QUALITY CHANGES THE WORLD

Wheel Loader
SW955K1

Operation and Maintenance Manual

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Front of Title Page

SW955K1 Wheeled Loader

Operation and Maintenance Manual

Warning
Please read and follow the important notes and instructions in this Manual and on the machine
nameplate. Otherwise, it might lead to serious injuries, death or property losses. Please keep this
Manual along with the machine for convenient reference.

Operation and Maintenance Manual - 06 - 2019

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Operation and Maintenance Manual - 06 - 2019

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Back of Title Page

SANY Group
Shanghai SANY Heavy Machinery Co., Ltd.
SANY Industrial Park, No. 1831, Xinyang Road, Fengxian District, Shanghai
Post code: 201413
After-sales Service Hotline: 4008 28 2318
Consulting and Complaint Tel.: 4008 87 9318
http://www.sanygroup.com

Along with the continuous updating of technologies and products, the material and technical
specifications will be changed without further notice. Copyright © 2013 All rights reserved by
SANY Group. This Manual shall not be duplicated, spreaded, sold or modified without the written
approval of SANY Group.

Operation and Maintenance Manual - 06 - 2019

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Operation and Maintenance Manual - 06 - 2019

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Division of Responsibilities

Important Statements
The wheel loader is a kind of multi-purpose earthwork construction machinery, mainly for
earthwork loading, but also for bulldozing, lifting, traction and other operations. It is used widely in
highway/railway/road construction, bridge construction, urban construction, airport port and water
conservancy construction. The loader has the functions of bulldozer and crane, which can
replace these mechanical operations. Other purposes beyond the specified operations are not
within the scope of operation. SANY will not be responsible for the consequences caused by the
operations not in accordance with the specified purposes.
SANY will not assume any responsibilities to the adverse consequences due to the following
circumstances:
 The consequences caused by failure to use the Loader properly according to the information
in this manual.
 Consequences of unauthorized refitting or modification of the Loader.
 Equipment damages or accidents due to failure to use authentic SANY parts or the use of
parts and tools which have not been tested or authorized by SANY.
 SANY will not assume any responsibilities to the machine troubles or damages due to force
majeure such as natural hazard (earthquake or typhoon etc.) and war etc.
SANY can not foresee all the possible hazards on operating site; therefore, the operating
personnel of the Loader and the customer shall pay high attention to the safety issues.
Different regions and local government organs for the Loader may have stricter operation
provisions. If the contents herein are in conflict with such safe operation provisions, the stricter
provisions shall prevail.
Responsibilities of SANY (as Manufacturer)
 Responsible for the quality of the Loader and the accuracy of accompanying documents.
 Fulfill the after-sales service commitment, and conclude all maintenance and repair work
performed by the after-sales service personnel into documents.
 Provide training for equipment operators and maintenance personnel as needed.
Responsibilities of Customer or Other Authorized Personnel
 The relevant personnel are allowed to operate and maintain the Loader only after they are
fully trained and understand the contents of spare parts drawing volume and operation &
maintenance manual.
 Confirm that the personnel operating and maintaining the Loader are competent to this work
and know corresponding responsibilities.
 Regularly inspect the safety awareness of relevant personnel when working.
 Stop the work of the Loader immediately if any trouble influencing the safety occurs.
 SANY’s service personnel shall have the right to perform relevant safety inspections for the
Loader when necessary.
 In addition to the inspections specified by SANY, it is also necessary to perform
corresponding inspection for the Loader according to relevant national and local regulations.
 Ensure the Loader to be maintained and repaired timely.
 Plan the use of the Loader carefully and consciously.

Operation and Maintenance Manual - 06 - 2019

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Responsibilities of All Operating Personnel
 They shall report to the supervisor timely if any abnormal phenomenon which might cause
abnormal operation or potential hazard of the Loader occurs, and shall correct the abnormal
situation if possible.
 All the personnel working around the Loader shall follow all the warning signals and pay
attention to the safety of themselves and other persons.
 All operating personnel shall understand the contents and procedures of operation items.
 Observe carefully whether there is any hazardous situation, and report any hazards to the
operator and the signalman such as high-voltage power line, irrelevant personnel and poor
ground condition etc.
Responsibilities of Management
Ensure that the operating personnel have been trained, fully understand the contents of
operation and maintenance manual provided by SANY, are in good health and have operation
permission; otherwise, they shall not operate the Loader.
 Ensure that the operating personnel have good judgment, cooperative consciousness and
psychological quality; otherwise, they shall not operate or maintain the Loader.
 Ensure that the signalman has good visual and auditory judgment, acknowledges the
standard commanding signals, sends clear and accurate signals, has enough experience to
identify the hazardous factors and is able to inform the operator to avoid timely.
 Ensure that the assistants can determine properly the model and working condition of road
Loader, and select appropriate Loader.
 Assign corresponding safety responsibility to the operating personnel of each item and
report the unsafe factors to the supervisor timely

