SANY SRSC4531G User manual

User Manual
Operation Manual
Reach Stacker
SRSC4531G
V. 07/2017 EN
Translation of the original user manual

Contact
SANY Europe GmbH
Sany Allee 1
50181 Bedburg
Germany
E-Mail: [email protected]
Web: www.sanyeurope.com
Tel.: -49 2272 90531 100
Fax: -49 2272 90531 109
Service Number: 00800 88888 318
Spare parts number: 13553769

EC declaration of conformity
1
3
EC declaration of conformity
According to the EC Machinery Directive 2006/42/EC (Annex II
A)
Manufacturer name and address:
SANY Europe GmbH
Sany Allee 1
50181 Bedburg
Germany
We hereby declare that the machine described below
Product designation Reach stacker
Type designation SRSC4531GC
complies with all the relevant regulations of Machinery Directive
2006/42/EC.
We declare compliance with other directives also
applicable to the machine:
▪EMC Directive (2014/30/EU)
▪Outdoor Noise Directive (2000/14/EC)
▪Vibration Directive (2002/44/EC)
▪Noise Directive (2003/10/EC)
Sound power (LwA) [dB] : 104
Applied harmonised standards:
▪EN 16307: Industrial trucks - Safety requirements and verifi-
cation
▪DIN EN 1459:2012-06 – Safety of industrial trucks – Forklifts
with variable reach
Authorised representative for the compilation of the
relevant technical documentation:
SANY Europe GmbH
Martin Wichmann
Sany Allee 1
50181 Bedburg
Germany
Bedburg
Haijun Deng, Managing Director
Name and position of the undersigned

Table of contents
4
Table of contents
1
EC declaration of conformity
3
2
Introduction
10
2.1
Foreword
10
2.2
Structure of the instructions
11
3
Safety
14
3.1
Intended use
14
3.2
Unintended use
14
3.3
Operator duties
16
3.4
Obligations of maintenance perso
n-
nel/specialised personnel
16
3.5
Hazards around the machine
17
3.6
Hazardous areas on the truck
19
3.6.1
General hazards on the truck
19
3.6.2
Hydraulic system hazards
20
3.6.3
Electrical dangers
22
3.7
Personal protective equip
ment
23
3.8
Safety systems an
d protective devices
24
3.9
S
afety markings
25
4
Machine description
29
4.1
Properties
29
4.2
Assembly overview
30
4.3
Cabin
31
4.3.1
Emergency exit (rear window)
33
4.3.2
Fire extinguisher
33
4.3.3
Seat occupancy sensor
34
4.3.4
Rear
-view mirror
34
4.3.5
Reversing camera
35
4.3.6
Window heater for cabin roof
35
4.4
Chassis
36
4.4.1
Counterweight
36
4.4.2
Movable counterweight
36
4.4.3
Maintenance accesses
37
4.4.4
Gas pressure spring
37

Table of contents
5
4.4.5
Additional grip
38
4.4.6
Stair lighting
38
4.5
Drive
39
4.5.1
Engine bay cover
39
4.5.2
Engine and gearbox
40
4.5.3
Exhaust after
-treatment system
41
4.5.4
Steering
43
4.6
Wheels
44
4.7
Electrical system and control
46
4.7.1
Lighting
47
4.7.2
Fuses
49
4.7.3
Socket
53
4.7.4
Emergency stop
54
4.7.5
Rotating beacon
55
4.7.6
Main switch
55
4.8
Hydraulic system
56
4.8.1
Parking brake
57
4.9
Boom
58
4.10
Spreader
59
4.11
Twistlocks
60
4.12
Options
61
4.12.1
360° camera system for panoramic viewing
61
4.12.2
Front camera system
63
4.12.3
Spreader camera system
65
4.12.4
Back
-up obstacle detector
66
4.12.5
Power supply 230/400 V
70
4.12.6
Tank heating management
71
4.12.7
Fire extinguishing system
73
4.12.8
Tyre pressure control system
74
4.12.9
Rear windscreen heating
75
4.12.10
Window heater for cabin roof
76
4.12.11
Lubrication system
77
4.13
Product marking
78
5
Operation and display elements
80
5.1
In the cab
80

