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SANY SY115C9, Safety, Operation And Manitenance Manual

The SANY SY115C9 offers a comprehensive Safety, Operation, and Maintenance Manual that ensures utmost safety for users. This essential manual is available for free download on our website, allowing you to conveniently access the information you need. Equip yourself with the necessary knowledge and guidelines to operate our top-quality product safely and efficiently. Visit 88.208.23.73:8080 to download your manual today.

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Maintenance

SY115C9/135C/155H Crawler Hydraulic Excavator

5-2

Safety, Operation and Maintenance Manual - Aug 2012

5.8.2.1  Air cleaner - clean/replace .................................................................. 5-29
5.8.2.2  Cooling system  - clean ....................................................................... 5-37
5.8.2.3  Track shoe bolts - inspect/tighten ....................................................... 5-41
5.8.2.4  Track tension - inspect/adjust ............................................................. 5-42
5.8.2.5  Bucket tips (lateral pin) - replace ........................................................ 5-45
5.8.2.6 Bucket Replacement ........................................................................... 5-47
5.8.2.7  Bucket clearance - adjust .................................................................... 5-49
5.8.2.8 Window washer 

fl

 uid  - check/re

fi

 ll ...................................................... 5-51

5.8.2.9  Air conditioner - inspect/service .......................................................... 5-52
5.8.2.10  Gas spring - inspect .......................................................................... 5-54
5.8.2.11  Air in hydraulic system - purge .......................................................... 5-55
5.8.2.12  Hydraulic circuit internal pressure - release ...................................... 5-58

5.8.3  Checks before starting ................................................................................. 5-59
5.8.4  Every 100 service hours .............................................................................. 5-60

5.8.4.1 Lubrication .......................................................................................... 5-60

5.8.5  Every 250 service hours .............................................................................. 5-63

5.8.5.1  Compressor belt tension - inspect/adjust ............................................ 5-63
5.8.5.2  Oil in engine oil pan and oil 

fi

 lter - change/replace ............................. 5-65

5.8.5.3 Primary fuel 

fi

 lter - replace .................................................................. 5-67

5.8.5.4 Secondary fuel 

fi

 lter - replace ............................................................. 5-71

5.8.6  Every 500 service hours .............................................................................. 5-74

5.8.6.1  Swing bearing - lubricate .................................................................... 5-74
5.8.6.2  Swing pinion gear grease - check/re

fi

 ll ............................................... 5-75

5.8.6.3  Coolant tank and radiator 

fi

 ns - inspect/clean ..................................... 5-76

5.8.6.4 Air conditioner 

fi

 lters - clean ................................................................ 5-77

5.8.6.5  Swing drive oil - check/re

fi

 ll ................................................................. 5-80

5.8.6.6  Final drive oil - check/

fi

 ll ...................................................................... 5-81

5.8.7  Every 1000 service hours ............................................................................ 5-82

5.8.7.1 Hydraulic oil 

fi

 lter - replace .................................................................. 5-82

5.8.7.2  Swing drive oil - change ...................................................................... 5-84
5.8.7.3  Engine exhaust pipe clamps - check .................................................. 5-85
5.8.7.4  Fan belt tension - check/replace ......................................................... 5-85
5.8.7.5  Nitrogen pressure in accumulator (breaker) - check ........................... 5-85

5.8.8  Every 2000 service hours ............................................................................ 5-86

5.8.8.1  Final drive oil - change ........................................................................ 5-86
5.8.8.2 Hydraulic tank 

fi

 lter screen - clean ...................................................... 5-88

Summary of Contents for SY115C9

Page 1: ...tor SY115C9 SY135C8 SY135C9 SY155H Safety Operation and Manitenance Manual 318A Lianggang Avenue Lingang Industrial Park Fengxian District Shanghai P R of China 201413 Tel 86 21 5700 8518 Service hotline 86 4006 098 318 E mail crd sany com cn Documentation No B06T01ENAM1 SY115C9 135C 155H 11644389 ...

Page 2: ... this manual and on the ma chine decals Failure to do can cause serious injury death or property damage Keep this manual with the machine for reading and future reference WARNING Operation and Maintenance Manual Safety Operation and Maintenance Manual Aug 2012 SY115C9 135C 155H Crawler Hydraulic Excavator ...

Page 3: ...ts revisions etc may result in differences between your machine and what is presented here Sany Group assumes no liability For more in formation Contact Sany Group Sany Group Sany Heavy Machinery Limited 318A Lianggang Avenue Lingang Industrial Park Fengxian District Shanghai P R of China 201413 http www sanygroup com Tel 86 21 5700 8518 Service hotline 86 4006 098 318 E mail crd sany com cn Safet...

Page 4: ...7 1 2 3 8 Optional Equipment 1 7 1 2 4 Page numbers 1 7 1 3 Your Sany Machine 1 8 1 3 1 Machine applications 1 8 1 3 2 Machine directions 1 8 1 3 3 Breaking in a new machine 1 9 1 3 4 Machine information 1 9 1 3 4 1 Product identification plate 1 9 1 3 4 2 Engine identification plate 1 10 1 3 4 3 Right and left drive motors 1 11 1 3 4 4 Swing motor 1 11 1 3 4 5 Hydraulic pump 1 11 1 3 4 6 Chassis ...

Page 5: ...lic lockout control 2 23 2 3 9 Handholds and steps 2 24 2 3 10 Overhead work 2 25 2 3 11 No sitting on attachment 2 25 2 3 12 Articulated parts 2 25 2 3 13 Preventing burns 2 25 2 3 13 1 Hot coolant 2 25 2 3 13 2 Hot oil 2 26 2 3 14 Preventing fire and explosion 2 26 2 3 14 1 Fire caused by fuel or oils 2 26 2 3 14 2 Fire caused by flammable materials 2 27 2 3 14 3 Fire caused by electric lines 2 ...

Page 6: ...ine 2 38 2 4 1 5 Engine starting rules 2 39 2 4 1 6 Safe starting 2 39 2 4 1 7 Starting engine in cold season 2 40 2 4 1 8 Engine starting aid 2 40 2 4 1 9 After starting the engine 2 41 2 4 2 Operation 2 42 2 4 2 1 Inspection before operation 2 42 2 4 2 2 Prior operation precautions 2 42 2 4 2 4 Travel directions 2 43 2 4 2 3 Rules for steering safety 2 43 2 4 2 5 Rules for traveling safety 2 45 ...

Page 7: ...ment precautions 2 63 2 5 11 Recoil spring 2 63 2 5 12 Welding operation 2 64 2 5 13 High pressure hoses 2 64 2 5 14 Pressurized fluid 2 65 2 5 15 Hot cooling system 2 66 2 5 16 Air conditioning system 2 66 2 5 17 High voltage precautions 2 67 2 5 18 Accumulator 2 67 2 5 19 Avoiding fire and explosion 2 68 2 5 20 Regular replacement of safety related parts 2 69 2 5 21 Maintenance operation 2 70 2 ...

Page 8: ...mperature 3 29 3 3 2 18 Service Call 3 30 3 4 Switches 3 31 3 4 2 1 Start switch 3 32 3 4 2 2 Fuel control dial 3 33 3 4 2 3 Work lamp switch 3 33 3 4 2 4 Wiper switch 3 35 3 4 2 5 Washer switch 3 36 3 4 2 6 Head lamp switch 3 36 3 4 2 7 Horn switch 3 37 3 4 2 8 Cab lamp 3 37 3 4 2 9 Cigar lighter 3 37 3 4 2 10 Preheat switch only for SY135C8M 3 38 3 4 2 11 Alternator indicator 3 38 3 5 Control le...

Page 9: ...A C operation precautions 3 72 3 16 Radio 3 74 3 16 1 Control panel 3 74 3 16 2 Radio operation 3 76 3 17 Auxiliary Power Supply 3 80 3 18 Fuses 3 80 3 19 Fusible Link 3 81 3 20 Controller 3 82 3 21 Toolbox 3 82 3 22 Grease pump frame 3 82 3 23 Fire extinguisher 3 83 4 Operation 4 1 Before Starting the Engine 4 5 4 1 1 Routine checks 4 5 4 1 2 Checks before starting 4 7 4 1 2 1 Fuel tank check dra...

Page 10: ... 3 Moving the machine backward 4 30 4 4 4 Parking the machine 4 31 4 5 Steering Operation 4 32 4 5 4 1 Steering with travel controls 4 32 4 5 4 2 Steering with machine stopped 4 32 4 5 4 3 Steering during traveling 4 33 4 5 4 4 Pivot turn 4 33 4 5 1 Swing operation 4 34 4 6 Work Equipment Control and Operation 4 35 4 7 Working mode 4 37 4 8 Restricted Operations 4 38 4 8 1 Operation with swinging ...

Page 11: ...ay 4 49 4 15 Locking the Machine 4 50 4 16 Operation in Cold Weather 4 50 4 16 1 Operation instruction 4 50 4 16 1 1 Fuel and lubricant 4 50 4 16 1 2 Battery 4 51 4 16 2 After each workday 4 52 4 16 3 After cold season 4 53 4 17 Long Term Storage 4 54 4 17 1 Before storage 4 54 4 17 2 During storage 4 55 4 17 3 After storage 4 56 4 17 4 Starting the engine after long term storage 4 56 4 18 Transpo...

Page 12: ... 2 Recommended oils 5 20 5 5 Tightening Torque Specification 5 22 5 6 Safety Related Parts 5 24 5 7 Maintenance Schedule 5 25 5 7 1 List of maintenance schedule 5 25 5 7 2 Hydraulic Breaker Service Interval 5 27 5 8 Maintenance Procedures 5 28 5 8 1 Maintenance after initial 50 service hours 5 28 5 8 1 1 Engine oil and filter change replace 5 28 5 8 1 2 Fuel filter replace 5 28 5 8 2 When Required...

Page 13: ...ck refill 5 75 5 8 6 3 Coolant tank and radiator fins inspect clean 5 76 5 8 6 4 Air conditioner filters clean 5 77 5 8 6 5 Swing drive oil check refill 5 80 5 8 6 6 Final drive oil check fill 5 81 5 8 7 Every 1000 service hours 5 82 5 8 7 1 Hydraulic oil filter replace 5 82 5 8 7 2 Swing drive oil change 5 84 5 8 7 3 Engine exhaust pipe clamps check 5 85 5 8 7 4 Fan belt tension check replace 5 8...

Page 14: ... 6 1 5 Hydraulic components handling precautions 6 10 6 2 Pseudo Failures 6 12 6 3 Towing the Machine 6 13 6 4 Towing Hook for Light Loads 6 15 6 5 Severe Operating Conditions 6 15 6 6 Engine Failures 6 16 6 6 1 Engine troubleshooting table 6 16 6 6 2 Coolant temperature high 6 19 6 6 3 Engine oil pressure low 6 20 6 6 4 When fuel exhausts 6 22 6 6 5 When engine rotates reversely 6 24 6 7 Failures...

Page 15: ... 2 2 1 Hydraulic circuit switching 8 8 8 2 2 2 Shifting to breaker general optional equipment 8 8 8 2 2 3 Connecting hydraulic oil circuit 8 9 8 2 2 4 Hydraulic oil passage 8 10 8 2 3 Optional equipment removal and installation 8 11 8 2 3 1 Removal 8 11 8 2 3 2 Optional equipment installation 8 13 8 2 4 Hydraulic oil and hydraulic tank filter change replace 8 15 8 2 5 Long term storage 8 16 8 2 6 ...

Page 16: ...oupler installation 8 26 8 7 2 Operating precautions 8 28 8 8 Refueling System 8 29 8 8 1 Introduction 8 29 8 8 2 Components 8 30 8 9 Central Lubrication System 8 31 8 9 1 Scheme and components 8 31 8 9 2 System working principle 8 33 8 9 3 Setting the lubrication time of electric grease pump 8 34 8 9 4 Technical description 8 35 8 9 5 Adding grease with electric pump 8 36 ...

Page 17: ...Table of Contents Safety Operation and Maintenance Manual Aug 2012 XIV SY115C9 135C 155H Crawler Hydraulic Excavator ...

Page 18: ...6 1 2 3 2 Safety 1 6 1 2 3 3 System functions 1 6 1 2 3 4 Operation 1 6 1 2 3 5 Maintenance 1 6 1 2 3 6 Troubleshooting 1 7 1 2 3 7 Specifications 1 7 1 2 3 8 Optional Equipment 1 7 1 2 4 Page numbers 1 7 1 3 Your Sany Machine 1 8 1 3 1 Machine applications 1 8 1 3 2 Machine directions 1 8 1 3 3 Breaking in a new machine 1 9 1 3 4 Machine information 1 9 1 3 4 1 Product identification plate 1 9 1 ...

Page 19: ... 2 Safety Operation and Maintenance Manual Aug 2012 1 3 4 6 Chassis serial number 1 12 1 3 4 7 Machine monitor 1 12 1 4 Table for serial number and distributor information 1 13 1 5 Correction Request Form Technical Publications 1 14 1 6 Contact Information 1 15 ...

Page 20: ...beginning any operations Items addressed in this manual are designed to help you Understand the structure and performance of your crawler hydraulic excavator Reduce improper operation and point out possible hazardous situations Increase equipment efficiency during op eration Prolong the service life of equipment Reduce maintenance costs Always keep this manual nearby and have all personnel involve...

Page 21: ... as needed If it was not already shipped with your machine the parts book for your machine is available directly from Sany CD A VCR on safety operation and maintenance of your excavator is delivered with the machine CD system requirements In order to use the Sany CD be sure of the following Hardware Intel Pentium II running at 500 MHz or above At least 128 MB RAM CD ROM drive Minimum screen resolu...

Page 22: ...destroy the old ones to prevent any confu sion in the future 1 2 2 Documentation storage Always keep the operator manual and load charts with the machine in the operator cab The parts book is best left either shelved in the workshop area or office It should always be available to the maintenance and service personnel as required These can be printed out from the CD 1 2 3 Manual organization The op...

Page 23: ... operating or maintaining this ma chine Failure to do so may result in serious injury or death 1 2 3 3 System functions This section provides an overview of all the controls alerts and operating systems on the machine It is important to study and become familiar with all systems before proceeding with any operations 1 2 3 4 Operation This section provides some basic operating procedures for this m...

Page 24: ...ed 1 2 3 7 Specifications This section provides general required ma chine information for this crawler hydraulic excavator Some information may vary due to design changes 1 2 3 8 Optional Equipment This section provides information regarding optional equipment for the excavator as autho rized by Sany If you will be using any optional equipment it is important to read the instruc tion manual for th...

Page 25: ...Hydraulic Excavators are designed for the following operations Excavating Leveling Digging Loading Demolishing In this manual the front back left or right di rection indicates when the cab faces the front and the final drive is behind of the machine the moving direction that you could see from the cab A Front B Back C Left D Right E Operator Seat F Sprocket Fig 1 2 A D F B C E CZ335 1101001 ...

Page 26: ...e break in period Let the machine warm up before any operation Avoid operating with severe loads or at high speeds Avoid sudden starts or fast movements or stops Always let the system cool down at the end of the working day 1 3 4 Machine information The serial numbers and model numbers on the components are the only numbers that your Sany distributor will need when ordering replacement parts or re...

Page 27: ... 03 C2 ENGINE POWER 72 7 kW 2200 r min MANUFACTURER ISUZU DATE OF MANUFACTURE POWER RANGE 37 kW 75 APPROVAL NO CN FC G2 0097 21 0003 ENGINE CODE CONFORMED TO NATIONAL STAGE II NON ROAD DIESL ENGINE EMISSION CONTROL STANDARD CZ155 1101002 MITSUBISHI FUSO TRUCK BUS CORPORATION ENGINE FAMILY ENGINE MODEL 4D34 TLU2B APPROVAL NUMBER ENGINE POWER 70kW 2050 r min THIS ENGINE CONFORMS TO CHINA NATIONAL ST...

Page 28: ... Model _____________________________ ID No _____________________________ 1 3 4 4 Swing motor 1 3 4 5 Hydraulic pump On top of swing motor Model ______________________________ ID No ______________________________ On bottom of pump Model ______________________________ ID No ______________________________ CZ235 3100801 CZ235 3100802 CZ235 3100803 Fig 1 6 Fig 1 7 Fig 1 8 ...

Page 29: ...ler Hydraulic Excavator An additional serial number is stamped on the front part of the travel carriage frame SYJ263038018060480 CZ235 3100804 1 3 4 6 Chassis serial number Fig 1 9 Fig 1 10 1 3 4 7 Machine monitor Location of machine monitor is shown in the right illustration CZ335 1101004 ...

Page 30: ...lic Excavator 1 4 Table for serial number and distributor information This location is for you to record information relating to your machine It is advised that you keep this manual with your machine at all times for reference Machine Serial No Engine Serial No Distributor Name Address Phone Numbers ...

Page 31: ... this manual please make a copy of this page fill out the information and send it to us attention Technical Publications See Contact Information on next page Date of this request Your Name Company Name Your Department Street Address City State ZIP Phone E mail Machine Model Serial No Description of Problem Wrong information unclear or erroneous procedure etc Corrective Action by You if any ...

Page 32: ...ation Thank you for purchasing a Sany machine In the event that you should need to contact us for any reason you can reach us as follows Sany Heavy Machinery Limited 318A Lianggang Avenue Lingang Industrial Park Fengxian District Shanghai P R of China 201413 Tel 86 21 5700 8518 Service hotline 86 4006 098 318 E mail crd sany com cn ...

Page 33: ...Introduction Safety Operation and Maintenance Manual Aug 2012 1 16 SY115C9 135C 155H Crawler Hydraulic Excavator B L A N K P A G E ...

Page 34: ... Safety decal locations 2 11 2 3 General Precautions 2 19 2 3 1 Safety rules 2 19 2 3 2 Abnormalities 2 19 2 3 3 Personal protective equipment 2 19 2 3 4 Fire extinguisher and first aid kit 2 21 2 3 5 Safety equipment 2 21 2 3 6 Cleaning your machine 2 22 2 3 7 Keeping the cab clean 2 23 2 3 8 Engaging the hydraulic lockout control 2 23 2 3 9 Handholds and steps 2 24 2 3 10 Overhead work 2 25 2 3 ...

Page 35: ... 30 2 3 20 Attachment combination 2 31 2 3 21 Cab windows glasses 2 31 2 3 22 Unauthorized modification 2 31 2 3 23 Job site investigation 2 31 2 3 24 Operation on soft ground 2 32 2 3 25 Overhead power cables 2 33 2 3 26 Ensuring a good visibility 2 34 2 3 27 Ventilating enclosed area 2 35 2 3 28 Asbestos hazard 2 35 2 3 29 Alternate exit 2 36 2 4 Safe Operation Precautions 2 37 2 4 1 Safe starti...

Page 36: ...54 2 4 6 Lifting objects with the machine 2 56 2 5 Precautions for Maintenance 2 57 2 5 1 Prior maintenance precautions 2 57 2 5 2 Select a working area 2 57 2 5 3 Preparing the machine 2 58 2 5 4 Preparing yourself 2 59 2 5 5 Lock out and tag out 2 60 2 5 6 Using proper tools 2 60 2 5 7 Maintenance with engine running 2 61 2 5 8 Working under the machine 2 61 2 5 9 Track maintenance 2 62 2 5 10 T...

Page 37: ...Safety Safety Operation and Maintenance Manual Sep 2012 2 4 SY115C9 135C 155H Crawler Hydraulic Excavator 2 5 21 Maintenance operation 2 70 2 5 22 Proper disposal of wastes 2 71 ...

Page 38: ...ate every possible circum stance that might involve a potential hazard during operation and maintenance The Safety messages in this manual and on the product are therefore not all inclusive If a procedure work method or operating technique that is not specifically recommended in this manual is used you must be sure that it is safe for you and for others You should also ensure that the product will...

Page 39: ...nformation specifications and illustra tions in this publication are on the basis of information that was available at the time that the publication was written Sany reserves the right to change these information at any time without prior notice Consult your Sany dis tributor to obtain the latest information or if you have any question on the information provided in this manual Before starting ope...

Page 40: ...echnical requirements necessary for using the machine in your country In case you question whether the machine is in accor dance with the standards and specifications of your country you may contact local Sany dis tributor before operating the machine 2 2 Safety Messages Safety precautions given in this manual and on machine decals both textual and graphical provide information of hazardous situat...

Page 41: ...or serious injury It indicates a potentially hazardous situation which if not avoided could result in death or serious injury It indicates a potentially hazardous situation which if not avoided may result in minor or moderate in jury It can also be used to alert unsafe operation as which may cause property loss DANGER CAUTION WARNING It indicates a situation which can cause damage to the machine p...

