS faulty the control module.
1. Engine misfires.
Control Internal fault in
9.9 629 2. Engine does not Change the control unit.
module EMS control module
start.

6.4.2 CUMMINS engine error codes
For the detailed information, see: “CUMMINS

ENGINE MANUAL”.

Code
Description Failure Symptom Suggested Actions
SPN / FMI
Engine speed limited to
1. Check the cabling between
Vehicle Speed Sensor max. engine speed. Road
84 / 2 control unit and component.
Circuit - data incorrect speed gover ner will not
2. Check the sensor.
work.
Engine speed limited to
Vehicle Speed Sensor 1. Check the cabling between
max. engine speed. Road
84 / 10 Circuit - tampering has control unit and component.
speed gover ner will not
been detected 2. Check the sensor.
work.
SAE J1939 Multiplexing Engine may only idle or
Use diagnostic menu to find the
91 / 19 Accelerator Pedal Sensor engine will not accelerate to
incorrect segment.
System Error full speed.
A c c e l e r a t o r P e d a l Severe der ate in p ower 1. Check the cabling between
91 / 3 Position Sensor Circuit - output of the engine. Limp control unit and component.
shorted high home capability only. 2. Check the sensor.
A c c e l e r a t o r P e d a l Severe der ate in p ower 1. Check the cabling between
91 / 4 Position Sensor Circuit - output of the engine. Limp control unit and component.
shorted low home capability only. 2. Check the sensor.
N o n e o n p e r f o r m a n c e . 1. Check the cabling between
Wate r in Fu e l S e ns o r
97 / 3 No water-in-fuel warning control unit and component.
Circuit - shorted high
available. 2. Check the sensor.
N o n e o n p e r f o r m a n c e . 1. Check the cabling between
Wate r in Fu e l S e ns o r
97 / 4 No water-in-fuel warning control unit and component.
Circuit - shorted low
available. 2. Check the sensor.
Water in Fuel Indicator Possible white smoke, loss
97 / 15 Drain water from the fuel.
High – Maintenance of power, or hard starting
Progressive power derate
Engine Oil Pressure Low Check the engine oil level, top up as
100 / 1 increasing in severity from
– critical needed.
time after alert.
Engine Oil Pressure None on performance. No 1. Check the cabling between
100 / 2 Sensor Circuit - data engine protection for oil control unit and component.
incorrect pressure. 2. Check the sensor.
100 / 3 Sensor Circuit - shorted engine protection for oil control unit and component.
high pressure. 2. Check the sensor.
100 / 4 Sensor Circuit - shorted engine protection for oil control unit and component.
low pressure. 2. Check the sensor.

Code
SPN / FMI
Engine Oil Pressure Low Check the engine oil level, top up as
100 / 18 None on performance.
– warning needed.
Intake Manifold Pressure 1. Check the cabling between
102 / 2 S e n s o r C i r c u i t - d at a Engine power derate. control unit and component.
incorrect 2. Check the sensor.
Derate in power output of
102 / 3 Sensor #1 Circuit - control unit and component.
the engine.
shorted high 2. Check the sensor.
Derate in power output of
102 / 4 Sensor #1 Circuit - control unit and component.
the engine.
shorted low 2. Check the sensor.
1. Check the coolant level in the
engine, top up as needed.
Intake Manifold Progressive power derate
2. Check that the charge-air cooler
105 / 0 Temperature #1 High - increasing in severity from
is clean, clean as needed.
critical time after alert.
3. Check that fan belts are intact.
Intake Manifold Possible white smoke. No 1. Check the cabling between
105 / 3 Temperature Sensor #1 engine protection for intake control unit and component.
Circuit - shorted high manifold air temperature. 2. Check the sensor.
I n t a k e M a n i f o l d Possible white smoke. No 1. Check the cabling between
105 / 4 Temperature Sensor #1 engine protection for intake control unit and component.
Circuit - shorted low manifold air temperature. 2. Check the sensor.
A mbi ent A ir Pre s sure 1. Check the cabling between
108 / 2 S e n s o r C i r c u i t - d at a Engine power derate. control unit and component.
108 / 3 Sensor Circuit – shorted Engine power derate. control unit and component.
high 2. Check the sensor.
108 / 4 Sensor Circuit – shorted Engine power derate. control unit and component.
low 2. Check the sensor.
2. Check that the radiator is clean.
3. Check if there is air in coolant
Engine Coolant Progressive power derate
system.
110 / 0 Temperature High – increasing in severity from
4. Check the cap on the expansion
critical time after alert.
tank.
6. Check the thermostat.

Code
SPN / FMI
Engine Coolant Possible white smoke. No 1. Check the cabling between
110 / 3 Temperature Sensor engine protection for engine control unit and component.
Circuit - shorted high coolant temperature. 2. Check the sensor.
Engine Coolant Possible white smoke. No 1. Check the cabling between
110 / 4 Temperature Sensor engine protection for engine control unit and component.
Circuit - shorted low coolant temperature. 2. Check the sensor.
2. Check that the radiator is clean.
3. Check if there is air in coolant
Engine Coolant Progressive power derate
system.
110 / 16 Temperature High – increasing in severity from
4. Check the cap on the expansion
warning time after alert.
tank.
6. Check the thermostat.
Progressive power derate 1. Check the coolant level in the
Engine Coolant Level Low
111 / 1 increasing in severity from engine, top up as needed.
- critical
time after alert. 2. Check the sensor.
Electrical Charging Warning lamp illuminated
167 / 1 System Voltage Low - until very low battery voltage Check batteries and alternator.
critical level condition is corrected.
Amber warning lamp
Electrical Charging
illuminated until high 1. Check fuses.
167 / 16 System Voltage High -
battery voltage condition is 2. Check batteries and alternator.
warning level
corrected.
Electrical Charging Amber lamp will light until
167 / 18 System Voltage Low - low battery voltage condition Check batteries and alternator.
warning level is corrected.
Battery #1 Voltage High - Possible electrical damage 1. Check fuses.
168 / 16
warning to all electrical components. 2. Check batteries and alternator.
Battery #1 Voltage Low - Engine may stop running or 1. Check fuses.
168 / 18
warning be difficult to start. 2. Check batteries and alternator.
Fuel injection disabled until
En gine S p e e d H i gh – Ease off throttle or select higher
190 / 0 engine speed fails below the
critical gear.
overspeed limit.
Engine can exhibit misfire
as control switches from
Engine Speed / Position
the primary to the backup 1. Check the cabling between
Sensor Circuit - lost both
190 / 2 speed sensor. Engine power control unit and component.
of two signals from the
is reduced while the engine 2. Check the sensor.
magnetic pickup sensor
operates on the backup
speed sensor.
Real Time Clock - power
251 / 2 None on performance. -
interrupt

Code
SPN / FMI
Accelerator Pedal Idle 1. Check the cabling between
558 / 2 Validation Circuit - data Engine will only idle. control unit and component.
558 / 4 V a l i d a t i o n C i r c u i t - Engine will only idle. control unit and component.
shorted low 2. Check the sensor.
558 / 13 Validation Circuit - out of Engine will only idle. control unit and component.
calibration 2. Check the sensor.
Possible no noticeable
performance effects
Fuel Pump Control or engine dying or har
1. Check fuses.
627 / 2 Module, Electronic starting. Fault information,
2. Check batteries and alternator.
Calibration Code Error trip information, and
maintenance monitor data
can be inaccurate.
Engine Control Module –
629 / 12 Engine may not start. Check the control unit.
critical internal failure
Possible no noticeable
performance effects
or engine dying or har
Engine Control Module – Re-program the software in control
630 / 2 starting. Fault information,
data lost unit engine.
trip information, and
maintenance monitor data
can be inaccurate.
One or more multiplexed
SAE J1939 Multiplexing devices will not operate Use diagnostic menu to find
639 / 9
PGN Timeout Error properly. One or more incorrect segment.
symptoms will occur.
At least one multiplexed
SAE J1939 Multiplexing Use diagnostic menu to find
639 / 13 d ev i c e w i l l n o t o p e r a t e
Configuration Error incorrect segment.
properly.
External Speed
Input (Multiple Unit Primary or secondary
644 / 2 control unit and component.
Sychronization) - data engines may be shut down.
incorrect
The fan may stay on 1. Check the cabling between
Fan Clutch Circuit -
647 / 4 continuously or not run at control unit and component.
shorted low
all. 2. Check the sensor.
Injector Solenoid Valve 1. Check the cabling between
Engine can misfire or
651 / 5 Cylinder #1 Circuit - open control unit and component.
possibly run rough.
circuit 2. Check the sensor.

Code
SPN / FMI
651 / 7 Cylinder #1 Circuit – out Engine will shut down. control unit and component.
of adjustment 2. Check the sensor.
652 / 5 Cylinder #2 Circuit – open control unit and component.
possibly run rough.
possibly run rough.
possibly run rough.
654 / 7 Cylinder #4 Circuit - out Engine will shut down. control unit and component.
possibly run rough.
Injecto r Solenoid Valve 1. Check the cabling between
656 / 5 Cylinder #6 Circuit - open control unit and component.
possibly run rough.
656 / 7 Cylinder #6 Circuit - out Engine will shut down. control unit and component.
Auxiliary Equipment 1. Check the cabling between
Possible engine power
703 / 11 Sensor Input # 3 (OEM control unit and component.
derate.
Switch) 2. Check the sensor.
Remote accelerator will not
Remote Accelerator 1. Check the cabling between
operate. Remote accelerator
974 / 3 Pedal Position Sensor control unit and component.
position will be set to zero
Circuit - shorted high 2. Check the sensor.
percent.

Code
SPN / FMI
Remote accelerator will not
Remote Accelerator 1. Check the cabling between
operate. Remote accelerator
974 / 4 Pedal Position Sensor control unit and component.
position will be set to zero
Circuit - shorted low 2. Check the sensor.
percent.
The engine will not respond
SAE J1939 Multiplexing to the remote throttle. 1. Check the cabling between
974 / 19 Remote Throt tle Dat a Engine may only idle. The control unit and component.
Error primary or cab accelerator 2. Check the sensor.
may be able to be used.
Engine Speed/Position
Sensor #1 (Crankshaft)
1043 / 3 Engine will only idle. control unit and component.
Supply Voltage Circuit -
shorted high
Engine Speed/Position
Sensor #1 (Crankshaft)
1043 / 4 Engine will only idle. control unit and component.
Supply Voltage Circuit -
shorted low
Sensor Supply Voltage #1
1079 / 3 Engine power derate. control unit and component.
Circuit -shorted high
Sensor Supply Voltage #1
1079 / 4 Engine power derate. control unit and component.
Circuit - shorted low
Engine will run poorly but
High Fuel Pressure
will be severely derated.
1347 / 3 Solenoid Valve #1 Circuit -
Fuel pressure will be higher
- shorted high
than commanded.
Engine will run poorly at
High Fuel Pressure
idle. Engine will have low
1347 / 4 Solenoid Valve #1 Circuit -
power. Fuel pressure will be
- shorted low
higher than commanded.
Fuel Pumping Element
Engine will not run or
1347 / 7 #1 (Front) - mechanically -
possible low power.
stuck

6.4.3 YUCHAI engine error codes
For the detailed information, see: “YUCHAI

ENGINE MANUAL”.

SPN
Description Possible Causes Suggested Actions
Code
1. Check if the plug of fuel pressure sensor is
connected correctly.
2. Check if the circuit of fuel pressure sensor is in
good condition.
1. Short circuit of positive
3. Check if the fuel pressure sensor is installed
Fuel pressure pole (+) or negative pole (-)
94 correctly.
sensor 2. Open circuit
4. Check the function of fuel pressure sensor.
3. Low pressure of oil supply
5. Check if the manual pump can be used to
increase the pressure.
6. Check the fuel pre-filter.
7. Check the fuel filter.
1. Drain the main fuel filter.
1. Water in fuel
Water in fuel 2. Check if the cable of indicator is short circuit or
2. Short circuit
97 or indicator open circuit.
3. Open circuit
malfunction 3. Check the function of indicator. Replace it if
4. Indicator error
necessary.
1. Low lubricating oil level 1. Check the lubricating oil level.
Lubricating
2. Short circuit of positive 2. Check if the harness to lubricating oil level
98 oil level and
pole (+) or negative pole (-) sensor is in good condition.
sensor
3. Open circuit 3. Check the function of lubricating oil level sensor.
1. Check if the harness to lubricating oil pressure
sensor is in good condition.
2. Check if the lubricating oil pressure sensor is
connected correctly.
Lubricating 1. Short circuit of positive
3. Check the lubricating oil level.
100 oil pressure pole (+) or negative pole (-)
4. Check if the lubricating oil filter is clogged.
sensor 2. Open circuit
5. Check the pressure valve and safety valve of
lubrication system.
6. Check the function of lubricating oil pressure
sensor.

SPN
Code
1. Check if the plug of supercharged air pressure
sensor is connected correctly.
2. Check if the circuit of supercharged air pressure
Supercharged pole (+) or negative pole (-)
3. Check if the supercharged air pressure sensor
102 pressure 2. Open circuit
is installed correctly.
sensor 3. High supercharged
4. Check the function of supercharged air pressure
pressure
sensor.
5. Check the function of turbocharger.
6. Check the fuel amount / pump nozzle.
2. Check the intercooler.
3. Check the function of coolant temperature
sensor.
1. High supercharged air 4. Check the function of thermostat.
Supercharged temperature 5. Check if the plug of supercharged air
105 air temperature 2. Short circuit of positive temperature sensor is connected correctly.
and sensor pole (+) or negative pole (-) 6. Check if the circuit of supercharged air
3. Open circuit temperature sensor is in good condition.
7. Check if the supercharged air temperature
sensor is installed correctly.
8. Check the function of supercharged air
temperature sensor.
1. Check if the plug of air filter is connected
correctly.
Air filter 2. Check if the circuit of air filter is in good
107 pole (+) or negative pole (-)
pressure condition.
2. Open circuit
3. Check if the air filter is installed correctly.
4. Check the function of air filter.

