SANY SAP90C-8 Guide

Quality Changes the World
Safety, Operation & Maintenance Manual
Sany Paver
SAP90C-8
SAP100C-8

Find manuals at https://best-manuals.com

SAP Series Paver
Safety, Operation & Maintenance Manual
Font-Arial Size:12pt
SAP Series Paver
Read and follow the safety precautions and instructions in this manual and on the machine
decals. Failure to do so can cause serious injury, death or property damage. Keep this
manual with the machine for reading and future reference.
WARNING
线粗：1pt
Safety, Operation and Maintenance Manual- December 2018
Find manuals at https://best-manuals.com

Font-Arial Size:12pt
SAP Series Paver
© 2018by Sany Group. All rights reserved. No part of this publication may be
reproduced, used, distributed or disclosed except during normal operation of the
machine as described herein. All information included within this publication was
accurate at the time of publication. Product improvements, revisions, etc., may
result in differences between your machine and what is presented here. Sany Group
assumes no liability. For more information, contact Sany Group.
Sany Group
SANY Automobile Manufacturing CO.,LTD
Sany Industry Zone,
Economic & Technical Development Zone
Changsha, Hunan, China 410100
http://www.sanyglobal.com
Tel: 0086-
4006098318
Font-Arial Size:12pt
Safety, Operation and Maintenance Manual- December 2018i
Scan here to download the Service Cloud APP
Android iOS
Find manuals at https://best-manuals.com

Responsibility
SAP Series Paver
Safety, Operation & Maintenance Manual - December 2016
Safety, Operation & Maintenance Manual - December 2018
DELINEATION OF RESPONSIBILITY
SPECIFIC DECLARATION
Pavers, which apply to pave various materials to produce a road base or surface, are special
machines for paving asphalt mixture, RCC base material, stabilized soil material and road
material (like graded broken stone). Any other use or any operation beyond the specied working
range is not authorized use. SANY expressly bears no liability for any consequence due to any
unauthorized use.
Information in this manual is used to guide qualied operators to operate and maintain pavers
correctly. Sany expressly bears no liability for any consequence due to any use not observing the
information in this manual.
It is forbidden to convert the paver without authorization. Sany expressly bears no liability
for any consequence. When crack or electrical malfunction on the paver occurs, please contact
the supplier, and don’t conduct welding or make changes without permission, or else, for any
consequence due to such contravention, Sany shall not bear any liability.
Use genuine spare parts from Sany. Sany expressly bears no liability for any machine
damage or accident due to the use of untested or unauthorized spare parts or tools.
Operate and maintain parts (such as engine, a/c) on the paver, and observe related
regulations on Users' guide supplied from their manufacturer.
Sany expressly bears no liability for any machine failure or damage due to force majeure of
natural disasters (earthquake, typhoon) and wars.
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 specic
safety rules of the countries may be stricter. If they differ from the regulations in this manual,
observe the stricter one.
Duty of Sany
• Be responsible for providing qualied products and correct documents.
• Fulll their promises on after-sales service, and document all maintenance and repair working
done by after-sales service personnel.
•Train the operation and maintenance personnel based on their needs.
Duty of owners or other anthorized personnel
• Only after each person involved in the product’s operation, maintenance and repair is trained
and fully understands the Parts Book and Operation and Maintenance Manual, can they operate
and maintain the paver.
•Ensure the operation and maintenance personnel are qualified and know their related
responsibilities.
Find manuals at https://best-manuals.com

SAP Series Paver
Responsibility
Safety, Operation & Maintenance Manual - December 2018 Safety, Operation & Maintenance Manual - December 2016
•Periodically check related personnel's safety consciousness during working.
•If any fault which will lead to unsafety occurs, stop the paver immediately.
•If necessary Sany service personnel have the right to check the paver for safety.
•Besides check items regulated by Sany, observe local laws and regulations to check the
paver.
•Ensure timely maintenance and repair on the paver.
•Carefully plan the use of the paver.
Duty of all working personnel
•If there is any abnormal symptom which may cause abnormal working of the paver or
potential hazard, report to your leader. If possible, correct fault in time.
•All personnel working around the paver must observe all warning signals and take care of
their own and others' safety.
•All personnel should know their working tasks and procedures.
•Watch something like high voltage wire, unrelated personnel and poor ground for potential
danger, and report to the operators and signalmen.
Duty of managers
•Ensure the operators are trained and fully understand the Operation and Maintenance Manual
supplied by Sany. Ensure they are in physical tness and have the certication of operation.
Otherwise, it is forbidden to operate the paver.
•Ensure the operators have good judgement ability, teamwork consciousness and
psychological quality. Otherwise, it is forbidden to operate or repair the paver.
•Ensure the signalmen have good vision and acoustic judgement, master standard command
signals. At the same time, they should have enough experience in recognizing danger factors
correctly, and inform the operators of danger factors to avoid them in time.
•Ensure assistant workers can identify the model and working condition to choose a proper
paver.
•Publicize safety consciousness to working personnel, and make them aware of safety
precations and their related responsibilities.
Find manuals at https://best-manuals.com

