A3 H-Type Container Handler SOM Manual-20170809

Quality Changes the World
Empty Container Handler
Safety, Operation & Maintenance Manual

Safety, Operation & Maintenance Manual - March 2017 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 - March 2017

Sany Port
SANY Maritime Heavy Industry Co.,LTD
SANY Industrial Park, Gaolan Port Economic And
Development Zone, Zhuhai City, Hunan Province, China
Tel: 0086-756-7266945
Fax: 0086-731-84031999-149
Website: www.sanyhi.com
Service hotline: 4008 87 8318
Consulting hotline: 4008 87 9318
© 2017 by Sany Port. All rights reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as described
herein. All information included within this publication was accurate at the time of
publication. Product improvements, revisions, etc., may result in differences between
your machine and what is presented here. Sany Port assumes no liability. For more
information, contact Sany Port.
Safety, Operation & Maintenance Manual - March 2017 III

SPECIFIC DECLARATION
SANY empty container handler is applicable for transferring, lifting and stacking containers on
ports, quaysides, and yards. Any other uses or operations beyond the specified working range are
not authorized uses. SANY expressly bears no liability for any consequences due to unauthorized
uses.
Information on this manual is used to guide qualified operators to operate and maintain container
handlers correctly. SANY expressly bears no liability for any consequences due to the violation of
following rules:
• The personnel should observe the information on this manual.
• It is forbidden to convert the machine without authorization.
• When cracks or electrical failures on the machine occur, please contact the supplier instead
of conducting welding or making changes without permission.
• Use genuine spare parts from SANY rather than untested or unauthorized spare parts or
tools.
• Machine failures or damages due to force majeure of natural disasters (earthquake, typhoon)
and wars are not the responsiblity of SANY.
SANY cannot predict every circumstance that might involve a potential hazard in operation or
maintenance. Operators and owners should highly attach importance to safety. Local specific
safety rules of the countries may be stricter. If they differ from the regulations on this manual,
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 empty container handler.
• Ensure the operation and maintenance personnel are qualified and know their related
responsibilities.
• Periodically check related personnel's safety consciousness during working.
• If any failure which would lead to unsafety occurs, stop the machine immediately.
• If necessary, SANY service personnel have the right to check the machine for safety.
• Except for checking items regulated by SANY, please do the related inspections according to
local laws and regulations.
• Ensure timely maintenance and repair on this machine.
• Carefully plan the use of this machine.
IV Safety, Operation & Maintenance Manual - March 2017

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 - March 2017 V

VI Safety, Operation & Maintenance Manual - March 2017

Empty Container Handler Table of Contents
Table of Contents
1. Introduction
1.1 Overview�� 1-3
1.2 Application Range�� 1-5
1.2.1 Intended use�� 1-5
1.2.2 Unintended use�� 1-6
1.3 Machine Authorizations��1-7
1.4 Your Documentation Package�� 1-8
1.4.1 CD system requirements�� 1-8
1.4.2 Recommendations on using the documentation�� 1-9
1.4.3 Documentation storage��1-10
1.4.4 Manual organization��1-10
1.5 Terminology��1-12
1.6 Machine Information��1-14
1.6.1 Machine nameplate��1-14
1.6.2 Engine nameplate��1-14
1.6.2.1 VOLVO engine nameplate��1-14
1.6.2.2 CUMMINS engine nameplate��1-15
1.6.2.3 YUCHAI engine nameplate��1-15
1.6.3 Spreader nameplate��1-16
1.6.3.1 SANY spreader nameplate��1-16
1.6.3.2 ELME spreader nameplate��1-16
1.6.4 Transmission case nameplate��1-17
1.6.4.1 DANA transmission case nameplate��1-17
1.6.4.2 ZF transmission case nameplate��1-17
1.6.5 Drive axle nameplate��1-18
1.7 Running in a New Machine ��1-19
1.8 Machine Serial No. and Distributor Info.�� 1-20
1.9 Correction Request Form��1-21
1.10 Contact Information�� 1-22
2. Safety
2.1 Safety Information�� 2-4
Safety, Operation & Maintenance Manual - March 2017 I

Table of Contents Empty Container Handler
2.1.1 Signal words�� 2-4

2.1.2 Examples of using signal words �� 2-5
2.1.3 Other signal words�� 2-5
2.1.4 Safety labels�� 2-6
2.1.4.1 Safety labels, location�� 2-8
2.1.4.2 Safety labels, content�� 2-9
2.2 General Precautions��2-16
2.2.1 Basic safety instructions��2-16
2.2.2 Personal protective equipment��2-17
2.2.3 Never operate while in bad health�� 2-20
2.2.4 No passenger in the cab�� 2-20
2.2.5 Hand signals��2-21
2.2.6 Preparing safety items��2-24
2.2.7 Checking safety equipment��2-24
2.2.8 Precautions in high voltage areas��2-25
2.2.9 Precautions in thunderstrike��2-28
2.2.10 Precautions in wind��2-28
2.2.11 Abnormal cases�� 2-29
2.2.12 Unauthorized modification�� 2-30
2.3 Safety During Operation��2-31
2.3.1 Work area safety��2-31
2.31.1 Work area requirements��2-31
2.3.1.2 Work area indications��2-31
2.3.2 Checks before operation�� 2-32
2.3.3 Keeping machine clean�� 2-34
2.3.4 Climbing on or off the machine safely�� 2-34
2.3.5 Start-up safety �� 2-36
2.3.5.1 Inside the operator cab�� 2-36
2.3.5.2 Adjusting the seat�� 2-36
2.3.5.3 Checking the seat belt�� 2-37
2.3.5.4 Machine starting precautions�� 2-37
2.3.5.5 Jump-start the engine, precautions�� 2-39
2.3.5.6 In cold weather�� 2-40
2.3.5.7 After starting the engine�� 2-40
2.3.6 Precautions for safe operation��2-41
2.3.6.1 Ensuring good visibility ��2-41
II Safety, Operation & Maintenance Manual - March 2017

2.3.6.2 Safety rules for traveling��2-41

2.3.6.3 Precautions while operating on slopes�� 2-43
2.3.6.4 Avoiding injury from reversing �� 2-43
2.3.6.5 Precautions while operating on snow or frozen surfaces�� 2-44
2.3.6.6 Preventing control failure�� 2-45
2.3.6.7 Never hoist a load except container�� 2-46
2.3.6.8 Never hoist the load over people�� 2-46
2.3.6.9 Never stand under the load�� 2-46
2.3.6.10 Precautions for operating emergency stop button�� 2-47
2.3.6.11 Precautions for operating safety bypass switch�� 2-47
2.3.7 Parking the machine securely�� 2-48
2.3.7.1 Parking requirements�� 2-48
2.3.7.2 Turning off the engine �� 2-49
2.4 Safety During Maintenance�� 2-50
2.4.1 Preparation for the work area�� 2-50
2.4.2 Warning label is important��2-51
2.4.3 Lockout/tagout procedures��2-51
2.4.4 Self-preparation before maintenance�� 2-52
2.4.5 Using tools correctly �� 2-52
2.4.6 Regular replacement of safety-related parts�� 2-52
2.4.7 Removing attachments carefully�� 2-53
2.4.8 Adding fluids to the machine�� 2-53
2.4.9 Towing or lifting the machine�� 2-54
2.4.10 Keep clear of moving machinery�� 2-55
2.4.11 Preventing hydraulic hazards �� 2-56
2.4.11.1 Checking rubber hose regularly�� 2-56
2.4.11.2 Releasing the pressure before maintenance�� 2-57
2.4.11.3 Replacing rubber hose regularly�� 2-58
2.4.11.4 Prevent heating near the hydraulic pipeline�� 2-59
2.4.11.5 Filling accumulator�� 2-59
2.4.11.6 Selecting oils and fuel�� 2-60
2.4.11.7 Handling hydraulic oil �� 2-60
2.4.12 Preventing burn and scald�� 2-61
2.4.12.1 Burn by high temperature liquid�� 2-61
2.4.12.2 Chemical burn�� 2-62
2.4.13 Preventing fire and explosion�� 2-64
Safety, Operation & Maintenance Manual - March 2017 III

2.4.13.1 Handling inflammables safely�� 2-64

2.4.13.2 Removing inflammables�� 2-64
2.4.13.3 Checking oil leakage�� 2-65
2.4.13.4 Checking short circuit�� 2-65
2.4.13.5 Preventing battery explosion�� 2-66
2.4.13.6 Checking ignition key�� 2-67
2.4.13.7 Evacuating from the machine�� 2-67
2.4.14 Preventing poisoning and asphyxiation�� 2-68
2.4.14.1 Handling chemicals safely�� 2-68
2.4.14.2 Preventing poisoning by paint �� 2-68
2.4.14.3 Preventing poisoning by off-gas�� 2-69
2.4.15 Preventing dust hazard��2-70
2.4.16 Working under machine��2-71
2.4.17 Precautions in welding��2-71
2.4.18 Safe maintenance of air conditioning system��2-72
2.4.19 Precautions in maintaining the engine��2-73
2.4.20 High voltage precautions�� 2-74
2.4.21 Precautions after maintenance�� 2-74
2.4.22 Handling waste properly�� 2-74
2.5 Tag��2-76
3. System Functions
3.1 Main Components of Machine�� 3-4
3.2 Cab Control System�� 3-6
3.2.1 Steering column�� 3-7
3.2.1.1 Steering wheel panel�� 3-7
3.2.1.2 Gear selector��3-11
3.2.1.3 Direction indication controller��3-12
3.2.1.4 Adjusting the angle of steering controller ��3-15
3.2.2 Pedal��3-15
3.2.3 Joystick��3-16
3.2.4 Right operation panel��3-17
3.2.4.1 Ignition switch��3-18
3.2.4.2 Safety bypass switch��3-19
3.2.4.3 Emergency stop switch��3-19
3.2.4.4 Rear wiper switch�� 3-20
IV Safety, Operation & Maintenance Manual - March 2017

3.2.4.5 Top wiper switch�� 3-20

3.2.4.6 Front wiper switch�� 3-21
3.2.4.7 Inner light switch�� 3-22
3.2.5 Front operation panel�� 3-23
3.2.5.1 Cab top light switch�� 3-23
3.2.5.2 Rear light switch�� 3-24
3.2.5.3 Mast light switch�� 3-24
3.2.5.4 Spreader light switch�� 3-25
3.2.5.5 Width light switch�� 3-26
3.2.5.6 Failure detection switch�� 3-26
3.3 Display�� 3-27
3.3.1 SANY display�� 3-27
3.3.1.1 Start menu�� 3-28
3.3.1.2 Main menu�� 3-28
3.3.1.3 Engine information menu�� 3-30
3.3.1.4 Gearbox information menu�� 3-31
3.3.1.5 Hydraulic information menu�� 3-32
3.3.1.6 Fault alarm menu�� 3-32
3.3.1.7 Digital input menu�� 3-33
3.3.1.8 Digital output menu�� 3-33
3.3.1.9 Analogy input menu�� 3-33
3.3.1.10 Analogy output menu�� 3-34
3.3.1.11 Setting menu�� 3-34
3.3.2.1 Start menu�� 3-36
3.3.2.2 Main menu�� 3-36
3.3.2.3 Language setting menu�� 3-38
3.3.2.9 Analogy information menu�� 3-41
3.3.2.11 Setting menu�� 3-42
3.4 Air Conditioning System�� 3-43
Safety, Operation & Maintenance Manual - March 2017 V

3.4.1 Control panel�� 3-43

3.4.1.1 Power switch�� 3-44
3.4.1.2 Fan speed switch�� 3-44
3.4.1.3 Temperature or Paging switch�� 3-45
3.4.1.4 Mode switch�� 3-45
3.4.1.5 Fresh air switch�� 3-46
3.4.2 Operation�� 3-47
3.4.3 Precautions�� 3-48
3.4.4 Troubleshooting�� 3-49
3.5 Electric Control Cabinet�� 3-50
3.6 Fuse�� 3-51
3.7 Fire Extinguisher�� 3-52
4. Operation
4.1 Before the Starting of Engine�� 4-3
4.1.1 Operator responsibility�� 4-3
4.1.2.1 Wiper water level, checking�� 4-5
4.1.2.2 Coolant level, checking�� 4-5
4.1.2.3 Engine oil level, checking�� 4-6
4.1.2.4 Transmission oil level, checking�� 4-6
4.1.2.5 Hydraulic oil level, checking�� 4-6
4.1.2.6 Fuel level, checking�� 4-7
4.1.2.7 Brake oil level, checking�� 4-8
4.1.2.8 Tyres, checking�� 4-8
4.1.2.9 Electrical components, checking�� 4-9
4.1.2.10 Working light, checking��4-10
4.1.2.11 Horn, checking��4-10
4.1.3 Adjustment before operation��4-11
4.1.3.1 Seat, adjusting�� 4-11
4.1.3.2 Rearview mirror, adjusting��4-13
4.1.3.3 Safety belt, adjusting��4-14
4.2 Starting the Machine��4-15
4.2.1 Start in normal weather��4-15
4.2.2 Start in cold weather��4-18
4.2.3 Start with booster batteries or starting generators��4-19
VI Safety, Operation & Maintenance Manual - March 2017

4.3 Stopping the Machine�� 4-21

4.3.1 Engine shutdown procedures�� 4-21
4.3.2 Emergency shutdown�� 4-23
4.4 Driving�� 4-24
4.4.1 How to drive�� 4-24
4.4.2 Driving forward�� 4-25
4.4.3 Driving backward�� 4-26
4.4.4 Turning around�� 4-26
4.4.5 Parking�� 4-27
4.5 Load Handling �� 4-28
4.5.1 Operation switches�� 4-28
4.5.2 Mast, operation�� 4-29
4.5.3 Spreader, operation�� 4-33
4.5.4 Load capacity diagram�� 4-36
4.5.4.1 Load capacity diagram of SDCY90K8H1 / SDCY90K8H2 / SDCY90K8H3 /
SDCY90K8H4 / SDCY90K8H8A / SDCY90K8H85A container handlers�� 4-37
SDCY90K6H4 container handlers�� 4-39
4.5.5 Picking up a container from a stack�� 4-40
4.5.6 Depositing a container on the stack�� 4-45
4.6 Store the Machine�� 4-50
4.6.1 Overnight storage�� 4-50
4.6.2 Short-Term Storage�� 4-50
4.6.3 Long-term storage�� 4-51
4.6.3.1 Preparations�� 4-51
4.6.3.2 During storage�� 4-52
4.6.3.3 Return to service�� 4-52
4.7 Transportation and Assembly�� 4-53
4.7.1 Guidelines�� 4-53
4.7.2 Disassembling the machine�� 4-54
4.7.2.1 Disassembling principles�� 4-54
4.7.2.2 Disassembly list �� 4-55
4.7.2.3 Hoisting points of parts�� 4-56
4.7.3 Packing requirements�� 4-59
Safety, Operation & Maintenance Manual - March 2017 VII

4.7.4 Transportation�� 4-60

4.7.4.1 Transporting by platform lorry�� 4-60
4.7.4.2 Transporting by container �� 4-60
5. Maintenance
5.1 Scheduled Maintenance, General Information �� 5-7
5.2 Tightening Torques ��5-11
5.2.1 General tightening torques��5-11
5.2.1.1 Fastener torque value��5-11
5.2.1.2 Hydraulic coupling torque values��5-12
5.2.1.3 Tapered connections��5-12
5.2.1.4 O-ring and flange connections��5-13
5.2.1.5 Low pressure hose clamps��5-14
5.2.2 Specific tightening torques ��5-15
5.3 Recommended Fuel, Coolant and Lubricant��5-16
5.3.1 Specification��5-16
5.3.2 Capacity of the tanks��5-18
5.3.3 Hydraulic oil, description��5-19
5.3.4 Quality of hydraulic oil, check�� 5-20
5.3.5 Urea�� 5-21
5.4 Lubricating Points�� 5-22
5.4.1 Lubricant�� 5-22
5.4.2 Lubricating points of whole machine�� 5-23
5.5 Scheduled Maintenance�� 5-25
5.5.1 Maintenance every day�� 5-25
5.5.2 Maintenance every 50 hours�� 5-26
5.5.6 Maintenance 1500 hours�� 5-29
5.6 Engine�� 5-31
5.6.1 General engine inspection �� 5-32
5.6.1.1 Charge air pipe, checking�� 5-32
5.6.1.2 Drive belt, checking and changing (engine option VOLVO)�� 5-33
VIII Safety, Operation & Maintenance Manual - March 2017

5.6.1.3 Drive belt, checking (engine option CUMMINS)�� 5-35

5.6.1.4 Drive belt, changing (engine option CUMMINS)�� 5-36
5.6.1.5 Air filter, checking�� 5-37
5.6.1.6 Air filter, cleaning�� 5-38
5.6.1.7 Engine mounting pad, checking�� 5-38
5.6.2 Lubrication system�� 5-39
5.6.2.1 Oil level, checking and topping up�� 5-39
5.6.2.2 Engine oil, changing�� 5-40
5.6.2.3 Oil filter, changing�� 5-41
5.6.3 Fuel system�� 5-42
5.6.3.1 Draining condensate, fuel system (engine option VOLVO)�� 5-42
5.6.3.2 Draining condensate, fuel system (engine option CUMMINS)�� 5-42
5.6.3.3 Fuel filter, replacing (engine option VOLVO)�� 5-43
5.6.3.4 Fuel pre-filter, changing (engine option VOLVO)�� 5-44
5.6.3.5 Fuel filter, changing (engine option CUMMINS)�� 5-45
5.6.3.6 Fuel pre-filter, changing (engine option CUMMINS) �� 5-45
5.6.3.7 Fuel system, bleeding (engine option VOLVO)�� 5-46
5.6.3.8 Fuel system, bleeding (engine option CUMMINS)�� 5-47
5.6.4 Cooling system�� 5-48
5.6.4.1 Coolant, mixing�� 5-49
5.6.4.2 Water quality�� 5-50
5.6.4.3 Coolant level, checking and topping up�� 5-50
5.6.4.4 Filling a completely empty system�� 5-51
5.6.4.5 Coolant, draining�� 5-52
5.6.4.6 Radiator, cleaning�� 5-53
5.6.4.7 Radiator fan, checking�� 5-53
5.6.4.8 Cooling system, cleaning�� 5-54
5.6.5 Air intake and exhaust system�� 5-56
5.6.5.1 Air leaks, checking �� 5-56
5.6.5.2 Turbocharger and blast pipe, checking�� 5-57
5.6.6 Urea filter element, changing�� 5-58
5.7 Transmission�� 5-59
5.7.1 Gearbox, function description�� 5-59
5.7.2 Attaching bolts of propeller shaft, checking�� 5-59
5.7.3 Speed sensor, checking�� 5-60
5.7.4 Attaching bolts and mounting pad, checking�� 5-60
Safety, Operation & Maintenance Manual - March 2017 IX

5.7.5 Propeller shaft, lubricating�� 5-61

5.7.6 TE Transmission calibration�� 5-61
5.7.7 Transmission oil, changing�� 5-62
5.7.8 Transmission oil level, checking�� 5-63
5.7.9 Transmission oil filter, changing�� 5-63
5.8 Drive Axle�� 5-64
5.8.1 Attaching bolts of drive axle to the frame, checking�� 5-64
5.8.2 Attaching bolts of drive axle to the propeller shaft, checking�� 5-64
5.8.3 Oil leakage of drive axle and brake components, checking�� 5-64
5.8.4 Brake function, checking�� 5-66
5.8.5 Breather connector, cleaning�� 5-66
5.8.6 Differential oil, replacing�� 5-67
5.8.7 Drive axle oil, changing�� 5-68
5.8.8 Brake pedal, checking and adjusting�� 5-69
5.8.9 Parking brake pads, changing�� 5-70
5.9 Steering Axle��5-71
5.9.1 Daily check��5-71
5.9.2 Steering axle, lubricating�� 5-72
5.9.3 Steering axle components, checking�� 5-72
5.9.4 Knuckle pin, checking�� 5-72
5.9.5 Stub axle, maintaining�� 5-73
5.9.6 Steering axle cradle, checking��5-74
5.9.7 Steering pressure, checking��5-74
5.10 Tyres and rims�� 5-75
5.10.1 Tyre, description�� 5-75
5.10.2 Tyre, inflating�� 5-77
5.10.3 Tyres, checking�� 5-78
5.10.4 Drive axle tyre, removing and installing�� 5-79
5.10.4.1 Drive axle tyre, removing�� 5-79
5.10.4.2 Drive axle tyre, installing�� 5-80
5.10.5 Steering axle tyre, removing and installing�� 5-81
5.10.5.1 Steering axle tyre, removing�� 5-81
5.10.5.2 Steering axle tyre, installing�� 5-82
5.10.6 Wheel rim, description�� 5-82
5.10.7 Rim, checking�� 5-83
5.10.8 Wheel rim, installing and removing�� 5-84
X Safety, Operation & Maintenance Manual - March 2017

5.10.8.1 Wheel rim, installing��5-84

5.10.8.2 Wheel rim, removing�� 5-87
5.11 Mast��5-88
5.11.1 Basic check��5-89
5.11.2 Fixed bolts, checking��5-89
5.11.3 Sliding blocks, checking��5-90
5.11.4 Chain, maintaining�� 5-91
5.11.5 Cylinder piston rod, maintaining�� 5-93
5.12 Spreader��5-94
5.12.1 Twistlock, lubricating��5-94
5.12.2 Sliding blocks of telescopic beam riser, lubricating ��5-94
5.12.3 Sliding block between the basic beam and telescopic beam, lubricating�� 5-95
5.12.4 Sideshift cylinder bearing, lubricating��5-95
5.12.5 Top and bottom sideshift sliding blocks, lubricating��5-95
5.12.6 Sliding block, checking��5-96
5.12.7 Twistlock, checking��5-96
5.12.8 Other maintenance items of spreader�� 5-97
5.13 Air Conditioning System��5-98
5.13.1 General recommendations ��5-98
5.13.2 Air conditioning, checking / performance test��5-99
5.13.3 Refrigerant quantity, checking �� 5-100
5.13.4 Refrigerant, filling�� 5-101
5.13.5 Cleanness of heat-exchanger plate in evaporator and condenser, checking
�� 5-102
5.13.6 Leakage or lack of oil in condenser, checking�� 5-102
5.13.7 Radiator, cleaning�� 5-103
5.13.8 Maintenance table for air conditioner�� 5-103
5.14 Hydraulic System�� 5-105
5.14.1 Hydraulic oil level, checking�� 5-105
5.14.2 Air filter element, changing�� 5-105
5.14.3 Hydraulic oil, changing�� 5-106
5.14.4 Oil return filter element, replacing�� 5-107
5.14.5 Hydraulic oil tank, cleaning�� 5-108
5.14.6 Accumulator�� 5-109
5.14.6.1 Brake system accumulator, checking�� 5-109
5.14.6.2 Accumulator, charging with nitrogen gas��5-110
Safety, Operation & Maintenance Manual - March 2017 XI

5.14.7 Hydraulic oil circuit, checking�� 5-111

5.14.8 Brake oil filter, changing�� 5-112
5.15 Electrical System�� 5-113
5.15.1 Battery�� 5-114
5.15.1.1 Battery, cleaning�� 5-114
5.15.1.2 Battery, checking�� 5-115
5.15.1.3 Battery, detecting�� 5-116
5.15.1.4 Battery, charging�� 5-117
5.15.1.5 Battery, using��5-120
5.15.1.6 Battery cables, checking��5-122
5.15.1.7 Battery, scheduled maintenance ��5-123
5.15.2 Fuses, changing��5-123
5.15.3 All working lights and indicators, checking ��5-124
5.15.4 Wiper, adjusting��5-124
5.15.5 Wiper, replacing��5-125
5.16 Maintenance Record List��5-126
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
6.4 Engine Error Codes �� 6-27
XII Safety, Operation & Maintenance Manual - March 2017

6.4.1 VOLVO engine error codes�� 6-27

6.4.2 CUMMINS engine error codes�� 6-36
6.4.3 YUCHAI engine error codes�� 6-42
6.5 Transmission Error Codes �� 6-47
6.6 Machine Error Codes �� 6-55
6.6.1 Error codes of H1 / H2 / H3 / H4 container handler�� 6-55
6.6.2 Error codes of H8 / H85 container handler�� 6-59
7. Specifications
7.1 Technical Specification��7-2
7.1.1 Basic parameters��7-3
7.1.2 System configuration�� 7-4
7.1.2.1 Engine configuration�� 7-4
7.1.2.2 Gearbox configuration�� 7-5
7.1.2.3 Drive axle configuration�� 7-5
7.1.2.4 Spreader configuration�� 7-5
7.2 Unit Conversion�� 7-6
7.2.1 Unit abbreviation explanation�� 7-6
7.2.2 Conversion table, SI units ��7-7
7.2.3 Conversion table, length�� 7-8
7.2.4 Conversion table, area �� 7-8
7.2.5 Conversion table, volume�� 7-8
7.2.6 Conversion table, weight �� 7-9
7.2.7 Conversion table, pressure�� 7-9
7.2.8 Conversion table, temperature�� 7-9
8. Optional Parts
8.1 Fire Detection and Alarm System / Automatic Extinguishing Device�� 8-3
8.1.1 Fire detection and alarm system�� 8-3
8.1.1.1 Function description�� 8-4
8.1.1.2 Precautions�� 8-6
8.1.1.3 Troubleshooting�� 8-7
8.1.1.4 Maintenance and repair�� 8-7
8.1.2 Automatic fire extinguishing device �� 8-9
8.1.2.2 Technical parameters��8-10
Safety, Operation & Maintenance Manual - March 2017 XIII

8.1.3 Electrical diagrams��8-11

8.2 Loudspeaker and Controller Kit��8-14
8.2.1 Control panel��8-14
8.2.2 Operations��8-14
8.2.3 Electrical wiring diagram��8-15
8.2.4 Precautions��8-16
8.3 Engine Idle Protection Function��8-16
8.4 Engine Preheating Protection Function��8-17
8.5 Engine Hour Meter��8-17
8.6 Twistlock Counter��8-17
8.7 Reversing Radar Display��8-18
8.8 Operator Presence System��8-18
8.9 Radio��8-19
8.9.2 Mute (Silence)�� 8-20
8.9.3 Sound�� 8-20
8.9.4 Audio setting�� 8-20
8.9.5 Radio�� 8-21
8.9.6 Radio troubleshooting�� 8-23
8.10 Automatic Lubrication System�� 8-24
8.10.1 Operation precautions�� 8-24
8.10.2 Time setting�� 8-25
9. Schematics
9.1 Symbol Explanation�� 9-2
9.2 Hydraulic Schematic Diagrams�� 9-4
9.3 Electrical Schematic Diagrams�� 9-7
9.4 Schematic Diagrams of Spreader System�� 9-22
9.4.1 Hydraulic schematic diagram of spreader system�� 9-23
9.4.1.1 ELME588 Spreader�� 9-23
9.4.1.2 SDJ90II Spreader�� 9-24
9.4.1.3 SDJ90H Spreader�� 9-25
9.4.2 Electrical schematic diagram of spreader system�� 9-26
9.4.2.1 ELME588 Spreader�� 9-26
9.4.2.2 SDJ90II Spreader�� 9-28
9.4.2.3 SDJ90H Spreader�� 9-30
XIV Safety, Operation & Maintenance Manual - March 2017

Empty Container Handler Introduction
Introduction
1. Introduction
1.1 Overview�� 1-3
1.2 Application Range�� 1-5
1.2.1 Intended use�� 1-5
1.2.2 Unintended use�� 1-6
1.3 Machine Authorizations��1-7
1.4 Your Documentation Package�� 1-8
1.4.1 CD system requirements�� 1-8
1.4.2 Recommendations on using the documentation�� 1-9
1.4.3 Documentation storage��1-10
1.4.4 Manual organization��1-10
1.5 Terminology��1-12
1.6 Machine Information��1-14
1.6.1 Machine nameplate��1-14
1.6.2 Engine nameplate��1-14
1.6.2.1 VOLVO engine nameplate��1-14
1.6.2.2 CUMMINS engine nameplate��1-15
1.6.2.3 YUCHAI engine nameplate��1-15
1.6.3 Spreader nameplate��1-16
1.6.3.1 SANY spreader nameplate��1-16
1.6.3.2 ELME spreader nameplate��1-16
1.6.4 Transmission case nameplate��1-17
1.6.4.1 DANA transmission case nameplate��1-17
1.6.4.2 ZF transmission case nameplate��1-17
1.6.5 Drive axle nameplate��1-18
Safety, Operation & Maintenance Manual - March 2017 1-1

Introduction Empty Container Handler
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 - March 2017

1. INTRODUCTION
Thank you heartedly for choosing
our SDCY90K8H1 / SDCY90K8H2
/ SDCY90K8H3 / SDCY90K8H4
/ SDCY90K7H1 / SDCY90K7H2 /
SDCY90K7H3 / SDCY90K7H4 /
SDCY90K8H8A / SDCY90K8H85A / Fig. 1-1 Read the Manual
SDCY90K7H8A / SDCY90K7H85A Empty
Container Handler. We are commited to
provide you with good-quality machine and
superior after-sales service.
1.1 Overview WARNING

WARNING
Before starting operation and maintenance,

This Safety, Operation & Maintenance Manual personnel shall observe the following
is a guide to handle the machine correctly. items:
It provides technique and safety information • Only the qualified and experienced
necessary for operation and maintenance of operators with official license
the machine. Please make sure to read every (according to the local laws) are
parts of this manual in detail. allowed to operate this machine.
• Always operate your machine according
to national, provincial, prefectural and
municipal laws and regulations.
• Read and understand the complete
manual.
• Read and understand safety notices in
this manual and safety labels on the
machine.
• Do not operate this machine under any
circumstances or in a manner that is
prohibited in this manual.
Failure to do this may result in personal

injuries or possibly death.

Information, specifications, and illustrations

in this publication are based on the
latest available information. Continuous
improvements in the design of 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
spec if ic ations and st andards of the
country of destination. If the machine
is purchased from another country or
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

Empty container handler is mainly used for
transferring, lifting and stacking containers on
ports, quaysides, and yards.
Empty container handlers are applicable

for the operation of 20’ and 40’ international
standard containers. Never hoist or transport
heavier load than the max. lifting capacity of
this machine. (For detailed information, see:
“Load capacity diagram” on page 4-36.)
Fig. 1-2 Empty Container Handler

The rules for intended and approved uses
of this machine must be followed under all
circumstances by the responsible personnel,
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 not sure 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 injuring yourself and other personnel.
Improper uses include:

• Transpor ting people. 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 public
areas with risks of explosion;
• Overloading the machine beyond its max.
lifting capacity listed in the load capacity
diagram on page 4-36;
• 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

o r abusing it mi ght r isk t he mac hine’s
performance, or result in potential hazard.
Improper operation may cause personal injury
or damage. SANY assumes no liability for
such losses.

1.3 Machine Authorizations
S A N Y p o r t m a c h i n e s h ave a l l p a s s e d
European CE authoriaztion, North America
ANSI authorizatin and Russia GOST Address: Sany Industry Town,
authorization. Economic and Technological
Development Zone, Changsha,
1417
Hunan, China
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 Fig. 1-3 CE Label
with CE, which certifies their conformity to the
European Union machine safety instructions.

1.4 Your Documentation Package
Several documentations will be packed along

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

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

1.4.2 Recommendations on using the

documentation
• This documentation applies only to 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
fully understand 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 this can vary in
different design.
CHAPTER 8: OPTIONAL PARTS

SANY has provided lots of optional parts for
the customer to install on the machine. This
section mainly introduces the functions and
operations of these optional parts.
CHAPTER 9: SCHEMATICS
This section provides the hydraulic and
electrical schematic diagrams of container
handler. 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
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 mast
The actions that should be performed daily to ensure the machine’s
Daily inspection
functionality
Display “Window” showing digital information on steering wheel panel in cab
Drive axle Receives torque from the drive train
Parts in machine involved in power transmission, engine, torque 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
Empty container handler Machine with special top lift attachment for containers
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
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
Hunan Sany Port Machinery Co., LTD
1 2
3 4
5 6
7 8
9
10 11
12
Fig. 1-4 Machine Nameplate
1.6.2 Engine nameplate

1.6.2.1 VOLVO engine nameplate
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

1.6.4 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. 1-10 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. 1-11 ZF Transmission Case Nameplate

1.6.5 Drive axle nameplate
TEL07366/8132
FAX07366/8169
73453 ABTSGMUND/GERMANY
Order Nr. 1
Fabrik Nr. 2
OIL : MIL - L - 2105 B SAE 90
Fig. 1-12 Drive Axle Nameplate

1.7 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 Industrial Park, Gaolan Port Economic and Development Zon, Zhuhai City,
Guangdong Province, China
Tel: 0086-756-7266945
Fax: 0086-731-84031999-149
Email: sanyport@sany.com.cn
Service hotline: 4008 87 8318
Consulting hotline: 4008 87 9318

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Empty Container Handler Safety
Safety
2. Safety
2.1 Safety Information�� 2-4
2.1.1 Signal words�� 2-4
2.1.2 Examples of using signal words �� 2-5
2.1.3 Other signal words�� 2-5
2.1.4 Safety labels�� 2-6
2.1.4.1 Safety labels, location�� 2-8
2.1.4.2 Safety labels, content�� 2-9
2.2 General Precautions��2-16
2.2.1 Basic safety instructions��2-16
2.2.2 Personal protective equipment��2-17
2.2.3 Never operate while in bad health�� 2-20
2.2.4 No passenger in the cab�� 2-20
2.2.5 Hand signals��2-21
2.2.6 Preparing safety items��2-24
2.2.7 Checking safety equipment��2-24
2.2.8 Precautions in high voltage areas��2-25
2.2.9 Precautions in thunderstrike��2-28
2.2.10 Precautions in wind��2-28
2.2.11 Abnormal cases�� 2-29
2.2.12 Unauthorized modification�� 2-30
2.3 Safety During Operation��2-31
2.3.1 Work area safety��2-31
2.31.1 Work area requirements��2-31
2.3.1.2 Work area indications��2-31

Safety Empty Container Handler

2.3.3 Keeping machine clean�� 2-34
2.3.4 Climbing on or off the machine safely�� 2-34
2.3.5 Start-up safety �� 2-36
2.3.5.1 Inside the operator cab�� 2-36
2.3.5.2 Adjusting the seat�� 2-36
2.3.5.3 Checking the seat belt�� 2-37
2.3.5.4 Machine starting precautions�� 2-37
2.3.5.5 Jump-start the engine, precautions�� 2-39
2.3.5.6 In cold weather�� 2-40
2.3.5.7 After starting the engine�� 2-40
2.3.6 Precautions for safe operation�� 2-41
2.3.6.1 Ensuring good visibility �� 2-41
2.3.6.2 Safety rules for traveling�� 2-41
2.3.6.3 Precautions while operating on slopes�� 2-43
2.3.6.4 Avoiding injury from reversing �� 2-43
2.3.6.5 Precautions while operating on snow or frozen surfaces�� 2-44
2.3.6.6 Preventing control failure�� 2-45
2.3.6.7 Never hoist a load except container�� 2-46
2.3.6.8 Never hoist the load over people�� 2-46
2.3.6.9 Never stand under the load�� 2-46
2.3.6.10 Precautions for operating emergency stop button�� 2-47
2.3.6.11 Precautions for operating safety bypass switch�� 2-47
2.3.7 Parking the machine securely�� 2-48
2.3.7.1 Parking requirements�� 2-48
2.3.7.2 Turning off the engine �� 2-49
2.4 Safety During Maintenance�� 2-50
2.4.1 Preparation for the work area�� 2-50
2.4.2 Warning label is important�� 2-51
2.4.3 Lockout/tagout procedures�� 2-51
2.4.4 Self-preparation before maintenance�� 2-52
2.4.5 Using tools correctly �� 2-52
2.4.6 Regular replacement of safety-related parts�� 2-52
2.4.7 Removing attachments carefully�� 2-53
2.4.8 Adding fluids to the machine�� 2-53
2.4.9 Towing or lifting the machine�� 2-54

2.4.10 Keep clear of moving machinery�� 2-55

2.4.11 Preventing hydraulic hazards �� 2-56
2.4.11.1 Checking rubber hose regularly�� 2-56
2.4.11.2 Releasing the pressure before maintenance�� 2-57
2.4.11.3 Replacing rubber hose regularly�� 2-58
2.4.11.4 Prevent heating near the hydraulic pipeline�� 2-59
2.4.11.5 Filling accumulator�� 2-59
2.4.11.6 Selecting oils and fuel�� 2-60
2.4.11.7 Handling hydraulic oil �� 2-60
2.4.12 Preventing burn and scald�� 2-61
2.4.12.1 Burn by high temperature liquid�� 2-61
2.4.12.2 Chemical burn�� 2-62
2.4.13 Preventing fire and explosion�� 2-64
2.4.13.1 Handling inflammables safely�� 2-64
2.4.13.2 Removing inflammables�� 2-64
2.4.13.3 Checking oil leakage�� 2-65
2.4.13.4 Checking short circuit�� 2-65
2.4.13.5 Preventing battery explosion�� 2-66
2.4.13.6 Checking ignition key�� 2-67
2.4.13.7 Evacuating from the machine�� 2-67
2.4.14 Preventing poisoning and asphyxiation�� 2-68
2.4.14.1 Handling chemicals safely�� 2-68
2.4.14.2 Preventing poisoning by paint �� 2-68
2.4.14.3 Preventing poisoning by off-gas�� 2-69
2.4.15 Preventing dust hazard�� 2-70
2.4.16 Working under machine��2-71
2.4.17 Precautions in welding��2-71
2.4.18 Safe maintenance of air conditioning system�� 2-72
2.4.19 Precautions in maintaining the engine�� 2-73
2.4.20 High voltage precautions��2-74
2.4.21 Precautions after maintenance��2-74
2.4.22 Handling waste properly��2-74
2.5 Tag�� 2-76

2. SAFETY
2.1 Safety Information
This manual provides detailed information

on basic safety precautions and preventive
measures during operation and maintenance
of this machine.
Before conducting operation and maintenance,
you must read and understand all safety labels
on the machine. Strictly follow the safety
rules and suggestions in this manual. Take
precautions to reduce the risk of 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

Other than 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.
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.

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

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

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

2.1.4.2 Safety labels, content
1. Warning label, caution for electricity
Keep the machine away from power lines.
For its location on machine, see position 1 in

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

danger of being hit by it.