SPN
Code
2. Check the intercooler.
3. Check if there is air in the cooling system.
4. Check the pressure cap on expansion water
tank.
1. High coolant temperature 5. Check the function of coolant temperature
Coolant
2. Short circuit of positive sensor.
110 temperature
pole (+) or negative pole (-) 6. Check the function of thermostat.
and sensor
3. Open circuit 7. Check if the plug of coolant temperature sensor
is connected correctly.
8. Check if the circuit of coolant temperature
9. Check if the coolant temperature sensor is
installed correctly.
1. High coolant temperature 1. Check the coolant level.
Low coolant
2. Short circuit of positive 2. Check the function of coolant level sensor.
111 level or sensor
pole (+) 3. Check if the circuit of coolant level sensor is in
malfunction
3. Sensor malfunction good condition.
1. Short circuit of negative
pole (-) 1. Check the power supply voltage of control unit.
Battery voltage 2. Malfunction of charging 2. Check the battery.
158
(SPN) generator 3. Check the charging generator.
3. Malfunction of battery or 4. Check the 8-pin plug.
battery cables
1. Check if the cable harness of lubricating oil
temperature sensor is in good condition.
2. Check if the lubricating oil temperature sensor is
pole (+) or negative pole (-)
Lubricating oil installed correctly.
175 2. Sensor malfunction
temperature 3. Check the lubricating oil level.
3. High lubricating oil
4. Check the lubricating oil temperature.
temperature
5. Check the functions of lubricating oil temperature
sensor.
High engine Stop the machine to check the causes of high
190 High engine rotate speed
rotate speed engine rotate speed.

SPN
Code
1. Check if the potentionmeter is installed correctly.
Malfunction
2. Check if the cable harness to potentionmeter is
of engine 1. Short circuit of positive
in good condition.
rotate speed pole (+) or negative pole (-)
608 3. Check the function of potentionmeter.
potentionmeter 2. Sensor malfunction
4. Check if the 8-pin plug is in good condition.
to CIU or data 3. Data line malfunction
5. Check if the cable harness betweeen CIU and
line
engine control unit is in good condition.
1. Check if the cable harness of lubricating oil
pressure sensor and supercharged air pressure
Power supply of 1. Short circuit
620 sensor is in good condition.
sensor 2. Sensor malfunction
2. Check the lubricating oil pressure sensor and
supercharged air pressure sensor.
1. Short circuit of positive 1. Check if the cable of relay input is in good
Power supply of
626 pole (+) or negative pole (-) condition.
relay (SPN)
2. Sensor malfunction 2. Check the function of relay.
1. Inner malfunction of
control unit
2. Malfunction of electrical
removable read-only
Control unit 1. Re-programme the control unit.
629 memorizer (EEPROM)
malfunction 2. Replace the CIU unit.
3. Malfunction of flash
memory, CIU
4. Malfunction of control
unit, CIU
Data collection 1. Inner malfunction of
1. Re-programme the control unit.
630 memorizer control unit
2. Replace the control unit when necessary.
(SPN) 2. Program malfunction
1. Check if the plug of engine rotate speed sensor
2. Check if the cable of engine rotate speed sensor
Camshaft 1. No signal
is in good condition.
636 speed sensor 2. Abnormal frequency
3. Check if the engine rotate speed sensor is
malfunction 3. Sensor malfunction
installed correctly.
4. Check the function of engine rotate speed
sensor.

SPN
Code
1. Check if the plug of engine rotate speed sensor
1. No signal
2. Check if the cable of engine rotate speed sensor
2. Abnormal frequency
Flywheel rotate is in good condition.
637 3. Sensor sends out
speed sensor 3. Check if the engine rotate speed sensor is
“interval” signals
installed correctly in the flywheel cover.
4. Sensor malfunction
4. Check the function of engine rotate speed
sensor.
1. Reprogramme the control unit.
2. Check if the 8-pin connector is in good condition.
Memorizer 3. Check if the cable harness between CIU and
639 Memorizer malfunction
malfunction engine control unit is in good condition.
4. Check if the plug hole 11 and 12 on CIU plug are
in good condition.
Cylinder 1
651
(SPN)
Cylinder 2 1. Check if the cable of pump nozzle is in good
652 condition.
(SPN)
Cylinder 3 1. Electrical malfunction 2. Check if the connector of pump nozzle is in
653
(SPN) 2. Difference of compressed good condition.
Cylinder 4 pressure or malfunction of 3. Check the fuel supply pressure.
654
(SPN) pump nozzle 4. Check the clearance of air valve.
Cylinder 5 5. Test the compressed pressure and check the
655
(SPN) cylinder.
Cylinder 6
656
(SPN)
1. Check if the power supply switch is connected
Start motor well.
677 pole (-)
(SPN) 2. Check if the cable of power supply switch is in
2. Too long operating time
good condition.
1. Short circuit of negative 1. Check if the power supply switch is connected
Stop input to pole (-) well.
970
CIU 2. Too long operating time 2. Check if the cable of power supply switch is in
3. Open circuit good condition.
1. Check if the power supply switch is connected
Start input to well.
520194 pole (-)
CIU 2. Check if the cable of power supply switch is in
good condition.
Stop inout to
520195 pole (-) Check if the power supply switch is connected well.
EMS

6.5 Machine Error Codes
Table 6-13 Machine Error Codes
No. Name Possible Causes Suggested Actions Reference

1. Check if there is leakage
Fuel level is too low,
in fuel tank.
01 FuelLevel_L checked to be lower than -
2. Check sensors and
50L.
wires.
1. see “Engine
oil, changing” on
1. Fill engine oil.
Engine oil pressure is too page 5-36
2. Change oil filter.
02 Engine_OilPress_L low, checked to be lower 1. see “Oil filter
3. Check oil level sensor
than 80kPa. / Bypass filter,
and their wires.
changing” on
page 5-37
1. Check if there are 1. see “Radiator,
impurities in engine radiator. cleaning” on page
Engine temperature is too
If yes, clean it. 5-43
03 Engine_Tem_H high, checked to be higher
2. Check coolant tank and 3. see “Radiator
than 98 °C.
pipes. fan, checking” on
3. Check fan and bulleys. page 5-44
1. Check if the coolant level
is really too low.
2. Check all the components
Engine coolant level is too with a multi-meter. 1. see “Coolant
04 Engine_Coolant_L low; signal of water level 3. Check if the switch is too level, checking”
switch is with error. dirty. on page 5-40
4. Check if the outlet
w ire s of t he sw itc h are
disconnected.
Battery voltage error,
1. Check the generator.
05 Battery_Voltage_Err checked to be lower than -
2. Check battery volume.
23V.
Signal line: 1010
1. Check if the temperature
is too high.
Gearbox temperature is 2. Check if the radiator
06 Gearbox_Temp_H too high, checked to be temperature control switch, -
higher than 90 °C. motor and radiator blade
are too dirty.
3. Check the parallel
resistance circuit.


Oil pressure of the Unscrew the sensor
gearbox is too low, and check if it is
07 Gearbox_OilPre_L -
checked to be lower than blocked, ineffective and
16bar. disconnected.
Brake oil temperature is Signal line: 1048
08 BrakeOil_Temp_H too high; the temperature Check components, circuits -
switch acts. and fan.
Signal line: 1012 and 1049
Brake oil pressure is too
Check hydraulic pressure
09 BrakeOil_Pre_L low; the parking pressure -
and circuits of parking
low switch acts.
valve, etc.
System oil pressure is too Chec k if the system oil
10 SystemOil_H high, checked to be higher pressure is higher than -
than 27MPa. 27MPa.
Signal line: 1046
1. Check the sensor plug.
2. Check if the sensor is
ineffective.
Hydraulic oil temperature 5. see “Radiator
3. Check if the radiator is
11 Hyd_OilTemp_H is too high, checked to be fan, checking” on
working.
higher than 65 °C. page 5-44
4. Check the temperature
control switch on it.
5. Check if the radiator
blade is too dirty.
1. Check if the machine is in
The front lean protection critical state of tipping over.
12 Front_Lean_Protect approach switch is with 2. Check whether the -
error. approach switch is
damaged.
Leaning back is forbidden,
The center line of the load
13 Load_too_Back please retract or lower the -
moves to tyres.
boom.
Spreader approach switch Check the approach switch
14 Lock_Unlock_Err -
is with error. of the spreader.
The load is detected to be
15 Loaded_too_High Lower the boom. -
too high.
Lower driving speed when
16 Loaded_Overspeeded Run overspeed with load. t h e m a c h i n e i s h e av i l y -
loaded.
T his is an alar m of t he
Use the safety bypass key
17 Safe_Bypass safety bypass key. Check if -
now.
it is used.


No time before receiving
Check if the engine CAN is
18 CANBus_Err any information from -
normal.
engine.
1. Retract the boom first if
the load percentage is too
large.
2. Check the approach
Overloaded or has a
19 Not_Safe switch for overturning -
danger of over-turning.
protection.
3. Check if wires of
the approach switch is
damaged.
First retract the boom and
Load more than rated lower it by using the safety
20 Weight_Over_45t -
weight of 45t. bypass key; overload is
forbidden.
1. see “Engine
oil, changing” on
Engine stops running due 1. Fill the engine oil.
page 5-36
to too low engine oil. It 2. Change the oil filter.
21 EngineOil_Flameout 1. see “Oil filter
can only be started after 3. Check the oil level sensor
/ Bypass filter,
10 minutes. and its wires.
changing” on
page 5-37
Observe the actual
machine speed and turbo
speed. This happens
Difference between shaft
mostly because of faults
22 Gearbox_slip speed and turbocharger -
inside the gearbox. When
speed is too large.
this fault is repeated, check
the gearbox as soon as
possible.
Check if the CAN line of the
Long time before receiving
23 Len_Angle_Error length & angle sensor is -
any length&angle signal.
connected properly.
1. Check whether power
supplying wires and
Signal of left rodless
signal lines are connected
24 Oilpre_L_Sensor_Err chamber sensor is -
normally.
incorrect.
2. Check if there is a fault in
sensor itself.


supplying wires and
Signal of right rodless
signal lines are connected
25 Oilpre_R_Sensor_Err chamber sensor is -
normally.
incorrect.
sensor itself.
supplying wires and
Signal of rod chamber signal lines are connected
26 Oilpre_O_Sensor_Err -
sensor is incorrect. normally.
sensor itself.
1. Check if the filter is too
dirty. If yes, clean or change
it.
27 Ctr_Filter_Blocking Filter signal error. -
2. Check switch
components with a
multimeter.
dirty. If yes, clean or change 1. see “Hydraulic
Hydraulic oilfilter is it. oil filter,
28 Hyd_Filter_Blocking
blocked. 2. Check switch changing” on
components with a page 5-102
multimeter.
dirty. If yes, clean or change
1. see “Brake oil
it.
29 Brake_Filter_Blocking Brake oil filter is blocked. filter, changing”
2. Check switch
on page 5-64
components with a
multimeter.
The declutch switch is
There is a signal of inef fective or stuck. If it
30 Foot_Switch_Error declutch detected for a is not pressed down for a -
long time. long time, please check the
signal line.
1. Check the relay and its
The boom angle increases wires.
31 Down_Valve_Err after the down valve is 2. Check the if -
electrified. electromagnetic plug is
loosened.


The machine speed is
1. Check if the sensor is
detected to be lower than
32 Speed_Sensor_Err ineffective and loosened. -
0.3 km/h at 1st or 2nd
2. Check the power supply.
gear.
This is a engine internal
The engine SPN is not
33 SPN_Alarm fault, please refer to -
detected to be 0.
relevant SPN code.
Check if the GPS power
There is no GPS signal line is fastened. This type
34 GPS_CAN_Alarm -
for a long time. of fault leads to locking the
machine.