Table of contents
6
5.1.1
Overview
80
5.1.2
Main display
82
5.1.3
Load pick
-up display
83
5.1.4
Direction lever and turn signal lever
84
5.1.5
Machine operation toggle switch
85
5.1.6
Attachment, cab, counterweight tilt switch
86
5.1.7
Machine control and display elements
89
5.1.8
Toggle switch windscreen wiper, light
90
5.1.9
Radio
92
5.1.10
Air conditioner
94
5.1.11
Auxiliary heating
95
5.1.12
Fire extinguishing system control unit
96
5.1.13
Operating the window heater
98
5.2
Outside the cab
99
5.2.1
Information display
99
5.2.2
Main switch
99
5.3
Software
100
5.4
Spreader
130
5.4.1
Mechanical locking indicator
130
5.4.2
Electronic twist lock indicator
130
5.4.3
Side shift display
132
6
Before starting operation
133
6.1
Cleaning before starting operations
133
6.2
Visual inspection
134
6.2.1
Escaping operating fluids
134
6.2.2
Safety markings
134
6.2.3
Steer axle visual inspection
135
6.2.4
Visual inspection of the tyres
135
6.2.5
Visual inspection of th
e boom
136
6.2.6
Spreader vis
ual inspection
136
6.2.7
Visu
al inspection of windscreen wipers
137
6.3
Fill levels
138
6.3.1
Checking fuel fill level and refuelling
138
6.3.2
Checking the filling level on the DEF
-Tank
and refilling the DEF
140
6.3.3
Check tyre pressure
142

Table of contents
7
6.3.4
Fill
-level for windscreen wiper fluid
144
6.3.5
Check the level of hydraulic oil.
145
6.3.6
Checking the brake oil fill level
145
6.3.7
Check coolant level and top up
147
6.3.8
Checking engine oil level and topping up
148
6.3.9
Check gearbox oil level and top up
149
6.4
Setting up the operating position
152
6.4.1
Adjusting the seat
152
6.4.2
Adjusting the steering wheel
154
6.5
Function check
156
6.5.1
Check the protective devices
156
6.5.2
Boom function check
156
6.5.3
Spreader function check
157
7
Operator control
158
7.1
Accessing the machine
158
7.2
Starting the machine
159
7.2.1
Starting at low temperatures
161
7.3
Operating the machine
163
7.3.1
Driving position
165
7.3.2
Driving forward
166
7.3.3
Driving in reverse
167
7.3.4
Driving in curves
168
7.3.5
Stopping
170
7.4
Stopping the machine
171
7.5
Operate the boom
173
7.5.1
Joystick
173
7.5.2
Controlling the boom
173
7.6
Moving the cab
177
7.7
Move the counterweight
179
7.8
Transport the load
180
7.8.1
Load diagram
181
7.8.2
Lifting containers
182
7.8.3
Drive with the load
184
7.8.4
Setting down containers
185

Table of contents
8
8
Cleaning
186
8.1
Cleaning at the end of operations
186
9
Machine configuration
187
9.1
Basic configuration and menu choice
188
10
Fault diagnostics
190
10.1
Operator
190
10.2
Maintenance personnel
190
10.3
Supposed errors
190
11
Error elimination
192
11.1
Troubleshooting in operation
192
11.2
Back
-up obstacle detector troubleshooting
205
11.3
Fuses
206
11.4
Parking brake emergency operation
207
11.5
Emergency operation
209
11.6
Manual cab movement
211
12
Annex
213
12.1
Equipment and options
213
12.2
Load tables
215
12.3
Reach Stacker technical data
217
12.4
Technical data for spreader
225
12.5
Operating material overview
228
12.5.1
Operating materials
228
12.5.2
Information for engine oil use
231
12.5.3
Information for gearbox oil use
232
12.5.4
Information for hydra
ulic oil use
232
12.5.5
Infor
mation about using oil for the spreader
slew gearbox
233
12.5.6
Information for using oil for the drive axle
234
12.
5.7
Information about the use of grease
234
12.5.8
Information about the use of fuel
234