Page 42: ...e safety related alert words above the following words are used in this manual to provide additional information to which extra attention must be paid Note It is followed by information on how to avoid reduction of machine service life Remark It is followed by very useful information 2 2 3 Safety decals Safety decals on the machine are used to alert operator or maintenance personnel that potential...

Page 43: ...azardous situation and how to avoid it Fig 2 2 is an example of graphical safety de cals The upper triangle indicates the type of haz ardous situation while the lower circle shows the way to avoid it Fig 2 2 2 2 3 1 Textual safety decals Textual safety decals use brief text to indicate hazardous situation and safety measures Fig 2 1 is an example of textual safety decals A820601990968 TO RELEASE P...

Page 44: ...fied in this manual shall not be performed at any time The following safety decals are used on the machine Be sure to recognize the correct locations and information on the decals To ensure that the decals can be read and understood easily they have to be at tached to the right locations and always kept clean The use of organic solution or gasoline to clean the decals is not allowed There are also...

Page 45: ...Safety Safety Operation and Maintenance Manual Sep 2012 2 12 SY115C9 135C 155H Crawler Hydraulic Excavator Fig 2 3 A 1 4 12 10 15 13 12 9 6 B A 18 7 11 2 8 5 17 16 14 3 B CZ335 1102001 ...

Page 46: ...ortation of your machine A820699001019 2 Lock the front window 3 Excavator control pattern Always lock the front window if it is open If the front window is unlocked in the open position it may fall and personal injury could result A820601990961 To prevent bodily injury or death be aware of the running condition and mode of your machine Pay attention to your surrounding and operate your machine sl...

Page 47: ...te exit A820601990969 A820601990974 A820699001020 4 High voltage Electrocution hazard Keep a safe distance from power transmis sion lines 5 Remove key after power off Before leaving your machine lower the work equipment to ground engage the hydraulic lockout control and remove the ignition key Fig 2 7 Fig 2 8 Fig 2 9 ...

Page 48: ...s the possibility of being hit by the machine Be away from the swing ing range Keep a safe distance from the machine when it is working It is possible to be hurt by the work equip ment Keep a safe distance from the machine when it is working 9 Hot surface Hot parts can cause burns Never touch any hot part A820699001016 A820601990963 Fig 2 10 Fig 2 11 10123433 WARNING Fig 2 12 ...

Page 49: ...re loosen only one turn A820699000948 A820600000002 WARNING Read the instruction before removing the cap of any pressure vessel To prevent squirting turn the cap slowly to release in ternal pressure before removing it A rotating part may cause injury Keep a safe distance from any rotating part The regulator valve under high pressure may eject and cause bodily injury Never loosen it over one turn F...

Page 50: ...ydraulic Excavator 13 Moving belt 14 Possible to fall A rotating belt is dangerous Stop the belt before maintenance It is possible to fall Stay away from the edge 15 Engine hood It is possible to fall Never step here A820699001017 STOP A820601990926 Fig 2 17 Fig 2 18 A820601990973 Fig 2 16 ...

Page 51: ...1023 CAUTION 18 Refill refrigerant 17 Water separator draining precautions A820699001284 Refill the refrigerant after replacing system component Direction to drain Direction to close Tighten it properly Never tighten it with extra force Over tightening could damage the water separator NOTICE A820601990962 Fig 2 19 Fig 2 20 Fig 2 21 ...

Page 52: ...erator or job site traffic signalman be sure to make all people understand all hand signals to be used 2 3 2 Abnormalities In case of any abnormalities found during operation and maintenance such as noise vi bration odor incorrect gauge display smoke or oil leakage contact your Sany distributor and take necessary measures Never operate the machine before the faults are corrected 2 3 3 Personal pro...

Page 53: ...other machine parts Long hair can be caught in moving parts Tie your hair if necessary to avoid such hazard Always have your hard hat and safety shoes on Wear safety goggles face masks gloves hearing protection and safety belt if necessary Make sure all PPEs are in good condi tion before use Never listen to radio or music with ear plugs on during operation Dust mask Wear all necessary PPEs as well...

Page 54: ...oning of fire extinguisher at any time Check the first aid kit regularly and replen ish it when necessary Make emergency scheme to deal with fire and accidents CZ335 1102003 Fig 2 23 2 3 5 Safety equipment To protect you and others around you your machine may be equipped with the following safety equipment Make sure that they are se cured in place and in good condition Falling object protective st...

Page 55: ...aning your machine Clean the windshields mirrors and lights Make sure that the operating area steps and handholds are free from oil grass snow ice or mud which can cause you to slip and fall Remove the mud on your soles before getting on the machine If the machine is checked or serviced with presence of mud or oil dirt it may cause you to slip or fall or dirt may get into your eyes Keep the machin...

Page 56: ...rticles such as flammable or explosive products into the cab 2 3 8 Engaging the hydraulic lockout control Before you rise from the operator seat e g to open or close the front window or to adjust the seat lower work equipment to ground place hydraulic lockout control 1 securely to the LOCK position and then stop the engine If hydraulic lockout control is FREE accidental touching of control levers ...

Page 57: ...e machine and maintain a 3 point contact with the handholds and steps in cluding tracks A 3 point contact can be both feet and one hand or both hands and one foot Never use any control lever as a handhold when mounting or dismounting the ma chine Never carry tools when mounting or dis mounting the machine Never work on an engine hood or cover with no non slip mat on it Always face the machine when...

Page 58: ... work equipment changes with movement of linkages Serious personal injury could result if one is stuck in between Never stay close to rotating or retracting ex tending components 2 3 13 Preventing burns 2 3 13 1 Hot coolant To prevent burns caused by hot coolant or steam when checking or discharging the coolant wait until the engine coolant is cool enough before proceeding Never open the cap of ra...

Page 59: ...32 Fig 2 33 CZ335 1102014 Fig 2 34 2 3 14 Preventing fire and explosion 2 3 14 1 Fire caused by fuel or oils Engine oil and fuel must be stored in des ignated place where unauthorized persons cannot enter Never smoke or use fire near fuel or en gine oil Check for missing or loose pipe clamps twisted hoses hoses rubbing against pipe line damaged oil cooler and loose bolts in flange of oil cooler so...

Page 60: ... as they can easily catch on fire All flammable materials should be moved to a safe place before carrying out grinding or welding operation on the chassis Never weld or flame cut the lines contain ing flammable fluid 2 3 14 2 Fire caused by flammable materi als Remove at any time dry leaves wood chips paper pieces dirt and other flamma ble materials built up or stuck on engine exhaust manifold bat...

Page 61: ...e oil disastrous fire or serious injury 2 3 14 5 Fire caused by illumination equip ment Anti blast illumination equipment shall be used to avoid explosion when fuel oil electrolyte window cleaning detergent or cooling fluid is being checked Instructions in this manual must be fol lowed when power outlet on the machine is used for illumination 2 3 14 6 Fire caused by heat shield Damage or missing o...

Page 62: ...part The grease in track tensioning device is under high pressure Improper handling may result in serious injury blindness or death Observe the following instructions Never disassemble grease nozzle or valve components These parts may eject Never stay in front of the valve Travel reducer is under pressure Gear oil is hot liquid Wait for it to cool down before loosening the plug to release pressure...

Page 63: ...sparent glass film to the windshield The operator shall wear a hard hat and goggles Keep the windshield shut in such condi tions and make sure other people are kept a safe distance away from the operating area Other guards may be necessary according to different working conditions In this case contact Sany distributor in advance 2 3 19 Attachment installation Installation of optional parts or atta...

Page 64: ...es no protection to the operator When the roof window is damaged replace it immediately with a new one 2 3 22 Unauthorized modification Any modification unauthorized by Sany may lead to safety problems personal injury or death Improper modification can affect ma chine s strength and operator s view Contact your Sany distributor before making any modi fication Sany assumes no responsibility for the...

Page 65: ...achine on a highway Be especially alert when operating on fro zen ground Increase of ambient tempera ture may result in soft and slippery ground When traveling or operating in shallow wa ter or soft ground check the type and con dition of rock bed as well as the depth and water flow before operation 2 3 24 Operation on soft ground Avoid traveling or operating your machine near cliffs road shoulder...

Page 66: ...al power company regarding safety measures A signalman is to be designated to give signals if your machine is too close to pow er cables Nobody is allowed to approach the ma chine when it is operated near high voltage cables If your machine is too close to the cable or touches the cable to prevent electrocu tion operator shall not leave the cab until machine power is surely cut off In addi tion No...

Page 67: ...ce without a clear view Check rear view mirrors on each workday Remove debris and adjust the view to en sure good visibility Working in a darkened area requires turn ing on work lamps and head lamps of the machine Set up auxiliary illumination on a job site if necessary Stop operation if you cannot have a clear view in days with fog snow rain or sand storm Road shoulder or soft ground should be ma...

Page 68: ...o remove the dust If the air contains asbestos dust operate the machine following the wind All persons shall wear acceptable filter mask Nobody is allowed to approach the ma chine during operation The regulations rules and environment cri terion at job site shall be observed No asbestos is used in this machine But after CZ335 1102022 Exposure to hazardous chemicals or dusts pose a serious danger i...

Page 69: ...e only the parts and components sup plied by Sany 2 3 29 Alternate exit If you are unable to open the cab door in case of emergency use the safety hammer to break the rear window to escape Remove the pieces of glass from the win dow frame before escaping Be careful not to be cut by broken glass Pay attention to the broken glass on the ground which may cause you to slip and fall ...

Page 70: ...in a three point contact one hand and two feet or two hands and one foot Never jump on off the machine Never mount a moving machine Never use any control lever as handhold Remove the mud oil dirt and water from the pedals handholds and your soles at all times The cab must be aligned with the under carriage centerline before you enter or exit the cab An unattended machine is dangerous CZ335 1102023...

Page 71: ...machine tips over Before operating the machine check carefully your seat belt the buckles and the anchor point Replace the seat belt if damage or excessive wear is observed When the machine is being operated keep your seat belt buckled up The seat belt must be replaced every three years regardless of its condition 2 4 1 4 Before starting the engine Before starting your daily work the following ite...

Page 72: ...fore starting the machine make sure nobody is on under or around the ma chine Sound the horn to warn people around Always start and operate the machine from the operator seat No one is allowed to stay on the machine except the operator Never start the engine by shorting the start motor circuit which is dangerous and may cause machine damage 2 4 1 6 Safe starting Ample ventilation must be provided ...

Page 73: ... in cold season When ambient temperature is blow 10ºC pre heat the engine before start it For de tailed information see Engine Preheat ing on page 4 25 When the machine is intended to work in areas where temperature is always below 15ºC fuel heating system is recommend ed to improve engine startup performance Sufficient warm up operation is necessary Incomplete warming up may result in slow reacti...

Page 74: ...reful not to allow the two ma chines to contact with each other Turn both start switches to OFF position when connecting the two machines Oth erwise the machine may move and cause danger when it is powered on Start with the positive terminal when con necting the jumper cable Start with the ground or negative terminal when discon necting the jump cable When disconnecting the jumper cable take care ...

Page 75: ...check oil or fuel for leakage When the travel control level is in neutral position test the engine s speed control device operate each control lever and confirm they work properly Understand the control mode of work equipment In case of any abnormality stop operation and take corrective measures immediately 2 4 2 2 Prior operation precautions To prevent serious injury or death follow the items bel...

Page 76: ...ward A sign for travel direction can be found on internal side of undercarriage When oper ator pushes control lever pedal the actual travel direction is the direction indicated by arrow Note In this manual the forward backward left or right direct is the direction seen from the cab when the cab is straight forward and the driv ing wheels are in the rear Fig 2 52 Fig 2 53 WARNING 2 4 2 3 Rules for ...

Page 77: ...al attention must be paid to opera tions under such circumstances If your vision is limited during reverse trav el assign a signalman and keep him within the range of your vision When a signalman is necessary on some occasions use hand signals specified in local regulations The machine can only be moved when both signalman and operator understand the signals Understand all vocal graphic and flag s...

Page 78: ...w speed and avoid sudden change of direction or the machine may tumble down If the work equipment hits the ground the machine will lose bal ance and get damaged When traveling on rough ground or on a steep slope the auto deceleration switch if equipped shall be switched off If the auto idle switch is on engine speed and travel speed may drop suddenly Avoid traveling over a barrier if possible If y...

Page 79: ...d im mediately to help stop the machine 20 30cm 8 12in CZ335 1102038 CZ335 1102039 CZ335 1102040 Driving the machine on a slope may cause it to slip or tumble down resulting in seri ous injury or death When driving the machine up a slope face the cab to the uphill direction when driving down a slope face the cab to the downhill direction Before traveling always check the hard ness of ground before...

Page 80: ...raveling on a slope place the control levers to neu tral position immediately and restart the engine CZ335 1102041 CZ335 1102042 Fig 2 63 Fig 2 64 2 4 2 7 Operation on an incline If you swing upper structure or operate work equipment on an incline you machine could loose balance and tip over causing serious injury or damage Therefore such operations must be performed carefully on a flat platform W...

Page 81: ...on frozen sur face which may become soft upon increase of ambient temperature Avoid deep snow which may cause your machine to tip over or to be buried in snow Be noted that you shall never be away from road shoulder and avoid being trapped in snow When cleaning the snow it is hard to see the snow covered road shoulder and ob jects near the road There is danger for your machine to tip over or hit t...

Page 82: ...g operation the track should be adjusted vertical to road shoulder or cliff with sprockets behind the cab so that the machine can retreat easily in case of an emergency CZ335 1102049 Fig 2 68 Never tear down under your machine which may cause your machine to destabi lize and roll over When operating on building or other structures strength of structure must be checked to avoid collapse of building...

Page 83: ...r your ma chine Generally speaking it is easier to tip over with the work equipment at one side than it is positioned in the front or rear CZ335 1102052 Fig 2 71 Lifting moving or swinging the bucket shall never pass over anybody or a truck s cab The falling of substances from the bucket or collision of buckets could result in per sonal injury or machine damage The use of crusher or other heavy wo...

Page 84: ...he earth Chock the tracks to prevent unexpected movement Never park your machine on a road under going construction If you have to park your machine in such a place flags are to be used on daytime and signal lamps at night to warn other people or vehicles according to local regulations 2 4 3 2 Machine shutdown Follow the procedures below to shut down the machine 1 Stop the machine 2 Position the m...

Page 85: ...roper loading and unloading of the ma chine may cause it to fall or tip over Follow the procedures below Load or unload the machine only on a solid and flat surface Keep it a safe distance away from road sides or a cliff Keep on lookers away Use an access ramp with enough strength Make sure that the width length and thick ness of the access ramp is capable of pro viding a safe loading unloading op...

Page 86: ...m has ad equate width strength and a proper grade The trailer may become less stable with the machine on it Retract the work equip ment and swing the upper structure slowly Once the machine is loaded lock the cab door Otherwise it may swing open during transportation Secure the machine with chains and chocks Secure all work equipment lower the buck et the arm and the boom and place them in positio...

Page 87: ...r Electrolyte may cause blindness if it contacts your eyes Flush immediately with plenty of clean wa ter under such circumstances and seek medical treatment To avoid battery induced explosion observe the following precautions Never allow tools and other metal parts to contact with battery terminals Keep tools or metal parts away from batteries Stop the engine and wait for one minute before you pro...

Page 88: ...he charg ing process at this time Restore the battery cover after charging Put the battery back to its original position When towing a damaged machine improper operation or use of unacceptable wire cable could lead to serious accident Never tow the machine on a slope Wear protective gloves and a had hat when using wire ropes Check the strength of wire cable and make sure it could bear the weight o...

Page 89: ...d slings that are damaged Anchor wire ropes or slings onto the desig nated lifting lug Never attach the shackle or sling onto the bucket tips Loosened bucket tips could cause the load to fall Never leave the operator seat when lifting is in progress To prevent the load from hitting any person or building inspect carefully the machine surroundings before swinging or operating the work equipment Nev...

Page 90: ...ut other maintenance work when your machine is moving Keep your hands feet and clothing away from rotating parts 2 5 2 Select a working area For maintenance work select a clean flat area with plenty of space ample sunlight and good ventilation Clean the working area by removing fuel lubricant and water and covering slippery ground with sand or other absorptive mate rials Never leave your hammer or...

Page 91: ...the tracks to prevent movement of the machine Turn the fuel control dial to first gear Run the engine at low speed for 5 minutes Turn the start switch to OFF position and stop the engine Turn the start switch to the ON position Operate the control levers 2 or 3 times in all directions to relieve internal pressure of the hydraulic system Remove the key from the switch Place the hydraulic lockout co...

Page 92: ...y Wear safety hat and goggles when you weld or cut with a torch Never carry out grinding flame cutting or welding without an aspirator and ventilation equipment Loud noise may impair your hearing per manent or temporary When maintaining the engine wear ear covers or ear plugs if you have to work in loud noise for a long time When using a hammer to strike hard metal parts such as pin bucket teeth c...

Page 93: ... the control levers or pedals could lead to serious accident Before maintenance attach a Never OP ERATE tag or similar sign to the machine s start switch or control levers to warn others that this machine is under maintenance Attach other warning tags around the ma chine if necessary 2 5 6 Using proper tools Use proper tools and use them correctly Us ing damaged inferior defective temporary tools ...

Page 94: ...arts like fan and fan belt Never leave or insert any tool or other ob jects in the fan or the fan belt which may cause the parts to break or fly Never touch any control lever If one of the control levers must be used give signal to other workers and warn them to move quickly to a safe area CZ335 1102077 Fig 2 95 Fig 2 96 Fig 2 97 CZ335 1102078 2 5 8 Working under the machine Never carry out mainte...

Page 95: ...ork ing on mud or snow covered ground mud or snow may attach to track components and causes over tension Adjust track ten sion properly Check for loosened or broken track shoes Check the pins and bushings for wear or damages Check the track rollers and car rier rollers WARNING If the track shoes are lifted and the ma chine is solely supported by the work equipment it is very dangerous to work unde...

Page 96: ...8 WARNING 2 5 10 Track tension adjustment precautions CZ335 1102081 Fig 2 99 When loosening the grease discharge plug 1 to reduce track tension the plug shall be unscrewed slowly for no more than one turn Keep your face hand foot or any other body part away from the grease discharge plug 2 5 11 Recoil spring The recoil springs are used to reduce the im pact of tension rollers It includes a high pr...

Page 97: ...aks from high pressure hose fault or even fire may occur If any bolt on hose is loose stop operation and tighten it to specified torque In case of hose damage stop opera tion immediately and contact Sany HM autho rized dealer Replace the hose immediately in case of the following problems Damage or leak of hydraulic hose fitting Damage or break of outer cover or ex posed steel wires of reinforcemen...

Page 98: ... Move the control levers to all directions to release the pressure in the accumulator Open fire is not allowed around the hydrau lic system Remove splashed hydraulic oil as quickly as possible Diesel oil or pressurized hydraulic oil can penetrate skin or eyes causing serious injury blindness or death It is hard to find the leaking of hydraulic oil with naked eyes A cardboard or wooden board is nec...

Page 99: ... 5 16 Air conditioning system CZ335 1102083 Refrigerant R134 a is a harmless gas under room temperature It will change into highly toxic gas when burning Refrigerant getting into eyes may cause blindness It may cause frostbite if splashed on your skin Keep fire source away when servicing air conditioning system In maintenance of air conditioning system observe the instruction on the refrigerant cy...

Page 100: ... fuel injector terminal or interior of en gine controller 2 5 18 Accumulator Accumulator contains highly pressurized ni trogen Improper operation of accumulator can cause explosion and serious accidents Therefore the following precautions must be observed Never disassemble the accumulator Never let the accumulator be near a fire source or exposed in flame Never punch weld or flame cut on accu mula...

Page 101: ...tank Be extremely care ful when adding fuel to a hot engine No sparks shall occur around the grounding nozzle Handle all solvents and dry chemicals in a place with good ventilation according to the steps indicated on vessel Clean the machine of all dust and residu als Never place greasy rag or other flam mable materials on machine When cleaning the parts and components use nonflammable solvents in...

Page 102: ...naturally when exceeding specific time limit Repeated use may lead to deteriora tion wear and damage hence the acci dents and serious injury Through merely visual inspection or feel it is hard to find out how long the parts could serve Therefore regular replacement is necessary Repair or replace any safety parts once found defective regardless of its service time Safety related parts are important...

Page 103: ...teners and connectors to specified torque Install all guards covers and hoods after repair and service Replace or repair dam aged guards Only the type of hydraulic oil approved or recommended by Sany should be used to make up the hydraulic system Start the engine and check for any leaks check the hydraulic system and operate all control devices to be sure of their prop er functioning Make road tes...