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Container Reach Stacker Specifications
Specifications
7. Specifications
7.1 Technical Specifications��7-2
7.1.1 Basic parameters��7-2
7.1.2 Technical parameters�� 7-8
7.1.3 Power system configuration��7-10
7.2 Unit Conversion�� 7-13
7.2.1 Unit abbreviation explanation�� 7-13
7.2.2 Conversion table, SI units �� 7-14
7.2.3 Conversion table, length�� 7-15
7.2.4 Conversion table, area �� 7-15
7.2.5 Conversion table, volume�� 7-15
7.2.6 Conversion table, weight �� 7-16
7.2.7 Conversion table, pressure�� 7-16
7.2.8 Conversion table, temperature��7-16

Specifications Container Reach Stacker
7. SPECIFICATIONS
7.1 Technical Specifications
7.1.1 Basic parameters
F
D E
A B
Fig. 7-1
Table 7-1
Item Unit C-type Container Reach Stacker

Machine weight kg 72000
A Overall length mm 11258
B Width of front wheel mm 4188
C Overall height mm 4770
D Wheel base mm 6000
E Width of rear wheel mm 3010
F Min. ground clearance mm 350
G Overall width mm 6042-12175
mm Load center 1965

Line 1 1-4 layer 45000
Kg
5 layer 43000
mm Load center 3815

Load
capacity
Kg 5 layer (8”6”) 30000
mm Load center 6315

Kg 4 layer (8”6”) 14000

F
D E
A B
Fig. 7-2
Table 7-2
Item Unit SRSC1009-6E Empty Container Reach Stacker

mm Load center 1965
Line 1
Kg 1st - 6th layer (8”6”) 10000
Load mm Load center 3815

Line 2
capacity Kg 1st - 5th layer 9000
mm Load center 6315

Line 3
Kg 1st - 4th layer 5000

F
D E
A B
Fig. 7-3
Table 7-3
Item Unit SRSC3515-3 Lightweight Container Reach Stacker

mm Load center 1965
Line 1
Load Kg 1st - 3rd layer 35000
capacity mm Load center 3815
Line 2
Kg 1st - 2nd layer 15000

F
D E
A B
Fig. 7-4
Table 7-4
Item Unit SRSC4535 Heavyweight Container Reach Stacker

mm Load center 1965

Line 1 1st - 4th layer 45000
Kg
5th layer 43000
capacity Line 2
mm Load center 6315
Line 3
Kg 1st - 3rd layer 19000

F
D E
A B
Fig. 7-5
Table 7-5
SRSC4535C / SRSC4535C1 Heavyweight Container
Item Unit
Reach Stacker
mm Load center 1965

Kg
5th layer 43000
mm Load center 3815

Load
capacity
Kg 5th layer (8”6”) 3100
mm Load center 6315

Line 3 1st - 3rd layer 19000
Kg 4th layer (8”6”) 15000

F
E
D
B
A
Fig. 7-6
Table 7-6
Item Unit SRSC4545C Heavyweight Container Reach Stacker

mm Load center 2100

Kg
5th layer 45000
capacity Line 2
mm Load center 6400
Line 3
Kg 1st - 3rd layer 40000

7.1.2 Technical parameters
Table 7-7 Technical Parameters

Model Technical Parameters
SDJ450 / SDJ450E-R1 Rotating Angle +105°/-195 °
/ SDJ450F-R1 / Side-shifting Distance ±800 mm
SDJ450F-R2 /
Max. Loading Capacity 45000 Kg
SDJ450F-R3 /
SDJ450F-R4 Applicable Range 20′-40′International Standard Container
Rotating Angle +105°/-195 °
Side-shifting Distance ±800 mm
ELME817
Applicable Range 20′-40′International Standard Container
Spreader
BROMMA RSX40
SDJE100-R1
Max. Lifting Height 15100mm
Boom
Angle 0-60°
Max. Lifting Speed (unloaded/loaded) 420/250mm/s
Max. Lowering Speed (unloaded/loaded) 360/300mm/s
C-type Container
Max. Travel Speed (unloaded/loaded) 25/21 km/h
Reach Stacker
Gradeability (unloaded/loaded) 39/32 %
Min. Turning Radius 8000mm
Overall Displacement 210 ml/r
Max. Working Pressure 260 bar
Boom
Angle 0-46°
SRSC3515-3 Max. Lowering Speed (unloaded/loaded) 360/300mm/s
Lightweight Container Max. Travel Speed (unloaded/loaded) 28/18 km/h
Reach Stacker Gradeability (unloaded/loaded) 36/22 %


Boom
Angle 0-64.5°
SRSC1009-6E Max. Lowering Speed (unloaded/loaded) 400/400mm/s
Empty Container Max. Travel Speed (unloaded/loaded) 28/25 km/h
Reach Stacker Gradeability (unloaded/loaded) 33/27 %
Boom
Angle 0-58°
SRSC4535
Heavyweight
Container Reach
Stacker
Boom
Angle 0-60°
SRSC4535C / Max. Lifting Speed (unloaded/loaded) 420/250mm/s

SRSC4535C1 Max. Lowering Speed (unloaded/loaded) 360/300mm/s
Heavyweight Max. Travel Speed (unloaded/loaded) 28/18 km/h
Container Reach Gradeability (unloaded/loaded) 38/24 %
Stacker Min. Turning Radius 8700mm
Boom
Angle 0-50°
SRSC4545C
Heavyweight
Container Reach
Stacker
Noise in Cab ≤72 dB
Lubrication Way Decentralized or Centralized Lubrication

7.1.3 Power system configuration
Table 7-8 Power System Configuration
SRSC45C30 / SRSC45C30-6 / SRSC45C32 / SRSC45C23

Model
/ SRSC4535C
Model No. VOLVO TAD1340VE
6 In-line Cylinders, 4 Strokes, Turbo Pressured, Centralized

Type
Air- Air Cooling, Electric Control, etc.
Engine Rated power 256kw/2100rpm
Max. torque 1745Nm/1260rpm
Exhaust gas standard EU Stage II
Average fuel consumption rate 197g/kWh
Gearbox Model No. DANA 15.5HR36000
Drive axle Model No. Kessler D102PL341
Model SRSC4545C / SRSC45C31
Type
Exhaust gas standard EU Stage II
Drive axle Model No. AxleTech PRC7534W4H
Model SRSC45C2 / SRSC4535 / SRSC45C22
Model No. Cummins QSM11

Type

Exhaust gas standard EU Stage III

Model SRSC45C5 / SRSC45C7

Model No. Yuchai YC6M360-30
Type
Exhaust gas standard China Stage III
Model SRSC45C1 / SRSC4535C1

Type
Model SRSC1009-6E
Model No. Cummins QSB6.7

Type

Model SRSC3515-3

Type
Gearbox Model No. DANA 340TE17000

7.2 Unit Conversion
7.2.1 Unit abbreviation explanation

Table 7-9 Unit Abbreviation Explanation
Name Abbreviation
Newton metre N.m
Kilo pound metre kpm
Kilo pascal kPa
Mega pascal MPa
Kilowatt kW
Kilojoule kj
British termel unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km

7.2.2 Conversion table, SI units
Table 7-10 SI Units Conversion Table
SI-unit Recalculation factor Non-SI Recalculation factor SI

Torque
N.m x 10.2 = kg·cm x 0.8664 =lb·in
N.m x 0.74 =lbf·ft x 1.36 =Nm
N.m x 0.102 =kg·m x 7.22 =lb·ft
2
Pressure (Pa=N/m )
kPa x 4.0 =in.H2O x 0.249 =kPa
kPa x 0.30 =in.Hg x 3.38 =kPa
kPa x 0.145 =psi x 6.89 =kPa
bar x 14.5 =psi x 0.069 =bar
2
kp/cm x 14.22 =psi x 0.070 =kp/cm2
N/cm2 x 145.04 =psi x 0.069 =bar
MPa x 145 =psi x 0.00689 =MPa
Power (W=J/s)
kW x 1.36 =hp (cv) x 0.736 =kW
kW x 1.34 =bhp x 0.746 =kW
kW x 0.948 =Btu/s x 1.055 =kW
W x 0.74 =ft·lb/s x 1.36 =W
Energy (J=Nm)
kJ x 0.948 =Btu x 1.055 =kJ
J x 0.239 =calorie x 4.19 =J
Speed and acceleration
m/s2 x 3.28 =ft/s2 x 0.305 =m/s2
m/s x 3.28 =ft/s x 0.305 =m/s
km/h x 0.62 =mph x 1.61 =km/h
Horsepower/torque
Bhp x 5252 rpm = TQ(lb·ft) TQ x rpm 5252 = bhp
Temperature
℃ =（ -32)/1.8 =（℃ x 1.8) +32
Flow factor
l/min (dm3/min) x 0.264 = US gal/min x 3.785 = liter/min

7.2.3 Conversion table, length
Table 7-11 Length Conversion Table
Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.083333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm - 1mm = 0.001 mm
7.2.4 Conversion table, area

Table 7-12 Area Conversion Table
Unit cm2 m2 km2 a ft 2 yd2 in2

cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
2
m 10000 1 0.000001 0.001 10.764 1.1958 1550.000
2
km - 10000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
2
ft - 0.092903 - 0.000929 1 0.1111 144.000
2
yd - 0.83613 - 0.008361 9 1 1296.00
2
in 6.4516 0.000645 - - 0.006943 0.000771 1
2 2
1 ha = 100a - 1 mile = 259 ha = 2.59 km
7.2.5 Conversion table, volume
Table 7-13 Volume Conversion Table
Unit cm3 = cc m3 l in3 ft3 yd3

cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
3
m 1000000 1 1000 61024 35.315 1.30796
3
dm (l) 1000 0.001 1 61.024 0.035315 0.001308
3
in 16.387 0.000016 0.01638 1 0.000578 0.000021
3
ft 28316.8 0.028317 28.317 1728 1 0.03704
3
yd 764529.8 0.76453 764.53 46656 27 1
3 3
1 gal (US) = 3785.41 cm = 231 in = 0.83267 gal (UK)

7.2.6 Conversion table, weight
Table 7-14 Weight Conversion Table
Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 100000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)
7.2.7 Conversion table, pressure
Table 7-15 Pressure Conversion Table
Unit kp/cm2 bar Pa=N/m2 kPa lbf/in2 lbf/ft2

kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in 2
0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1

kg/cm2 = 735.56 Torr (mmHg) = 0.96784 atm
7.2.8 Conversion table, temperature
Table 7-16 Temperature Conversion Table
°F °C °F °C °F °C °F °C °F °C °F °C
-90 -67.78 -40 -40 10 -12.22 60 15.56 110 43.33 160 71.11
-80 -67.22 -30 -34.44 20 -6.67 70 21.11 120 48.89 170 76.67
-70 -56.67 -20 -28.89 30 -1.11 80 26.67 130 54.44 180 82.22
-60 -51.11 -10 -23.33 40 -4.44 90 32.22 140 60 190 87.78
-50 -45.56 -0 -17.78 50 -10 100 37.78 150 65.56 200 93.33
t°C = 5 (T°F-32) / 9, T°F = (9*t°C+160) / 5

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Container Reach Stacker Optional Parts
Optional Parts
8. Optional Parts
8.1 Fire Detection and Alarm System / Automatic Extinguishing Device�� 8-3
8.1.1 Fire detection and alarm system�� 8-4
8.1.1.1 Product features�� 8-4
8.1.1.2 Application site and environmental conditions�� 8-5
8.1.1.3 Technical features�� 8-5
8.1.1.4 Function description�� 8-6
8.1.1.5 Precautions�� 8-8
8.1.1.6 Troubleshooting�� 8-9
8.1.1.7 Maintenance and repair�� 8-9
8.1.2 Automatic fire extinguishing device ��8-11
8.1.2.1 Precautions��8-11
8.1.2.2 Technical parameters��8-12
8.1.3 Electrical diagrams��8-13
8.2 Loudspeaker and Controller Kit��8-16
8.2.2 Operations��8-16
8.2.3 Electrical wiring diagram��8-17
8.2.4 Precautions��8-18
8.3 Engine Idle Protection Function��8-18
8.4 Engine Preheating Protection Function��8-19
8.5 Engine Hour Calculator��8-19
8.6 Twistlock Calculator��8-19
8.7 Reversing Radar Display�� 8-20
8.8 Radio�� 8-20

Optional Parts Container Reach Stacker

8.8.2 Mute (Silence)�� 8-22
8.8.3 Sound�� 8-22
8.8.4 Audio setting�� 8-22
8.8.5 Radio�� 8-23
8.8.6 Radio troubleshooting�� 8-25
8.9 CCTV System�� 8-26
8.9.1 Safety precautions�� 8-26
8.9.2 Major parts�� 8-27
8.9.3 Installation�� 8-28
8.9.4 Vehicle DVR�� 8-29
8.9.4.1 Physical interfaces�� 8-29
8.9.4.2 Shift switch�� 8-30
8.9.4.3 Disassembly of hard disk�� 8-30
8.9.5 Troubleshooting the CCTV system�� 8-32
8.9.6 Wiring diagram�� 8-33
8.10 Flowmeter�� 8-34
8.11 Automatic Lubrication System�� 8-35
8.11.1 Operation precautions�� 8-35
8.11.2 Time setting�� 8-36

8. OPTIONAL PARTS
8.1 Fire Detection and Alarm

System / Automatic Extinguishing
Device
With the fire detection and alarm switch on the

right operation panel pressed down, the fire
detection and alarm system will be started.
Fig. 8-1

8.1.1 Fire detection and alarm system
Fire detection and alarm system (FZZK /

W03( (Hereinafter referred to as system)
uninterruptedly monitors (Engine compartment)
ambient temperature real-time, recognizes and
analyzes signals from each region, as well as
realizes monitoring alarm and automatic fire
disposal function through the linear heat / fire
detection components by the cabin detection
host. The system also has online automatic
fault detection and alarm function, high
Fig. 8-2
temperature / fire alarm function and automatic
fire extinguishing function.
8.1.1.1 Product features
• Wide temperature operating range:

Fire detection alarm host: -40°C ---- +85°C
NTC temperature probe assembly: -40°C
---- +200°C
• High explosion-proof, dust-proof level
• Modular design, independent functional
units
• NTC temperature detection components
with wide detection range, high sensitivity
and flexible installation location
• Self-examination of power supply and
system, failure alarm, fire extinguishing
device failures / start alarm
• Uninterrupted monitoring of temperature
c hange, forewar ning and automat ic
processing functions when the temperature
is abnormal
• Ear ly m onito r ing of mult i -zone f ire,
intelligent judgment of f ire situation,
automatic fire extinguishing device

8.1.1.2 Application site and environmental

conditions
• Ambient temperature not exceeding 110°C

• Relative humidity less than 95% (40±2°C)
• Locations where high temperature and fire
disaster are easy to take place
8.1.1.3 Technical features
Basic technical parameters of cabin NTC fire

detection component:
• Detection ambient temperature:- 40°C-
200°C
• Humidity: ≤95﹪RH (40 + 2°C)
• Temperature sensitivity: 0.1 °C
• Monitoring angle: 360°
Basic technical parameters of fire detection

alarm host:
• Forewarning temperature: 110°C (analog
signals)
• Absolute temperature of fire disaster:
130°C
• B a s e t e m p e r a t u r e f o r d e t e c t i n g
temperature difference: 85°C
• Minimum speed to react temperature
difference: 30°C /MIN
• Failure inspection frequency: 0.1HZ
• Fire response time: 2S
Electrical parameters of fire detection and
alarm system:
• Operating voltage: 18V - 32VDC (Normally
energized state)
• Operating current:
Inspection status: ≤100mA (12V-24VDC)
Start status: ≤1.2A (12V-24VDC)
Fault output L+ drive: ≤50mA (12V-24VDC)
Temperature warning output T+ drive: ≤3A
(12V-24VDC)

8.1.1.4 Function description
Detection function:
When the system is initially installed, it would
enter the inspection status after power on.
High temperature alarm and automatic fire

extinguishing function:
When the cabin detection host detects that the
temperature of cabin NTC detector reaches
110°C, the system would warn the operator
of high temperature through an external
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 would flash for 1 second every 12
seconds.
NOTE:
The failure of any one circuit does not affect its
other functions.
Intelligent identification of fire signal and

automatic fire extinguishing function:
When the cabin NTC fire detector detects
that the ambient temperature is above 85 °C,
the rise rate is greater than 30 °C / min, or
absolute temperature of fire disaster is higher
than 130 °C, the system would intelligently
reckon that a fire disaster is happening.
Therefore it would f irstly star t the high
temperature forewarning function as soon
as the temperature reaches 110 °C and then

automatically start the fire extinguisher if the

temperature continues to rise and reaches 130
°C.
Fire extinguisher alarm function:

When the device begins spraying, the system
would inform the operator through an external
device that fire disaster is happening and the
fire extinguisher is putting out the fire.
Manual fire extinguishing function:

The operator, who discovered the fire foremost,
can manually start the fire extinguishing device
by himself.
NOTE:
Once the fire extinguisher is automatically
star ted af ter fire disaster, make sure to
disconnect the power supply of this machine
as well as replace the host and detector
harness for preventing any unknown damages.