Table of contents
9
12.5.9
Information about the use of DEF
234
Glossary
236
Index
239

2
Introduction
Foreword
10
Introduction
Foreword
The user manual must be read and understood before starting
and operating the machine, or carrying out maintenance and
repairs.
The instructions in the user manual must be followed. These
instructions are a requirement for safe machine operation and
for the safety of personnel.
Failure to observe safety regulations can lead to material dama-
ge, serious injuries or even death.
The user manual helps with:
▪Using the machine in an optimal manner
▪Preventing accidents
▪Avoiding machine malfunctions due to improper operation
▪Avoiding improper use
▪Increasing reliability
▪Minimising repair costs and downtime
▪Extending the machine's service life
A printed copy of the operating manual must available in the
machine.
The instructions are provided both in form of a manual and a
CD. The CD can be used to print individual chapters of the in-
structions, for instance for service technicians.
In order to use the CD, a PC with a CD-ROM drive and "Acrobat
Reader" software, version 9 of higher, is required.
The original user manual was created in German.
All other versions of this user manual are translati-
ons of the original user manual. In the case of
doubt, the German wording shall prevail.

Structure of the instructions
Introduction
2
11
Structure of the instructions
Structure of the instructions
This user manual consists of:
▪Operating manual for the machine operator
▪Maintenance manual for the maintenance technician
▪Diagrams for the maintenance technician
▪Installation instructions for the assembly personnel or Loa-
ding information for the carrier.
The user manual will be supplied in hard copy in the local lan-
guage of the operating company . The loading instructions are
provided in the form of a card. A CD ROM is included that also
contains the original user manual in German. This user manual
also includes functions that are marked as options. These func-
tions are not included in every machine.
Chapter structure
The operating and maintenance instructions are divided into
chapters and subchapters.
Header
The header contains the number of pages, the chapter heading
(in bold) and the heading of the respective subchapter. The
chapter numbers with an orange background are provided on
the outer edge as an aid to orientation.
Handling instructions
The handling instructions show how to perform a task step by
step. The handling instructions include:
▪No, one or more than one operational requirement. A
pointed arrow (➢) introduces an operational requirement.
▪Operational steps. Every operational step includes instruc-
tions. The operational steps are numbered in the order they
are to be completed.
▪No, one or more than one interim result. An empty arrow (⇨)
introduces an interim result. Interim results are followed by
additional operational steps.
▪At least one final result. A double arrow (») introduces a final
result.
If the carrying out the handling instructions or an operational
step is connected with a danger, relative safety instructions will
make reference to this prior to the handling instructions or the
operational step.

2
Introduction
Structure of the instructions
12
Markings
Markings are used to make the text easier to follow. The follo-
wing markings are used:
[F1] Keys, softkeys, switches, buttons
[F1]+[F2] Press key combinations at the same
time
[F1] [F2] Press key combinations in succession
«Menu» Menu names, system messages
«Menu» «Submenu» Menu sequences
(1) Position numbers that are found in the
figures
Safety instructions
Most accidents are caused by failure to follow the safety instruc-
tions. In this user manual, dangers are pointed out by safety
instructions. The safety instructions are structured as follows.
CAUTION
Type and source of the danger
Description of the imminent danger, for example an imminent
injury.
•1. Measures for averting the danger
•2. Measures for averting the danger
Safety instructions are classified by a danger sign (exclamation
mark in a yellow warning triangle), a signal word (DANGER,
WARNING, CAUTION or ATTENTION) and a corresponding
colour (red, orange, yellow or blue).

Structure of the in
structions
Introduction
2
13
Signal word
Colour
Meaning
Red For an immediate thread of dan-
ger. If the danger is not averted,
threat of death or serious injuries.
Orange
For a possibly dangerous situation.
If this situation is not averted, it
may result in death or serious
injuries.
Yellow
For a possibly dangerous situation.
If this situation is not averted, it
may result in minor, reversible
injuries.
Blue If refers to possible threats of
machine damage.
Other information
Introduces important information, such as manufactu-
rer recommendations for the smooth operation of the
machine.