Page 104: ...isposal Potential harmful substances used in Sany products include hydraulic oil fuel cooling liquid refrigerant filter and batteries etc Use leak proof vessels to hold discharged fluids Never use food or beverage contain ers Never dump waste fluids directly to the ground sewage or water source Leaking of refrigerant from air conditioner can spoil the atmosphere of the globe Related laws and regul...

Page 105: ...Safety Safety Operation and Maintenance Manual Sep 2012 2 72 SY115C9 135C 155H Crawler Hydraulic Excavator B L A N K P A G E ...

Page 106: ...e Setup 3 13 3 3 2 4 Main Menu 3 14 3 3 2 5 Engine Throttle Signals 3 15 3 3 2 6 Main Pump Signals 3 15 3 3 2 7 Input Switch Signals 3 16 3 3 2 8 Output Switch Signals 3 16 3 3 2 9 Machine Configuration 3 17 3 3 2 10 Failure codes 3 17 3 3 2 11 Maintenance Information 3 18 3 3 2 12 Engine Speed Calibration 3 23 3 3 2 13 Language Selection 3 25 3 3 2 14 GPS Monitoring Information 3 26 3 3 2 15 Syst...

Page 107: ...0 3 5 2 Travel controls 3 41 3 5 3 Joystick controls 3 42 3 6 Roof Hatch 3 44 3 6 1 Opening the roof hatch 3 44 3 6 2 Closing the roof hatch 3 44 3 7 Windshield 3 45 3 7 1 Opening the window 3 45 3 7 2 Closing the window 3 48 3 7 3 Removing the lower window 3 50 3 8 Alternate Exit 3 51 3 9 Door Catch 3 52 3 10 Cover cap with a Latch 3 52 3 10 1 Opening closing the cover with lock 3 53 3 10 2 Openi...

Page 108: ...al Aug 2012 3 3 SY115C9 135C 155H Crawler Hydraulic Excavator 3 16 2 Radio operation 3 76 3 17 Auxiliary Power Supply 3 80 3 18 Fuses 3 80 3 19 Fusible Link 3 81 3 20 Controller 3 82 3 21 Toolbox 3 82 3 22 Grease pump frame 3 82 3 23 Fire extinguisher 3 83 ...

Page 109: ...System Functions Safety Operation and Maintenance Manual Aug 2012 3 4 SY115C9 135C 155H Crawler Hydraulic Excavator ...

Page 110: ... 2012 3 5 SY115C9 135C 155H Crawler Hydraulic Excavator 3 SYSTEM FUNCTIONS 3 1 Machine Overview 1 2 3 4 5 6 7 8 9 10 CZ335 1103001 1 Bucket 2 Bucket cylinder 3 Arm 4 Arm cylinder 5 Boom 6 Boom cylinder 7 Sprocket 8 Track frame 9 Track shoe 10 Track idler Fig 3 1 ...

Page 111: ...rol 4 Left joystick control 5 Foot rest 6 Travel control pedals 7 Travel control levers 8 Monitor 9 Horn button 10 Right joystick control 11 Indicator lights 12 Start switch 13 Fuel control dial 14 Work lamp switch 15 Wiper switch 16 Washer switch 17 Head lamp switch 18 Cigar lighter 19 Cab lamp switch 20 Preheat switch only for SY135C8M CZ155 1103001 24V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ...

Page 112: ...0m 12 25 31 09 03 05 Alert and signal indicators Screen Operation keys Alert indicator Signal indicator Page heading Screen display Function icons Function keys Navigation keys Fig 3 3 Fig 3 4 XP1351106028a A B C 2 1 Sany Hydraulic Excavator 3 3 1 Monitor introduction Alert indicator 1 The indicator is on when machine controller detects any fault warning the user that the machine has a problem Sig...

Page 113: ...ed every 2s 6 Engine total operating hours h m 7 Maintenance prompt if any 8 GPRS signal indicating whether the com munication signal is 1023 9 System calendar Y M D 10 System clock h m s Operation keys The operation keys include function keys and navigation keys 1 Function keys F1 F2 F3 F4 F5 See Fig 3 6 Function of each key is defined by the icon displayed above it Function of each key is define...

Page 114: ...roller changes engine speed to idle in order to reduce fuel consumption and noise If the controller detects any operation or gear position change under idling state the engine will restore its original speed automatically Auto idle function is disabled under L mode Common icons and function keys Function key Icon Function Range F1 S Select a working mode S H L B F2 Switch to idle non idle Idle non...

Page 115: ... h m 5 Press F1 to select a working mode S H L B S 6 Press F2 to switch on off auto idle OFF ON OFF 7 Failure code if any is refreshed every 2s 8 Press F3 to change travel speed Hi Lo Hi 9 The icon appears if some maintenance is Table 3 2 XP1351106002 1 S 12 S Lo 0000h 00m 12 25 31 09 03 05 6 11 12 3 7 9 1 4 2 13 14 10 15 5 8 Sany Hydraulic Excavator Fig 3 7 Navigation key Function Enter Enter an ...

Page 116: ... codes 12 Press F5 to access System Information 13 System clock h m s 14 System calendar Y M D 15 Fuel control dial position 1 11 Keypad input F1 Select a working mode S H L or B F2 Select auto idle or full speed F3 Select high low travel speed F4 View Failure Code F5 View System Information Access Service Call View Maintenance Information if any maintenance is to be done ...

Page 117: ... at where the cursor is located 3 Press F2 to move the cursor the left right digit 4 System clock setup 5 Press F4 to access Unlock the System 6 Press F5 to return to the Main Page Keypad input Increase decrease the value at the digit where the cursor is located Move the cursor to the left right digit F1 Increase the value at where the cursor is located F2 Move the cursor to the left right digit F...

Page 118: ...2 3 Time Setup Set up the time of system clock Screen output 1 Date and time 2 Enter time setup 3 Return to System Information Keypad input Increase decrease the value by 1 Move the cursor F1 Enter time setup F5 Return to the System Information Fig 3 9 XP1351106004 1 2 3 2010 09 30 13 32 55 08 E Y M D h m s TZ Time Setup ...

Page 119: ... engine hydraulic system etc e Auto setup of fuel control dial positions 1 11 and engine speed f System language setup g GPS information 3 Press F1 to scroll through the Main Menu 4 Press F2 to access item selected 5 Press F4 to access System Setup 6 Press F5 to return to the Main Page Keypad input Scroll through the Main Menu F2 Access the item selected F4 Acdess System Setup F5 Return to the Mai...

Page 120: ...ng parameters of the main pump Screen output 1 Real time display of main pump signals collected by the controller 2 Press F1 to view Input Switch Signals 3 Press F5 to return to the Main Menu Keypad input F1 View Input Switch Signals F5 Return to the Main Menu ESC Return to the Main Menu Fig 3 11 Fig 3 12 XP1351106006 1 2 3 Fuel level 68 Oil pressure kPa 450 Hyd oil temp C 0 Throttle gear N 1 Engi...

Page 121: ...signals Screen output 1 Real time display of output switch signals 2 Press F1 to view Engine Throttle Signals 3 Press F5 to return to the Main Menu Keypad input F1 View Engine Throttle Signals F5 Return to the Main Menu ESC Return to the Main Menu XP1351106008 1 2 3 Start input Shutdown input Secondary boosting Hydraulic pilot Air filter plugged Water Separator Coolant temp high Travel indication ...

Page 122: ...n information 2 Press F5 to return to the Main Menu Keypad input F5 Return to the Main Menu ESC Return to the Main Menu Fig 3 15 Fig 3 16 XP1351106010 2 1 Machine model Machine number Engine number Hydraulic system Control system SY135C8B 018998 ISUZU_II KPM_N SYFCS Machine Configuration 4 5 XP1351106011 1 2 3 Failure code 4 Number of failures 1 01 HCU system alarm 02 TRU system alarm 03 Oil press...

Page 123: ...ause rolling mainte nance 5 Press F5 to return to the Main Page Keypad input F1 Maintenance is OK F4 Start Pause rolling maintenance informa tion F5 Return to the Main Page ESC Return to the Main Page Enter Maintenance is OK XP1351106012 1 2 3 4 5 Every 50 Service Hours Grease the swing bearing Slowly rotate the bearing as you grease it Change engine oil and replace its filter element initial repl...

Page 124: ...enance is OK F4 Start Pause rolling maintenance informa tion F5 Return to the Main Page ESC Return to the Main Page Enter Maintenance is OK Fig 3 18 XP1351106013 1 2 3 4 5 Every 250 Service Hours Replace the fuel filter element Clean the primary filter element of air cleaner check the secondary filter element replace all filter elements when necessary Check the grease of swing system add grease to...

Page 125: ...Pause rolling maintenance informa tion F5 Return to the Main Page ESC Return to the Main Page Enter Maintenance is OK Fig 3 19 XP1351106014 1 2 3 4 5 Every 500 Service Hours Perform maintenance for every 250 service hours Clean the radiator inside and outside Replace water separator filter element Grease the swing bearing Replace return pilot suction filter elements Replace air filter elements int...

Page 126: ... that mainte nance is done 4 Press F4 to start pause rolling mainte nance 5 Press F5 to return to the Main Page Keypad input F1 Maintenance is OK F4 Start Pause rolling maintenance informa tion F5 Return to the Main Page ESC Return to the Main Page Enter Maintenance is OK Fig 3 20 XP1351106015 1 2 3 4 5 Every 1000 Service Hours Perform maintenance for every 500 service hours Grease the swing syste...

Page 127: ...ne 4 Press F4 to start pause rolling mainte nance 5 Press F5 to return to the Main Page Keypad input F1 Maintenance is OK F4 Start Pause rolling maintenance informa tion F5 Return to the Main Page ESC Return to the Main Page Enter Maintenance is OK XP1351106016 1 2 3 4 5 Perform maintenance for every 1000 service hours Check the engine starter and bumper rubber Change hydraulic oil gear oil and co...

Page 128: ...o start stop auto speed setup 5 Press F5 to return to the Main Menu Keypad input F1 Select a working mode S H L or B F2 Select auto idle full speed F3 Start stop auto gear position setup F4 Start stop auto speed setup F5 Return to the Main Menu ESC Return to the Main Menu Increase the allowable deviation by 1 Decrease the allowable deviation by 1 Increase the allowable deviation by 5 Decrease the ...

Page 129: ...er 2 seconds the monitor shows the value for current gear position The calibration of this gear position is done 6 After setting up the 11 gear positions the red gear position calibration icon turns blue meaning the calibration is done successfully 7 Press F5 or ESC to exit gear position calibration 3 Failure to follow the above steps will fail the calibration Speed calibration 1 Auto speed calibr...

Page 130: ...e Screen output 1 List of language options 2 Press F1 to scroll down the list 3 Press F2 to select a language 4 Press F5 to return to the Main Menu Keypad input F1 Scroll down the list of system languages F2 Select a system language F5 Return to the Main Menu ESC Return to the Main Menu Move up or down the list XP1351106018 1 2 3 4 中 文 English Language Selection Fig 3 23 ...

Page 131: ...Latitude and S for South Latitude 3 The letter P stands for the height above the seal level and N for the height below the seal level 4 The signal to noise ratio ranges from 0 to 99 which is indicated by a bar The value on the right of the bar is real S N ratio 5 If the elevation value is not zero and no value is displayed for the longitude and latitude GPS data are being received but the location...

Page 132: ...Press F2 to move the cursor the left right digit 4 Press F3 to check the validity of pass code If it is correct you are able to access System Setup if wrong you will be prompted by Pass code invalid try again 5 Press F5 to return to the Main Page XP1351106020 1 2 3 5 4 System Setup Please enter the password Keypad input F1 Increase decrease the value at where the cursor is located F2 Move the curs...

Page 133: ... Setup is OK 4 Return to the Main Menu Keypad input Increase decrease machine serial number by 100 Increase decrease machine se rial number by 1 Depress the key to quickly increase decrease machine serial number by 10 F1 Select an item to set up F2 Setup is OK F5 Return to the Main Menu and save the setup ESC Return to the Main Menu and save the setup XP1351106021 1 4 2 3 Machine serial No 018998 ...

Page 134: ...lant Temperature Displaying the coolant temperature Screen output 1 Coolant temperature 2 Press F5 to return to the Main Menu Keypad input F5 Return to the Main Menu Remark To access the Coolant Temperature page you need to enter the pass code on the Sys tem Setup page Fig 3 27 XP1351106022 1 2 Coolant temp 80 Coolant Temperature ...

Page 135: ...eturn to the Main Page ESC Return to the Main Page Enter Call the service center Remark If the call fails to be connected through it will be hold Calling Please wait A successful call will have such a feedback that The service center has received your trouble information We will contact you as soon as possible XP1351106026 2 1 3 4 Call command 0004 1 Use the key F1 to start or finish altering the ...

Page 136: ...C 155H Crawler Hydraulic Excavator 3 4 Switches 1 Start switch 2 Fuel control dial 3 Work lamp switch 4 Wiper switch 5 Washer switch 6 Head lamp switch 7 Horn switch 8 Cab lamp switch 9 Cigar lighter 10 Preheat switch only for SY135C8M 1 2 3 4 5 6 7 8 9 10 24V CZ135B 1103007 Fig 3 29 ...

Page 137: ...the position Release the key immediately after the engine is started The key will return to ON position B automat ically D HEAT This is engine preheating position Insert the key and turn it counterclockwise to HEAT posi tion Keep the key in this position to preheat the engine Releasing the key it will return to OFF position A automatically and stops pre heating C B A D CZ335 1103036 O N OFF H E A ...

Page 138: ...sition b Full Speed MAX Turn it clockwise to MAX position 3 4 2 3 Work lamp switch The switch is used to turn on or turn off the work lamp a b CZ335 1103038 An exposed harness or loose plugging of harness could cause short circuit between power supply positive wire and work lamp internal grounding wire during excavator operation which may burn the work lamp or the entire chassis harnesses or cause...

Page 139: ...unding wire 6 Internal power supply positive socket 7 Bulb power supply positive plug 8 Bulb Note The bulb is connected with power supply posi tive harness plug CZ335 1103040 7 6 5 8 CZ335 1103250 Fig 3 35 Fig 3 36 Fig 3 37 4 Replacing the bulb 1 Remove work lamp screw and open the work lamp 2 Remove the bulb and pull out the plug 7 from the socket 6 3 Install a new bulb and insert the power suppl...

Page 140: ...When it is raining or the windshield is dirty you can press the wiper switch to activate the windshield wiper CZ335 1103043 CZ335 1103044 Working range When you use the wiper press the washer switch to spray some detergent in order to prevent damaging the wiper due to fric tion NOTICE Fig 3 38 Fig 3 39 Fig 3 40 CZ335 1103042 Wiper Switch ...

Page 141: ...the washer keeps spraying detergent Releasing the switch it goes back to its origi nal position automatically and stops spraying 3 4 2 6 Head lamp switch Head lamp switch is used to switch on or switch off the lamps on top of the cab CZ335 1103047 Before pressing the button make sure that the windshield of cab is closed CAUTION Fig 3 41 Fig 3 42 Fig 3 43 CZ335 1103045 Washer Switch CZ335 1103046 H...

Page 142: ...amp switch to turn on off the cab lamp a ON b OFF Note The cab lamp can be switched on even if the start switch is in the OFF position 3 4 2 9 Cigar lighter The cigar lighter is used to light a cigarette Pushing in the lighter it returns to its original position after a few seconds Pull it out to light a cigarette The socket of cigar lighter can be used as a power source for devices rated not more...

Page 143: ... start to preheating Maintaining the key in this position the en gine keeps preheating After releasing the key the key will return to OFF position A automatically and the engine will stop preheating 3 4 2 11 Alternator indicator The alternator indicator is illuminated when the start switch is energized the indicator goes off while the engine is running and the alternator is working regularly check...

Page 144: ...nd Maintenance Manual Aug 2012 3 39 SY115C9 135C 155H Crawler Hydraulic Excavator 3 5 Control levers and pedals 1 Hydraulic lockout control 2 Travel controls 3 Left joystick control 4 Right joystick control 1 2 4 3 CZ335 1103052 Fig 3 49 ...

Page 145: ...aulic lockout control 1 is a device used to lock out control levers of work equipment swing system travel system and attachment if equipped LOCK position Push down the hydraulic lockout control to engage it The machine will not move even if you maneuver the controls FREE position The machine moves ac cording to operation of control levers This lever is a hydraulic lockout control When it is engage...

Page 146: ...s opposite to maneuvering di rection of travel control lever Machine moves forward when you pull control levers and back a a a a b b b b N N CZ335 1103054 WARNING Fig 3 51 ward when you push them The left and right directions are reversed too Check direction of track frame before you maneuver travel control levers If the sprocket is in the rear the track frame faces the front With automatic decele...

Page 147: ...outside the window which may other wise put you in danger of being hurt by the boom if the joystick is moved un expectedly If the window is broken or missing replace it immediately It is important to know the positions and functions of each joystick control Unexpected movement of machine could cause personal injury WARNING Left joystick operation Forward Arm OUT Backward Arm IN Left Left swing Rig...

Page 148: ...to the level set by fuel dial control If travel control levers and joystick controls are in neutral position engine speed will decrease by 100 rpm About four seconds later engine will drop to the level about 1 400 rpm set for automatic deceleration Releasing control lever or joystick it goes back to neutral position automatically and ma chine function stops Right joystick operation Forward Boom DO...

Page 149: ...rd the roof hatch 3 6 2 Closing the roof hatch Hold grip A to pull downward the roof hatch The locks B will be engaged automatically If the locks are not engaged properly open the roof hatch and try to close it again A B CZ335 1103060 Secure the lockout control to the LOCK position when leaving the operator s seat Serious accidents can be caused if any control lever or pedal is maneuvered by mista...

Page 150: ...ng the windshield bottom window or cab door Serious accidents can be caused if any control lever or pedal is maneuvered by mistake when the lockout control is in FREE position Before opening or closing any window park your machine on a level ground lower the work equipment to ground and stop the engine When opening the windshield hold tight the grip with both hands and pull the win dow upward Neve...

Page 151: ...tor 3 Check the wiper blade which shall be stored in the right bracket 4 Hold the left and right handholds A of the windshield and pull the two levers B in order to release the locks on top of the windshield The windshield will be unlocked CZ335 1103062 A CZ335 1103063 A B CZ335 1103064 Fig 3 59 Fig 3 60 Fig 3 61 ...

Page 152: ...vator 5 In the cab hold the lower handhold C with your left hand and the upper handhold D with your right hand and push the win dow upward Continue to push the window toward the latch E in the rear of the cab till it is locked securely D C CZ335 1103065 CZ335 1103066 E E CZ335 1103067 Fig 3 62 Fig 3 63 Fig 3 64 ...

Page 153: ...ned with the arrow on lever B the lock is not engaged Repeat step 5 to engage the lock B F CZ335 1103068 3 7 2 Closing the window 1 Park your machine on a level ground lower the work equipment to ground and stop the engine 2 Secure the hydraulic lockout control 1 to LOCK position 3 Hold the left and right handholds A and pull the lever B downward to release the lock A B CZ335 1103069 Close the win...

Page 154: ...with your left hand and upper handhold D with your right hand push the window forward and lower the window slowly 5 When the bottom of windshield reaches the top of bottom window push forward the top of windshield in order to engage both the left and right latches G of the locks D C CZ335 1103070 G CZ335 1103072 CZ135B 1103009 Fig 3 68 Fig 3 69 ...

Page 155: ... lock is not engaged Repeat step 5 to engage the lock B F CZ335 1103068 3 7 3 Removing the lower window Open the windshield hold the grip 1 to pull upward in order to remove the lower wind shield It will be difficult to remove the windshield in case of sand or dust building up at the bottom of the windshield Moreover the sand or dust may be brought into the cab along with the glass when storing th...

Page 156: ... you are unable to open the cab door in case of emergency use the hammer to break the rear window and escape Never use the hammer for other purposes CZ215 1103029 Sign of alternate exit Safety hammer CZ215 1103030 Fig 3 73 Fig 3 74 CAUTION Broken glass can cut Be careful not to be hurt by broken glass when you escape from a broken window ...

Page 157: ... catch 1 after the door is opened 3 9 Door Catch 3 10 Cover cap with a Latch Use the start switch key to open close the cap or cover Insert the key to its shoulder A The key could be broken if turned before it is fully inserted 1 2 CZ335 1103082 A CZ335 1103083 Park your machine on a level ground before unlocking the cab door Never unlock the door on a slope The door may shut suddenly and cause in...

Page 158: ...key hole after removing the key Otherwise invasion of foreign bodies could make the switch sluggish or fail ing A longer travel distance is required to tighten the cover with lock Make sure the cover is turned in position before you turn the key to lock the cover If the key is turned when the cover is not in position the lock plate will press against inner wall of filler opening and cause damage t...