8.1.1.5 Precautions
The following steps should be performed after

the initial installation, repair and maintenance
of this product. Otherwise, the system may be
unable to work normally.
1. Do not directly connect the host with
the connector of fire extinguisher when
testing after installation. Instead, connect
a 12V-24V test lamp with the F + and
F- driving lines of system host or use a
multimeter to measure the voltage at both
ends.
2. If the light blinks in 1 minute, it indicates
that the system is incorrectly installed.
Eliminate the failure immediately. If the
light does not blink in 1 minute, it indicates
that the system is correctly installed and
the host can work normally. Go on to the
next step for checking the cabin detector.
3. H e a t a n y o n e o f t h e c a b i n N T C
temperature detectors with a lighter or by
other means to simulate the occurrence of
fire disaster. If the 12V-24V test light turns
on or the multimeter displays 12V-24V,
it means that the host and detectors are
working normally.
4. Disconnect the power supply, and then the
host is recovered to original status. That is,
the device is a qualified product which can
be used normally.
5. After the installation and detection, connect
the power supply of machine and install
the fire extinguisher. The fire extinguishing
and alarm system is ready to function now.

8.1.1.6 Troubleshooting
1. During the inspection, check whether

there is short or open circuit of the cabin
NTC temperature detectors and f ire
extinguisher. If yes, eliminate the fault.
2. When one circuit of NTC temperature
detectors 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 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 started.
4. If the fault output L + driving line is
constantly 12V-24V high level after the
system is started, it means that the host
cannot work normally. Replace the host
immediately.
5. Once the cabin catches fire and the host
starts extinguishing the fire, the system
cannot be automatically recovered until the
power is off.
6. After the fire disaster, please disconnect
the power supply to replace the host and
temperature sensor. Strictly check and test
the replaced harness and sensors to avoid
potential hazards.
8.1.1.7 Maintenance and repair
1. The host and cabin NTC temperature

detectors should be installed just before
the debugging. Store them properly before
installation.

2. B e f o r e t h e m a i n t e n a n c e o r r e p a i r,
disconnect the power supply of host to
avoid wrong alarm linkage. Af ter the
maintenance or repair, remember to
connect the power supply 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
20cm to places where its temperature will
exceed 100 °C when the engine is working
normally (such as exhaust pipes, engine
housing, etc.).
4. Frequently check if the surface of NTC
temperature detectors are clean and wipe
them regularly. Otherwise, the sensitivity
of NTC temperature detectors would be
affected or even worse the detectors may
not alarm when the fire happens.
5. Never use non - prescr ibed and non -
standard 12V-24V power supply to avoid
damage to the host.
6. Never perform maintenance or repair when
the host is electrified.
7. Host and detectors should be installed
firmly. The internal and external iron
grounding should also be firm.
8. Carry out a mock fire test every six months
to test if the NTC temperature sensor is
working properly.
9. Pay attention to protect NTC temperature
detectors and harness from collision
and damage during the maintenance. If
necessary, replace it immediately.
10. W h e n t h e h o s t c o m p o n e n t s a r e i n
malfunction, contact SANY to replace a
new host component. Personnel should
not randomly disassemble the host and
NTC temperature detectors to avoid
unnecessary losses.

8.1.2 Automatic fire extinguishing

device
Automatic fire extinguishing device, specially

designed for inf lammable par ts of high
temperature, is of certain aseismatic capacity
and applies to harsh working environments.
The device consists of: dr y powder
extinguisher, driving medium, extinguishing
tank, constant pressure release valve, multi-
nozzle distribution pipe, trigger component 1. Nozzle 4. Pipe connector
(electric trigger and thermal trigger to be 2. Powder chamber 5. Hose
chosen) etc. Be equipped with early fire 3. Dual driving chamber
detection and alarm system, it can warn Fig. 8-3 Fire Extinguishing Device
the early fire in the protected area, and
automatically start extinguishing fire in time.
8.1.2.1 Precautions
• Naked flame or electriferous operation is

forbidden during the installation.
• Ensure that the nozzle of the f ire
extinguishing device should be 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.

8.1.2.2 Technical parameters
Table 8-1
Items FZBA0.4-C/GW FZBA1-C/GW

Fire extinguisher weight (g) 400 1000
Whole protection volume (m³) ≥4 ≥8
Electric or temperature
Start-up mode Electric or temperature control
control
Injection time (s) ≤5 ≤5
environmental temperature (°C) -40 - 90 -40 - 90
Safe current (mA) ≤150 ≤150
Start-up current (mA) ≥600 ≥600
voltage (V) DC6V-24V DC6V-24V
Weight (g ) 1735 ± 5 4420 ± 5
Dimensions (mm) Ø60*300 Ø89*350

Fig. 8-4
Overall Diagram of FZZK / W03 Fire Detection Alarm System
Engine cabin fire extinguishing device
To fire extinguisher
Solid gas transfer type
172133-1 male end

Power supply negative V- (black) Power supply positive V+ (red)

Break it to
put out
the fire
Fire extinguisher output G (green)
Red 0.5mm
Fire extinguisher output A (blue)
Thermal cable
8.1.3 Electrical diagrams
Black 0.5mm
172134-1 female end 24V+power supply 1mm2
172133-1 male end Fire extinguisher output A 1mm2

Fire extinguisher output G 1mm2
see from end panel
To manual switch
To at least 3 circuits of fire extinguisher
Instrument panel
Sound & light alarm lamp
see from end panel

171898-1
Yellow lamp female end
+24V power supply
Black
Fire extinguisher Fire- 1mm2 Temperature sensor 1
Buzzer Fire extinguisher Fire+ 1mm2
Yellow Green 24V+ power supply 1mm2
Green lamp Yellow Cabin high temperature alarm output T+ 1mm2
Green Failure detection ouput L+ 1mm2 Temperature sensor 2
174200-1 male end 172136-1 172135-1

female end male end
172132-1 female end Temperature sensor 3
To soud & light alarm lamp 171897-1
see from end panel
To FZZK/W03 control box male end
Temperature sensor 4
Yellow, green, black
Cabin NTC temperature

detector components
Fire detection alarm

Instrument panel Frame harness system Pay attention to keep the detector 20MM away from
the places of high temperature during the installation
Battery cabin Engine cabin
Safety, Operation & Maintenance Manual - September 2014

Optional Parts
8-13
8-14
Unmarked Tolerance
Size Table
Fig. 8-5
Size Tolerance
FZZK / W03 Fire Detection Alarm System A direction

Optional Parts
Structure Size Diagram
FZZK / W03
Sensor connector
Fire Detection
Alarm System
Power supply,
Length L = 300+/-20mm self-inspection feedback,
high temperature feedback
fire extinguisher connector

Fig. 8-6
FZZK / W03 Fire Detection Alarm System Wiring Diagram
Cabin sensor connector

FZZK / W03
Fire detection Alarm
System
The length of sensor harness is 3M. If it is too short to install,
A direction please contact the manufacturer to alter the harness or length
the harness.
Power supply, high temperature,

detection fire extinguisher connector
Installed in the cabin Sensor components
Postpositive engine is installed in the battery cabin

Prepositive engine is installed near the instrument panel

AL-001
AN-001A1
NTC-MF58-1
FZZK/W03
Optional Parts
8-15
8.2 Loudspeaker and Controller

Kit
Main functions and features:

• Speaking prior to alarm.
• Volume adjustable.
• Microphone & Loudspeaker available.
• Various tones to choose.
• Visible and audible alarm synchronous
(optional).
Fig. 8-7 Loudspeaker
• Several kinds of combination mode for
choice.
• Nice appearance, convenient operation.
8.2.1 Control panel
Control panel of call controller is composed

of alarm indicator light, power supply indicator
light, power supply switch, alarm light switch,
tone selection, alarm switch, volume (-), and
volume (+) keys.
Fig. 8-8 Control Panel

8.2.2 Operations
1. Connect the power supply, and the red

indicator light on control panel turns on.
Press the power switch on panel, and this
light goes out. Meanwhile 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 would work and the horn
would give out an alarm. Press this switch
again, and the system stops working.
4. Press the tone button, and A, B, E tones
would alarm circularly. Please select the
appropriate tone according to your own
requirement.
5. Press the volume (-) and volume (+) keys
to increase or decrease the volume. When
the alarm system is working, press these
two keys to adjust the alarm volume. Press
the mike switch, and the speaking function
is activated. Hold this switch and press the
volume (-) and volume (+) keys to adjust
the speaking volume.
8.2.3 Electrical wiring diagram
Fig. 8-9 Electrical Diagram

8.2.4 Precautions
• The control box of this product can only be

installed indoor;
• Connect the wire correctly. Never make
the load short circuit.
• Check if the rated voltage of alarm is in
accordant with that of power supply.
• Standardize the horn power.
• It is a nor mal phenomenon that the
temperature in control box rises up during
the operation.
• Never open the c ontrol box without
permission.
• Any questions in operation, please contact
SANY.
8.3 Engine Idle Protection

Screen Setting
Function
F3
Choose the engine idle protection function at F4

the setting menu of display.
Spreader prevent
Within 60 seconds after the engine is started, F5:Save energy enable

there is no response from throttle and the F6:Auto lock enable
engine keeps running at idle. After 60 seconds,
it is able to operate the machine normally and F2:Idle Protect
there is no limitation to the throttle. The screen Return Adjust Bright Contrast save ener Auto lock
displays “Idle_Protect”.
Fig. 8-10 Setting Menu
When the engine is running over 9000rpm,

switching ignition key to P position cannot stop
the engine immediately. This protection allows
a few seconds for the engine to run idle before
stopping. But the emergency stop button is still
effective even if the idle protection function is
activated.

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.
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.
Fig. 8-11 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.
Fig. 8-12 Twistlock Calculator

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
convenience of reversing.
Fig. 8-13 Reversing Radar Display
8.8 Radio
This machine has equipped with an optional

radio (1). It is located at the left side of the
console. See Fig. 8-14.
1
5
Fig. 8-14

8.8.1 Control panel
8 7 13
TA DISC
SOUND LOUD
AF AST PRISAT
9 11
1 4 BAND
VOLUME
2 VOCAL ROCK CLASSIC 5
VOLUME JAZZ FLAT POP
3 TA AF AST
RDS
9 12
321 456 10 10
Fig. 8-15 Radio Screen
Key description
1. 1………………Preset button 1
6. 6( )………Preset button 6 (traffice tune)
Short press: TA on/off Long press: AF on/off
7. …………Select sound / audio styles
8. ………………Power on/off
9. ……Increase the volume
……Decrease the volume
10. …………Tuner mode
Short press: Auto search
Long press: Manual search
11. ………FM/AM
12. …………RDS on/off
13. ………………Display

8.8.2 Mute (Silence)
Short press button to mute or cancel the

mute (silence).
NOTE:
The silenc e per iod may be inter r upted
by AL ARM announcement or traf f ic
announcement messages (if TA is switched
on).
Fig. 8-16 Power Supply Button
8.8.3 Sound
Whether you listen to Jazz, Vocal, Pop, Classic

or Rock music, this button is the perfect choice
for your setting.
Press to select BASS-Treb for your

own sound style, or adjust the settings with the
volume up/down buttons to select one of the
pre-define sound styles:
-BASS-TRE: Self settings
-FLAT: Original
-JAZZ: Jazz music
-VOCAL: Speech Fig. 8-17 Sound Button
-POP: Pop music
-CLASSIC: Classical music
-ROCK: Rock music
8.8.4 Audio setting

• Press to select desired audio mode.
-Sound style BASS-TRE, FLAT,
JAZZ, VOCAL, POP,
CLASSIC, ROCK
-BASS low notes
-TREBLE high notes
-BALANCE left-right
-FADER rear-front
Fig. 8-18 Sound Type
-LOUD OFF, LOW, MID, HIGH

• Press the volume button to adjust the

selected audio mode. After 5 seconds the
display returns to show the last mode of
operation. Adjustment of Bass and Treble
setting is only possible when BASS-TRE is
selected as the sound style.
8.8.5 Radio
11
Waveband
• Press to select the desired band:
10 10
12
Automatic search
• Press or to tune to a station of a lower
frequency or of a higher frequency. Fig. 8-19 Band Button
• To search for another station, press the
button again.
Manual tuning (if you know the frequency

of the required station)
• Long press the search button or for
more than 2 seconds, and the manual
tuning is activated.
• Then press or to tune to a station of a
lower frequency or of a higher frequency.
• If no station is searched in 5 seconds, the
system would return to its last operation.

