SANY SMG200 User manual

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Motor Grader
SMG200
Safety, Operation & Maintenance Manual

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Safety, Operation and Maintenance Manual-January 2017
SMG200 Motor Grader
Operation & Maintenance Manual
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
SMG200 Motor Grader
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Safety, Operation and Maintenance Manual-January 2017
SMG200 Motor Grader
Sany Group
SANY Automobile Manufacturing CO.,LTD
Sany Industry Zone
Economic & Technical Development Zone
Changsha, Hunan, China 410100
http://www.sanygroup.com
Tel: [phone]
Scan here to download the Service Cloud APP
Android iOS
©2016 by 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.
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Safety, Operation and Maintenance Manual-January 2017 1
DELINEATION OF RESPONSIBILITY
Specific Declaration
A grader is an enginnering vehicle with a blade used to finish soil and create a flat surface. Graders
are commonly used in the construction and maintenance of gravel road and subgrade. Graders
are also used to strip topsoil or greensward, produce ditches, finish side slope. Graders can mix
up, backfill, bulldoze and pave materials. If equipped with a front dozer blade, it can pave, stack
and backfill loose materials. If equipped with a rear scarifier, it can loose hard and dense soil. Any
other use or any operation beyond the specified working range is not authorized use. Sany ex-
pressly bears no liability for any consequence due to any unauthorized use.
Information in this manual is used to guide qualified operators to operate and maintain graders cor-
rectly. Sany expressly bears no liability for any consequence due to any use not observing the in-
formation in this manual.
It is forbidden to convert the grader without authorization. Sany expressly bears no liability for any
consequence. When crack or electrical malfunction on the grader occurs, please contact the sup-
plier, and don’t conduct welding or make changes without permission, or else, for any conse-
quence 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 grader, 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 main-
tenance. Operators and owners should highly attach importance to safety. Local specific safety
rules of the countries may be stricter. If they differ from the regulations in this manual, observe the
stricter one.
Duty of Sany
•Be responsible for providing qualified products and correct documents.
•Fulfill 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.
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2Safety, Operation and Maintenance Manual-January 2017
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 Safety, Operation and Maintenance Manual, can they
operate and maintain the grader.
•Ensure the operation and maintenance personnel are qualified and know their related
responsibilities.
•Periodically check related personnel's safety consciousness during working.
•If any fault which will lead to unsafety occurs, stop the grader immediately.
•Sany service personnel have the right to check the grader for safety.
•Besides check items regulated by Sany, observe local laws and regulations to check the grader.
•Ensure timely maintenance and repair on the grader.
•Carefully plan the use of the grader.
Duty of All Working Personnel
•If there is any abnormal symptom which may cause abnormal working of the grader or potential
hazard, report to your leader. If possible, correct fault in time.
•All personnel working around the grader must observe all warning signals and take care of their
own and others' safety.
•All personnel should know their working tasks and procedures.
•Watch surrounding things like high voltage wire, unrelated personnel and poor ground for poten-
tial danger, and report to the operators and signalmen.
Duty of Managers
•Ensure the operators are trained and fully understand the Safety, Operation and Maintenance
Manual supplied by Sany. Ensure they are in physical fitness and have the certification of opera-
tion. Otherwise, it is forbidden to operate the grader.
•Ensure the operators have good judgment ability, teamwork consciousness and psychological
quality. Otherwise, it is forbidden to operate or repair the grader.
•Ensure the signalmen have good vision and acoustic judgment, master standard command sig-
nals. At the same time, they should have enough experience in recognizing danger factors cor-
rectly, 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
grader.
•Make each working person take their related responsibilities, and require them to report unsafe
factors to their leader in time.
