Sany Container Reach Stacker Safety, Operation & Maintenance Manual – PDF DOWNLOAD

Sany Container Reach Stacker Safety, Operation & Maintenance Manual – PDF DOWNLOAD

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Sany Container Reach Stacker Safety, Operation & Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 588
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Sany Container Reach Stacker Safety, Operation & Maintenance Manual – PDF DOWNLOAD

1. Introduction

• 1.1 Overview
• 1.2 Application Range
  • 1.2.1 Intended Use
  • 1.2.2 Unintended Use
• 1.3 CE Authorization
• 1.4 Your Documentation Package
  • 1.4.1 CD System Requirements
  • 1.4.2 Recommendations on Using the Documentation
  • 1.4.3 Documentation Storage
  • 1.4.4 Manual Organization
• 1.5 Terminology
• 1.6 Machine Information
  • 1.6.1 Machine Nameplate
  • 1.6.2 Engine Nameplate
    • 1.6.2.1 Volvo Engine Nameplate
    • 1.6.2.2 Cummins Engine Nameplate
    • 1.6.2.3 Yuchai Engine Nameplate
  • 1.6.3 Spreader Nameplate
    • 1.6.3.1 SANY Spreader Nameplate
    • 1.6.3.2 ELME Spreader Nameplate
    • 1.6.3.3 BROMMA Spreader Nameplate
  • 1.6.4 Transmission Case Nameplate
    • 1.6.4.1 Dana Transmission Case Nameplate
    • 1.6.4.2 ZF Transmission Case Nameplate
• 1.7 Running in a New Machine
• 1.8 Machine Serial No. and Agent Info.
• 1.9 Correction Request Form
• 1.10 Contact Information

2. Safety

• 2.1 Safety Information
  • 2.1.1 Signal Words
  • 2.1.2 Examples of Using Signal Words
  • 2.1.3 Other Signal Words
  • 2.1.4 Safety Labels
• 2.2 Machine Labels
  • 2.2.1 Safety Labels – Location
  • 2.2.2 Safety Labels – Content
• 2.3 General Precautions
  • 2.3.1 Basic Safety Instructions
  • 2.3.2 Personal Protective Equipment
  • 2.3.3 Never Operate While in Bad Health
  • 2.3.4 No Passenger in the Cab
  • 2.3.5 Hand Signals
  • 2.3.6 Preparing Safety Items
  • 2.3.7 Checking Safety Equipment
  • 2.3.8 Precautions in High Voltage Areas
  • 2.3.9 Precautions in Thunderstroke
  • 2.3.10 Precautions in Wind
  • 2.3.11 Abnormal Cases
  • 2.3.12 Unauthorized Modification
• 2.4 Safety During Operation
  • 2.4.1 Work Area Safety
    • 2.4.1.1 Work Area Requirements
    • 2.4.1.2 Work Area Indications
  • 2.4.2 Checks Before Operation
  • 2.4.3 Keeping Machine Clean
  • 2.4.4 Mounting and Dismounting the Machine Safely
  • 2.4.5 Start-Up Safety
    • 2.4.5.1 Inside the Operator Cab
    • 2.4.5.2 Adjusting the Seat
    • 2.4.5.3 Checking the Seat Belt
    • 2.4.5.4 Machine Starting Precautions
    • 2.4.5.5 Jump-Start the Engine, Precautions
    • 2.4.5.6 In Cold Weather
    • 2.4.5.7 After Starting the Engine
  • 2.4.6 Precautions for Safe Operation
    • 2.4.6.1 Ensuring Good View
    • 2.4.6.2 Safety Rules for Traveling
    • 2.4.6.3 Precautions While Operating on Slopes
    • 2.4.6.4 Avoiding Injury from Reversing
    • 2.4.6.5 Preventing Control Failure
    • 2.4.6.6 Never Hoist the Load Except Container
    • 2.4.6.7 Never Hoist the Load Over Others’ Head
    • 2.4.6.8 Never Stand Under the Load
    • 2.4.6.9 Precautions for Operating Emergency Stop Button
    • 2.4.6.10 Precautions for Operating Safety Bypass Switch
  • 2.4.7 Parking the Machine Securely
    • 2.4.7.1 Parking Requirements
    • 2.4.7.2 Turning Off the Engine