Page 159: ... key to locked posi tion B and remove the key 3 Turn the cover 1 to shield key hole 1 B A CZ215 1103002 Fig 3 78 3 10 2 Opening closing the cap with lock Opening the cap 1 Insert the key 2 Turn the key counterclockwise and open the cap with its lever Position A unlocked Position B locked Closing the cap 1 Close the cap properly and insert the key 2 Turn the key clockwise and remove the key A B CZ3...

Page 160: ...H Crawler Hydraulic Excavator 3 11 Cup Holder A cup holder has been designed and installed to the left side of operator in order to hold bev erage As shown in the illustration the cup holder can be folded to prevent damage when it is not used CZ335 1103086 CZ335 1103087 Fig 3 80 Fig 3 81 ...

Page 161: ...is used to keep your drinks warm in winter and cool in summer Cool or warm air is sent into the storage box according to the setting of air condi tioner 3 13 Literature Bag The bag is located on the back of the op erator seat The safety operation and maintenance manuals can be stored in this bag for you to refer to at any time Fig 3 82 Fig 3 83 Fig 3 84 CZ335 1103088 Closed CZ335 1103089 Open ...

Page 162: ... Manual Aug 2012 3 57 SY115C9 135C 155H Crawler Hydraulic Excavator 3 14 Ashtray The ashtray is above the cigar lighter Make sure that the cigarette is extin guished before closing the ash tray CZ335 1103091 Closed CZ335 1103092 Open Fig 3 85 Fig 3 86 ...

Page 163: ...ch 2 Fan switch 3 Temperature switch 4 Air outlet selector switch 5 Automatic control switch 6 Fresh air Recirculation switch 7 LCD panel 8 Air conditioner switch 9 Sunlight sensor Fig 3 87 6 1 2 3 4 5 7 8 9 CZ215 1103037 FULL AUTO AIRCONDITIONER Monitor OFF CZ335 1103094 Fig 3 88 1 Power off switch This switch 1 is used to stop the fan and air conditioner When the power off switch 1 is pressed th...

Page 164: ... changes automatically in the automatic control mode LCD panel and air flow a Low b Moderate 1 c Moderate 2 d Moderate 3 e Moderate 4 f High CZ335 1103095 a b c d e f LCD Display Air Flow Fig 3 89 Table 3 5 3 Temperature switch This switch 3 is used to control the tempera ture inside the operator cab The temperature can be set between 18 64 4 and 32 89 6 Press to increase the preset tempera ture P...

Page 165: ...2 0 Maximum heating 4 Air outlet selector switch This switch 4 is used to select the position of each air outlet When the switch 4 is pressed the LCD panel will display the mode selected The air will come out of the outlet displayed The outlet is switched automatically in au tomatic control mode A Air outlet for back 4 B Air outlet for face 1 C Air outlet for defrosting 1 4 CZ335 1103097 LCD Fig 3...

Page 166: ...A B C D Front outlet for face Auto operation disabled Front and back outlets for face Front and back outlets for face and feet Air outlet for feet Air outlet for feet and de froster Auto operation disabled Air outlet for defroster Auto operation disabled Remark Air comes out of the outlet identified with D air outlet for feet 1 D CZ335 1103100 Fig 3 94 Table 3 7 ...

Page 167: ...de The indicator above the switch goes out Remark When automatic control is selected the air flow may remain at HIGH if the temperature is set at 18 64 4 or 32 89 6 But this is not a fault 6 Fresh air recirculation switch This switch 6 is used to open or close the fresh air inlet After the switch is pressed the indicator above the switch is illuminated to indicate a state of taking in fresh air Fr...

Page 168: ...he fan is working the LCD displays b press the air conditioner switch 8 to activate the air conditioner The indicator above the switch will be illu minated Press this switch again to deacti vate the air conditioner The indicator goes out The air conditioner is disabled when the fan is switched off outlet position disap pears from the LCD display 9 Sunlight sensor The sunlight sensor will adjust th...

Page 169: ...switch 5 The LCD panel will display the temperature a and air flow b The indicators above the automatic switch 5 and air conditioner switch 8 will be illuminated 2 Use the temperature switch 3 to set a comfortable climate By setting the tempera ture the air conditioner will change auto matically its air flow air outlet position and fresh air recirculation air in order to achieve the preset tempera...

Page 170: ...s low the air flow will be restricted to prevent blowing the cooling air Stopping AUTO operation Press the OFF switch 1 in order to stop auto matic operation Manual operation 1 Press fan switch 2 to regulate air flow Check the temperature a and the air flow b displayed on the LCD display 7 d e CZ335 1103107 OFF CZ335 1103094 CZ335 1103095 b a c CZ335 1103103 Fig 3 103 Fig 3 104 Fig 3 105 Fig 3 106...

Page 171: ...ioner switch 8 3 Press the temperature switch 3 to set the internal temperature of the operator cab 4 Press the air outlet selector switch 4 to set it to the desired mode The display at c on the LCD panel 7 will change accord ingly b a c CZ335 1103103 CZ335 1103096 A C CZ335 1103104 MODE CZ335 1103225 Fig 3 107 Fig 3 108 Fig 3 109 Fig 3 110 ...

Page 172: ...Stopping manual operation Press the switch OFF 1 to stop the manual operation Cooling air for face and warm air for feet In order to direct cooling air to your face and warm air to your feet observe the following procedures 1 Press the fan switch 2 to adjust the air flow Check the LCD screen 7 for the temperature a and air flow b b a c CZ335 1103103 OFF CZ335 1103094 CZ335 1103095 CZ335 1103102 Fi...

Page 173: ...e air outlet selector switch 4 in order to display on the LCD panel the im age as shown in the right illustration 3 Turn on the air conditioner switch 8 4 Press the fan switch 2 temperature switch 3 and fresh air recirculation switch 6 as desired A C CZ335 1103104 CZ335 1103226 Fig 3 115 Fig 3 116 Fig 3 117 6 2 3 CZ335 1103108 ...

Page 174: ...fan switch 2 to regulate the air flow Meanwhile check the temperature a and air flow b displayed on the LCD panel 7 2 Press the air outlet selector switch 4 and set the air outlet mode on the LCD panel as shown the right illustration f or g f g CZ335 1103109 CZ335 1103095 MODE CZ335 1103225 b a c CZ335 1103103 Fig 3 118 Fig 3 119 Fig 3 120 Fig 3 121 ...

Page 175: ...awler Hydraulic Excavator 3 Press the fresh air recirculation switch 6 to open the air inlet 4 Press the temperature switch 3 and set the temperature on the LCD panel 7 to the maximum 32 5 Adjustment Rear air outlet A CZ335 1103102 CZ335 1103096 Fig 3 122 Fig 3 123 A CZ135B 1103011 Fig 3 124 ...

Page 176: ...tor Air outlet for face B Defrosting outlet C The air outlet D toward feet is fixed and nonadjustable Turn on the air conditioner switch 8 when operating in rainy season defogging the windows or carrying out dehumidifying op eration A C CZ335 1103104 D CZ335 1103100 Fig 3 125 Fig 3 126 C B CZ335 1103099 Fig 3 127 ...

Page 177: ... sunlight sensor clean and free from debris or it will influence the function of sunlight sensor Ventilation When the air conditioner has been operat ing for hours the fresh air recirculation mode shall be switched to fresh air mode every hour for ventilation If you smoke when air conditioner is run ning the smoke may hurt your eyes In this case the fresh air recirculation mode shall be switched t...

Page 178: ... not been used for a long time it is necessary to of ten run the engine at low speed and con duct cooling dehumidifying and heating operations for several minutes in order to prevent loss of oil film on each component The air conditioner will not work if the in ternal temperature of cab is low You can circulate fresh air into the cab so as to in crease the temperature Switch on the air conditioner...

Page 179: ...witch Press the power switch 1 in order to turn on the radio The frequency is shown on the LCD dis play 7 Press the power switch again in order to turn off the radio Sound effects conversion Pressing the switch 2 each time the sound effects will be displayed in turn VOL BAS TRE Balance The host machine will return to frequency display in terms of no operation within 5 seconds The state of sound ef...

Page 180: ...he radio depressing the button AS PS 5 for more than 2 seconds will acti vate the auto scanning of current stations Six radio stations that have the strongest signal will be stored in turn to the 6 buttons 1 6 Now you can play any of the preset stations Tuning in preset stations 1 2 3 4 5 and 6 If the buttons 6 have been preset with some stations you can press any of the buttons to play the preset...

Page 181: ...et buttons 6 for at least 1 5 seconds in order to tune in the preset sta tion 1 2 3 4 5 6 H M ADJ TUNING PRESRT STATION VOL SANY AS PS SEL TIME AM FM TIME ADJ AM FM ST 6 7 2 1 8 CZ335 1103112 Fig 3 129 Remark The AS PS button can be used to preset the stations automatically Searching radio station 1 Press the power switch 1 in order to show the frequency on display 7 2 Press one of the tuning butt...

Page 182: ...eased to 0 BAS Bass Press the SEL key 2 in or der to access sound effect and select BAS Press VOL key 10 within 5 seconds in order to change the bass level between 7 and 7 TRE Treble Press the SEL key 2 in or der to access sound effect and select TRE Press VOL key 10 within 5 seconds in or der to change the treble level between 7 and 7 BAL Balance Press the SEL key 2 in order to access sound effec...

Page 183: ...hours or minutes H key Hour adjustment Pressing this key once will increase 1 hour M key Minute adjustment Pressing this key once will increase 1 min ute by pressing the H key or the M key the hours or minutes will keep going till the key is re leased ADJ key When pressing the ADJ key the time will be preset as following When it displays 00 05 minutes the time will return to 00 minute and 00 secon...

Page 184: ...tenna Radio operation precautions To be safe the volume should be kept at a level that you could hear the outside sound during operation The penetration of water into the loud speaker or radio may lead to unexpected trouble In this case be careful of not get ting the device wet Never use benzol diluent or other solvent to clean the control panel or buttons Soft dry cloth shall be used for cleaning...

Page 185: ...mark Never use this power supply for 12V devices 3 18 Fuses Remark Before replacing a fuse make sure that the start switch is in OFF position The fuse panel is located at the right rear of operator s seat Fuses can protect electrical devices and wires from burning The fuse should be replaced if it is eroded produces white powder or becomes loose in the fuse panel Replace the fuse with one of the s...

Page 186: ...0A GPS F15 15A Cigar lighter 10 15 15 15 5 20 5 5 5 10 10 10 15 20 F2 F4 F5 F6 F8 F10 F11 F13 F1 F3 F7 F9 F14 F15 CZ135B 1103013 Fig 3 134 Table 3 8 3 19 Fusible Link The fusible link 1 could possibly fail if the starter motor does not work with the start switch in ON position Open the fuse compart ment cover to access the fusible link on the back side of the seat in order to check and re place it...

Page 187: ...which can cause failure Never disassemble the controller in case of any failure Please contact Sany distributor for repair 3 21 Toolbox Store your tools in this box CZ135B 1103014 Fig 3 136 Fig 3 137 CZ135B 1103015 CZ135B 1103016 3 22 Grease pump frame The grease pump frame is inside the access door at the left rear part of the machine When the grease pump is not in service place it on the frame F...

Page 188: ...n the rear of op erator cab The following precautions must be observed in order to deal with unexpected fire Read instruction label on fire extinguisher and know how to use fire extinguisher in event of fire Check fire extinguisher regularly in order to make sure it is in the guarantee period If your extinguisher has expired replace it immediately CZ335 1103120 Fig 3 139 ...

Page 189: ...System Functions Safety Operation and Maintenance Manual Aug 2012 3 84 SY115C9 135C 155H Crawler Hydraulic Excavator B L A N K P A G E ...

Page 190: ... 2 5 Coolant check refill 4 10 4 1 2 6 Oil in engine oil pan check refill 4 11 4 1 2 7 Electric wires check 4 12 4 1 2 8 Fuel tank check refuel 4 13 4 1 2 9 Work lamp switch check 4 14 4 1 2 10 Horn check 4 15 4 1 3 Adjustment before operation 4 15 4 1 3 1 Operator seat 4 15 4 1 3 2 Rear view mirrors 4 17 4 1 3 3 Seat belt 4 19 4 1 4 Before Starting the Engine 4 20 4 2 Engine Starting 4 22 4 2 1 E...

Page 191: ...rce 4 38 4 8 3 Operation when hydraulic cylinder reaches its stroke end 4 39 4 8 4 Operation with bucket landing force 4 39 4 8 5 Operation with machine weight 4 40 4 8 6 Hard rocky ground 4 40 4 8 7 Sudden shift of travel speed during fast traveling 4 41 4 9 General Operation 4 41 4 9 1 Traveling operation 4 41 4 9 2 High speed travel 4 41 4 9 3 Permissible depth of water 4 42 4 10 Traveling on S...

Page 192: ...54 4 17 1 Before storage 4 54 4 17 2 During storage 4 55 4 17 3 After storage 4 56 4 17 4 Starting the engine after long term storage 4 56 4 18 Transportation Information 4 57 4 18 1 Transport methods 4 57 4 18 2 Loading unloading machine to from a trailer 4 57 4 18 2 1 Loading the machine 4 59 4 18 2 2 Securing the machine 4 61 4 18 2 3 Rear view mirrors 4 62 4 18 2 4 Unloading the machine 4 63 4...

Page 193: ...Operation Safety Operation and Maintenance Manual Sep 2012 4 4 SY115C9 135C 155H Crawler Hydraulic Excavator ...

Page 194: ...other hot components The leak of oil or fuel may cause the machine to catch on fire Careful inspection is necessary Contact your Sany distributor if any fault of your ma chine must be corrected Check and clean the following items each day before starting the engine 1 Check the work equipment cylinders arms and hoses for cracks excessive wear or loosening Repair it in case of any problem 2 Remove t...

Page 195: ...s and step for any problem like loose bolts Repair it in case of any problem Tighten the loose bolts 7 Check the gauges and monitor Check the gauges and monitor in the cab Change the parts or components in case of any problem Clean their surfaces 8 Clean and check rear mirrors Clean and check the rear mirrors for any damage Repair it in case of any damage Clean the mirrors and adjust their positio...

Page 196: ...o CLOSE position S 5 Reinstall the lower cover plate 4 1 2 2 Water separator check drain 1 Open the pump compartment door on the right side of the machine Water separator is integrated with fuel pre filter 1 2 Through transparent cover 2 you can observe water level and volume of sedi ment In case of water or sediment built up at bottom place a vessel under drain hose 4 to receive drainage 3 Open d...

Page 197: ...ased to make it move smoothly 1 Place a vessel under the additional fuel filter cartridge 1 2 Open the drain valve 3 and drain all water and sediment behind the transparent cover 2 and drain the fuel accumulated in cartridge 1 3 Remove the drain valve 3 after confirming that nothing is coming out of the drain hose 4 4 Apply suitable amount of grease to the O ring 5 Pay attention to not greasing th...

Page 198: ...ump chamber door on the right in order to check the oil level gauge G Oil level should be maintained between H and L marks Note Never add oil to a level above the H mark which may ruin hydraulic devices and cause oil to squirt If the oil level is above the H mark stop the engine and wait for the oil to cool down Place a container under the drain plug P beneath the hydraulic tank and discharge exce...

Page 199: ...ou have to wait for the temperature to cool down and then slowly turn the cap to release internal pressure WARNING 1 CZ135B 1103021 FULL LOW 2 CZ135B 1103022 Fig 4 10 Fig 4 11 1 The level of coolant must remain between the upper and lower limits marked on the tank when the engine is running If water level is below the lower limit it is neces sary to add coolant to radiator and coolant to auxiliary...

Page 200: ... 37 4 1 2 6 Oil in engine oil pan check refill 1 Open the engine s hood 2 Take out oil dipstick G and wipe the oil off the dipstick with cloth 3 Insert the dipstick G to bottom and then pull it out H L CZ335 1103131 4 Oil level should be between the H and L marks on dipstick G Add oil through opening F if oil level is below the L mark After shutting off the engine the compo nents and oil are still...

Page 201: ...n the machine see Recommended Fluids on page 5 17 4 1 2 7 Electric wires check Check whether the fuse is damaged whether the fuse with proper capacity is used whether any wire connection is off whether wire sheath is broken Check for loose terminals Fix it if any Moreover pay special attention to electric wires when checking battery engine start motor and alternator Make sure to check for flammabl...

Page 202: ...el to the tank till the float level meter G reaches the highest point Fuel tank capacity 240L When the fuel tank is full top a of the float level meter G is positioned at about 50mm Fig 4 16 Fig 4 17 Never make fuel splash or overflow during refueling which can cause fire Clean the fuel completely in case of splashing Remove the fuel if it flows onto ground or sand Fuel is flammable and dangerous ...

Page 203: ...seal in lock cover If the seal is contaminated by iron scraps stone pieces or other foreign bodies it would be damaged during tightening and im proper sealing of lock cover could result a F G CZ335 1103135 3 Add fuel and press down the float level meter G with the filler cap F Pay atten tion to not letting the level meter G be stuck on the cover plate of filler cap F Screw on the cap F tightly 4 1...

Page 204: ...t Sany distributor for repair Fig 4 21 CZ335 1103138 Horn Button 4 1 3 Adjustment before operation It is necessary to adjust seat position be fore operating or after changing operator Adjust the seat so as to enable operator to easily manipulate the control levers ped als and switches from the seat 4 1 3 1 Operator seat A Forward and backward adjustment Pull the lever 1 upward slide the seat to de...

Page 205: ...ackrest adjustment Lift lever 2 move the backrest to an optimum position at where operation can be easily con ducted and release the lever Make sure the backrest does not interferes with the cover plate of the air conditioner at rear when adjusting the inclination of backrest Be careful with the control levers which shall not be touched by armrest C Height adjustment The seat can be raised by 30 m...

Page 206: ...ockout control F Suspension adjustment if equipped Turning the lever 6 counterclockwise will bring you a hard suspension which is suitable for heavy operator turning the lever 6 clock wise will bring you a soft suspension which is suitable for light operator Remark To achieve the best adjustment adjust the reading kg on dial 7 to weight of operator 4 1 3 2 Rear view mirrors The rear mirrors must b...

Page 207: ...en adjusting mirror angle if the mirror can not move smoothly you may loosen bolt 2 and bolt 3 to release the mirror Torque of bolt 2 4 0 5 4 N m 0 41 0 55 kgf m Adjustment of rear mirror is accomplished when side of machine can be seen in the mir ror as shown in the right illustration 2 1 4 3 CZ335 1103143 CZ335 1103144 Fig 4 27 Fig 4 28 Rear mirror B Adjust installation of rear mirror B so that ...

Page 208: ...he belt if excessive wear or damage is observed Replace the seat belt every 3 years re gardless of its condition See the produc tion date on the back of the belt Be sure to fasten your seat belt during ma chine operation Never twist the seat belt Buckle up and release The seal belt has a coiler and belt length needs no adjustment 1 Buckle up Hold clip 2 and pull the belt out of coiler 1 Check that...

Page 209: ... if left touched CZ335 1103149 F L Before starting the engine check the hydraulic lockout control whether it is secured in locked position If the hydraulic lockout control is not secured in position accidental touch ing of control lever or pedal when start ing the engine may lead to unexpected movement of machine which could cause serious accident When rising from operator seat make sure the hydra...

Page 210: ...n check the following Two seconds after the key is turned to ON po sition default screen will be displayed under normal condition as shown in the right illustra tion Engine coolant temperature gauge 3 Fuel level gauge 4 Failure code 5 A B C CZ335 1103150 Fig 4 34 Fig 4 35 CZ135 1103002 F1 F2 F3 F4 F5 ESC Enter 1 S 12 S Lo A B C 0000h 00m 12 25 31 09 03 05 3 4 5 Sany Hydraulic Excavtor ...

Page 211: ...arting it After the engine is started operation is not allowed until oil pressure stays in the nor mal range Never manipulate any control lever or pedal in case of abnormal oil pres sure Always start the engine from the opera tor seat Never start the engine in a way that may cause short circuit which can lead to serious injury or fire Sound the horn and start the engine after you have confirmed th...

Page 212: ...avator 1 Check if the hydraulic lockout control 1 is in the LOCK position L If it remains in FREE position F the engine cannot be started 2 Turn the fuel control dial 2 to MIN posi tion 3 Turn the ignition key to ON position B CZ335 1103153 A B C CZ335 1103154 F L CZ335 1103149 Fig 4 37 Fig 4 38 Fig 4 39 ...

Page 213: ...re is low the engine may fail to start after the start switch is kept at START position for more than 10 seconds In this case wait at least for 1 minute before re starting the engine 6 Wait until engine oil pressure alarm is reset even if the engine is started Never maneuver any control lever or pedal when engine oil is abnormal Note If oil pressure remains abnormal after 4 5 seconds immediately s...