Fig. 2-3.
Fig. 2-5 Overhead Danger
3. Warning label, spreader
Never stand close to the spreader. There is a

danger of being hit by it.

Fig. 2-3.
Fig. 2-6 Attachment Warning

4. Label, no passing through
Passing through is prohibited where this label

is glued.

Fig. 2-3.
Fig. 2-7 No Passing Through
5. Label, no climbing
Never climb on the place glued with this no

climbing label.

Fig. 2-3.
Fig. 2-8 No Climbing
6. Label, line of sight
Always travel with container bottom on your

line of sight.

Fig. 2-3.
Fig. 2-9 Line of Sight

7. Label, tyre pressure
The pressure range of tyres should be 138 Psi

- 152 Psi.

Fig. 2-3.
Fig. 2-10 Tyre Pressure
8. Warning label, tyre precautions
Observe the precautions listed in the right

illustration when repairing or maintaing the
tyres.

Fig. 2-3.
Fig. 2-11 Tyre Precautions
9. Label, pre-tightening the hub screw
During 200 hours after the machine is started

for the first time or the new tyre is replaced,
be sure to pre-tighten the hub screw every 50
hours.

Fig. 2-3.
Fig. 2-12 Pre-tightening the Hub Screw

10. Warning label, no ether
Do not use ether to avoid explosion and

severe injury.

Fig. 2-3.
Fig. 2-13 No Ether
11. Warning label, fire is prohibited
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. 2-14 Fire is Prohibited
12. Warning label, electrical hazard
Always disconnect and lock the power before

servicing the machine.

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

13. Warning label, chemical hazard
The battery contains corrosive and hazardous

materials. Do not pucture the battery.

Fig. 2-3.
Fig. 2-16 Chemical Hazard
14. Label, battery disconnect
Disconnect the battery before servicing the

machine.

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

hit by the machine. Do not go nearby or stay
there.

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

16. Warning label, caution for disassembling

counterweights
Do not stand under or on counterweights when

assembling or disassembling them.

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

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

distance of at least 8m.

Fig. 2-3.
Fig. 2-20 Stay Clear
18. Warning label, head injury
Keep away from the machine in the operation

process and be cautious of the hanged
objects.

Fig. 2-3.
Fig. 2-21 Head Injury

19. Label, no riders
Only the operator is allowed in the cab if not

otherwise indicated when the machine is
traveling.

Fig. 2-3.
Fig. 2-22 No Riders
20. Label, stand clear of moving machine
Never stand in places where there is a label

as shown in the right illustration.

Fig. 2-3.
Fig. 2-23 Stand Clear of Moving Machine
21. Label, burn hazard
Do not touch the places glued with the label in

the right illustration.

Fig. 2-3.
Fig. 2-24 Burn Hazard

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

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

are allowed to operate and maintain this
machine.
• A l w a y s ke e p t h e m a c h i n e i n g o o d
condition.
• The safety information in this manual does
not substitute for any rules or laws in your
country. Know the local safety rules and
laws. Make sure that equipment fitted to
your machine abide by these rules and
laws.
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.

2.2.2 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 that is hanging loose.
• work without putting on safety helmet.
• wear loose clothing, including rings,
earrings or similar accoutrement.
• wear music earphone while operating.
Failure to do so may result in 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 harm.
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 foot injuries
caused by following reasons:
1. hitting hard objects
2. stepping on sharp objects
3. heavy objects falling down
Be sure to wear safety shoes while operating,

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

grinding parts. Splashing objects such as
dust, sand or metal scraps can cause serious
injuries.
Hold a protective mask in hand while welding.
Fig. 2-28 Safety Goggle

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

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

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

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

injuries. Make sure to put on protective gloves
under below circumstances:
• during the repair:
• when handling hot, freezing, corrosive,
wood materials;
• when handling steel wires or metals with
sharp edges.
• when the environment temperature is
extremely 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, freezing, corrosion, stab, scratch, etc.
Do not wear clothes with wide sleeves, wide

pants, etc, since these type of garments may
hook on the control lever or protrusion of
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.
2.2.3 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.
2.2.4 No passenger in the cab
No other passenger except the operator is

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

2.2.5 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 efficient machine operation. Both
personnel must know proper hand signals for
each movement of the machine or load.
RAISE LOAD
With forearm vertical and index finger pointing
up, move the hand in a small horizontal circle.
RAISE
LOAD
Fig. 2-34
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 handler operator or
signalman should brief each other to
ensure that they understands each 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
person at a time giving machine signals.
• An operator should move loads only based
on signals from a designated signalman
who wears distinctive clothing.
• The signalman must have a clear view of
the load and machine at all times.
• The signalman must keep all personnel
outside the container handler’s operating
area. Any requests or questions should
only be addressed to the signalman.
• The signalman should never direct a load
over a people.

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

precautions:
• Fire extinguisher and first aid kit should be
available.
• Read and understand the instruction label
on fire extinguisher. Use fire extinguisher
correctly. Fig. 2-40 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.
• Prepare and implement emergency plan to
deal with fire and accidents.
CAUTION
CAUTION
Firefigher should put on a fire-fighting

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

To protect yourself and others, your machine
may be f it ted with the following safet y
equipment. Ensure that each item is securely
in place and in operating condition.
• Guard against falling objects
• Handrail
• Lights
• Safety labels Fig. 2-41 Check Safety Signs
• Horn
• Reverse 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.

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

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

maintained irrespective the voltage is. During
operation no part of the load, machine or
additional equipment employed should exceed
Fig. 2-42 Electricity Attack
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!
• High voltage charge 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-voltage wires or near
high-voltage 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 completed.
• Operate the equipment at a slower-than-
normal speed in the vicinity of power lines.
• When working around overhead power
lines, shut down and ground them, or
take other protective measures such as
guarding or insulating the lines.
• If the power lines are not shut down, Table. 2-1 Safety Distance
operate the equipment in the area ONLY if
a safe minimum clearance (see Table 2-1) Cable Voltage Safety Distance
is maintained. 6,600 V about 2m (7ft)
22,000 V about 3m (10ft)
66,000 V about 4m (14ft)
154,000 V about 5m (17ft)
187,000 V about 6m (20ft)
275,000 V about 7m (23ft)
500,000 V about 12m (38ft)
• If maintaining safe clearance by visual

means is difficult, designate a 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 shut down.
5. NO ONE must attempt to come close to
the equipment until the power has been
turned off.
6. If it is absolutely necessary to leave the
cab, jump completely clear of the vehicle.
Maintain balance and land with both feet,
legs, arms and hands still together. Your
hands, arms or any part of your body
should not touch the equipment during the
jump.
7. Once on the ground continue to jump away
from the affected area as far as possible.
DO NOT walk or run as this will cause an
electrical arc resulting in serious injury or
death.

2.2.9 Precautions in thunderstorm
If thunderstorm occurs, operator and others

around may be caught in danger. Some parts
of the machine could be damaged.
• Make sure to stop operating if there is the
possibility of thunderstorm.
• Lower the load to ground and stop the
engine.
• Leave the machine and hide in a secure
area.
• After the thunderstorm, check all parts
of the machine before re-operating it. If Fig. 2-43 Thunderstorm
any faults found, contact the local SANY
distributors to troubleshoot and fix it.
Check the faults:

• whether the machine is burnt or damaged
• whether the electrical equipment are
working normally
• whether all the functions are in good
condition
NOTE:
When a machine is traveling across the
puddles, always maintain the machine 700mm
above the water (not flooding the battery).
2.2.10 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 it is
blowing.
SANY recommends that operation of this

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

Table 2-2 Wind Speed and Their Effects
Wind Force
Wind Speed Visible Indicator
Beaufort km/h (mph) Effects of wind as observed on land
Designation
Scale
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 handler 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
2.2.11 Abnormal cases
In case of any faults 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.

2.2.12 Unauthorized modification
• Installation of optional parts or attachments

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

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

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

substantially f irm, smooth, level and
prepared ground.
• There is a possibility of tipping when the
machine works on wharf or yard with poor
road conditions, this can lead 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.
Fig. 2-44 Do not Work on Uneven Ground
• When working on a narrow site, try to
operate the machine in a small working
radius, and assign a signalman when
necessary.
• Pay special attention to avoid slipping
when working on frozen ground.
• It is prohibited to perform any operations
on uneven road or muddy road. Drive the
machine only on even and firm ground.
• Reinforce the ground prior to work when it
is too loose or soft.
2.3.1.2 Work area indications
Do not start working before the area has

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

2.3.2 Checks before operation
Check the machine carefully before starting it

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

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

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

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

• Check if the hydraulic pipes are in good

condition without oil leaks or leaking, also
if the electric wiring are secured.
Fig. 2-49 Check Hydraulic Pipe
• Check whether the engine oil level, fuel

level, hydraulic oil level and coolant level
are correct.
Fig. 2-50 Check Oil Level
• Check whether the twistlocks are in good

condition, such as looseness, deformation,
cracks etc.
• Check for alarm.
Fig. 2-51 Check Twistlock

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

daily before starting your work.
• Make sure that the operating area, steps
and handrails are free from oil, grease,
snow, ice or mud, this can cause slipping.
Remove all mud, oils or any debris from
the soles of your shoes before climbing the
steps to the operator cab.
• Never use caustic soaps, high-pressure
water or steam cleaners to clean the
electrical system, for these could damage
the system or cause intermittent system
failures.
Fig. 2-52 Avoid Cleaning the Electrical System

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

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

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

immediately. Tighten any oose bolts.

• Always maintain both feet and one hand or
one foot and both hands with the handrails,
steps, walkway and platforms to ensure
that you can support yourself properly.
• Wear shoes with a high slip-resistant
sole material. Clean any mud or debris
from shoes before entering the container
handler cab or climbing onto the container
handler superstructure.
• Do not climb on or off the machine when
you are carrying tools or supplies.
Fig. 2-53 Climb on the Machine
• Never leave tools or similar objects on the
machine walkway or service areas. These
could drop and get stuck in the machine
operating systems.
• Do not climb on the engine hood, cover,
covering parts or counterweight without
the antislip sticker.
• Do not step on surfaces of the empty
container handler 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 empty container
handler cab or deck by any other means
than the access system’s provided steps
and grab handles.
• Never modify empty container handler’s
access system in any way that has not Fig. 2-54 Avoid Slipping
been evaluated and approved by SANY.
WARNING
WARNING
• Always face the machine when climbing

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

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

following:
• Never allow other personnel inside the
operator cab regardless of the situation
and never bring objects into the operator
cab that could restrict your movement or
vision in any manner.
• Close or latch all doors or windows in
place.
• Check the work area to ensure that all
personnel and equipment are clear from
your machine. Before starting the machine,
sound 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.
2.3.5.2 Adjusting the seat
Incorrect 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. 2-55 Adjust the seat
from the seated position.

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

be injured or thrown out of the cab, or crushed
by the tipping machine. Operators should
observe the following:
• Before operating, carefully check the
strap, buckle and fastener of the seat belt.
If any abrasion or damages are found,
replace the seat belt or its components
immediately.
• When the machine is traveling, always
Fig. 2-56 Check the Seat Belt
sit in the seat and fasten the seat belt to
minimize the probability of injury resulted
from accident.
• To reduce the danger, it is preferred to
replace the seat belt every three years.
2.3.5.4 Machine starting precautions
DANGER
DANGER
Prior to operation, be sure that you can

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

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

WARNING
WARNING
Never start the container handler by

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

following:
• Ask for inspection and maintenance
records and verify that the appropriate
safety, operation & maintenance manual is
inside the cab.
• Walk around the machine and check for
nearby and unauthorized personnel and
objects.
• Do not start the machine if warning plates
have been attached to the control levers.
• Sound the horn to warn others in the area
before starting the engine, moving the
machine or starting any operations.
• Always use the ignition switch to start the
container handler 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 handler
clearly.
• Ample ventilation must be guaranteed if
you have to start the engine or operate the
machine in an enclosed environment.

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

must be carried out according to instruction of
the operation section (For detailed information:
see: “Star t with booster bat teries or
starting generators” on page 4-19). 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 the other
handles the battery).
• Wear goggles and rubber gloves before
starting the engine with jumper cable.
• When jumper cable is used to connect
a mechanically machine with a faulty
machine, main power switch of both
machines should be turned off.
• 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. 2-57)
first. When disconnecting jumper cable, 1
disconnect the grounding or negative (-) 2
(position in Fig. 2-57) first.

• Prevent the clips of jumper cable from
touching each other or the machine when
removing the jumper cable.
Fig. 2-57 Booster Battery

2.3.5.6 In cold weather
Cold weather operation requires additional

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

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

or driving the machine in a place with a poor
visibility.
• Check rearview mirrors, remove debris
and adjust the view before operation.
• Pr i o r to o p e r at i o n, b e su r e t h at a l l
personnel understand the signals and
gestures.
• Turn on working lights and headlights of
the machine when working in a dark 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 poor visibility, a
signalman should be available if necessary.
Operator shall pay special attention to
the marks and follow the instructions of
signalman.
2.3.6.2 Safety rules for traveling
• Do not operate machine over the max

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

may tumble down.

• Avoid traveling over a barrier if possible.
If you have to do that, lower the work
equipment close to ground and drive
slowly.
• Before passing through a 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 propeller shaft.
WARNING
WARNING
When operating the machine on uneven

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

possibly death.

2.3.6.3 Precautions while operating on

slopes
When operating on slopes, obser ve the

following rules:
1. The machine must move up and down
slopes slowly.
2. Do not turn the machine on slopes, nor
drive across slopes.
3. The load must fac e uphill when the
machine is driving up or down gradients of
over 10%.
Fig. 2-58 Operate on Slope
2.3.6.4 Avoiding injury from reversing
In the reversing process, personnel around the

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

• Look around to make sure that nobody
is standing close to the machine before
reversing. Keep the traveling alarm device
in working condition. Always keep alert
whether someone enters the work area.
• Keep the windows, rearview mirrors and Fig. 2-59 Avoid Injury from Reversing
lights clean and in good condition.
• Before moving the machine, warn others
with horn or other signals.
• In the reversing process, if your sight is
blocked, assign a signalman. Always keep
the signalman within your visual field.
• The machine can’t be moved until both
signalman and operator understand the
meaning of all flags, signals and marks.
• Avoid sudden acceleration or braking when
reversing. In addition, the driver should
adjust the speed properly in reversing
process to avoid slippage or tipping.
Fig. 2-60 Avoid Injury from Reversing

2.3.6.5 Precautions while operating on

snow or frozen surfaces
Be careful when traveling or operating the

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

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

order to avoid control failure, you should:
• D o n o t l i f t a c o nt a i n e r w i t h we i g h t
exceeding the max. load capacity of the
machine.
• Make the unloaded engine run idle for 3~5
minutes to make it cool down. Then shut
down the engine and pull the ignition key
out.
• Park the machine on a horizontal ground Fig. 2-61 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
caseof the machine tipping, never try to jump
out of the machine. Otherwise, serious or fatal
crush damage can occur. The tipping speed
of machine is much higher than your jumping
speed.
Fig. 2-62 Go to Hospital
• In case of tipping accidents, always stay

in the cab holding the steering wheel tight.
Never try to jump out of the cab.
Fig. 2-63 Never Jump Down

2.3.6.7 Never hoist a load except container
Container handler is prohibited to hoist any

load except for containers. For instance, never
tighten a sling on spreader for lifting other
load. Otherwise, personnel may be seriously
injured.
SANY number
Fig. 2-64
2.3.6.8 Never hoist the load over people
The load hoisted over people may fall down

and result in personal injuries.
Never hoist the load over people. Besides, do
not let any person stand under the load.
Fig. 2-65
2.3.6.9 Never stand under the load
Personnel under the load may be seriously

hurt if the load falls down. Do not let any
person stand under the load.
Fig. 2-66

2.3.6.10 Precautions for operating

emergency stop button
The emergency stop button can also be used

to brake the machine in emergency cases.
However it can only be used when the brake
system fails in a real emergency situation.
NOTE:
It is prohibited to use the emergency stop
button when the brake pedal is still working
normally or in not real emergency situations.
Fig. 2-67 Emergency Stop Button

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

bypass switch
OPERATING RULES OF SAFETY BYPASS

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

be kept by a special technician. Only in
special cases can it be used after approval
by the principals of relevant departments.
• When using this function, note to find out
the condition of work area to ensure the
safe operation.
• SANY assumes no responsibilities for any Fig. 2-68 Safety Bypass Switch
accidents caused by improper operation of
the safety bypass function.

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

safe area away from tracks and truck lanes.
Fig. 2-69 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. 2-70 Park Ground
It is not allowed to park the machine on uneven

and loose ground.
Fig. 2-71 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. 2-72 Caution for Parking on Slope
2.3.7.2 Turning off the engine
Before maintaining the machine:

1. Park the machine on solid and even
horizontal ground.
2. Retract the spreader and lower it to its
lowest position.
3. Turn the gear selector to neutral position.
Run engine idle for 3 - 5 minutes to cool it
down.
4. Turn the ignition key to ON position (B
Fig. 2-73 Secure the Wheel
in Fig. 2-74). Move the joystick forward,
back ward, lef t ward and right ward
respectively t wo or three times to
depressurize the hydraulic system.
E A B
5. Turn the key to OFF position (A in Fig. 2-74)
to stop the engine.
P
6. Turn the key to E position as shown in Fig.
2-74. And remove it from the switch.
7. Close all the doors and windows in cab.
8. Dismount the machine safely. Never jump
out of it. For detailed information, see:
“Climbing on or off the machine safely”
on page 2-34.
9. Put blocks under the wheel to avoid the
Fig. 2-74 Ignition Switch
machine from moving.

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

below rules should be followed:
• Only approved and qualified personnel can
conduct the maintenance or repair.
• Comprehend fully all the maintenance
information covered in this manual prior to
maintenance.
Fig. 2-75 Read the Manual
• Maintenance personnel shall be physically
suited for this work, especially their health
and eyesight.
• Do not spray water or steam in the cab.
• N e v e r a d d l u b r i c a n t s o r p e r f o r m
maintenanc e when your mac hine is
moving.
• Keep your hands, feet and clothing away
from rotating parts.
2.4.1 Preparation for the work area
Before maintenance, you should:

• Choose a clean and even area with
enough space, light, good ventilation to
conduct the maintenance.
• Clean the working ground. Wipe away the
fuel, lubrication oil and water. Spread sand
or other absorbing materials on sliding
ground.
• Do not leave any tools in work area.
Fig. 2-76 Prepare for the Work Area

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

the joystick during the maintenance, serious
ac cidents would happen. Before any
maintenance work on the machine, be sure to:
• Set the WARNING LABEL of “Shut down!
Under maintenance!” on the steering wheel
SHUT DOWN
UNDER MAINTENANCE
or ignition switch.
• If necessary, place a warning label around
the machine.
Fig. 2-77 Warning Label
2.4.3 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. 2-78 Lock
lockout / tagout device to 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.

2.4.4 Self-preparation before

maintenance
For detailed information, see: “Personal

protective equipment” on page 2-17.
Fig. 2-79 Protective Equipment
2.4.5 Using tools correctly
• Only use appropriate tools in a correct

m a n n e r. U s i n g d a m a g e d , i n f e r i o r,
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. 2-80 Tools
is complete.
• Always put shop tools back in their proper
storage location when finished.
2.4.6 Regular replacement of safety-

related parts
For the consideration of operating the machine

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

2.4.7 Removing attachments carefully
• When removing large and heav y

attachments, always be sure to use the
correct lifting equipment rated for the
capacity of the load you will be lifting.
• After the attachment or part has been
removed, store it where it cannot fall or
move. Always be sure that the attachment
is stable on a solid surface and clear of all
walkways or fire exits.
• W h e n i nst a l li n g a n d u s i n g o pt i o n a l Fig. 2-81 Crushed by Removed Attachments
attachments, read and follow Chapter 8 for
the instructions.
• Do not use attachments that are not
authorized by SANY. Use of unauthorized
attachments could result in hazards and
adversely affect proper operation and
useful life of the machine. Any injuries,
accidents, product failures resulting from
the use of unauthorized attachments will
not be the responsibility of SANY.
2.4.8 Adding fluids to the machine
Before adding fluids, shut down the engine

and allow the systems to cool to outdoor
ambient temperature before removing any
caps. Failure to do so may result in serious
burns or a sudden loss of fluid. Read and
understand the following:
• Refueling the machine could pose some
hazards.
• Grease, fuel, oil or coolant spills pose a
hazard if not cleaned up immediately.
Fig. 2-82 Refueling
• When refueling or adding any fluids to
the machine, be sure you are in a well-
ventilated area.
• Never smoke or allow open flames near
while refueling the machine.
• Never mix gasoline with diesel or fuel.

Gasoline is extremely flammable and could

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

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

machine is towed or lifted incorrectly or if the
wrong cables or towing points are selected.
Adhere to the following:
• Use only the designated lift points to lift the
machine and designated tow points to tow
the machine. Be sure that the lift and tow
points are in good condition.
• Always tow or lift in the direction indicated
by the label. If the label is missing or
damaged, contact your SANY distributors
Fig. 2-83 Hoisting Point
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 everybody is clear of the
machine, or they could be hurt.

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

WARNING
crushed by moving parts of this container
handler.
Keep clear of moving machinery
Barricade the entire area where the container Death or serious injury can occur
handler is working and keep all unnecessary
personnel out of the work area.
Never allow anyone to stand or work near

the container handler while the machine is in
Fig. 2-84 Keep Clear of Moving Machinery
operation.

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

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

• C h e c k w h e t h e r t h e hy d r a u l i c h o s e
connection in good condition.
Fig. 2-85 Check the Rubber Hose
• Check whether the housing of of hydraulic
hose is in good condition.
• Check whether the external surface of
hose do not expand.
• Check whether the hose is not bent or
flatted.
• Check whether the external bracket of
hose is not loose.
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.

2.4.11.2 Releasing the pressure before

maintenance
1. Park the machine.

2. Retract the spreader and lower it to its
lowest position.
3. Stop the engine.
4. Release the pressure in hydraulic system.
5. Turn the ignition key to ON position (B in
Fig. 2-86). 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. 2-86).
Turn off the main power. Fig. 2-86 Ignition Key
• Open the pressure-releasing valve on the

accumulator charging valve to release the
pressure in brake system.
Fig. 2-87 Release the Brake Pressure

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

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

can result in accidents such as fire disaster,
splashed liquid onto skin, or fallen work device
Fig. 2-88 Replace the Rubber Hose
on personnel, etc. These could lead to serious
burn, necrosis or other injuries or death.
Fig. 2-89 Avoid Hydraulic Injury 1
Fig. 2-90 Avoid Hydraulic Injury 2

2.4.11.4 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. 2-91 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.
2.4.11.5 Filling accumulator
The accumulator is filled with nitrogen. Wrong

operation will lead to explosion, causing
machine damage and personal injury. Pay
attention to the following items when dealing
with accumulators:
• Do not dismantle the accumulator.
• Keep the accumulator away from fire.
• D o n o t d r i l l h o l e s i n o r w e l d t h e
accumulator.
• Do not crash or roll the accumulator. Avoid
Fig. 2-92 Caution for Filling Accumulator
any shock of accumulator.
• Drain the air before dealing with the
accumulator. Please contact SANY to
conduct this operation.

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

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

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

• It is prohibited to wash the contaminated

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

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

hose 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. 2-93 Caution for Burn
• Do not open the radiator cap before the
engine cools down.
• Turn the cap slowly when opening it.
Remove the cap after the pressure has
fully released.
• Start the check or maintenance after the
oil and parts cooled down.

In case of burn or scald:

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

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

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

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

on the metal surface. Then, wash this part

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

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

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
in different directions.
• Consult a doctor immediately.
Fig. 2-94 Go to Hospital

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

fire may occur. Pay attention to below items:
• Handle fuel carefully, because it is a highly
flammable substance.
• Never f ill fuel to the mac hine while
smoking, or near a naked fire and sparks.
• Shut down the engine before refilling fuel.
• Always fill fuel outdoors.
• Store the flammable liquid (all fuels, most Fig. 2-95 Avoid Fire
lubricants and some coolants) in a place
away from fire hazard.
• Do not burn or puncture the pressured
container.
• Do not store oily cloth. They can be ignited
or combusting spontaneously.
2.4.13.2 Removing inflammables
Splashed fuel, oil, waste, grease, scrap,

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

the splashed or accumulated inflammables
immediately to prevent fire. Fig. 2-96 Remove Inflammable

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

result in fire. Personnel should observe the
following regulations to prevent fire:
• Check whether the clamp is in place and
secure.
• Check whether the hose is not twisted.
• Check whether the hose and pipeline do
not rub each other.
• Check whether the oil c ooler is not
Fig. 2-97 Check Oil Leakage
damaged .
• Check whether the flange bolt of oil cooler
is secure.
• Check whether the oil hoses and high
temperature par ts (e.g. turbocharger,
exhaust pipeline, silencer) have the contact
protection.
• Check whether the pipe connectors of
high temperature parts (e.g. turbocharger,
exhaust pipeline, silencer) are secure and
not leaking.
• Tighten, repair or replac e all loose,
damaged or lost clamps, pipelines, hoses,
oil coolers, or flange bolts.
• Do not bend or strike high pressure
pipelines.
• Do not install any bent or damaged
pipelines, tubes, or hoses.
2.4.13.4 Checking short circuit
Short circuit can result in fire. Pay attention to

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

2.4.13.5 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 hazards. Be
sure to follow below regulations:
• Keep the battery away from children.
• Do not smoke near the battery.
• Avoid open fires and kindling materials
while charging or using the battery.
• Never put the battery under direct sunlight Fig. 2-98 Battery Explosion
in hot seasons.
• Avoid battery terminals contact with tools
and other metal objects.
• Switch the main power switch to OFF
position before operating the battery.
• Wear protective goggles and rubber gloves
during battery operation.
• Never discharge or charge the battery too
much.
• Connect the battery with proper cables.
Connect plus-cable (red) first and then
minus-cable (black). Make sure that all the
terminals are firmly fixed.
• Disconnect the battery approx. one minute
after the engine is turned off. Remove
minus-cable (black) first and then plus-
cable (red).
• If c harging a bat ter y removed f rom
machine, put it in a ventilated place before
opening the battery cover.
• If the battery temperature exceeds 45°C, Fig. 2-99 Cables
stop charging until the battery temperature
reaches room temperature. Reduce half of
the electric current and continue charging.
• If the battery starts to splash sulfuric acid,
stop charging immediately.
• If the battery magic eye shows green,
the battery has been fully charged. Stop
charging it.
• Fit the battery cover after charging. And
install it in the correct position.

• If electrolyte splashes on bare skin, wash

with soap and a lot of water immediately.
• If electrolyte has gotten into eyes, rinse
immediately with water and contact a
doctor immediately.
2.4.13.6 Checking ignition key
If the engine is shut down when the machine

P
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 to
confirm whether the engine shuts down. Fig. 2-100 OFF Position
• In case of any abnormality, make sure to
fix it before operating the machine.
2.4.13.7 Evacuating from the machine
If the engine is not stopped when a fire disaster

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

you may put out the fire as long as you are
able to evacuate from the danger in time.
In case of fire, you must:

• switch the ignition key to OFF position (see
Fig. 2-100) and make sure that the engine
is stopped. Evacuate from the machine.
• call the fire agency.
• if time permits, put the gear selector to
neutral position and press brake button to
keep it in the “P” position (see Fig. 2-100).
• if time permits, use the fire extinguisher. Fig. 2-101 Evacuate

2.4.14 Preventing poisoning and

asphyxiation
2.4.14.1 Handling chemicals safely
Direct contact with harmful chemicals can

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

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

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

away the paint remover with soap and

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

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

is started or operated in an enclosed
environment. Fig. 2-103 Avoid Poisoning by Off-gas
• If a person is poisoned by off-gas in the
enclosed environment, open the doors
and windows first to reduce the level of
harmful gases before conducting the first
aid treatment.
• Put the poisoned person to a ventilated
place or outdoors. If the poisoned person
is unconscious, make him/her lie sideways.

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

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

2.4.16 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. 2-104 Work under Machine
empty tyres or stands to suppor t the
machine. These things may collapse under
continuous load. Never use only a jack to
support the machine.
2.4.17 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 strike may occur if welding is

performed incorrectly. Observe the following:
• O n l y q u a l i f i e d w e l d e r w i t h p r o p e r
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
electronic control device and bearing.
• Before welding on the machine or engine
equipped with electronic control device,
you should turn the main power switch
Fig. 2-105 Remove the Cables
to OFF position first. And then remove
the positive and negative cables from the
battery.
• Prevent wire harness from contacting with
sparks generated in the welding process.

Follow standard procedures in welding:

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

conditioning system
Make sure to observe below items:

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

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

2.4.19 Precautions in maintaining the

engine
To prevent injury, no maintenance shall be

carried out when the engine is running. If
maintenance has to be done on a running
engine, there should be at least two personnel
handling the maintenance according to the
following rules:
• One person should always be seated in
operator’s seat and ready to shut down
the engine at any time. All personnel must Fig. 2-106 Caution for Fan
keep 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 do not put your hand or foot
into there. Otherwise, you may be clamped
or crushed.
• Pay special attention to rotating parts like
fan and fan belt, you may get caught by
them when standing close to.
Fig. 2-107 Be Clamped by the Rotating Parts
• Do not leave or insert any tools or other

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

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

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

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

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 correct.
• Operate all control devices to be sure of
their proper functioning. Make road test if
necessary.
2.4.22 Handling waste properly
The potential harmful substances used in this

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

the ground, in the sewer or into any water

source.
• Consult the local environmental protection
organization or recovery center for the
correct method of recovering or handling
the waste.
• Use a leakage -proof container when
draining the liquid. Do not use food or
beverage container, this might mislead
somebody to drink accidentally.
• Leakage of refrigerant into the air can
damage the atmosphere. For detailed
information, see: “Safe maintenance of
air conditioning system” on page 2-72.
NOTE:
The following substances and liquids must
be delivered to 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
duster cloth etc.).
Fig. 2-111 Do not Drop Waste Randomly
NOTICE
NOTICE
Pay attention to the following to prevent

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

2.5 Tag
SANY cannot predict every circumstance

that might involve a potential hazard in
o p e r at i o n o r m a i nte n a n c e. T h e s af et y
chapter in this manual may not include every
possibly dangerous circumstance. But the
safety measures and regulations you have
understood will 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
empty container handler.
Safety is your career and responsibility.

Wish you work pleasantly!

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Empty Container Handler System Functions
System Functions
3. System Functions
3.1 Main Components of Machine�� 3-4
3.2 Cab Control System�� 3-6
3.2.1 Steering column�� 3-7
3.2.1.1 Steering wheel panel�� 3-7
3.2.1.2 Gear selector��3-11
3.2.1.3 Direction indication controller��3-12
3.2.1.4 Adjusting the angle of steering controller ��3-15
3.2.2 Pedal��3-15
3.2.3 Joystick��3-16
3.2.4 Right operation panel��3-17
3.2.4.1 Ignition switch��3-18
3.2.4.2 Safety bypass switch��3-19
3.2.4.3 Emergency stop switch��3-19
3.2.4.4 Rear wiper switch�� 3-20
3.2.4.5 Top wiper switch�� 3-20
3.2.4.6 Front wiper switch�� 3-21
3.2.4.7 Inner light switch�� 3-22
3.2.5 Front operation panel�� 3-23
3.2.5.1 Cab top light switch�� 3-23
3.2.5.2 Rear light switch�� 3-24
3.2.5.3 Mast light switch�� 3-24
3.2.5.4 Spreader light switch�� 3-25
3.2.5.5 Side light switch�� 3-26
3.2.5.6 Failure detection switch�� 3-26

System Functions Empty Container Handler
3.3 Display�� 3-27

3.3.1.1 Start menu�� 3-28
3.3.1.2 Main menu�� 3-28
3.3.1.9 Analogy input menu�� 3-33
3.3.1.10 Analogy output menu��3-34
3.3.1.11 Setting menu�� 3-34
3.3.2.1 Start menu�� 3-36
3.3.2.2 Main menu�� 3-36
3.3.2.3 Language setting menu�� 3-38
3.3.2.6 Hydraulic information menu��3-40
3.3.2.7 Digital input menu��3-40
3.3.2.8 Digital output menu��3-40
3.3.2.9 Analogy information menu�� 3-41
3.3.2.11 Setting menu�� 3-42
3.4 Air Conditioning System��3-43
3.4.1.1 Power switch��3-44
3.4.1.2 Fan speed switch��3-44
3.4.1.3 Temperature or Paging switch��3-45
3.4.1.4 Mode switch��3-45
3.4.1.5 Fresh air switch��3-46
3.4.2 Operation�� 3-47
3.4.4 Troubleshooting��3-49
3.5 Electric Control Cabinet��3-50

3.6 Fuse�� 3-51

3.7 Fire Extinguisher�� 3-52

3. SYSTEM FUNCTIONS
3.1 Main Components of Machine
Empty container handler is composed of

power drive system (1), steering system (2),
frame (3), mast assembly (4), spreader (5), cab
and operation console assembly (6), hydraulic
system (7), and electrical system (8), etc.
Refer to Fig. 3-1 and Table 3-1.
5
3
1 8 2
Fig. 3-1 Main Components of Empty Container Handler

Table 3-1
Position Item Function
Engine and transmission case constitute the power drive
1 Power drive system system of empty container handler, 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 Frame is the mounting base as well as the support for all parts.
Mast assembly supports the spreader and allows it to move up
4 Mast assembly
or down to perform the hoisting of container.
Spreader assembly is the main working mechanism which is
5 Spreader assembly capable of pitching, sliding, 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 operations of the machine are 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 motions of the
working mechanisms such as mast and spreader.
Electrical system consists of control circuits of traveling, driving,
8 Electrical system and working mechanisms. Working mechanism is controlled
through the circuits.

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

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

3.2.1 Steering column
Steering column is composed of steering

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

sw itc he s on t he steer ing w heel pane l,
including left steering indicator light (1), fault
indicator light (2), parking indicator light (3),
right steering indicator light (4), parking switch
(5), warning light switch (6) and headlight
switch (7).
Fig. 3-4 Steering Wheel Panel

Left steering indicator light (1 in Fig. 3-4)
This left steering indicator light would

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

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

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

blink if the right steering light is turned
on.
Parking switch (5 in Fig. 3-4)

2
This switch is used to turn the parking
brake on or off.
Press the parking brake switch (1), and the

parking indicator light (2) will be turned on.
NOTICE
NOTICE
1
Always release the parking brake before
travel, or the drive axle will be damaged. Fig. 3-5 Parking Brake Switch

Warning light switch (6 in Fig. 3-4)
This switch is used to turn on or off the

warning light.
Fig. 3-6 Warning Light Switch
Press down the warning light switch. The

warning light on the top of cab and warning
indicator light in the cab will begin blinking.
Fig. 3-7 Warning Light

Headlight switch (7 in Fig. 3-4)

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

frame.
Fig. 3-9 Headlight Location

3.2.1.2 Gear selector
Gear selector (2 in Fig. 3-3) 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. 3-10 Flipping Forward
1
2
3
1
2
3
1
2
3
Fig. 3-11 Flipping
The tail 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. 3-12 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. 3-13 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. 3-3)

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

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

the driver whether the steering light turns on
normally.
Fig. 3-14 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. 3-15 Left Steering Indicator
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. 3-16 Right Steering Indicator
Front steering lights are fitted together with

headlights.
Fig. 3-17 Front Steering Light

Rear steering lights, located at the end of main

frame, are fitted together with tail lights.
Fig. 3-18 Tail Light

Horn button
Horn buttons are located at the ends of

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

continuously.
Washer switch
Fig. 3-19 Horn 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
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. Fig. 3-20 Washer Switch
• 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 the desired angle.
Steering wheel angle adjusting handle (1)

1. Loosen the handle.
2. Adjust the steering wheel to a desired
position.
3. Tighten up the handle after the adjustment.
1
Steering column angle adjusting pedal (2)
1. Step on the pedal.
2. Adjust the steering column to a desired
2
position.
3. Release the pedal.
Fig. 3-21 Adjustment Handle and Pedal
3.2.2 Pedal
Brake pedal (3)

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

Accelerator pedal is used to speed up the
machine.
3 4
Fig. 3-22 Pedal

3.2.3 Joystick
3
Joystick is located at the right of cab seat. 2
5
It can be swayed in different directions to
control telescopic and pitching of the mast. Six
buttons at its front are to control telescoping, 1 6
side-shifting, locking and unlocking of the
spreader. Two buttons at its back are joystick 7
enable switch and spare switch. 4
8
With the joystick on / off switch on right

operation panel pressed down, the joystick
can be switched and thus realize the singal
operation of mast to all four directions without
pressing the joystick enable switch at the back 1. Spreader locking
of joystick. 2. Spreader 20 feet
3. Spreader unlocking
4. Spreader side-shifting leftward
NOTE:
5. Spreader side-shifting rightward
To avoid incorrect operation, the driver should
6. Spreader 40 feet
turn off the joystick on / off switch on right
7. Spare switch
operation panel before leaving the cab.
8. Joystick enable
Fig. 3-23 Joystick
When a combination operation is needed,

push the joystick directly.
NOTE:
Reaction 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
6
Right operation panel is composed of the 7
following switches: 8
9
1. Ignition key switch
2. Safety bypass switch
3. Buzzer 10
4. Emergency stop switch 2
5. Rear wiper switch 4
6. Top wiper switch
7. Front wiper switch
8. Joystick on / off switch
9. Alarm resetting switch 1
10. Inner light switch 3
Fig. 3-24 Right Operation panel

3.2.4.1 Ignition switch

E A B
Ignition switch (position 1 in Fig. 3-24) 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.
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.
Release 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 it is at position E, the engine is stopped.
NOTICE
NOTICE
Stopping engine on high speed would
shorten the service life of engine. Unless
in emergency, never stop the machine
running at high speed. Otherwise, machine
faults such as wear crack on cylinder
cover, burnt bearings of turbocharger etc.
may occur.