Preselected stations
Manually storing stations in a preset

By using the preset keys (1 to 5), five stations
per band can be stored and recalled.
• Tune to the desired station.

• Press the desired preset key (1 to 5) for
more than 2 seconds to store the current
tuned station.
Fig. 8-20 Station Button
Preset, recalling
Press the desired preset key (1 to 5) to recall

the stored station.
Automatically storing stations (AUTO-

STORE)
• You can automatically store 5 strongest

FM stations on the FM AST band or
5 strongest MW(AM) stations on the
MW(AM) AST band. When you use Auto-
Store, the new stations replac e any
stations previously stored in the FM AST
band or the MW(AM) AST band.
• Press to activate auto-store.
• The system gives out a beep and then
mutes.
• When the station is stored successfully,
you can hear a beep followed by the
storing.
• Sometimes it may be impossible to find 5
stations.

8.8.6 Radio troubleshooting
When you suspect that your radio is not

functioning normally, please check the below
troubleshooting table before calling for service.
If you still have to send your radio set for

service, always send the complete set (with
detachable panel). Do not try to open the set
to service it yourself.
Table 8-2 Radio Troubleshooting Table
No. Fault Troubleshooting method

The set does not function. No 1. Check the fuse (set and car) and connections.
1
display 2. Check the operating voltage.
1. Adjust the volume of the set.
The set functions with no
2 2. Check the radar and balance settings.
sound.
3. Check the aerial and its connection.
1. Check that the aerial is fully extended and properly
connected.
The system cannot be tuned 2. Check that the negative terminal (brown lead) is
3
to a desired station. connected to the machine frame.
3. Desired station is too weak. Try the manual tuning
function.
Display shows frequency 1. The set is tuned to non-RDS station
4
instead of station name 2. The RDS function is switched off.

8.9 CCTV System
LD Series CCTV System is widely used on

hoisting machiner y, handling machiner y,
loading equipment and other specialized
equipment. With this equipment, operator can
easily get actual information to work safely and
conveniently.
8.9.1 Safety precautions
Personnel should observe the following items:

• The installation of this system should
b e o p e r ate d un de r t h e gui danc e of
professionals or technicians.
• Outdoor equipment is waterproof, but
when being applied, please make sure that
the connections such as screw holes fixed
to the chassis should be waterproof. Or
you shall take the consequences caused
by leakage.
• Please read the manual carefully to avoid
damage to devices caused by misuse.
• Pay attention to protect equipment from
scuffing.
• Remember not to maintain it by yourself
so as to avoid damage to equipment or
other dangers. It is recommended that
all maintenance work should be made by
professionals or technicians.
• K e e p t h e e q u i p m e n t a w a y f r o m
e nv i r o n m e nt f i l l e d w i t h f l a m m a b l e,
explosive or corrosive gases.
• Please use the original accessories or the
ones recommended by the manufacturers
of accessories.

8.9.2 Major parts
This CCTV system is composed of the front

camera part, the transmission part and the
display and control part in driver's cabin. It can
supply six video images for the operator and
display them on a 10.4 inch LCD monitor.
1. The camera
Four spreader cameras are mounted on four
corners of the spreader. Two fixed cameras
were installed separately at the underside
of boom and the rear of reach stacker. The
cameras are used to capture the video signal.
2. The transmission part

The video signal collected by the cameras
is transmitted from the junction device near
camera through composite cable (including
video, power supply) to the driver’s cabin.
3. Monitor and controller in the driver’s

cabin
There are a set of shift switches and a set of
10.4 LCD monitor in the driver’s cabin. The
display modes of six cameras are switched by
the shift switch.

8.9.3 Installation
The installation locations and functions of

CCTV devices are included in below table:
Table 8-3
No. Device Location Function

Aseismatic camera system Respectively at the
Monitoring the work of spreader
of spreader 1-4 upper left, lower left,
1 upper right, and lower
Wiring, and providing power to the
Junction box 1-4 right corners of the
camera system
spreader
Monitoring the situation in front of the
Front view semi-fixed camera
machine
5 At the bottom of boom
Junction box 5
camera system
Monitoring the situation behind the
Rear view semi-fixed camera
machine
6 At the rear of machine
Junction box 6
camera system
Receiving and processing the camera
7 Vehicle DVR In the driver's cabin
video signal
Controlling the switchover of display
8 Shift switch In the driver's cabin
modes
9 LCD monitor In the driver's cabin Displaying the video image
NOTE:
The distance between camera and junction
box should be less than 1.5m.

8.9.4 Vehicle DVR
8.9.4.1 Physical interfaces
Fig. 8-21
Table 8-4 The Interface Description of Vehicle

DVR
Physical Interface Connection Descriptions

CH1, CH2, CH3, CH4 1 - 4 channel: video and audio input, power output, four-core air plug.
CH5-CH8 5 - 8 channel: video and audio input, power output.
OUT Video and audio output, power output, four-core air plug.
RS232 RS232 serial port, power output, five-core air plug.
RS422 communication interface, reporting interface preserved, ten-core air
RS422
plug.
POWER Power input device and start control interface, six-core air plug.
3G (ANT1/ANT2) 3G main and auxiliary antenna interface.
WIFI (ANT3) WIFI antenna interface
USB USB drive interface
LAN Network cable interface
ALARM IN (1-3) Alarm signal input, support high / low level triggered.
ALARM OUT (1A 1B 2A 2B) Alarm signal output, switch signal.
Common ground terminal corresponded to the level signal of alarm input and
m
travelling input.

8.9.4.2 Shift switch
There are four gears of the shift switch: 0

1
• Turn the shift switch to gear 0, and the
2
images of all the six cameras can be
3
displayed together for the operator to
observe comprehensively the surrounding
circumstances.
image of f ront view c amera c an be
displayed for the operator to observe the
situation in front of machine.
• Tur n the shif t switch to gear 2, and
the image of rear view camera can be
displayed for the operator to observe the
situation at the rear of machine.
images of four cameras installed at the
spreader can be displayed for the operator
to obser ve t he wor k ing situat i on of
spreader.
Fig. 8-22
8.9.4.3 Disassembly of hard disk
We have installed a hard disk in the vehicle

DVR for image storage. However, considering
the limited storage space of hard disk and the
mobile working environment of machine, it is
recommended to maintain the hard disk once
a month (Remove the hard disk from the DVR
and import the stored information into a user-
specified storage device). The disassembly
steps of hard disk are listed as follows:
NOTE:
Be sure to disconnect the system power
before disassembly.

1. Prepare fo r t he fo ll ow ing to o ls and

materials: 2.5 inch SATA hard disk, anti-
static gloves, the key of hard disk lock,
cross screwdriver, the screws of hard disk.
Fig. 8-23
2. Turn on the hard disk lock with the key.

Loosen the fastening bolts on the hard disk
box by screwing them anti-clockwise. Then
pull the hard disk box out with two hands.
Fig. 8-24
3. Remove the screws fixing the hard disk in

sequence (see Fig. 8-). In order to avoid
damage to the hard disk, it is suggested to
support the underside of hard disk before
removing the screws.
Fig. 8-25

4. Remove the screws and then upturn the

hard disk box. Pull the hard disk gently out
of the box and take it out.
Fig. 8-26
8.9.5 Troubleshooting the CCTV system
Table 8-4
Part Symptom Analysis Detection method Solution
Make sure whether there
is some video signal of
The camera and cable Change the cable if
No video output are damaged. camera. Then check if
Camera there is no image.
there are images on the
System signal of camera monitor.
No video output signal of
The camera is damaged. Change the camera.
camera.
Measure the input
There is no power voltage of power
-
DVR can’t display supplied for DVR. supply with a
DVR
any images multimeter.
The switch of DVR is
- Change the switch.
damaged.
Check if the DVR Connect this camera
displays this camera. into the system.
Check if the cable
The screen of
between DVR and Reconnect the video
LDC monitor is No video signal input.
monitor is connected cable.
blue
well.
Check if the DVR is Check the power
turned on. indicator light of DVR.
Monitor
Check if the power
Reconnect the power
output cable of monitor
cable.
is connected.
T h e s c r e e n o f The power supply is not
Ch eck i f the re is AC M e a s u r e i t w i t h a
LDC monitor is connected or the monitor
power input of monitor. multimeter.
black is damaged.
Send it back to the
manufacturer for
repair.

8.9.6 Wiring diagram
On the upper left corner of the spreader

Operator Cabin Composite Monitoring the work of the spreader
Cable
Junction Equipment 1
cable 11
On the lower left corner of the spreader

Composite Monitoring the work of the spreader
Cable
Junction cable 12
Equipment 7
On the spreader
Monitoring the work of the spreader
Composite
Cable 2-7 Cable
cable 13
cable 14
RS 422 POWER
POWER IN
Composite
CH 1 CH 3 OUT RS 232 Cable
CH 2 CH 4
CH 5 CH 6 ALARM
IN 1-3 123456
控制电缆
Composite
Cable Junction Equipment 5
Cable 1
cable 15 Junction Equipment 6
2 3 cable 16
1 4 switch
Composite
Cable
外部电源直流
DC 6V~24V
+-
10.4"LCD Monitor
Fig. 8-27
NOTE:
The control cable is a four-core wire, with
one core as common terminal (negative) and
three cores as control terminals (front, rear,
spreader). The voltage between control and
common terminals should be 5V ( low level ) or
6-36V ( high level ) when the switch is turned
off.

8.10 Flowmeter
Flowmeter is a gauge for measuring the flow. It

can be supplied to customers as an accessory
tool.
Quick connectors are installed to connect the
flowmeter between oil pump and main valve.
A warning label is suspended at the quick
connector to avoid hydraulic harm. See Fig.
8-28.
Fig. 8-28
Steps to measure the flow:

Release the pressure after the machine is
stopped. Then loosen the quick connector
at the oil outlet of pump. Connect the quick
connectors at two sides of flowmeter with
that at the oil outlet of pump. Note to match
the male and female heads. Tighten up all
the connectors before measuring the flow.
Start the machine to measure the outlet flow
of pump. The overall flow of system is the
summation of two pump flows.

8.11 Automatic Lubrication Lubrication Overflow

pump valve Grease nipple
System
The automatic lubrication system is composed

of machine lubrication system and spreader
lubrication system. The lubrications of machine
and spreader are respectively driven by two
automatic lubrication pumps. The lubrication is
totally automatic. Therefore, it is unnecessary
for the operator to lubricate.
The machine lubrication pump is located at the

Fig. 8-29
left of machine back.
The spreader lubrication pump is located at

the upper of spreader main beam.
8.11.1 Operation precautions
Pay special attention to below items when

operating the automatic lubrication system:
●● Check if there is enough grease in the oil
reservoir of lubrication pump. Fill in grease
in time. Never make the oil pump run RS-1407033-1
without grease.
●● Make sure that the upper cover of oil Fig. 8-30
reservoir is tightened to prevent dust and
dirt from entering. 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 temperature is low.
●● Check if grease spills over from the
ove r f l o w va l ve o f o i l p u m p. I f ye s ,
troubleshoot it immediately.
●● Usually the lubrication time is set to be 6
minutes and the intermittent time is set
to be 3 hours when the machine leaves
factory.