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 Table of Contents

Table of Contents
1. Preface...................................................................................................................... 1-1
1.1 Preface ........................................................................................................................... 1-3
1.2 Safety Information........................................................................................................... 1-4
1.3 Brief introduction ............................................................................................................. 1-6
1.3.1 Brief introduction ............................................................................................... 1-6
1.3.2 Direction of the Machine.................................................................................... 1-6
1.3.3 Running-in of New Machine .............................................................................. 1-6
1.4 Product Information ........................................................................................................ 1-7
1.4.1 Product Information ........................................................................................... 1-7
1.4.2 Engine S/N Nameplate ...................................................................................... 1-7
2. Safe ........................................................................................................................ 2-1
2.1 Safety Nameplate ........................................................................................................... 2-5
2.1.1 Safety Nameplate.............................................................................................. 2-5
2.1.2 Positions of Safety Nameplates ......................................................................... 2-5
2.1.4 Description of Safety Signs ............................................................................... 2-7
2.2 Safety Information......................................................................................................... 2-13
2.2.1 Safety Regulations .......................................................................................... 2-13
2.2.2 If Finding Abnormal Situation........................................................................... 2-13
2.2.3 Protective Articles for Operating Personnel ..................................................... 2-14
2.2.4 Fire Extinguisher and First Aid Kit ................................................................... 2-14
2.2.5 Safety Equipment ............................................................................................ 2-15
2.2.6 Keep the Machine Clean ................................................................................. 2-16
2.2.7 Keep Cab Clean .............................................................................................. 2-16
2.2.8 Armrest and Ladder ........................................................................................ 2-16
2.2.9 Precautions for Work on High.......................................................................... 2-17
2.2.10 Nobody is Allowed To Be on Accessories ........................................................ 2-17
2.2.11 Do Not Get Stuck on Hinge Position................................................................ 2-17
2.2.12 Do Not Get Burned.......................................................................................... 2-18
2.2.12.1 Hot Coolant ........................................................................................... 2-18
2.2.12.2 Hot Oil ................................................................................................... 2-18
2.2.13 Fire and Explosion Protection.......................................................................... 2-19
2.2.13.1 Fire Hazard from Fuel Oil or Engine Oil ................................................. 2-19
2.2.13.2 Fire Hazard from Stacking of Inflammable Materials ............................. 2-19
2.2.13.3 Fire Hazard from Electric Wires ............................................................. 2-20
2.2.13.4 Fire Hazard from Hydraulic Pipeline ...................................................... 2-20
2.2.13.5 Fire Hazard from Lighting Equipment .................................................... 2-20

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Table of Contents

2.2.13.6 Fire hazard caused by thermal shroud .................................................. 2-20

2.2.14 Actions under Fire Hazard .............................................................................. 2-20
2.2.15 Windshield Cleaning Solution ......................................................................... 2-20
2.2.16 Prevent Parts Flying out ................................................................................. 2-21
2.2.17 Prevent Falling Objects, Flying Substances and Foreign Matters ................... 2-21
2.2.18 Installation of Accessories .............................................................................. 2-21
2.2.19 Cab Window Glass ......................................................................................... 2-22
2.2.20 Unapproved refitting ....................................................................................... 2-22
2.2.21 Investigate Construction Site in Advance ........................................................ 2-22
2.2.22 Operation on soft ground ................................................................................ 2-22
2.2.23 Do Not be Close to High Voltage Cables ........................................................ 2-23
2.2.24 Ensure good sight........................................................................................... 2-23
2.2.25 Ventilation of Work Environment ..................................................................... 2-24
2.2.26 Prevention of Asbestos Dust Hazard .............................................................. 2-24
2.2.27 Emergency Exit of Cab ................................................................................... 2-25
2.3 Operate the Machine Safely ......................................................................................... 2-25
2.3.1 Start the Machine Safely................................................................................. 2-25
2.3.1.1 Get on the Machine Safely .................................................................... 2-25
2.3.1.2 Adjustment of Seat ............................................................................... 2-25
2.3.1.3 Fasten Seat Belt Properly ..................................................................... 2-26
2.3.1.4 Inspections before Starting Engine ....................................................... 2-26
2.3.1.5 Startthe Machine Safely ........................................................................ 2-27
2.3.1.6 Starting Engine in Cold Weather ........................................................... 2-27
2.3.1.7 Auxiliary Equipment for Starting ............................................................ 2-27
2.3.1.8 After Starting Engine............................................................................. 2-28
2.3.2 Operations ...................................................................................................... 2-28
2.3.2.1 Inspection before Operations ................................................................ 2-28
2.3.2.2 Precautions before Operations ............................................................. 2-28
2.3.2.3 Safety Rules for Changing the Machine Direction ................................. 2-29
2.3.2.4 Safety Rules for Traveling ..................................................................... 2-30
2.3.2.5 Drive the Machine Safely ...................................................................... 2-30
2.3.2.6 Operate on Slope ................................................................................. 2-31
2.3.2.7 Operate in Snowy Days ........................................................................ 2-32
2.3.2.8 Operating in Water and Swampy Areas ................................................ 2-33
2.3.2.9 Operating in Cold Weather ................................................................... 2-33
2.3.2.10 Prohibited Operations ........................................................................... 2-34
2.3.4 Parking of the Machine ................................................................................... 2-35