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Safety, Operation and Maintenance Manual-January 2017 I
Table of Contents
1 Introduction........................................................................................................................1-1
1.1 About This Manual ................................................................................................................1-3
1.2 Contact Information ..............................................................................................................1-4
1.3 Your Documentation Package.............................................................................................1-4
1.3.1 Introduction....................................................................................................................1-4
1.3.2 Safety, Operation & Maintenance Manual ................................................................1-4
1.3.3 Parts Book .....................................................................................................................1-4
1.4 Your Sany Machine...............................................................................................................1-5
1.4.1 Directional Reference of the Machine .......................................................................1-5
1.4.2 Serial Number Location ...............................................................................................1-5
1.4.3 Record of Serial Number and Dealer Information ...................................................1-7
1.4.4 Cab Interior....................................................................................................................1-8
1.5 Correction Request...............................................................................................................1-9
2 Safety.....................................................................................................................................2-1
2.1 Safety - General ....................................................................................................................2-5
2.1.1 Introduction....................................................................................................................2-5
2.1.2 Hazard Alerts in This Manual......................................................................................2-5
2.1.3 Operator Safety Information .......................................................................................2-7
2.1.4 Mount and Dismount the Machine .............................................................................2-8
2.2 Machine Safety......................................................................................................................2-9
2.2.1 Authorized Use of the Machine ..................................................................................2-9
2.2.2 Unauthorized Use of the Machine..............................................................................2-9
2.2.3 Escape Tool................................................................................................................ 2-10
2.2.4 Fire Safety .................................................................................................................. 2-10
2.2.5 Electrical Fires ........................................................................................................... 2-10
2.2.6 Fire Extinguisher.........................................................................................................2-11
2.2.7 In Case of Fire.............................................................................................................2-11
2.2.8 Crushing Hazards.......................................................................................................2-11
2.2.9 Unauthorized Machine Modifications ..................................................................... 2-12
2.3 Job Safety ........................................................................................................................... 2-12
2.3.1 Introduction................................................................................................................. 2-12
2.3.2 Personal Protective Equipment (PPE) ................................................................... 2-13
2.3.3 Travel and Operation Precautions .......................................................................... 2-13
2.3.4 Electrocution Hazard................................................................................................. 2-15
2.3.5 Dust and Chemical Hazards .................................................................................... 2-18
2.4 Maintenance Safety ........................................................................................................... 2-18
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II Safety, Operation and Maintenance Manual-January 2017
2.4.1 Introduction................................................................................................................. 2-18
2.4.2 Lockout/Tagout Procedures..................................................................................... 2-20
2.4.3 Clean the Machine .................................................................................................... 2-20
2.4.4 Fluid Systems............................................................................................................. 2-20
2.4.5 Electrical System ....................................................................................................... 2-22
2.4.6 Environmental Precautions...................................................................................... 2-23
2.5 Machine Decals.................................................................................................................. 2-23
3 System Functions...........................................................................................................3-1
3.1 Main Body Components.......................................................................................................3-5
3.1.1 Introduction....................................................................................................................3-5
3.1.2 Frame .............................................................................................................................3-6
3.1.3 Swing Support...............................................................................................................3-7
3.1.4 Tandem Drive Case......................................................................................................3-8
3.1.5 Transmission Assembly...............................................................................................3-8
3.1.6 Front Axle ......................................................................................................................3-9
3.1.7 Work Implement............................................................................................................3-9
3.1.8 Moldboard......................................................................................................................3-9
3.1.9 Engine ......................................................................................................................... 3-10
3.2 Optional Work Equipment..................................................................................................3-11
3.2.1 Introduction..................................................................................................................3-11
3.2.2 Front Push-Plate.........................................................................................................3-11
3.2.3 Front Harrow .............................................................................................................. 3-12
3.2.4 Front Counterweight ................................................................................................. 3-13
3.2.5 Rear Scarifier ............................................................................................................. 3-14
3.3 Cab Interior ......................................................................................................................... 3-15
3.3.1 Introduction................................................................................................................. 3-15
3.3.2 Control Levers............................................................................................................ 3-16
3.3.3 Front Control Console............................................................................................... 3-22
3.3.4 Steering Wheel .......................................................................................................... 3-25
3.3.5 Brake Pedal................................................................................................................ 3-26
3.3.6 Throttle Pedal............................................................................................................. 3-27
3.3.7 Right Control Console............................................................................................... 3-27
3.3.8 Inching Pedal ............................................................................................................. 3-31
3.3.9 Fuses........................................................................................................................... 3-32
3.3.10 Wall-Mounted Control Panel.................................................................................. 3-34
3.4 Other Operator Controls and Switches........................................................................... 3-42
3.4.1 Door Release Lever .................................................................................................. 3-42
3.4.2 Battery Disconnect Switch ....................................................................................... 3-42
3.4.3 Back-up Alarm ........................................................................................................... 3-44
3.4.4 Cab Interior Lights ..................................................................................................... 3-44
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Safety, Operation and Maintenance Manual-January 2017 III
3.4.5 Radio/MP3 Player ..................................................................................................... 3-45
