SANY SAP90C-8 Guide

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Safety, Operation & Maintenance Manual
Sany Paver
SAP90C-8
SAP100C-8

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SAP Series Paver
Safety, Operation & Maintenance Manual
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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
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Safety, Operation and Maintenance Manual- December 2018
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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
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Safety, Operation and Maintenance Manual- December 2018i
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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.
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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.
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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
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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
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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
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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
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