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 Table of Contents

2.3.3.1 Selection of Parking Lot......................................................................... 2-35

2.3.3.2 Turn off the Machine .............................................................................. 2-35
2.3.3.3 Stop ...................................................................................................... 2-36
2.3.4 Transportation ................................................................................................. 2-38
2.3.5 Storage battery ............................................................................................... 2-39
2.3.6 Towing (rescue and towing) ............................................................................. 2-40
2.4 Safe Maintenance Instructions ...................................................................................... 2-43
2.4.1 Precautions before Maintenance ..................................................................... 2-43
2.4.2 Self-preparation............................................................................................... 2-44
2.4.3 Preparation of Working Area ........................................................................... 2-44
2.4.4 Steps for Switching off Engine before Maintenance ........................................ 2-45
2.4.5 Warning Signs ................................................................................................. 2-45
2.4.6 Appropriate Tools ............................................................................................ 2-46
2.4.7 Maintenance when Engine Running ................................................................ 2-46
2.4.8 Work Beneath the Machine ............................................................................. 2-46
2.4.9 Be Careful for Hot Cooling System .................................................................. 2-47
2.4.10 Safe Operation of High Pressure Hose ........................................................... 2-47
2.4.11 Be Careful for High Pressure Liquid ................................................................ 2-48
2.4.12 Welding Operation .......................................................................................... 2-48
2.4.13 Maintain Air Conditioning System Safely ......................................................... 2-49
2.4.14 Precautions for High Voltage ........................................................................... 2-49
2.4.15 Accumulator .................................................................................................... 2-50
2.4.16 Prevent Fire Hazard and Explosion ................................................................. 2-50
2.4.17 Regular Replacement of Safety-related Parts ................................................. 2-51
2.4.18 Execute Maintenance ...................................................................................... 2-51
2.4.19 Dispose Wastes Properly ................................................................................ 2-52
2.5 ..................................................................................................................................... 2-52
3. Specifications and Dimensions .......................................................................... 3-1
3.1 Specification ................................................................................................................... 3-3
3.2 Technical parameters ...................................................................................................... 3-4
3.2.1 Complete machine ............................................................................................ 3-4
3.2.2 Engine............................................................................................................... 3-4
3.2.3 Electrical System............................................................................................... 3-5
3.2.4 Gearbox ............................................................................................................ 3-5
3.2.5 Driving axle ....................................................................................................... 3-5
3.2.6 Braking system ................................................................................................. 3-5
3.2.7 Steering system ................................................................................................ 3-5

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Table of Contents

3.2.8 Wheel ............................................................................................................... 3-6

3.2.9 Cab................................................................................................................... 3-6
3.2.10 Hydraulic System.............................................................................................. 3-7
4. Operations ............................................................................................................ 4-1
4.1 General Drawing of the Machine .................................................................................... 4-5
4.2 Control Devices and Instruments Description ................................................................. 4-5
4.2.1 Combination meter ........................................................................................... 4-5
4.2.2 Display the page operation method for every page ........................................... 4-7
4.2.4 Switch............................................................................................................. 4-23
4.2.4 Control Lever and Pedal ................................................................................. 4-25
4.2.4.1 ............................................................................................................. 4-25
4.2.4.2 Control Lever for Selector ..................................................................... 4-26
4.2.4.4 Braking pedal........................................................................................ 4-26
4.2.4.4 Steering Wheel Adjustment Device ....................................................... 4-26
4.2.4.5 Accelerator pedal .................................................................................. 4-26
4.2.4.6 Control Lever for Boom and Bucket ...................................................... 4-27
4.2.5 Cup Holder ..................................................................................................... 4-27
4.2.6 Information Pack............................................................................................. 4-27
4.2.7 Emergency Exit .............................................................................................. 4-28
4.2.8 Fire extinguisher ............................................................................................. 4-28
4.2.9 electrical elements .......................................................................................... 4-28
4.2.9.1 Battery .................................................................................................. 4-28
4.2.9.2 Negative Switch .................................................................................... 4-29
4.2.9.3 Starting motor ....................................................................................... 4-30
4.2.9.4 Alternator .............................................................................................. 4-30
4.2.9.5 Lamps................................................................................................... 4-32
4.2.9.6 Sensor .................................................................................................. 4-34
4.2.9.7 Pressure switch .................................................................................... 4-34
4.2.9.8 Backward Alarm .................................................................................... 4-35
4.2.9.9 Power management module ................................................................. 4-35
4.2.10 Wiper Cleaning Kettle ..................................................................................... 4-36
4.2.11 Air conditioning system ................................................................................... 4-36
4.2.11.1 Introduction and Composition ............................................................... 4-36
4.2.11.2 Technical parameter ............................................................................. 4-37
4.2.11.3 Working principle .................................................................................. 4-37
4.2.11.4 User’s guide ......................................................................................... 4-38
4.2.11.5 Air Conditioner Vent .............................................................................. 4-41

IV Operation and Maintenance Manual - 06 - 2019

 Table of Contents

4.2.12 Radio .............................................................................................................. 4-42