3. System Functions

• 3.1 Main Components of Machine
  • 3.1.1 Power Driving System
    • 3.1.1.1 Engine
    • 3.1.1.2 Torque Converter – Gearbox
    • 3.1.1.3 Transmission Shaft
    • 3.1.1.4 Drive Axle
    • 3.1.1.5 Tyre
  • 3.1.2 Steering System
  • 3.1.3 Main Frame System
  • 3.1.4 Boom System
  • 3.1.5 Spreader System
  • 3.1.6 Hydraulic System
  • 3.1.7 Electrical System
• 3.2 Cab Control System
  • 3.2.1 Steering Controller
    • 3.2.1.1 Steering Wheel Panel
    • 3.2.1.2 Gear Selector
    • 3.2.1.3 Direction Indication Controller
    • 3.2.1.4 Adjusting the Angle of Steering Controller
  • 3.2.2 Pedal
  • 3.2.3 Joystick
  • 3.2.4 Right Operation Panel
    • 3.2.4.1 Ignition Switch
    • 3.2.4.2 Emergency Retraction / Lowering Switch
    • 3.2.4.3 Emergency Stop Switch
    • 3.2.4.4 Safety Bypass Switch
    • 3.2.4.5 Cab Moving Switch
    • 3.2.4.6 Counterweight Moving Switch (Optional)
    • 3.2.4.7 Parking Switch
    • 3.2.4.8 Fuel Heating Switch (Optional)
    • 3.2.4.9 Hydraulic Oil Preheating Switch (Optional)
  • 3.2.5 Front Operation Panel
    • 3.2.5.1 Spreader Light Switch
    • 3.2.5.2 Boom Light Switch
    • 3.2.5.3 Rear Light Switch
    • 3.2.5.4 Front Wiper Switch
    • 3.2.5.5 Top Wiper Switch
    • 3.2.5.6 Rear Wiper Switch
• 3.3 Display
  • 3.3.1 Menu Introduction
  • 3.3.2 Introduction and Operation of Display Area
    • 3.3.2.1 Start Menu
    • 3.3.2.2 Main Menu
    • 3.3.2.3 Engine Information Menu
    • 3.3.2.4 Hydraulic System Menu
    • 3.3.2.5 Gearbox Information Menu
    • 3.3.2.6 Fault Alarming Menu
    • 3.3.2.7 Digital Input Menu
    • 3.3.2.8 Digital Output Menu
    • 3.3.2.9 Analogy Input Menu
    • 3.3.2.10 Analogy Output Menu
• 3.4 Air Conditioning System
  • 3.4.1 Control Panel
    • 3.4.1.1 Power Switch
    • 3.4.1.2 Fan Speed Switch
    • 3.4.1.3 Temperature or Paging Switch
    • 3.4.1.4 Mode Switch
    • 3.4.1.5 Fresh Air Switch
  • 3.4.2 Operation
  • 3.4.3 Precautions
  • 3.4.4 Troubleshooting
• 3.5 Electric Control Cabinet
• 3.6 Fuse
• 3.7 Fire Extinguisher