3.2.4.2 Safety bypass switch

1
The bypass switch (1) is used to operate
the empty container handler when machine
function has stopped due to unexpected
factors. If this condition occurs the operator
must contact their supervisor and a SANY
representative to resolve the underlying
problem.
2
Fig. 3-26 Safety Bypass Switch
When the safety bypss function is activated,

t he buz ze r (2) near t he s afet y by pas s
would begin to make alarm. Meanwhile, the
malfunction indicator light will begin to flash
and the screen would display “Safety Bypass
Switch Activated”. The protection is canceled.
Fig. 3-27 Malfunction Indicator Light
3.2.4.3 Emergency stop switch
The emergency stop switch is used to shut

1
down the entire electrical system and stop all
movements of the empty container handler.
This 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 emergency circumstance.
Fig. 3-28 Emergency Stop Switch

3.2.4.4 Rear wiper switch

rear wiper.
Fig. 3-29 Rear Wiper Switch
The rear wiper is located at the back of cab.
Fig. 3-30 Rear Wiper
3.2.4.5 Top wiper switch

top wiper.
Fig. 3-31 Top Wiper Switch

The top wiper is located at the top of cab.
Fig. 3-32 Top Wiper
3.2.4.6 Front wiper switch

front wiper.
Fig. 3-33 Front Wiper Switch
The front wiper is located at the front of cab.
Fig. 3-34 Front Wiper

3.2.4.7 Inner light switch
The inner lights are located at both sides of

inner cab. There are two inner lights in the
cab.
Moving the switch below the inner light will

turn on or off the lights.
Fig. 3-35 Inner Light Switch
• A: ON positon. The light is on.

• B: OFF position. The light is off
NOTE:
Even if the ignition key is at position O, the
inner light could be turned on.
Fig. 3-36 Inner Light

3.2.5 Front operation panel
The switches on front operation panel consist

of cab top light switch (1), rear light switch (2),
mast light switch (3), spreader light switch (4),
width light switch (5), and failure detection
switch (6). See Fig. 3-39.
Fig. 3-37 Front Operation Panel
3.2.5.1 Cab top light switch

light on the roof of cab.
Fig. 3-38 Cab Top Light Switch
There are four lights located on the roof of

cab.
Fig. 3-39 Cab Top Light

3.2.5.2 Rear light switch

rear light.
Fig. 3-40 Rear Light Switch
There are two rear lights located at the back of

cab.
Fig. 3-41 Rear Light
3.2.5.3 Mast light switch

mast light.
Fig. 3-42 Mast Light Switch

There are two mast lights located on the mast.
Fig. 3-43 Mast Light
3.2.5.4 Spreader light switch

spreader light.
Fig. 3-44 Spreader Light Switch
There are four spreader lights located on the

spreader, each two at both ends of spreader.
Fig. 3-45 Spreader Light

3.2.5.5 Side light switch

side light.
Fig. 3-46 Width Light Switch
There are two side lights respectively located

at the flank of front and rear mudguards.
Fig. 3-47 Width Light
3.2.5.6 Failure detection switch
This switch is used to detect the engine failure.

Press down the button, and the detection
indicator light blinks.
Fig. 3-48 Failure Detection Switch

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

function display area (2), and operation buttons
F1-F6 (3).
Menu display area displays system parameters

and fault information. When a fault occurs,
main menu will display the real -time
information about this fault.
The functions of 6 operation buttons from F1
to F6 are corresponded to the indications on
function display area. By pressing relevant
buttons, the desired menu can be displayed.
NOTE:
SANY display is normally used in H1 / H2 / H3
/ H4 container handlers.
1 10 15 15
20
25 F1
5 20 10 30
0
0
0 25 L 0 35 F2
x100 RPM Km/h
0
G Y R
0.0
F3 3
F4
0.0 m
Manual:
Gear: 0.0 t F5
Load: 0%
F6
Fig. 3-49 SANY Display

3.3.1.1 Start menu
When the ignition key is turned to position O,

the screen would display start menu as shown
in the right figure.
Quality Changes the World
Initializing
Fig. 3-50 Start Menu
3.3.1.2 Main menu

20
10 15 25
15
About 2 seconds after the star t menu is 5 20

0 10 30
0 L
displayed, menu 2 will be shown automatically 0 25 35
0
x100 RPM
as Fig. 3-51 under normal circumstances. Or G Y R
Km/h
you can press F1 directly to enter main menu. 0 0.0
Main menu displays engine rotation speed, Manual:

0.0 m
vehicle speed, fuel level, traveling gear, Gear: 0.0 t
hoisted weight, and spreader lights. Load: 0%
Below are the explanations of information

shown on main menu. Fig. 3-51 Main Menu
indicates the fuel level
1). Engine rotation speed

The left instrument in Fig. 3-51 indicates the
actual rotation speed of engine.
Displayed speed on instrument alters within
the range of 0-25. It signifies the rotation
speed of 0-2500 rpm/min.
2). Vehicle speed

The right instrument in Fig. 3-51 indicates the
actual traveling speed of machine.
Displayed speed on instrument alters within
the range of 0-30. It signifies the vehicle speed
of 0-3000 km/h.

3). Traveling gear

• Manual signifies the gear position at the
gear selector.
• Gear signifies the actual traveling gear of
machine.
• With gear selector rotated to 1, the Manual:
machine travels at 1st gear. With gear
selector rotated to 2, the machine travels Gear:
at 2nd gear. With gear selector rotated
to 3, the machine travels at 1st - 3th gear
automatically.
Fig. 3-52 Traveling Gear
4). Spreader indicators

Three spreader indicator lights on this menu
signify the conditions of spreader twistlocks.
• W hen the lef t indic ator light s up, it
G Y R
indicates that the spreader is locked;
• When the middle indicator lights up, it
indicates that the spreader is seated;
• When the right indicator lights up, it
indicates that the spreader is unlocked;
Fig. 3-53 Spreader Indicators
5). Torque percentage
Torque percentage is aimed at protecting the

machine.
• Torque percentage≤90%: safe for lifting
load
Load: 0%
• To r qu e p e r c e nt a g e > 9 0%: a l a r m f o r
dangerous working condition
• Torque percentage=100%: impossible to
tilt and lower the mast Fig. 3-54 Torque Percentage

3.3.1.3 Engine information menu

Engine
Press F1 to enter engine information menu.

0 RPM 0 H
indicates the engine rotation speed

0 0 L
℃
indicates the engine water temperature
indicates the engine oil pressure 0 KPa 0.0 V
indicates the engine working hours

SPN： 0 0 Year 0 Number

Fig. 3-55 Engine Information Menu
indicates the system voltage
SPN indicates the engine SPN codes
H4 container handlers equipped with stage IV

engines will display the second engine infor-
mation menu as shown in the right figure.
ENGINE
●● The Regen_Inhabit_Lamp indicated that Regen_Inhibit_L Wait_To_Star

regeneration disabled (inhabit) switch is amp t_Lamp
active, therefore automatic and manual DPF_Lamp Amber_Warning_La

mp
(non-mission) exhaust system cleaning
HEST_Lamp Red_Stop_Lamp
cannot occur.
DEF_Tan
●● The DFP_Lamp notifies the operator that DEF_Low_Lamp
K Level
0
the after-treatment system has not auto Regeneratio
0 0
regenerated at the required time limit and n Inhibit
Regeneratio
requires an exhaust system cleaning. n Force
0 0
●● The HEST lamp will illuminate during

manual (non-mission) exhaust system Fig. 3-56 Engine Information Menu 2 (For
cleaning and when the exhaust Machines Equipped with Stage IV Engine)
temperature exc eeds the c alibrated
temperature threshold.
●● The DEF_ Low_ Lamp signal controls
an indicator lamp or LED that is used to
alert the machine operator that the diesel
exhaust fluid is low and must soon be
replenished.
●● The Wait_To_Start_Lamp indicates the
driver has turned the keyswitch to an
engine run position, but should wait to start
the machine.

●● The A mber_War ning _ Lamp displays

messages that require prompt operator
attention and diagnostics messages.
●● The Red_Stop _Lamp displays critical
operator messages and diagnostics fault
codes.
The regeneration inhabit switch disallows any
automatic or manual (non-mission) exhaust
system cleaning.
The regeneration force switch initiates a
manual (non-mission) exhaust system cleaning
of the af ter-treatment system when the
machine is in non-mission condition.
3.3.1.4 Gearbox information menu Gear Information
Press F2 to enter gearbox information menu. 0.0 km/h
Gearbox parameters: 0 RPM Manual:
indicates the driving speed 0 Bar Gear:
indicates the gearbox rotation speed 0 ℃
indicates the gearbox oil temperature 0 Year 0 Number
indicates the gearbox oil pressure Fig. 3-57 Gearbox Information Menu
Traveling gear information:
Manual indicates respectively 1st gear, 2nd

gear, and auto gear
Gear indicates the actual traveling gear

3.3.1.5 Hydraulic information menu

Hydraulic
Press F3 to enter hydraulic information menu. Length 0.0 m Weight_Fix t

0.0
This menu displays lock length, system System 0.0 MPa Load 0 %
pressure, lock counting, load weight, and load
percentage.
Count_Lock 0
Fig. 3-58 Hydraulic System Menu
3.3.1.6 Fault alarm menu Alarm_1

01.Loaded_overspeed 13.Engine_OilPress_L
02.GearboxTemp_H
Press F4 to enter fault alarm menu. 14.Battery_voltage_L
03.Hyd_OilTemp_H 15.Safety_bypass
04.Oilwater_Alarm 16.LockUnlock_Alarm
In alarming, the on the left changes into . 05.ACC_PL_Alarm 17.Load_Over_90%
06.Engine_coolant_L 18.Over_Load
1). Fault alarm menu 1 07.HYD_FJ_Alarm 19.SYMT_CanFault
08.Brake_FJ_Alarm 20.CAN_ERROR
The default menu of fault alarm menus is as 09.Senser_Error 21.GPS_LOCKED
shown in the right figure. 10.FuelLevel_L 22.RollOver_limit_Alarm

11.GearboxlPressure_L 23.BrkOilTemp_Alarm
12.Engine_Tem_H 24.Altimetry_Sensor_Err
Fig. 3-59 Fault alarm menu 1
Alarm_2
2). Fault alarm menu 2
25.WarmUp_Alarm
Press F4 on fault alarm menu 1 to enter fault 26.IdleSpeed_Alarm

27.Engine_preheating
alarm menu 2.
28.GearBox_Error_Alarm
29.SPN_Alarm
NOTE: 30.Engine_Status_Alarm
Only the fault alarm menu 2 of machine 31.DEF_Tank_L_Alarm
equipped with stage IV engine will display

alarm information item 29-31.

3.3.1.7 Digital input menu Digital In

For Shift Brak Temp H Sprd Lock
Press F5 to enter digital input menu. Back Shift Hyd Temp H Sprd Unlock
Shift 1 ACC Press L Sprd Left
When a specific signal is “1” (activated), the Shift 2 Cool Water L Sprd Right
Shift 3 Water In Fuel
on the left changes into . Sprd Out
DI Handbrake Brak Filter J Sprd In
Foot Brake Hyd Filter J Proximity1
Neutral Shift Lift interrupt Proximity2
Sprd Seated Allow Lower
Sprd Unlocked Spread Act
Sprd Locked Engine Preheat
Alarm Reset Safe Bypass
Fig. 3-61 Digital Input Menu
3.3.1.8 Digital output menu Digital Out

For Valve Sprd Lock Valve
Press F3 on digital input menu to enter digital Back Valve Sprd Unlock Valve
output menu. Gear Valve1 Sprd Left Valve
Gear Valve2 Sprd Right Valve
Soud Alarm Sprd Extend Valve
When a specific signal is “1” (activated), the
DO N Sprd Ret Valve
on the left changes into . DO HandBrake Lam Locked
Sprd Move Unlocked
HighSpeed Lock Seated
Down Valve1 Spare
Down Valve2 Spare
DO AddLift Valve
Fig. 3-62 Digital Output Menu
3.3.1.9 Analogy input menu

Analogy Input
Engine Spd 0 RPM Fuel Lev 0.0 L

Press F4 on digital input menu to enter Water Temp 0 ℃ NULL 0
analogy input menu. Engine Press 0 KPa
Batter Vol 0.0 V
Gear Speed 0 RPM
Gear Temp 0 ℃
Gear Press 0 Bar
Drive Speed 0.0 Km/h
Handle LR 0
Handle FB 0
Load Pre 0.0 MPa
Pedal Pos 0
Fig. 3-63 Analogy Input Menu

3.3.1.10 Analogy output menu

Analogy Output
Mast Lift PWM 0 Batter Vo 0.0 V
Press F5 on digital input menu to enter Mast Down PWM 0
analogy output menu. Mast Fore PWM 0

Mast Back PWM 0
Lock Count 0
Load Weight 0.0 T
Load Percent 0
Lock High 0.0 m
Total Fuel Count 0 L
Work Fuel Count 0 L
Drive Fuel Count 0 L

Non Work Fuel Co 0 L
Fig. 3-64 Analogy Output Menu
3.3.1.11 Setting menu

Parameter Setting
Press F6 to enter password menu.

2016-03-08
Enter in the correct password, and it is able
to display setting menu. Only the SANY
authorized distributors and SANY service 0 * ** **
engineers have the password to access the
menus.
Fig. 3-65 Setting Menu

3.3.2 IFM Display
Display is composed of menu display area (1),

function display area (2), and operation buttons
F1-F8 (3).
Menu display area displays system parameters

and fault information. When a fault occurs,
main menu will display the real -time
information about this fault.
The functions of 8 operation buttons from F1
to F8 are corresponded to the indications on
function display area. By pressing relevant
buttons, the desired menu can be displayed.
NOTE:
IFM display is normally used in H8 / H85
container handlers.
2013-10-28 17:44:5
15 15
10 20 10 20
℃ 0.0 L
5 25
0
5 25
1
0 30 0 30
X100PRM Km/h
LOAD: 0 %
0.000 m 0.0 T
Fig. 3-66 IFM Display

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

the screen would display start menu as shown
in the right figure.
Fig. 3-67 Start Menu
3.3.2.2 Main menu 2013-10-28 17:44:5
15 15
10 20 10 20
About 2 seconds after the star t menu is 0 ℃ 0.0 L
5 25 5 25
displayed, menu 2 will be shown automatically
0 30 0 30
as Fig. 3-68 under normal circumstances. X100PRM Km/h
Main menu displays engine rotation speed, LOAD: 0 %

vehicle speed, fuel level, engine water 0.000 m 0.0 T
temperature, torque percentage, mast height,

load weight, spreader lights, and timing
information.
Fig. 3-68 Main Menu
Below are the explanations of information
shown on main menu.

15
10 20
1). Engine rotation speed
The right instrument indicates the actual 5 25
rotation speed of engine. 0 30

Displayed speed on instrument alters within X100PRM
the range of 0-23. It signifies the rotation
speed of 0-2300 rpm/min.
Fig. 3-69 Engine Rotation speed Instrument

2). Vehicle speed

The right instrument indicates the actual
traveling speed of machine.
15
Displayed speed on instrument alters within 10 20
the range of 0-30. It signifies the vehicle speed
5 25
of 0-3000 km/h.
0 30
Km/h
Fig. 3-70 Vehicle Speed Instrument
3). Torque percentage

Torque percentage is aimed at protecting the
machine. LOAD: 0 %
• Torque percentage≤90%: safe for lifting
load
• To r qu e p e r c e nt a g e > 9 0%: a l a r m f o r
dangerous working condition Fig. 3-71 Torque Percentage
• Torque percentage=100%: impossible to
lift and extend the spreader
4). Spreader indicators

Three spreader indicator lights on this menu
signify the conditions of spreader twistlocks.
• Left lamp (green) indicates the unlocking

condition;
• Middle lamp (yellow) indicates the seating
Fig. 3-72 Spreader Indicators
condition;
• Right lamp (red) indicates the locking
condition.
5). Mast height, load weight
indicates the mast height

0.000 m 0.0 T
indicates the load weight
Fig. 3-73 Mast Height and Load Weight

6). Timing information
This area displays the current time.
2013-10-28 17:44:5
Fig. 3-74 Timing Information
3.3.2.3 Language setting menu

Test
Press F1 to enter language setting menu. It is
able to select the program language between
Chinese and English.
Chinese English
English Home
Fig. 3-75 Language Setting Menu
3.3.2.4 Engine information menu

0 ℃
Press F2 to enter engine information menu.
0.0 L
0.0 Bar
SPN 0 0 RPM
indicates the fuel level Stop_Case 0 0 H
indicates the engine oil pressure Fuel_Rate 0 ml/h 0.0 V
indicates the engine rotation speed
indicates the engine working hours Fig. 3-76 Engine Information Menu
indicates the system voltage

This menu also displays the engine SPN 2014-01-03 10:06:43

codes, engine stop reason and fuel consump-
Total_Fuel 0 L
tion rate.
Work_Fuel 0 L Idel_Fuel 0 L
Press F2 on the engine information menu to

enter fuel consumption menu. No. List_Time Total_Fuel
0 25.01.2014 09:50:35 0
No. List_Time Work_Fuel Idel_Fuel
1 25.01.2014 09:50:36 00
Return Next Page Last Page First Page LTDS NTDS Copy Remove
Fig. 3-77 Fuel Consumption Menu
3.3.2.5 Gearbox information menu

0 IN OUT
℃
F 1
Press F3 to enter gearbox information menu. 0.0 Bar
N
R
2
A
Gearbox parameters: 0 RPM

Hand_Brake
0.0 Km/h
indicates the gearbox oil temperature Equip_Num

0 Declutch
Product_Year 2013
indicates the gearbox oil pressure
indicates the gearbox rotation speed
indicates the driving speed

Fig. 3-78 Gearbox Information Menu
Traveling gear information:
F/N/R indicates respectively forward, neu-

tral, and reverse gear
1/2/A indicates respectively 1st gear, 2nd
gear, and auto gear
When the parking brake is applied, the at

the right of Hand_Brake would turn into .
When the machine is declutched, the at the

right of Declutch would turn into .

3.3.2.6 Hydraulic information menu

GantryL_PWM 0.0 Rec_M_PWM 0.0 1Accu_Pre
0.0 Mpa
Press F4 to enter hydraulic information menu. GantryD_PWM 0.0 Rec_P_PWM 0.0 2Accu_Pre 0.0 Mpa
GantryF_PWM 0.0 0.0 0.0

This menu displays the output value of S_Energy_DL 3Accu_Pre Mpa
lifting proportional solenoid valve, lowering GantryB_PWM 0.0 S_Energy_DR 0.0 4Accu_Pre 0.0 Mpa
proportional solenoid valve, mast forward

M_R_PWM 0.0 B/M_Speed 0.0 RPM
proportional solenoid valve, mast backward
proportional solenoid valve, energy-saving
accumulator pressure, pump motor rotation
speed, and unload pressure.
Fig. 3-79 Hydraulic Information Menu
3.3.2.7 Digital input menu

Digital_Input
Forward Spreader_Act Locked
Press F5 to enter digital input menu. Backward Spreader_Lock Unlocked
One_Shift Spreader_Unlock Seated
When a certain signal is “1” (real), the at the Two_Shift Autolock BrkOil_TH
right of the words changes into . Auto_Shift Spreader_SHL Down_Interrupt

HandBrake Spreader_SHR HYD_TH
Footbrake Spreader_EXT Safety_Bypass

HYD_FJ Spreader_RET Brake_FJ
Alarm_Reset Coolant_L GantryCheck_Sensor01
ACC_PL OilWater_J GantryCheck_Sensor02
Fig. 3-80 Digital Input Menu
3.3.2.8 Digital output menu Digital_Output
Forward_Valve HS_Lock Locked_Lamp

Backward_Valve
Press F3 on digital input menu to enter digital Spreader_Lock Unlocked_Lamp
1ST_Valve Spreader_Unlock
output menu. 2ND_Valve
Seated_Lamp
Spreader_SHL Down Valve01
3RD_Valve Spreader_SHR Down_Valve02

When a certain signal is “1” (real), the at the NULL Spreader_EXT Lift_Valve01
right of the words changes into . HandBrake Spreader_RET EneSave_Valve04
Alarm EneSave_Valve02 EneSave_Valve05
EneSave_Valve01 EneSave_Valve03 Switch_Valve01
Fig. 3-81 Digital Output Menu

3.3.2.9 Analogy information menu

Analog_Input
Press F4 on digital input menu to enter Gearbox_Pressure 0 bar G_Container 0.0 T

TURB_RPM 0 Rpm Load_Percent 0 %
analogy information menu.
Gearbox_Temp 0 ℃ Count_Lock 0
Engine_RPM 0 Rpm Running_Hour 0 H
Oil_Pressure 0 Kpa Fuel_Level 0.0 L
Coolant_Temp 0 ℃ Sys_Voltage 0.0 V
MOVE_SPEED 0.0 Km/h NUll 0.0 Mpa
Pedal_Position 0
Load_Pressure 0 Mpa
Fig. 3-82 Analogy Information Menu
3.3.2.10 Fault alarm menu Alarm_Info1

01：High_Speed 21：GPS_Locked
11：Gear_Oil_Pre_L
02：GearBox_Temp_H 22：Tilting_Protect
Press F6 to enter fault alarm menu. 12：Water_Temp_H
03：Hyd_Oil_Temp_H 13：Oil_Pre_L 23：Brak_Oil_Temp_H
04：Oil_Water_Fuel 14：Battery_Alarm 24：Height_Sensor_Err

In alarming, the at the left changes into . 05：Accu_Pre_L 25：WarmUp_Alarm
15：Safe_Bypass_Alarm
06：Water_Level_L 16：Lock_Error 26：IdleSpeed_Alarm
07：Hyd_Filter_Jam 17：Load_Over_90% 27：AccuPre_High
18：Over_Load 28：1AccuPre_High
08：Brak_Filter_Jam
09：Senser_Error 19：SYMT_Comm_Error 29：2AccuPre_High
10：Fuel_Lever_L 20：CAN_Fail_Alarm 30：3AccuPre_High
C_Alarm
Press F8 on fault alarm menu 1 to enter fault Alarm_Info2

alarm menu 2. 31：4AccuPre_High
32：Eng_Preheating
33：Preheating_Over
34：LenAng_CAN_Err
C_Alarm

Press F5 on fault alarm menu to enter current Alarms_Current

alarm menu. NO Code Alarm_Start_Times Alarm_Description
0 0 NULL
This menu displays the alarm details. 0 0 NULL
0 0 NULL
0 0 NULL
0 0 NULL
0 0 NULL
0 0 NULL
0 0 NULL
0 0 NULL
0 0 NULL
Return Next Page Last Page First Page Last Page
Fig. 3-85 Current Alarm Menu
3.3.2.11 Setting menu Password_System
Press F7 to enter password menu.
Enter in the correct password, and it is able to 0 0 0 0 0 0

display setting menu.

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. 3-87 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. 3-88 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. 3-89 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. 3-90 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. 3-91 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. 3-92 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. 3-93 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. 3-94 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. 3-95 Temperature or Paging Switch

3. Press to adjust the air volume.
Fig. 3-96 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 2 3 4 5 6
SYMC Controller
1. Breaker 5. Large current relay

2. Monopole breaker 6. SANY controller
3. Fuse protector 7. Intermediate relay
4. Intermittent relay
Fig. 3-97 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 3-4 Specifications of the Fuse
Code Fuse Function

QF1 63A Battery
QF2 63A Battery
QF3 32A Air conditioner power supply
FU1 20A Start the engine
FU2 15A Working light of machine body
FU3 15A Brake oil radiating
FU4 15A Spreader power supply
FU5 15A Spreader light switch
FU6 10A Headlight
FU7 10A Cab lighting
FU8 10A Front wiper
FU9 10A Steering indication system
FU10 10A Reversing light
FU11 10A Brake system
FU12 10A Rear light
FU13 10A Mast light
FU14 10A Width light control
FU15 10A Radio control
FU16 10A Oil radiating system
FU17 10A Power supply of spreader motion control
FU18 10A Controller power supply
FU19 10A Controller power supply
FU20 10A Gear selector
FU21 10A Fuel level signal
FU22 10A Gearbox oil pressure

Code Fuse Function

FU23 5A Alarm light
FU24 5A Spare
FU25 5A Top wiper
FU26 5A Rear wiper
FU27 5A Display
FU28 5A Distant terminal
3.7 Fire Extinguisher
There are a total two fire extinguishers in the

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

the following items:
NOTE:
• Make sure to put fire extinguishers in
cab and read carefully the instructions.
Understand its usage under emergency Fig. 3-98 Fire Extinguisher
circumstances.
• Check whether the lead wire and shell
of fire extinguisher are in good condition
daily. If damaged, change it immediately.
Check the electrical wiring of circular
fire extinguisher and change the wires if
damaged.
• Be sure that the fire extinguisher is in the
guarantee period. If the fire extinguisher
exceeds the guarantee period, you must
change it in time.
• Change the fire extinguisher at least every
two years.

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Empty Container Handler Operation
Operation
4. Operation
4.1 Before the Starting of Engine�� 4-3
4.1.1 Operator responsibility�� 4-3
4.1.2.1 Wiper water level, checking�� 4-5
4.1.2.2 Coolant level, checking�� 4-5
4.1.2.3 Engine oil level, checking�� 4-6
4.1.2.4 Transmission oil level, checking�� 4-6
4.1.2.5 Hydraulic oil level, checking�� 4-6
4.1.2.6 Fuel level, checking�� 4-7
4.1.2.7 Brake oil level, checking�� 4-8
4.1.2.8 Tyres, checking�� 4-8
4.1.2.9 Electrical components, checking�� 4-9
4.1.2.10 Working light, checking��4-10
4.1.2.11 Horn, checking��4-10
4.1.3 Adjustment before operation��4-11
4.1.3.1 Seat, adjusting��4-11
4.1.3.2 Rearview mirror, adjusting��4-13
4.1.3.3 Safety belt, adjusting��4-14
4.2 Starting the Machine��4-15
4.2.1 Start in normal weather��4-15
4.2.2 Start in cold weather��4-18
4.2.3 Start with booster batteries or starting generators��4-19
4.3 Stopping the Machine�� 4-21
4.3.1 Engine shutdown procedures�� 4-21
4.3.2 Emergency shutdown�� 4-23

Operation Empty Container Handler
4.4 Driving�� 4-24

4.4.1 How to drive�� 4-24
4.4.2 Driving forward�� 4-25
4.4.3 Driving backward�� 4-26
4.4.4 Turning around�� 4-26
4.4.5 Parking�� 4-27
4.5 Load Handling �� 4-28
4.5.1 Operation switches�� 4-28
4.5.2 Mast, operation�� 4-29
4.5.3 Spreader, operation�� 4-33
4.5.4 Load capacity diagram�� 4-36
SDCY90K6H4 container handlers�� 4-39
4.5.5 Picking up a container from a stack�� 4-40
4.5.6 Depositing a container on the stack�� 4-45
4.6 Store the Machine�� 4-50
4.6.1 Overnight storage�� 4-50
4.6.2 Short-Term Storage�� 4-50
4.6.3 Long-term storage�� 4-51
4.6.3.1 Preparations�� 4-51
4.6.3.2 During storage�� 4-52
4.6.3.3 Return to service�� 4-52
4.7 Transportation and Assembly�� 4-53
4.7.1 Guidelines�� 4-53
4.7.2 Disassembling the machine�� 4-54
4.7.2.1 Disassembling principles�� 4-54
4.7.2.2 Disassembly list �� 4-55
4.7.2.3 Hoisting points of parts�� 4-56
4.7.3 Packing requirements�� 4-59
4.7.4 Transportation�� 4-60
4.7.4.1 Transporting by platform lorry�� 4-60
4.7.4.2 Transporting by container �� 4-60

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

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

• The operator must be provided with

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

while a load is on the machine. Failure to
follow this warning could result in death,
serious injury or equipment damage.
WARNING
WARNING
Always operate the machine slowly

and cautiously, avoiding sudden, rapid
movements.
Failure to follow this warning could result
in death, serious injury, loss of control of
the machine or equipment damage.
4.1.2 Checks before operation
Every time before starting the machine or

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

4.1.2.1 Wiper water level, checking
The wiper water tank is located in front of the

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

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

1. C oolant level should be maint ained
between the MAX and MIN markings on
tank when the engine is operating. If the
coolant level is below the MIN marking, it Fig. 4-2 Expansion Water Tank
is time to fill in coolant through the filling
port (1) until it reaches the MAX marking. CAUTION
CAUTION
Tighten up the cap after filling in coolant.
Never start the machine when the coolant
2. If the tank is empty, the coolant may be
is insufficient. Never open the tank cap
leaking. Check the coolant pipelines for
(1) when the engine is running or touch it
leakage. If yes, fix the trouble immediately
within 10 minutes after the engine is turned
Top up the tank if the coolant level is low.
off. Coolant temperature and the pressure
3. Clean the expansion tank when it is too
in tank are still high even if the engine
dirty to see the level.
is stopped. Removing the cap to check
the coolant level at this time may lead to
REMARK:
personal scald.
Tank capacity: 45-48 L (9.9-10.6 gal)
Therefore, firstly loosen the cap 1/4 turn to
For detailed information, see: “Capacity of
check whether the expansion tank is under
the tanks” on page 5-18.
high pressure. If yes, open the cap after the
pressure is lower.

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

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

checking and topping up” on page 5-39.
Tank capacity: 30 - 35L (6.6-7.7 gal)
4.1.2.4 Transmission oil level, checking
Check oil level daily with engine running at

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

oil level, checking” on page 5-63.
Tank capacity: 45L (9.9 gal)
4.1.2.5 Hydraulic oil level, checking
Hydraulic oil directly determines whether the

hydraulic system would work normally. Be sure
to check the level daily.
For detailed information, see “Hydraulic oil
level, checking” on page 5-105.
Tank capacity: 535L (117.7 gal)

4.1.2.6 Fuel level, checking
WARNING
WARNING
Do not splash or outflow the fuel. Failure

to do this could result in fire hazard.
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 (1).
After the check, turn the switch back to 0 ℃
position O. 0.0 L
1
0.0 Bar
SPN 0 0 RPM
Stop_Case 0 0 H
Fuel_Rate 0 ml/h 0.0 V
Fig. 4-3 Display Menu

2. If the fuel level is low, release the cap
of filling port on fuel tank, and fill in fuel
through the filling port until oil floater
reaches its highest point.
REMARK:
Tank capacity: 350 - 410L (77-90 gal)
Fig. 4-4 Oil Filling Port of Fuel Tank

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

by level-temperature indicator mounted on
the tank. The oil level must be maintained
between the Max and Min markings. You
can also check the quality of brake oil by its
color. When the oil level is lower than the Min
marking, refill the tank up to the H marking.
Change the oil when it is necessary.
Fig. 4-5 Brake Oil Tank

REMARK:
Tank capacity: 100L (22 gal)
4.1.2.8 Tyres, checking 1
Carry out a visual inspection of the tyre. Make

sure that the rim and hub cover (1) are not
2
deformed, on 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
inspected by the maintenance personnel
before being used. 3
Tyre pressure should be 0.95-1.05 Mpa.

Fig. 4-6 Check Points of Tyre
DANGER
DANGER
A splashed lock ring or exploding tyre can

be deadly to anyone close to the tyre.
Only properly trained personnel are

allowed to serve the tyres. Failure to do
this could result in serious injury or death.
Fig. 4-7 Tyre Explosion

4.1.2.9 Electrical components, checking
Check the following electrical components:

• Check if the fuses are not blown and
conforms to the subscribed value.
• Check for open circuit or short circuit in
cables, and if the cover of cables is not
damaged.
• Check if the terminals are secure. If loose,
tighten them up.
• Also, pay particular attention to the cables
when checking the battery, engine, 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 top surface of battery clean and
check the air vent on battery cover. If it is
clogged by dirt or dust, wash the battery
cover and clean the air vent.

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

light switch.
• Check if the working light can be turned on
normally.
• Check for dirt or damage of the working
light.
• Check whether the working light is on.
• If the working light is off, maybe the bulb is
burnt out or the electricity is disconnected. Fig. 4-8 Working Light
Please contact SANY authorized
distributors to repair it.
4.1.2.11 Horn, checking
Start the machine. And press down the horn

switch.
• Check whether the horn can sound.
• Check whether the horn sound is sound.
• If the horn does not alarm or the horn
sound is abnormal, please contact SANY
authorized distributors to repair it.
Fig. 4-9 Horn

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

then release it to get it locked.
Distance: 120mm
2
3
4
4
5
4
6
Fig. 4-10 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. 4-11 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. 4-12 Handle to Adjust the Backrest
4. Adjustment of safety belt
For detailed information, see: “Safety belt,

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

becomes firm to accommodate the drivers of
large weight.
Turn this handle to right, and the suspension
becomes soft to accommodate the drivers of
5
small weight.
Weight range: 50 to 130 KG
Fig. 4-13 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. 4-14 Adjust the Seat Height

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

operation.
Failure to do this can result in injuries to

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

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

1. Rotate the rearview mirrors to a correct 1
angle.
2. If the mirror cannot move smoothly when
the angle is being adjusted, loosen the
fixing bolts of mirror and the bolts in fixing
lever of mirror.
3. Take the view of machine’s profile in mirror
as the standard while adjusting the angle
of rearview mirror.
Fig. 4-15 Rearview Mirror

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

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

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

1. Press down the button (5) on shackle (4).
2. Pull out the lock tongue (3) from the
Fig. 4-16 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 start the engine by short
circuiting the engine, because this
could result in severe personal injury or
fire disaster.
• Make sure that there is no one or no
obstacles around the machine. Then
press down the horn and start the
engine.
• Do not use the starting auxiliary liquid
that could cause explosion.
• Exhaust air is poisonous. Pay particular
attention to the ventilation while
starting engine in the closed space.
1. Insert the main power key into the main

circuit switch and turn it clockwise.
Fig. 4-17 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. 4-18 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 starter motor for longer

than 15 seconds. In case of start failure,
wait for 10 seconds between one start
attempt and another.
The ignition key should not stay at position

III for more than 10 seconds. If the engine
continuously fails to start for three times,
make sure to find out the reason and solve the
problem before attempting 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
60˚C, do not run it under high acceleration 60°c
or at full load.
0°c
- 5°c
Fig. 4-20 Temperature Gauge
The following conditions must be met to start

0 ℃
the engine.
• Observe if there is any alarm information 0.0 L
showing on the display. If there is, correct
0.0 Bar
standards.
SPN 0 RPM
• Put the gear selector in the neutral 0
position. Stop_Case 0 0 H
• Release the emergency stop button.
Fuel_Rate 0 ml/h 0.0 V
• 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
engine.
Fig. 4-21 Engine Information Menu
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. 4-22 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 to start again. If the
engine continuously fails to start for several
times, do not attempt start it again before
finding out the reason and solving the problem.
Besides, ask the maintenance personnel to
check the air intake preheating system.

4.2.3 Start with booster batteries or

starting generators
WARNING
WARNING
Booster batteries should only be connected

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

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

end and with the positive (+) terminal of the
battery on machine at the other end.
• b. Connect another jumper cable with the
negative (-) terminal of the booster battery
and with the grounding connector (the one
away from the battery) on the machine
frame at the other end. Fig. 4-23 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
batteries and/or starting generators.
Batteries can explode if a spark or flame
comes near the battery, and could result in
ANTIDOTES Recommended by Batter y

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

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

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

the gearbox and the propeller shaft.
2 3
Fig. 4-24 Brake Pedal
3. When the machine is totally still, press

down the parking switch (4), and the
parking indicator light (5) will illuminate. 5
Fig. 4-25 Parking Switch
4. Put the gear selector (1) in the neutral

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

1
2
minutes if it has been running constantly

3
1
under load.
1 2
3
1
2
3
Fig. 4-26 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 Fig. 4-28 Main Power Supply Switch
suspended. It could inadvertently lower,
possibly causing serious injury or death.
WARNING
WARNING
When the machine is loaded with tilted

mast, do not brake it suddenly. If not
avoided, this could result in injury or
possibly death.

4.3.2 Emergency shutdown

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

the arrow direction as shown in right illustration RS-1406049-1
to cancel the emergency stop.
Fig. 4-29 Emergency Stop Switch
If the emergency stop but ton has been
used twice, replace the brake lining block
immediately. Be sure to readjust it for a good
parking brake effect if the parking brake has
been separated from the machine.
NOTE:
It is prohibited to use the emergency stop
button when the brake pedal is still working
normally or in not real emergency situations.

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.
1. Adjust the operator’s seat to a comfortable

and suitable position.
F
2. Run the engine idle and select driving 1
2
N
direction and traveling gear with the gear 3
R
selector (1).
3. Release the parking brake (2), and step on 2
the accelerator pedal (3). 1 3
4. Before changing the gear, release the
accelerator pedal first, and then speed up Fig. 4-30 Driving
normally after the desired gear has been
selected.
5. Keep stepping on the accelerator pedal
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.
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
4.4.2 Driving forward

1
1. Push the gear selector (1) forward.
2. Release the parking brake (2).
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. 2
4 3
Fig. 4-31 Driving Forward

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

1
2. Step on the accelerator pedal (3) to speed
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. 4-32 Driving Backward
4.4.4 Turning around
With the help of a hydraulic assisted system,

the machine is characterized by a relatively
small turning torque.
To minimize unnecessary tyre wear, do not
the steering wheels when the machine is
stationary.
Do not continue turning the steering wheel
when it has reached its turning limit.
O t h e r w i s e , s t e e r i n g c o m p o n e n t s m ay
overheat.
WARNING
WARNING
To maintain machine stability and prevent Fig. 4-33 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
2
The parking brake switch (1) is located on the
left of front operation panel. Press the parking
brake switch (1), and the parking indicator light
(2) would be turned on.
Do not use this parking brake switch for a

short-time stop, unless in emergency. 41
If the driver leaves the seat without pressing
the parking brake switch, the machine would
give off an alarm. Fig. 4-34 Parking
NOTE:
The parking system is located on the propeller
shaft. Switch on the parking brake, and the
propeller shaft will be locked. Do not use the
parking brake to brake the machine unless in
emergency.