4.2.12.1 Function Description of Control Panel ................................................... 4-42
4.2.12.2 Radio Operating Instructions ................................................................. 4-43
4.2.12.3 Operating Instructions for MP3 Player ................................................... 4-43
4.2.12.4 Other Operating Instructions ................................................................. 4-44
4.2.13 Door lock ......................................................................................................... 4-45
4.2.14 Cover with Lock............................................................................................... 4-46
4.2.14.1 .............................................................................................................. 4-46
4.2.14.2 Open and close the cover with lock ....................................................... 4-46
4.2.14.3 Open and Close Hood with Lock ........................................................... 4-47
4.2.15 Tool Kit ............................................................................................................ 4-47
4.4 Operation and Control of the Machine .......................................................................... 4-48
4.3.1 Before Starting Engine .................................................................................... 4-48
4.3.1.1 Walkaround Inspection .......................................................................... 4-48
4.3.1.2 Inspection before Starting...................................................................... 4-49
4.3.1.3 Adjustment before Operation ................................................................. 4-55
4.3.1.4 Operation before Starting Engine .......................................................... 4-57
4.3.2 Start Engine .................................................................................................... 4-58
4.3.4 Turn off Engine ................................................................................................ 4-59
4.3.4 Operation of the machine ................................................................................ 4-60
4.3.4.1 Gear shift .............................................................................................. 4-60
4.3.4.2 Brake..................................................................................................... 4-61
4.3.4.3 Stop ...................................................................................................... 4-61
4.3.5 Control and Operation of Working Device ....................................................... 4-62
4.3.6 Prohibited Operations ..................................................................................... 4-63
4.3.7 Allowable Water Depth .................................................................................... 4-63
4.3.8 Operate on Slope ............................................................................................ 4-64
4.3.8.1 .............................................................................................................. 4-64
4.3.8.2 Traveling Downhill ................................................................................. 4-64
4.3.8.3 The engine Stalls on a Slope ................................................................. 4-64
4.3.8.4 Cab door on slope ................................................................................. 4-64
4.3.9 Measures in Case of Seizing ........................................................................... 4-64
4.3.10 Recommended Purposes ................................................................................ 4-65
4.3.10.1 Recommended Purposes ...................................................................... 4-65
4.3.10.2 Loading operation.................................................................................. 4-65
4.3.10.3 Bulldozing Operation ............................................................................. 4-68
4.3.10.4 Scraping Operation ............................................................................... 4-69

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Table of Contents

4.3.10.5 Lifting Operation ................................................................................... 4-69

4.3.11 Replace Bucket Teeth ..................................................................................... 4-69
4.3.12 Parking of the Machine ................................................................................... 4-70
4.3.13 Machine Inspection after Daily Operation ....................................................... 4-70
4.3.14 Locking ........................................................................................................... 4-71
4.3.15 Operations in Cold Weather............................................................................ 4-71
4.3.15.1 Operating Instructions in Cold Weather ................................................ 4-71
4.3.15.2 After Cold Season................................................................................. 4-72
4.3.16 Long-term Storage.......................................................................................... 4-72
4.3.16.1 Before Storage ..................................................................................... 4-72
4.3.16.2 During Storage ..................................................................................... 4-72
4.3.16.4 After Storage ........................................................................................ 4-72
4.4 Transportation .............................................................................................................. 4-73
4.4.1 .................................................................................................................... 4-73
4.4.2 Transportation Method .................................................................................... 4-73
4.4.4 Loading and Unloading Machine with Trailer .................................................. 4-73
4.4.3.1 ............................................................................................................. 4-73
4.4.3.2 Loading................................................................................................. 4-73
4.4.3.4 Fixing of the Machine ............................................................................ 4-74
4.4.3.4 Unload .................................................................................................. 4-74
4.5 Hoisting ........................................................................................................................ 4-75
5. Maintenance ............................................................................................................. 5-1
5.1 ....................................................................................................................................... 5-5
5.2 Treat the Oil, Fuel Oil and Coolant ................................................................................. 5-5
5.2.1 Oil ..................................................................................................................... 5-5
5.2.2 Fuel Oil ............................................................................................................. 5-5
5.2.3 Coolant of cooling system................................................................................. 5-6
5.2.4 Lubricating Grease ........................................................................................... 5-7
5.2.5 Storage of Engine Oil and Fuel Oil ................................................................... 5-7
5.2.6 Filter core ......................................................................................................... 5-7
5.3 Maintenance of Electrical System .................................................................................. 5-7
5.4 Quick-wear Parts............................................................................................................ 5-8
5.5 Recommended Fuel Oil, Coolant and Lubricating Oil ..................................................... 5-8
5.6 Tightening Torque......................................................................................................... 5-11
5.7 Key Parts Related to Safety ......................................................................................... 5-13
5.8 Maintenance Plan ........................................................................................................ 5-14
5.9 Maintenance Procedures ............................................................................................. 5-16