4. Operation

• 4.1 Before the Starting of Engine
  • 4.1.1 Checks Before Operation
    • 4.1.1.1 Wiper Water Tank, Checking
    • 4.1.1.2 Expansion Water Tank, Checking
    • 4.1.1.3 Engine Oil Level, Checking
    • 4.1.1.4 Gearbox Oil Level, Checking
    • 4.1.1.5 Hydraulic Oil Level, Checking
    • 4.1.1.6 Fuel Tank, Checking
    • 4.1.1.7 Brake Oil Tank, Checking
    • 4.1.1.8 Tyres, Checking
    • 4.1.1.9 Electrical Components, Checking
    • 4.1.1.10 Working Light, Checking
    • 4.1.1.11 Horn, Checking
  • 4.1.2 Adjustment Before Operation
    • 4.1.2.1 Seat, Adjusting
    • 4.1.2.2 Rearview Mirror, Adjusting
    • 4.1.2.3 Safety Belt, Adjusting
• 4.2 Starting the Machine
  • 4.2.1 Start in Normal Weather
  • 4.2.2 Start in Cold Weather
  • 4.2.3 Start with Booster Batteries or Starting Generators
• 4.3 Stopping the Machine
• 4.4 Driving
  • 4.4.1 How to Drive
  • 4.4.2 Driving Forward
  • 4.4.3 Driving Backward
  • 4.4.4 Turning Around
  • 4.4.5 Parking
• 4.5 Load Handling
  • 4.5.1 Joystick
  • 4.5.2 Boom, Operation
  • 4.5.3 Spreader, Operation
  • 4.5.4 Hook, Operation
  • 4.5.5 Load Capacity Diagram
    • 4.5.5.1 Load Capacity Diagram of C-Type Container Reach Stackers
    • 4.5.5.2 Load Capacity Diagram of SRSC1009-6E Empty Container Reach Stacker
    • 4.5.5.3 Load Capacity Diagram of SRSC4545C Heavyweight Container Reach Stacker
    • 4.5.5.4 Load Capacity Diagram of SRSC4535 Heavyweight Container Reach Stacker
    • 4.5.5.5 Load Capacity Diagram of SRSC3515-3 Lightweight Container Reach Stacker
  • 4.5.6 Picking up a Container from the Stack
  • 4.5.7 Depositing a Container on the Stack
• 4.6 Transportation and Assembly
  • 4.6.1 Guidelines
  • 4.6.2 Packing, Requirements
  • 4.6.3 Transportation
    • 4.6.3.1 Transporting by Platform Lorry
    • 4.6.3.2 Transporting by Container
    • 4.6.3.3 Detailed Caution in Unloading
    • 4.6.3.4 Unloading the Machine
    • 4.6.3.5 Loading the Machine
  • 4.6.4 Assembly and Disassembly Preparations
    • 4.6.4.1 Safety Precautions
    • 4.6.4.2 Requirements for Crew Members
    • 4.6.4.3 Tools for Assembly and Disassembly
    • 4.6.4.4 Assembly Alerts of the Components
    • 4.6.4.5 Hoisting Points of Parts
  • 4.6.5 Assembly
    • 4.6.5.1 Prepare the Work Area
    • 4.6.5.2 Rear Counterweight, Installation
    • 4.6.5.3 Sliding Counterweight, Installation
    • 4.6.5.4 Pitching Cylinder, Installation
    • 4.6.5.5 Boom, Installation
    • 4.6.5.6 Spreader, Installation
    • 4.6.5.7 Lights, Installation
    • 4.6.5.8 Final Check
  • 4.6.6 Disassembly
    • 4.6.6.1 Prepare the Work Area
    • 4.6.6.2 Lights, Removal
    • 4.6.6.3 Spreader, Removal
    • 4.6.6.4 Boom, Removal
    • 4.6.6.5 Pitching Cylinder, Removal
    • 4.6.6.6 Sliding Counterweight, Removal
    • 4.6.6.7 Rear Counterweight, Removal