8.11.2 Time setting
When the operator has changed the time

setting by accident, it is able to set up the
lubrication time and intermittent time according
to below steps.
1. Move the protective cover at the base, and

then set up the time.
NOTE:
Make sure to tighten the protective cover after
the time setting.
RS-1407034-1
Fig. 8-31
2. Set up the intermittent time:

3
By rotating the blue switch, 15 kinds of
intermittent time can be set up. 9
NOTE:
If the button is located at position 0, the right
diode would light up and the system would
send out the malfunction signal. Meanwhile
the intermittent time is defaulted to be the Blue switch to set up Forcible start key to activate
intermittent time intermittent lubrication
initial time.
Fig. 8-32
Table 8-5 Intermittent Time Setting Table
Position 1 2 3 4 5 6 7 8 9 A B C D E F
Minute 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60
Hour 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

3. Set up the lubrication time:

3
By rotating the red switch, 15 kinds of
lubrication time can be set up. 9
NOTE:
Never located the button at position 0.
Red switch to set up

lubrication time
Fig. 8-34
Table 8-6 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

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GE
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A
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P
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K
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N
............................................................................................................
A
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L
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B
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Container Reach Stacker Schematics
Schematics
9. Schematics
9.1 Symbol Explanation��9-2
9.2 Hydraulic Schematic Diagrams��9-3
9.2.1 C-type / SRSC4535 / SRSC4535C / SRSC4535C1 container reach stackers��9-4
9.2.2 SRSC4545C container reach stackers��9-5
9.2.3 SRSC3515-3 container reach stackers��9-6
9.2.4 SRSC1009-6E container reach stackers��9-7
9.3 Electrical Schematic Diagrams��9-8
9.3.1 C-type container reach stacker��9-8
9.3.2 Empty container reach stacker��9-23
9.4 Schematic Diagrams of Spreader System��9-36
9.4.1 Hydraulic schematic diagram of spreader system��9-37
9.4.1.1 SDJ450 Spreader��9-37
9.4.1.2 SJD450F-R3 / SDJE100-R1 Spreader��9-38
9.4.1.3 SJD450E-R1 / SJD450F-R1 Spreader��9-39
9.4.1.4 ELME817 Spreader��9-40
9.4.1.5 BROMMA RSX40 Spreader��9-41
9.4.2 Electrical schematic diagram of spreader system��9-42
9.4.2.1 SDJ450 Spreader��9-42
9.4.2.2 SDJ450F-R1 Spreader�� 9-44
9.4.2.3 SDJ450E-R1 Spreader��9-46
9.4.2.4 SDJ450F-R3 Spreader��9-48
9.4.2.5 SJE100-R1 Spreader��9-50
9.4.2.6 ELME817 Spreader��9-52
9.4.2.7 BROMMA RSX40 Spreader��9-54

Schematics Container Reach Stacker
9. SCHEMATICS
1 2
3 4
9.1 Symbol Explanation
5 6
The following symbols are standard ones used in
wiring and hydraulic diagrams.
7 8 M
1. Electric control signal 21. Counter
2. Electric force 22. Flow control valve 9 10
3. Hydraulic control signal 23. Check valve

4. Hydraulic force 24. Hydraulic cylinder 11 12
5. Hydraulic motor 25. Double-acting hydraulic cylinder

6. Hydraulic oil pump with variable displacement 26. Single-acting hydraulic cylinder 13 14
7. Hydraulic oil pump with fixed displacement 27. Valve block U

8. Electric motor 15 16
28. Shuttle valve P
9. Accumulator 17 18
29. Fuse protecter
10. Disc brake 30. Relay 19 20
11. Filter 31. Solenoid valve 21 22
12. Radiator 32. Breaker
23 24
13. Heater 33. Resistor
14. Bulb 34. Proximity switch 25
15. Analog signal output pressure sensor 35. Temperature switch
16. Pressure meter 26 27
36. Limit switch
17. Temperature gauge 37. Button
28 29
18. Fluid level gauge 38. Emergency stop switch
19. Flow gauge 39. Buzzer 30 31
20. RPM meter 40. Horn 32 33
34 35
36 37
38 39
40
Fig. 9-1 Symbols

9.2 Hydraulic Schematic Diagrams
Table 9-1 Hydraulic Diagram List of Container Reach Stacker
Machine Model Page Diagram

SRSC45C30 / SRSC45C30-6 / SRSC45C1 /
SRSC45C2 / SRSC45C5 / SRSC45C7 /
SRSC45C22 / SRSC45C23 / SRSC45C31 / P 9-4 Fig. 9-2
SSRSC45C32 / SRSC4535 / SRSC4535C /
SRSC4535C1
SRSC4545C P 9-5 Fig. 9-3
SRSC3515-3 P 9-6 Fig. 9-4
SRSC1009-6E P 9-7 Fig. 9-5

9.2.1 C-type / SRSC4535 / SRSC4535C / SRSC4535C1 container reach stackers
Counterweight Cab moving

Telescopic cylinder moving Spreader anti-swinging
Left pitching cylinder Right pitching cylinder (optional)
Steering mechanism 9 10 11
7 8 22 22 23
21
5 6 24
15 4
3
14 13 17 16 17 16
12 20 1 2 1918
1. Double pump 2. Oil pump 3. Pilot oil supply valve group 4. Accumulator 5. Oil filter 6. Main valve 7. Dynamic steering mechanism
8. Dynamic flow amplifier 9. Telescopic cylinde valve group 10. Left pitching cylinder control block 11. Right pitching cylinder control block 12. Brake control valve group 13. Accumulator
14. Oil return filter 15. Radiator 16. Cooling transferring valve group 17. Wind cooler 18. Back pressure valve group 19. Oil return filter
20. Brake valve 21. Mobile valve group 22. Tubular bi-directional balance valve 23. Anti-swinging valve group 24. Spreader multi-channel body
Fig. 9-2

9.2.2 SRSC4545C container reach stackers
Telescopic cylinder Left pitching cylinder Right pitching cylinder

Counterweight moving
(optional) Spreader anti-swinging
Cab moving
Steering mechanism 9 10 11
7 8
22 22 23
21
5 6
15 3
14 13 17 16 17 16
12 20 1 2 19 18
1. Double pump 2. Oil pump 3. Confluent integrated valve group 4. Accumulator 5. Oil filter 6. Main valve 7. Dynamic steering mechanism
20. Brake valve 21. Mobile valve group 22. Tubular bi-directional balance valve 23. Anti-swinging valve group
Fig. 9-3

9.2.3 SRSC3515-3 container reach stackers
Telescopic cylinder Spreader anti-swinging

Left pitching cylinder Right pitching cylinder
9 10 11
Steering system
7 8 23
To spreader
slewing
valve group
Oil leakage way
Oil return way
Pressurized oil
5 6 22
Oil-collection block
Travelling brake oil

Cooling Cooling
oil oil
inlet outlet
Parking brake cylinder
21
15 4
3
14 13 17 16 17
12 2 18
20 1 19
1. Double pump 2. Oil pump 3. Pilot oil supply valve group 4. Accumulator 5. Oil filter 6. Main valve 7. Dynamic steering mechanism
20. Prefill valve 21. Brake valve 22. Spreader multi-channel body 23. Anti-swinging valve group
Fig. 9-4

9.2.4 SRSC1009-6E container reach stackers
19
Telescopic cylinder Pitching cylinder Pitching cylinder
Side-shifting & telescoping & locking valve group
5 6 7
Side-shifting Left locking Left telescoping

cylinder cylinder cylinder
Telescopic & locking valve group
Damping cylinder
Right locking cylinder Right telescoping cylinder
9
4
10
18 8
13 12
11 14 15 14 15
Torque converter oil outlet
3
Torque converter oil inlet
1 2 16 17
1. Double pump group 2. Double gear pump 3. Spreader transitional valve group valve 4. Multi-way valve 5. Telescopic cylinde valve group 6. Left pitching cylinder control block
7. Right pitching cylinder control block 8. Priority valve 9. Steering mechanism 10. Brake control valve group 11. Prefill valve 12. Brake valve
13. Oil return filter 14. Wind cooler 15. Cooling transferring valve group 16. Back pressure valve group 17. Oil return filter 18. Accumulator 19. Spreader
Fig. 9-5

9.3 Electrical Schematic Diagrams
9.3.1 C-type container reach stacker
Table 9-2 Electrical Diagram List of Container Reach Stacker
Name Page Diagram

Diagram Description P 9-9 Fig. 9-6
VOLVO Engine Circuit Diagram P 9-10 Fig. 9-7
CUMMINS Engine Circuit Diagram P 9-11 Fig. 9-8
YUCHAI Engine Circuit Diagram P 9-12 Fig. 9-9
Air Conditioner Wiring Diagram P 9-13 Fig. 9-10
Washing and Wiping System Diagram P 9-14 Fig. 9-11
Signal System Diagram P 9-15 Fig. 9-12
Auxiliary Electrical Control Diagram P 9-16 Fig. 9-13
Working Illuminating System Diagram P 9-17 Fig. 9-14
Spreader Control System Diagram P 9-18 Fig. 9-15
Controller Diagram 1 P 9-19 Fig. 9-16
CAN BUS Communication Diagram P 9-22 Fig. 9-19

Symbol Explanation Function Description Harness Explanation
Line Symbol Name Line Name Explanation Line Name Explanation
Relay Description part Front control panel harness

Power supply and engine
Fuse part Right control panel harness
Illumination auxiliary control Control panel harness of
Battery part steering mechanism
Engine PLC part Air conditioner harness
Motor Drag-chain harness 1

Radio,
loudspeaker Drag-chain harness 2
Loudspeaker Drag-chain harness 3

Middle front frame body
Valve
harness
Rotary switch, Torque converter / gear
rocker switch solenoid valve harness
Button Power supply harness
Steering mechanism Rear frame body harness
Temperature sensor Oblique boom harness
Pressure switch Boom harness 1
Proximity switch Boom harness 2
Illumination lamp
Signal lamp
Horn, buzzer
Potentialmeter
Breaker
Pressure sensor
Fig. 9-6 Diagram Description

VOLVO Engine Wiring Diagram
Wiring
Stop Ignition
EDC-III Digital Fuel Control Device Start Preheat Electrified
8-core Socket Controller CR0200

/Controller SYMC
Emergency Start
Battery Generator Starter Engine Start Switch Stop Control EDC Power Supply Start Heating
Power Supply System Engine Control System
Fig. 9-7 VOLVO Engine Circuit Diagram

CUMMINS Engine Wiring Diagram
Wiring
Start Input Electrified
ECM Engine Digital Fuel 31-pin

Socket
Start Control
Control Device 50-pin Socket
Power Supply Emergency

Battery Relay Preheat Generator Starter Engine Start Switch Stop Control ECM Power Supply Preheat Relay
Fig. 9-8 CUMMINS Engine Circuit Diagram

YUCHAI Engine Wiring Diagram
Wiring
Start Input
Controller CR0200
Start Control
42-pin Plug-in Parts Plug 2-pin Plug-in Parts Plug
Power Supply Generator Starter Engine Start Switch Emergency Stop Control Heating Relay
Battery Relay Preheat Start Relay Start Ignition Power Supply
Fig. 9-9 YUCHAI Engine Wiring Diagram

SONGZ Air Conditioner Wiring Diagram
Red
Air Conditioner
Control Panel
Yellow /
Black Yellow Blue Black Purple
(Upper)
Flash Light
(Middle)
Nearby Light
(Lower)
Distant Light
Condenser Distant / nearby Left Front Left Front Right Front Right Front
Power Supply Clutch Condenser Fan Distant Lamp Nearby Lamp Taillamp Rear Lamp
Pressure Switch Lamp Switching Nearby Lamp Distant Lamp
Air Conditioner System Light System
Fig. 9-10 Air Conditioner Wiring Diagram

Wiper Intermittent
Relay
Washer Water Pump Wiper Control Switch Front Wiper Switch Front Wiper Top Wiper Rear Wiper
Washer, Wiper System
Fig. 9-11 Washer & Wiper Electrical Diagram

Rever-
sing
Radar
Reversing Reversing Flash Light Direction Indication Front Right Rear Right Front Left Brake Parking Signal
Horn Switch Electric Reversing Parking
Rear Left
Horn Lamp Alarm Radar Circuit Switch Lamp Steering Lamp Steering Lamp Steering Lamp Steering Lamp Brake Switch Lamp Indication Switch
Signal System
Fig. 9-12 Signal System Diagram

Detector 1
Display
Detector 2
Camera
Main engine
Detector 3
Detector 4
Reversing Radar
Left/Right
Tape Radio Stereo Top Lamp Door Switch
Cab Forward Shifting CabShifting
Backward
Cab Shifting Oil Supply Valve Camera System (optional) Brake Oil Cooling Hydraulic Low Temperature Relief Heating (optional)
Auxiliary Electrical Appliance Control
Fig. 9-13 Auxiliary Electrical Control Diagram

Spare Power
Boom Lamp Alarm Lamp Width Lamp Supply
Work Light, Signal System of Reach Stacker
Fig. 9-14 Working Light System Diagram

Input Signal of Spreader System

Spreader Spreader Spreader Spreader Spreader Spreader Spreader Spreader Vertical
Clockwise Anticlockwise
40 feet 20 feet Rotating Rotating Left-shifting Right-shifting Releasing Locking Movement
Spreader Circuit
Controller CR0200/SYMC
Spreader Main Oil Supply Locking Seating Releasing Spreader Automatic

Spreader Lamp Switch Power Supply Electromagnetic Valve Lamp Lamp Lamp Safety Bypass Twistlock
Output Signal of Spreader System
Fig. 9-15 Spreader System Diagram

Controller Throw-out Throw-out Gearbox Gearbox

Backward Forward Gear Gear Gear of Gear Controller Gearbox Turbine RPM Parking
Power Supply 1 Signal 1 Signal 2
of Gear Pressure Power Supply 2 Pressure Temperature Pressure Switch
Signal 3 Switch Switch
Controller CR0200 / Controller SYMC
Engine Forward Backward Gear Gear Gear Parking

Twistlock Solenoid
Working Solenoid Solenoid Solenoid Solenoid Solenoid
Counter Valve
Hour Counter Valve Valve Valve 1 Valve 2 Valve 3
(Optional)
Fig. 9-16 Controller Diagram 1

Boom Right Pitching Right Pitching Left Pitching

Pitching Extend Boom Pitching Boom Emergency Parking
Cab Forward Shifting Main System Engine Engine
Boom Movement Accelerator Emergency Safety Cylinder No-rod Cylinder Rod Cylinder No-rod
Up/down / Retract Down Locking Pitching Down Switch
Protection Signal Pressure Stopping Preheating
Forerunner Pedal Retraction (preserved) Bypass Chamber Pressure Chamber Pressure Chamber
Signal Signal
Switch Key Switch Switch Measure Measure Pressure Measure Measure
Controller CR0200
/ Controller SYMC Controller CR0200 / SYMC
Boom Extension Boom Retraction Boom Pitching Boom Pitching Boom Quick
Boom Quick
Boom Quick Extension Boom Emergency Pitching Cylinder Pitching Proportional Proportional Up Proportional Down Proportional Extension Pitching Cylinder Quick
Electromagnetic Electromagnetic Electromagnetic Electromagnetic Auxiliary Extension Lifting Electromagnetic Valve
Electromagnetic Valve Retraction Valve Down Electromagnetic Valve Valve Valve Valve Valve Relay
Control

Low Pressure Water Level Brake Oil

Tilting Forward Fuel Oil Hydraulic Oil Control Oil Speed
Malfunction Reset / Mute of Parking Brake Switch Filter Clogging Filter Clogging Filter Clogging
Protection Signal Level (preserved) Proximity Switch
Accumulator
Controller CR0200 / SYMC
Hydraulic Oil Gearbox Oil