3.5 Monitor................................................................................................................................. 3-50
3.5.1 Initialization Screens ................................................................................................. 3-50
3.5.2 Main Menu Screen .................................................................................................... 3-51
3.5.3 Operating System Screens ...................................................................................... 3-57
4 Operation.............................................................................................................................4-1
4.1 New Machine Run-In ............................................................................................................4-5
4.2 Pre-Start Checks...................................................................................................................4-6
4.2.1 Introduction....................................................................................................................4-6
4.2.2 Operation & Maintenance Manual .............................................................................4-6
4.2.3 Daily Maintenance Record..........................................................................................4-6
4.2.4 Exterior...........................................................................................................................4-7
4.2.5 Interior ............................................................................................................................4-7
4.3 Monitor / First-Time Setup .................................................................................................4-11
4.3.1 Access the Main Menu ..............................................................................................4-11
4.4 Engine Procedures ............................................................................................................ 4-15
4.4.1 Introduction................................................................................................................. 4-15
4.4.2 Engine Start-Up Procedures.................................................................................... 4-16
4.4.3 Idle the Engine ........................................................................................................... 4-18
4.4.4 Engine Warm-Up ....................................................................................................... 4-18
4.4.5 Cold-Weather Operation .......................................................................................... 4-19
4.5 Travel Operations............................................................................................................... 4-20
4.5.1 Introduction................................................................................................................. 4-20
4.5.2 Before Travel.............................................................................................................. 4-21
4.5.3 Steering....................................................................................................................... 4-22
4.5.4 Travel Forward........................................................................................................... 4-23
4.5.5 Travel in Reverse....................................................................................................... 4-24
4.5.6 Reverse from a Steep Slope or Ditch ..................................................................... 4-26
4.6 Control the Work Equipment ............................................................................................ 4-27
4.6.1 Introduction................................................................................................................. 4-27
4.6.2 Grade on the Left....................................................................................................... 4-27
4.6.3 Grade on the Right .................................................................................................... 4-29
4.6.4 Grade Around an Obstacle ...................................................................................... 4-31
4.6.5 Grade on S-Shape Curves....................................................................................... 4-31
4.6.6 Cut a Left Side V-Ditch.............................................................................................. 4-34
4.6.7 Cut a Right Side V-Ditch........................................................................................... 4-36
4.6.8 Cut a Flat-Bottom Ditch ............................................................................................ 4-38
4.6.9 Clean a Left Ditch ...................................................................................................... 4-40
4.6.10 Clean a Right Ditch ................................................................................................. 4-41
4.6.11 Clean a Left Road Shoulder................................................................................... 4-43
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IV Safety, Operation and Maintenance Manual-January 2017
4.6.12 Clean a Right Road Shoulder................................................................................ 4-44
4.6.13 Scrape a Wet Ditch ................................................................................................. 4-45
4.6.14 Grade On a Slope ................................................................................................... 4-46
4.6.15 Scrape a Right-Side Slope..................................................................................... 4-47
4.6.16 Left-Side Vertical Operation................................................................................... 4-49
4.6.17 Right-Side Vertical Operation ................................................................................ 4-52
4.6.18 Operate the Scarifier............................................................................................... 4-54
4.6.19 Operate the Push-Plate.......................................................................................... 4-56
4.6.20 Operate the Centershift Cylinder .......................................................................... 4-58
4.7 Park the Machine ............................................................................................................... 4-59
4.7.1 Stop the Machine....................................................................................................... 4-59
4.7.2 Engine Shutdown (Normal)...................................................................................... 4-59
4.7.3 Engine Shutdown (Electrical Malfunction) ............................................................. 4-60
4.7.4 Leave the Machine .................................................................................................... 4-61
4.8 Tow the Machine ................................................................................................................ 4-61
4.9 Transport the Machine....................................................................................................... 4-63
4.9.1 Preparation Before Loading..................................................................................... 4-63
4.9.2 Check Before Loading .............................................................................................. 4-63
4.9.3 Load............................................................................................................................. 4-63
4.9.4 Transportation............................................................................................................ 4-64
4.9.5 Unload......................................................................................................................... 4-64
5 Maintenance.......................................................................................................................5-1
5.1 General Maintenance Information ......................................................................................5-5
5.1.1 Introduction....................................................................................................................5-5
5.1.2 Checks Before Maintenance.......................................................................................5-5
5.1.3 Checks After Maintenance or Repairs.......................................................................5-6
5.1.4 Hour Meter Reading.....................................................................................................5-6
5.1.5 Genuine Sany Replacement Parts ............................................................................5-7
5.1.6 Sany-Approved Lubricants..........................................................................................5-7
5.1.7 Weld, Drill, Cut or Grind on the Machine...................................................................5-7
5.1.8 Clean Parts or the Machine.........................................................................................5-8
5.1.9 Covers and Locks.........................................................................................................5-8
5.1.10 Hydraulic Oil Inspection.............................................................................................5-8
5.1.11 Inspection and Maintenance in Adverse Environments........................................5-9
5.2 Torque Values ......................................................................................................................5-11
5.2.1 Introduction..................................................................................................................5-11
5.2.2 Specific Torque Values ..............................................................................................5-11
5.2.3 General Torque Values ..............................................................................................5-11
5.3 Fluids & Lubricants ............................................................................................................ 5-13
5.3.1 Introduction................................................................................................................. 5-13
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