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 Table of Contents

5.9.1 Inspection Every 10 Hours or Every Day ......................................................... 5-16

5.9.1.1 Check of Hydraulic System for Leakage ................................................ 5-16
5.9.1.2 Check of Battery.............................................................................................. 5-16
5.9.1.3 Check of Engine Oil Level ..................................................................... 5-16
5.9.1.4 Inspect the coolant level ........................................................................ 5-17
5.9.1.5 Inspect the hydraulic oil level ................................................................. 5-17
5.9.1.6 Check of Fuel Level and Removal of Water and Impurities from the
Primary Fuel Filter ................................................................................. 5-18
5.9.1.7 Check of Hydraulic System for Leakage ................................................ 5-19
5.9.1.8 Check of Tires (Air Pressure and Damage) ........................................... 5-19
5.9.1.9 Lubrication of Transmission Shaft, Hinge and Operating Device ........... 5-20
5.9.2 Maintenance Every 50 Hours .......................................................................... 5-21
5.9.2.1 Maintenance Every 50 Hours ................................................................ 5-21
5.9.2.2 Tighten All Connecting Bolts of Transmission Shaft ............................... 5-21
5.9.2.3 Cleaning of Battery Terminals and Apply Vaseline ................................. 5-21
5.9.2.4 Check of Clearance between the Brake Disc and the Friction
Plate of the Parking Brake ..................................................................... 5-21
5.9.4 Maintenance Every 100 Hours ........................................................................ 5-21
5.9.3.1 Maintenance every 100 hours ............................................................... 5-21
5.9.3.2 Cleaning of Engine Cylinder Head ......................................................... 5-21
5.9.3.3 Change of Engine or Transmission Oil and Replace Filter elements...... 5-21
5.9.4 Maintenance every 250 hours ......................................................................... 5-21
5.9.4.1 Maintenance every 250 hours ............................................................... 5-22
5.9.4.2 Check of Rim Mounting Bolts, Transmission and Engine
Mounting Bolts ...................................................................................... 5-22
5.9.4.3 Check of All Stressed Welds and Fixing Bolts for Operating Device,
Front and Rear Frames ......................................................................... 5-22
5.9.4.4 Check of Oil Level for Front and Rear Axles .......................................... 5-22
5.9.4.5 Check of Service Brake ......................................................................... 5-23
5.9.4.6 Check of Parking Brake ......................................................................... 5-24
5.9.4.7 Check of Brake Disc for Wear ............................................................... 5-24
5.9.4.8 Check and Cleaning of Air Filter Element .............................................. 5-24
5.9.4.9 Check Whether the Pipe Clamp and Hoop of the Hydraulic System
are Abnormal ......................................................................................... 5-25
5.9.5 Maintenance every 500 hours ......................................................................... 5-26
5.9.5.1 Maintenance every 500 hours ............................................................... 5-26
5.9.5.2 Replace the Primary Fuel filter core ...................................................... 5-26
5.9.5.3 Replace the Fine Fuel Filter Element..................................................... 5-29
5.9.5.4 Change of Engine Oil and Replacement of Oil Filter Element ................ 5-31

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Table of Contents

5.9.5.5 Replacement of Transmission Filter Element ........................................ 5-32

5.9.5.6 Check and Cleaning of Radiator and Cooler Plate ................................ 5-33
5.9.5.7 Check of Transmission Oil Level ........................................................... 5-34
5.9.5.8 Maintenance of Breathing Valve in Hydraulic Oil Tank .......................... 5-35
5.9.6 Maintenance every 1000 hours....................................................................... 5-36
5.9.6.1 Maintenance every 1,000 hours ............................................................ 5-36
5.9.6.2 Check, Clean and Replace the Air Cleaner Element ............................. 5-36
5.9.6.3 Check All Fastening Parts of Engine Exhaust Pipe Clamp .................... 5-38
5.9.6.4 Replacement of Transmission Filter ...................................................... 5-38
5.9.6.5 Change of Transmission Oil and Cleaning of Suction Screen ............... 5-38
5.9.6.6 Replacement of Filter Element of Suction Return Oil Filter ................... 5-39
5.9.6.7 Replacement of Pilot/Brake Filter.......................................................... 5-41
5.9.6.8 Check the Nitrogen Pressure in the Accumulator .................................. 5-41
5.9.7 Maintenance every 2000 hours....................................................................... 5-43
5.9.7.1 Maintenance every 2,000 hours ............................................................ 5-43
5.9.7.2 Change of Front and Rear Axle Oil ....................................................... 5-43
5.9.7.3 Change the Engine Coolant and Clean the Inside of the Cooling
System ................................................................................................. 5-44
5.9.7.4 Inspect alternator .................................................................................. 5-45
5.9.7.5 Check the Engine Valve Clearance and Adjust ..................................... 5-45
5.9.8 Maintenance every 4000 hours....................................................................... 5-45
5.9.8.1 Maintenance every 4,000 hours ............................................................ 5-46
5.9.8.2 Check the Water Pump ......................................................................... 5-46
5.9.8.3 Check the Starting Motor ...................................................................... 5-46
5.9.8.4 Check whether the High-Pressure Pipe Clamp is Loose and
whether the Rubber is Hardened .......................................................... 5-46
5.9.8.5 Check the Working Condition of the Compressor.................................. 5-46
5.9.8.6 Change the Oil in the Hydraulic Tank .................................................... 5-46
5.9.9 Maintenance Every 6,000 Hours..................................................................... 5-47
5.9.10 Maintenance every 8000 hours....................................................................... 5-47
5.9.10.1 Maintenance every 8000 hours ............................................................. 5-47
5.9.10.2 Replace the High Pressure Pipeline Clamp .......................................... 5-47
5.9.11 Maintenance every 10000 hours..................................................................... 5-47

VIII Operation and Maintenance Manual - 06 - 2019

 Preface

Preface
1. Preface...................................................................................................................... 1-1
1.1 Preface ........................................................................................................................... 1-3
1.2 Safety Information........................................................................................................... 1-4
1.3 Brief introduction ............................................................................................................. 1-6
1.3.1 Brief introduction ............................................................................................... 1-6
1.3.2 Direction of the Machine.................................................................................... 1-6
1.3.3 Running-in of New Machine .............................................................................. 1-6
1.4 Product Information ........................................................................................................ 1-7
1.4.1 Product Information ........................................................................................... 1-7
1.4.2 Engine S/N Nameplate ...................................................................................... 1-7

Operation and Maintenance Manual - 06 - 2019 1-1

Preface

Warning
Please read and fully understand the precautions in this Manual and described in the safety
nameplate on the machine. When operating or repairing the machine, please follow those
precautions strictly; otherwise, the wrong operation might lead to machine damages or personal
injuries.