4.5 Load Handling
4.5.1 Operation switches
3 9
2 10
5 11
12
13
1 6
14
7
4
8 17
18
15
16
3. Spreader 4. Spreader 5. Spreader

1. Spreader locking 2. Spreader 20 feet
unlocking shifting leftward shifting rightward
8. Joystick
6. Spreader 40 feet 7. Spare switch
enable
12. Joystick on / 13. Alarm
9. Rear wiper 10. Top wiper 11. Front wiper
off resetting
14. Inner light
18. Emergency
15. Ignition key 16. Buzzer 17. Safety bypass
stop
Fig. 4-35 Joystick

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

security of machine, this container handler has
been equipped with a switch “B” at the back of
joystick and a switch “F” on the right operation B
panel.
Fig. 4-36 Enable Buttons
See the functions of enable switchs in below

table.
Table 4-1
Key Function Category

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

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

Mast, tilting forward:

2. Turn the hydraulic joystick rightward.
Fig. 4-39 Mast Tilting Forward
Mast, tilting backward:

2. Turn the hydraulic joystick leftward.
Fig. 4-40 Mast Tilting Backward

Mast, lowering in emergency
When the torque percentage of load is larger

than 100% or the mast / spreader sensor
is functioning abnormally, the mast can be
lowered in emergency following the steps
below.
1. Open the covering board at the head part

of machine.
Fig. 4-41
2. Loosen the fastening nut of one-way

throttle valve on transition valve block.
Then loosen the bolt for 2-3 turns with
inner hexagon spanner.
Fig. 4-42
3. Turn on the safety bypass and push the

joystick forward at the same time. Then the
mast can be lowered urgently.
Fig. 4-43

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. A B C
Fig. 4-44 Spreader Light

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;
When light C turns red, it indicates that the
twistlock is UNLOCKED.
Spreader, locking:
1. When the spreader is seated, light B will
turn yellow.
2. If the operator has set up the automatic
locking program, the controller will send
a locking signal and thus realize the
automatic locking of spreader. Then, light
A will turn green.
3. If the operator has not set up the automatic
locking program, spreader will be locked
and light A will turn green after the locking
switch on joystick is pressed down. Fig. 4-45 Spreader Locking Switch
Spreader, unlocking:
1. When the spreader is seated, press down
the unlocking switch and joystick enable
switch to unlock the spreader.
2. Then light C turns red and light A goes out.
WARNING
WARNING
NEVER 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
death. Fig. 4-46 Spreader Unlocking Switch

Spreader, side-shifting (leftward):

When the spreader is not seated, press down
the side-shifting switch (left), and the spreader
would shift leftward.
Fig. 4-47 Spreader Side-shifting Leftward

Spreader, side-shifting (rightward):
When the spreader is not seated, press
down the side-shifting switch (right), and the
spreader would shift rightward.
Fig. 4-48 Spreader Side-shifting Rightward

Spreader 40 feet
Press down the spreader 40 feet switch, and
the spreader would be automatically extended
for operating the container of 40 feet.
Fig. 4-49 Spreader 40 Feet
Spreader 20 feet
Press down the spreader 20 feet switch, and
the spreader would be automatically retracted
for operating the container of 20 feet.
Fig. 4-50 Spreader 20 Feet

4.5.4 Load capacity diagram
WARNING
WARNING
Overload is absolutely prohibited during

the operations, for it could result in injury
or possibly death.
This container handler 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.

4.5.4.1 Load capacity diagram

of SDCY90K8H1 / SDCY90K8H2
SDCY90K8H8A / SDCY90K8H85A container
handlers
Standard
container
Superstandard 8’6”
container
Standard
container
8’6”
Superstandard
container
Standard
container
8’6”
Superstandard
container
Standard
container
8’6”
Superstandard
container Standard
container
8’6”
Superstandard Standard
container container
8’6”
container container
8’6”
container container
8’6”
Fig. 4-51 Load Capacity Diagram 1


of SDCY90K7H1 / SDCY90K7H2
SDCY90K7H8A / SDCY90K7H85A container
handlers
Standard
container
8’6”
Superstandard
container
Standard
container
8’6”
Superstandard
container
Standard
container
8’6”
Superstandard
container
Standard
container
8’6”
Superstandard
container
Standard
container
8’6”
Superstandard
Standard
container
container
8’6”
Superstandard
container Standard
container
8’6”


of SDCY90K6H1 / SDCY90K6H2 /
SDCY90K6H3 / SDCY90K6H4 container
handlers
Superstandard
container
Superstandard
container
Superstandard
container
Superstandard
container
Superstandard
container

4.5.5 Picking up a container from a

stack
1. Approach the stack with the mast in the

vertical position.
NOTE:
The right light (red) is lit, indicating that the
spreader is unlocked.
Fig. 4-54
2. Lift the spreader and tilt the mast forward

slightly when the machine is near the
stack.
NOTE:
Fig. 4-55

3. Approach the stack slowly and lift the

spreader to the correct height for picking
up the container, making sure that the
spreader is positioned centrally with
respect to the container (take the vertical
parts of container as a guide).
NOTE:
Fig. 4-56
4. Lower the spreader and check whether

the twistlocks enter the container’s blocks
correctly.
NOTE:
Fig. 4-57

5. Proceed with the next step after confirming

that the twistlocks have entered in the
corner blocks and are seated correctly.
Otherwise, re-operate from step 4.
NOTE:
The middle light (yellow) will illuminate if the
spreader is successfully seated.
spreader is still unlocked.
Fig. 4-58
6. Lock the container, and then the right light

goes off. If not, unlock and lift the spreader.
Re-operate from step 4.
NOTE:
The left light (green) will illuminate if the
spreader is locked.
The middle light (yellow) is lit, indicating that
the spreader is seated.
Fig. 4-59

7. Lift the spreader carefully until the yellow

light goes off after confirming that the
container is locked. Then proceed with the
next step.
NOTE:
The left light (green) is lit, indicating that the
spreader is locked.
Fig. 4-60
8. Tilt the mast steadily backward.
NOTE:
spreader is locked.
Fig. 4-61

9. Make sure that no personnel or vehicle is

behind the machine. Reverse away from
the stack without steering for at least 3m
or making any sudden operations.
NOTE:
spreader is locked.
Fig. 4-62
10. Lower the mast until the container is at the

traveling position.
NOTE:
spreader is locked.
Fig. 4-63

11. Drive the machine with container to its

destination slowly without suddenly braking
the machine. The container should not
block the view of operator.
NOTE:
spreader is locked.
Fig. 4-64
4.5.6 Depositing a container on the

stack
1. Approach the stack with the mast tilted

backward.
NOTE:
spreader is locked.
WARNING
WARNING
Never lift the spreader during the locking Fig. 4-65

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

2. Lift the spreader to a proper height for

depositing the container when the machine
is near the stack.
NOTE:
spreader is locked.
Fig. 4-66
3. Move the container slowly towards the top

of stack.
NOTE:
spreader is locked.
Fig. 4-67

4. Center the container over the stack by

side-shifting the spreader and tilting the
mast forward.
NOTE:
spreader is locked.
Fig. 4-68
5. Lower the container onto the stack to make

it properly seated. Or lift the spreader
again and re-operate from step 4.
NOTE:
spreader is still locked.
The middle light (yellow) will illuminate if the
spreader is successfully seated.
Fig. 4-69

6. Unlock the twistlocks once the container

is completely seated. If one or more
twistlocks are not released, relock the
container and lift the spreader. Re-operate
from step 4.
NOTE:
The red light (green) will illuminate if the
spreader is successfully unlocked.
The middle light (yellow) is lit, indicating that
the spreader is seated.
Fig. 4-70
7. Lift the spreader carefully away from the

container until all the twistlocks are out
of the corner blocks. Or lower down the
spreader and re-operate from step 6.
NOTE:
The red light (green) is lit, indicating that the
Fig. 4-71

8. Make sure that no personnel or vehicle is

behind the machine. Reverse away from
the stack without turning for at least 3m or
making any sudden operations.
NOTE:
Fig. 4-72
9. Lower the mast until the spreader is at the

traveling position.
NOTE:
Fig. 4-73

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

surface away from people, traffic or other
machines.
2. Lower the attachment.
3. Run the engine at idle speed for 3 - 5
minutes to allow for heat dissipation.
Extend this cool-down time in hot weather.
4. Shut down the engine.
5. Remove the ignition switch when the
engine comes to a complete stop.
NOTICE
NOTICE
Always remove the ignition switch and Fig. 4-74

take it with you, even if you are leaving the
machine for only a moment. Keep it with
you to prevent unauthorized operation
of the machine. Failure to follow this
notice can cause damage to the machine,
personal property and / or the environment.
6. Close and lock the windows.

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

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

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

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

surface away from people, traffic or other
P
machines.
2. Lower the attachment completely.
3. Run the engine at idle speed for 3 - 5
minutes to allow for heat dissipation.
Extend this cool-down time in hot weather.
4. Shut down the engine.
5. Remove the ignition key when the engine
comes to a complete stop. TY-1509015-1
Fig. 4-75 Ignition Key

NOTICE
NOTICE
Always remove the ignition switch and

take it with you, even if you are leaving the
machine for only a moment. Keep it with
you to prevent unauthorized operation
of the machine. Failure to follow this
notice can cause damage to the machine,
personal property and / or the environment.
6. Close and lock the windows.

7. Exit the cab and lock the cab door.
8. Fill the fuel tank to the maximum level.
9. Apply spray lubricant to any exposed
piston rods.
10. Change the engine oil.
11. Turn the main power switch to the off TY-1509014-1
position and remove the handle.
Fig. 4-76 Main Power Switch

4.6.3.2 During storage
WARNING
WARNING
When operating the machine inside a

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

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

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

4.7 Transportation and Assembly
4.7.1 Guidelines
Empty container handler is a special type of

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

frame, mast, spreader, twistlock assembly,
cab, swinging cylinder, exhaust tail pipe and
handrails assembly. Other small parts are
packed in two or three wooden cases based
on their properties. All these parts should be
fixed and protected to avoid paint damage.
Our professional transpor ting team will

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

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

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

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

4.7.2.2 Disassembly list
Before transportation, the container handlers

should be first disassembled into several parts:
main frame (1), cab (2), mast (3), spreader (4),
twistlock assembly (5), swinging cylinder (6),
exhaust tail pipe (7) and handrail assembly (8),
etc.
7
5
2
1 8
Fig. 4-77

4.7.2.3 Hoisting points of parts
Label, hoisting point:

Please choose suitable hoisting points before
using a hoisting equipment.
NOTE:
It is the machine owner’s responsibility to
ensure all hoisting chain cables, hangers and
hook blocks are in safe condition and with
sufficient capacity rating to hoist the attached Fig. 4-78 Hoisting Point Label
load.
1. Hoisting points of main frame
There are 4 hoisting points on the main frame,

each two at both sides of machine (position 1
and position 2 in Fig. 4-79).
1 2
Fig. 4-79 Hoisting Points of Main Frame

2. Hoisting points of mast
Three are 4 hoisting points on the mast, each

two at both sides of mast (position 1, 2, 3, 4 in
Fig. 4-80).
1 3
2
4
Fig. 4-80 Hositing Points of Mast

3. Hoisting points of spreader
There are 2 hoisting points on the spreader;

each one at both sides of spreader (position 1
and position 2 in Fig. 4-81).
1
2
Fig. 4-81 Hoisting Points of Spreader
4. Hoisting points of cab

1 2 3 4
There are 4 hoisting points on the cab, all at
the top of cab (position 1, 2, 3, 4 in Fig. 4-82).
Fig. 4-82 Hoisting Points of Cab

4.7.3 Packing requirements
• Pack all the dismounted parts except main

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

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

yard by road, it can be disassembled into
several parts and bound to two platform trucks
for transportation. Weight of the parts should
not exceed load capacity of the platform
truck. Binding positions should be protected
to avoid paint damage. Load the main frame
and cab to a platform truck. Bind and pack the
mast, spreader, twistlock assembly, swinging
cylinders, exhaust tail pipe and handrail
together as the hoisting assembly. Load the
hoisting assembly and the spare parts case
together to another platform truck.
4.7.4.2 Transporting by container
If the machine is to be transferred to a distant

place by sea, a total two containers should be
prepared. Encase the main frame and cab in
a 40 feet frame container. Besides, load the
other parts such as mast, spreader in a 40
feet standard container. All the parts should be
fixed inside the containers to avoid moving.

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Empty Container Handler Maintenance
Maintenance
5. Maintenance
5.1 Scheduled Maintenance, General Information �� 5-7
5.2 Tightening Torques ��5-11
5.2.1 General tightening torques��5-11
5.2.1.1 Fastener torque value��5-11
5.2.1.2 Hydraulic coupling torque values��5-12
5.2.1.3 Tapered connections��5-12
5.2.1.4 O-ring and flange connections��5-13
5.2.1.5 Low pressure hose clamps��5-14
5.2.2 Specific tightening torques ��5-15
5.3 Recommended Fuel, Coolant and Lubricant��5-16
5.3.1 Specification��5-16
5.3.2 Capacity of the tanks��5-18
5.3.3 Hydraulic oil, description��5-19
5.3.4 Quality of hydraulic oil, check�� 5-20
5.3.5 Urea�� 5-21
5.4 Lubricating Points�� 5-22
5.4.1 Lubricant�� 5-22
5.4.2 Lubricating points of whole machine�� 5-23
5.5 Scheduled Maintenance�� 5-25
5.5.1 Maintenance every day�� 5-25

Maintenance Empty Container Handler

5.6 Engine�� 5-31
5.6.1 General engine inspection �� 5-32
5.6.1.1 Charge air pipe, checking�� 5-32
5.6.1.2 Drive belt, checking and changing (engine option VOLVO)�� 5-33
5.6.1.3 Drive belt, checking (engine option CUMMINS)�� 5-35
5.6.1.4 Drive belt, changing (engine option CUMMINS)�� 5-36
5.6.1.5 Air filter, checking�� 5-37
5.6.1.6 Air filter, cleaning�� 5-38
5.6.1.7 Engine mounting pad, checking�� 5-38
5.6.2 Lubrication system�� 5-39
5.6.2.1 Oil level, checking and topping up�� 5-39
5.6.2.2 Engine oil, changing�� 5-40
5.6.2.3 Oil filter, changing�� 5-41
5.6.3 Fuel system�� 5-42
5.6.3.1 Draining condensate, fuel system (engine option VOLVO)�� 5-42
5.6.3.2 Draining condensate, fuel system (engine option CUMMINS)�� 5-42
5.6.3.3 Fuel filter, replacing (engine option VOLVO)�� 5-43
5.6.3.4 Fuel pre-filter, changing (engine option VOLVO)�� 5-44
5.6.3.5 Fuel filter, changing (engine option CUMMINS)�� 5-45
5.6.3.6 Fuel pre-filter, changing (engine option CUMMINS) �� 5-45
5.6.3.7 Fuel system, bleeding (engine option VOLVO)�� 5-46
5.6.3.8 Fuel system, bleeding (engine option CUMMINS)�� 5-47
5.6.4 Cooling system�� 5-48
5.6.4.1 Coolant, mixing�� 5-49
5.6.4.2 Water quality�� 5-50
5.6.4.3 Coolant level, checking and topping up�� 5-50
5.6.4.4 Filling a completely empty system�� 5-51
5.6.4.5 Coolant, draining�� 5-52
5.6.4.6 Radiator, cleaning�� 5-53
5.6.4.7 Radiator fan, checking�� 5-53
5.6.4.8 Cooling system, cleaning�� 5-54
5.6.5 Air intake and exhaust system�� 5-56
5.6.5.1 Air leaks, checking �� 5-56

5.6.5.2 Turbocharger and blast pipe, checking��5-57

5.6.6 Urea filter element, changing��5-58
5.7 Transmission��5-59
5.7.1 Gearbox, function description��5-59
5.7.2 Attaching bolts of propeller shaft, checking��5-59
5.7.3 Speed sensor, checking��5-60
5.7.4 Attaching bolts and mounting pad, checking��5-60
5.7.5 Propeller shaft, lubricating��5-61
5.7.6 TE Transmission calibration��5-61
5.7.7 Transmission oil, changing��5-62
5.7.8 Transmission oil level, checking��5-63
5.7.9 Transmission oil filter, changing��5-63
5.8 Drive Axle��5-64
5.8.1 Attaching bolts of drive axle to the frame, checking��5-64
5.8.2 Attaching bolts of drive axle to the propeller shaft, checking��5-64
5.8.3 Oil leakage of drive axle and brake components, checking��5-64
5.8.4 Brake function, checking��5-66
5.8.5 Breather connector, cleaning��5-66
5.8.6 Differential oil, replacing��5-67
5.8.7 Drive axle oil, changing��5-68
5.8.8 Brake pedal, checking and adjusting��5-69
5.8.9 Parking brake pads, changing�� 5-70
5.9 Steering Axle�� 5-71
5.9.1 Daily check�� 5-71
5.9.2 Steering axle, lubricating�� 5-72
5.9.3 Steering axle components, checking�� 5-72
5.9.4 Knuckle pin, checking�� 5-72
5.9.5 Stub axle, maintaining�� 5-73
5.9.6 Steering axle cradle, checking�� 5-74
5.9.7 Steering pressure, checking�� 5-74
5.10 Tyres and rims�� 5-75
5.10.1 Tyre, description�� 5-75
5.10.2 Tyre, inflating�� 5-77
5.10.3 Tyres, checking�� 5-78
5.10.4 Drive axle tyre, removing and installing�� 5-79
5.10.4.1 Drive axle tyre, removing�� 5-79

5.10.4.2 Drive axle tyre, installing�� 5-80

5.10.5 Steering axle tyre, removing and installing�� 5-81
5.10.5.1 Steering axle tyre, removing�� 5-81
5.10.5.2 Steering axle tyre, installing�� 5-82
5.10.6 Wheel rim, description�� 5-82
5.10.7 Rim, checking�� 5-83
5.10.8 Wheel rim, installing and removing�� 5-84
5.10.8.1 Wheel rim, installing�� 5-84
5.10.8.2 Wheel rim, removing�� 5-87
5.11 Mast�� 5-88
5.11.1 Basic check�� 5-89
5.11.2 Fixed bolts, checking�� 5-89
5.11.3 Sliding blocks, checking�� 5-90
5.11.4 Chain, maintaining�� 5-91
5.11.5 Cylinder piston rod, maintaining�� 5-93
5.12 Spreader�� 5-94
5.12.1 Twistlock, lubricating�� 5-94
5.12.2 Sliding blocks of telescopic beam riser, lubricating �� 5-94
5.12.3 Sliding block between the basic beam and telescopic beam, lubricating�� 5-95
5.12.4 Sideshift cylinder bearing, lubricating�� 5-95
5.12.5 Top and bottom sideshift sliding blocks, lubricating�� 5-95
5.12.6 Sliding block, checking�� 5-96
5.12.7 Twistlock, checking�� 5-96
5.12.8 Other maintenance items of spreader�� 5-97
5.13 Air Conditioning System�� 5-98
5.13.1 General recommendations �� 5-98
5.13.2 Air conditioning, checking / performance test�� 5-99
5.13.3 Refrigerant quantity, checking ��5-100
5.13.4 Refrigerant, filling��5-101
5.13.5 Cleanness of heat-exchanger plate in evaporator and condenser, checking
��5-102
5.13.6 Leakage or lack of oil in condenser, checking��5-102
5.13.7 Radiator, cleaning��5-103
5.13.8 Maintenance table for air conditioner��5-103
5.14 Hydraulic System��5-105
5.14.1 Hydraulic oil level, checking��5-105

5.14.2 Air filter element, changing��5-105

5.14.3 Hydraulic oil, changing�� 5-106
5.14.4 Oil return filter element, replacing��5-107
5.14.5 Hydraulic oil tank, cleaning��5-108
5.14.6 Accumulator�� 5-109
5.14.6.1 Brake system accumulator, checking�� 5-109
5.14.6.2 Accumulator, charging with nitrogen gas��5-110
5.14.7 Hydraulic oil circuit, checking�� 5-111
5.14.8 Brake oil filter, changing�� 5-112
5.15 Electrical System�� 5-113
5.15.1 Battery�� 5-114
5.15.1.1 Battery, cleaning�� 5-114
5.15.1.2 Battery, checking��5-115
5.15.1.3 Battery, detecting��5-116
5.15.1.4 Battery, charging�� 5-117
5.15.1.5 Battery, using��5-120
5.15.1.6 Battery cables, checking��5-122
5.15.1.7 Battery, scheduled maintenance ��5-123
5.15.2 Fuses, changing��5-123
5.15.3 All working lights and indicators, checking ��5-124
5.15.4 Wiper, adjusting��5-124
5.15.5 Wiper, replacing��5-125
5.16 Maintenance Record List��5-126

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

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

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

Always inspect the drained oils and old filters
for signs of metal particles and impurities. Re-
port to the man in charge if any abnormality is
found in the filter or oil.

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

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

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

checking the machine or changing oils.

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

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

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

If any hydraulic components have been
replaced or removed, always bleed the air
from the system before resuming operation.
Be sure there are no 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.
SECURING OF 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 secure.

CLEANING PARTS OF THE MACHINE

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

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

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

5.2 Tightening Torques
Premature component failure could occur if

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

5.3 Recommended Fuel, Coolant

and Lubricant
Fuel, hydraulic oil, and coolant recommend

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

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

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

Recommended Oil Adherence Under Different

Temperature
Filling Position Oil Quality
°C -30 -20 -10 0 +10 +20 +30 +40 +50
°F -22 -4 +14 +32 +50 +68 +86 +104 +122
Caterpillar TO-4
DANA HR36000 series SAE 10
Allison C-4
DANA TE10 series
DANA TE14 series DEXRON-III only DEXRON III
DANA TE17 series
Drive axle Gear oil
SAE 75W-90
KESSLER series API GL-5 SAE 80W-90
SAE 85W-140
Hydraulic system Hydraulic oil
ISO-L HV32
ISO 6743-4 ISO-L HV46
ISO-L HV68
Brake system Hydraulic oil
Travel brake and outer HV(94%) +

ISO-L HV 32 / 46 / 68 or 5W-30
cooling system only LZ9990A(6%)
Light diesel for vehicle meeting EN590 or GB/ T 19147 standard. It is

Fuel recommended to use 0# diesel in summer and -35# diesel in winter. Machine
equipped with stage IV engines should apply ultra-low sulfur diesel.
Grease 2# or general lithium-based grease
Anti-freezing fluid of ethylene glycol or propylene glycol (For the information of
Engine coolant mixing proportion, see: “Coolant, mixing” on page 5-40.). VOLVO engines
adopt the VOLVO anti-freezing fluid VCS.
Freezing oil (air
PAG100
conditioning system)
Cooling oil (drive axle
Transmission oil Donax TD 5W-30
brake system)
Refrigerant (air
R134a
conditioning system)
Urea (Stage IV engines
AUS32 specific urea solution meeting ISO 22241-1 standard only
only)
NOTE:
* If the friction disc contains graphite, do not
use this oil.
DEXRON is the regristed brand of US GM
Co., LTD

5.3.2 Capacity of the tanks
Table 5-10 Oil Capacity Table
Items Capacities (unit: L/gal)

Hydraulic oil tank 535 L (117.7 gal)
Fuel tank 350-410 L (77-90 gal)
Brake oil tank 100 L (22 gal)
Engine oil 30-35 L (6.6-7.7 gal)
Engine coolant 45-48 L (9.9-10.6 gal)
Gearbox and torque converter 45 L (9.9 gal)
Main reducer of drive axle 50-55 L (11-12 gal)
Hub reduction 3.2 L (0.7 gal)
Values in the above table are only used for

reference.
Oil level indicator is installed on the side of oil
tank for oil level checking.

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

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

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

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

quality on the spot:
Table 5-11 Evaluation Method of Oil Quality
Color Odor Pollution Status Measures

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

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

5.3.5 Urea
Vehicle urea solution is colorless, transparent,

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

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

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

should avoid the long-term storage as far
as possible. Besides, it is better not to store
the urea solution in the environment whose
temperature is higher than 25°C.
Table 5-12
Urea Storage
Temperature (°C) Storage term (month)

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

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

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

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
and apply grease on the contact surface of
sliding block.

5.4.2 Lubricating points of whole

machine
The movable connecting shafts, mast and

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

Table 5-13 Lubricating Points of Whole Machine (Corresponded to Fig. 5-6)
No. Position Oil change intervals

1 Transmission case (1 point)
2 Hub reduction of drive axle (2 points) Every 1000 hours or 1 year
3 Differential mechanism of drive axle (1 point)
4 Connection between mast and frame (2 points)
Lower roller and sliding block (decided by the mast
5
type)
Connection between mast and tilt cylinder (2 Every 60 hours or weekly
6
points)
7 Upper chain wheel of lifting cylinder (2 points)
8 Guide rail (all the surfaces)
9 Diesel engine (1 point) Every 250 hours
10 Radiator (1 point) Every 1000 hours or 1 year
Connection between tilt cylinder and frame (2
11
points)
12 Steering axle (13 points)
13 Wheel hub (2 points)
14 Inner mast (1 point)
Every 60 hours or weekly
15 Chain (all the chains)
16 Spreader roller (4 points)
17 Support lug of spreader cylinder (3 points)
18 Sideshift surface of spreader (4 points)
19 Propeller shaft (3 points)
20 Hydraulic oil tank (1 point) Every 2000 hours or 1 year
21 Brake oil tank (1 point) Every 500 hours or half year

5.5 Scheduled Maintenance
5.5.1 Maintenance every day

Table 5-14
System Maintenance Item Reference
Check for coolant and engine oil leaks. null
See “Drive belt, checking” on page 5-33
Check the drive belt.
and page 5-35
Check the air filter indicator. See “Air filter, checking” on page 5-37
S e e “C o o l a n t l eve l , c h e c k i n g a n d
Engine Check the coolant level.
topping up” on page 5-50
See “Oil level, checking and topping
Check the engine oil level.
up” on page 5-39
Check the fuel level. See “Fuel level, checking” on page 4-8
Check the engine radiator. null
Check the gearbox for oil leaks. null
See “Attaching bolts of propeller shaft,
Check the attaching bolts of propeller shaft.
checking” on page 5-59
Transmission Check if the attaching bolts and mounting pad See “Attaching bolts and mounting pad,
is loosened. checking” on page 5-60
See “Transmission oil level, checking”
Check the transmission oil level.
on page 5-63
Steering Axle Check and tighten the hub bolts. null
Check the mast. See “Basic check” on page 5-89
Mast system
Check the fixed bolts of mast. See “Fixed bolts, checking” on page 5-89
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 5-124
System
Clean the battery. null
Check the tyre pressure. See “Tyre, inflating” on page 5-77
Check the movements of emergency stop
null
Others device.
Check the overload control system. null
Fill in lubricants. null

5.5.2 Maintenance every 50 hours
Table 5-15

Check the drive axle and brake components See “Oil leakage of drive axle and brake
for oil leakage. components, checking” on page 5-64
Drive Axle
See “Breather connector, cleaning” on
Clean the breather connector.
page 5-66
See “Steering axle, lubricating” on page
Steering Axle Lubricate the steering axle.
5-72
See “Sliding blocks, checking” on page
Check the sliding blocks of mast.
Mast System 5-90
Check the mast chain. See “Chain, maintaining” on page 5-91
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 5-99
See “Refrigerant quantity, checking” on
Check the quantity of refrigerant.
page 5-100
Check the pipeline. null
Check the cables. null
Check if the fixing bolts of air compressor
Air null
are tightened.
Conditioning
Check if the fixing bolts of air conditioner are
System null
tightened.
See “Leakage or lack of oil in condenser,
Check the air condenser for oil leakge.
See “Cleanness of heat-exchanger plate
Check the cleanness of heat-exchanger
in evaporator and condenser, checking”
plate.
on page 5-102
Check the filter screen of evaporator. null

Table 5-16
Clean the engine surface. null

Clean the air filter. See “Air filter, cleaning” on page 5-38
Check the air intake system and exhaust
null
Engine system for leaks.
Replace the engine oil. See “Engine oil, changing” on page 5-40
Replace the engine oil filter. See “Oil filter, changing” on page 5-41
Replace the coolant filter. null
Check the attaching bolts of drive axle to See “Attaching bolts of drive axle to frame,
frame. checking” on page 5-64
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
propeller shaft. propeller shaft, checking” on page 5-64
See “Brake pedal, checking and adjusting”
Check and adjust the brake pedal.
on page 5-69
Check if the steering shaft is worn. null
Check the knuckle pin. See “Knuckle pin, checking” on page 5-73
Steering Axle Check the stub axle. See “Stub axle, maintaining” on page 5-74
See “Steering pressure, checking” on page
Check the steering pressure.
5-75
Air Fill the refrigerant. See “Refrigerant, filling” on page 5-101
Conditioning
Clean the radiator. See “Radiator, cleaning” on page 5-103
System
Hydraulic See “Hydraulic oil level, checking” on page
Check the hydraulic oil level.
System 5-105
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 5-117
Check and adjust the wiper. See “Wiper, adjusting” on page 5-124
Check if the lubrication system is working
Others null
normally.

Table 5-17
Check the charge-air pipes. See “Charge air pipes, checking” on page 5-32
Clean the ventilation pipe of crankcase. null
Engine Replace the air filter. null
Bleed the fuel system. See “Fuel system, bleeding” on page 5-46
Adjust the valve. null
Check the speed sensor. See “Speed sensor, checking” on page 5-60
Check and lubricate the propeller shaft. See “Propeller shaft, lubricating” on page 5-61
Transmission
See “Transmission oil filter, changing” on page
Replace the transmission oil filter.
5-63
Check and tighten the bolts. null
See “Steeing axle components, checking” on
Check the steering axle components.
Steering Axle page 5-73
See “Steering axle cradle, checking” on page
Check the steering axle cradle.
5-74
Inflate the tyre. See “Tyre, inflating” on page 5-77
Tyre System
Check the rim. null
Lubricate the twistlock. See “Twistlock, lubricating” on page 5-94
Lubricate the sliding blocks of telescopic See “Sliding blocks of telescopic beam riser,
beam riser. lubricating” on page 5-94
Lubricate the sliding blocks between the See “Sliding block between the basic beam
basic beam and telescopic beam. and telescopic beam, lubricating” on page 5-95
Spreader
See “Sideshift cylinder bearing, lubricating”
System Lubricate the sideshift cylinder bearing.
on page 5-95
Lubricate the top and bottom sideshift See “Top and bottom sideshift sliding blocks,
sliding blocks. lubricating” on page 5-95
Check the nylon sliding blocks. See “Sliding block, checking” on page 5-96
Check the twistlock. See “Twistlock, checking” on page 5-96
Check the oil pipes and suppor ting
null
bracket.
See “Air filter element, changing” on page
Hydraulic Replace the air filter.
5-105
System See “Oil return filter element, replacing” on
Replace the oil return filter element.
page 5-107
Replace the brake oil filter and brake oil. See “Brake oil filter, changing” on page 5-112
Check the harness of cab steering
null
Electrical mechanism for abnormality.
System Check the cables. See “Battery cables, checking” on page 5-122
Replace the fuses. See “Fuses, changing” on page 5-123

Table 5-18

See “Fuel filter, replacing” on page 5-43 and
Replace the fuel filter.
page 5-45
Engine
See “Fuel pre-filter, replacing” on page 5-44
Replace the fuel pre-filter.
and page 5-46
Transmission Replace the transmission oil. See “Transmission oil, changing” on page 5-62
Check the manual brake function. See “Brake function, checking” on page 5-66
Drive Axle Check and replace the differential oil. See “Differential oil, replacing” on page 5-67
Check and replace the drive axle oil. See “Drive axle oil, changing” on page 5-68
Others Clean the whole machine. null
5.5.6 Maintenance 1500 hours
Table 5-19

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 5-111

Table 5-20

Test the diesel. null
See “Drive belt, changing” on page 5-33 and
Change the drive belt.
page 5-36
Engine
Clean the radiator. See “Radiator, cleaning” on page 5-53
See “Turbocharger and blast pipe, checking”
Check the turbocharger.
on page 5-57
See “TE transmission calibration” on page
Calibrate the TE transmission.
Transmission 5-61
Test the transmission oil. null
Replace the hydraulic oil. See “Hydraulic oil, changing” on page 5-106
Hydraulic
See “Hydraulic oil tank, cleaning” on page
System Clean the oil tank.
5-108
Electrical
Replace the wiper. See “Wiper, replacing” on page 5-125
System
Clean fuel tank of possible impurities null
Others
Test the brake system pressure. null
Table 5-21

See “Filling a completely empty system” on
Replace the coolant.
page 5-51 and “Coolant, draining” on page 5-52
Clean the cooling system. See “Cooling system, cleaning” on page 5-39
Clean and adjust the fuel injection pump. null
Clean and adjust the engine fuel injector. null
Engine
Check the water pump. null
Check the radiator fan. See “Radiator fan, checking” on page 5-53
Check the fan hub. See “Fan hub, checking” on page 5-40
See “Engine mounting pad, checking” on page
Check the engine mounting pad.
5-38
See “Wheel rim, installing and removing” on
Replace the wheel rim.
page 5-84
Tyre See “Drive axle yre, removing and installing”
Replace the tyre of drive axle.
System on page 5-79
S e e “ S t e e r i n g a x l e t y r e , r e m ov i n g a n d
Replace the tyre of steering axle.
installing” on page 5-81

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. 5-7 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.
5.6.1.1 Charge air pipe, checking
Inspect the condition of the charge air pipe,

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

5.6.1.2 Drive belt, checking and changing

(engine option VOLVO)
CAUTION
CAUTION
Pinch hazard. Keep fingers clear.
NOTE:
Always change a belt that is oily, worn or
damaged.
Check
Check the drive belt after operation, when the

belt is hot. It should be possible to depress the
drive belt about 3-4 mm (0.12–0.16") between
the pulleys. The drive belt has an automatic
belt tensioner and therefore does not need to
be adjusted.
Replacement
1. Remove the right belt guard.
Fig. 5-9

2. Undo the belt tensioner and restrain it with

a mandrel. Remove the old drive belt.
Fig. 5-10
3. Fit the new drive belt.

4. Remove the mandrel restraining the belt
tensioner.
5. Re-install the belt guards.
6. Check that the belts are correctly aligned in
their grooves and are correctly tensioned.
It should be possible to depress the drive
belt about 3-4 mm (0.12–0.16”) between
the pulleys.
Fig. 5-11

5.6.1.3 Drive belt, checking (engine option

CUMMINS)
Check drive belt every day. If the belt is worn

or cracked, be sure to replace it. Tiny cracks
along the width direction of belt are allowed.
Cracks along its length direction are not
allowed. The belt of sleek and lucent surface is
slippery, adjust the slippery belt immediately.
The damage of belt may be caused by the

following reasons:
• Incorrect tension
• Incorrect belt length
Fig. 5-12
• No aligning belt wheel
• Incorrect installation
• Bad working environment
• Oil or grease on the belt

5.6.1.4 Drive belt, changing (engine option

CUMMINS)
1. Lift up the belt tensioner to remove the

drive belt.
NOTE:
The belt tensioner is tensioned in the direction
that the springs are bent over the tensioner
arm. To reduce the tension on the belt, rotate
the tensioner in order to tighten the springs
more firmly.
Fig. 5-13
NOTICE
NOTICE
Do not use excessive force in either

the winding direction or in the opposite
direction. After the tensioner has been
wound to its positive stop, continued
winding can case the belt tensioner to
break.
2. Lift up the belt tensioner and install the

drive belt. If it is difficult to install the drive
belt (the belt seems too short), first place
the belt in the grooved belt pulley. Then
continue to hold up the belt tensioner and
pry the belt over the coolant pump’s belt
pulley.
3. Loosen the belt tensioner and check that
the belt is sitting correctly in the grooves
and is correctly tensioned.

5.6.1.5 Air filter, checking
NOTE:
• T h e m a i nte n a n c e a n d r e p l a c e m e nt
intervals is just for reference.
• The service life of filter core is within 200
working hours (working in desert) and
1600 working hours (on clean ground).
• Replace the main filter every 800 working
hours.
• Replace the filter at least a year under any
circumstances. Replace a worn, bent or Fig. 5-14 Air Filter Indicator
damaged filter immediately.
The engine is equipped with electronic air filter

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

following steps: 1
1. Loosen the cover clamp (2). 3
2. Remove the filter core cover (3).
3. Drag out the filter core (1) and clean it
(For detailed information, see: “Air filter, 1. Filter core 2. Cover clamp 3. Cover
cleaning” on page 5-38. Fig. 5-15 Air Filter of Machine Equipped with
Stage III engine
NOTE:
Pay attention not to let dust into the filter seat
(or filter net, if installed) when cleaning the
filter core.
Fig. 5-16 Air Filter of Machine Equipped with

Stage IV engine

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

air.
2. Pressurize the air to 3 Bar. Put the nozzle
at 5 cm around the filter element and start Fig. 5-17 Cleaning Air Filter
to clean it from the inner to the outer.
3. Never knock the filter element with the
hard surface of nozzle.
NOTE:
Never clean the filter element for more than 6
times. If done, replace it.
5.6.1.7 Engine mounting pad, checking
Functions of engine mounting pad:

• Fix the engine on the frame
• Reduce the shock when the engine is
started, running and stopped.
NOTICE
NOTICE
Silicone oil in the engine mounting pad 1
would turn solid if it is used for a long time.
Thus the ineffectiveness of the engine 1
mounting pad would occur, and result
in serious engine fault or transmission Fig. 5-18 Engine Mounting Pad
malfunction.
• Check whether the silicone oil in engine

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

5.6.2 Lubrication system
5.6.2.1 Oil level, checking and topping up
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.
MAX
Steps to check engine oil level: MIN
1. Open the engine bonnet.

2. Take the dipstick out and wipe away the oil
Fig. 5-19 Check Engine Oil Level (VOLVO
on it.
engine)
3. Plug the whole dipstick in oil tank and then
take it out.
4. The oil level must be maintained between
the MAX and MIN markings. If it is below
the MIN marking, fill in oil through the filling
port.
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.
5. If the oil level is proper, tighten up the cap

of filling port and close the engine bonnet. 2
1
REMARK:
Tank capacity: 30-35 L (6.6-7.7 gal) 1. Dipstick
2. Filling port
Fig. 5-20 Check Engine Oil Level (CUMMINS
engine)

5.6.2.2 Engine oil, changing
Keep an eye on the engine oil volume

while filling the oil. High engine oil level will
cause foam, thus decreasing the lubrication
effect. And low level means that engine oil
is insufficient for running through the whole
lubrication system.
CAUTION
CAUTION
Hot oil and hot surfaces can cause burns.

Always follow the recommended oil change
interval and always change the oil filter in
connection with oil changes.
1. Run the engine until warm.

2. Remove the drain plug. Drain the oil.
NOTE:
Collect the old oil and old filters and hand
them to a re-cycling station.
3. Install the drain plug with a new gasket.

