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
- 2.4.1 Work Area Safety
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
- 3.1.1 Power Driving 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
- 3.2.1 Steering Controller
- 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
- 3.4.1 Control Panel
- 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
- 4.1.1 Checks Before Operation
- 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
- 5.12.1 SANY / ELME Spreader
- 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
- 5.15.1 Battery
- 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
- 8.1.1 Fire Detection and Alarm System
- 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
- 9.4.1 Hydraulic Schematic Diagram of Spreader System
S.S 07/24