Page 214: ...t switch When preheating indicator c lights engine preheating begins See the following table for preheating period Temperature ºC 0 10 10 0 10 Preheating period 10s 20s 30s 2 For models SY115C9 SY135C8 SY 135C9 and SY155H Turn fuel control dial to the MIN position b Turn ignition key to the HEAT position a The preheat indicator c will be on and the engine begins preheating The preheat in dicator c...

Page 215: ... the engine has to be run at idle speed it is necessary to add load to it or run it at a moderate speed 4 2 2 Warm up operation Never enter into operation immediately after starting the engine Proceed and check the following items 1 Adjust fuel control dial to make the engine run unloaded at low speed about 1 100 rpm for about five minutes 2 Adjust fuel control dial to make the engine run at moder...

Page 216: ...the engine suddenly except for emergency Never shut off the engine suddenly if the engine is too hot Run the engine at low idle in order to let it cool down gradually Stop the engine 1 Run the engine at idle speed for about five minutes to cool it down gradually 2 Turn the start switch key 1 to OFF posi tion A to shut off the engine 3 Remove the key 1 from the start switch A B C CZ335 1103158 1 CZ...

Page 217: ...e moving the machine Check the correct travel direction before operating travel control lever or pedal If the track frame faces the rear behind the sprockets the machine will move in a direction opposite to the operat ing direction of travel control lever or pedal Both the forward and backward travels are reversed and the leftward and rightward travels as well 4 4 1 Before moving the machine Turn ...

Page 218: ... weather In addition if the undercarriages is stuck with mud and the ma chine s travel speed becomes irregular it is necessary to remove the mud from the under carriage 40 50cm CZ335 1103163 F L A CZ335 1103164 A CZ335 1103165 2 Operate the left and right travel control levers or the left and right travel pedals according to the following instruction When the sprocket A is under the rear part of m...

Page 219: ...ormal in cold weather Moreover if the tracks are stuck by mud and the machine s travel speed becomes irregular it is necessary to remove the mud from the tracks A CZ335 1103166 A CZ335 1103167 40 50cm CZ335 1103163 F L 2 Operate the left and right travel control levers or the left and right travel pedals as the following When the sprocket A is under the rear part of machine Slowly pull the control...

Page 220: ...r 4 4 4 Parking the machine Never park your machine suddenly Before parking your machine leave yourself enough space so that you could leave the ma chine easily Place the left and right travel control levers 1 to neutral position before parking your ma chine N N CZ335 1103169 Fig 4 52 Fig 4 53 1 CZ335 1103168 ...

Page 221: ...enly if possible Stop your machine before making a turn especially before a pivot turn Operate travel controls 1 according to the following instructions A B CZ335 1103170 Fig 4 54 Fig 4 55 4 5 4 2 Steering with machine stopped When turning to the left side Push the right travel control lever to turn the machine to the left side in forward travel Pull the right travel control lever to turn the mach...

Page 222: ...ring traveling A Turning left during forward travel B Turning left during backward travel Remark Operate the right travel control lever in the same way to turn your machine to the right side during traveling A B CZ335 1103171 CZ335 1103172 4 5 4 4 Pivot turn Pull the left travel control lever and push the right one to make a pivot turn to the left side Remark Pull the right travel control lever an...

Page 223: ...the machine is safe before carrying out swinging opera tion When the engine s speed decreases due to automatic idling function the engine s speed could increase abruptly if any con trol lever is maneuvered Be careful with the operation of control levers Maneuver the left joystick 1 in the illustrated directions to swing the turntable of upper structure A Swing to left B Swing to right A B CZ335S 1...

Page 224: ...rk equipment is controlled through the joy sticks Note that joystick control will return to neutral position when released and movement of work equipment will be held Operation of the control levers while the engine is idling may cause engine speed to increase abruptly Be careful with the operation of joystick controls CAUTION Fig 4 60 Swing control Move the left joystick left or right to control ...

Page 225: ... speed to a moderate level if no operation is performed within 5 seconds This will happen even if you turn the fuel con trol dial to the MAX position Remark This machine includes an energy accumulator installed in oil control lines Turning the start switch key to ON position and placing the hy draulic lockout control to the FREE position within 15 minutes after shutting off the engine allows you t...

Page 226: ...rking modes selection key 1 the working modes will be cycled H S L B at 2 on the screen Mode Suitable Operations H Heavy loaded operation for such as ore excavation S Standard operation for such as earth removing B Breaking operation performed with breaker L Light loaded operation for level ing ground or trimming a slope Note If breaking operation is performed in a mode other than mode B the hydra...

Page 227: ...increase abrupt ly if you maneuver any control lever when the automatic idling function is active 4 8 1 Operation with swinging force Never use the swinging force to compact the ground or break objects Doing this is danger ous In addition the service life of machine would be reduced considerably CZ335 1103181 CZ335 1103182 4 8 2 Operation with traveling force Never cut your bucket into ground and ...

Page 228: ...cause personal injury Avoid operating the machine when its hydraulic cylinder is fully re tracted or extended 4 8 4 Operation with bucket landing force 1 Never use the bucket s landing force for excavating digging breaking or pile driving operation which may otherwise reduce the service life of the machine considerably 2 To avoid damage of hydraulic cylinders never use the bucket to strike or comp...

Page 229: ...Operation with machine weight Never use the weight of machine to excavate 4 8 6 Hard rocky ground Never try to directly excavate hard rocky ground Perform excavation after breaking the rocks through other means By doing so dam age to your machine could be minimized in addition to cost reduction CZ335 1103185 Fig 4 70 ...

Page 230: ...bring strong impact on the chas sis especially the tracks and cause damage to the machine In this case remove the bar riers or bypass them You can also take other actions to avoid barriers If there is no way to avoid traveling over barri ers drive your machine slowly while keeping its work equipment close to ground and run ning the track over barriers along the track s centerline CZ335 1103187 Fig...

Page 231: ...er operate your machine in water un less the foundation of job site is strong enough so that the level of water could not reach the center of carrier roller If the swing bearing swing gear and cen tral swing joint are soaked in water the drain plug should be opened to remove mud and water Clean the swinging area and reinstall the plug Lubricate the mesh gear and swing bearing inside the swing unit...

Page 232: ...when it skids or be comes instable If the track shoes skid or the power of tracks is unable to help your machine run up a slope never use the pulling force of arm to run up the slope as that could dam age your machine CZ335 1103192 Fig 4 77 1 The travel control lever and fuel control dial are used to keep your machine traveling at a low speed when running down a steep slope When angle of the slope...

Page 233: ... on a slope never perform swinging operation with the left joystick The upper turntable will swing naturally under its weight When your machine is on a slope never open or close the cab door which can change suddenly the force on machine Always keep the cab door in an opening or closing position 4 11 Removing Machine from Mud Be careful with operation and avoid being trapped in the mud If your mac...

Page 234: ...chine Retract the arm as you do in normal excavation place the travel control lever in FORWARD position and drive your machine out 4 12 Recommended Applications Besides the following applications the scope of application could be expanded by using various additional attachments 4 12 1 Backhoe operation Backhoe operation is suitable for digging an area which is lower than your machine When your mac...

Page 235: ... Parallel Fig 4 84 4 12 3 Loading operation In a place where the swinging angle is small working efficiency can be improved by parking the dump truck at where the operator could see easily It is more convenient to load more material if the truck is loaded from rear rather than from its sides CZ335 1103200 Fig 4 85 The digging range of arm is from 30 to 45 as relative to the machine The angle may v...

Page 236: ...ocks You can also penetrate the bucket into ground as additional safety support If any of the control levers is moved unexpect edly the machine may move suddenly and cause serious accidents Make sure that the hydraulic lockout control has been placed in locked position before you leave the cab 1 Place both right and left travel control levers 1 in neutral position to stop your machine 120 CZ335 11...

Page 237: ...lic Excavator 2 Turn fuel control dial to low idle MIN posi tion in order to reduce engine speed 3 Lower the bucket horizontally until its bot tom is in contact with ground CZ335 1103207 CZ335 1103149 F L CZ335 1103153 Fig 4 89 Fig 4 90 Fig 4 91 4 Place hydraulic lockout control in LOCK position L ...

Page 238: ... Shutdown on page 4 27 CZ135 1103005 F1 F2 F3 F4 F5 ESC Enter 1 S 12 S Lo A B C 0000h 00m 12 25 31 09 03 05 2 1 Sany Hydraulic Excavator 4 14 Checks after Each Workday 1 Inspect your machine and check the work equipment the exterior of machine and the undercarriage Check for leaks of oil or coolant Repair it in case of any problem 2 Refuel the tank to maximum level 3 Check the engine compartment f...

Page 239: ...ind left access door on some models 5 Left door of machine 6 Right door of machine 7 A C fresh air inlet Remark Use start switch key to lock and open these locations 4 16 Operation in Cold Weather 4 16 1 Operation instruction The engine possibly fails to start and the cool ant may freeze under low temperature In this case the following instructions must be fol lowed 4 16 1 1 Fuel and lubricant Fue...

Page 240: ...mmable so no naked fire is allowed to approach it Never smoke while disposing antifreeze liquid WARNING Note Please use Sany genuine efficient anti freeze liquid as the coolant In principle we never recommend you choosing any other type of coolant See Cooling system clean on page 5 37 for more information about the mixing ratio of anti freeze liquid when changing the coolant 4 16 1 2 Battery Batte...

Page 241: ...n move your machine the next day Open the drain valve to discharge accu mulated water of the fuel system so as to prevent it from freezing Refill the fuel tank to the maximum level In this way when ambient temperature drops the condensate in the tank could be mini mized After operation in water or mud remove the water on the undercarriage according to the following instruction so as to extend its ...

Page 242: ...H Crawler Hydraulic Excavator 4 16 3 After cold season When the season changes and the weather gets warm perform as described below The fuel or lubricant of any components shall be replaced with the one of specified viscosity For more information see Recommended Fluids on page 5 17 ...

Page 243: ...to store your machine outdoors choose a level ground and cover your machine with canvas Refill your fuel tank to its maximum level in order to avoid accumulation of water Lubricate your machine and change its oil before storing it Apply grease to the exposed part of the piston rod of hydraulic cylinder Disconnect the battery s negative terminal and reinstall its cover or remove the bat tery from y...

Page 244: ...5ºC Before operating the work equipment wipe off all the grease from the piston rod of hy draulic cylinder If your machine is equipped with air condi tioner switch on the air conditioner for 3 5 minutes once a month which can lubricate all parts of its compressor The engine shall run at low idle speed when air conditioner is working In addition check its refrigerant twice a year 4 17 2 During stor...

Page 245: ...age perform as described below Wipe off the grease from the piston rod of hydraulic cylinder Apply lubricant or grease to all necessary locations The moisture of air can mix with oils when your machine has been stored for a long time Check the oils before and after start ing the engine If the oil contains water re move the water timely 4 17 4 Starting the engine after long term storage Before star...

Page 246: ...butor for more information 4 18 2 Loading unloading machine to from a trailer The following instruction must be followed when loading unloading the machine Choose a hard level ground to load and unload your machine Keep a safe dis tance to sides of road Auto idle must be switched off If the auto idle switch is activated the machine may move suddenly The travel speed must be set to low Lo Run the e...

Page 247: ... be extra careful with your machine which may tip over due to insta ble base If the work equipment has been installed on the machine it must be retracted slowly to avoid the machine loosing balance Considering operating safety a signal man shall be assigned to alert preventing the machine from falling off the ramp The following items must be carefully ob served Use an access ramp with enough width...

Page 248: ...eight of machine supports must be placed under the ramps to prevent their bending 3 Set the travel speed selector switch to low speed Lo Press travel speed button 6 to change travel speed Lo Hi which will be dis played at 5 on the display screen 4 Press button 8 to turn off auto decelera tion Use the fuel control dial to set engine speed to low idle When machine is running in auto idle mode the sc...

Page 249: ...e centerline of ma chine shall match the centerline of trailer Align your machine with the ramp and trav el slowly Lower the work equipment as low as pos sible if it causes no trouble On an access ramp only the travel lever can be maneuvered Never maneuver any other control levers 7 Drive the machine slowly forward till all tracks are on the trailer and have full contact with trailer floor 8 When ...

Page 250: ...le them to be within the sphere of ma chine width To prevent damage to the bucket cylinder during transit place a wood block under the top end of the bucket linkage so as to prevent the bucket cylinder from touching the trailer floor Check if the engine hood is locked Seize the grip of engine hood and lift it slightly If it is not open it indicates that the hood catch is engaged If the hood is not...

Page 251: ... chains or wire ropes with sufficient strength It is important to keep the machine in a proper position in order to ensure that the machine could not slip to the sides CZ335 1103237 CZ335 1103251 F L Fig 4 106 Fig 4 107 4 18 2 3 Rear view mirrors The rear view mirror is located in the position shown in the right illustration If the rear view mirror is broken or it is nec essary to reinstall the mi...

Page 252: ...on a hard level ground and keep a safe distance from roadside as well 2 Apply braking to the trailer and chock the trailer under its wheels to prevent moving Use two access ramps 2 and place them at the left and right sides respectively The two ramps shall parallel each other and have equal distance to trailer centerline 3 Ramp grade 4 shall not exceed 15 If the ramps bend too much under the weigh...

Page 253: ...with retracted arm When the machine runs on the access ramp never penetrate the bucket into ground which could damage the hy draulic cylinder 10 While the machine is on the ramp it is CZ335 1103242 90 110 CZ335 1103243 Fig 4 113 Fig 4 114 6 Set the travel speed selector switch to low speed Lo Press travel speed button 6 to change travel speed Lo Hi which will be dis played at 5 on the display scre...

Page 254: ...ct when wire rope forms a bigger sling angle with the hook If two or more ropes are used the load on each rope increases with sling angle The fol lowing table shows variation of allowable load kN kg with different angles when two ropes are used to lift a load If a single rope is capable of lifting 9 8 kN 1000 kg in vertical position two ropes will be able to lift 19 6 kN 1000 kg perpendicularly Ho...

Page 255: ...two or more rope symmetrically Select a suitable wire rope according to the object to be lifted See the table below Wire Rope Standard bright wire rope Z JISG3525 No 6 6X37 A type Wire Rope Nominal Diameter Allowable Load mm kN Ton 10 8 8 0 9 12 12 7 1 3 14 17 3 1 7 16 22 6 2 3 18 28 6 2 9 20 35 3 3 6 25 55 3 5 6 30 79 6 8 1 40 141 6 14 4 50 221 6 22 6 60 318 3 32 4 4 18 3 2 Choosing a wire rope N...

Page 256: ...tructure parallel Before lifting the lockout control must be put to locked position in order to prevent unexpected movement of the machine Keep the machine parallel to the ground during lifting Never lift the machine at fast speed which may otherwise overload the wire cables or slings and result in rupture Besides the attitudes recommended in the following procedure never use any other at titudes ...

Page 257: ...et 1 2 Fully extend the bucket cylinder and the arm cylinder and use the boom cylinder to lower the work equipment to the ground as shown in the right illustration 1 CZ335 1103245 CZ335 1103251 F L 5 Run a wire rope between the first two track rollers and between the last two track rollers For machines installed with roller guard the ropes shall go through under the tracks 6 Adjust the wire rope l...

Page 258: ...Operation Safety Operation and Maintenance Manual Sep 2012 4 69 SY115C9 135C 155H Crawler Hydraulic Excavator B L A N K P A G E ...

Page 259: ...Operation Safety Operation and Maintenance Manual Sep 2012 4 70 SY115C9 135C 155H Crawler Hydraulic Excavator B L A N K P A G E ...

Page 260: ... 13 5 2 5 Electrical system 5 14 5 2 6 Hydraulic system 5 14 5 3 Replacement Parts 5 16 5 4 Recommended Fluids 5 17 5 4 1 Fluid capacities 5 19 5 4 2 Recommended oils 5 20 5 5 Tightening Torque Specification 5 22 5 6 Safety Related Parts 5 24 5 7 Maintenance Schedule 5 25 5 7 1 List of maintenance schedule 5 25 5 7 2 Hydraulic Breaker Service Interval 5 27 5 8 Maintenance Procedures 5 28 5 8 1 Mai...

Page 261: ...ry 250 service hours 5 63 5 8 5 1 Compressor belt tension inspect adjust 5 63 5 8 5 2 Oil in engine oil pan and oil filter change replace 5 65 5 8 5 3 Primary fuel filter replace 5 67 5 8 5 4 Secondary fuel filter replace 5 71 5 8 6 Every 500 service hours 5 74 5 8 6 1 Swing bearing lubricate 5 74 5 8 6 2 Swing pinion gear grease check refill 5 75 5 8 6 3 Coolant tank and radiator fins inspect cle...

Page 262: ...ange 5 93 5 8 8 6 Alternator inspect 5 95 5 8 8 7 Engine valve clearance check adjust 5 95 5 8 9 Every 4000 service hours 5 95 5 8 9 1 Coolant pump inspect 5 95 5 8 9 2 Start motor check 5 95 5 8 9 3 Accumulator control oil circuit replace 5 96 5 8 9 4 High pressure tube clamps and rubber check 5 97 5 8 9 5 Compressor working condition inspect 5 97 5 8 10 Every 8000 service hours 5 98 5 8 10 1 Hig...

Page 263: ...Maintenance Safety Operation and Maintenance Manual Aug 2012 5 4 SY115C9 135C 155H Crawler Hydraulic Excavator ...

Page 264: ...use genuine Sany engine oil and grease Select engine oil and grease of suit able viscosity according to ambient tempera ture Window washer fluid Use automotive windshield washer fluid only which shall not be contaminated by foreign substances Oil and lubricants Always use clean oils and greases Keep the oil reservoir and grease reservoir clean which shall be free from any impurities Drained oil an...

Page 265: ... weld and the grounding point choose another grounding point away from these parts Never use a grounding point in the vicinity of the work equipment pin or hydraulic cyl inder Never apply more than 200V continuously Preventing things from falling into machine When opening the access window or tank filler for inspection make sure that the nuts bolts or tools are not left inside the machine Failure ...

Page 266: ... brand or grade drain the old lubricant completely and replace with the new brand Securing access cover When servicing the machine with the access covers open use a locking lever to secure the cover to certain position Otherwise the cover can be swung close by wind and cause bodily injury Purging air from hydraulic system When any hydraulic units have been repaired or replaced or any hydraulic lin...

Page 267: ...il leakage occurs when the engine speed increases and the oil is under pressure Checks after the operation when the en gine has been shut down Whether you have missed the items to be checked or maintained Whether all the checks and mainte nance have been performed correctly Whether any tools and parts are left in the machine It is very dangerous to have a foreign object blocked in the link age Whe...

Page 268: ... blood in human body lubricant shall be handled carefully in order to pre vent impurities such as water metal par ticles and dust Item Type Engine Oil Pan Diesel Oil CH 4 15W 40 Swing Drive Gear Oil 85W 140 Final Drive Hydraulic System Caltex HDZ46 Radiator TEEC L35 antifreeze Table 5 1 5 2 General Service Use genuine Sany replacement parts grease and oil Never change or refill oil with a differen...

Page 269: ... elements must be replaced when changing the oil In replacement of engine oil filter element acceptable clean oil shall be filled into the new filter element prior to installation Use the oils approved by Sany Never use the hydraulic oil that has not been approved by Sany which can block filter cartridge Remove the remaining oil as much as pos sible from the lines and cylinders when changing the h...

Page 270: ...revention of impurities when storing or refilling the fuel Note Always use diesel oil as the fuel To ensure favorable consumption and exhaust of the fuel the engine installed to your ma chine uses high pressure oil injection unit with mechanical control The unit contains high precision components that require high quality lubrication Therefore the use of low viscosity fuel with low lubricating cap...

Page 271: ...rmed in the engine and radiator Over heat can occur due to unfavorable heat exchange The water with overall hardness lower than 10 PPM is recommended when diluting the coolant Precautions in this manual must be fol lowed when using antifreeze Anti freezing coolant is flammable There fore it must be kept away from naked fire If the engine is overheating wait for the engine to cool down before refil...

Page 272: ...s outdoors cover them properly with waterproof can vas or take other protective measures To prevent deterioration of oil or fuel during long term storage use the oil or fuel that has been stored earlier than others 5 2 4 Filter element Filter element is extremely important for safety It can prevent failures by keep ing important devices free from impurities coming from oil path or air path All fil...

Page 273: ... controller Contact your Sany distributor before installing radio receiver or other wireless devices Operating on beach requires cleaning the electrical system thoroughly in order to prevent corrosion When installing an electrical device connect it to dedicated power source Never connect other power sources to the fuse start switch or battery relay 5 2 6 Hydraulic system During operation and immed...