Table of Contents
SAP Series Paver
I
Safety, Operation & Maintenance Manual - December 2018
Table of Contents
Introduction
About This Manual..................................................................................................................... 1-3
Contact Information ................................................................................................................... 1-3
Your Documentation Package ................................................................................................... 1-4
Safety, Operation & Maintenance Manual .......................................................................... 1-4
Parts Book .......................................................................................................................... 1-4
Maintenance Log ................................................................................................................ 1-4
Organization Of This Manual..................................................................................................... 1-5
Table of Contents ................................................................................................................ 1-5
Introduction ......................................................................................................................... 1-5
Safety.................................................................................................................................. 1-5
System Functions ............................................................................................................... 1-5
Operation ............................................................................................................................ 1-5
Maintenance ....................................................................................................................... 1-5
Troubleshooting .................................................................................................................. 1-5
Specications...................................................................................................................... 1-5
Serial Number Location............................................................................................................. 1-6
Record of Serial Number and Dealer Information............................................................... 1-6
Correction Request Form .......................................................................................................... 1-7
Safety
General...................................................................................................................................... 2-5
Hazard Alerts In This Manual.............................................................................................. 2-6
Diesel Engine Exhaust........................................................................................................ 2-7
Battery Posts, Terminals and Related Accessories............................................................. 2-7
Operator Safety Information................................................................................................ 2-8
Operator is Important .......................................................................................................... 2-8
Operator Qualications ....................................................................................................... 2-9
Machine Safety ................................................................................................................. 2-10
Mount and Dismount the Machine .................................................................................... 2-10
Unauthorized Machine Modications .................................................................................2-11
Find manuals at https://best-manuals.com

Table of Contents SAP Series Paver
II
Safety, Operation & Maintenance Manual - December 2018
Job Safety.................................................................................................................................2-11
Job Site Safety .........................................................................................................................2-11
Surface and Underground Hazards......................................................................................... 2-12
High Voltage Areas.................................................................................................................. 2-12
Pre-Start Checks ..................................................................................................................... 2-13
Start-Up Safety........................................................................................................................ 2-13
Personal Protective Equipment ............................................................................................... 2-14
Fire Safety ............................................................................................................................... 2-16
Fluid Fires ......................................................................................................................... 2-16
Electrical Fires .................................................................................................................. 2-17
Fire Extinguisher and First Aid Kit..................................................................................... 2-17
Fire-prevention during operation....................................................................................... 2-17
Dust and Chemical Hazards.................................................................................................... 2-19
Dust Hazards .................................................................................................................... 2-19
Safety Data Sheets (SDS) ................................................................................................ 2-20
Maintenance Safety................................................................................................................. 2-20
Clean the Machine ............................................................................................................ 2-20
Use the Correct Tools ....................................................................................................... 2-21
Jack Up the Machine............................................................................................................... 2-22
Rotating Parts ................................................................................................................... 2-22
Remove Attachments........................................................................................................ 2-22
Weld, Drill, Cut or Grind on the Machine .......................................................................... 2-23
Fluid Systems.......................................................................................................................... 2-24
Add Fluids to the Machine ................................................................................................ 2-24
Refuel................................................................................................................................ 2-24
High-Pressure Fluid Lines................................................................................................. 2-25
Accumulator ...................................................................................................................... 2-25
Electrical System..................................................................................................................... 2-25
Battery Safety ................................................................................................................... 2-26
Disconnect the Battery...................................................................................................... 2-26
Jump-Start Safety ............................................................................................................. 2-26
Environmental Precautions...................................................................................................... 2-27
Product-Specic Safety ........................................................................................................... 2-27
Lockout/Tagout Procedures .............................................................................................. 2-27
Lock Out of Operation ................................................................................................ 2-28
Find manuals at https://best-manuals.com