4. Change the oil filter, refer to “Oil filter,
changing” on page 5-41.
5. Fill oil to the correct level, refer to “Oil
level, checking and topping up” on page
5-39.
NOTE: Fig. 5-21 Drain plug

Do not fill above the MAX level.
6. Start the engine and let it idle. Check that

the oil pressure is normal.
7. Stop the engine. Check that there is no
oil leakage around the filters. Check the
oil level and top up with oil as necessary.
Refer to “Oil level, checking and topping
up” on page 5-39.

5.6.2.3 Oil filter, changing
CAUTION
CAUTION
Hot oil and hot surfaces can cause burns.

Always follow the recommended oil change
intervals.
Always change the oil filter at the same
time as the oil change.
Removal
1. Drain the oil according to the instructions
in “Engine oil, changing” on page 5-40.
NOTE:
Place a collection vessel underneath the filter
to avoid oil spillage.
2. Clean around the oil filter.

3. Carefully remove the filter cover together
with the filter
4. Remove the O-ring and filter from the
cover.
5. Let the oil drip off into a collection vessel.
Installation
1. Lubricate the new O-ring and the gasket of
the new filter before installation.
2. Install the new filter and new O-ring in the
Fig. 5-22 Change Oil Filter (VOLVO engine)
filter cover. Make sure the filter is correct
installed in the cover.
3. Install the filter cover and filter in the
bracket. Tighten the cover to: 40 Nm (29.5
lbf.ft.)
4. Fill with required volume of oil; refer to
“Engine oil, changing” on page 5-40.
5. Start the engine and check that there is no
oil leakage from the oil filter or drain plug.
6. Switch the engine off and check the oil
level after a few minutes. Top up with oil as
necessary.
Fig. 5-23 Change Oil Filter (CUMMINS engine)

5.6.3 Fuel system
5.6.3.1 Draining condensate, fuel system

(engine option VOLVO)
1. Stop the engine and close the fuel tap.

2. Put a collection vessel under the fuel pre-
filter to collect the condensate and fuel.
3. Open the drain plug (1) at the bottom of the
water separator (2).
4. Drain the water contained in the water
separator into the collection vessel.
NOTE: 2
Do not drain the water separator completely.
1
5. Tighten the drain plug and open the fuel

tap.
6. Start the engine and check there is no fuel
leakage from water separator. Fig. 5-24
5.6.3.2 Draining condensate, fuel system

(engine option CUMMINS)
1. Open the drain plug and drain fuel / water.
NOTICE
NOTICE
Do not over-tighten the drain plug, as the
threads may be damaged.
2. Close the drain plug by pushing the nipple

up and tightening it by hand. Bleed the fuel
system. Fig. 5-25
3. Start the engine and check sealing.

5.6.3.3 Fuel filter, replacing (engine option

VOLVO)
NOTICE
NOTICE
Risk of material damage. Use only a fuel

filter approved by the manufacturer. The
wrong type of fuel filter may damage the
fuel injection circuit.
NOTE:
Working with the fuel system requests special
cleanliness.
Removal
1. Clean around the filter cover and housing.
2. Carefully remove the fuel filter cover and
filter.
NOTE:
Be prepared to gather up fluid. The filter is still Fig. 5-26
full of fuel and there is a risk of spillage when
the cover is removed.
3. Remove the O-ring and filter. Let the fuel

drip off into a collection vessel.
Installation
1. If the new filter housing is completely
empty, lubricate with diesel around the
inner section of the filter sealing surface.
2. Lubricate the O-ring with diesel before
installing the filter cover.
3. Install the filter in the filter cover. Make
sure the filter seats properly in the cover.
4. Install the filter cover and filter in the
bracket. Carefully screw in the cover and
check that the Oring does not get twisted.
Re - lubric ate the seal as nec essar y.
Tighten the cover to: 25 Nm (18.4 lbf. ft.)
5. Bleed the fuel system according to “Fuel
system, bleeding” on page 5-46.
6. Start and warm up the engine. Check that
no leakage occurs.

5.6.3.4 Fuel pre-filter, changing (engine

option VOLVO)
CAUTION
CAUTION
Always use protective gloves for work

which includes contact with oil, fuel etc.
Otherwise, personal injuries may occur.
NOTE:
Put a collection vessel under the fuel filter 4
to collect the condensate and fuel. Store the
used filter in a suitable container.
3
Removal
1. Undo the cable (1) from the water trap
sensor.
2. Clean thoroughly around the pre-fuel filter 2
and water separator 1
3. Open the drain plug (2) in the base of the
fuel prefilter and drain the filter. Fig. 5-27
4. Tighten the drain plug again.
5. Remove the fuel pre-filter (4) and seal
together with the lower section of the
water separator (3). Put the used filter in a
suitable container.
6. Clean the lower section of the water
separator and the contact surfaces.
Installation
1. Clean the seal surfaces thoroughly and
lubricate the gasket with diesel.
2. Lubricate the new O-ring with diesel and
install the lower part of the water separator
to the new filter.
3. Screw the filter onto the filter bracket by
hand until the rubber seal bottoms on the
mating surface. Then tighten a further 1/2–
2/3 turns.
4. Connect the cable from the water trap
sensor.
5. Open fuel taps and purge the system.
6. Start the engine and check that no leakage
Fig. 5-28
occurs.

5.6.3.5 Fuel filter, changing (engine option

CUMMINS)
1. Remove the fuel filter.

2. Clean the filter’s contact face on the filter
bracket.
3. Moisten the O-ring on the new filter with
fuel.
NOTICE
NOTICE
Do not fill the new fuel filter with fuel before

installing. There is a risk that impurities
might get into the fuel system and cause
malfunction or damage.
Fig. 5-29
4. Install the new filter on the engine. Screw

on the fuel filter until it makes contact with
the contact face. Then tighten a further 3/4
turn.
5. When needed, bleed the fuel system.
5.6.3.6 Fuel pre-filter, changing (engine

option CUMMINS)
1. Open the drain plug and drain any water.

2. Remove the filter.
3. Check that the new filter is absolutely
clean and that the gasket is intact. Brush a
little oil on the gasket.
4. Screw the filter onto the filter bracket.
5. Bleed the fuel system.
Fig. 5-30

5.6.3.7 Fuel system, bleeding (engine

option VOLVO)
The system does not need to be purged unless

it has been run completely dry. Bleeding is
then done with the hand pump on the fuel filter
bracket.
NOTE:
Put a collection vessel under the fuel filter to
collect the condensate and fuel.
1. Remove the protective cap on the bleeder

nipple.
2. Loosen the nipple, at least two turns.
Fig. 5-31
3. Connect a transparent hose to the nipple.

Feed the hose to the collection vessel to
avoid spillage.
4. Tighten the bleeder nipple while fuel is
flowing out.
5. Remove the hose.
6. Tightening the bleeder nipple with torque
3.5 Nm.
Fig. 5-32

7. Bleed the fuel system by pump up fuel with

the hand pump (2) until air-free fuel flows
out. Pump rapidly, to maintain pressure in
the pump.
NOTE:
Bleeding is not complete while resistance is
felt in the pump.
8. Wait 15 seconds and then repeat step 7.

9. Fit the protective cap on the bleeding
nipple.
Fig. 5-33
5.6.3.8 Fuel system, bleeding (engine

option CUMMINS)
The fuel system must be bled after fuel filter

replacement, if the fuel tank has been run dry
or after long periods of operation for example.
1. Open the air bleeder screw.

2. Turn the hand pump anticlockwise to open
the pump.
3. Pump until the fuel is completely free of air
bubbles.
4. Tighten the air bleeder screw and close Fig. 5-34
the fuel hand pump.

5.6.4 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.

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

and ecologically damaging. Shall not be
consumed!
Glycol is flammable.
Ethylene glycol should not be mixed with
other types of glycol.
Mix: Fig. 5-35 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 5-50.
• It is extremely important that the correct
concentration of coolant is added to the
system. Mix them in a separate clean
vessel before filling the cooling system.
Make sure that the liquids mix.
NOTE:
VOLVO engine adopts the VOLVO anti-
freezing fluid VCS which does not need to be
mixed.

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

Total hardness .................................... < 9.5° dH
Chloride ............................................... < 40 ppm
Sulfate ............................................... < 100 ppm
pH value ................................................. 5.5-9
Silica (acc. to ASTM D859) ..... < 20 mg SiO2/l
Iron (acc. to ASTM D1068) ........... < 0.10 ppm
Manganese (acc. to ASTM D858) ...... < 0.05
ppm
Conductivity (acc. to ASTM D1125) ....< 500
Fig. 5-36 Water
μS/cm
Organic content, CODMn (acc. ISO8467) ......
< 15 mg KMnO4/l
5.6.4.3 Coolant level, checking and topping

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

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

engine stopped. Check the coolant level daily
before starting.
Fig. 5-37 Check Coolant Level
1. Open the filler cap (1).

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

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

2. Open filler cap (1).
3. Fill with coolant, so that the level is
between the MIN and MAX marks. Fill
slowly, to allow air to flow out.
Fig. 5-38 Filler
NOTE:
Do not start the engine until the system is
completely filled and bled.
4. Start the engine when the cooling system

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

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

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

2. Remove the filler cap (1).
3. Open all drain points. Drain the coolant
from the radiator and engine block, using
the drain hose. The drain plugs are
situated under the radiator on the right side
of the engine block.
Fig. 5-39 Filler Cap
4. 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
and cause damage due to freezing.
5. Check whether the installation has any
further taps or plugs at the lowest points of
the cooling water pipes.
6. 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.

5.6.4.6 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 Fig. 5-40 Radiator
parts for damage. If necessary, replace it.
NOTICE
NOTICE
Never flush the radiator with high-pressure
water. Or the radiator may be damaged.
5.6.4.7 Radiator fan, checking

1
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.
Damaged or bent fan blades c a n n o t 2
function normally, even resulting in
personal injuries or property loss.
1. Check the radiator fan everyday. Fig. 5-41 Radiator Fan

2. Check if the fan blade (1) is cracked, if the
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).

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

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

information, see: “Coolant, draining” on
page 5-52.
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
5-49 and “Filling a completely empty
system” on page 5-51.

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

pipe or damaged / loose clamp in the inlet
pipeline.
2. If necessary, replace the damaged pipe
and tighten all loose clamps to ensure that
the air intake system is sealed.
Torque: 8 N.m
3. Check if the air intake pipeline is not Fig. 5-42 Inlet Pipe
corroded, because it will lead to the
corrosive materials and dir t into inlet
system.
4. Dismantle if necessary and clean the air
intake pipeline.
Noise can be created due to the air leaking

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

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

the engine to avoid impurities and scraps
into engine. If the inlet pipe is damaged or
loose, infilterd air will enter into the engine
and lead to early wear or failure of engine.

5.6.5.2 Turbocharger and blast pipe,

checking
Before starting the engine, check if there is

leakage of oil pipes in the turbocharger and of
all the blast pipe connectors. If yes, replace all
the damaged sealing ring, connecting pipes
and couplings where the leakage occurs. If
the ventilation hole in crankcase is blocked,
increasing pressure will lead to the entrance
of oil into the air-intake system of turbocharger
and engine.
Fig. 5-43
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 king pin of turbocharger can
rotate freely.
4. If any problem occurs, please contact
SANY to repair it.

5.6.6 Urea filter element, changing
1. Use a 27mm spanner to unscrew the urea

filter cover (1).
2. Take out the filter balance tube (2). 3
3. Take out the used filter element(3) and plug 2
the new one into the urea supply module. 1
4. Tighten up the filter cover again after
changing the filter element with a torque of
20 n.m [177 in-lb].
NOTE:
Fig. 5-44
1. Check if the inner screw thread of filter
cover is damaged when changing the filter
element. If yes, replace it with a new filter
cover.
2. It is unnecessary to seal the urea filter
cover with O-rings.
3. Change the urea filter element every 4500
hours.
CAUTION
CAUTION
Never let the urea inject into your eyes,

otherwise you may get you hurt. In this
case, rinse your eyes with water for 15
minutes.

5.7 Transmission
5.7.1 Gearbox, function description

Gearbox converts the engine power to drive
axle via the propeller shaft and also the power
to drive hydraulic oil pumps for hydraulic
system and brake system.
The gearbox is fully automatic with torque

converter. It has four forward gears and four
reverse gears.
NOTICE
NOTICE
High modulation (that is, soft operation /

intensive slipping between gear positions)
results in high gearbox wear and high oil
temperature.
NOTE:
• The sensor for oil temperature generates
a warning when the oil gets warmer than
100 °C.
• If the oil temperature sensor indicates 125
°C, the gearbox declutches.
5.7.2 Attaching bolts of propeller shaft,

checking
Loose bolts will easily rupture under load and

vibration. Fixed bolts of propeller shaft should
be checked carefully before torque force is
transmitted.
1. Check if the attaching bolts of propeller

shaft are secure; TY-1405119-1
Fig. 5-45 Attaching Bolts of Propeller Shaft

2. Check if the universal joint bearing is in

good condition;
3. Tighten the loose bolts of propeller shaft

with a torque of 65 N.m.
TY-1405120-1
Fig. 5-46 Universal Joint
5.7.3 Speed sensor, checking
Speed sensor is located at the connecting

parts between gearbox and propeller shaft (4).
Check if the speed sensor (3) or its bearing is 1
2
damaged to ensure that speed signals of the
machine can be transmitted to relative control
system exactly. Thus, steering can be carried
out only in low speed, and transmission device TY-1405123-1
can be protected. Fig. 5-47 Speed Sensor
5.7.4 Attaching bolts and mounting pad,

checking
1
Functions of mounting pad 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 mounting pad (2) and
damping pad (1);
• if bolts are tight.
2
Fig. 5-48 Attaching Bolts and Mounting Pad

5.7.5 Propeller shaft, lubricating
1. Inject the grease into lubrication points (see

arrow in Fig. 5-49) 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.
NOTE:
Manually lubricate the propeller shaft even
if the machine is equipped with a central Fig. 5-49
lubrication system.
DANGER
DANGER
Always turn off the engine before operating

Never touch a running propeller shaft, or
serious injuries even death could occur.
Fig. 5-50
5.7.6 TE Transmission calibration
Apart from calibrating the analog input signals,

the TCON.H f ir mware also c ontains an
automatic transmission calibration procedure,
which is able to optimize the shift quality of the
transmission. An automatic calibration has to
be done:
• When the machine is built at the OEM
• When an overhaul of the transmission is
done
• When the transmission is repaired
• When the TCON.H is replaced
• Recommended after each 2000 hours
dr i v i n g i n g e a r (f o r wa r d o r r eve r s e
selected)

5.7.7 Transmission oil, changing
1. Let the engine run idle.

2. Check the transmission oil level. For
detailed information, see: “Transmission
oil level, checking” on page 5- 63. If
necessary, fill transmission oil through the
oil filler (1).
NOTE: 1
• Wipe off the dipstick before checking.
• The oil dipstick is long. Use gloves.
Fig. 5-51 Change Transmission oil 1
• Make sure that the drain plug’s washer
seal is also removed.
• Place a container under the drain plug to
receive the drained oil.
3. Remove the drain plug (2) for transmission

oil and let the oil drain into the container.
4. Check the transmission oil prefilter (3).
If the filter core is damaged, replace it
immediately.
5. When the transmission oil has drained,
fit the drain plug (2). Make sure that the
3
washer for the oil plug is included.
6. Remove the gearbox dipstick and fill new
transmission oil through the dipstick’s hole 2
to the correct level.
7. Turn on the main electric power and start Fig. 5-52 Change Transmission oil 2
the engine. Let the engine run idle for at
least two minutes.
8. Check the transmission oil level with the
engine running at idle and top up to the
marking for correct level.
9. Check the drain plug’s sealing.
10. Operate and warm up the gearbox until the
operating menu shows oil temperatures
between 60-65 ℃ .
11. Let t h e e n g i n e r u n i d l e. C h e c k t h e
transmission oil level.

5.7.8 Transmission oil level, checking
The oil level must be maintained between the

H and L markings. The oil level should be at
the H marking.
1. Check the oil level with the engine at
idle, gearbox in neutral position and at
operating temperature (approx. 60-65 °C).
2. Fill transmission oil if needed. (Tank
capacity: 45 L [9.9 gal] )
3. I t i s r e c o m m e n d e d t h a t t h e o i l b e
filled when the gearbox is at operating
temperature. Fill----wait a moment----
check the oil level with dipstick.
NOTICE
NOTICE
Work carefully when filling transmission
oil to prevent other fluids or particles from
contaminating the oil, which means risk of
gearbox damage.
5.7.9 Transmission oil filter, changing

NOTE:
The gearbox does not need to be emptied of
oil before the filter is changed.
If the transmission oil is to be changed,
change the transmission oil before starting the
engine.
1. Park the machine in service position.
2. Remove the oil filter with the filter tool.
3. Lubricate the O-ring on the new oil filter
with transmission oil.
4. Install the new filter on the gearbox.
Tighten to contact and then another 2 / 3
turn.
5. Turn on the main electric power and start Fig. 5-53 Transmission oil Filter
the engine. Let the engine run at idle.
6. Check the transmission oil filter’s sealing.
7. Check the transmission oil level, see
“Transmission oil level, checking” on
page 5-63.

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 when machine
is overloaded and vibrating.
• Ruptured attaching bolts would lead to
serious damage to machine, or even
personal injuries. Fig. 5-54 Attaching Bolts of Drive Axle to the
• Tighten the attaching bolts with 1600 N.m Frame
(oiled bolt).
5.8.2 Attaching bolts of drive axle to the

propeller shaft, checking
Tighten the attaching bolt (1) with 65 N.m (oiled

bolt).
Fig. 5-55 Attaching Bolts of Drive Axle to the

Propeller shaft
5.8.3 Oil leakage of drive axle and brake
components, checking
Check the oil-immersion disc brake and its

connecting pipe;
Fig. 5-56

Check the parking brake system and its

connecting pipe;
Fig. 5-57
Check the connection between main reducer

and axle shell;
Fig. 5-58
Check the drive wheel;
Fig. 5-59

5.8.4 Brake function, checking
Brake system is applied to stop a traveling

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

function:
1. Star t the engine and run it until the
accumulator is pressurized.
2. Stop the engine, and turn the ignition key
to position I.
Fig. 5-60 Manual Brake Sheet
3. Release the parking brake, and check if
the parking brake pliers can move on the
bracket.
4. Check if the space between brake liner
and brake disc meets the need of braking.
Adjust it if necessary.
WARNING
WARNING
Always block the tyres to ensure that the

machine would not move when the parking
brake is released. The machine may move
and could result in injur y or possibly
death.
CAUTION
CAUTION
Hydraulic oil is of high temperature and

pressure, spray of it will result in wound,
burn, tetter or mania. Therefore release
the pressure of hydraulic system before
doing hydraulic related work. Avoid direct
contact with hydraulic oil, and remember
to wear gloves properly.
5.8.5 Breather connector, cleaning
Clean the breather connector to release

pressure 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. 5-61 Breather Connector

5.8.6 Differential oil, replacing

1 2
NOTE:
20 mm
Only replace the oil after the engine is shut
down.
1. Remove the oil drain plug (3) and oil filling

plug (2). Drain the oil into proper container
and check if there are metal scraps in the
oil.
2. Clean the inner of shell body with gasoline. 3
Drain all the gasoline before filling in new
1. Opening
oils.
2. Plug hole / Oil filling plug
3. Check if there are metal scraps around the
3. Oil drain plug
oil drain plug and retighten it.
Fig. 5-62
4. Fill in new oil into the oil filling plug until the
oil overflows.
5. Retighten the oil filling plug.
6. After the test and trial running, recheck the
oil level from oil filling plug to make sure
that no oil leakage is happening.
NOTE:
Replace the differential oil of new machine
after it has run for the first 100 hours.

5.8.7 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. 5-63 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 oi 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.
5.8.8 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.
TY-1407020-1
3. Check that the pedal’s travel is smooth.
4. Grease the pedal hinges with grease. Fig. 5-64 Brake Hinge
5. Check that the rubber on the pedal is intact
and that the tread pattern isn’t worn out.
Change it if needed.

5.8.9 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. 5-65 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.

5.9 Steering Axle
5.9.1 Daily check
3
5
1. Connecting shaft of frame 4. Link arm

2. End cover of king pin 5. Stub axle
3. Steering cylinder
Fig. 5-66 Main Components of Steering Axle
1. Check the wear condition of connecting shaft (1). Inject with grease every 50 hours.
2. Remove the end cover of king pin (2) to check the wear condition of king pin. Inject grease
onto it every 50 hours.
3. Check steering cylinder (3) for leakage. Check piston rod for deformation. Replace or repair
parts with damage.
4. Check whether the link arm (4) is worn, if worn it must be replaced immediately.
5. Check whether the link arm (4) can rotate smoothly. Inject grease onto the connecting pin
shafts of both ends every 50 hours.
6. If the machine has driven for a long distance with insufficient tyre pressure, stop the machine
immediately, and remove the wheels. Then check the condition of the stub axle (5).
7. If there is abnormal noise from the stub axle shaft or the steering tyre is abnormal when the
machine is steering, it can be concluded that the stub axle shaft is seriously worn. Replace it
immediately.

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. 5-67 Lubricate Steering Axle
5.9.3 Steering axle components,

checking
• Check if the steering cylinder, stub axle

and its bearing, steering wheel bearing,
steering connecting shaft, damping pad,
and counterweight, etc are tightened.
• Check if there is abnormal clearance and
damage on the steering axle.
• Check if the steering axle is leaking oil.
DG-1407124-1
Fig. 5-68
5.9.4 Knuckle pin, checking

3
1. Clean the knuckle pin (1) and bearing (2).

2. Check if the knuckle pin (1) can rotate
smoothly.
3. Check if the fixed bolts (3) are tightened.
1
2
DG-1407125-1
Fig. 5-69

5.9.5 Stub axle, maintaining

2
1. Remove the wheel ring cover (1).
2. Check the stub axle (4) for deformation, 5
fatigue and damage as early as possible;
replace it with a new one if there is
4
damage.
3. If the wheel ring bearing (3) is loose,
3
adjust the nut (2) of wheel ring to adjust its
clearance. Take proper pre-screw measure 6
to prevent from speeding up damage of
other components. 1
4. Inject grease through the grease nipple (6)
to lubricate the king pin (5) until it is hard to
inject further.
1. Hub cover 4. Stub axle

2. Hub nuts 5. Steering shaft
3. Hub bearing 6. Grease nipple
Fig. 5-70

5.9.6 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. Lift the machine under the rear counter-
weight.
NOTE:
Do not lift under the steering axle. Fig. 5-71 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.
5.9.7 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 an important component of wheel vehicles,

tyre technologies 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 empty

container handler is extremely dangerous.
At least two professional technicians are
needed, and high alert is required during
the work.
Failure to do this could result in injury or

possibly death.
5.10.1 Tyre, description
Tyres are the points of contact between the

machine and the ground, and they absorb
unevennesses and provide suspension.
Specification of the tyre in this machine is
14.00-24-28PR.
CAUTION
CAUTION
Type of the tyre should be the same or

have the same performance of the original
Fig. 5-72 Tyre
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 wear. The wear
limit of tyres should be the same to ensure the
identical outer radius. Tyre should be replaced
when the tread at 1/4 of the tyre edge is worn
to a depth of 2-3 mm.
NOTE:
Before starting the machine, check if crack,
corrosion, excessive or uneven weari exists
on the tyre surface. Replace tyres that are
seriously worn in time. Check and clean
impurities such as glass from the tyre. Check
the air pressure of tyre, and charge air in
time when the pressure is low, because low
pressure reduces stability and load capacity of
the overall machine.
DANGER
DANGER
Stop the machine when the tyre

temperature is too high. Park the machine
in a cool place to let it cool down. Never
discharge the air to release pressure or
splash water on the tyre to cool it down,
for these could cause tyre explosion and
personal injuries.
Replace the tyre timely when it reaches it

max. wear limit. Otherwise, tyre explosion
and personal injuries or even death can
occur.

5.10.2 Tyre, inflating
Always follow the instructions for inflating tyres

to avoid the risk of accidents.
• Only use approved rim components.
• If the tyre has been completely deflated,
the tyre must be dismantled and the rim
checked for damage.
• Never install rim components by striking
with a hammer during inflating. Never
strike fully or partly inflated tyres or rim
assemblies.
Fig. 5-73 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 tyre pressure may apply when changing
tyre or rim version, contact SANY.

5.10.1.3 Tyres, checking
• Check for uneven and accelerated wear

which is caused by mechanical problems
such as uneven brake action. Make sure
that such malfunctions are corrected
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 Drive axle tyre, removing and

installing
Most load of the machine is on drive axle, and

the tyre pressure may increase under different
working conditions. When the machine is
lifting containers, drive axle loads almost total
weight of the machine.
WARNING
WARNING
Discharge the air before replacing tyre. If

the valve core is blocked, use a saw blade
to saw a notch with a depth of about 1/3 of
the diameter.
In replacing, always lay blocks under
the steering axle before lifting the drive
axle, otherwise personal injuries would
be caused by unexpected move of the
machine.
Failure to follow this could result in injury
or possibly death.
5.10.4.1 Drive axle tyre, removing

1. Put two jacks of 10t 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. 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. 5-74 Drive Axle Tyre
and outer tyres.
3. Loosen all nuts symmetrically.
4. Remove all nuts except three proportionally
spaced ones.
5. Support the outer tyre with a forklift or

other reliable lifting devices.

6. Remove the rest three nuts and displace
the outer tyre.
7. Take down the spacer ring between tyres.
8. Displace inner tyre safely with a forklift or
other lifting device.
5.10.4.2 Drive axle tyre, installing
1. Remove the dust and impurities on hub

surface and in inner ring of wheel rim.
2. Mount the inner tyre to drive axle with a
forklift or other lifting devices, with the lock
ring outwardly.
3. Mount the spacer ring.
4. Mount the outer tyre to drive axle with a
ring inwardly.
5. Mount the open end thimble.
6. Mount the pressure plate symmetrically
Fig. 5-75 Drive Axle Tyre
and tighten the nuts with a torque of 650
N.m.
7. Turn the tyre for several circles and ensure
that swing range at the max. radius do not
exceed 3 mm.
8. 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.

5.10.5 Steering axle tyre, removing and

installing
WARNING
WARNING
Discharge the tyre before replacing. Failure

to follow this could result in injury or pos-
sibly death.
NOTE:
If the valve core is blocked, use a saw blade
to saw a notch with a depth of about 1/3 of the
diameter.
5.10.5.1 Steering axle tyre, removing

1. Lay two jacks of 20t under the steering
axle. They should be placed symmetrically
around the centerline of frame, with their
centers 1.4m away from each other. After
all the positions have been checked to be
right, lift the drive axle until the tyres are
50mm clear from the ground.
2. 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 Fig. 5-76 Jack
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.
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.

5.10.5.2 Steering axle tyre, 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 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
with a torque of 600 N.m. Fig. 5-77 Steering Axle Tyre
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.
5.10.6 Wheel rim, description

3
W heel r im f it s direc tly on hub, and it s 2
dimensions must be the same to that of the
hub. Only use the wheel rim that is approved
by SANY.
Our container handler applies three-element-

type wheel rim. The wheel rim is composed of 1
wheel rim body, retainer ring, and lock ring.
1. Wheel rim body

2. Lock ring
3. Retainer ring
Fig. 5-78 Wheel Rim

5.10.7 Rim, checking
Perform the following checks to minimize the

risk of accidents for all split rims.
• Always use the correct tyre dimension and
design corresponding to the manufacturer’s
rim type and dimension. Oversize tyres
may not be used.
• Replace all damaged, worn or corroded
rims or mounting parts.
• Check the rim in connection with tyre
change or once a year.
1. Dismantle the rim.

2. Carefully clean the outside of the rim edge
with a steel brush.
3. Measure the wear condition of lock ring.
• The lock ring’s wearing on the tyre bead
often results in a mark A in the figure. The
mark shows up between the lock ring’s
ends.
• Measure the depth of this wearing with a
steel ruler and sliding gauge. If the 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. 5-79 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. 5-80

5.10.8 Wheel rim, installing and

removing
5.10.8.1 Wheel rim, installing
CAUTION
CAUTION
Be sure to work according to the correct

procedures while installing or removing
the tyre from wheel or rim. If the procedure
is wrong, the tyre may rupture and thus
lead to personal injury.
If the personnel has insufficient experience,
or the appropriate tools for work are not
sufficient, do not install or remove the tyre.
Under such circumstances, contact the
authorized and professional staff related
for tyres to deal with it.
Wheel rim can be assembled or disassembled

horizontally and vertically. Before assembly
or disassembly, always remove the valve core
and release all the air out from the tyre.
1. Clean the rim seat and tyre seat with a

wire brush.
2. Check if there are any damages or nails
in the tyre. Clean the inner and outer
surfaces of tyre and clear all the impurities
before installing the inner tube.
Fig. 5-81

3. Put the inner tube into the outer tube

slowly and carefully from the bottom. Then
inflate the inner tube for its extension in the
outer tube to avoid folds.
Fig. 5-82
4. Mount the cushion belt from the top of

outer tube and check if it is folded and
placed between the tyre beads. If the
clearance between the tyre beads is too
small, expand it with a jack and lubricate
the cushion belt and inner tube with dry
lubricants such as soap.
5. Clean the dusts and rusts on lock ring with
steel brush. Pay special attention to clean
the groove of lock ring and replace the
cracked parts.
6. Insert the rear wheel flange into the rim
seat and the lock pin into the groove.
Fig. 5-83

7. Hoist or roll the tyre to where the rim is

placed. Check if the valve core rod is in the
valve core hole before mounting the tyre
into the rim.
If the tyre is not hoisted for assembling,
lower the position of rim for the
convenience of installing the outer tube.
8. Insert two A-type tools near the valve
groove. Put the tyre bead onto the side
wheel flange and fix it onto the rim seat. A
9. Insert two B-type tolls into the grooves
of A-type tools as a pivot. Press the tyre
bead bezel in. Keep one tool there and pry
the tyre bead into tyre bead bezel little by B
little with the other tool.
10. After the installation of rim, insert one
B-type tool into the lock ring groove as a
pivot and pry the tyre bead bezel into lock
ring groove for 30mm.
Fig. 5-84
11. Push the lock ring completely in with
the sharp head of B-type tool along the
perimeter of lock ring groove.
12. Pull the tyre bead bezel out carefully with
the crowbar until it contacts with the lock
ring.
13. Check if the lock pins at both sides of
wheel flange engage with each other.
Mount the tyre bead correctly onto the
rim and inflate it with the pressure of 525
Kpa. Before adjusting the air pressure,
release all the air to correct the torsion or
deformation. It is necessary to inflate it for
twice to prevent the inner tube from early
damage.
14. Before staring the machine, check if the
air pressure is appropriate. Recheck the
air pressure when the machine has been
running for the initial two or three times Fig. 5-85
after the tyre is installed.

5.10.8.2 Wheel rim, removing
NOTE:
• Always remove the valve core and release
all the air in tyre before removal.
• If all the air in tyre is released, dismount
the t yre and check the steel rim for
damage.
1. Before dismounting the tyre, remove

the valve core and release all the air.
Remember to mount the valve cap after
releasing the air to prevent the metal screw
from damaging when dismounting the tyre.
2. Choose proper tools and methods to lower
the tyre bead onto the drainage groove
at the inner of rim. Pay attention not to
damage the tyre bead.
3. Insert two crowbars into the groove of
rim seat to take the lock ring out. Insert
a B-type tool between the wheel flange
and tyre bead bezel to pull the bezel into
lock ring groove. Then remove the bezel
together with wheel flange.

5.11 Mast
6
Mast system of forklift truck is composed of
outer mast (1), inner mast (2), lifting cylinder (3),
tilt cylinder (4), chain, sliding blocks, etc. The
mast angle is adjusted through the telescopic
movement of tilt cylinder, while the mast height
is adjusted by that of lifting cylinder. Under the
function of these two cylinders, the machine
realizes the cargo operation.
1
NOTE:
The maintenance items of different masts
are the same. Below only introduces the 2
maintenance of K8C mast.
1. Outer mast 4. Tilt cylinder

2. Inner mast 5. Drag-chain
3. Lifting cylinder 6. Pulley
Fig. 5-86

5.11.1 Basic check
• Visually check the mast pillar for

deformation and check if the paint on
machine is twinkled.
In normal conditions, the left / right pillars
should be parallel and symmetrical with the
center. If the deformation of pillars is found
to be serious, check immediately whether
its connections are cracked.
• Inspect carefully the crinkle and flake

Fig. 5-87
of painting because it always indicates
cracks of weldment. If yes, weld it again
immediately.
When welding, remove paint on the
welding area thoroughly and re-paint it
again after the welding is finished.
5.11.2 Fixed bolts, checking

1
2
• Check if the connecting bolts on mounting
pad of tilt cylinder (1, 2) and lifting cylinder
(3, 4) are damaged. If yes, replace them
timely.
• Check if the fixed bolts are connected
correctly and tightened up. If necessary,
adjust and tighten them again.
3
4
Fig. 5-88

5.11.3 Sliding blocks, checking
Check if the sliding block is loose. If yes,

adjust it with gaskets.
The steps to replace the sliding blocks:

1. U s e a f i l l e r g a u g e t o m e a s u r e t h e
clearance between the sliding block of
outer mast and web plate of inner mast.
2. If the clearance is over 2mm, remove the
sliding block seat, gasket and sliding block
to measure the thickness of sliding block.
3. When the thickness is between 31mm and
33mm, adjust the clearance with gaskets.
When the thickness of sliding block is less
than 31mm, replace it with a new sliding
block. Fig. 5-89 Sliding Block of Mast
Check if the sliding block of side-sliding

bracket is lubricated well. The good lubrication
of sliding block can reduce the wear and
increase its service life.
1. The thickness of sliding plate is 35mm.
When the wear of sliding block exceeds
2mm. adjust it with gaskets.
2. When the the thickness is less than
30mm, the mounting bolts of sliding block
will come into contact with the outer mast,
resulting in the abrasion of mast. Thus
replace it with a new sliding block.

5.11.4 Chain, maintaining
• Check and Lubrication Period of Chain

Lubrication frequency of chain depends on
working environment.
When the chain is working in normal
conditions, check and lubricate it every
100 hours.
When it is working in tough conditions, like
in dusty air or in extreme cold weather, it is
suggested to check and lubricate it every
50 hours.
NOTE:
Remember to remove the grease on the chain
before checking it, and lubricate it properly
before using it again.
• Lubricant of Chain
After the chain is cleaned by solvent, soak
the chain with SAE20/50 multi-level lean
oil to lubricate it sufficiently.
• Lubrication Method of Chain

1. Manual Lubrication:
Inject grease periodically with a brush
or a grease bottle. It is recommended to
lubricate it once after 50 operating hours.
The lubrication amount and frequency
should ensure that the chain is just wet
enough and clean lubricant can saturate
into the joints.
2. I n j e c t i n g L u b r i c a t i o n o r P r e s s u r e
Lubrication:
Inject grease drop or grease mist into
the gap between edges of chain plate.
Lubrication amount and frequency should
be just enough to make lubricant saturate
into the chain.

3. M a t t e r s t o b e c o n c e r n e d f o r c h a i n
lubrication: 1
• The lubricants should be saturated into
every gaps between chain plates. The
wearing place beween pin and chain
sections should be lubricated well.
• Always slide the chain on chain wheel for
the best lubrication effect.
• If there is abrasive materials (such as
sands) attached on the chain, be sure to
lubricate it after cleaning the dirts off the
cahin completely.
• When the chain is lubricated before it is Fig. 5-90 Chain Gap
cleaned, the abrasive materials may enter
into the chain and cause the wearing of
chain.
• Check Extension of the Chain

The chain may not have lengthened more
than 3%. Measure the length of the 25
links that during lifting first (and most often)
break over the chain wheel. This is where
lengthening is greatest.
NOTE:
Compare with the values in below table. If Fig. 5-91 Distance Between 2 Pins
the 3% limit is exceeded, the chains must be
replaced.
Table 5-22 Measurement Index of Chain

P-measurement P-measurement Measurement over 25 links [mm]
[in] [mm] New chain Max. Measurement
2 50.8 1270 1308
2 1/2 63.5 1587.5 1635
P-measurement = the distance between 2 pins
• Check Connecting Joints for Cracks.

Check key str uctural mechanism
frequently. If cracks are found and properly
handled, further damage can be prevented.

• Check the Chain for Mechanical

Damage
The chain is a key structural component
for directly lifting loads, whose structural
stability directly influences the reliability
and safety of whole machine.
• Check the Chain for Corrosion
• Check the Chain Connectors

Inspect the chain connectors regularly. Check
if the connectors are cracked. If yes, change it.
Table 5-23 Inspection Plan

Work Time Inspection Interval
Within 5000 hours Every 1000 hours
5000-10000 hours Every 300 hours
10000-20000 hours Every 200 hours
Above 20000 hours Every 150 hours
5.11.5 Cylinder piston rod, maintaining
Perform the following maintenance during

transporting, installing and operating the
cylinder piston rod:
• After coating or assembling the cylinder,
seal the exposed section of piston rod with
anti-rust oil or grease to prevent corrison.
• During the long transportation or ocean
shipping, seal and pack the exposed
section of piston rod with anti-rust oil or
hydraulic oil.
• If the machine installed with cylinder will be
parked for more than half month, coat the
exposed section of piston rod with antirust
oil or hydraulic oil. Besides, check and
maintain the cylinder every week regularly.
• When operating the machine, keep the
surface of piston rod clean. Clear the
piston rod of mud or dust. Pay attention not
to bump, cut or damage the piston rod.

5.12 Spreader
5.12.1 Twistlock, lubricating
Spreader is the major working mechanism

for lifting the container. Lubricate spreader
twistlock properly to reduce its wear and
extend its service life.
All spreaders have four grease nipples which

should be lubricated every 250 hours. All
protective sleeves have a grease nipple (A). All
twistlocks have a grease nipple (B).
Check the wear and possible damages of

twistlock and its protective sleeve when
lubricating. Replace them if necessary.
Fig. 5-92
5.12.2 Sliding blocks of telescopic beam

riser, lubricating
There is no fixed grease nipple at sliding

blocks of telescopic beam riser. Lubricate the
sliding block and its working track every 500
hours.
When lubricating, check the wear condition of

the nylon sliding block. Replace it before the
twistlock riser rubs against the sliding block
seat of the telescopic beam riser.
Fig. 5-93

5.12.3 Sliding block between the basic

beam and telescopic beam, lubricating
There is a total of totally 16 lubricating points.