Page 274: ...tion or maintenance of the hydraulic circuit always bleed the air from the hydraulic tank to remove the internal pressure Periodic maintenance includes the inspection of the hydraulic oil lever replacement of the filter and refilling of hydraulic oil When the high pressure hose etc Is removed check the O ring for damage If necessary re place it After the hydraulic filter element and strainer are c...

Page 275: ... ondary B222100000453 SY115C9 SY135C8 C9 SY155H B222100000415 SY135C8 M Filter 1 Every 250 hours Oil filter B222100000488 SY115C9 SY135C8 C9 SY155H B222100000386 SY135C8 M Filter 1 Every 250 hours Pilot filter B229900000063 Filter element O ring seal 1 1 Every 500 hours Hydraulic oil filter 60101257 60101256 Filter element oil suction Filter element oil return 1 1 Every 1000 hours Air filter main ...

Page 276: ...d when starting the engine at temperatures below 0 C 32 F even if the daytime temperatures rise above 0 C 32 F Use the recommended oils according the ambient temperatures given in the following table When the sulfur content of fuel is less than 0 5 change the fuel according to the required maintenance interval given in this manual If the sulfur content is more than 0 5 change the fuel according to...

Page 277: ...ulic Excavator Fluid Ambient Temperature Recommended fluids 22 4 14 32 50 68 86 104 122 F 30 20 10 0 10 20 30 40 50 C Oil 5W 30 5W 40 10W 30 15W 40 Note 1 40 Hydraulic oil HDZ32 ISO VG32 HDZ46 ISO VG46 Diesel fuel 30 diesel 10 light diesel 0 light diesel Coolant Note 2 TEEC 135 antifreeze Table 5 3 ...

Page 278: ...r before using any oils other than those recommended by Sany Note 1 The HTHS high temperature high shear viscosity at 150 C required by ASTM D4741 must be equal to or more than 3 5 mPa S Sany strongly recommend the use of engine oil 15W 40 Note 2 Coolant 1 The coolant is also an important fluid against corrosion and freezing Antifreezing coolant is also necessary in regions where freezing preventi...

Page 279: ...on is high or the ambient temperature is too low it is necessary to use the fuel whose cetane number is more than 40 in order to pre vent flameout and too much smoke When the fuel of low sulfur content is used its cloud point shall be at lease 10 C lower than the expected minimum fuel temperature Cloud point is the temperature at which the waxy crystals begin to form The universal diesel fuel of c...

Page 280: ...d slowly while paying close attention to the system s running condi tion Operating your machine with the hydraulic oil temperature being below 20 C could damage the hydraulic ele ments Anti friction hydraulic oil L HM46 is widely used in temperate zones Low temperature anti friction hydraulic oil L HV32 whose pour point is 42 C is used in extremely cold regions below 30 C such as Russia and Northe...

Page 281: ...g 5 1 Thread Diameter a mm Square Size b mm Tightening Torques Target Values Torque Limits N m kgf m lbft N m kgf m lbft 6 10 13 2 1 35 9 8 11 8 14 7 1 2 1 5 8 7 10 8 8 13 31 3 2 23 1 27 34 2 8 3 5 20 3 25 3 10 17 66 6 7 48 5 59 74 6 0 7 5 43 4 54 2 12 19 113 11 5 83 2 98 123 10 0 12 5 72 3 90 4 14 22 177 18 130 2 157 196 16 0 20 0 115 7 144 7 16 24 279 28 5 206 1 245 309 25 0 31 5 180 8 227 8 18 ...

Page 282: ...l joint Nominal Thread Number a Square Size b mm Tightening Torques Target Values Permissible Range N m kgf m lbft N m kgf m lbft 9 16 18UNF 19 44 4 5 32 5 35 63 3 5 6 5 25 3 47 11 16 16UN 22 74 7 5 54 2 54 93 5 5 9 5 39 8 68 7 13 16 16UN 27 103 10 5 75 9 84 132 8 5 13 5 61 5 97 6 1 14UNS 32 157 16 0 115 7 128 186 13 0 19 0 94 137 4 13 16 12UN 36 216 22 0 159 1 177 245 18 0 25 0 130 2 180 8 1 7 16...

Page 283: ...l also be replaced while replacing the hose O ring gasket and other similar parts shall also be replaced while replacing a hose Consult your Sany distributor to replace the following safety related parts on a regular basis No Safety related parts subject to regular replacement Quantity Frequency 1 Fuel hose fuel tank water separator 1 Every 2 years or 4000 hours whichever occurs first 2 Fuel hose ...

Page 284: ...cleaner clean replace 5 29 Cooling system clean 5 37 Track shoe bolts inspect tighten 5 41 Track tension inspect adjust 5 42 Bucket tips lateral pin replace 5 45 Bucket Replacement 5 47 Bucket clearance adjust 5 49 Window washer fluid check refill 5 51 Air conditioner inspect service 5 52 Gas spring inspect 5 54 Air in hydraulic system purge 5 55 Hydraulic circuit internal pressure release 5 58 Ch...

Page 285: ... replace 5 85 Nitrogen pressure in accumulator breaker check 5 85 Every 2000 service hours 5 86 Final drive oil change 5 86 Hydraulic tank filter screen clean 5 88 Nitrogen pressure in accumulator control oil circuit check 5 89 Hydraulic circuit internal pressure release 5 92 Oil in hydraulic tank change 5 93 Alternator inspect 5 95 Engine valve clearance check adjust 5 95 Every 4000 service hours...

Page 286: ...nt is to be replaced accord ing the right chart when the breaker has served for 250 hours breaker operating proportion more 50 Remark 100 breaker operation means that the break er is used all the time while 0 means that the breaker never used 5 7 2 Hydraulic Breaker Service Interval For machines equipped with a hydraulic breaker the hydraulic oil deteriorates faster than that of machines operating...

Page 287: ...cedures of changing engine oil and replacing oil filter see Oil in engine oil pan and oil filter change replace on page 5 65 5 8 1 2 Fuel filter replace For the procedures of replacing fuel filters see Primary fuel filter replace on page 5 67 and Secondary fuel filter replace on page 5 71 The following maintenance is to be carried out after initial 50 service hours Consult your Sany distributor fo...

Page 288: ... against the filter The use of compressed air could cause debris to fly out and result in personal injury Always wear goggles dust proof mask or other protective gear It is dangerous to pull out the outer filer element with force When you work on a overhead place or at where you cannot stand firmly be careful that the counter acting force resulted from pulling of the outer filter element could cau...

Page 289: ...rubber seal is broken or deformed con siderably replace the vacuum valve 4 5 6 4 CZ335 1104004 Cleaning the outer filter element Note Never disassemble the secondary air cleaner element 6 which will allow dirt to pass through and cause engine failure Never use a screwdriver or other tools Note Never place the filter under direct sunlight be fore and after cleaning 1 Open the left rear door of the ...

Page 290: ...element 5 use clean cloth or tape to cover the secondary air cleaner element 6 in order to prevent entering of dirt 5 Wipe or brush off the dirt from the cover 3 and the inside of air cleaner housing 1 6 Wipe off the dirt built up on the cover 3 and the vacuum valve 4 7 Use dry compressed air less than 0 69 MPa 7kgf cm2 99 4 PSI to blow along the inside of the pleats toward the primary air cleaner...

Page 291: ... an O ring that has been cleaned could result failure Never use them again 10 Check the new filter or the cleaned filter for dirt or oil stains on the sealing area Wipe off the dirt or oil stains 11 Push the primary air cleaner element straight forward into the air cleaner hous ing You can hold the primary air cleaner element and shake it slightly in order to insert the primary air cleaner element...

Page 292: ...he cover 3 according to the follow ing steps 1 Align the cover 3 with the filter 2 Let the end of latch 2 catch the flange of the air cleaner housing 3 To lock the latches 2 engage the latches in a diagonal sequence top bottom left right like tightening the bolts 4 The vacuum valve 4 shall face toward the ground A when installing the cover 3 5 When the cover 3 is installed inspect the air cleaner ...

Page 293: ...n it in both directions in order to pull it out Never remove the inner filter element 6 3 After removing the outer filter element 5 check the inner filter element to see if it displaces or tilts Push it back to position in case of displacement or tilting 4 Wipe or brush off the dirt from the cover 3 and the inside of air filter housing 1 5 Wipe off the dirt built up on the cover 3 and the vacuum v...

Page 294: ...g area Therefore fake parts shall not be used under any cir cumstances 6 Remove the secondary air cleaner element 6 and install a new secondary air cleaner element immediately Insert the secondary air cleaner element securely 7 Push the primary air cleaner element 5 straightly into the air cleaner housing When pushing the primary air cleaner ele ment you may hold the primary air cleaner element an...

Page 295: ...ll face toward the ground A when installing the cover 3 5 When the cover 3 is installed inspect the air cleaner housing shall not have a larger clearance with the cover 3 Reinstallation is necessary in case of larger clearance 9 Use a new sticker to replace sticker 7 on cover 3 Note The latches 2 and housing of air cleaner could be damaged when you insert filter ele ment with expanded rubber on th...

Page 296: ...d firmly Take care that the counter acting force of pulling the outer filter element could cause you to fall Anti freezing coolant Interval for cleaning the inside of the cooling system and changing anti freezing coolant TEEC L35 antifreeze Every years or 2000 hours whichever occurs first Always prepare your machine as required and lock tag it out before proceeding See Preparing the machine on pag...

Page 297: ... than the actual temperature when selecting a mixture ratio The mixture ratio is determined by ambient temperature The mixture ratio shall not be lower than 30 antifreeze total volume of coolant 100 in even the regions where freezing prevention is unnecessary in order to prevent corrosion of the cooling system The undiluted antifreeze will freeze at 15 5 Do not store the undiluted antifreeze in an...

Page 298: ... in order to prevent skin contract of the water containing antifreeze In case of con tact with your eyes flush with large amount of clean water and refer to medical care immediately To change the coolant or drain the ra diator coolant when repairing your ma chine consult professional company or your Sany distributor to dispose the coolant containing antifreeze Never drain the coolant to sewage or ...

Page 299: ...g method 7 Close the drain valve 2 8 Reinstall the bottom cap 9 Fill the coolant containing antifreeze till the fluid overflows from the filler opening The mixture ratio of antifreeze and water is to be determined according to the chart of mixing values of antifreeze and coolant 10 Run the engine at low speed for about five minutes and then at high speed for five minutes in order to eliminate the ...

Page 300: ...g the machine on page 2 58 and Lock out and tag out on page 2 60 Tightening Three grouser track shoe 1 Tighten the bolts to torque values of 600N m 680N m 61 2kgf 69 4kgf or 441Ibft 500Ibft Make sure that the nuts and track shoe are in close contact with the link mating surface 2 Inspect and tighten again by 120º 10º Tightening sequence Tighten the bolts in the sequence shown in the right illustra...

Page 301: ...ore proceeding See Preparing the machine on page 2 58 and Lock out and tag out on page 2 60 Inspection 1 Run the engine at low idle speed Travel the machine forward a distance that is equivalent to the length of an unfolded track Park your machine 2 Place a straight edge on top of the track grousers between the idler 1 and the carrier roller 2 as shown in the right illustration 3 Measure the maxim...

Page 302: ...e 3 Check the track tension again Readjust the tension if it is still beyond the standard range 4 Continue to add grease till the distance S becomes null 0 If the tension is still loose it is probably because the pin roll and bushing are overworn The pin rolls or bushings must be swapped or replaced Contact your Sany distributor for repair The screw plug 1 is possible to fly out under high pressur...

Page 303: ... before you re duce track tension To reduce track tension slowly turn valve 1 counterclockwise with a long socket wrench The grease will come out of the grease fitting Loosening valve 1 only one turn is enough to reduce track tension If grease does not come out smoothly drive your machine back and forth for a short distance When suitable sag of track is achieved turn valve 1 clockwise to 78 4 N m ...

Page 304: ...ut control is free unexpected movement of the work equipment could cause sever ac cident If you drive the pin with great force the pin may fly out and cause an accident Keep irrelevant people a safe distance from the area Debris may fly out during replacement Always wear safety goggles gloves and other necessary protective gear Always prepare your machine as required and lock tag it out before pro...

Page 305: ...nt 4 Remove the tip and check the latch for any damage Replace it if necessary The latches and tips worn short must be replaced with new ones 5 Clean the installation surface Mount the new bucket tip 2 to its adapter Push part of the pin 1 into the tip and hammer it in completely in order to lock the bucket tip onto its adapter 1 2 CZ335 1104025 2 1 CZ335 1104026 No Item No Item 1 Bucket 8 Latch 2...

Page 306: ... sur rounding area is clear of people before doing the job Never stand behind the bucket when removing the pin shaft pay special at tention to not placing your foot under the bucket when working at one of the sides Never get your finger pinched while re moving or installing the pin shaft Never put your finger into the pin bore during alignment CAUTION Park your machine on a hard level ground Desig...

Page 307: ...fficulties while removing it Note Make sure the pin roll is free from mud or sand after removal Both ends of the bushing are installed with seals against dust Be careful not to damage them 2 Remove the nuts and screws on the plate retaining arm pin A and link pin B take out arm pin A and link pin B and then remove the bucket 3 Align arm 5 with the bore for bucket replacement and the link 6 with bo...

Page 308: ...of the end face Replace any broken seals when replacing a bucket The use of broken seals could allow sand or dust to penetrate through to the pin roll and cause its abnormal wear 3 3 CZ335 1103204 5 8 2 7 Bucket clearance adjust The bucket linking clearance must be readjust ed after your machine has been operated for a period of time When the linking clearance is excessively large or small it is n...

Page 309: ...rate result with a feeler gauge 5 Loosen the four plate mounting bolts 2 in order to detach the plate 3 The spacer has an opening so it is unnecessary to remove the bolt when making adjustment 6 Remove the spacer equivalent to the measured clearance a For example If the clearance is 3 mm 0 118 in remove two 1 0 mm 0 039 in spacers and one 0 5 mm 0 02 in spacer or one 2 0 mm 0 078 in spacer and one...

Page 310: ...he detergent is to be diluted with water according the ratios listed below Operating Regions Mixture Ratio Anti Freezing Temperature General Detergent 1 3 Water 2 3 10 14ºF Cold regions in winter Detergent 1 2 Water 1 2 20 4ºF Frigid regions in winter Pure detergent 30 22ºF There are two types of detergent one for 10 4 F common and one for 30 22ºF frigid regions which can be selected according to ...

Page 311: ...condition of refrigerant gas flowing to the tube The refrigerant flows without bubble per fect The refrigerant flow contains bubbles that pass continuously refrigerant level low Colorless and transparent no refrigerant Remark The appearance of bubbles indicates low re frigerant level Please consult Sany distributor to add refrigerant Running the air conditioner with low refrigerant level could dam...

Page 312: ...00 hours Compressor Function Every 4000 hours V belt Loose and bent Every 250 hours Deterioration wear scratch and cracking Every 250 hours Noise odor smell or abnormal heat When required Fan motor and fan Function check for abnormal noise When required Air conditioner air flow switch Air flow control switch and switching function Daily Control unit Function make sure the function is normal When r...

Page 313: ...hatch cannot be kept open Oil or air leaks from the air spring The Gas Spring contains high pressurized nitrogen Wrong operation can cause ex plosion and result in machine damage and personal injury or death The following items shall be observed when dealing with the Gas Spring Be away from naked fire Never drill or weld the Gas Spring Never hammer the Gas Spring or ex pose it under any impact Alw...

Page 314: ...nnected hose To prevent overflow hose opening must be higher than oil level in hydraulic tank 3 Tighten the plug 1 and reconnect the drain hose after purging the air Note If drain hose is reconnected before tightening the plug 1 oil will squirt out of the plug 1 If the pump is operated when it is not fully filled with hydraulic oil extra heat will be generated and pump damage could result 2 Starti...

Page 315: ...he engine at low speed Loosen the hose 3 at the port S Check if oil comes out of the hose 3 from the port S Note Do not operate the swing drive under any cir cumstances 2 If no oil is seen shut off the engine Remove the hose 3 from the port S and add hydraulic oil to the motor shell 3 Tighten the hose 3 at the port S after purging the air from the swing motor 4 With the engine running at low idle ...

Page 316: ... minutes Repeat this operation for both tracks and run the tracks back and forth uniformly 6 Eliminate air from attachment if equipped If a breaking hammer or other attachment has been installed run the engine at low idle speed and operate the attachment control pedal repeatedly about 10 times till the air is expelled from the oil path com pletely Note If manufacturer of the attachment has pro vid...

Page 317: ...lic tank in order to release the internal pressure 5 8 2 12 Hydraulic circuit internal pressure release The hydraulic circuit is always under pressure In this case the pressure in hydraulic circuit is to be released when checking or replacing the hoses or fit tings Without doing so the pressur ized oil will squirt out and cause seri ous personal injury After the engine is stopped the com ponents a...

Page 318: ...Drain water and sediment from fuel tank Check water separator and drain water and sediment Check oil level in hydraulic tank and refill the tank Check coolant level and add coolant Check oil level in engine oil pan and add oil Check electric wires Check fuel level and refuel the tank Check work lamp switch Check the function of horn Check engine lower exhaust pipe and keep it clean Check exhaust p...

Page 319: ...age 2 60 3 Use a grease gun to inject grease through the greasing points indicated in Fig 5 53 4 Finally wipe off the used grease that has been squeezed out If the lubricated components produce abnormal noise additional lubrication is re quired besides regular maintenance A new machine shall be greased every 10 hours within the initial 50 hours After operating in water the machine s wet pin rolls ...

Page 320: ... 61 SY115C9 135C 155H Crawler Hydraulic Excavator 1 Boom cylinder root pin 2 2 Boom root pin 2 3 Boom cylinder piston rod end 2 4 Arm cylinder root pin 1 5 Boom arm joining pin 2 1 1 CZ335 1104047 3 3 4 2 2 CZ335 1104048 5 CZ335 1104049 Fig 5 54 Fig 5 55 Fig 5 56 ...

Page 321: ...Crawler Hydraulic Excavator 6 Arm cylinder piston rod end 1 7 Bucket cylinder root pin 1 8 Arm Bucket joining pin 1 9 Rod joining pin 2 10 Bucket cylinder piston rod end 1 11 Bucket rod joining pin 1 6 7 CZ335 1104051 Fig 5 57 Fig 5 58 Fig 5 59 8 CZ135B 1104016 9 10 9 11 CZ135B 1104017 ...

Page 322: ...middle section of the belt be tween the drive pulley 1 and the compressor pulley 2 in order to check the deflection A which should be 5 8mm 0 20in 0 31in Reference Use a tension meter to check the belt tension of the compressor New Belt Used Belt 637 108 N 65 11 kgf 441 88 2 N 45 9 kgf Adjustment 1 Loosen the bolts 1 and 2 2 Move the compressor 3 and its bracket 4 in order to adjust belt tension 3...

Page 323: ...addition make sure that the V belt must not rub against the bottom of the V groove Consult Sany distributor to replace the belt timely in case of the following conditions The fan belt has been stretched and little margin is left for adjustment Cuts or cracks are found in the belt The belt skids or squeaks A newly installed V belt shall be readjusted after one hour operation ...

Page 324: ...d tag out on page 2 60 When the engine has just been stopped the parts and oil are still hot and can cause serious burn Wait until they are cool enough before doing the job WARNING 1 Remove the bottom cover of the machine Place a container under the drain valve Choose a container of a proper size ac cording to the capacity table The oil will be drained into the container through a piece of clean c...

Page 325: ...e installation requires contact of the sealing surface with that of the filter seat 2 Turn the filter 3 4 1 turn 6 After replacement of the filter open the engine s hood and fill engine oil through the filler to a level between the H and L marks of the dipstick 7 Run the engine idly for a short time and then turn off the engine Check again the oil level which shall be between the H and L marks of ...

Page 326: ... replacement work shall be carried out after the internal pressure drops to a safe level Be away from fire sources Note Sany genuine fuel filter is a special filter of effective filtration The filter must be re placed with a genuine one The use of other parts may allow dirt or de bris to get into the fuel system and cause the injection system failure Therefore avoid using any substitutes It is mor...

Page 327: ...replace the O ring seal 4 7 Apply oil to seal surface during installa tion Make the seal and filter have a close contact before further tightening the filter by 1 4 1 2 turn If the bowl 2 was over tightened the O ring seal might be damaged and fuel leak could result If the bowl 2 was not tightened enough fuel will leak through the gap with O ring seal To prevent such problems always tighten it to ...