Table of Contents
SAP Series Paver
III
Safety, Operation & Maintenance Manual - December 2018
Return to Operation.................................................................................................... 2-28
Machine Decals ................................................................................................................ 2-29
Location...................................................................................................................... 2-30
Type and Meaning...................................................................................................... 2-32
Authorized Use of the Machine......................................................................................... 2-39
Unauthorized Use of the Machine..................................................................................... 2-39
Job Site Precautions ......................................................................................................... 2-39
Surface and Underground Hazards............................................................................ 2-39
Job Site Working Clearances ..................................................................................... 2-41
Precautions before working .............................................................................................. 2-41
Precautions for asphalt paving.......................................................................................... 2-42
Precautions for screed operation ...................................................................................... 2-42
Precautions for operation at night ..................................................................................... 2-42
Machine Parking ............................................................................................................... 2-43
Before leaving the machine........................................................................................ 2-43
Loading machine ........................................................................................................ 2-43
Towing machine.......................................................................................................... 2-43
Hoisting machine........................................................................................................ 2-44
System Functions
General Notes ........................................................................................................................... 3-3
Power System ........................................................................................................................... 3-4
Electrical System....................................................................................................................... 3-5
General ............................................................................................................................... 3-5
Layout of electrical components on main control console .................................................. 3-7
Panel of main control console............................................................................................. 3-8
Use of display ................................................................................................................... 3-19
Layout of electric control cabinet ...................................................................................... 3-35
Fuses in electric control cabinet........................................................................................ 3-36
Layout of electrical component in screed panel................................................................ 3-37
Sockets on rear wall plate................................................................................................. 3-38
Hydraulic System..................................................................................................................... 3-39
Traction drive system ........................................................................................................ 3-39
Auger system .................................................................................................................... 3-40
Conveyor system .............................................................................................................. 3-41
Tamping system ................................................................................................................ 3-42
Find manuals at https://best-manuals.com

Table of Contents SAP Series Paver
IV
Safety, Operation & Maintenance Manual - December 2018
Vibration system................................................................................................................ 3-42
Auxiliary system ................................................................................................................ 3-43
Hydraulic accessories ....................................................................................................... 3-43
Accessories and Other Devices .............................................................................................. 3-44
Traction drive system ........................................................................................................ 3-44
Conveyor........................................................................................................................... 3-48
Auger system ................................................................................................................... 3-53
Central lubrication system................................................................................................. 3-55
Cleaning system ............................................................................................................... 3-57
Towed arm ........................................................................................................................ 3-58
Hopper .............................................................................................................................. 3-60
Tractor............................................................................................................................... 3-61
Control system .................................................................................................................. 3-61
Seat fence......................................................................................................................... 3-63
Canopy.............................................................................................................................. 3-64
Covering parts................................................................................................................... 3-65
Screed unit .............................................................................................................................. 3-66
Mechanical extension screed............................................................................................ 3-66
Hydraulic extension screed............................................................................................... 3-75
Operation
Operator qualications............................................................................................................... 4-5
Initial use of the paver ............................................................................................................... 4-5
Use of the operation system...................................................................................................... 4-6
Use of the console .............................................................................................................. 4-6
Use of the display ............................................................................................................... 4-7
Use of the screed panel ...................................................................................................... 4-8
Machine assembly................................................................................................................... 4-10
Mechanical extension screed assembly and adjustment.................................................. 4-10
Hydraulic extension screed assembly and adjustment ..................................................... 4-22
Auger assembly ................................................................................................................ 4-35
Electrical device installation .............................................................................................. 4-41
Operation before starting the machine .................................................................................... 4-44
Operator’s seat adjustment............................................................................................... 4-44
Pre-operational check ....................................................................................................... 4-44
Check before starting the engine ...................................................................................... 4-45
Find manuals at https://best-manuals.com

Table of Contents
SAP Series Paver
V
Safety, Operation & Maintenance Manual - December 2018
Engine start-up ........................................................................................................................ 4-48
Starting the engine in cold weather................................................................................... 4-49
Jump-start the engine ....................................................................................................... 4-49
Adjustment without load .......................................................................................................... 4-51
Adjusting the propel system ............................................................................................. 4-51
Adjusting the hopper ......................................................................................................... 4-53
Adjusting the conveyor system ......................................................................................... 4-54
Adjusting the auger system............................................................................................... 4-56
Adjusting the leveling system............................................................................................ 4-57
Adjusting the screed system ............................................................................................. 4-57
Adjusting the towed arm ................................................................................................... 4-59
Adjusting the central lubrication system............................................................................ 4-60
Construction ............................................................................................................................ 4-61
Line of direction................................................................................................................. 4-61
Adjusting the indicator pole............................................................................................... 4-61
Spraying diesel oil............................................................................................................. 4-62
Placing the screed ............................................................................................................ 4-62
Adjusting and operating the auto-leveling system ............................................................ 4-63
Butting the truck ............................................................................................................... 4-67
Feeding the hopper .......................................................................................................... 4-67
Operating the conveyor..................................................................................................... 4-67
Operating the auger ......................................................................................................... 4-67
Moving the paver .............................................................................................................. 4-67
Moving the truck away ...................................................................................................... 4-68
Receiving the material ...................................................................................................... 4-68
Distributing the material........................................................................................................... 4-69
Adjustment during paving ....................................................................................................... 4-70
Adjusting the paving evenness ........................................................................................ 4-70
Adjusting the paving thickness.......................................................................................... 4-70
Adjusting the material level ............................................................................................... 4-70
Stop the machine..................................................................................................................... 4-71
Stop the machine in case of emergency ................................................................................. 4-72
Transportation information....................................................................................................... 4-73
Loading and unloading...................................................................................................... 4-73
Packing ............................................................................................................................ 4-74
Precautions for transporting the machine ......................................................................... 4-75