5. Maintenance

• 5.1 Scheduled Maintenance, General Information
• 5.2 General Tightening Torques
• 5.3 Recommended Fuel, Coolant and Lubricant
  • 5.3.1 Specification
  • 5.3.2 Capacity of the Tanks
    • 5.3.2.1 C-Type / SRSC4535 Container Reach Stackers
    • 5.3.2.2 SRSC4545C Container Reach Stacker
    • 5.3.2.3 SRSC3515-3 Container Reach Stacker
    • 5.3.2.4 SRSC1009-6E Container Reach Stacker
  • 5.3.3 Application Principle
  • 5.3.4 Hydraulic Oil, Description
  • 5.3.5 Quality of Hydraulic Oil, Check
• 5.4 Lubricating Points
  • 5.4.1 Lubricant
  • 5.4.2 Lubricating Points of Whole Machine
  • 5.4.3 Lubricating Points of Engine and Gearbox
  • 5.4.4 Lubricating Points of Drive Axle
• 5.5 Scheduled Maintenance
  • 5.5.1 Maintenance Every Day
  • 5.5.2 Maintenance Every 50 Hours
  • 5.5.3 Maintenance Every 250 Hours
  • 5.5.4 Maintenance Every 500 Hours
  • 5.5.5 Maintenance Every 1000 Hours
  • 5.5.6 Maintenance 1500 Hours
  • 5.5.7 Maintenance 2000 Hours
  • 5.5.8 Maintenance 6000 Hours
• 5.6 Engine
  • 5.6.1 General Engine Inspection
  • 5.6.2 Charge Air Pipe, Checking
  • 5.6.3 Drive Belt, Checking
  • 5.6.4 Generator Belt, Replacing
  • 5.6.5 Drive Belt, Replacing
  • 5.6.6 Air Filter, Checking / Changing
  • 5.6.7 Air Filter, Cleaning
  • 5.6.8 Lubrication System
    • 5.6.8.1 Engine Oil, Changing
    • 5.6.8.2 Oil Filter / Bypass Filter, Changing
  • 5.6.9 Cooling System
    • 5.6.9.1 Coolant, Mixing
    • 5.6.9.2 Water Quality
    • 5.6.9.3 Coolant Level, Checking
    • 5.6.9.4 Coolant, Filling
    • 5.6.9.5 Coolant, Draining
    • 5.6.9.6 Coolant Filter, Changing
    • 5.6.9.7 Radiator, Cleaning
    • 5.6.9.8 Radiator Fan, Checking
    • 5.6.9.9 Fan Hub, Checking
    • 5.6.9.10 Cooling System, Cleaning
• 5.6.10 Fuel System
  • 5.6.10.1 Fuel Filter, Replacing
  • 5.6.10.2 Diesel Filter, Changing
  • 5.6.10.3 Oil-Water Separator with Water Monitor, Replacing
  • 5.6.10.4 Oil-Water Separator, Draining
  • 5.6.10.5 Fuel System, Bleeding
• 5.6.11 Inlet System, Checking Leakage
• 5.6.12 Attaching Bolts of Engine Seat, Checking
• 5.6.13 Shock Absorber, Checking
• 5.6.14 Turbocharger and Blast Pipe, Checking
• 5.7 Transmission
  • 5.7.1 Gearbox, Function Description
  • 5.7.2 Attaching Bolts of Transmission Shaft, Checking
  • 5.7.3 Speed Sensor, Checking
  • 5.7.4 Attaching Bolts and Fixed Seat, Checking
  • 5.7.5 Transmission Shaft, Lubricating
  • 5.7.6 Gearbox Oil, Changing
  • 5.7.7 Gearbox Oil Level, Checking
  • 5.7.8 Gearbox Oil Filter, Changing
• 5.8 Drive Axle
  • 5.8.1 Attaching Bolts of Drive Axle to the Frame, Checking
  • 5.8.2 Attaching Bolts of Drive Axle to the Transmission Shaft, Checking
  • 5.8.3 Oil Leakage of Drive Axle and Brake Components, Checking
  • 5.8.4 Drive Axle Oil, Changing
  • 5.8.5 Breather Connector, Cleaning
  • 5.8.6 Brake Pedal, Checking and Adjusting
  • 5.8.7 Parking Brake Pads, Changing
  • 5.8.8 Brake Oil Filter, Changing