Malfunction Malfunction Sound High Hydraulic High Brake Oil Flash Light Hydraulic Oil Brake Oil Parking Signal
Temperature Temperature
Indication & Light Alarm Oil Temperature Temperature Signal Temperature Temperature Cooling Fan Indication
Cooling Fan

Controller
Displayer CR1050
EDCIII 8-Pin Controller SYMC Controller CR0200
Length / Angle Spreader 24-pin
Sensor / SYLD
Socket Socket
Engine
Engine
To Controller
CUMMINS Engine 9-pin

ECM 50-Pin Detection Plug
Socket
Fig. 9-19 CAN BUS Communication Diagram

9.3.2 Empty container reach stacker
Table 9-3 Electrical Diagram List of Empty Container Reach Stacker
Name Page Diagram

Diagram Description P 9-24 Fig. 9-20
CUMMINS Engine Circuit Diagram P 9-25 Fig. 9-21
Air Conditioner Wiring Diagram P 9-26 Fig. 9-22
Washing and Wiping System Diagram P 9-27 Fig. 9-23
Signal System Diagram P 9-28 Fig. 9-24
Auxiliary Electrical Control Diagram P 9-29 Fig. 9-25
Working Illuminating System Diagram P 9-30 Fig. 9-26
Spreader Control System Diagram P 9-31 Fig. 9-27
CAN BUS Communication Diagram P 9-35 Fig. 9-31

Symbol Explanation Function Description Harness Explanation
Line Symbol Name Line Name Explanation Line Name Explanation
Relay Description part Front control panel harness

Power supply and engine
Fuse part Right control panel harness
Illumination auxiliary control Control panel harness of
Battery part steering mechanism
Engine PLC part Air conditioner harness
Motor Drag-chain harness 1

Radio,
loudspeaker Drag-chain harness 2
Loudspeaker Drag-chain harness 3

Middle front frame body
Valve
harness
Rotary switch, Torque converter / gear
rocker switch solenoid valve harness
Button Power supply harness
Steering mechanism Rear frame body harness
Temperature sensor Oblique boom harness
Pressure switch Boom harness 1
Proximity switch Boom harness 2
Illumination lamp
Signal lamp
Horn, buzzer
Potentialmeter
Breaker
Pressure sensor
Fig. 9-20 Diagram Description

CUMMINS QSB6.7 Engine Wiring Diagram
Wiring
Start Input Electrified

4-core
ECM Engine Digital 50-core
Socket
Fuel Control Device Socket
Start Control J3

Detection Plug
Power Supply Emergency

Battery Relay Preheat Generator Starter Engine Start Switch Stop Control ECM Power Supply Preheat Relay
Fig. 9-21 Cummins Engine Diagram

SONGZ Air Conditioner Wiring Diagram
Red
Air Conditioner
Control Panel
Yellow /
Black Yellow Blue Black Purple
(Upper)
Flash Light
(Middle)
Nearby Light
(Lower)
Distant Light
Condenser Distant / nearby Left Front Left Front Right Front Right Front
Power Supply Clutch Condenser Fan Distant Lamp Nearby Lamp Taillamp Rear Lamp
Pressure Switch Lamp Switching Nearby Lamp Distant Lamp
Air Conditioner System Light System
Fig. 9-22 Air Conditioner Wiring Diagram

Wiper Intermittent
Relay
Washer Water Pump Wiper Control Switch Front Wiper Switch Front Wiper Top Wiper Rear Wiper
Washer, Wiper System
Fig. 9-23 Washer & Wiper Electrical Diagram

Rever-
sing
Radar
Reversing Reversing Flash Light Direction Indication Front Right Rear Right Front Left Brake Parking Signal
Horn Switch Electric Reversing Parking
Rear Left
Horn Lamp Alarm Radar Circuit Switch Lamp Steering Lamp Steering Lamp Steering Lamp Steering Lamp Brake Switch Lamp Indication Switch
Signal System
Fig. 9-24 Signal System Diagram

Cab Top
Brake Oil Cooling Hydraulic Low Temperature Overflow Heating (optional)
Lamp
Auxiliary Equipment Control
Fig. 9-25 Auxiliary Electrical Equipment Diagram

Spare Power
Boom Lamp Alarm Lamp Width Lamp Supply
Work Light, Signal System of Reach Stacker
Fig. 9-26 Working Light System Diagram

Input Signal of Spreader System

Spreader Spreader Spreader Spreader Spreader Spreader Spreader Spreader Vertical
Clockwise Anticlockwise
40 feet 20 feet Rotating Rotating Left-shifting Right-shifting Releasing Locking Movement
ELME Spreader Circuit
Controller CR0200
Spreader Spreader Main Locking Seating Releasing Spreader Automatic

Spreader Lamp Switch Power Supply Oil Supply
Movements Solenoid Lamp Lamp Lamp Safety Bypass
Valve Twistlock
Output Signal of Spreader System
Fig. 9-27 Spreader Controller Diagram

Controller Throw-out Throw-out Gearbox Gearbox

Backward Forward Gear Gear Gear of Gear Controller Gearbox Turbine RPM Parking
Power Supply 1 Signal 1 Signal 2
of Gear Pressure Power Supply 2 Pressure Temperature Pressure Switch
Signal 3 Switch Switch
Controller CR0200
Engine Forward Backward Gear Gear Parking

Twistlock Solenoid
Working Solenoid Solenoid Solenoid Solenoid
Counter Valve
Hour Counter Valve Valve Valve 1 Valve 2
(Optional)

Boom Right Pitching Right Pitching Left Pitching Engine

Pitching Extend Accelerator Boom Pitching Boom Emergency Parking Engine
Boom Movement Emergency Safety Cylinder No-rod Cylinder Rod Cylinder No-rod Main System Stall
Down Locking Pitching Down Switch Pressure Stopping Directive Preheating
Forerunner Up/down / Retract Pedal Retraction Bypass Chamber PressureChamber Pressure Chamber
Measure Signal Signal
Switch Key Switch Switch Measure Measure Pressure Measure
Controller CR0200 Controller CR0200
Boom Boom Quick

Boom & Spreader Boom ExtensionBoom Retraction Boom Lifting Boom Lowering Boom Quick
Boom Quick Extension Emergency Boom Confluent Boom Confluent Extension Pitching Cylinder Quick Idle Protection
Running Failure Retraction Confluent Pro- Valve 2
Lowering Solenoid Valve Proportional Proportional Proportional Proportional Extension
Lifting Solenoid Valve Output Relay Electrification
Valve 1 Auxiliary
Solenoid Valve Valve portional Valve Solenoid Valve Solenoid Valve Solenoid Valve Solenoid Valve
Control
Relay

Low Pressure Brake Oil

Tilting Forward Fuel Oil Hydraulic Oil Control Oil Speed
Malfunction Reset / Mute of Parking Brake Filter Clogging Filter Clogging Filter Clogging
Protection Signal Level Proximity Switch
Accumulator
Controller CR0200
Hydraulic Oil Gearbox Oil

Malfunction Malfunction Sound High Hydraulic High Brake Oil Flash Light Hydraulic Oil Brake Oil Parking Signal
Temperature Temperature
Indication & Light Alarm Oil Temperature Temperature Signal Temperature Temperature Cooling Fan Indication
Cooling Fan

Controller
Displayer CR1050
EDCIII 8-Pin Controller SYMC Controller CR0200
Length / Angle Spreader 24-pin
Sensor / SYLD
Socket Socket
Engine
Engine
To Controller

ECM 50-Pin Detection Plug
Socket
Fig. 9-31 CAN BUS Communication Diagram

9.4 Schematic Diagrams of Spreader System
Table 9-4 Schematic Diagram List of Spreader System

Name Spreader Model Page Diagram
SDJ450 P 9-37 Fig. 9-32
SDJ450F-R3 / SDJE100-R1 P 9-38 Fig. 9-33
Hydraulic Diagram SDJ450E-R1 / SDJ450F-R1 P 9-39 Fig. 9-34
ELME817 P 9-40 Fig. 9-35
BROMMA RSX40 P 9-41 Fig. 9-36
P 9-42 Fig. 9-37
SDJ450
P 9-43 Fig. 9-38
P 9-44 Fig. 9-39
SDJ450F-R1
P 9-45 Fig. 9-40
P 9-46 Fig. 9-41
SDJ450E-R1
P 9-47 Fig. 9-42
P 9-48 Fig. 9-43
SDJ450F-R3
P 9-49 Fig. 9-44
P 9-50 Fig. 9-45
SDJE100-R1
Electrical Diagram P 9-51 Fig. 9-46
P 9-52 Fig. 9-47
ELME817
P 9-53 Fig. 9-48
P 9-54 Fig. 9-49
P 9-55 Fig. 9-50
P 9-56 Fig. 9-51
BROMMA RSX40 P 9-57 Fig. 9-52
P 9-58 Fig. 9-53
P 9-59 Fig. 9-54
P 9-60 Fig. 9-55

9.4.1 Hydraulic schematic diagram of spreader system
9.4.1.1 SDJ450 Spreader
Side-shifting cylinder Side-shifting cylinder
Damping (anti-swinging) cylinder
Left locking Right locking

cylinder cylinder
Left telescoping Right telescoping

cylinder cylinder
Fig. 9-32 Hydraulic Schematic Diagram of SDJ450 Spreader

9.4.1.2 SJD450F-R3 / SDJE100-R1 Spreader
Side-shifting & telescoping & locking valve group Telescoping & locking valve group
Solenoid reversing valve Solenoid reversing valve
Solenoid reversing valve

Dual one-way throttle valve
Dual one-way throttle valve

Solenoid reversing valve Solenoid reversing valve
Overflow valve
Overflow valve Overflow valve
Side-shifting cylinder Left telescoping cylinder Right telescoping cylinder
Left locking cylinder Right locking cylinder
Fig. 9-33 Hydraulic Schematic Diagram of SJD450F-R3 / SDJE100-R1 Spreader

9.4.1.3 SJD450E-R1 / SJD450F-R1 Spreader
Left locking cylinder Left locking cylinder
Slewing motor

Left side-shifting Right side-shifting
cylinder cylinder
Telescopic motor
Oil leakage way

Oil return way
Pressurized oil
Fig. 9-34 Hydraulic Schematic Diagram of SJD450E-R1 / SJD450F-R1 Spreader

9.4.1.4 ELME817 Spreader
Fig. 9-35 Hydraulic Schematic Diagram of ELME817 Spreader

9.4.1.5 BROMMA RSX40 Spreader
Fig. 9-36 Hydraulic Schematic Diagram of BROMMA RSX40 Spreader

9.4.2 Electrical schematic diagram of spreader system
9.4.2.1 SDJ450 Spreader
Power supply + Cab operation directives

Right rotating Left side- Right side- Main beam Main beam Locking Unlocking 30” (optional) Safety bypass Automatic twist-
Left rotating shifting shifting extending retracting lock (optional)
From cab
From cab
SYMC controller
From cab
Right telescope Left rotation Right rotation Left telescope

Left locked Right locked Left unlocked Right unlocked Left/front seated Right/front seated Left/rear seated Right/rear seated in position buffering
buffering in position
Position sensor signal
Fig. 9-37 Electrical Schematic Diagram of SDJ450 Spreader 1

Control signal output (solenoid valve)

Left main beam Right main beamLeft main beam Right main beam Left side- Left side- Right side- Right side-
Left locking Right locking Left unlocking Right unlocking extending extending retracting retracting shifting shifting shifting shifting Brake released 1 Brake released 2 Left rotating Right rotating Quick valve Left valve
buffering Right buffering
valve
SYMC controller
Main oil Locked alarm Locked signal Seated alarm Seated signal Unlocked Unlocked Lifting interru- Working condi-
supply valve lamp lamp alarm lamp signal pted signal tion indication
To body To cab To cab To cab Power supply - CAN BUS (optional)
Fig. 9-38 Electrical Schematic Diagram of SDJ450 Spreader 2

9.4.2.2 SDJ450F-R1 Spreader

From cab
SYMC controller
From cab
Left rotation Right rotation Left anti- Right anti- Anti-striking

20” in position Left locked Right locked Left unlocked Right unlocked Left/front seatedRight/front seated Left/rear seated Right/rear seated in position in position 40” buffering 40” in position 20” buffering striking sensor striking sensor Debugging button effective Input spare Input spare
Position Sensor Signals
Fig. 9-39 Electrical Schematic Diagram of SDJ450F-R1 Spreader 1


main beam Right main beamLeft main beam Right main beam Left side- Left side- Right side- Right side- Throttle
Left locking Right locking Left unlocking Right unlocking Leftextending extending retracting retracting shifting shifting shifting shifting Brake released 1 Brake released 2 Left rotating Right rotating Quick valve valve
SYMC controller
To body To cab To cab To cab Power supply - CAN BUS

9.4.2.3 SDJ450E-R1 Spreader

From cab
SYMC controller
From cab
Right locked Left unlocked Right unlocked Left/front seated Right/front seated Left/rear seated Right/rear seated Left rotation Right rotation Anti-striking Input spare
Left locked in position in position Debugging button effective Input spare
Fig. 9-41 Electrical Schematic Diagram of SDJ450E-R1 Spreader 1


Left main beam Right main beamLeft main beam Right main beam Left side- Left side- Right side- Right side- Overflow
Left locking Right locking Left unlocking Right unlocking extending extending retracting retracting shifting shifting shifting shifting Brake released 1 Brake released 2 Left rotating Right rotating Quick valve valve
SYMC controller
Fig. 9-42 Electrical Schematic Diagram of SDJ450E-R1 Spreader 2