Page 328: ...s the filter seat Further turn it by 3 4 turn If the filter cartridge was over tightened the seal might be damaged and fuel leak could result If the filter cartridge was not tightened enough fuel will leak through the gap with seal Always tighten it to the specified torque 10 Check drain valve 1 to see if it is tight ened properly 11 Release the air after replacing filter 3 Air purging steps 12 Fi...

Page 329: ...ter start the engine and run the engine at low idle for 10 min utes Check the filter seal and the cover for fuel leak Check the tightening degree of the filter when fuel leak is found If fuel leak still exists repeat step 1 through step 7 to remove the filter If the seal is found damaged or cut by foreign substance replace filter cartridge Repeat step 8 through step 14 to install a new fil ter car...

Page 330: ...he replacement work must be carried out after the internal pressure drops to a safe level Be away from fire sources Note Sany genuine fuel filter is a special filter of effective filtration The filter must be re placed with a genuine one The use of other parts may allow dirt or de bris to get into the fuel system and cause the injection system failure Therefore avoid using any substitutes It is mo...

Page 331: ...er seat Apply a thin layer of oil to sealing surface of filter cartridge and install filter cartridge to filter seat Replace internal seal 2 with a new one Note Never add fuel to new filter cartridge Remove cap B and install filter cartridge Always prepare your machine as required and lock tag it out before proceeding See Preparing the machine on page 2 58 and Lock out and tag out on page 2 60 2 C...

Page 332: ...eps 7 Refill fuel tank until the float reaches the maximum level 8 Loosen plug 3 of fuel filter 9 Turn counterclockwise the handle 4 of start priming pump 10 Push and pull the handle 4 to pump fuel 11 Tighten plug 3 when fuel coming out of plug of fuel filter contains no foam Tightening torque 9 8 2 0 N m 1 0 0 2 kgf m 12 Operate the priming pump 5 6 times and turn handle 4 clockwise to tighten it...

Page 333: ... engine disengage hydraulic lockout control and raise the bucket 20 30 mm off ground Swing upper structure by 45 degrees and add grease through steps 1 and 2 4 Repeat step 3 twice to accomplish greas ing Note The grease is used to prevent distortion and noise of joints It is necessary to add grease to any com ponent that appears inflexible or noisy after operation for a long period Wipe off the us...

Page 334: ...ch should be 14 mm 0 6 in at minimum at where the pinion gear passes 3 Check the grease to see whether it is milk white Milk white grease indicates that the grease has been contaminated Consult Sany distributor in order to change the grease Total grease volume 15 L 3 97 US gal 4 Use the bolts 1 to reinstall the cover 2 A 3 S CZ335 1104069 2 CZ335 1104070 1 2 CZ335 1104068 Always prepare your machi...

Page 335: ...t and tag out on page 2 60 1 Open engine hood 1 2 Loosen screws 3 and 8 Pull up screens 2 and 9 3 Clean the screens 4 Inspect the coolant tank 4 intercooler fins 5 A C condenser fins 6 and the hydraulic oil radiator fins 7 Compressed air can be used to remove dirt and leaves sticking to the fins Steam or water can also be used to clean the fins However a safe distance to the machine shall be kept ...

Page 336: ...ve been swept to the outside 7 Reinstall cleaned screens 2 and 9 and tighten them with screws 3 and 8 Fig 5 82 10 CZ135B 1104026 5 8 6 4 Air conditioner filters clean Note The filter shall be cleaned every 500 hours but operating your machine in a dusty place requires cleaning the filter more frequently Remark An air filter plugged with dust will reduce air flow and cause the air conditioning unit...

Page 337: ...and remove the air recirculation filter 3 2 Use compressed air to clean the filter If the filter bears oil or too much dirt clean it with moderate detergent After the filter has been flushed with water it must be dried completely before reuse This filter shall be replaced every year with a new one If a plugged air filter cannot be cleaned with compressed air or flushing water replace it immediatel...

Page 338: ...flushed with water it must be dried completely before reuse This filter shall be replaced every year with a new one If a plugged air filter cannot be cleaned with compressed air or flushing water replace it immediately 3 After cleaning restore the filter 6 tighten the nut 5 and close the cover Lock the cover with your start switch key and then remove the key 4 CZ335 1104077 4 6 5 CZ335 1104078 S L...

Page 339: ...ck G loosen the drain valve P to drain excessive oil If the oil level is too high consult Sany distributor for inspection Place a container under the drain valve before draining the oil 6 After checking the oil level or refilling the oil insert the dipstick G into the hole and restore the filler cap When the engine has just been stopped the parts and oil are still hot and can cause serious burn Wa...

Page 340: ...e a 10 mm wrench 1 Adjust the filler cap screw F to the upper position in order to make the line through the oil inspection screw plug L and the drain screw plug P perpendicular to the ground 2 Use a proper screwdriver to eliminate the dirt from the hexagonal socket of screw plug in order to avoid damage to the bolt 3 Use a spanner to remove the screw plug L When the oil level reaches the point 10...

Page 341: ...rs Also perform maintenance for every 100 250 and 500 service hours in the meantime 5 8 7 1 Hydraulic oil filter replace When the engine has just been stopped the parts and oil are still hot and can cause serious burn Wait for the temperature to cool down before doing the job Note For machines equipped with a hydraulic breaker the hydraulic oil deteriorates faster than that of machines operating w...

Page 342: ...may fly out due to the action of the spring 2 In this case hold down the cap when remov ing the bolts CZ335 1104086 1 CZ335 1104087 Breather valve Butterfly nut Fig 5 92 Fig 5 93 5 Remove the spring 2 valve 3 and strainer 4 before disassembling the filter 5 Check the bottom of the filter box and remove the dirt if any Keep the hydrau lic oil free from any dirt 6 Clean the disassembled parts with c...

Page 343: ... the parts and oil are still hot and can cause serious burn Wait until they are cool enough before doing the job Always prepare your machine as required and lock tag it out before proceeding See Preparing the machine on page 2 58 and Lock out and tag out on page 2 60 P CZ335 1104084 WARNING Remark If the gear oil flows out in a thin thread pat tern you can end the draining operation When the tempe...

Page 344: ... exhaust pipe clamps check Consult Sany distributor to check the fastening conditions of the air cleaner turbocharger post cooler engine clamps 5 8 7 4 Fan belt tension check replace Check the tension of fan belt Replace the fan belt in case of cracks or damage Contact your Sany distributor if you have any troubles 5 8 7 5 Nitrogen pressure in accumulator breaker check If equipped Special tools wi...

Page 345: ...er to release the pressure Never stand in front of the screw plug Always prepare your machine as required and lock tag it out before proceeding See Preparing the machine on page 2 58 and Lock out and tag out on page 2 60 Refilling capacity See Fluid capacities on page 5 19 Prepare a wrench 1 Adjust the filler cap screw F to the upper position in order to make the line through the oil inspection sc...

Page 346: ...ator P in order to drain the oil Remark Check the O ring on screw plug and replace the O ring if broken 5 Tighten the plug P and remove the plugs F and L 6 Fill oil through the opening of the plug F 7 When the oil is seen coming out of the opening L reinstall the plug F and L and tighten them to 58 8 19 6N m ...

Page 347: ...en 4 4 Clean the screen 4 of all dirt Flush it with cleaning oil Replace the screen if dam aged 5 During installation fix the screen 4 to the bigger part 5 of the oil tank before assembling 6 When assembling take advantage of the bulged part of the cap 1 to hold the spring 2 before tightening the bolts When the engine has just been stopped the parts and oil are still hot and can cause serious burn...

Page 348: ...e the opening from which oil may squirt when disassembling a hydraulic device In addition loosen the bolts slowly Never dismantle the accumulator Be away from fire sources Never punch or weld the accumulator Never bump or roll the accumulator Keep it free from any impacts Vent the air completely when handling the accumulator Consult your Sany distributor to do this job Functions of the accumulator...

Page 349: ...a is clear without personnel or any barriers Check the nitrogen pressure through the fol lowing steps 1 Park your machine on a hard level ground 2 Keep the work equipment 1 5m 4ft 11in above the ground at maximum reach with the arm fully extended and the bucket fully turned outward The step 3 through step 5 shall be conducted within 15 seconds The accumulator s pressure drops gradu ally since stop...

Page 350: ...r it reaches the ground F L CZ335 1104098 Fig 5 104 6 A work equipment lowering and touching the ground under gravity indicates that the accumulator functions normally In case that the work equipment is unable to lower or is held half way the pressure in the hydraulic circuit accumulator may have dropped already Consult Sany distributor for such inspec tion 7 After checking through the a m steps p...

Page 351: ...mulator will drop grad ually after the engine is stopped There fore the pressure can only be released when the engine has just be turned off F L CZ335 1104100 A B C CZ335 1104101 F L CZ335 1104098 3 Turn off the engine 4 Turn the start switch to ON position B 5 Place the lockout control to FREE position F and then cycle the work equipment control lever in all directions in order to release the pre...

Page 352: ... Unscrew the bolts of the bottom cover plate and remove the cover plate 2 Swing the upper structure in order to posi tion the drain plug beneath the hydraulic tank between the tracks 3 Retract the arm and bucket cylinders and lower the boom in order to enable the bucket tips to touch the ground 4 lace the hydraulic lockout control to the LOCK position and turn off the engine When the engine has ju...

Page 353: ...94 6 10 5 kgf m or 683 5 76 0lbft Do not get oil on your body when re moving the drain plug P 7 Fill the hydraulic oil as required through the filler F Check the oil level which shall be between the H and L marks of dipstick For more information on applicable hy draulic oil see Recommended Flu ids on page 5 17 For more information on oil level inspec tion see Cooling system clean on page 5 37 8 El...

Page 354: ...necessary for inspection and maintenance Consult Sany distributor to do this job 5 8 9 Every 4000 service hours Also perform maintenance for every 100 250 500 1000 and 2000 service hours in the meantime 5 8 9 1 Coolant pump inspect Check coolant pump for leak of water or oil In case of any problem contact your Sany dis tributor for disassembly repair or replacement 5 8 9 2 Start motor check Consul...

Page 355: ...s pressurized nitrogen which may explode due to im proper operation thus resulting in machine damage and personal injury The following items must be observed when handling the accumulator Some pressure remains in the hydrau lic circuit Never face the opening from which oil may squirt when disassem bling a hydraulic device In addition loosen the bolts slowly Never dismantle the accumulator Be away ...

Page 356: ...e bolts on the five mounting clamps of high pressure tubes between feed pump and injection nozzle Check for any aged rubber Con tact your Sany distributor to replace any part that fails CZ335 1104106 Fig 5 113 5 8 9 5 Compressor working condition inspect The following two items are to be inspected 1 Whether the compressor and the magnetic clutch are switched on off when switching on off the air co...

Page 357: ...erform maintenance for every 100 250 500 1000 2000 and 4000 service hours in the meantime 5 8 10 1 High pressure tube clamps re place Contact your Sany distributor to replace the high pressure tube clamps on the engine 5 8 11 Every 10000 service hours Contact your Sany distributor for an overall maintenance if your machine has worked for 10 000 hours ...

Page 358: ...Maintenance Safety Operation and Maintenance Manual Aug 2012 5 99 SY115C9 135C 155H Crawler Hydraulic Excavator B L A N K P A G E ...

Page 359: ...Maintenance Safety Operation and Maintenance Manual Aug 2012 5 100 SY115C9 135C 155H Crawler Hydraulic Excavator B L A N K P A G E ...

Page 360: ...6 12 6 3 Towing the Machine 6 13 6 4 Towing Hook for Light Loads 6 15 6 5 Severe Operating Conditions 6 15 6 6 Engine Failures 6 16 6 6 1 Engine troubleshooting table 6 16 6 6 2 Coolant temperature high 6 19 6 6 3 Engine oil pressure low 6 20 6 6 4 When fuel exhausts 6 22 6 6 5 When engine rotates reversely 6 24 6 7 Failures of the Electrical System 6 25 6 7 1 Electrical system troubleshooting tab...

Page 361: ...SY115C9 135C 155H Crawler Hydraulic Excavator 6 2 Safety Operation and Maintenance Manual Aug 2012 6 8 3 3 Disconnecting the jumper cables 6 34 6 9 Failures of the Hydraulic System 6 35 6 10 Other Common Failures 6 39 ...

Page 362: ...corrosion of start motor terminal and wiring Tighten or replace Tighten or replace Tighten or replace Hydraulic mechanical equipment 1 Check for abnormal noise and smell 2 Check for oil leakage 3 Carry out air bleeding Repair Repair Bleed air Electrics electrical equipment 1 Check battery voltage engine stopped 2 Check battery electrolyte level 3 Check for discolored burnt exposed wiring 4 Check f...

Page 363: ...rough ques tions Failure encountered Working condition when failure occurs Working environment Repair and maintenance history 2 Determine possible locations of failure Refer to Troubleshooting Section in this manual in order to find possible locations of the failure 3 Prepare tools for troubleshooting Tools required T connector Hydraulic gauge etc Refer to the Parts Book and prepare necessary repl...

Page 364: ...d operate the machine to make sure that the symptom does exist Simply determine location of failure and make repair before performing trouble shooting Checks before starting Other checking items Refer to Troubleshooting Section in this manual and choose troubleshooting pro cedure according to machine symptom be fore performing the service work 8 Work out a service plan Repair in work shop Repair o...

Page 365: ...ine to cool down before troubleshooting Take care not to touch any hot parts or be caught by any rotating parts Before disconnecting any electrical wir ing always disconnect the negative post of battery Before removing the plug or cap from any vessel that contains pressurized oil water or air release the internal pressure When installing a measuring equipment be sure to connect it prop erly The ai...

Page 366: ...e and at the same time will also lose the confidence of the user or operator For this reason when carrying out trouble shooting it is necessary to carry out thor ough prior investigation and to carry out troubleshooting in accordance with the fixed procedure 2 Points to ask user or operator 1 Have any other problems occurred apart from the problem that has been reported 2 Was there anything strang...

Page 367: ...nsidered to be necessary 4 Confirming failure Confirm the extent of the failure your self and judge whether to handle it as a real failure or as a problem with the method of operation etc When operating the machine to reenact the troubleshooting symptoms do not carry out any investigation or measure ment that may make the problem worse 5 Troubleshooting Use the results of the investigation and ins...

Page 368: ...e discon necting or connect connectors 2 Before carrying out troubleshooting check that all the related connectors are properly inserted Disconnect and connect the related con nectors several times to check 3 Always connect any disconnected connec tors before going on to the next step If the power is turned ON with the con nectors still disconnected unnecessary abnormality displays will be generat...

Page 369: ...f disassembly or maintenance work is carried out on hydraulic equipment in the field there is danger of dust entering the equipment It is also difficult to confirm the performance after repairs so it is desir able to use unit exchange Disassembly and maintenance of hydraulic equipment should be carried out in a specially pre pared dust proof workshop and the per formance should be confirmed with s...

Page 370: ...the new oil and will shorten the life of the hydraulic oil 5 Flushing operations After disassembling and assembling the equipment or changing the oil use flushing oil to remove the contaminants sludge and old oil from the hydraulic cir cuit Normally flushing is carried out twice primary flushing is carried out with flushing oil and secondary flushing is carried out with the specified hydraulic oil...

Page 371: ...The brake valve produces noise when starting or stopping swinging operation The travel motor produces noise when the machine travels downhill at low speed 6 2 Pseudo Failures Note that the following failures are pseudo ones The arm speed may drop suddenly when retracting the arm with the work equipment lowering unloaded and the arm in a nearly vertical position CZ335 1103213 CZ335 1103214 Fig 6 5 ...

Page 372: ...erwise result in acci dents While towing the machine do not use wire cables with broken wires A re duced diameter B or knot C in order to prevent rupture of the wire cables Always wear protective gloves when handling wire cables Never tow the machine on a slope Never stand between the towing ma chine and the towed machine when performing towing operation Operate the machine slowly and avoid imposi...

Page 373: ...stration Place wood blocks or other protective materials between where the wire cable contacts the machine in order to prevent friction between the wire cable and the ma chine Keep the wire cable parallel to the ground and align its direction with that of the track frame Move at a speed of 1Km h when towing the machine Tow the machine to a place suitable for repair Never tow the machine over a lon...

Page 374: ...machine slowly and avoid im posing sudden load on wire cable The track frame has an eye which can be hooked when towing a light object 6 5 Severe Operating Conditions When performing excavation in water if the installation pins of work tool go below wa ter surface it is necessary to add grease to the pins before each operation For heavy loaded operation and deep ex cavation it is necessary to add ...

Page 375: ...nsor internal failure Check repair Replace Check repair Replace Unable to power off the machine Battery relay failure Breakdown of surge diode Replace Replace Auto idle fails Boom up signal failure Boom down signal failure Arm in signal failure Arm out signal failure Bucket dig signal failure Bucket dump signal failure Swing signal failure Travel signal failure Attachment signal failure Controller...

Page 376: ...oller failure Replace Check repair Check repair Replace Dual travel speed failure Dual travel speed solenoid valve failure Open circuit of wire Short circuit of wire grounding failure Replace Check repair Check repair Engine coolant tempera ture reading incorrect Coolant temperature sensor failure Open circuit of wire Short circuit of wire grounding failure Wire short circuited with 24V Replace Ch...

Page 377: ...ure reading incorrect 5V power supply failure Open circuit of signal line Short circuit of signal line Sensor failure Repair replace Check repair Check repair Replace Bucket dump pilot pres sure reading incorrect 5V power supply failure Open circuit of signal line Short circuit of signal line Sensor failure Repair replace Check repair Check repair Replace Swing pilot pressure reading incorrect 5V ...

Page 378: ...lant temperature can cause engine parts to burn Refill the coolant slowly in several times Quick filling of low temperature coolant can cause engine cracks When the coolant temperature gauge shows a temperature higher than 100 C the coolant temperature alert indicator will be on Stop op erating your machine and keep engine running at a speed a little higher than idle in order to reduce temperature...

Page 379: ...ncounters higher coolant temperature the cooling system has a problem Always prepare your machine as required and lock out tag out your machine before proceed ing See Preparing the machine on page 2 58 and Lock out and tag out on page 2 60 Fig 6 11 Fig 6 12 1 CZ215 1105003 6 6 3 Engine oil pressure low When oil pressure low alert indicator is on shut down the engine immediately Dam age could occur...

Page 380: ...he dipstick into oil and then slowly pull it out If oil level between the marks L and H the amount of oil is good If oil level is low refill it immediately If engine oil is contaminated change the oil immediately Replace the dipstick 1 after checking 3 If engine oil level is normal but abnormal pressure of engine oil is altered contact your Sany distributor in time to solve the problem Fig 6 13 bl...

Page 381: ...lashed onto the exhaust pipe and other places These oil and fuel can cause fire or slipping accident The space for air purging operation is limited Take care not to be cut by the edges When fuel exhausts it is necessary to refuel the engine and purge air from the fuel system before restarting it Fig 6 15 WARNING 1 Turn counterclockwise the handle 1 of manual pump to release it Fig 6 16 2 Loosen ai...

Page 382: ...torque 9 8 2 0N m 1 0 2 kgf m 5 Continue to operate the manual pump until heavy resistance is felt Resistance of pump operation may not rise when fuel temperature is low It is neces sary to operate the pump continuously and repeatedly 6 After purging the air completely remove splashed fuel before starting the engine 7 Make sure no fuel leaks Make sure no fuel leaks from filter and its housing Fuel...

Page 383: ...y smoke coming out air cleaner Tachometer and oil pressure gauge giving no response Low oil pressure alert indicator on Check and clean the air cleaner and intake hoses after shutting down the engine Replace any defective air cleaner or hose immediately Reverse rotation of engine can burn the engine within several minutes or cause severe injury Shut down the engine imme diately once reverse rotati...

Page 384: ...place Check repair Replace Unable to power off the machine Battery relay failure Breakdown of surge diode Replace Replace Auto idle fails Boom up signal failure Boom down signal failure Arm in signal failure Arm out signal failure Bucket dig signal failure Bucket dump signal failure Swing signal failure Travel signal failure Attachment signal failure Controller failure Check repair Check repair Ch...

Page 385: ...oller failure Replace Check repair Check repair Replace Dual travel speed failure Dual travel speed solenoid valve failure Open circuit of wire Short circuit of wire grounding failure Replace Check repair Check repair Engine coolant tempera ture reading incorrect Coolant temperature sensor failure Open circuit of wire Short circuit of wire grounding failure Wire short circuited with 24V Replace Ch...

Page 386: ...ure reading incorrect 5V power supply failure Open circuit of signal line Short circuit of signal line Sensor failure Repair replace Check repair Check repair Replace Bucket dump pilot pres sure reading incorrect 5V power supply failure Open circuit of signal line Short circuit of signal line Sensor failure Repair replace Check repair Check repair Replace Swing pilot pressure reading incorrect 5V ...