• 5.9 Steering Axle
  • 5.9.1 Daily Check
  • 5.9.2 Steering Axle, Lubricating
  • 5.9.3 Steering Knuckle, Maintaining
  • 5.9.4 Steering Axle Cradle, Checking
  • 5.9.5 Steering Pressure, Checking
• 5.10 Tyres and Rims
  • 5.10.1 Tyre, Description
  • 5.10.2 Tyre, Inflating
  • 5.10.3 Tyres, Checking
  • 5.10.4 Wheel Rim, Description
  • 5.10.5 Rim, Checking
  • 5.10.6 Wheel Rim, Installing and Removing
    • 5.10.6.1 Wheel Rim, Installing
    • 5.10.6.2 Wheel Rim, Removing
  • 5.10.7 Tyre, Removing and Installing (Drive Axle)
    • 5.10.7.1 Tyre of Drive Axle, Removing
    • 5.10.7.2 Tyre of Drive Axle, Installing
  • 5.10.8 Tyre, Removing and Installing (Steering Axle)
    • 5.10.8.1 Tyre of Steering Axle, Removing
    • 5.10.8.2 Tyre of Steering Axle, Installing
• 5.11 Boom
  • 5.11.1 Basic Boom, Checking
  • 5.11.2 Sliding Blocks, Checking
  • 5.11.3 Sliding Blocks of the Fixed Arm, Replacing
  • 5.11.4 Sliding Blocks of the Telescopic Arm, Replacing
  • 5.11.5 Pitching Cylinder, Checking
• 5.12 Spreader
  • 5.12.1 SANY / ELME Spreader
    • 5.12.1.1 Twistlock, Checking
    • 5.12.1.2 Twistlock, Lubricating
    • 5.12.1.3 Sensor / Indicator of Twistlock, Checking
    • 5.12.1.4 Fixed Bolts of Spreader Rotating Gearbox, Checking
    • 5.12.1.5 Sliding Blocks of Spreader, Checking
  • 5.12.2 BROMMA Spreader
    • 5.12.2.1 General Precautions
    • 5.12.2.2 After 50 Hours
    • 5.12.2.3 After 250 Hours
    • 5.12.2.4 After 500 Hours
    • 5.12.2.5 After 1000 Hours
    • 5.12.2.6 After 2000 Hours
    • 5.12.2.7 After 4000 Hours
    • 5.12.2.8 After 8000 Hours
• 5.13 Air Conditioning System
  • 5.13.1 General Recommendations
  • 5.13.2 Air Conditioning, Checking / Performance Test
  • 5.13.3 Refrigerant Quantity, Checking
  • 5.13.4 Refrigerant, Filling
  • 5.13.5 Cleanness of Heat-Exchanger Plate in Evaporator and Condenser, Checking
  • 5.13.6 Leakage or Lack of Oil in Condenser, Checking
  • 5.13.7 Radiator, Cleaning
  • 5.13.8 Maintenance Table for Air Conditioner
• 5.14 Hydraulic System
  • 5.14.1 Hydraulic Oil Level, Checking
  • 5.14.2 Hydraulic Oil Filter, Changing
  • 5.14.3 Hydraulic Oil, Changing
  • 5.14.4 Oil Return Filter Element, Replacing
  • 5.14.5 Hydraulic Oil Tank, Cleaning
  • 5.14.6 Parking Brake Unit, Checking and Adjusting
  • 5.14.7 Accumulator
    • 5.14.7.1 Brake System Accumulator, Checking
    • 5.14.7.2 Accumulators, Charging with Nitrogen Gas
  • 5.14.8 Hydraulic Oil Circuit, Checking
• 5.15 Electrical System
  • 5.15.1 Battery
    • 5.15.1.1 Battery, Cleaning
    • 5.15.1.2 Electrolyte, Filling
    • 5.15.1.3 Battery, Checking
    • 5.15.1.4 Battery, Charging
    • 5.15.1.5 Battery, Using
    • 5.15.1.6 Battery Cables, Checking
    • 5.15.1.7 Battery, Scheduled Maintenance
  • 5.15.2 Fuses, Changing
  • 5.15.3 All Working Lights and Indicators, Checking
  • 5.15.4 Wiper, Adjusting
  • 5.15.5 Wiper, Replacing
• 5.16 Maintenance Record List