1-2 Operation and Maintenance Manual - 06 - 2019

 Preface

1. Preface
1.1 Preface
Overview
This Operation and Maintenance Manual is a guide for using the machine properly, and mainly
provides the technical and safety information for operation. Make sure to read every part of this
Manual.
Only the operating personnel who hold the license from competent local authority (according to
the local law), is qualified and experienced are allowed to operate this machine. Operate the
machine always in accordance with relevant laws and regulations of the state, province,
autonomous region and municipality. The operation safety information and description herein
should be taken only as recommendations and warnings.
SANY Heavy Machinery Co., Ltd. is unable to foresee all kinds of potential hazardous situation in
the operation and maintenance; thus, the safety information in this Manual and on the machine
will not include all the possible safety measures. You are responsible to take all necessary
measures to ensure the safety when using the methods or actions which are not recommended
or allowed particularly in this manual.
Any unauthorized modification or misuse of the machine may affect the performance of the
Loader or cause greater safety risks, such as setting the fuel quantity beyond the specified value
or overloading the machine. Please drive and operate this machine carefully. Mis-operation and
misuse may also cause damage. Sany Heavy Machinery will not be responsible for the loss
caused by the above failures.
The machine involved in this manual is operated for various operations under normal conditions.
Please do not operate it in any inflammable and explosive environment or area containing
asbestos dust.
Please select the suitable Loader for plateau operation when it is used in an area with an altitude
of more than 2,000 m.
This machine has been tested for electromagnetic capacitance according to EN 13309-2000.
Therefore, all unapproved electronic accessories, such as communication equipment, shall be
tested before the installation and operation to confirm that there is no electromagnetic
interference to the machine before the operation.
All the data, graphic charts and specifications herein are the latest product information available
when it is published. SANY Heavy Machinery Co., Ltd. reserves the right to change it from time
to time without advance notice. Please contact with SANY Heavy Machinery Co., Ltd. or its
authorized agents for the latest information about the machine or the problems concerning data
in this manual.
Application scope of standard excavator: altitude up to 2,000m and atmospheric temperature at -
30℃ to +50℃.

□Attention
Before starting operation and maintenance, the operating personnel and maintenance personnel
must:
 Read and understand this Manual.
 Read the safety notices in this Manual and the safety nameplate on the machine, and fully
understand them.
 Not use or operate the machine for the purposes prohibited herein in any cases.
 If the fuel oil volume, particle or latitude exceeds the maximum value specified for this model

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Preface

and application, it might lead to injuries, and such circumstance will not be covered by the
quality warranty.
 Always keep this Manual in the cab for the convenience of reference.
 If this manual is lost or become illegible, please contact SANY Heavy Machinery authorized
dealer immediately for new one or replacement.
 This Manual shall be regarded as a permanent integral part of this machine. This Manual
shall be handed over to the new user together with the machine if the machine is to be sold.
 The machine provided by SANY Heavy Machinery Co., Ltd. to the purchasing country
complies with all the applicable specifications and standards. If the machine is purchased
from another country or from the person of another country, some safety devices and
technical requirements may not be available for your country. Please contact with the
authorized agent of SANY Heavy Machinery Co., Ltd. before use if you have any doubt
about whether the machine meets the local use standards and specifications.

1.2 Safety Information

For helping you use this machine safely, this Manual provides the safety precautions and
nameplates fixed on the machine and gives instructions for the purpose of describing the
potential hazardous situation and giving methods for avoiding such hazardous situation.
The user and after-sales personnel must be familiar with all kinds of warning signs and warning
symbols on the machine before operating and maintaining the machine, strictly follow the safety
criterion and suggestions herein and take positive safety preventive measures and
countermeasures for the purpose of minimizing the risks of personal injuries, the machine
damages due to improper repair or the risks arisen from unsafe factors.
1. Safety Warning
The safety warning is composed of safety warning symbols and mark words. It is used to remind
you the potential hazardous situation which might lead to personal injuries or damages. The
safety warning may be classified with the mark words according to the severity corresponding to
the hazardous situation. 3 kinds of mark words are used in this Manual: Danger, Warning and
Attention, which means:
□ Danger It would lead to major injuries and even death if such hazard was not avoided.

It could lead to major injuries and even death if such potential hazard was not
□ Warning
avoided.

It could lead to medium or minor injuries if such potential hazard was not avoided.
□ Attention “Attention” also could be used to remind the occasions of unsafe operations which
might lead to personal injuries, machine and environmental damages.