Lubricate the sliding block and its working
track every 500 hours.

sliding block seat of cross beam rubs against
the telescopic beam.
Fig. 5-94
5.12.4 Sideshift cylinder bearing,

lubricating
There are two grease nipples in the joint

bearing of every oil cylinder, with 4 lubricating
points in common. Add lubricant to the grease
nipple every 500 hours.
Fig. 5-95
5.12.5 Top and bottom sideshift sliding

blocks, lubricating
There is no fixed grease nipple. Lubricate the

sliding block and its working track (C) every
500 hours.

main beam assembly rubs against the sliding
block plate and the guide plate of main beam
rubs against the baffler of sliding block.
C
5
Fig. 5-96

5.12.6 Sliding block, checking
Check the wear condition of nylon sliding block

and lubricate its working track. If the thickness
of sliding block is about 18mm, replace it with
a new one immediately.
• When the telescopic beam is extended,
dismount the sliding block mounting to
replace the sliding blocks on basic beam
and sliding bracket without moving the
Fig. 5-97 Thickness
beam.
• When replacing the sliding block on riser,
be sure to remove the twistlock first.
5.12.7 Twistlock, checking
The twistlock is a device easy that is exposed

to damage. Be sure to inspect it periodically
and lubricate it once every month. When there
is wear or damage of the twistlock, lubricate or
replace it.
When the twistlock is excessively worn, that is,

the size of cross section is smaller than 30mm,
replace it. If the worn part is beyond the range
of shaded area in Fig. 5-103, replace the
Fig. 5-98
twistlock immediately.
Generally the twistlock should be replaced

after it has operated for over 5000 working
hours.

5.12.8 Other maintenance items of

spreader
1. Check the main spreader components for

damage, crack and distortion.
2. Check if the signal and safety system of
spreader is operating normally.
3. Check the pressure of spreader hydraulic
system at regular intervals.
4. Check all the hydraulic cylinders for leaks.
If necessary, re-seal the cylinders.
5. Check all the hydraulic hoses for damage
or leaks. If damage or leaking, replace
them.

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 area;
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 re dite d
company.
WARNING
WARNING
Electric fans can cause injury to hands.

Risk of personal injury.
Avoid placing hands near the cooling fans
when the engine is running.

5.13.2 Air conditioning, checking /

performance test
NOTICE
NOTICE
If the pressure in the refrigerant circuit

gets too low, the low-pressure monitor
p o w e r s u p p l y t o t h e c o m p r e s s o r ’s
magnetic clutch would break down, which
causes the air conditioning unit to stop
functioning.
Please check the air conditioning system

during continuous operation 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 at maximum.
2
Sight glass inspection
insufficient injuection
2. Start the engine and let it run idle.
3. Switch on the air conditioning at max.. Fig. 5-99 Check Refrigerant Quantity
cooling and fan.
4. Check that a few bubbles are visible in the
sight glass on the receiver dryer.
5. Bubbles in the glass means that the
quantity of refrigerant is incorrect or that
the condenser is defective, clogged by e.g.
dust, or that the ambient temperature is
very high.
It is the easiest way to detect bubbles by

examing the sight glass while the compressor
is being star ted. Visible bubbles should
not normally be noticeable when the air
conditioning system is in operation. Bubbles

can occur if the system contains the incorrect

quantity of refrigerant, in connection with the
compressor stopping and starting, and if the
condenser is defective or at very high ambient
temperatures.
NOTE:
Reliable checking of refrigerant quantity
through the sight glass can only be made
when the ambient temperature is above
approx. 15 °C.
5.13.4 Refrigerant, filling
The type of refrigerants and freezing oil should

be up to the requirements of air conditioning
system. Choose the refrigerant of genuine
quality.
Check the system for leakage.

1. Fill 150cc of cooling lubricants. Make sure
that no water or dirty oil enters into the
system.
2. Vacuum the system for no less than 40
minutes.
3. Fill the refrigerants according to the
specified quantity of system. Too much
or too little refrigerants will influence the
cooling effect.
4. Check the condition of system and if it is
leaking air.
Run the air conditioning system for no less

than 30 minutes when filling refrigerants.
During that period, check the system pressure
of pipeline, condenser fan, circulating fan
to ensure that the air conditioning system is
properly installed for use.

5.13.5 Cleanness of heat-exchanger

plate in evaporator and condenser,
checking
Clean the evaporator and condenser at least

once every year by below means:
• Use high-pressure hydraulic 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. 5-100 Evaporator
NOTE:
High-pressure hydraulic gun and pneumatic
gun pressure should be adjusted before
cleaning. Do not punch down the fin. As to
those dirty cores, especially the evaporator
core with dust strainer mesh unwashed for
a long time, use fin detergent special for air
conditioner to wash after diluted because the
fins are covered with lots of dust and dirt.
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 5-24 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 spreader
lowered and retracted.

2. Check the oil level in the hydraulic tank.
The oil level should be visible from the
level indicator glass. Top up with oil when
Fig. 5-101 Hydraulic Oil Level
needed.
Tank capacity: 535 L / 117.7gal
NOTICE
NOTICE
Do not overfill!
Leakage and environmental damage!
5.14.2 Air filter element, changing
NOTICE
NOTICE
Ensure cleanliness around the filter and

filling point when working on the hydraulic
tank.
Dirt particles may cause damage to the

machine.

1. Turn off the engine and main electric

power.
2. Remove the cover plate over the hydraulic
1
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 conditions of these parts.
5. Clean the filter housing’s parts.
6. Fit the new filter and assemble the filter
unit.
7. Install the filter unit and the cover. Tighten Fig. 5-102 Air Filter
the screws crosswise.
8. Check the oil level with dipstick in the
hydraulic oil tank. The oil level shall be
at the top of the level glass. Top up as
needed.
5.14.3 Hydraulic oil, changing
NOTICE
NOTICE
Ensure cleanliness around the filter and
filling point when working on the hydraulic
tank.
Dirt particles may cause damage to the
machine.
1. Turn off the engine and main electric

power.
2. Remove the 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 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 “Air filter element,
changing” on page 5-105.
6. Fill new hydraulic oil through the filler hole
on the filter’s cover. Then the oil can be
filterd 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 on the

top of hydraulic oil tank. Blocked filter element
will influence the flow of oil, resulting in high
pressure at the oil outlet of pump and bursting
of oil pipe.
Steps to replace the filter element:

1. Dismantle the hydraulic oil return filter from
DGH-1703001-1
the hydraulic oil tank.
2. Loosen the fixed screws in the filter.
3. Take out the filter element. Fig. 5-103 Oil Return Filter
4. Replace with a new filter element.
WARNING
WARNING
Hot, pressurized oil!

Personal injury, burn injury!
Always depressurize the hydraulic system
before operation. Avoid skin contact with
the oil, and use protective gloves.
Failure to follow the above instructions

5.14.5 Hydraulic oil tank, cleaning

This machine adopts anti-wear hydraulic oil.
Be sure to clean the oil tank every half year.
The steps to clean the oil tank are as follows:

1. Remove the oil drain plug at the bottom of
hydraulic oil tank. Drain out the hydraulic
oil in the tank and pipeline.
2. Remove the cover of cleaning hole.
3. Clean the oil tank with cleanout fluid (diesel,
etc.) .
4. Af ter the tank is cleaned, install the
cleaning hole cover.
5. Open the air filter cover on the tank. Fill
filterd hydraulic oil into the tank until the
oil reaches the “H” marking as shown on
dipstick.

5.14.6 Accumulator
This machine is equipped with one brake

system accumulator has a charging pressure
of 100 bar and oil pressure of 175 bar. H8
type container handlers (SDCY90K8H8A,
SDCY9 0K8H85A , SDCY9 0K87H8A ,
SDCY90K7H85A) are also equipped with four
energy collection accumulators.
WARNING
WARNING
• Hydraulic oil-way remains pressurized.

Do not stand in oil spraying direction
when dismantling the hydraulic
devices. Besides, loosen the screws
slowly.
• Do not dismantle the accumulator.
• Keep the accumulator away from fire.
• Do not drill holes on or weld on the
accumulator.
• Do not crash or roll the accumulator.
Avoid any shock of accumulator.
• Drain the air before dealing with the
accumulator. Please contact SANY to
conduct this operation.
Failure to follow above items may lead to
serious personal injuries or even death.
5.14.6.1 Brake system accumulator, 2

checking
P
The accumulator is f illed with nitrogen.
1
Improper operations will lead to explosion
causing machine damage and personal
injuries. Pay attention to the following items
when dealing with accumulators:
1. Start the engine (1); let it run until the

accumulator is fully pressurized.

2. Stop the engine, and turn the ignition key

to position 2 in Fig. 5-104. Step on the
brake pedal (3) to its bottom and hold it
there for a short interval, then repeat this
operation several times.
3. Make sure that at least 8 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.
3
NOTE: Fig. 5-105 Brake Pedal

If the brake cannot function normally for 8
times before the alarm light turns on, it means
that there is a failure of the accumulator. Find
out the cause and eliminate the failure as
soon as possible. The accumulator should be
charged again.
5.14.6.2 Accumulator, charging with

nitrogen gas
The accumulator has already been 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 pressurized 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. 5-106 Accumulator
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.
5.14.7 Hydraulic oil circuit, checking
By observing and touching, check for loose

bolts or oil leaks on installation position of
hydraulic oil circuit. If yes, contact SANY
authorized distributors to replace the parts. TY-1407026-1
Fig. 5-107 Hydraulic Oil Hose

5.14.8 Brake oil filter, changing
NOTE:
The filter protects the brake system from
impur ities. It is ver y impor t ant that no
impurities enter the brake system when
changing the filter.

2. Depressurize the hydraulic and brake
system.
DGH-1703002-1
NOTE: Fig. 5-108 Brake Oil Filter

Leave the valves open when changing.
3. Remove the drain plug on the underside of

the filter. Let the oil drain. Wait a while as
the oil drains slowly.
4. Remove the filter housing.
NOTE:
The filter housing is heavy. Loosen it carefully.
5. Remove the filter insert.
NOTE:
Note the position of O-rings.
6. Clean the filter housing.

7. Fit the O-rings on the filter cartridge and
filter housing. Lubricate the O-rings with
hydraulic oil.
8. Fit the new filter insert to the filter bracket.
9. Fit the filter housing and the drain plug.
10. Close the valves that were opened to
release the pressure in the hydraulic
system.
11. Start the engine and check that the filter
housing does not leak.

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 blowing of a fuse always indicates a
fault in the electric system. Eliminate the
fault prior to fitting a new fuse.
Failure to follow the above instruction

5.15.1 Battery
WARNING
WARNING
Risk of fire and explosion! Avoid contact

with flames or sparks.
Never confuse the positive terminal with
the negative one.
Battery electrolyte contains corrosive
sulphuric acid.
Avoid contact with skin, eyes, and clothes
when moving the batteries. Use gloves and
protective glasses. If electrolyte splashes
on bare skin, wash with soap and a lot of Fig. 5-109 Precautions for Battery
water immediately. If electrolyte has gone
into eyes, rinse with water and contact a
doctor immediately.
5.15.1.1 Battery, cleaning
Keep the battery clean and dry. Dirt and

oxidated materials on battery and battery
connector may cause electrical leakage,
decreased voltage and discharge, especially
in the wet weather.
Use copper wire brush to clean the oxidated

materials off battery connector. Tighten the
cable connector and lubricate with protective
grease or vaseline. Fig. 5-110 Clean the Battery

5.15.1.2 Battery, checking
CAUTION
CAUTION
Battery electrolyte is very caustic. Avoid

any contact with battery electrolyte.
• If electrolyte comes into contact with
clothing, skin or eyes, flush the areas
immediately with water.
• In case of eye contact, rinse with plenty
of water and see a doctor at once!
The battery is fitted in the battery compartment

on the left side of machine.
• Check the battery for cracks in the casings,
and leaked electrolyte.
• Remove any corrosion on battery terminals
and check the connections for tightness.
• Tighten up the terminals and coat with
non-acidic grease.

5.15.1.3 Battery, detecting
Due to improper usage or maintenance, the

battery may be unable to be started normally.
Detect the battery as follows.
1. Common detect equipment

• Multimeter
• Electric conductometer
• Gravimeter
2. Detection measures
Estimate the service condition of battery
through magic eye or with the multimeter.
Through magic eye:

• Green magic eye signifies the normal
battery.
• Black magic eye signifies lack of voltage.
Charge the battery immediately.
• W h i t e m a g i c e y e s i g n i f i e s l a c k o f
electrolyte. Change the batter y
immediately.
With the multimeter:
• If the battery voltage is higher than 12.5V,
the battery is normal.
• If the battery voltage is between 11.5V and
12.5V, the battery lacks of voltage. Charge
the battery and check its voltage again.
• If the battery voltage is lower than 11.5V,
the battery discharges too much or there
is malfunction of this battery. Charge the
battery and check its voltage again.

5.15.1.4 Battery, charging
DANGER
DANGER
Danger of explosion!
Hydrogen 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.
Principles of charging common batteries:
1. The current and time for charging the

battery can be referred to below table:
Table 5-25 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 NOTICE
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 at 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.
Principles of charging maintenance-free

batteries:
Precautions of charging batteries:

• Detect the battery before charging (For
detailed information, see: chapter 5.16.1.4
“Battery, detecting”). Only if the battery
needs to be charged can the charging be
started.
• Do not charge the batteries of broken
cover, with white magic eye or whose
electrolyte is frozen.
• Always charge the battery in the ventilated
area.

• If the battery temperature exceed 50°C

during the charging procedures, reduce
the charging voltage properly or stop the
charging. If acid fluid sprays out from the
exhaust hole or the magic eye is white,
stop the charging immediately and discard
the battery as useless.
Charging procedures:
1. Select a proper charging equipment.
2. Connect the terminals of battery when the
charging equipment is turned off.
3. Connect the plus cable (normally red)
of generator with the positive terminal of
battery. Connect the minus cable (blue
or black) of generator with the negative
terminal of battery. Make sure they are
firmly connected.
4. Turn on the charging switch of generator.
Slowly adjust the charging voltage or
cur rent from small to large with the
generator adjuster.
5. When the magic eye turns green, the
battery is finished charging.
6. After the charging, turn off the charging
switch of generator first. Then disconnect
the cables of battery (never remove the
charging cables during the charging).

5.15.1.5 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
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.
8. It is hard to prevent natural creepage
caused by machine load. If the machine is
to be stored for over 10 days, be sure to
remove the cable connected to negative
terminal to avoid serious discharge of
battery.
9. The start time of machine is 3-5 seconds.
The interval between two starts should be
no less than 15 seconds. If the machine
cannot be started, check the battery and
its start circuit. This usually happens in
winter.
10. Improper disposal of battery can result in
envirionmental pollution. It is suggested
to handle the used batteries to Recycling
Institues.

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 5-26 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. 5-111 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. 5-112 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 5-26
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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............................................................................................................
............................................................................................................
GE
............................................................................................................
............................................................................................................
A
............................................................................................................
P
............................................................................................................
............................................................................................................
K
............................................................................................................
N
............................................................................................................
A
............................................................................................................
L
............................................................................................................
............................................................................................................
B
...........................................................................................................
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Empty Container Handler 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
6.4 Engine Error Codes �� 6-27
6.4.1 VOLVO engine error codes�� 6-27
6.4.2 CUMMINS engine error codes�� 6-36
6.4.3 YUCHAI engine error codes�� 6-42
6.5 Transmission Error Codes �� 6-47
6.6 Machine Error Codes �� 6-55
6.6.1 Error codes of H1 / H2 / H3 / H4 container handler�� 6-55
6.6.2 Error codes of H8 / H85 container handler�� 6-59

Troubleshooting Empty Container Handler
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
Hard to start the Blocked air filter or air intake Check the air intake system
-
engine pipe of engine for blockage.
see “Fuel system”
Fault in oil circuit of fuel system Check the fuel system.
on page 5-42
Insufficient starting voltage Check the voltage of battery. -
The engine is over The EDC fuel control unit is
Check the fuel control unit. -
rewing faulty
The corrugated pipes
have cracks and air The quality of pipe itself Replace it. -
leakage
The rotation speed of The EDC fuel control unit is
Check the fuel control unit. -
engine is not stable faulty
No fuel in tank Check if fuel is used up. -
Check if fuel oil circuit is
Engine stops Blockage in fuel pipe -
blocked.
unexpectedly
Check if fuel enters into the
Air entering in fuel pipe -
fuel pipe.
see “Coolant
Insufficient coolant in water Check if the coolant of water level, checking
tank tank is sufficient. and topping up”
on page 5-50
Engine overheating or
Malfunction of thermostat Check the thermostat. -
running hot
see “Drive belt,
Check if the fan belt is
The fan belt is loose checking” on page
loosened.
5-33
The water pump is damaged Check water pump. -
There is oil in water The engine oil cooler is Check if engine oil cooler is
-
but no water in oil damaged damaged. If yes, replace it.


The quality of cylinder head Replace the cylinder head. -
see “Coolant
The cylinder head has
C h e c k i f t h e c o o l a n t i s level, checking
crack Insufficient coolant
sufficient. and topping up”
on page 5-50
The lubrication oil The cylinder gasket or cylinder Check if cylinder gasket or
-
level in oil pan rises head has crack cylinder head has crack.
unexpectedly and Check if the cylinder liner is
The cylinder liner is damaged -
water enters oil damaged.
The oil level is too low Refill the lubrication oil. -
see “Oil filter,
The oil filter is blocked Replace the filter. chaging” on page
Lubrication oil
5-41
pressure is too low
see “Engine oil,
The lubrication oil is too thin Replace the lubrication oil. changing” on page
5-40
The water tank has refer to “Shop
The water tank is damaged Replace it.
leak Manual”
The engine oil cooler The engine oil cooler is refer to “Shop
Replace it.
has leakage (gearbox) damaged Manual”
Check if the fuel oil circuit is
The fuel supply is insufficient -
unblocked.
The fuel 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
blocked. checking” on page
5-57
The speed of engine
Check if the fuel oil circuit is
is automatically The fuel supply is not smooth. -
blocked.
decreased
The pre-filter and filter The diesel is too dirty Chang the diesel. -
elements for engine
The diesel tank is dirty Clean fuel tank. -
diesel are blocked
The exhaust pipe is damaged Replace the pipe.
The exhaust pipe of
The flange of exhaust pipe is
engine has leakage Tighten the flange. -
loosened
see “Drive belt,
The engine fan belt is The quality of belt itself Replace belt. changing” 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 rings are worn Replace the piston rings. -
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,
filter, connecting hoses, and controls, including
the engine, as a complete system.
Torque converter transmission troubles fall

into three general categories: mechanical,
hydraulic and electrical problems. In addition
to the mechanical and electrical components,
all of which must be in the proper condition
a n d f u n c t i o n i n g c o r r e c t l y, t h e c o r r e c t
functioning of the hydraulic circuit is most
important. Transmission fluid is the “life blood”
of the transmission. It must be supplied in an
adequate quantity and delivered to the system
at the correct pressures to ensure converter
operation, to engage and hold the clutches
from slipping, and to cool and lubricate the
working components.

6.3.2.2 Troubleshooting procedures
Step 1: Stall test

Use a stall test to 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 "Transmission
Check the oil level. oil level, checking"
Insufficient oil
on page 5-63
Slipping of clutch
Damage of charge pump Check the charge pump. -
Wear of the clutch abrasion refer to “Shop
Replace the clutches.
sheet Manual”
see "Transmission
Low or high oil level Check the level of lubrication oil. oil level, checking"
on page 5-63
High oil temperature Worn charge pump Check the charge pump. -
Step the clutch in braking and
The clutch does not release
check if the clutch switch is -
when braking
operating.
Abnormal meshing of gear Check the meshing of gear. -
Too much noise Abrasion or damage of Replace the damaged or
-
bearing abraded bearing.
see "Transmission
Low oil level Check the oil level. oil level, checking"
Inadequate oil on page 5-63
pressure displayed Damage of charge pump Check the charge pump. -
by oil pressure Damage of the clutch Check the presssure-adjusting
-
gauge pressure-adjusting valve valve.
Damage of the clutch oil- Replace the damaged sealing
-
sealing part part.
Check the signal of control unit
-
of gearbox.
The gearbox can Fault in control unit of Check if the solenoid coil of
-
not switch gears gearbox gearbox solenoid valve is blown.
Check if the valve core is
-
blocked.
The gear cannot be
shifted manually
The contact is faulty Check the contact. -
Faulty of control
lever
see "Attaching bolts
Excessive vibration The mounting bolts are of propeller shaft,
Tighten the mounting bolts.
and noise in cab loose checking" on page
5-47

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 circuit has air leakage. and brake
brake is not sufficient components,
The brake components are checking” on page
Check the brake components.
worn out 5-64
Check if the fan of cooling
The oil temperature of braking system can rotate or fan flanks refer to “Shop
Too much noise
system is high are damaged. Replace it if Manual”
necessary.
Adjust the distance of brake
Failure of brake valve -
valve.
Check the clearance of brake
Failure of brake -
sheet.
Failure of pressure relay Clean or replace it. -
No service brake or see “Brake system
the service brake accumulator,
Failure of accumulator Check the accumulator.
functions bad checking” on page
5-109
refer to “Shop
Failure of gear pump Replace it.
Manual”
refer to “Shop
Failure of brake valve group Clean or replace it.
Manual”
Failure of parking brake Clean the parking brake. -
Clean the solenoid valve or
No parking brake or Failure of solenoid valve -
replace it.
the parking brake
High oil return back pressure Check the oil return pipe. -
functions bad
refer to “Shop
Failure of brake valve Clean or replace it.
Manual”

6.3.4 Troubleshooting the steering

system
Table 6-4

refer to “Shop
Insufficient oil supply Check the system pressure.
Manual”
Failure of hydraulic steering
Clean and replace it. -
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 feed to oil
No output of oil pump -
circuit.
Electrical failure Replace the circuit. -
No spreader
Solenoid valve is damaged Replace the solenoid valve. -
movements
The valve core is blocked Clean the valve core. -
Bad connection caused by wiring
Check and fix the fault. -
fault
The corresponding solenoid valve
Clean the solenoid valve. -
is clamped
Only a few of
The coil of solenoid valve is
spreader functions Replace the coil. -
damaged
are effective
The controller of spreader is Replace the spreader refer to “Shop
damaged controller. Manual”
Check and repair it. Replace
Fault in button of joystick -
the joystick if necessary


see “Fuses,
The power supply fuse of spreader
Replace the fuse. changing” on
control device is blown
page 5-123
The hoses of general oil supplying
Inspect and fix it. -
No movement of valve have some malfunction
the spreader Check and resume it. Replace
General oil supplying valve has
the general oil supplying valve -
some malfunction
if necessary.
refer to “Shop
Spreader controller is damaged Replace it.
Manual”
The yellow indicator Wrong induction distance of
Adjust the distance. -
light blinks or seated sensor
illuminates all the Seat 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 unlock sensor
or illuminate when Unlock sensor is damaged Replace the sensor. -
the spreader is refer to “Shop
The red indicator light is damaged Replace the indicator light.
unlocked Manual”
The green indicator Wrong induction distance of lock
light does not blink sensor
or illuminate when Lock sensor is damaged Replace the sensor. -
the spreader is The green indicator light is refer to “Shop
Replace the indicator light.
locked damaged Manual”

6.3.6 Troubleshooting the mast system
Table 6-6
Fault Causes of faults Methods Reference

The mast sways too Too much side gap of outer Adjust the sliding block in outer
-
much mast mast.
The spreader support Too much side gap between Adjust the sliding block in inner
-
sways too much spreader and inner mast mast.
Malfunction of oil pump Repair or replace it. -
Malfunction of multi-way valve Clean or replace it. -
Malfunction of logic valve or the
electromagnetic valve that is Clean or replace it. -
Mast unable to lift or
controlled by logic valve
descend
Malfunction of the oil circuit Replace the gear pump or relief refer to “Shop
controlled by multi-way valve valve. Manual”
Malfunction of overflow valve Replace the sealing elements. -
Electrical malfunction Replace the electrical elements. -
refer to “Shop
Malfunction of overflow valve Clean or replace it.
Manual”
Mast descends
Malfunction of logic valve or the
automatically
electromagnetic valve that is Clean or replace it. -
controlled by logic valve
see “Fuses,
Power supply fuse of mast
No operation of the Replace the fuse. changing” on
control circuit is blown
mast page 5-123
Circuit malfunction Check and repair it. -
No lifting movement
Check and synchronize the
of mast after normal
Spreader not fully or locking action of spreader;
operation; Mast able -
incompletely locked lock or unlock the spreader
to lift when safety
completely.
bypass turned off

6.3.7 Troubleshooting the air

conditioning system
Table 6-7

Cab temperature is lower
Set a lower temperature. -
than the set temperature
Turn on the refrigeration mode
High temperature changes
after the temperature is getting -
during one day
higher.
Belt is loose Tighten the belt. -
Check if the inserting fuse in
see “Fuses, changing”
electric cabinet is blown. If yes,
on page 5-123
change the fuse.
Fuse of condenser burns
Check if the fuse is fixed. -
out
Check if the plug-in part of
No refrigeration controller and condenser coil -
effect has good contact effect.
Plug-in part of condenser
Insert the plug-in part again. -
clutch coil is loose
Coil is too tight or plug-
in part has poor contact Fix the coil terminals. -
effect
Turn off the refrigeration mode. -
see “Leakage or lack
Check the condenser for of oil in condenser,
Refrigerant is leaking
leakage. checking” on page
5-102
Inform SANY to deal with it. -
Most of the air outlets are Adjust the cab temperature.
-
blocked Open all the air outlets.
Poor refrigeration
Bad sealing of cab Close all the windows and doors. -
effect
see “Refrigerant,
Refrigerant is not enough Fill in refrigerant.
filling” on page 5-101
Check the output, grounding and
Connecting wire to engine
connecting wire of conditioner. -
is loose or ruptured
Connect the wire again.
Small air volume or see “Fuses, changing”
Fuse is blown Change the fuse.
no air on page 5-123
Speed governing
resistance of evaporator is Inform SANY to deal with it. -
damaged

6.3.8 Troubleshooting the hydraulic system
Table 6-8
Failure
Possible Causes Suggested Actions Reference
Symptom
refer to “Shop
Failure of cooler Replace it.
Manual”
Hydraulic motor of cooling circuit is refer to “Shop
Replace the hydraulic motor.
damaged Manual”
High oil 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. -
faulty
Low flow of cooler Clean the cooler. -
Outer radiator fins are too dirty Wash the outer radiator fins. -
Hydraulic oil of substandard quality see "Hydraulic oil,
Replace the hydraulic oil. changing" on page
Hydraulic oil of substandard viscosity
5-106
Long-term use of hydraulic oil
Periodical filtration. -
without filtrating or replacing it
see "Oil return filter
The constant entrance of dust, sand Replace the filter core
Hydraulic oil is element, replacing"
and other debris periodically.
polluted and on page 5-107
deteriorated High temperature; oxidation
see "Hydraulic oil,
metamorphism
Replace the hydraulic oil. changing" on page
Entry of water and air, as a result of
106
cavitation, erosion, etc.
see "Air filter
Clogged filter Clean it or replace it. element, changing"
on page 5-105
Leaking of Damaged or distorted sealing parts Replace the sealing parts. -
hydraulic oil Joints and pipelines are loose Tighten the loose parts. -
see “Fuses,
The fuse of cooling system is burnt Replace the fuse. changing” on page
The hydraulic
5-123
or brake
The temperature switch is damaged Replace the switch. -
cooling system
The contact of relay controlling the
does not cool Replace the contact. -
cooling system is fused
automatically
Failure of cooler solenoid valve Replace it. -
Failure of cooler 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
Possible Causes Suggested Actions Reference
Symptom
see
"Troubleshooting
Open circuit or short circuit Check and fix it.
the cable harness"
on page 6-19
Non-operation of
Magnet rusted Scrub the magnet. -
magnetic valve
Replace the spool or seal
Spool abrasion or seal-ring aging -
ring.
Severe oil carbon pollution in the valve Scrub the magnet. -
Failure of deflection spring Replace the spring. -
Air ejection from
Failure of magnetic valve Replace the valve. -
magnetic valve
see
"Troubleshooting
Open circuit Check and fix it.
Water level the cable harness"
switch alarms for on page 6-19
full tank Fault of structure of water level switch Replace the switch. -
The water level switch is reversely
Reinstall the switch. -
installed
see
"Troubleshooting
Open circuit Check and fix it.
No indication of the cable harness"
fuel level on page 6-19
Reverse connection of power line and
Reconnect the lines. -
signal line
Line abrasion, there is contact
Inaccuracy
resistance between signal line and Check and fix it. -
of fuel level
power line
indication
Failure of sensor Replace the sensor. -
see
Non-operation "Troubleshooting
Failure of circuit Check and fix it.
of temperature the cable harness"
switch on page 6-19
Switch damaged Replace the switch. -
Faulty of Adjusted value of temperature switch
Replace it. -
temperature is inaccurate
switch The temperature switch is deffective Check and fix it. -


see
"Troubleshooting
Non-operation of Failure of circuit Check and fix it. the cable
pressure switch harness" on page
6-19
Switch damaged Replace the switch.
Adjusted value of pressure switch
Faulty of pressure Readjust it. -
is inaccurate
switch
The pressure switch is defective Replace it. -
see
"Troubleshooting
Open circuit Check and fix it. the cable
No signal of pressure
harness" on page
sensor
6-19
Reverse connection of signal line
Reconnect the lines. -
and power line
Line abrasion: there is contact
resistance between signal line and
Faulty of pressure Check and fix it. -
its housing, or power line and its
sensor signal
housing
The sensor is defective Replace it. -
Incorrect signal of
throttle. Start the engine
and run it at its max. Reverse connection of power line
Check and fix it. -
speed. Step on the of pedal and ground wire
throttle, but the rotate
speed decreases
The rocker switch is damaged Replace it. -
see
No operation of rocker "Troubleshooting
switch The lead is peeled Check and fix it. the cable
harness" on page
6-19
The bulb is damaged Replace the bulb. -
see
"Troubleshooting
No indicator light
Failure of circuit Check and fix it. the cable
harness" on page
6-19


The contact spring is too soft Adjust the elasticity of spring. -
The connection iron
The bottom plate is eneven Remove the protruding part. -
of contactor does
The connection iron or
not fall when the 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. -
hot The contact is serious burnt Replace the contact. -
The contact pressure is
Replace the contact. -
inadequate
The contact is covered with Find out the reason and eliminate
-
P o o r c o n t a c t o f dust, dirt or is blown the failure.
relay Adjust the elasticity of spring.
The contact spring is too soft -
Replace it as necessary.
The contact is wrong Replace the contacts. -
There are sparks on Adjust the elasticity of spring.
The contact spring is too soft -
the contact when Replace it as necessary.
the relay is closed The contact is burnt, poor
Replace it. -
contact
Pool connection of armature
Clean the connection surface. -
Abnormal noise of and iron core
DC contactor Large pressure of contact Replace the contact spring and
-
pressure contactor if necessary.
Battery switch The contacts are fused together Replace the contacts or switch. -
cannot be
The mechanical part is clamped Repair it to make it flexible. -
disconnected
see
"Troubleshooting
N on - operation of Open circuit Check and fix it. the cable
preheater harness" on page
6-19
Heater damaged Replace it. -


see
"Troubleshooting
Short circuit of horn power wire
The horn alarms all Check and fix it. the cable
and control power line
the time when the harness" on page
power is on 6-19
The contact of relay controlling the
Replace the relay. -
horn is fused
The contact head is loose Retighten the contact. -
see “Fuses,
The fuse of control circuit is blown Replace the fuse. changing” on
Press down the wiper page 5-123
The zero wire is not connected in
button, but the wiper Re-connect the zero wire. -
the control circuit
motor is not starting
Check the relay, and
The start relay is damaged -
replace it as necessary.
Check the button, and
The wiper button is deffective -
see
"Troubleshooting
Sound & light alarm The lead is peeled or open circuit Check and fix it. the cable
does not work harness" on page
6-19
The alarm is damaged Replace it. -
see
"Troubleshooting
Open circuit Check and fix it. the cable
harness" on page
6-19
see “Fuses,
The fuse of power supply is blown Replace the fuse. changing” on
Non-operation of
page 5-123
display when the
see
system is powered
"Troubleshooting
Failure of circuit Check and fix it. the cable
harness" on page
6-19
Check and recover the
Endless loop of program -
program.
The controller is damaged Replace the controller. -


The contact head is loose Retighten the contact. -
see “Fuses,
The fuse of control circuit is blown Replace the fuse. changing” on
page 5-123
Rotate the ignition
The gear selector is not at neutral Rotate the gear selector to
switch, but the engine -
does not start position neutral position.
Check the relay, and
The start relay is damaged -
Check the switch, and
The ignition switch is deffective -
Find out the reason and
Pool contact of ignition switch -
eliminate the failure.
see “Fuses,
Rotate the ignition Replace the fuse body after
The fuse of control circuit is blown changing” on
switch, but the inspection.
page 5-123
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 fix it. the cable
The travelling speed
harness" on page
is not displayed and
6-19
the machine can only
The speed sensor is damaged Replace it. -
travel 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
Check the connector and wire. -
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
The ignition switch is turned off Turn on the ignition switch. -
Cab cannot be Solenoid valve is damaged Check the solenoid valve. -
moved The connector is loose or the
wire is dropped
The ignition switch is turned off Turn on the ignition switch. -
Counterweight Solenoid valve is damaged Check the solenoid valve. -
cannot be moved The connector is loose or the
wire is dropped
The menus cannot Too much redundancy data Refresh the page. -
be displayed The screen is disturbed by Eliminate the interference
-
normally with magnetism source.
distorted figures The screen is damaged Replace the screen. -
see
"Troubleshooting
Canbus failure Check and recover the wire. the cable
harness" on page
6-19
The data displayed
Canbus terminal resistance is
on the screen is Replace the resistance. -
damaged
abnormal
see
"Troubleshooting
The lead is peeled Check and recover the wire. the cable
harness" on page
6-19


see “Fuses,
The fuse of power supply is
blown
page 5-123
Failure of controller Check it. -
Failure of program -
No operation of program.
controller Controller damaged Replace the controller. -
see
"Troubleshooting
Failure of input or output circuit Check the circuit. the cable
harness" on page
6-19
see “Fuses,
The fuse of power supply is
No operation of blown
page 5-123
extended block
Failure of extended block -
communication circuit.
Communication fault Check if the circuit is
Failure of the communication
between engine and disconnected or if there is -
circuit
controler water in circuit.
Communication fault Check if the circuit is
between controller disconnected or if there is -
circuit
and I/O water in circuit.
Check if the circuit is
disconnected or if there is -
circuit
Communication fault water in circuit.
between controller Check if the terminal resistor
and display is burnt or poorly connected.
Failure of terminal resistor -
Check if the terminal resistor is
on its plug.
Check if the circuit is
disconnected or if there is -
circuit
Communication fault water in circuit.
between controller Check if the terminal resistor
and length & angle is burnt or poorly connected.
sensor Failure of terminal resistor Check if the terminal resistor -
is in its plug, or replace the
sensor.

6.4 Engine Error Codes
6.4.1 VOLVO engine error codes
For the detailed information, see: “VOLVO

ENGINE MANUAL”.
Table 6-10 Engine Error Codes

Code SPN
Description Possible Causes Failure Symptom Suggested Actions
No. Code
1.1 No faults
2.1 97 Water in fuel Water in fuel None Empty the primary fuel filter
1. Check the coolant level.
2.2 111 Coolant level Low coolant level Engine stopped 2. Check the function of coolant
level monitor.
1. Check that the coolant level
1. Short circuit to
Coolant level sensor cable is not damaged.
2.3 111 positive (+) None
sensor 2. Check the function of coolant
2. Fault in sensor
level sensor.
1. Check that the sensor
1. No signal connector is correctly installed.
2. Abnormal 2. Check that the engine speed
Engine is very
frequency sensor cable is not damaged.
Flywheel difficult to start and
2.4 637 3. “Intermittent” 3. Check that the engine speed
speed sensor runs roughly when it
signal from the sensor is correctly installed in
starts.
sensor the flywheel housing.
4. Fault in sensor 4. Check the function of engine
speed sensor.
1. Check that the engine speed
sensor connector is correctly
installed.
Engine takes
1. No signal 2. Check that the engine speed
Camshaft longer to start than
2. Abnormal sensor cable is not damaged.
2.5 636 drive speed normal. Engine
frequency 3. Check that the engine speed
sensor runs normally when
3. Fault in sensor sensor is correctly installed in
running.
the upper timing gear cover.
4. Check the function of engine
speed sensor.
After the engine has stopped,
Engine speed too
2.6 190 Engine speed None look for the reason for the high
high
speed.

Code SPN
No. Code
1. Engine goes to
idle 1. Check that the potentiometer
2. If you release the has been connected correctly.
Speed
1. Shorted to positive accelerator first and 2. Check that the cable harness
potentiometer
2.8 608 (+) or negative (-) then press it down to the potentiometer has not
connected to
2. Fault in sensor again, the engine been damaged.
CIU
can be forced to 3. Check the potentiometer
run using the idle function.
contact.
1. Check the indicator cables for
1. Short circuit breaks and short circuits.
Indicator for
2.9 97 2. Open circuit None 2. Check the function of
water in fuel
3. Fault in indicator indicator. Change it as
necessary
1. Short circuit 1. Check that the oil pressure
Oil pressure to positive (+) or sensor cable is not damaged.
3.1 100 None
sensor negative (ground) (–) 2. Check that the oil pressure
2. Open circuit sensor is correctly connected.
1. Check that the boost
temperature sensor connector is
correctly installed.
2. Check that the boost
1. Short circuit
Boost temperature sensor cable is not
to positive (+) or
3.2 105 temperature None damaged.
negative (ground) (–)
sensor 3. Check that the boost
2. Open circuit
temperature sensor is correctly
installed.
4. Check the function of boost
temperature sensor.
1. Check that the coolant
temperature sensor connector is
correctly installed.
2. Check that the coolant
1. Short circuit
Coolant Preheating is also temperature sensor cable
to positive (+) or
3.3 110 temperature activated when the is not damaged.
negative (ground) (–)
sensor engine is hot. 3. Check that the coolant
2. Open circuit.
temperature sensor is correctly
installed.
4. Check the function of coolant
temperature sensor.