Table of Contents SAP Series Paver
VI
Safety, Operation & Maintenance Manual - December 2018
Transferring the machine .................................................................................................. 4-75
Storing the machine .......................................................................................................... 4-76
Lifting the machine............................................................................................................ 4-77
Maintenance
General...................................................................................................................................... 5-3
Notes on maintenance ........................................................................................................ 5-3
Notes on fuel system .......................................................................................................... 5-3
Notes on engine performance............................................................................................. 5-4
Notes on hydraulic system.................................................................................................. 5-4
Notes on cooling system..................................................................................................... 5-4
Engine oil ............................................................................................................................ 5-5
Fuel ..................................................................................................................................... 5-6
Mineral hydraulic oil ............................................................................................................ 5-6
Lubricant in reduction gearbox............................................................................................ 5-6
Coolant................................................................................................................................ 5-6
Maintenance.............................................................................................................................. 5-8
Routine maintenance .......................................................................................................... 5-8
Regular maintenance.......................................................................................................... 5-9
Technical maintenance for long-time storage ................................................................... 5-10
Maintenance for the engine ...............................................................................................5-11
Maintaining the hydraulic system...................................................................................... 5-24
Maintaining the electric system......................................................................................... 5-27
Replacing the gear oil in transfer case.............................................................................. 5-29
Routine maintenance of engine and reducer .................................................................... 5-29
Lubricating points.............................................................................................................. 5-31
Routine inspection of tamper blade, base plate, auger blade and conveyor .................... 5-32
Hydraulic system............................................................................................................... 5-32
Electrical system ............................................................................................................... 5-33
Propel system ................................................................................................................... 5-33
Screed............................................................................................................................... 5-34
Grease points ................................................................................................................... 5-34
Fuel, lubricant and lling amount ...................................................................................... 5-35
Check the bolts ................................................................................................................. 5-35
Repair...................................................................................................................................... 5-37
General ............................................................................................................................. 5-37

Table of Contents
SAP Series Paver
VII
Safety, Operation & Maintenance Manual - December 2018
Replacing the conveyor chain........................................................................................... 5-38
Adjusting the tension of conveyor chain ........................................................................... 5-40
Replacing and tensioning the conveyor drive chain.......................................................... 5-41
Removing and installing the conveyor .............................................................................. 5-42
Replacing the conveyor reducer ....................................................................................... 5-42
Replacing and tensioning the auger chain........................................................................ 5-44
Adjusting the tension of auger chain................................................................................. 5-45
Replacing the conveyor reducer ....................................................................................... 5-46
Replacing the travel reducer ............................................................................................. 5-48
Replacing the rubber track shoe ....................................................................................... 5-50
Replacing the track roller .................................................................................................. 5-50
Installing and removing the hopper................................................................................... 5-50
Replacing the propel pump ............................................................................................... 5-52
Replacing the tamper motor.............................................................................................. 5-53
Replacing the oil cylinders ................................................................................................ 5-54
Adjusting auxiliary system pressure.................................................................................. 5-61
Adjusting and replacing lubrication system....................................................................... 5-67
Troubleshooting
Troubleshooting for Tractor ....................................................................................................... 6-3
Troubleshooting for power system ...................................................................................... 6-3
Troubleshooting for traction drive system ..........................................................................6-11
Troubleshooting for conveyor............................................................................................ 6-12
Troubleshooting for central lubrication system.................................................................. 6-13
Troubleshooting for cleaning device ................................................................................. 6-14
Troubleshooting for tractor ................................................................................................ 6-14
Troubleshooting for operating system............................................................................... 6-14
Troubleshooting for screed...................................................................................................... 6-15
Troubleshooting for hydraulic system...................................................................................... 6-17
Troubleshooting for travel hydraulic system...................................................................... 6-17
Troubleshooting for auger hydraulic system ..................................................................... 6-18
Troubleshooting for conveyor hydraulic system................................................................ 6-19
Troubleshooting for tamper hydraulic system ................................................................... 6-20
Troubleshooting for vibrator hydraulic system............................................................ 6-21
Troubleshooting for auxiliary system .......................................................................... 6-22
Troubleshooting for electrical system................................................................................ 6-25