Examples of Safety Warning

□Attention
 Be sure to engage the mechanical lock on the locked position when standing up from the
driver’s seat.
 It would lead to major injuries or death if it was touched accidentally when the control lever is
not locked.

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 Preface

2. Safety Nameplate
The safety nameplate is fixed on the machine to remind the operator or maintenance personnel
on site the potential hazards when operating or maintaining the machine. “Safety nameplate in
text” and “safety nameplate in graph” are used on this machine to indicate the safety measures.
a. Examples of safety nameplate in text

Figure 1-1
b. Example of safety nameplate in graph

Figure 1-2

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Preface

1.3 Brief introduction

1.3.1 Brief introduction
SANY Wheeled Loader is designed mainly for the following work:
 Loading
 Bulldozing operation
 Lifting operation
 Traction operation
Refer to relevant part of operation and maintenance manual for details.
The number in the figure is corresponding to the number in the [ ] of the text (for example: 1 →
[1]). In this Manual, the measurement is subject to international system of unit (SI).
1.3.2 Direction of the Machine
In this manual, Front, Back, Left and Right refer to the front, back, left and right of the operator
during the normal operation.

Front

Left Right

Rear

Figure 1-3
1.3.3 Running-in of New Machine
The machine of SANY Heavy Machinery Co., Ltd. has been adjusted and tested before delivery.
However, the influence will be influenced seriously and the service life of machine will be
shortened if the machine is operated under full load before the running-in period.
It is necessary to perform the running-in for the machine in the first 100 hours (according to the
indication of service hours on the displayer).
Be sure to fully understand the contents herein and pay attention to the following points in the
running-in process:

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 The engine runs at the idle speed for 3 ~ 5 minutes after starting.
 Avoid operating at high speed under heavy load.
 Avoid starting engine suddenly, or accelerating suddenly, unnecessary stop or changing
directly after starting the engine.
1.4 Product Information
1.4.1 Product Information
Please inform the authorized agent of SANY the following information when requiring
maintenance or ordering replacement parts.
Machine S/N Nameplate
The serial number plate is located on the left side of the front frame (see the figure below).

Figure 1–4
1.4.2 Engine S/N Nameplate
The engine nameplate is located on the air valve cover on the top of the engine.

Figure 1–5

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 Safe

Safe
2. Safe ........................................................................................................................ 2-1
2.1 Safety Nameplate ........................................................................................................... 2-5
2.1.1 Safety Nameplate.............................................................................................. 2-5
2.1.2 Positions of Safety Nameplates ......................................................................... 2-5
2.1.4 Description of Safety Signs ............................................................................... 2-7
2.2 Safety Information......................................................................................................... 2-13
2.2.1 Safety Regulations .......................................................................................... 2-13
2.2.2 If Finding Abnormal Situation........................................................................... 2-13
2.2.3 Protective Articles for Operating Personnel ..................................................... 2-14
2.2.4 Fire Extinguisher and First Aid Kit ................................................................... 2-14
2.2.5 Safety Equipment ............................................................................................ 2-15
2.2.6 Keep the Machine Clean ................................................................................. 2-16
2.2.7 Keep Cab Clean .............................................................................................. 2-16
2.2.8 Armrest and Ladder ........................................................................................ 2-16
2.2.9 Precautions for Work on High.......................................................................... 2-17
2.2.10 Nobody is Allowed To Be on Accessories ........................................................ 2-17
2.2.11 Do Not Get Stuck on Hinge Position................................................................ 2-17
2.2.12 Do Not Get Burned.......................................................................................... 2-18
2.2.12.1 Hot Coolant ........................................................................................... 2-18
2.2.12.2 Hot Oil ................................................................................................... 2-18
2.2.13 Fire and Explosion Protection.......................................................................... 2-19
2.2.13.1 Fire Hazard from Fuel Oil or Engine Oil ................................................. 2-19
2.2.13.2 Fire Hazard from Stacking of Inflammable Materials ............................. 2-19
2.2.13.3 Fire Hazard from Electric Wires ............................................................. 2-20
2.2.13.4 Fire Hazard from Hydraulic Pipeline ...................................................... 2-20
2.2.13.5 Fire Hazard from Lighting Equipment .................................................... 2-20
2.2.13.6 Fire hazard caused by thermal shroud .................................................. 2-20
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Safe