Code SPN
No. Code
1. Check that the boost pressure
installed.
1. Short circuit Engine smokes
Boost 2. Check that the boost pressure
to positive (+) or more than normally
3.4 106 pressure sensor cable is not damaged.
negative (ground) (–) during acceleration /
sensor 3. Check that the boost pressure
2. Open circuit load increase.
sensor is correctly installed.
4. Check the function of boost
pressure sensor.
Engine control
module reduces
1. Check the function of
engine power
turbocharger compressor.
Boost Boost pressure too (unless the
3.5 106 2. Check the function of boost
pressure high protection has been
pressure sensor.
shut off with the
3. Check fuel volume / injector.
VODIA diagnostic
tool).
1. Check that the fuel pressure
installed.
1. Short circuit
Fuel pressure to positive (+) or
3.6 94 None sensor cable is not damaged.
sensor negative (ground) (–)
2. Open circuit
sensor is correctly installed.
4. Check fuel pressure sensor
function.
1. Check that the cable harness
1. Short circuit to the oil temperature sensor
Oil
to positive (+) or has not been damaged.
3.7 175 temperature None
negative (ground) (–) 2. Check that the oil temperature
sensor
2. Open circuit sensor has been connected
correctly.
1. Check if it is possible to
increase pressure with the hand
3.8 94 Fuel pressure Low supply pressure None pump.
2. Check the fuel filter.
3. Check the fuel pre-filter.
1. Faulty alternator
Battery Check the supply voltage from
3.9 158 2. Faulty battery, None
voltage, EMS the control unit.
battery cables

Code SPN
No. Code
1. The engine 1. Check that connections to
1. Short circuit
cannot be started. the ignition key have not been
Start output to positive (+) or
2. The engine starts damaged.
4.6 677 / Start motor negative (–)
immediately when 2. Check that the cable harness
relay 2. Activated for too
the ignition is turned to the ignition key has not been
long
on. damaged.
1. Short circuit to Engine can only be
520 Stop input Check that the starter switch
4.8 negative (-) stopped with the
195 EMS connections are not damaged.
2. Open circuit auxiliary stop.
1. The engine 1. Check that connections to
1. Short circuit to cannot be started. the ignition key have not been
520 Starter input negative (-) 2. The engine starts damaged.
5.2
194 CIU 2. Activated for too immediately when 2. Check that the cable harness
long the ignition is turned to the ignition key has not been
on. damaged.
1. Engine can only
be stopped with the
auxiliary stop.
2. Engine stops. A
1. Short circuit to
fault is displayed for 1. Check that the starter switch
negative (-)
Stop input 40 seconds and the connections are not damaged.
5.3 970 2. Open circuit
CIU engine can not be 2. Check that the ignition switch
3. Activated for too
started during this cable is not damaged.
long
time. When a fault
is active, the engine
can be started but
not stopped.
1. Preheating can
1. Short circuit
not be activated. 1. Check that the relay input
Preheating to positive (+) or
5.4 626 2. Preheating cable is not damaged.
relay negative (ground) (–)
relay is constantly 2. Check the function of relay.
2. Open circuit
connected.
5.7. 98 Oil level Oil level is too low Warning indication Check the oil level.
1. Warning
indication.
2. The engine
1. Check the oil level.
control module
Oil Oil temperature is 2. Check the oil temperature.
5.8 175 limits engine output
temperature too high 3. Check the function of oil
(unless protection
temperature sensor.
has been turned off
with the diagnosis
tool VODIA).

Code SPN
No. Code
1. Short circuit
to the oil level sensor has not
Oil level to positive (+) or
5.9 98 None been damaged.
2. Check the function of oil level
2. Open circuit
sensor.
2. Check the intercooler
Engine control
(cleanliness).
module reduces
3. Check if there is air in the
engine power
cooling system.
Coolant Coolant temperature (unless the
6.1 110 4. Check the pressure cap on
temperature is too high protection has been
the expansion tank.
shut off with the
5. Check the function of coolant
VODIA diagnostic
temperature sensor.
tool).
thermostat.
Engine control
module reduces
2. Check the intercooler
engine power
(cleanliness).
Boost Boost temperature is (unless the
6.2 105 3. Check boost temperature
temperature too high protection has been
sensor the function of.
shut off with the
VODIA diagnostic
thermostat.
tool).
1. Check that the 8-pin
connector is not damaged.
Data link Instruments and
Faulty data link 2. Check that the cables
6.4 639 (CAN), warning lights stop
(CAN), CIU between the CIU and the engine
CIU working.
management unit are not
damaged.
Internal fault in
control module.
Engine not
2. Check that the cables
operating: engine
between the CIU and the engine
2017 / PSID Data link (CAN), can not be started.
6.5 639 management unit are not
201 EMS 2 Engine operating:
damaged.
engine idles and can
3. Check that sleeves 11 and 12
only be stopped with
in the connector on the CIU are
the auxiliary stop
not damaged.
(AUX-stop).

Code SPN
No. Code
Engine control 1. Check the oil level.
module reduces 2. Check that the air filters are
engine power not blocked.
Oil pressure is too (unless the 3. Check system pressure
6.6 100 Oil pressure
low protection has been valves and safety valves in the
shut off with the oil system.
VODIA diagnostic 4. Check the function of oil
tool). pressure sensor.
Engine stopped. The
Check that the oil pressure in
520 Piston cooling Piston cooling fault is de-activated
6.7 the engine exceeds 175 kPa
192 pressure pressure is too low at engine speed
(25.4 psi).
below 1000 rpm.
1. Check that the piston cooling
pressure sensor contact is
1. Short circuit correctly installed.
Piston cooling
520 to positive (+) or 2. Check that the cable harness
6.8 pressure None
192 negative (ground) (–) to the piston cooling pressure
sensor
2. Open circuit sensor has not been damaged.
3. Check the function of piston
cooling pressure sensor.
1. Short circuit to 1. Check the supply voltage
negative (-) from the control unit.
Battery Problems in engine
6.9 158 2. Faulty alternator 2. Check the battery.
voltage, CIU starting.
3. Faulty battery or 3. Check the alternator.
battery cables 4. Check the 8-pin contact.
1. Check that the injector cables
are not damaged.
1. Engine runs on 5
1. Electrical fault 2. Check that the injector
cylinders.
Injector, 2. Faulty connections are not damaged.
7.1 651 2. Abnormal sound.
cylinder #1 compression or 3. Check fuel supply pressure.
3. Reduced
injector 4. Check the valve clearance.
performance.
5. Do a compression test and
check cylinder #1.
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #2.

Code SPN
No. Code
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #3.
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #4.
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #5.
are not damaged.
1. Engine runs on 5
cylinders.
3. Reduced
performance.
check cylinder #6.
Crankcase The engine is 1. Check whether the crankcase
ventilation shut down (if the ventilation is blocked.
Crankcase ventilation
7.7 153 pressure protection has not 2. Check whether cylinder liner,
pressure too high
(TAD950- been shut off by the piston or piston rings
952VE) parameter tool). are worn or damaged.

Code SPN
No. Code
1. Check that the crankcase
ventilation pressure
sensor contact is correctly
Crankcase
installed.
ventilation 1. Short circuit
pressure to positive (+) or
7.8 153 None to the crankcase
ventilation pressure sensor has
(TAD950- 2. Open circuit
not been damaged.
952VE)
crankcase ventilation pressure
sensor.
1. Fault in cable
Internal EGR harness (boost Engine control 1. Check the cable harness
8.5 2791 (TAD950- pressure sensor) module reduces (boost pressure sensor).
952VE) 2. Mechanical fault engine power. 2. Check the IEGR.
on the IEGR
1. Faulty values in oil
pressure and boost
pressure sensors.
2. Fault for oil 1. Check that the cable harness
620/ pressure and boost to oil pressure and boost
1079/ Power supply 1. Shortcut pressure sensor. pressure sensor has not been
9.3
1080 to sensor 2. Fault in sensor 3. Low engine damaged.
output. 2. Check the oil pressure and
4. The instrument boost pressure sensors.
displays zero oil
pressure and boost
pressure.
Faulty data 2. Check that the cables
9.2 608 Faulty data link None.
link (J1587) between the CIU/DCU and the
engine management unit are not
damaged.

Code SPN
No. Code
1. Faulty values in oil
pressure and boost
pressure sensors.
2. Fault for oil 1. Check that the cable harness
pressure and boost to oil pressure and boost
620/ Power supply 1. Shortcut pressure sensor. pressure sensor has not been
9.3
1079 to sensor 2. Fault in sensor 3. Low engine damaged.
output. 2. Check the oil pressure and
4. The instrument boost pressure sensors.
displays zero oil
pressure and boost
pressure.
Data set 1. Internal fault in 1. Re-program the control
memory control module Engine does not module.
9.8 630
EEPROM, 2. Programming start. 2. If the fault remains, change
CIU faulty the control module.
1. Faulty EEPROM, 1. CIU returns to
CIU factory setting.
Fault in
2. Faulty flash 2. Engine goes to 1. Re-program the unit.
9.8 629 control unit,
memory, CIU idle. 2. Change the CIU unit.
CIU
3. Fault in control 3. Engine can not be
module, CIU started.
Memory fault in
Engine might not
9.9 639 Memory fault engine management Re-program the unit.
start.
system
Data set 1. Internal fault in 1. Re-program the control
memory control module Engine does not module.
9.9 630
EEPROM, 2. Programming start. 2. If the fault remains, change
EMS faulty the control module.
1. Engine misfires.
Control Internal fault in
9.9 629 2. Engine does not Change the control unit.
module EMS control module
start.

6.4.2 CUMMINS engine error codes
For the detailed information, see: “CUMMINS

ENGINE MANUAL”.

Code
Description Failure Symptom Suggested Actions
SPN / FMI
Engine speed limited to
1. Check the cabling between
Vehicle Speed Sensor max. engine speed. Road
84 / 2 control unit and component.
Circuit - data incorrect speed gover ner will not
2. Check the sensor.
work.
Engine speed limited to
Vehicle Speed Sensor 1. Check the cabling between
max. engine speed. Road
84 / 10 Circuit - tampering has control unit and component.
speed gover ner will not
been detected 2. Check the sensor.
work.
SAE J1939 Multiplexing Engine may only idle or
Use diagnostic menu to find the
91 / 19 Accelerator Pedal Sensor engine will not accelerate to
incorrect segment.
System Error full speed.
A c c e l e r a t o r P e d a l 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.
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.

SPN
Code
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.
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.

SPN
Code
1. Reprogramme the control unit.
2. Check if the 8-pin connector is in good condition.
Memorizer 3. Check if the cable harness between CIU and
639 Memorizer malfunction
malfunction engine control unit is in good condition.
4. Check if the plug hole 11 and 12 on CIU plug are
in good condition.
Cylinder 1
651
(SPN)
Cylinder 2 1. Check if the cable of pump nozzle is in good
652 condition.
(SPN)
Cylinder 3 1. Electrical malfunction 2. Check if the connector of pump nozzle is in
653
(SPN) 2. Difference of compressed good condition.
Cylinder 4 pressure or malfunction of 3. Check the fuel supply pressure.
654
(SPN) pump nozzle 4. Check the clearance of air valve.
Cylinder 5 5. Test the compressed pressure and check the
655
(SPN) cylinder.
Cylinder 6
656
(SPN)
1. Check if the power supply switch is connected
Start motor well.
677 pole (-)
(SPN) 2. Check if the cable of power supply switch is in
2. Too long operating time
good condition.
1. Short circuit of negative 1. Check if the power supply switch is connected
Stop input to pole (-) well.
970
CIU 2. Too long operating time 2. Check if the cable of power supply switch is in
3. Open circuit good condition.
1. Check if the power supply switch is connected
Start input to well.
520194 pole (-)
CIU 2. Check if the cable of power supply switch is in
good condition.
Stop inout to
520195 pole (-) Check if the power supply switch is connected well.
EMS

6.5 Transmission Error Codes
For the detailed information, see: “DANA

TRANSMISSION MANUAL”.
Table 6-13 Tranmission Error Codes

Code No. Description Limitation Suggested Actions
Memory error in control Transmission in locked Contact SANY distributors for more
00.50
unit transmission neutral position information.
00.51
00.52
00.53
Signal from sensor oil
1. Check cabling to sensor oil pressure.
pressure indicates low Transmission in locked
20.60 2. Check sensor oil pressure (with
oil pressure when there neutral position
engine on / off).
should be pressure
Signal from sensor oil
pressure indicates low Transmission in locked
20.61 2. Check sensor oil pressure (with
oil pressure when there neutral position
engine on / off).
should be pressure
Electrical malfunction Perform checks according to error code
20.62 Control unit activates
sensor oil pressure 50.XX.
Electrical malfunction Transmission in locked
20.63 -
solenoid valve drive neutral position
Electrical malfunction Transmission in locked
20.64 -
solenoid valve drive neutral position
Solenoid valve drive reacts Transmission in locked
20.65 -
too slow neutral position
Control unit saves stored
1. Check cabling to control unit.
information to flash
30.04 Low battery voltage 2. Check alternator, battery and cabling
memory and restarts to
between battery and alternator.
clear memory
Control unit receives
reduced proportional 1. Check voltage feed.
30.05 High battery voltage control precision 2. If auxiliary start equipment is
depending on reduced connected, disconnect it.
PWM work cycle
Reference voltage to Control unit receives 1. Check voltage feed.
31.00
sensors is too low reduced sensor signals 2. Check control unit.
Reference voltage to Control unit receives 1. Check voltage feed.
31.01
sensors is too high reduced sensor signals 2. Check control unit.


Incorrect direction from Control unit locks Check cabling to gear selector with
40.06
gear selector transmission in neutral regards to forward and reverse signal.
Control unit does not
Incorrect gear selection allow change of range, Check cabling to gear selector with
41.06
from gear selector however, operation of regards to signal range.
machine is possible
1. Check transmission with purpose to
Control unit indicates that understand if and, if that is the case,
42.04 Actual gear ratio too low one or several clutches which clutch is slipping.
are slipping 2. Check the set transmission ratio for
the control unit.
1. Check transmission with purpose to
Control unit indicates that understand if and, if that is the case,
42.05 Actual gear ratio too high one or several clutches which clutch is slipping.
are slipping 2. Check the set transmission ratio for
the control unit.
Signal from sensor engine 1. Check cabling to sensor temperature
rpm and oil temperature Control unit indicates the torque converter.
43.03
transmission outside valid error 2. Check sensor temperature torque
range converter.
Control unit indicates the 1. Check cabling to sensor temperature
Torque converter error to make operator torque converter.
43.07
temperature exceed 100°C aware of the warning's 2. Check sensor temperature torque
level converter.
The control unit protects
the transmission and does
not allow the temperature
1. Check cabling to sensor temperature
in the torque converter
Torque converter torque converter.
43.08 to exceed the limit value.
temperature exceed 125°C 2. Check sensor temperature torque
The control unit locks the
converter.
transmission in neutral,
engine is restricted to
50% of max. rpm
Sensor oil pressure short-
50.00 Control unit activates 2. Check sensor oil pressure (with
circuited to ground
engine on / off).
Sensor oil pressure not
50.01 Control unit activates 2. Check sensor oil pressure (with
connected or open circuit
engine on / off).


The control unit limits
the transmission's
temperature 1. Check cabling to sensor oil sump
Sensor engine rpm and oil
measurement to the temperature transmission.
51.00 temperature transmission
lowest value in its 2. Check sensor engine rpm and oil
short-circuited to ground
settings, which results temperature transmission.
in poor temperature
compensation
the transmission's
Sensor engine rpm and oil temperature 1. Check cabling to sensor oil sump
temperature transmission measurement to the temperature transmission.
51.01
not connected or short- highest value in its 2. Check sensor engine rpm and oil
circuited to ground settings, which results temperature transmission.
in poor temperature
compensation
the transmission's
temperature
1. Check cabling to sensor oil sump
Sensor oil temperature measurement to the
52.00 temperature transmission.
short-circuited to ground highest value in its
2. Check sensor oil temperature.
settings, which results
in poor temperature
compensation
the transmission's
temperature
1. Check cabling to sensor oil sump
Sensor oil temperature measurement to the
52.01 temperature transmission.
short-circuited to ground highest value in its
2. Check sensor oil temperature.
settings, which results
in poor temperature
compensation
Analogue input 3 short-
53.00 - -
circuited to ground
Analogue input 3 not
53.01 - -
connected
54.00 - -
circuited to ground
54.01 - -
connected
55.00 - -
circuited to ground


55.01 - -
connected
56.00 - -
circuited to ground
56.01 - -
connected
When only one rpm signal
which is not the engine 1. Check cabling between control unit
Sensor drum rpm short-
60.00 rpm signal is incorrect, and component.
circuited to ground
the control unit calculates 2. Check component.
the missing rpm.
Sensor drum rpm not
connected
the missing rpm.
Sensor rpm output shaft
the missing rpm.
Sensor rpm output shaft
not connected
the missing rpm.
Sensor engine rpm short-
circuited to ground
the missing rpm.
Sensor engine rpm not
connected or open circuit
the missing rpm.
Sensor rpm turbine short-
circuited to ground
the missing rpm.


Sensor rpm turbine not
connected
the missing rpm.
Electric malfunction
solenoid valve forward,
cables are short circuited
70.00 to each other, signal cable Control unit activates Check cabling to solenoid valve forward.
short-circuited to voltage
or positive cable short-
circuited to ground
Electric malfunction 1. Check cabling to solenoid valve
70.01 solenoid valve forward or Control unit activates forward.
short-circuited voltage 2. Check solenoid valve forward.
1. Check cabling to solenoid valve
solenoid valve forward,
70.02 Control unit activates forward.
control current above
2. Check solenoid valve forward.
1400mA
solenoid valve forward, 1. Check cabling to solenoid valve
70.03 control current outside Control unit activates forward.
approved interval. 2. Check solenoid valve forward.
Incorrect impedance
Electric malfunction gear 2
/ 4, cables short-circuited
to each other, signal cable
71.00 Control unit activates Check cabling to solenoid valve gear.
circuited to ground
Electric malfunction gear
1. Check cabling to solenoid valve gear.
71.01 2 / 4, open circuit or short- Control unit activates
2. Check solenoid valve gear 2/ 4.
circuited voltage
Electric malfunction gear 1. Check cabling to solenoid valve gear
71.02 2 / 4,control current above Control unit activates 2 / 4.
1400mA 2. Check solenoid valve gear 2/ 4.
solenoid valve gear 1. Check cabling to solenoid valve gear
71.03 2 / 4,control current Control unit activates 2 / 4.
outside approved interval 2. Check solenoid valve gear 2/ 4.
(incorrect impedance)


solenoid valve reverse,
cables are short circuited
72.00 to each other, signal cable Control unit activates Check cabling to solenoid valve reverse.
circuited to ground
72.01 Control unit activates reverse.
open circuit or short-
2. Check solenoid valve reverse.
circuited voltage
72.02 Control unit activates reverse.
control current above
2. Check solenoid valve reverse.
1400mA
solenoid valve reverse, "1. Check cabling to solenoid valve
72.03 control current outside Control unit activates reverse.
approved interval. 2. Check solenoid valve reverse.
Incorrect impedance
Electric malfunction gear 1
/ 3, cables short-circuited
to each other, signal cable Check cabling to solenoid valve gear 1 /
73.00 Control unit activates
short-circuited to voltage 3.
circuited to ground
73.01 1 / 3, open circuit or short- Control unit activates 1 / 3.
circuited voltage 2. Check solenoid valve gear 1 / 3.
73.02 1 / 3,control current above Control unit activates 1 / 3.
1400mA 2. Check solenoid valve gear 1 / 3.
solenoid valve gear 1. Check cabling to solenoid valve gear
73.03 1 / 3,control current Control unit activates 1 / 3.
outside approved interval 2. Check solenoid valve gear 1 / 3.
Analogue output signal 4
74.00 related error; output signal - -


74.01 not connected or short- - -
circuited to voltage
Analogue output signal
74.02 4 control current above - -
1400mA
4 control current outside
74.03 - -
approved interval
75.00 5 output signal short- - -
circuited to ground
75.01 not connected or short- - -
75.02 5 control current above - -
1400mA
5 control current outside
75.03 - -
approved interval
Electric malfunction brake,
Control unit indicated the
76.00 cable short-circuited to Check cabling to solenoid valve brake.
error, no limitation
ground
Electric malfunction brake,
76.01 cable not connected or Check cabling to solenoid valve brake.
Electric malfunction brake, 1. Check cabling to solenoid valve
76.02 control current above brake.
1400mA 2. Check solenoid valve brake.
brake, control current Control unit indicated the
76.03 brake.
outside approved interval error, no limitation
2. Check solenoid valve brake.
Electric malfunction drive,
Transmission in locked 1. Check cabling to solenoid valve drive.
80.00 cable short-circuited to
neutral position 2. Check solenoid valve drive.
ground
80.01 cable not connected or


Electric malfunction gear 1. Check cabling to solenoid valve 2 / 4.
81.00 selection 2 / 4, cable Control unit activates 2. Check solenoid valve gear selection
short-circuited to ground 2 / 4.
1. Check cabling to solenoid valve 2 / 4.
selection 2 / 4, cable
81.01 Control unit activates 2. Check solenoid valve gear selection
not connected or short-
2 / 4.
Electric malfunction gear 1. Check cabling to solenoid valve 1 / 3.
82.00 selection 1 / 3, cable Control unit activates 2. Check solenoid valve gear selection
short-circuited to ground 1 / 3.
1. Check cabling to solenoid valve 1 / 3.
selection 1 / 3, cable
82.01 Control unit activates 2. Check solenoid valve gear selection
not connected or short-
1 / 3.
83.00 cable short-circuited to
ground
83.01 cable not connected or
90.XX-99. Transmission in locked Contact SANY distributors for more
System error
XX neutral position information.

6.6 Machine Error Codes
6.6.1 Error codes of H1 / H2 / H3 / H4

container handler
Table 6-14
No. Name Possible Causes Suggested Actions Reference

1. Lower the traveling speed.
The traveling speed
2. Lower the load height.
Code 01 Loaded_overspeed is above the safety -
3. Decrease the forward tilting
speed limit.
angle of mast.
1. Check whether the radiator
temperature control switch,
Gearbox temperature
driving motor and the radiator
is too high, checked
Code 02 GearboxTemp_H fin are dirty. -
to be higher than 120
2. Check whether the voltage-
°C.
distributing circuit of resistor is
normal.
1. Check whether the sensor
connector is normal.
Hydraulic oil 2. Check whether the sensor is
temperature is too effective.
Code 03 Hyd_OilTemp_H -
high, checked to be 3. Check the radiator or the
higher than 65 °C. temperature control switch on
it. Check if the radiator fin is
dirty.
1. Check if the filter is too dirty
or clogged. Replace or clean it
The signal of oil-
if necessary.
Code 04 Oilwater_Alarm water separator is -
2. Check the switch
abnormal.
components with universal
meter.
The pressure switch Check if the parking oil-way
Code 05 ACC_PL _Alarm of accumulator pressure and circuit of parking -
functions. valve are normal.


2. Check the switch
components with universal 1. see “Coolant
The signal of coolant
meter. level, checking
Code 06 Engine_coolant_L level switch is
3. Check if the switch is too and topping up”
abnormal.
dirty. on page 5-50
4. Check if the wire-out of
switch is disconnected.
or clogged. Replace or clean it 1. see “Air
The signal of
if necessary. filter element,
Code 07 HYD_FJ_Alarm hydraulic oil filter is
2. Check the switch changing” on
abnormal.
components with universal page 5-105
meter.
1. see “Brake oil
The signal of brake if necessary.
Code 08 Brake_FJ_Alarm filter, changing”
oil filter is abnormal. 2. Check the switch
on page 5-112
meter.
1. Check the function of sensor.
The signal of sensor
Code 09 Sensor_Error 2. Check if the wires are loose. -
is abnormal.
3. Check the power supply.
1. see “Fuel
The fuel level is lower 1.Check the oil level of tank.
Code 10 FueLevel_L level, checking”
than 50L. 2.Check the sensor and circuit.
on page 4-8
1. Dismantle the sensor to see
if it is blocked.
The pressure is lower
Code 11 GearboxPressure_L 2. Check the function of sensor. -
than 16 bar.
3. Check the disconnection
alarm of sensor.
1. see “Radiator,
cleaning” on
1. Check if the engine radiator page 5-53
The water is dirty. If yes, clean it. 2. see “Coolant
Code 12 Engine_Tem_H temperature of engine 2. Check the water level and level, checking”
is above 103°C. pipe of tank. on page 4-6
3. Check the fan and belt. 3. see “Radiator
fan, checking”
on page 5-53


1. Check if the oil is refilled
during maintenance. 1. see “Oil level,
Oil pressure of
2. Check if the filter is changed checking and
Code 13 Engine_OilPress_L engine oil is lower
at regular intervals. topping up” on
than 55 kpa.
3. Check the oil sensor and page 5-39
circuit.
1. Check the working condition
Battery voltage is of generator.
Code 14 Battery_voltage_L -
lower than 23V. 2. Check if there is enough
power for battery.
Use the safety Check if the safety bypass is
Code 15 Safe_bypass -
bypass. functioning.
Spreader proximity Check the working condition of
Code 16 LockUnlock_Alarm -
switch is abnormal. spreader proximity switch.
1. Check if the load percentage
Load percentage is
is too large.
Code 17 Load_Over_90% above 90% of the -
2. Check if the heavy pressure
maximum load.
sensor is working normally.
The lifting weight is is too large.
Code 18 Over_Load -
above the max. load. 2. Check if the heavy pressure
No receiving of GPS 1.Check if the GPS power line
Code 19 SYMT_CanFault internal signal for is connected well. -
long interval. 2. Check the signal of GPS
No receiving of
Check the working condition of
Code 20 CAN_ERROR engine signal for long -
CAN bus
interval.
1. The machine is locked
Code 21 GPS_LOCKED GPS locked. remotely. -
2. No signal for a long time.
1. Check if the lifting height is
too high.
Reach the critical
2. Check if the lifting speed is
Code 22 RollOver_Limit_Alarm condition of -
too fast.
overturning.
3. Check if the tilting angle is
too large.
Brake oil temperature Check hydraulic pressure and

Code 23 BrkOilTemp_Alarm -
is too high. circuits of parking valve, etc.
Height sensor is 1. Check the function of sensor.

Code 24 Altimetry_Sensor_Err -
abnormal. 2. Check if the wires are loose.


Engine preheating
Check if the engine preheating
Code 25 WarmUp_Alarm time is over 20 -
system is normal.
seconds
Turbocharger needs plent y
lubrication after the engine is
Unable to speed up
Code 26 IdleSpeed_Alarm started. It is unable to speed -
the machine
up the engine when the rotate
speed is limited.
Check if the ignition switch
Code 27 Engine_preheating Engine preheating is rotated to the preheating -
position.
Check the transmission SPN

Code 28 GearBox_Error_Alarm Transmission failure. -
codes.
Code 29 SPN_Alarm Gearbox malfunction Check the gearbox error codes. -
The engine situation Check the engine indicator

Code 30 Engine_Status_Alarm indicator light is in lights to prevent the engine -
alarm from damaging.
1. Check if the urea level is too
T h e u r e a l e v e l i s low.
Code 31 DEF_Tank_L_Alarm -
lower than 30L 2. Fill in urea to prevent
abnormality.
NOTE:
Only the container handlers equipped with
stage IV engines can display alarm information
item 29-31.

6.6.2 Error codes of H8 / H85 container

handler
Table 6-15

1. Lower the traveling speed.
The traveling speed
2. Lower the load height.
Code 01 High_Speed is above the safety -
3. Decrease the forward tilting
speed limit.
angle of mast.
1. Check whether the radiator
temperature control switch,
Gearbox temperature
driving motor and the radiator
is too high, checked
Code 02 GearBox_Temp_H fin are dirty. -
to be higher than 120
2. Check whether the voltage-
°C.
distributing circuit of resistor is
normal.
1. Check whether the sensor
connector is normal.
Hydraulic oil 2. Check whether the sensor is
temperature is too effective.
Code 03 Hyd_Oil_Temp_H -
high, checked to be 3. Check the radiator or the
higher than 65 °C. temperature control switch on
it. Check if the radiator fin is
dirty.
The signal of oil-
if necessary.
Code 04 Oil_Water_Fuel water separator is -
2. Check the switch
abnormal.
meter.
The pressure switch Check if the parking oil-way
Code 05 Acc_Pre_L of accumulator pressure and circuit of parking -
functions. valve are normal.
2. Check the switch
components with universal 1. see “Coolant
The signal of coolant
meter. level, checking
Code 06 Water_Level_L level switch is
3. Check if the switch is too and topping up”
abnormal.
dirty. on page 5-50
4. Check if the wire-out of
switch is disconnected.


or clogged. Replace or clean it 1. see “Air
The signal of
if necessary. filter element,
Code 07 Hyd_Filter_Jam hydraulic oil filter is
2. Check the switch changing” on
abnormal.
components with universal page 5-105
meter.
1. see “Brake oil
The signal of brake if necessary.
Code 08 Brak_Filter_Jam filter, changing”
oil filter is abnormal. 2. Check the switch
on page 5-112
meter.
1. Check the function of sensor.
The signal of sensor
Code 09 Sensor_Error 2. Check if the wires are loose. -
is abnormal.
3. Check the power supply.
1. see “Fuel
The fuel level is lower 1.Check the oil level of tank.
Code 10 Fue_Level_L level, checking”
than 50L. 2.Check the sensor and circuit.
on page 4-8
1. Dismantle the sensor to see
if it is blocked.
The pressure is lower
Code 11 Gear_Oil_Pre_L 2. Check the function of sensor. -
than 16 bar.
3. Check the disconnection
alarm of sensor.
1. see “Radiator,
cleaning” on
1. Check if the engine radiator page 5-53
The water is dirty. If yes, clean it. 2. see “Coolant
Code 12 Water_Temp_H temperature of engine 2. Check the water level and level, checking”
is above 103°C. pipe of tank. on page 4-6
3. Check the fan and belt. 3. see “Radiator
fan, checking”
on page 5-53
1. Check if the oil is refilled
during maintenance. 1. see “Oil level,
Oil pressure of
2. Check if the filter is changed checking and
Code 13 Oil_Pre_L engine oil is lower
at regular intervals. topping up” on
than 55 kpa.
3. Check the oil sensor and page 5-39
circuit.
1. Check the working condition
Battery voltage is of generator.
Code 14 Battery_Alarm -
lower than 23V. 2. Check if there is enough
power for battery.


Use the safety Check if the safety bypass is
Code 15 Safe_Bypass_Alarm -
bypass. functioning.
Spreader proximity Check the working condition of
Code 16 Lock_Error -
switch is abnormal. spreader proximity switch.
Load percentage is
is too large.
Code 17 Load_Over_90% above 90% of the -
2. Check if the heavy pressure
maximum load.
The lifting weight is is too large.
Code 18 Over_Load -
above the max. load. 2. Check if the heavy pressure
No receiving of GPS 1.Check if the GPS power line
Code 19 SYMT_Comm_Error internal signal for is connected well. -
long interval. 2. Check the signal of GPS
No receiving of
Check the working condition of
Code 20 CAN_Fail_Alarm engine signal for long -
CAN bus
interval.
1. The machine is locked
Code 21 GPS_Locked GPS locked. remotely. -
2. No signal for a long time.
1. Check if the lifting height is
too high.
Reach the critical
2. Check if the lifting speed is
Code 22 Tilting_Protect condition of -
too fast.
overturning.
3. Check if the tilting angle is
too large.
Brake oil temperature Check hydraulic pressure and
Code 23 Brak_Oil_Temp_H -
is too high. circuits of parking valve, etc.
Height sensor is 1. Check the function of sensor.
Code 24 Height_Sensor_Err -
abnormal. 2. Check if the wires are loose.
Engine preheating
Check if the engine preheating
Code 25 WarmUp_Alarm time is over 20 -
system is normal.
seconds
Turbocharger needs plent y
lubrication after the engine is
Unable to speed up
Code 26 IdleSpeed_Alarm started. It is unable to speed -
the machine
up the engine when the rotate
speed is limited.


1. Check if the sensor is
The pressure of abnormal.
energy-saving 2. Check if the wiring of this
Code 27 AccuPre_High -
accumulators are too sensor is disconnected.
high. 3. Check if the pressure of this
sensor is too high.
Code 28 1AccuPre_High -
accumulator is too sensor is disconnected.
sensor is too high.
sensor is too high.
sensor is too high.
sensor is too high.
Check if the ignition switch
Code 32 Eng_Preheating Engine preheating is rotated to the preheating -
position.
Engine preheating
It is the leave-factory quality
Code 33 Preheating_Over time is over 5 -
checking process.
seconds
No receiving signal 1. C h e c k i f t h e s e n s o r i s
Code 34 LenAng_CAN_Err from length & angle normal.
sensor 2. Check if its wiring is normal.

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Empty Container Handler Specifications
Specifications
7. Specifications
7.1 Technical Specification��7-2
7.1.1 Basic parameters��7-3
7.1.2 System configuration�� 7-4
7.1.2.1 Engine configuration�� 7-4
7.1.2.2 Gearbox configuration�� 7-5
7.1.2.3 Drive axle configuration�� 7-5
7.1.2.4 Spreader configuration�� 7-5
7.2 Unit Conversion�� 7-6
7.2.1 Unit abbreviation explanation�� 7-6
7.2.2 Conversion table, SI units ��7-7
7.2.3 Conversion table, length�� 7-8
7.2.4 Conversion table, area �� 7-8
7.2.5 Conversion table, volume�� 7-8
7.2.6 Conversion table, weight �� 7-9
7.2.7 Conversion table, pressure�� 7-9
7.2.8 Conversion table, temperature�� 7-9

Specifications Empty Container Handler
7. SPECIFICATIONS
7.1 Technical Specification
Fig. 7-1 Technical Specification

7.1.1 Basic parameters
Table 7-1 Basic Parameters
SDCY90K8H2 / SDCY90K7H2 / SDCY90K6H1 /
Permissible SDCY90K8H3 / SDCY90K7H3 / SDCY90K6H2 /
Item Unit
error SDCY90K8H4 / SDCY90K7H4 / SDCY90K6H3 /
SDCY90K8H8A / SDCY90K7H8A / SDCY90K6H4
SDCY90K8H85A SDCY90K7H85A
A Overall length ±1% mm 6916 6900 6916
Overall width (without
B ±1% mm 4200 4100 4200
spreader)
Overall width (with
C ±1% mm 5852-11985 6038-12170 5852-11985
spreader)
D Overall height (not lifted) ±1% mm 12300 10873 9517
E Overall height of spreader ±1% mm 2250 2250 2250
F Overall height (max. lifted) ±1% mm 4550±15 4550 4550±15
Machine weight ±3% kg 41000 39800 38500
Max. lifting weight - kg 9000 9000 9000
6 layers (8′6″)
8 layers (8′6″) or 7 layers (8′6″) or
Max. layer - layer or
7 layers (9′6″) 6 layers (9′6″)
5 layers (9′6″)
0%~
Max. lifting height mm 21250 18750 16050
+1.5%
Front suspension distance ±1% mm 1167 1140 1167
Max. lifting speed
±10% mm/s 600/450 600/550 600/450
(unloaded/loaded)
Max. lowering speed
±10% mm/s 600/600 600/600 600/600
(unloaded/loaded)
Max. traveling speed
±10% km/h 27/22 27/22 27/22
(unloaded/loaded)
Hill climbing capacity
- % 35/25 35/25 35/25
(unloaded/loaded)
Tilting angle of mast (forward/ ±0.5/
° 2/4 2/4 2/4
backward) ±1
0%~
Min. grounding clearance mm 323 323 288
+5%
Min. turning radius ±5% mm 6000 6000 6000
Overall displacement - ml/r 170 170 163
Max. working pressure ±2% bar 240 240 240
Cab noise ≤ dB 70 72 70

7.1.2 System configuration
7.1.2.1 Engine configuration
Table 7-2 Engine Configuration
SDCY90K8H1 / SDCY90K7H1 / SDCY90K6H1 / SDCY90K8H8A /

Model
SDCY90K8H85A / SDCY90K7H8A / SDCY90K7H85A
Model No. VOLVO TAD851VE

6 In-line Cylinders, 4 Strokes, Turbo Pressured, Centralized Air-air Cooling,
Type
Electric Control, etc.
Rated power 185kW/2200rpm
Max. torque 1160Nm/1350rpm
Exhaust gas standard EU Stage III
Model SDCY90K8H2 / SDCY90K7H2 / SDCY90K6H2
Model No. Cummins QSB6.7
Type
Rated power 164kw/2300rpm
Model SDCY90K8H3 / SDCY90K7H3 / SDCY90K6H3
Model No. VOLVO TAD871VE

Type
Rated power 185kW/2200rpm
Model SDCY90K8H4 / SDCY90K7H4 /SDCY90K6H4
Model No. Cummins QSB6.7 Tier4

Type
Rated power 168KW/2200rpm
Exhaust gas standard EU Stage IV

7.1.2.2 Gearbox configuration
Table 7-3 Gearbox Configuration
SDCY90K8H1 / SDCY90K7H1 / SDCY90K6H1 / SDCY90K8H8A /

SDCY90K8H85A / SDCY90K7H8A / SDCY90K7H85A / SDCY90K8H2
Machine model
/ SDCY90K7H2 / SDCY90K6H2 / SDCY90K8H3 / SDCY90K7H3 /
SDCY90K6H3 / SDCY90K8H4 / SDCY90K7H4 /SDCY90K6H4
Gearbox model No. DANA 13.7HR32300

Type Hydraulic torque conversion
Gear shifting way Auto/Manual
Gear position 3 Positions of Forward/Backward
Speed ratio 4.04-1.94-0.93
7.1.2.3 Drive axle configuration
Table 7-4 Drive Axle Configuration
SDCY90K8H1 / SDCY90K7H1 / SDCY90K6H1 / SDCY90K8H8A

/ SDCY90K8H85A / SDCY90K7H8A / SDCY90K7H85A /
Machine model SDCY90K8H2 / SDCY90K7H2 / SDCY90K6H2 / SDCY90K8H3 /
SDCY90K7H3 / SDCY90K6H3 / SDCY90K8H4 / SDCY90K7H4 /
SDCY90K6H4
Drive axle model No. Kessler D81 PL488

Max. allowable static axle load 420 kN (26km/h)
Max. allowable dynamic axle load 600kN
7.1.2.4 Spreader configuration
Table 7-5 Spreader Configuration
Model Technical Parameters

Rotating angle +105°/-195 °
Side-shifting distance ±600 mm
ELME588
Max. load capacity 9000 Kg
Applicable range 20′-40′ international standard containers
Rotating angle +105°/-195 °
SDJ90II / Side-shifting distance ±600 mm
SDJ90H Max. load capacity 9000 Kg
Applicable range 20′-40′ international standard containers

7.2 Unit Conversion
7.2.1 Unit abbreviation explanation
Table 7-6 Unit Abbreviation Explanation
Name Abbreviation
Newton metre Nm
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 7-7 SI Units Conversion Table
SI-unit Recalculation factor Non-SI Recalculation factor SI

Torque
Nm x 10.2 = kg·cm x 0.8664 =lb·in
Nm x 0.74 =lbf·ft x 1.36 =Nm
Nm 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 7-8 Length Conversion Table
Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.083333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm - 1mm = 0.001 mm
7.2.4 Conversion table, area

Table 7-9 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 7-10 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 7-11 Weight Conversion Table
Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 100000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)
7.2.7 Conversion table, pressure
Table 7-12 Pressure Conversion Table
Unit kp/cm2 bar Pa=N/m2 kPa lbf/in2 lbf/ft2

kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 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 7-13 Temperature Conversion Table
°F °C °F °C °F °C °F °C °F °C °F °C
-90 -67.78 -40 -40 10 -12.22 60 15.56 110 43.33 160 71.11
-80 -67.22 -30 -34.44 20 -6.67 70 21.11 120 48.89 170 76.67
-70 -56.67 -20 -28.89 30 -1.11 80 26.67 130 54.44 180 82.22
-60 -51.11 -10 -23.33 40 -4.44 90 32.22 140 60 190 87.78
-50 -45.56 -0 -17.78 50 -10 100 37.78 150 65.56 200 93.33
t°C = 5(T°F-32)/9, T°F = (9*t°C+160)/5

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Empty Container Handler Optional Parts
Optional Parts
8. Optional Parts
8.1 Fire Detection and Alarm System / Automatic Extinguishing Device�� 8-3
8.1.1 Fire detection and alarm system�� 8-3
8.1.1.1 Function description�� 8-4
8.1.1.3 Troubleshooting�� 8-7
8.1.1.4 Maintenance and repair�� 8-7
8.1.2 Automatic fire extinguishing device �� 8-9
8.1.2.2 Technical parameters��8-10
8.1.3 Electrical diagrams��8-11
8.2 Loudspeaker and Controller Kit��8-14
8.2.2 Operations��8-14
8.2.3 Electrical wiring diagram��8-15
8.3 Engine Idle Protection Function��8-16
8.4 Engine Preheating Protection Function��8-17
8.5 Engine Hour Meter��8-17
8.6 Twistlock Counter��8-17
8.7 Reversing Radar Display��8-18
8.8 Operator Presence System��8-18
8.9 Radio��8-19
8.9.2 Mute (Silence)�� 8-20

Optional Parts Empty Container Handler
8.9.3 Sound�� 8-20

8.9.4 Audio setting�� 8-20
8.9.5 Radio�� 8-21
8.9.6 Radio troubleshooting�� 8-23
8.10 Automatic Lubrication System�� 8-24
8.10.1 Operation precautions�� 8-24
8.10.2 Time setting�� 8-25

8. OPTIONAL PARTS
8.1 Fire Detection and Alarm

System / Automatic Extinguishing
Device
With the fire detection and alarm switch on the

right operation panel pressed down, the fire
detection and alarm system will be activated.
DG-1407120-1
Fig. 8-1
8.1.1 Fire detection and alarm system
Fire detection and alarm system (FZZK /

W03( (Hereinafter referred to as system)
continuously monitors (Engine compartment)
ambient temperature real-time, recognizes and
analyzes signals from all areas of machine,
as well as realizes monitoring alarm and
automatic fire disposal function through the
linear heat / fire detection components by the
cabin detection host. The system also has
online automatic fault detection and alarm
Fig. 8-2
function, high temperature / fire alarm function
and automatic fire extinguishing function.