3
Safety
Intended use
14
Safety
Intended use
The machine is only intended for lifting, transporting and sta-
cking loads.
The spreader may only be used to fasten freight containers,
swap bodies and semi-trailers suitable for crane lifting.
The container must have the following characteristics:
▪Length: 20 ft, 30 ft, 35 ft or 40 ft
▪Width: 8 ft
▪The upper side of the container must be flat.
▪The container must be equipped with ISO corner fittings on
the upper corners.
The semi-trailer must have standardised lifting points.
▪Maximum slope of
– 3.5 % when stacking and driving when loaded in a lon-
gitudinal direction
– 6 % when stacking and driving when loaded in a trans-
verse direction
– 18 % when driving in a longitudinal direction
– 20 % when driving in a transverse direction
The maximum load weight to be handled and the stacking
height are specified in the load table See also Load diagram
[Page 181].
The vehicle is to be used on non-public premises such as har-
bour facilities, container loading stations or factory premises.
The machine may only be operated with the cabin doors closed
and the seatbelt fastened.
The following environmental conditions must be observed at all
times:
▪Ambient temperature -20 °C up to + 40 °C
▪Altitudes of up to 2000 m
▪Wind speed: up to 12.2 m/s (wind force 6 on the Beaufort
scale)
Proper usage also includes observing the user manual and
complying with the maintenance and inspection requirements.
Unintended use
SANY accepts no liability for damage caused to people, the
environment or the machine for improper use.
Improper use includes any use other than the intended use, and
in particular:

Unintended use
Safety
3
15
▪Transporting/lifting objects using cables, chains or other
items attached to the boom.
▪Pulling or pushing loads.
▪Pulling fixed objects.
▪Transport of people other than in the cab. In the cab, there is
room for the operator and another person on an auxiliary
seat. Other than that, transporting other people if forbidden.
▪Transporting people inside or on containers.
▪Transporting objects that lie outside of the specified stowage
possibilities.
▪The vehicle is not type-approved. Therefore, driving on and
crossing public roads is prohibited.
▪Starting, retracting and operating in areas at risk of explosi-
on.
▪Overloading the machine above the loads listed in the load
table.
▪Leaving the machine with a hanging load.

3
Safety
Operator duties
16
Operator duties
The machine operator must be at least 18 years old and be in
possession of the qualifications required locally by law:
▪Professional suitability according to national standards
▪Safety briefing
The operator has the following responsibilities:
▪Operating the machine
▪Daily check of the machine for visible damage and defects.
▪Immediately reporting damage and defects found as well as
any changes in operational performance to the appropriate
maintenance personnel
▪Checking fill levels and topping up the operating fluids
▪Lubricating moving parts
▪If present, filling up the lubricating grease at a central lubri-
cation system
Obligations of maintenance
personnel/specialised personnel
Maintenance/specialist personnel have the following responsibi-
lities:
▪Performing all maintenance work thoroughly and on-time
according the maintenance schedule
▪Observance of the maintenance schedule
▪Maintenance and servicing obligation
Operating the machine
If maintenance or assembly personnel have to opera-
te the machine, the same obligations as for the opera-
ting personnel additionally apply.