2.2.14 Actions under Fire Hazard .............................................................................. 2-20

2.2.15 Windshield Cleaning Solution ......................................................................... 2-20
2.2.16 Prevent Parts Flying out ................................................................................. 2-21
2.2.17 Prevent Falling Objects, Flying Substances and Foreign Matters ................... 2-21
2.2.18 Installation of Accessories .............................................................................. 2-21
2.2.19 Cab Window Glass ......................................................................................... 2-22
2.2.20 Unapproved refitting ....................................................................................... 2-22
2.2.21 Investigate Construction Site in Advance ........................................................ 2-22
2.2.22 Operation on soft ground ................................................................................ 2-22
2.2.23 Do Not be Close to High Voltage Cables ........................................................ 2-23
2.2.24 Ensure good sight........................................................................................... 2-23
2.2.25 Ventilation of Work Environment ..................................................................... 2-24
2.2.26 Prevention of Asbestos Dust Hazard .............................................................. 2-24
2.2.27 Emergency Exit of Cab ................................................................................... 2-25
2.3 Operate the Machine Safely ......................................................................................... 2-25
2.3.1 Start the Machine Safely................................................................................. 2-25
2.3.1.1 Get on the Machine Safely .................................................................... 2-25
2.3.1.2 Adjustment of Seat ............................................................................... 2-25
2.3.1.3 Fasten Seat Belt Properly ..................................................................... 2-26
2.3.1.4 Inspections before Starting Engine ....................................................... 2-26
2.3.1.5 Startthe Machine Safely ........................................................................ 2-27
2.3.1.6 Starting Engine in Cold Weather ........................................................... 2-27
2.3.1.7 Auxiliary Equipment for Starting ............................................................ 2-27
2.3.1.8 After Starting Engine............................................................................. 2-28
2.3.2 Operations ...................................................................................................... 2-28
2.3.2.1 Inspection before Operations ................................................................ 2-28
2.3.2.2 Precautions before Operations ............................................................. 2-28
2.3.2.3 Safety Rules for Changing the Machine Direction ................................. 2-29
2.3.2.4 Safety Rules for Traveling ..................................................................... 2-30
2.3.2.5 Drive the Machine Safely ...................................................................... 2-30
2.3.2.6 Operate on Slope ................................................................................. 2-31
2.3.2.7 Operate in Snowy Days ........................................................................ 2-32
2.3.2.8 Operating in Water and Swampy Areas ................................................ 2-33
2.3.2.9 Operating in Cold Weather ................................................................... 2-33
2.3.2.10 Prohibited Operations ........................................................................... 2-34
2.3.4 Parking of the Machine ................................................................................... 2-35
2.3.3.1 Selection of Parking Lot ........................................................................ 2-35
2.3.3.2 Turn off the Machine ............................................................................. 2-35

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 Safe

2.3.3.3 Stop ...................................................................................................... 2-36

2.3.4 Transportation ................................................................................................. 2-38
2.3.5 Storage battery ............................................................................................... 2-39
2.3.6 Towing (rescue and towing) ............................................................................. 2-40
2.4 Safe Maintenance Instructions ...................................................................................... 2-43
2.4.1 Precautions before Maintenance ..................................................................... 2-43
2.4.2 Self-preparation............................................................................................... 2-44
2.4.3 Preparation of Working Area ........................................................................... 2-44
2.4.4 Steps for Switching off Engine before Maintenance ........................................ 2-45
2.4.5 Warning Signs ................................................................................................. 2-45
2.4.6 Appropriate Tools ............................................................................................ 2-46
2.4.7 Maintenance when Engine Running ................................................................ 2-46
2.4.8 Work Beneath the Machine ............................................................................. 2-46
2.4.9 Be Careful for Hot Cooling System .................................................................. 2-47
2.4.10 Safe Operation of High Pressure Hose ........................................................... 2-47
2.4.11 Be Careful for High Pressure Liquid ................................................................ 2-48
2.4.12 Welding Operation .......................................................................................... 2-48
2.4.13 Maintain Air Conditioning System Safely ......................................................... 2-49
2.4.14 Precautions for High Voltage ........................................................................... 2-49
2.4.15 Accumulator .................................................................................................... 2-50
2.4.16 Prevent Fire Hazard and Explosion ................................................................. 2-50
2.4.17 Regular Replacement of Safety-related Parts ................................................. 2-51
2.4.18 Execute Maintenance ...................................................................................... 2-51
2.4.19 Dispose Wastes Properly ................................................................................ 2-52
2.5 ..................................................................................................................................... 2-52

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Safe

Warning
Please read and fully understand the precautions in this Manual and described in the safety
nameplate on the machine. When operating or repairing the machine, please follow those
precautions strictly; otherwise, the wrong operation might lead to machine damages or personal
injuries.

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2. Safe
2.1 Safety Nameplate
2.1.1 Safety Nameplate
The following warning signs and safety nameplates are used on this machine.
 Be sure to understand the correct position and contents of the nameplates fully.
 In order to ensure that the label contents can be read normally, make sure that they are in
the correct position and keep the label clean at all times. Do not use organic solvent or
gasoline when cleaning the sign. Otherwise the paint on the sign will peel off.
 In addition to the warning sign and safety nameplate, there are also other nameplates which
shall be treated in the same way.
 If the nameplates are damaged, lost or become illegible, it is necessary to replace them with
new parts. Refer to this Manual or the real nameplates for details concerning part No. of
nameplate.
2.1.2 Positions of Safety Nameplates

Figure 2-1
[1] Warning sign of safety belt [5] Be careful not to touch the sign
[2] Indication sign for control [6] Warning label of “Hurt by Jamming”
[3] Lubrication and maintenance chart [7] Warning sign for reading the instructions
[4] Indication sign of lifting hook point [8] Shipping fixed-point sign

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Safe

Figure 2-2
[9] Warning sign for splashing prevention [13] Warning sign for no sitting
[10] Warning sign for beating by fan [14] Unlocking sign
[11] Warning signs to prevent falling [15] No trampling sign
[12] Warning nameplate for hot parts [16] Safety warning sign for belt

2-6 Operation and Maintenance Manual - 06 - 2019

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