Table of Contents SAP Series Paver
VIII
Safety, Operation & Maintenance Manual - December 2018
Troubleshooting for electrical system ......................................................................... 6-25
Troubleshooting for circuit .......................................................................................... 6-27
Troubleshooting for sensor......................................................................................... 6-28
Troubleshooting for switch.......................................................................................... 6-29
Troubleshooting for controller..................................................................................... 6-31
Troubleshooting for other faults.................................................................................. 6-32
Specications
Dimension of the Equipment ..................................................................................................... 7-3
Specications of the Equipment ................................................................................................ 7-4

BLANK PAGE
Table of Contents
SAP Series Paver
Safety, Operation & Maintenance Manual - December 2018
IX

Table of Contents SAP Series Paver
X
Safety, Operation & Maintenance Manual - December 2018
BLANK PAGE

Introduction
SAP Series Paver
Safety, Operation & Maintenance Manual - December 2018
Introduction
About This Manual..................................................................................................................... 1-3
Contact Information ................................................................................................................... 1-3
Your Documentation Package ................................................................................................... 1-4
Safety, Operation & Maintenance Manual .......................................................................... 1-4
Parts Book .......................................................................................................................... 1-4
Maintenance Log ................................................................................................................ 1-4
Organization Of This Manual..................................................................................................... 1-5
Table of Contents ................................................................................................................ 1-5
Introduction ......................................................................................................................... 1-5
Safety.................................................................................................................................. 1-5
System Functions ............................................................................................................... 1-5
Operation ............................................................................................................................ 1-5
Maintenance ....................................................................................................................... 1-5
Troubleshooting .................................................................................................................. 1-5
Specications...................................................................................................................... 1-5
Serial Number Location............................................................................................................. 1-6
Record of Serial Number and Dealer Information............................................................... 1-6
Correction Request Form .......................................................................................................... 1-7
1-1

Introduction SAP Series Paver
Safety, Operation & Maintenance Manual - December 2018
1-2
WARNING
Read and understand all safety precautions and instructions in this manual
before reading any other manuals provided with this machine and before
operating or maintaining it. Failure to do this could result in death or serious
injury.

1-3
SAP Series Paver
Safety, Operation & Maintenance Manual - December 2018
Introduction
ABOUT THIS MANUAL
This manual provides safety, operation, maintenance and technical specication information. If
you sell the machine, a copy of this manual must be provided to the new owner.
It is important to read this manual carefully
before beginning any operation or
maintenance. All personnel involved with this
machine must read this manual periodically to
remain knowledgeable about its operation and
maintenance.
Items addressed in this manual are designed
to help you:
●Understand the different systems and
performance of your machine.
●Reduce improper operation.
●Point out possible hazardous situations when operating and maintaining the machine.
●Increase machine efciency during operation.
●Prolong the service life of your machine.
●Reduce maintenance costs.
Continuing improvements in the design of this machine can lead to changes in details which
may not be covered in this manual. Always consult your Sany dealer for the latest available
information on your machine or if you have questions regarding information in this manual.
CONTACT INFORMATION
Thank you for purchasing a SANY product. If you need to contact us for any reason, you can
reach us as follows:
●Sany Industry Town, Changsha National Economic & Technical Development Zone, Hunan,
China
●Post code: 410100
●Tel: [phone]
●E-mail: [e-mail]
Fig.1-1

1-4
SAP Series Paver
Safety, Operation & Maintenance Manual - December 2018
Introduction
YOUR DOCUMENTATION PACKAGE
This documentation applies only to this machine and should not be used with any other
machines. The documentation for this machine includes the following items:
Safety, Operation & Maintenance Manual
A copy of this manual should be made available to maintenance personnel when maintaining the
machine. See “Organization Of This Manual” on page <OV> for complete details.
Parts Book
The Parts book consists of parts lists and matching drawings used for ordering spare parts as
needed. The Parts book is best left in the workshop area or ofce. It should always be available
to the maintenance and service personnel.