Hazards around the machine
Safety
3
17
Hazards around the machine
Not all dangers related to the machine environment can be
avoided.
Subsoil
The machine may tip over on uneven, muddy, icy or soft
ground, thereby causing fatal or serious injury to persons
present. The machine can be damaged.
▪Only operate the machine on firm subsoil.
▪Only operate the machine on firm, smooth and even ground.
▪In the case of an ice hazard, pay careful attention and make
sure that the subsoil is not slippery, by scattering salt, for
example.
▪Do not park the machine on a slope.
▪Secure parked machines against rolling away by placing
chocks under the wheels, for example.
Wind
The wind can have a considerably adverse affect on lifting the
load. If the wind speed is too high, the machine may tip over or
lose its load(s), thereby causing fatal or serious injury to per-
sons present. The machine itself may also be damaged.
▪Only operate the machine at wind speed of up to maximum
12.2 m/s (wind force 6 on the Beaufort scale).
Power supply lines
Due to its height, the machine may collide with power supply
lines, which could result in fatal or serious injury to persons
present. The machine can be damaged.
▪Do not operate the machine under power supply lines.
▪Observe the applicable local regulations.
▪The safety distance from power supply lines must be obser-
ved. This minimum distance must be complied with by all
parts of the machine as well as the load.
Rated voltage [V]
Safety distance [m]
Up to 1,000 V 1
Above 1,000 to 110 000 3
Above 110,000 to 220 000 4
Above 220,000 to 380,000 5
In the case of unknown rated voltage 5
The safety distance must also be observed when moving loads
and load handling devices outwards.

3
Safety
Hazards around the machine
18
Explosive or fire-endangered environments
The machine's consumables, such as fuel, oil, lubricant and
coolant, are easily flammable and combustible. An explosive
gas can be formed during charging of the battery. When opera-
ting the machine near an open fire or sparks, there is a fire and
explosion hazard for the machine. This could lead to death or to
significant injury. The machine can be damaged.
▪Do not operate the machine in a combustible or explosive
environment, for example in environments with combustible
dust.
▪Only operate the machine in well ventilated rooms.
▪No smoking or open flames when refuelling.
▪No smoking or open flames when working on the battery.
Thunderstorms
When operating the machine during a thunderstorm, there is a
possibility that the machine's control system will be damaged.
Therefore stop operation when a thunderstorm is approaching .

Hazardou
s areas on the truck
Safety
3
19
Hazardous areas on the truck
General hazards on the truck
Location
Danger
(1) Below the load-lifting tool Danger of banging your
head
(2) Battery compartment Chemical burns caused by
acid
(3) Below the hydraulic cylin-
ders on the platforms
Danger of being injured or
hit by moving hydraulic
cylinders when extending
and retracting the spreader.
Location
Danger
(4) Between the extendable
counterweight and cabin
Danger of crushing when
retracting the counter-
weight.
(5) Exhaust Burns, poisoning caused by
inhalation of exhaust fumes
(6) Behind extendable coun-
terweight
Danger of being knocked
over by extending counter-
weight.
(7) Metal grating steps, engine
bay cover, walkway
Danger of slipping and
falling, particularly in wet,
snowy and icy conditions
(8) Tank filler neck Poisoning caused by inha-
lation, severe to fatal burns
if fumes ignite
(9) Engine compartment Danger of fire
(10) Tyres Danger of injury caused by
tyres coming loose under
high pressure

3
Safety
Hazardous areas on the truck
20
Hydraulic system hazards
Location
Danger
(1) Transition between high-
pressure hose and boom
load lifting tool
Hydraulic oil leaking under
high pressure; danger of
eye injuries, bruises
(2) High pressure hose on the
energy chain on the boom
Hydraulic oil leaking under
high pressure; danger of
eye injuries, bruises
Location
Danger
(3) Connections for operating
hydraulics behind the side
panels
Hydraulic oil leaking under
high pressure; danger of
eye injuries, bruises during
maintenance work
(4) Connections for brake
hydraulics behind the side
panels
Hydraulic oil leaking under
high pressure; danger of
eye injuries, bruises during
maintenance work
(5) Lift cylinder connections Hydraulic oil leaking under
high pressure; danger of
eye injuries, bruises
(6) High-pressure hose on the
energy chain under the
cabin
Hydraulic oil leaking under
high pressure; danger of
eye injuries, bruises
(7) Transition from the machi-
ne to the boom via the high
pressure hose
Hydraulic oil leaking under
high pressure; danger of
eye injuries, bruises
In addition to components that generate pressure, high-pressure
hoses and their respective connections are particularly ha-
zardous.