9.4.2.4 SDJ450F-R3 Spreader

Left rotating Right rotating Left side- Right side- Main beam Main beam Locking Unlocking Safety bypassEnable switch Single hook Single hook Double hook Double hook Hook moving Hook moving
shifting shifting extending retracting extending retracting extending retracting forward backward
From cab From cab
SYMC controller
From cab
Left/front hook Left/rear hook Left hook Right hook Left hook Right hook
20” right Left rotation Right rotation Right/front hook Right/rear hook moving moving
Left locked Right locked Left unlocked Right unlocked Left/front seated Right/front seated Left/rear seated Right/rear seated in position 20” left 40” right 40” left moving forward moving
in position in position in position in position in position forward backward backward
Position Sensor Signals Hook moving forward / leftward solenoid valve


Left main beam Right main beamLeft main beam Right main beam Left side- Left side- Right side- Right side-
Left locking Right locking Left unlocking Right unlocking extending extending retracting retracting shifting shifting shifting shifting Brake released 1 Brake released 2 Left rotating Right rotating Quick valve Left valve
buffering Right buffering
valve
SYMC controller
Left/front hook Right/front hook Left/front hook Right/front hook Left/rear hook Right/rear hook Left/rear hook Right/rear hook Main oil Locked alarm Locked Seated Seated Unlocked Unlocked Working condi-
extending extending retracting retracting extending extending retracting retracting supply valve lamp signal alarm signal alarm lamp signal tion indication
lamp
Control signal output (solenoid valve) To body To cab To cab To cab Power supply -

9.4.2.5 SJE100-R1 Spreader

From cab
From cab
SYMC controller
From cab
Left rotation Right rotation Left anti-striking Right anti-striking Anti-striking Input spare Input spare
20” right Left locked Right locked Left unlocked Right unlocked Left/front seated Right/front seated Left/rear seated Right/rear seated 20” left 40” right 40” left Debugging button effective
in position in position sensor sensor
Fig. 9-45 Electrical Schematic Diagram of SJE100-R1 Spreader 1


Right locking Left main beam Right main beam Left main beam Right main beam Left side- Right side- Left buffering Right buffering
Left locking Left unlocking Right unlocking extending extending retracting retracting shifting shifting Brake released 1 Brake released 2 Left rotating Right rotating Quick valve valve valve
SYMC controller
Fig. 9-46 Electrical Schematic Diagram of SJE100-R1 Spreader 2

9.4.2.6 ELME817 Spreader
Fig. 9-47 Electrical Schematic Diagram of ELME817 Spreader 1

Fig. 9-48 Electrical Schematic Diagram of ELME817 Spreader 2

9.4.2.7 BROMMA RSX40 Spreader
-X1 Power / /9.01
-X1 Gnd / /8.01
-X9 Power / /9.01
-X6 Gnd / /8.06
-X9 Power / /9.02
-X6 Gnd / /8.03
601C
701C
704A
606B
704B
606C
- + - - - - - -
+ + + + + +
-S13 Analogue -S97 -S99 -S1 -S5 -S9 -S10
Pink
Yellow
White
Grey
Green
Brown
-XP2 44 22 55 66 33 11
408
409
428
410
429
411
430
601A
701A
/9.01 / -X1 Power
/8.01 / -X1 Gnd
-XP4 :8 :2 7 :9 :2 8 :1 0 :2 9 :1 1 :3 0
-B1
I IW 03 I IX 0.01 I IX 0.02 I IX 0.03 I IX0.04 I IX0.05 I IX0.06 I IX0.7
O O O O O O O O
S1 S5 S9 S10
S13 S97 S99
Spare Unlocked Locked Landed Landed
Telescope pos. Rotation stop c.w Rotation stop c.c.w
left left left near side left far side
Fig. 9-49 Electrical Schematic Diagram of BROMMA RSX40 Spreader 1

-B1
QX 0.00 QX 0.01 QX 0.02 QX 0.03

O O O O
PWM I PWM I PWM I PWM I
-XP4 :4 4 :4 5 :4 6 :4 7
447
445
446
444
+ - + - + - + -
-S3 -S7 -S11 -S12
-Y19 -Y20 -Y21 -Y22

1 1 1 1
A 2 B 2 A 2 B 2
Pink
Yellow
White
Grey
Green
Brown
-XP3 44 22 55 66 33 11
Pink
Yellow
White
Grey
Green
Brown
603A
603B
604A
604B
/8.04 / -X5 -XP30 44 22 55 66 33 11
/8.05 / -X5
/8.03 / -X3 Gnd
/8.03 / -X3 Gnd
420
402
421
438
601B
701B
/9.01 / -X1 Power
/8.01 / -X1 Gnd
-XP4 :2 0 :2 :2 1 :3 8
-B1
I IX 0.12 I IX 0.13 I IX 0.14 I IX 0.15
O O O O
S3 S7 S11 S12
Y19 Y20 Y21 Y22 Sensor
Unlocked Locked Landed Landed
Side shift to left Side shift to right Rotate c.w Rotate c.c.w power 24Vdc
right right right far side right near side

-B1
QX 0.04 QX 0.05 QX 0.06 QX 0.07

O O O O
PWM I PWM I PWM I PWM I
-XP4 :3 6 :5 4 :1 7 :5 3
454
436
-Y100 -Y101
1 1
B 2 B 2
6053
603C
/8.04 / -X5
/8.03 / -X3 Gnd
-XP4 :1 9 :5 5 :1 8 :3 7
-B1
I IX1.04 I IX1.05 I IX1.06 I IX1.07
O O O O
Y100 Y101
Prop. Prop. Spare Spare Spare Spare Spare Spare
Rotate side shift/ telescope

-B1
QX 0.13 QX 0.14 QX 0.15

O O O
I I I
-XP4 :4 2 :4 3 :4
404
-XPHL4 11
-HL4
-XPHL4 22
6041
-X4
-XP4 :3 9 :3 :4 0 :2 2 :4 1
-B1
I IX1.08 I IX1.09 I IX1.10 I IX1.11 I IX1.12
O O O O O
Working light left

Spare Spare Spare Spare Spare Spare Spare
Cmd

-B1
QX 1.00 QX 1.01 QX 1.02 QX 1.03 QX 1.04 QX 1.05 QX 1.06 QX 1.07

O O O O O O O O
I I I I I I I I
-XP4 :4 8 :4 9 :3 1 :5 0 :5 1 :5 2 :1 6 :3 5
449
431
450
451
452
416
435
448
-XP6 11 22 33
11 -Y7 -Y8 -Y17 -Y18

-XPHL5
1 1 1 1
2 2 2
-HL5 -HL1 -HL2 -HL3
A 2 B 2 A 2 B 2
1 1 1
-XPHL5 22 Green Yellow Red
6042
-XP6 44
-X4
6021
602A
602B
602C
602D
/8.06 / -X6 Gnd

/8.02 / -X2 Gnd
/8.02 / -X2 Gnd
/8.02 / -X2 Gnd
/8.02 / -X2 Gnd
Working light right Y7 Y8 Y17 Y18 HL1 HL2 HL3

Cmd TWL unlock TWL lock Extend Retract Green locked Yellow landed Red unlocked

.
601A -X1 Gnd / /3.09
-X1
601B -X1 Gnd / /3.09

601
:Gnd
.
601C -X1 Gnd / /4.09
602A
-X2 Gnd / /7.02
602B
-X2 Gnd / /7.03
-X2
-X2

602
:Gnd
602C
-X2 Gnd / /7.04
602D
-X2 Gnd / /7.05
-B1
6021
-X6 Gnd / /3.09
-XP4
603A
GND S 608A -X3 Gnd / /4.01
-X8 Gnd / /9.05
-X3
:1
-X3
603B
-X3 Gnd / /4.02
-X8 Gnd / /9.09
603
:Gnd
603C -X3 Gnd / /5.02

-X8
GND O
608B -X8 Gnd / /9.05
Gnd
:1 5
:Gnd
608C
to Control system B1
GND A
607A
:1 2
-X5
6051
-X5 / /5.01
6052
-X5 / /4.03
6053
-X5 / /4.04
-X7
-X10
607C
:Gnd
-XP1
609A
606
11
-X9
607B
:Gnd
609B
-X6
22
:Gnd
606B -X6 Gnd / /3.09
610A 606C

-X6 Gnd / /7.06
22
22
Gnd
from Truck
.
9-59
Schematics
-X1 Power / /3.09
-X1 Power / /3.09
-X1 Power / /4.09
-X9 Power / /3.09
-X9 Power / /3.09

-XP5 33 22 44 55 11
701A
701B
704A
704B
701C
/8.03 / -X8 Gnd
Black
Blue
White
Red
:Power
-X1
701
/8.04 / -X8 Gnd
Red
423
-XP1 14
14 15
15 -XP14 22 11 44
:Power
-X9 CANopen cable must be
Twisted pair
/8.03 / -X8 Gnd

XP5 BLUE
405
XP5 WHITE
432 BLUE
414 WHITE
434 424
1 1
-R1 -R2
120 Ohm 120 Ohm
2 2
709A
710A
710B
-XP4 :3 4 :5 :2 3 -XP4 :1 3 :2 4 :1 4 :3 2 :2 6 :2 5 :3 3 :6 :7
-XP1 18
18 33 44 -B1
TxD
RxD
GND
O
S
R
Error
Can L
Can L
Can H
Can H
Test
VBB
VBB
VBB
2A Fuse 10A Fuse
Main supply Main supply

Error / Test CANopen1 CANopen2 RS-232
from Truck to Control system B1

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SDCY90K8C15 Hurdling Single-container Handler
Safety, Operation & Maintenance Manual June-2012 I

www.sanygroup.com
Sany Industrial Town, Changsha Economic & Technical Development Zone, Changsha
Hunan, China
Tel: 0086-0731-84031711
Fax: 0086-0731-84031999-654
B03T01ENAO2-SRSC45CX / SRSC4535 / SRSC4535C1 / SRSC4545C / SRSC1009-6E

/ SRSC3515-3

Sany Src45 Manual

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Quality Changes the World

Container Reach Stacker

Safety, Operation & Maintenance Manual

Safety, Operation & Maintenance Manual - September 2014 I

Container Reach Stacker

II Safety, Operation & Maintenance Manual - September 2014

Address: SANY Industry Town, Changsha Economic &

Duty of Owners or Other Authorized Personnel

IV Safety, Operation & Maintenance Manual - September 2014

Duty of All Working Personnel

Safety, Operation & Maintenance Manual - September 2014 V

VI Safety, Operation & Maintenance Manual - September 2014

Safety, Operation & Maintenance Manual - September 2014 I

II Safety, Operation & Maintenance Manual - September 2014

2.4.6.1 Ensuring good view �������������������������������������������������������������������������������� 2-42

Safety, Operation & Maintenance Manual - September 2014 III

2.5.13.1 Handling inflammables safely���������������������������������������������������������������� 2-64

IV Safety, Operation & Maintenance Manual - September 2014

Safety, Operation & Maintenance Manual - September 2014 V

3.3.2.10 Analogy output menu���������������������������������������������������������������������������� 3-53

VI Safety, Operation & Maintenance Manual - September 2014

4.2.2 Start in cold weather��������������������������������������������������������������������������������������� 4-20

Safety, Operation & Maintenance Manual - September 2014 VII

4.6.3.5 Loading the machine������������������������������������������������������������������������������ 4-58

VIII Safety, Operation & Maintenance Manual - September 2014

5.3.4 Hydraulic oil, description����������������������������������������������������������������������������������5-16

Safety, Operation & Maintenance Manual - September 2014 IX

5.6.9.9 Fan hub, checking���������������������������������������������������������������������������������� 5-44

X Safety, Operation & Maintenance Manual - September 2014

Safety, Operation & Maintenance Manual - September 2014 XI

5.12.2.8 After 8000 hours����������������������������������������������������������������������������������� 5-92

XII Safety, Operation & Maintenance Manual - September 2014

Safety, Operation & Maintenance Manual - September 2014 XIII

7.2.7 Conversion table, pressure������������������������������������������������������������������������������ 7-16

XIV Safety, Operation & Maintenance Manual - September 2014

Safety, Operation & Maintenance Manual - September 2014 XV

Safety, Operation & Maintenance Manual - September 2014 1-1

1.7 Running in a New Machine ������������������������������������������������������������������������������������1-19

1-2 Safety, Operation & Maintenance Manual - September 2014

Before starting operation and maintenance,

Safety, Operation & Maintenance Manual - September 2014 1-3

Information, specifications, and illustrations

1-4 Safety, Operation & Maintenance Manual - September 2014

1.2 Application Range

1.2.1 Intended use

Container reach stacker is a type of auxiliary

• At the small ports and quaysides, container

• At the railway and highway transfer

Container reach stackers are applicable for

The rules for intended and approved uses

The user, and not SANY, is responsible for any

Safety, Operation & Maintenance Manual - September 2014 1-5

Machines covered by this manual are used for

1.2.2 Unintended use

If any procedures or actions not specified,

Improper uses include:

1-6 Safety, Operation & Maintenance Manual - September 2014

Modifying the machine without any approval

All machines and equipment (some equipment

Fig. 1-3 CE Label

Safety, Operation & Maintenance Manual - September 2014 1-7

1.4 Your Documentation Package

Several documentations will be packed for you

1.4.1 CD system requirements

2.4.6.1 Ensuring good view �� 2-42

2.5.13.1 Handling inflammables safely�� 2-64

3.3.2.10 Analogy output menu�� 3-53

4.2.2 Start in cold weather�� 4-20

4.6.3.5 Loading the machine�� 4-58

5.3.4 Hydraulic oil, description��5-16

5.6.9.9 Fan hub, checking�� 5-44

5.12.2.8 After 8000 hours�� 5-92

7.2.7 Conversion table, pressure�� 7-16

1.7 Running in a New Machine ��1-19