Page 387: ... temperature higher than 90 C for 10s 12 Motor working range irregular Motor feedback voltage lower than 0 25V or higher than 4 75V for 3s 20 Front pump pressure sensor abnormal Front pump pressure collecting volt lower than 0 25V or higher than 4 75V for 3s 21 Rear pump pressure sensor abnormal Rear pump pressure collecting volt lower than 0 25V or high er than 4 75V for 3s 22 Bucket dig pilot pr...

Page 388: ...proportional valve current lower than 200mA for 3s and controller PWM output higher than 10V 37 Rear pump proportional valve undercurrent Rear pump proportional valve current lower than 200mA for 3s and controller PWM output higher than 10V 38 Front pump proportional valve Front pump proportional valve feedback current lower than 150mA or higher than 1350mA for 3s and controller PWM duty output hi...

Page 389: ...the positive terminal while installing the bat tery Be especially careful with your tools which may produce sparks when touching the positive terminals and the chassis A loose terminal can result in improper contact which may cause sparks and explosion Check that which terminal is positive and which one is negative when removing or installing the terminals Fig 6 21 2 1 1 2 CZ335 1103219 6 8 1 Batt...

Page 390: ...e charger s positive clip to the battery s positive terminal Connect the charger s negative clip to the bat tery s negative terminal The wire clips must be fixed Regulate the charging current to 1 10 of the rated capacity of battery In case of quick charging regulate the charging cur rent to a level below the rated capacity of battery Larger charging current may cause leakage or evaporation of ele...

Page 391: ...r enough from the battery But the work tool shall be excluded as the work tool is not a good conductor When removing the jumper cables pay extra attention to the cables whose clips shall not contact with each other or with the chassis Fig 6 23 CZ335 1103221 WARNING Note The start system of the machine is sup plied with a 24V power source Two 12V batteries are connected serially to supply power to ...

Page 392: ... Connect the jumper cables in the numbered sequence as shown in the diagram 1 Connect the clip of jumper cable A to the positive terminal of battery C of the faulty machine 2 Connect the clip on the other end of jumper cable A to the positive terminal of bat tery D of the normal machine 3 Connect the clip of jumper cable B to the negative terminal of battery D of the nor mal machine 4 Connect the ...

Page 393: ...un it at high idle 3 Turn the start switch of the faulty machine to START position and start the engine If the engine fails to start wait for two minutes before attempting to restart it 6 8 3 3 Disconnecting the jumper cables After the engine is started disconnect the jumper cables in steps reversed to their con nection 1 Disconnect the clip of the jumper cable B from the swivel frame E of the fau...

Page 394: ... speed slow Right pilot valve boom circuit failure Pressure sensor failure Boom control valve spool failure Boom control valve retaining valve failure Boom control valve Safety valve and feed valve seal failure Boom cylinder failure Check repair Replace Repair replace Repair replace Repair replace Check repair Arm speed slow Left pilot valve arm circuit failure Pressure sensor failure Arm control ...

Page 395: ... Proportional solenoid valve sluggish Travel valve spool sluggish Central swivel joint sluggish Travel motor failure Travel pilot pressure sensor failure Repair replace Replace Repair replace Repair replace Repair replace Repair replace Repair replace Replace Travel speed slow Travel pilot valve failure Pilot relief valve failure Sensor failure Travel control valve spool failure Travel control val...

Page 396: ...e Bad acceleration performance on one side or swing speed slow Pilot valve failure Swing motor pressure compensation valve fail ure Swing motor feed valve seal failure Leak on one side the shuttle valve of swing pilot pressure sensor Repair replace Repair replace Replace Repair replace Too much overrun in swing stoppage In both directions Bad adjustment or failure of swing motor safety valve Swing...

Page 397: ...y Excessive hydraulic drift of swing When swing brake engaged Swing brake control line failure Swing motor parking brake failure Check repair Repair replace When swing brake disengaged Swing control valve spool failure Swing motor relief valve failure Swing motor feed valve failure Repair replace Repair replace Repair replace Table 6 5 ...

Page 398: ...ss air flow Air intake side blocked Evaporator or condenser fin plugged giving ineffective heat conduction Fan vane seized or damaged Clean replace Compressor not work ing or working with diffi culty Compressor clutch not picking up due to wire break or defective contact of electri cal circuit Loose compressor belt Wire break or failure of compressor clutch coil Insufficient or excessive refrigera...

Page 399: ...gative Expansion valve thermo tube or bulb leaks Replace expansion valve High pressure gauge reads higher Both high low pressure gauges read higher than standard value Air trapped in circulation system Excessive refrigerant refilled Empty the system and vacuate to refill refrigerant Drain refrigerant to the specified level Bad condens ing effect of condenser Condenser blocked by dust and debris Co...

Page 400: ...Troubleshooting Safety Operation and Maintenance Manual Aug 2012 6 41 SY115C9 135C 155H Crawler Hydraulic Excavator B L A N K P A G E ...

Page 401: ...Troubleshooting Safety Operation and Maintenance Manual Aug 2012 6 42 SY115C9 135C 155H Crawler Hydraulic Excavator B L A N K P A G E ...

Page 402: ...Specifications SY115C9 135C 155H Crawler Hydraulic Excavator Specifications Safety Operation and Maintenance Manual Aug 2012 7 1 7 Specifications 7 1 Machine Dimensions 7 3 7 2 Working Ranges 7 4 ...

Page 403: ...Specifications SY115C9 135C 155H Crawler Hydraulic Excavator 7 2 Safety Operation and Maintenance Manual Aug 2012 ...

Page 404: ...2200 A Shipping length mm 7280 7700 7700 B Total width mm 2550 2550 2550 C Shipping height mm 2810 2815 2815 D Top width mm 2480 2490 2580 E Total height to top of cab mm 2810 2740 2740 F Standard width of track shoe mm 500 500 500 G Gauge mm 1990 1990 1990 H Min ground clearance Excluding grouser mm 422 425 425 I Tail swing radius mm 2325 2240 2240 J Track grounding length mm 2680 2930 2930 K Tra...

Page 405: ...Specifications Safety Operation and Maintenance Manual Aug 2012 7 4 SY115C9 135C 155H Crawler Hydraulic Excavator 7 2 Working Ranges f a g b c d e Fig 7 2 ...

Page 406: ...C9 SY135C8 C9 SY155H a Max cutting height mm 7780 8645 8625 b Max dumping height mm 5530 6175 6120 c Max digging depth mm 5165 5500 5520 d Max vertical digging depth mm 4925 4890 5005 e Max horizontal reach mm 7605 8290 8330 f Min swing radius mm 2600 2500 2315 g Maximum height at minimum swing radius mm 5995 6500 6495 Table 7 2 ...

Page 407: ...Specifications Safety Operation and Maintenance Manual Aug 2012 7 6 SY115C9 135C 155H Crawler Hydraulic Excavator B L A N K P A G E ...

Page 408: ... 1 2 Selector valve 8 7 8 2 1 3 Control pedal 8 7 8 2 2 Hydraulic circuit 8 8 8 2 2 1 Hydraulic circuit switching 8 8 8 2 2 2 Shifting to breaker general optional equipment 8 8 8 2 2 3 Connecting hydraulic oil circuit 8 9 8 2 2 4 Hydraulic oil passage 8 10 8 2 3 Optional equipment removal and installation 8 11 8 2 3 1 Removal 8 11 8 2 3 2 Optional equipment installation 8 13 8 2 4 Hydraulic oil an...

Page 409: ...ns 8 22 8 6 Hydraulic Breaker Lubrication 8 25 8 7 Quick Coupler and Control System 8 26 8 7 1 Quick coupler installation 8 26 8 7 2 Operating precautions 8 28 8 8 Refueling System 8 29 8 8 1 Introduction 8 29 8 8 2 Components 8 30 8 9 Central Lubrication System 8 31 8 9 1 Scheme and components 8 31 8 9 2 System working principle 8 33 8 9 3 Setting the lubrication time of electric grease pump 8 34...

Page 410: ...ptional equipment to be used Only Sany approved optional equipment can be installed Sany assumes no re sponsibility to accidents losses or failures caused by any attachment that has not been approved by Sany 8 1 2 Reading the instruction books Read and understand the instruction books of your machine and of attachment or op tional equipment before installation and operation If the instruction book...

Page 411: ...ance after removal To prevent the machine from tipping over support your machine if necessary before removing the heavy component Before or after the optional equipment has been installed or removed make sure that it is stable without the danger to tip For more information about removal and installation please consult Sany distributor 8 1 4 Operation precautions Keep the following procedures in mi...

Page 412: ...lculated accu rately A larger space must be prepared before performing the swinging opera tion When the lifting of heavy optional equipment is held the distance mov ing downward is relatively longer due to gravity In this case it should be lowered to the ground instead of being held in air Never swing lower or stop your ma chine suddenly in order to prevent it from tipping over Never extend or ret...

Page 413: ...cation of the components 1 Stop valve 2 Selector valve 3 Control pedal Fig 8 1 8 2 1 1 Stop valve Stop valve stops hydraulic oil flow a Unlocked position allows flow of the hy draulic oil b Locked position stops flow of the hydraulic oil Switch the valve to locked position when re moving or installing an optional equipment Fig 8 2 2 3 1 CZ135B 1105001 1 a b CZ135B 1105002 ...

Page 414: ...3 Fig 8 3 Control pedal is used to control the optional equipment When the front center or rear of the pedal is pushed down the optional equipment will op erate as the following Hydraulic breaker Front A Operate Center N Stop Rear B Stop For other optional equipment consult its man ufacturer for installation in order to confirm the operation of pedal and optional equipment be fore operating your m...

Page 415: ...ety valve s standard pressure was set at the factory before the machine was delivered When mode B is selected the pressure is set to 20 6MPa 210kgf cm2 2980PSI when the mode of hydraulic shear is chosen the pressure is set to 27 4MPa 280 kgf cm2 3980PSI Readjustment may be necessary according to the type of optional equipment In this case please contact Sany distributor for adjustment 8 2 2 1 Hydr...

Page 416: ...hydrau lic oil the arrow indicated direction is parallel to the longitudinal direction of arm b locked stops flow of the hydraulic oil the arrow indicated direction is per pendicular to the longitudinal direction of arm 2 Remove the screw plug 3 from the end of the stop valve line Note The disassembled parts should not be lost or damaged 3 The optional equipment manufacturer is responsible to conn...

Page 417: ...oil passage The operating directions of the pedal and hydraulic path are shown below By pushing the front of the pedal the hydraulic oil flows to the left of the work equipment by pushing the rear the hydraulic oil flows to the right Only the front part of the pedal can be oper ated upon the installation of breaker CZ335 1105007 Fig 8 8 ...

Page 418: ...d and shut down the engine 2 Turn the start switch to ON position B and place the lockout control to FREE position F 3 After finishing step 2 fully cycle each control level and control pedal for 2 3 times within 15 seconds in order to release the internal pressure remained in the hydraulic lines 4 Place the lockout control to LOCK position L F L CZ335 1105009 F L CZ335 1105010 A B C CZ215 1105002 ...

Page 419: ...ion b a unlocked allows flow of the hydraulic oil the arrow indicated direction is parallel to the longitudinal direction of arm b locked stops flow of the hydraulic oil the arrow indicated direction is per pendicular to the longitudinal direction of arm 7 Disconnect the hose at the side of the optional equipment Install the screw plugs to the two outlets The screw plugs are used to prevent that t...

Page 420: ...ntrol level and optional equipment con trol pedal for 2 3 times within 15 seconds in order to release the internal pressure remained in the hydraulic lines A B CZ335 1105014 F L CZ335 1105009 A B C CZ215 1105002 9 Check the oil level in the hydraulic tank af ter the bucket has been installed properly 8 2 3 2 Optional equipment installation 1 Remove the bucket 2 Place the optional equipment to a fl...

Page 421: ...he inlet and outlet lines to the side of the arm to FREE position a a unlocked allows flow of the hydraulic oil the arrow indicated direction is parallel to the longitudinal direction of arm b locked stops flow of the hydraulic oil the arrow indicated direction is perpendicu lar to the longitudinal direction of arm 11 Check the oil level in hydraulic tank after installation of the optional equipme...

Page 422: ...in the Maintenance Section Table 8 1 Change interval hours Machine with Hydraulic Breaker Machine with Common Bucket Hydraulic oil 600 1500 or 2500 or 4000 Filter cartridge 100 1000 Note The figures in the above table are determined at 100 percent operation with hydraulic breaker As the operating hours of hydraulic breaker reduce the change intervals could be prolonged corre spondingly as shown in...

Page 423: ...e overflow pressure of the safety valve in the stand by valve has been set to 27 4MPa 280 kgf cm2 3980PSI except mode B The pressure to activate the safety valve in the stand by valve has been set to 24 5MPa 250 kgf cm2 3550PSI except mode B The overflow pressure of the safety valve in the stand by valve has been set to 15 17MPa 153 174 kgf cm2 2178 2469 PSI mode B The pressure to activate the saf...

Page 424: ...n optional equipment with out approval from Sany distributor could lead to safety problems which may impair the operation and service life of your machine Sany assumes no responsibility for any injuries accidents or damage re sulted from the installation of unauthor ized optional equipment 8 3 1 Work equipment combination There is the danger of impacting the cab or machine body due to the type or ...

Page 425: ... when you dig or load hard soil or soft soil containing stone pieces Digging or loading materials of specific gravity 1 8 t m3 Bucket Type Capacity m3 cu yd Outer Width mm ft in Weight Kg lb Stand Arm m ft in Remark Rockwork SY115C9 0 48 0 64 882 2ft 10in 405 893 2 36 7 ft 9 in Standard Rockwork Earthwork SY135C8 0 53 0 71 880 2ft 10in 480 1058 2 5 8 ft 2 in Standard 0 53 0 71 946 3 ft 1 in 478 10...

Page 426: ...e bucket tips service life could be impaired such as loading hard rocks Would be used at where the bucket tips will not penetrate into the soils such as handling gravels after blasting or loosening the soils Would be used at where heavy load operation is carried out such as tapping or pulling the rock with bucket tips 8 3 2 2 Earthwork bucket tips Would be used at where the bucket tips will penetr...

Page 427: ...tor The type of optional equipment to be in stalled and the model of special optional equipment may vary according to the mod el of your hydraulic cylinder In this case for selecting the optimum optional equip ment please consult Sany distributor 8 4 1 Hydraulic breaker Major applications Crushing rocks Demolition Road Engineering This optional equipment can be used widely for such as demolishing ...

Page 428: ...to the object to be broken during breaking operation 2 Press the breaker chisel tightly onto the working surface when striking and slightly raise the front of the undercarriage about 5 mm 0 2 in from the ground as shown in the right illustration This clearance above ground shall not exceed 5 mm 0 2 in 3 If the same surface cannot be penetrated or broken by the chisel within one minute under contin...

Page 429: ...cylinder Fig 8 26 R CZ335 1105020 5 Always press the chisel properly on the working surface in order to prevent striking without resistance Fig 8 27 CZ335 1105021 8 5 Restricted Operations Do not operate your machine in any of the fol lowing manners in order to ensure a longer service life and safe operation Do not operate any of the oil cylinders to its full stroke A distance of 5 cm 2 in is to b...

Page 430: ...g 2012 8 23 SY115C9 135C 155H Crawler Hydraulic Excavator Fig 8 29 2 Breaking with swinging force CZ335 1105023 Fig 8 30 3 Moving the chisel during striking operation CZ335 1105024 4 Keep the chisel level or upward during striking operation CZ335 1105025 Fig 8 31 ...

Page 431: ...C9 135C 155H Crawler Hydraulic Excavator 5 Swing the chisel when the rock has been penetrated CZ335 1105026 6 Pecking operation CZ335 1105027 Fig 8 32 Fig 8 33 7 Raise your machine above ground by fully extending the bucket cylinder and by the pushing force CZ335 1105028 Fig 8 34 ...

Page 432: ...raulic Breaker Lubrication Grease the breaker at the correct point Note Greasing in an improper manner could add grease more than desired As a result soil and sand may enter the hydraulic system which can damage the hydraulic components when using the breaker CZ335 1105029 CZ335 1105030 CZ335 1105031 Fig 8 35 Fig 8 36 Fig 8 37 ...

Page 433: ... coupler as shown in the right illustration 2 Depress the quick coupler operation button 1 auto reset on the left joystick in order to slowly reduce the opening of the flexible jaws and the fixed jaws of quick coupler 3 Make the quick coupler s fixed jaws to slowly grip the bucket s support pin 2 as shown in the right illustration CZ335 1105032 Safety pin Jaw 1 CZ335 1105033 2 3 CZ335 1105034 Fig ...

Page 434: ...55H Crawler Hydraulic Excavator 4 Extend the bucket cylinder to slowly move the flexible jaws of quick coupler toward the bucket s support pin 3 5 Make sure that the jaws of quick coupler grip completely the support pin 3 of the bucket 2 3 CZ335 1105035 2 3 CZ335 1105034 Fig 8 41 Fig 8 42 ...

Page 435: ...e bucket and other optional equipment will make the swing diameter longer during the operation In this case they could possibly impact the cab or boom of your excavator So be careful with the operation After the quick coupler has been installed retract the bucket to its position the bucket cylinder is fully extended before retracting the arm when carrying out retracting the operation To avoid dama...

Page 436: ...at you are using an optional equipment that has been approved by Sany Sany assumes no re sponsibility for any failure and accident result ed from installation of any optional equipment that has not been approved by Sany CZ335 1105040 Fig 8 47 8 8 Refueling System 8 8 1 Introduction Sany excavators are equipped with a fueling system which uses a refueling pump assem bly The refueling pump assembly ...

Page 437: ... can see the control switch and the refueling pump 2 Fig 8 50 3 CZ135B 1105005 The main structure of the refueling pump 2 is shown in the right illustration Technical specifications of the refueling pump Pump flow rate 46L min Rated voltage 24V Rate speed 2800 rpm Coupling thread 3 4 G Weight 3 5kg Packing dimension 215 120 160mm The fuel level control relay 3 is shown in the right illustration Th...

Page 438: ...Y115C9 SY135C8 9 and SY155H adopt a 18 point lubrication scheme A sketch on distribution of excavator lubricating points is shown below 2 System components Electric grease pumping section It is composed of the pump mounting base the electric pump the pumping unit the safety valve and the filter 13 14 15 16 17 18 12 11 10 9 7 8 3 4 5 6 1 2 CZ135B 1105006 1 CZ135B 1105007 Fig 8 51 Fig 8 52 ...

Page 439: ... installed to the boom root are shown in the right illustration Secondary distributor C mounted to the arm A B CZ335 1105043 Boom C CZ335 1105044 Arm D CZ335 1105045 Linkage Secondary distributor D mounted to the inside of the linking rod Major lines configuration The system s major lines include high pressure hoses straight connectors el bows straight expansion core bent expan sion core steel wir...

Page 440: ...n system which is shown in the illustration below Operating principle The pressurized grease from the electric plunger pump goes through the pumping unit safety valve and filter to the main distributor where the grease is sent through the tubes to three secondary distributors and then supplied in turn to each lubricating point according to a certain proportion Fig 8 56 CZ335 1105046 Electric greas...

Page 441: ... LED indicator of the electronic controller will be illuminated for 25 seconds indicating that the system is ready for lubrication By pressing the start button on the motor s shell or instrument panel the lubrication cycle begins Upon completion of the lubrication cycle the motor of lubricating pump stops and the shutdown cycle begins Subsequent lubrication will start according to the predetermine...

Page 442: ...ontrol unit and damage may result in 8 9 4 Technical description 1 The system will lubricate for 10 minutes every half an hour which was set at the factory before delivery 2 After operating for 100 hours you can adjust increase or decrease the lubricating time ac cording to actual condition The lubricating interval however shall not be changed 3 Clean lithium base grease NLG12 is recommended for t...

Page 443: ...tral lubrication system lubricates your machine in the follow ing three ways 1 Standard Method Manual or pneumatic grease gun is used to add grease through the ball type nozzle 1 as shown in the following illustration Fig 8 59 1 CZ335 1105049 2 Add grease through the connector as shown in the illustration below Fig 8 60 CZ335 1105050 Remove grease fitting and connect the quick coupler Gasket ...

Page 444: ...he grease gun as shown in the illustration below Note Please consult Sany distributor if you need to install the central lubrication system Make sure that you are using accessories specified by Sany Sany assumes no responsibility for failures and accidents caused by the installation of any accessories that have not been approved by Sany Fig 8 62 CZ335 1105052 Grease gun Coupler ...

Page 445: ...Optional Equipment Safety Operation and Maintenance Manual Aug 2012 8 38 SY115C9 135C 155H Crawler Hydraulic Excavator B L A N K P A G E ...

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