6. Troubleshooting

• 6.1 Precautions
• 6.2 Troubleshooting Procedures
• 6.3 Common Troubleshooting Methods
  • 6.3.1 Troubleshooting the Engine System
  • 6.3.2 Troubleshooting the Transmission System
    • 6.3.2.1 Overview
    • 6.3.2.2 Troubleshooting Procedures
    • 6.3.2.3 Troubleshooting Table
  • 6.3.3 Troubleshooting the Drive Axle and Brake System
  • 6.3.4 Troubleshooting the Steering System
  • 6.3.5 Troubleshooting the Spreader System
  • 6.3.6 Troubleshooting the Mast System
  • 6.3.7 Troubleshooting the Air Conditioning System
  • 6.3.8 Troubleshooting the Hydraulic System
  • 6.3.9 Troubleshooting the Electrical System
    • 6.3.9.1 Troubleshooting the Cable Harness
    • 6.3.9.2 Troubleshooting Table
• 6.4 Engine Error Codes
  • 6.4.1 VOLVO Engine Error Codes
  • 6.4.2 CUMMINS Engine Error Codes
  • 6.4.3 YUCHAI Engine Error Codes
• 6.5 Machine Error Codes

7. Specifications

• 7.1 Technical Specifications
  • 7.1.1 Basic Parameters
  • 7.1.2 Technical Parameters
  • 7.1.3 Power System Configuration
• 7.2 Unit Conversion
  • 7.2.1 Unit Abbreviation Explanation
  • 7.2.2 Conversion Table, SI Units
  • 7.2.3 Conversion Table, Length
  • 7.2.4 Conversion Table, Area
  • 7.2.5 Conversion Table, Volume
  • 7.2.6 Conversion Table, Weight
  • 7.2.7 Conversion Table, Pressure
  • 7.2.8 Conversion Table, Temperature

8. Optional Parts

• 8.1 Fire Detection and Alarm System / Automatic Extinguishing Device
  • 8.1.1 Fire Detection and Alarm System
    • 8.1.1.1 Product Features
    • 8.1.1.2 Application Site and Environmental Conditions
    • 8.1.1.3 Technical Features
    • 8.1.1.4 Function Description
    • 8.1.1.5 Precautions
    • 8.1.1.6 Troubleshooting
    • 8.1.1.7 Maintenance and Repair
  • 8.1.2 Automatic Fire Extinguishing Device
    • 8.1.2.1 Precautions
    • 8.1.2.2 Technical Parameters
  • 8.1.3 Electrical Diagrams
• 8.2 Loudspeaker and Controller Kit
  • 8.2.1 Control Panel
  • 8.2.2 Operations
  • 8.2.3 Electrical Wiring Diagram
  • 8.2.4 Precautions
• 8.3 Engine Idle Protection Function
• 8.4 Engine Preheating Protection Function
• 8.5 Engine Hour Calculator
• 8.6 Twistlock Calculator
• 8.7 Reversing Radar Display
• 8.8 Radio
  • 8.8.1 Control Panel
  • 8.8.2 Mute (Silence)
  • 8.8.3 Sound
  • 8.8.4 Audio Setting
  • 8.8.5 Radio
  • 8.8.6 Radio Troubleshooting
• 8.9 CCTV System
  • 8.9.1 Safety Precautions
  • 8.9.2 Major Parts
  • 8.9.3 Installation
  • 8.9.4 Vehicle DVR
    • 8.9.4.1 Physical Interfaces
    • 8.9.4.2 Shift Switch
    • 8.9.4.3 Disassembly of Hard Disk
  • 8.9.5 Troubleshooting the CCTV System
  • 8.9.6 Wiring Diagram
• 8.10 Flowmeter

9. Schematics

• 9.1 Symbol Explanation
• 9.2 Hydraulic Schematic Diagrams
  • 9.2.1 C-Type / SRSC4535 / SRSC4535C / SRSC4535C1 Container Reach Stackers
  • 9.2.2 SRSC4545C Container Reach Stackers
  • 9.2.3 SRSC3515-3 Container Reach Stackers
  • 9.2.4 SRSC1009-6E Container Reach Stackers
• 9.3 Electrical Schematic Diagrams
  • 9.3.1 C-Type Container Reach Stacker
  • 9.3.2 Empty Container Reach Stacker
• 9.4 Schematic Diagrams of Spreader System
  • 9.4.1 Hydraulic Schematic Diagram of Spreader System
    • 9.4.1.1 SDJ450 Spreader
    • 9.4.1.2 SJD450F-R3 / SDJE100-R1 Spreader
    • 9.4.1.3 SJD450E-R1 / SJD450F-R1 Spreader
    • 9.4.1.4 ELME817 Spreader
    • 9.4.1.5 BROMMA RSX40 Spreader
  • 9.4.2 Electrical Schematic Diagram of Spreader System
    • 9.4.2.1 SDJ450 Spreader
    • 9.4.2.2 SDJ450F-R1 Spreader
    • 9.4.2.3 SDJ450E-R1 Spreader
    • 9.4.2.4 SDJ450F-R3 Spreader
    • 9.4.2.5 SJE100-R1 Spreader
    • 9.4.2.6 ELME817 Spreader
    • 9.4.2.7 BROMMA RSX40 Spreader