8.1.1.1 Function description
Detection function:
When the system is installed, it will enter the
inspection status after power on.
High temperature alarm and automatic fire

extinguishing function:
When the cabin detection host detects that
the temperature of c abin NTC detector
reaches 110°C, the system would warn the
operator of high temperature through an alarm
device. After the operator cools down the
cabin and recovers the temperature, the high
temperature alarm would be automatically
canceled as long as the host detects that the
temperature has dropped to below 110 °C.
Fault detection function:

When there is short or open circuit to the
connecting wires of cabin fire detection
components, fire extinguishing device and
control system host, the system would perform
automatic fault detection and the detection
alarm light will flash for 1 second every 12
seconds.
NOTE:
The failure of any one circuit does not affect its
other functions.
Intelligent identification of fire signal and

automatic fire extinguishing function:
When the cabin NTC fire detector detects
that the ambient temperature is above 85 °C,
the rise rate is greater than 30 °C / min, or
absolute temperature of fire disaster is higher
than 130 °C, the system would intelligently
reckon that a fire disaster is happening.
Therefore it would f irstly star t the high
temperature forewarning function as soon
as the temperature reaches 110 °C and then

automatically start the fire extinguisher if the

temperature continues to rise and reaches 130
°C.
Fire extinguisher alarm function:

When the device begins spraying, the system
would inform the operator through an 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.

8.1.1.2 Precautions
The following steps should be performed after

the initial installation, repair and maintenance
of this product. Otherwise, the system may be
unable to work normally.
1. Do not directly connect the host with
the connector of fire extinguisher when
testing after installation. Instead, connect
a 12V-24V test lamp with the F + and
F- driving lines of system host or use a
multimeter to measure the voltage at both
ends.
2. If the light blinks in 1 minute, it indicates
that the system is incorrectly installed.
Eliminate the failure immediately. If the
light does not blink in 1 minute, it indicates
that the system is correctly installed and
the host will function properly. Go on to the
next step for checking the cabin detector.
3. H e a t a n y o n e o f t h e c a b i n N T C
temperature detectors with a lighter or by
other means to simulate the occurrence of
fire disaster. If the 12V-24V test light turns
on or the multimeter displays 12V-24V,
it means that the host and detectors are
working normally.
4. Disconnect the power supply, and then the
host is recovered to original status. That is,
the device is a qualified product which can
be used normally.
5. After the installation and detection, connect
the power supply of machine and install
the fire extinguisher. The fire extinguishing
and alarm system is ready for operation.

8.1.1.3 Troubleshooting
1. During the inspection, check whether

there is short or open circuit of the cabin
NTC temperature detectors and f ire
extinguisher. If yes, eliminate the fault.
2. When one circuit of NTC temperature
detectors is in malfunction, the system
would report the fault without influencing
the operations and functions of the other
two circuits.
3. If the fire extinguisher has several faulty
circuits simultaneously, the system would
not report the fault as long as there is one
normal circuit. When the fire extinguisher
is in malfunction, it would be unable to
put out a fire although the host can be
activated.
4. If the fault output L + driving line is
constantly 12V-24V high level after the
system is started, it means that the host
cannot function normally. Replace the host
immediately.
5. Once the cabin catches fire and the host
starts extinguishing the fire, the system
cannot be automatically recovered until the
power is off.
6. After the fire disaster, please disconnect
the power supply to replace the host and
temperature sensor. Strictly check and test
the replaced harness and sensors to avoid
potential hazards.
8.1.1.4 Maintenance and repair
1. The host and cabin NTC temperature

detectors 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 area where the temperature will
exceed 100 °C when the engine is working
normally (such as exhaust pipes, engine
housing, etc.).
4. Frequently check if the surface of NTC
temperature detectors are clean and wipe
them regularly. Otherwise, the sensitivity
of NTC temperature detectors would be
affected or even worse the detectors may
not alarm when the fire happens.
5. Never use non - prescr ibed and non -
standard 12V-24V power supply to avoid
damage to the host.
6. Never perform maintenance or repair when
the host is powered.
7. Host and detectors 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 is installed securely.
• The extinguisher with electric trigger
device must apply the nominal operating
voltage and current.
• Check fire extinguishing device regularly. If
this device has been damaged or started,
make sure to replace it.
• Keep the storage warehouse dry and well
ventilated.
• Load and put the device gently to prevent
collisions. Avoid exposure or rain.

8.1.2.2 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
Safety, Operation & Maintenance Manual - March 2017

Battery cabin Engine cabin
Optional Parts
8-11
8-12
Unmarked Tolerance
Size Table
Fig. 8-5
Size Tolerance
FZZK / W03 Fire Detection Alarm System A direction

Optional Parts
Structure Size Diagram
FZZK / W03
Sensor connector
Fire Detection
Alarm System
Power supply,
Length L = 300+/-20mm self-inspection feedback,
high temperature feedback
fire extinguisher connector

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
8-13
8.2 Loudspeaker and Controller

Kit
Main functions and features:

• Speaking prior to alarm.
• Volume adjustable.
• Microphone & Loudspeaker available.
• Various tones to choose.
• Visible and audible alarm synchronous
(optional).
Fig. 8-7 Loudspeaker
• Several kinds of combination mode for
choice.
• Good appearance, convenient operation.
8.2.1 Control panel
Control panel of call controller is composed

of alarm indicator light, power supply indicator
light, power supply switch, alarm light switch,
tone selection, alarm switch, volume (-), and
volume (+) keys.
Fig. 8-8 Control Panel

8.2.2 Operations
1. Connect the power supply, and the red

indicator light on control panel turns on.
Press the power switch on panel, and this
light goes out. At this time, the control box
enters standby mode. Press the power
switch again to enter work mode.
2. Press the alarm light switch on the panel,
and the yellow indicator light turns on.
Press this switch again, and this light goes
out.

3. When the alarm switch is pressed, the

alarm system will work and the horn will
sound an alarm. Press this switch again,
and the system stops working.
4. Press the tone button, and A, B, E tones
will alarm circularly. Please select the
appropriate tone according to your own
requirement.
5. Press the volume (-) and volume (+) keys
to increase or decrease the volume. When
the alarm system is working, press these
two keys to adjust the alarm volume. Press
the mike switch, and the speaking function
is activated. Hold this switch and press the
volume (-) and volume (+) keys to adjust
the speaking volume.
8.2.3 Electrical wiring diagram
Fig. 8-9 Electrical Diagram

8.2.4 Precautions
• The control box of this product can only be

installed indoors;
• Connect the wire correctly. Never make
the wires short circuit.
• Check if the rated voltage of alarm is in
accordance with that of power supply.
• Standardize the horn power.
• It is a nor mal phenomenon that the
temperature in control box rises during the
operation.
• Never open the c ontrol box without
permission.
• Any questions in operation, please contact
SANY.
8.3 Engine Idle Protection PARAMATER SETTING

Function Adjusting value
Item Feedback value
Automatic lock 0000 No
Choose the engine idle protection function at Curve selection 0000 Opti-index 1.2
the setting menu of display. Slope selection 0000 2-section slope
Pre-buffer index 0000 0
Auto speeding 0000 0 Item
Within 60 seconds after the engine is started, Switch
Idle_Protect 0000 No
there is no response from throttle and the
engine keeps running at idle. After 60 seconds, Send
it is able to operate the machine normally and

Back
there is no limitation to the throttle.
When the engine is running at maximum rpm,
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.
TY-1407006-1
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.
TY-1407007-1
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 Operator Presence System
The operator presence system (OPS) feature

has an electrical switch in the seat which
senses the presence of the operator. This
allows the transmission in internal combustion
engine trucks to be engaged only when the
operator is in the seat.
The operator can activate / deactivate this
protection function and adjust the protection
time through the display menu. The OPS is
defaulted to be activated and its protection
time is defaulted to be 1 minute when the
machine leaves factory. The protection time
can be adjusted in the range of 0-60 minutes.

8.9 Radio
This machine has equipped with an optional

radio. It is located at the left side of the
console.
TY-1509020-1
Fig. 8-14 Radio
8.9.1 Control panel
8 7 13
TA DISC
SOUND LOUD
AF AST PRISAT
9 11
1 4 BAND
VOLUME
2 VOCAL ROCK CLASSIC 5
VOLUME JAZZ FLAT POP
3 TA AF AST
RDS
9 12
321 456 10 10
1. 1………………Preset button 1 9. ……Increase the volume

2. 2………………Preset button 2 ……Decrease the volume
3. 3………………Preset button 3 10. …………Tuner mode
4. 4………………Preset button 4 Short press: Auto search
5. 5………………Preset button 5 Long press: Manual search
6. 6( )………Preset button 6 (traffice tune) 11. ………FM/AM
Short press: TA on/off Long press: AF on/off 12. …………RDS on/off
7. …………Select sound / audio styles 13. Display
8. ………………Power on/off
Fig. 8-15 Radio Panel

8.9.2 Mute (Silence)
Short press button to mute or cancel the

mute (silence).
NOTE:
The silenc e per iod may be inter r upted
by AL ARM announcement or traf f ic
announcement messages (if TA is switched
on).
Fig. 8-16 Power Supply Button
8.9.3 Sound
Whether you listen to Jazz, Vocal, Pop, Classic

or Rock music, this button is the perfect choice
for your setting.
Press to select BASS-Treb for your

own sound style, or adjust the settings with the
volume up/down buttons to select one of the
pre-define sound styles:
-BASS-TRE: Self settings
-FLAT: Original
-JAZZ: Jazz music
-VOCAL: Speech Fig. 8-17 Sound Button
-POP: Pop music
-CLASSIC: Classical music
-ROCK: Rock music
8.9.4 Audio setting

• Press to select desired audio mode.
-Sound style BASS-TRE, FLAT,
JAZZ, VOCAL, POP,
CLASSIC, ROCK
-BASS low notes
-TREBLE high notes
-BALANCE left-right
-FADER rear-front
Fig. 8-18 Sound Type
-LOUD OFF, LOW, MID, HIGH

• Press the volume button to adjust the

selected audio mode. After 5 seconds the
display returns to show the last mode of
operation. Adjustment of Bass and Treble
setting is only possible when BASS-TRE is
selected as the sound style.
8.9.5 Radio
11
Waveband
• Press to select the desired band:
10 10
12
Automatic search
• Press or to tune to a station of a lower
frequency or of a higher frequency. Fig. 8-19 Band Button
• To search for another station, press the
button again.
Manual tuning (if you know the frequency

of the required station)
• Long press the search button or for
more than 2 seconds, and the manual
tuning is activated.
• Then press or to tune to a station of a
lower frequency or of a higher frequency.
• If no station is searched in 5 seconds, the
system would return to its last operation.

Preselected stations
Manually storing stations in a preset

By using the preset keys (1 to 5), five stations
per band can be stored and recalled.
• Tune to the desired station.

• Press the desired preset key (1 to 5) for
more than 2 seconds to store the current
tuned station.
Fig. 8-20 Station Button
Preset, recalling
Press the desired preset key (1 to 5) to recall

the stored station.
Automatically storing stations (AUTO-

STORE)
• You can automatically store 5 strongest

FM stations on the FM AST band or
5 strongest MW(AM) stations on the
MW(AM) AST band. When you use Auto-
Store, the new stations replac e any
stations previously stored in the FM AST
band or the MW(AM) AST band.
• Press to activate auto-store.
• The system gives out a beep and then
mutes.
• When the station is stored successfully,
you can hear a beep followed by the
storing.
• Sometimes it may be impossible to find 5
stations.

8.9.6 Radio troubleshooting
When you suspect that your radio is not

functioning normally, please check the below
troubleshooting table before calling for service.
If you still have to send your radio set for

service, always send the complete set (with
detachable panel). Do not try to open the set
to service it yourself.
Table 8-2 Radio Troubleshooting Table
No. Fault Troubleshooting method

The set does not function. No 1. Check the fuse (set and car) and connections.
1
display 2. Check the operating voltage.
1. Adjust the volume of the set.
The set functions with no
2 2. Check the radar and balance settings.
sound.
3. Check the aerial and its connection.
1. Check that the aerial is fully extended and properly
connected.
The system cannot be tuned 2. Check that the negative terminal (brown lead) is
3
to a desired station. connected to the machine frame.
3. Desired station is too weak. Try the manual tuning
function.
Display shows frequency 1. The set is tuned to non-RDS station
4
instead of station name 2. The RDS function is switched off.

8.10 Automatic Lubrication

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
fully automatic. Therefore, it is not necessary
for the operator to lubricate.
The machine lubrication pump is located at the

right of frame cover plate (see Fig. 8-21). Lubrication pump
The spreader lubrication pump is located at

the sideshift bracket of spreader.
8.10.1 Operation precautions
Pay special attention to below items when

operating the automatic lubrication system:
DG-1512022-1
●● Check if there is enough grease in the
grease reservoir of lubrication pump. Fill Fig. 8-21
in grease in time. Never make the grease
pump run without grease.
●● Make sure that the upper cover of grease
reservoir is tightened to prevent dust and
dirt from 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
overflow valve of grease pump. If yes,
troubleshoot it immediately.
●● Usually the lubrication time is set to be 6
minutes and the intermittent time is set
to be 3 hours when the machine leaves
factory.

8.10.2 Time setting
When the operator has changed the time

setting by accident, it is able to set up the
lubrication time and intermittent time according
to below steps.
1. Move the protective cover at the base, and

then set up the time.
NOTE:
Make sure to tighten the protective cover after
the time setting.
RS-1407034-1
Fig. 8-22
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. 8-23
Table 8-3 Intermittent Time Setting Table
Position 1 2 3 4 5 6 7 8 9 A B C D E F
Minute 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60
Hour 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

3. Set up the lubrication time:

3
By rotating the red switch, 15 kinds of
lubrication time can be set up. 9
NOTE:
Never located the button at position 0.
Red switch to set up

lubrication time
Fig. 8-24
Table 8-4 Lubrication Time Setting Table
Position 1 2 3 4 5 6 7 8 9 A B C D E F
Second 8 16 24 32 40 48 56 64 72 80 88 96 104 112 120
Minute 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

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Empty Container Handler Schematics
Schematics
9. Schematics
9.1 Symbol Explanation��9-2
9.2 Hydraulic Schematic Diagrams��9-3
9.3 Electrical Schematic Diagrams��9-6
9.4 Schematic Diagrams of Spreader System��9-21
9.4.1 Hydraulic schematic diagram of spreader system��9-22
9.4.1.1 ELME588 Spreader��9-22
9.4.1.2 SDJ90II Spreader��9-23
9.4.1.3 SDJ90H Spreader��9-24
9.4.2 Electrical schematic diagram of spreader system��9-25
9.4.2.1 ELME588 Spreader��9-25
9.4.2.2 SDJ90II Spreader��9-27
9.4.2.3 SDJ90H Spreader��9-29

Schematics Empty Container Handler
9.1 Symbol Explanation

1 2
The following symbols are standard ones used in 3 4

wiring and hydraulic diagrams.
5 6
1. Electric control signal 21. Counter

2. Current flow 22. Flow control valve 7 8 M
3. Hydraulic control signal 23. Check valve
4. Hydraulic flow 24. Hydraulic cylinder 9 10
5. Hydraulic motor 25. Double-acting hydraulic cylinder
6. Hydraulic oil pump with variable displacement 26. Single-acting hydraulic cylinder 11 12
7. Hydraulic oil pump with fixed displacement 27. Valve block
8. Electric motor 28. Shuttle valve 13 14
9. Accumulator 29. Fuse protecter
U
10. Disc brake 30. Relay 15 P 16
11. Filter 31. Solenoid valve 17 18
12. Radiator 32. Breaker 19 20
13. Heater 33. Resistor
21 22
14. Bulb 34. Proximity switch
15. Analog signal output pressure sensor 35. Temperature switch 23 24
16. Pressure meter 36. Limit switch 25

17. Temperature gauge 37. Button
18. Fluid level gauge 38. Emergency stop switch 26 27
19. Flow gauge 39. Buzzer
28 29
20. RPM meter 40. Horn
30 31
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 Empty Container Handler
Machine Model Page Diagram

P 9-4 Fig. 9-2
SDCY90K8H4 / SDCY90K7H4
SDCY90K7H8 / SDCY90K7H85 / SDCY90K8H8
P 9-5 Fig. 9-3
/ SDCY90K8H85

Fig. 9-2 Hydraulic Schematic Diagram 1

Fig. 9-3 Hydraulic Schematic Diagram 2

9.3 Electrical Schematic Diagrams
Table 9-2 Electrical Diagram List of Empty Container Handler
Name Page Diagram

Diagram Description P 9-7 Fig. 9-4
VOLVO Engine Circuit Diagram (TAD851VE) P 9-8 Fig. 9-5
CUMMINS Engine Circuit Diagram (QSB6.7) P 9-9 Fig. 9-6
CUMMINS Engine Circuit Diagram (QSB6.7 Tier 4F) P 9-10 Fig. 9-7
Working Illumination System Diagram P 9-11 Fig. 9-8
Washing and Wiping System Diagram P 9-12 Fig. 9-9
Travelling Control System Diagram P 9-13 Fig. 9-10
Working Illuminating System and Radio Diagram P 9-14 Fig. 9-11
Air Conditioning and Cooling System Diagram P 9-15 Fig. 9-12
Spreader Control System Diagram P 9-16 Fig. 9-13
Controller Diagram 1 P 9-17 Fig. 9-14
Controller Diagram 2 P 9-18 Fig. 9-15
CAN Bus Communication Network P 9-19 Fig. 9-16
Gearbox Controller Diagram P 9-20 Fig. 9-17

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
Fuse engine part Right control panel harness
Battery Illumination auxiliary Control panel harness of

control part steering mechanism
Engine PLC part Cab top harness
Motor Cab working lamp harness

Radio,
loudspeaker Right frame head harness
Loudspeaker Frame head harness
Valve Power system harness

Rotary switch,
Rear frame body harness
rocker switch
Spreader control
Button harness
Steering Frame left harness
mechanism
Temperature Power supply harness
sensor
Pressure switch Mast control harness
Proximity switch Mast signal harness
Illumination lamp
Signal lamp
Horn, buzzer
Potentialmeter
Breaker
Pressure sensor
Fig. 9-4 Diagram Description

VOLVO EURO III Engine Circuit Diagram
Frame SYMC (B1:15)
8-core Plug-in Parts Socket
EMS2 Diesel Engine Controller
Power Supply Switch Start Key Start Engine Stall Directive / Diagnosis Electrification of
Generator Start Motor Start Relay Stop CAN2 Bus
(optional contact) Battery Preheat Output Output Emergency Stop Interface Control System
Power Supply System Start Control VOLVO TAD851VE Diesel Engine EMS2 Control
Fig. 9-5 VOLVO Engine Circuit Diagram (TAD851VE)

CUMMINS QSB6.7 Engine Circuit Diagram
Wiring
Power on
4-core ECM Engine Digital 50-core Socket

Socket J3 Fuel Control Device
CUMMINS Engine 9-pin

Detection Plug
Power Supply Switch Power Charging Start Start Key Start Emergency Engine Controller ECM
Start Relay Power Preheat Relay Diagnosis Interface CAN1 Bus
(optional contact) Battery Relay Preheat Indication Motor Start
Supply Generator
Output Output Stop Power Supply Supply
Power Supply System Start Control CUMMINS QSB6.7 Diesel Engine Controller
Fig. 9-6 CUMMINS QSB6.7 Engine Circuit Diagram

CUMMINS QSB6.7 T4 Engine Circuit Diagram
After-treatment System Power

Wiring
Power on ECM Engine

ECM Engine Controller CM2350A Socket J2 Controller CM2350A
Socket J1
Power Supply Switch Power Charging Start Start Key Start Emergency Engine Controller ECM Water Oil-water DEF Urea Pipe DEF Supply DEF Jar DEF Rotate Start Air-inlet SCR Catalyzer Control Module /
Preheat Start Relay CAN1 Bus
(optional contact) Battery Relay GeneratorIndication Motor Output Output Stop Power Supply Power Level Separator Heat Relay SM Aftertreatment
Control Relay Preheat Injection Speed Lock Preheat DOC Gas Emission Control Module
Measure
Power Supply System Start Control CUMMINS QSB6.7 T4 Diesel Engine Controller CUMMINS Urea Jar Module
Fig. 9-7 CUMMINS QSB6.7 T4 Engine Circuit Diagram

Frame CR0200 (CPU2:37)

Frame SYMC (B1:21)
(Up)
Flash Light
(Middle)
Nearby Light
(Down)
Distant Light
Frame SYMC (B2:12)
Left Front Right Front Lamp Distant / Passby Right Positon Loudspeaker Body Work Left Swing Right Swing Water
Left Positon Lamp Cab Top (back) Cab Top (front) Cab Light Alarm Lamp
Lamp Light Control Lamp (optional) Lamp Switch (Double-Container Optional) Preheat
Front Lamp Positon Lamp Body Work Lamp
Fig. 9-8 Working Illumination System Diagram

Wiper Intermittence
Relay
Washer Water Front Window Washer Front Wiper Top Window Washer Rear Window Wiper Rear Window Washer
Spare Fuse Wiper Control Switch High-speed Control Low-speed Control Front Wiper Wiper Controller & Top Wiper
Pump Electromagnetic Valve Switch Electromagnetic Valve Electromagnetic Valve
Fig. 9-9 Washing and Wiping System Diagram

Visible
Reversing
Radar
Steering Indication Front Back Front Back Reversing Front Back Reversing Visible Reversing Left Right High-speed Parking Brake Buffer Pressing
Electric Horn Parking Brake
Control Left Steering Light Right Steering Light Gear Reversing Light Buzzer Radar System (optional) Brake Light Parking Chain Switch (optional)
Steering Indication System Brake System Parking System
Fig. 9-10 Travelling Control System Diagram

Left Right Left Right Loudspeaker Loudspeaker

Rear Lamp Mast Lamp Front Width Lamp Rear Width Lamp
Radio
(right) (left)
Width Lamp Control Radio Control
Fig. 9-11 Working Illuminating System and Radio Diagram

Red
Air Conditioner
Control Panel Yellow/
Black Yellow Blue Black Purple
Air Conditioner Condenser Condenser Pressure System Temperature Oil Solenoid Brake Oil Solenoid Spare Power
Clutch Switch Switch Cooler Valve Temperature Switch Valve Supply
Power Supply Fan Temperature
Hydraulic Cooling System Oil Radiation Brake Oil Radiation

Air Conditioner System
System (optional)
Fig. 9-12 Air Conditioning and Cooling System Diagram

Double-container
Spreader Power Spreader Spreader Spreader LeftSpreader Right Spreader Spreader Safety Bypass (optional) Spreader Lamp Switch
Supply Locking Unlocking Side-shifting Side-shifting Extension Retraction Switch Spreader Left Spreader Right
Rotating Rotating
SANY Spreader
Spreader Twistlock Unlocking Seating

Lowering Indicator Indicator Indicator Spreader Lamp (spare)
Interruption Light Light Light
Signal (Green) (Red) (Yellow)
Fig. 9-13 Spreader Control System Diagram

Spreader Twistlock Unlocking Seating

Engine Engine
Spreader Spreader
Spreader Spreader Spreader Spreader Mast Operation Mast Lifting Mast Tilting Alarm Reset Lowering Indicator Indicator Indicator Emergency Preheat
Pushing Pushing Swinging Swinging Safety Bypass Forerunner Switch / Lowering Forward / Interruption Light Light Light Stop
Stop Controller Power Supply
Locking Unlocking Forward Button Signal Signal
Backward Forward Backward Backward
Signal (green) (Red) (Yellow)
Controller SYMC / IFM Controller CR0200
Spreader Spreader Spreader Spreader Locking Unlocking Seating Mast Mast Mast Mast Mast Tilting Mast Tilting Spreader
Mast Lifting Mast Lifting Lowering Lowering Forward Lifting
Backward Oil Supply Confluent Lifting
Spreader Spreader Indicator Indicator Indicator Lowering Lowering Proportional Proportional Proportional Proportional Proportional Confluent
Pushing Pushing Swinging Swinging Lamp Lamp Lamp Solenoid Solenoid Solenoid
Proportional Proportional
Solenoid Grounding
Locking Unlocking Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid
Forward Backward Forward Backward (green) (Red) (
Yellow) Valve 1 Valve 2 Valve 1 Valve 2 Valve 1 Valve 2 Valve Valve Valve Valve 1 Valve 2
Fig. 9-14 Controller Diagram 1

Neutral Throw-out Height Detection Left Hydraulic Main Low Water High
Hydraulic Oil
Forward Backward Gear I Gear II Parking
Brake
of GearGearbox Speed Oil Temperature Driving Speed Height Detection Proximity Height Detection Fuel Oil Rodless Pump Outlet
Oil-Water Hydraulic/ Brake Oil Low
Accumulator / Brake Oil
Gear Detection Proximity Chain Weighing Anti-clogging Gearbox
Level Signal Pressure Chamber Seperator Clogging Level of Engine
Gear Gear Pressure Switch Transmit Signal
of Gearbox
Proximity Switch Switch 1
Switch 2 Rectification Pressure Pressure
Water Tank
Temperature
(Spare) Proximity Switch Pressure (optional) Alarm
Controller SYMC / IFM Controller CR0200
Length & Angle Forward Backward Gear Gear Light & Sound Neutral High-Speed Electric- 90% Load Overload Hour Meter Twistlock
Sensor Power Solenoid Solenoid Solenoid Solenoid Gear Parking Parking Indication control Calculator Flash Relay Engine Protection
Valve 2 Alarm Interlock Interlock Throttle Alarm (yellow) Alarm (red) (optional)
Supply Valve Valve Valve 1 (optional)
Fig. 9-15 Controller Diagram 2

Length & Angle SYMC Controller / IFM Display SYCD-1121

Sensor Controller CR0200
Serial port commnication 9-pin plug
Mast Length & Angle Sensor (optional) Main Controller Communication SYCD-1121 Communication Interface
CAN-BUS Communication
Fig. 9-16 CAN BUS Communication System

Controller Engine Gearbox Gearbox

Electrification Middle Shaft Output Shaft Temperature Temperature 1st / 3rd Pressure 2nd Pressure
Power Rotate Speed Turbine Sensor Sensor
Signal Sensor Sensor Rotate Speed Switch Sensor
Supply 1
TE Gearbox Controller APC200
1st / 3rd 2nd F/R

Gearbox Grounding Proportional Proportional Proportional 1st / 3rd F/R/N
Selection Selection Serial Port
Valve Valve Valve
Fig. 9-17 Gearbox Controller Diagram

9.4 Schematic Diagrams of Spreader System
Table 9-3 Schematic Diagram List of Spreader System

Name Spreader Model Page Diagram
ELME 588 P 9-22 Fig. 9-18
Hydraulic Diagram SDJ90II P 9-23 Fig. 9-19
SDJ90H P 9-24 Fig. 9-20
P 9-25 Fig. 9-21
ELME 588
P 9-26 Fig. 9-22
P 9-27 Fig. 9-23
Electrical Diagram SDJ90II
P 9-28 Fig. 9-24
P 9-29 Fig. 9-25
SDJ90H
P 9-30 Fig. 9-26

9.4.1 Hydraulic schematic diagram of spreader system
9.4.1.1 ELME588 Spreader
Fig. 9-18 Hydraulic Schematic Diagram of ELME588 Spreader

9.4.1.2 SDJ90II Spreader
Fig. 9-19 Hydraulic Schematic Diagram of SDJ90II Spreader

9.4.1.3 SDJ90H Spreader
Pressure-measuring connector
Overflow valve
Solenoid switching valve
Solenoid switching valve Solenoid switching valve
Two-way throttle valve
Hydraulic lock valve group
Twistlock cylinder Twistlock cylinder Sideshift cylinder
Telescopic cylinder Telescopic cylinder
Fig. 9-20 Hydraulic Schematic Diagram of SDJ90H Spreader

9.4.2 Electrical schematic diagram of spreader system
9.4.2.1 ELME588 Spreader
Fig. 9-21 Electrical Schematic Diagram of ELME588 Spreader 1

Fig. 9-22 Electrical Schematic Diagram of ELME588 Spreader 2

9.4.2.2 SDJ90II Spreader
Power supply + Cab operation directives

Left side- Right side- Main beam Main beam Automatic twist-
shifting shifting extending retracting Locking Unlocking Safety bypass lock (optional)
Battery Left arm Right arm

Left locked Right locked Left unlocked Right unlocked Left seated Right seated suspended suspended
Power supply Position sensor signal Power supply - CAN BUS
Fig. 9-23 Electrical Schematic Diagram of SDJ90II Spreader 1

Control signal output (solenoid valve)

Left main beam Right main beam Left main beam Right main beam Left side- Right side-
Power supply + Left locking Right locking Left unlocking Right unlocking retracting shifting Input spare Input spare Input spare
extending extending retracting shifting
Main oil Locked alarm Locked signal Seated alarm Unlocked Unlocked Lifting interru- Lowering interru- Working condi-
Seated signal Spreader lamps
supply valve lamp lamp alarm lamp signal pted signal pted signal tion indication Output spare Output spare Output spare Output spare
To cab To cab To cab
Fig. 9-24 Electrical Schematic Diagram of SDJ90II Spreader 2

9.4.2.3 SDJ90H Spreader
Power supply + Cab operation directives

Left side- Right side- Main beam Main beam Automatic twist-
shifting shifting extending retracting Locking Unlocking Safety bypass lock (optional)
Battery Left arm Right arm

Left locked Right locked Left unlocked Right unlocked Left seated Right seated suspended suspended
Power supply Position sensor signal Power supply - CAN BUS
Fig. 9-25 Electrical Schematic Diagram of SDJ90H Spreader 1

Control signal output (solenoid valve)

Left main beam Right main beam Left main beam Right main beam Left side- Right side-
Locking Unlocking extending extending retracting retracting shifting shifting
Main oil Locked alarm Locked signal Seated alarm Unlocked Unlocked Lifting interru- Lowering interru- Working condi-
Seated signal Spreader lamps
supply valve lamp lamp alarm lamp signal pted signal pted signal tion indication
To cab To cab To cab
Fig. 9-26 Electrical Schematic Diagram of SDJ90H Spreader 2

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www.sanygroup.com
SANY MARITIME HEAVY INDUSTRY CO., LTD

Sany Industrial Park, Gaolan Port Economic & Development Zone, Zhuhai City,
Guangdong Province, China
Tel: 0086-756-7266945
Fax: 0086-731-84031999-149
B03T01ENAR1-SDCY90K8HX / SDCY90K7HX / SDCY90K6HX

A3 H-Type Container Handler SOM Manual-20170809

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Quality Changes the World

Empty Container Handler

Safety, Operation & Maintenance Manual

Safety, Operation & Maintenance Manual - March 2017 I

Empty Container Handler

II Safety, Operation & Maintenance Manual - March 2017

Safety, Operation & Maintenance Manual - March 2017 III

Duty of Owners or Other Authorized Personnel

IV Safety, Operation & Maintenance Manual - March 2017

Duty of All Working Personnel

Safety, Operation & Maintenance Manual - March 2017 V

VI Safety, Operation & Maintenance Manual - March 2017

Safety, Operation & Maintenance Manual - March 2017 I

II Safety, Operation & Maintenance Manual - March 2017

2.3.6.2 Safety rules for traveling��������������������������������������������������������������������������2-41

Safety, Operation & Maintenance Manual - March 2017 III

2.4.13.1 Handling inflammables safely���������������������������������������������������������������� 2-64

IV Safety, Operation & Maintenance Manual - March 2017

3.2.4.5 Top wiper switch������������������������������������������������������������������������������������� 3-20

Safety, Operation & Maintenance Manual - March 2017 V

VI Safety, Operation & Maintenance Manual - March 2017

Safety, Operation & Maintenance Manual - March 2017 VII

VIII Safety, Operation & Maintenance Manual - March 2017

5.6.1.3 Drive belt, checking (engine option CUMMINS)�������������������������������������� 5-35

Safety, Operation & Maintenance Manual - March 2017 IX

5.7.5 Propeller shaft, lubricating������������������������������������������������������������������������������� 5-61

X Safety, Operation & Maintenance Manual - March 2017

5.10.8.1 Wheel rim, installing������������������������������������������������������������������������������5-84

Safety, Operation & Maintenance Manual - March 2017 XI

5.14.7 Hydraulic oil circuit, checking����������������������������������������������������������������������� 5-111

XII Safety, Operation & Maintenance Manual - March 2017

6.4.1 VOLVO engine error codes����������������������������������������������������������������������������� 6-27

Safety, Operation & Maintenance Manual - March 2017 XIII

XIV Safety, Operation & Maintenance Manual - March 2017

Safety, Operation & Maintenance Manual - March 2017 1-1

1.7 Running in a New Machine ������������������������������������������������������������������������������������1-19

1-2 Safety, Operation & Maintenance Manual - March 2017

1.1 Overview WARNING

Before starting operation and maintenance,

Failure to do this may result in personal

Safety, Operation & Maintenance Manual - March 2017 1-3

Information, specifications, and illustrations

1-4 Safety, Operation & Maintenance Manual - March 2017

1.2 Application Range

1.2.1 Intended use

Empty container handlers are applicable

Fig. 1-2 Empty Container Handler

The user, and not SANY, is responsible for any

Machines covered by this manual are used for

Safety, Operation & Maintenance Manual - March 2017 1-5

1.2.2 Unintended use

If any procedures or actions not specified,

Improper uses include:

Modifying the machine without any approval

1-6 Safety, Operation & Maintenance Manual - March 2017

1.3 Machine Authorizations

All machines and equipment (some equipment

Safety, Operation & Maintenance Manual - March 2017 1-7

1.4 Your Documentation Package

Several documentations will be packed along

1.4.1 CD system requirements

The requirements of computer configuration

1-8 Safety, Operation & Maintenance Manual - March 2017

2.3.6.2 Safety rules for traveling��2-41

2.4.13.1 Handling inflammables safely�� 2-64

3.2.4.5 Top wiper switch�� 3-20

5.6.1.3 Drive belt, checking (engine option CUMMINS)�� 5-35

5.7.5 Propeller shaft, lubricating�� 5-61

5.10.8.1 Wheel rim, installing��5-84

5.14.7 Hydraulic oil circuit, checking�� 5-111

6.4.1 VOLVO engine error codes�� 6-27

1.7 Running in a New Machine ��1-19