SANY SY35U Operation And Maintenance Manual Download

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SY35U Excavator OMM

Maintenance

SANY

Operation and Maintenance Manual — 0120

5-59

TABLE OF

CONTENTS

INTRODUCTION

SAFETY

MACHINE

CONTROLS

MACHINE

OPERA

TION

MAINTENANCE

SPECIFICA

TIONS

OPTIONAL

EQUIPMENT

Replace the Hydraulic Oil Pilot Filter

1. Prepare the machine for service. See “Maintenance Safety” on page

2-8.

2. Relieve system pressure. See “Relieve Hydraulic System Pressure” on page

5-56.

3. Remove two fasteners (1) and the front cover (2).

4. Place a container under the pilot filter bowl (3) to catch

any spilled oil.

5. Loosen and remove the pilot filter bowl.

6. Remove the filter element from the housing. Clean the

interior of the housing and bowl.

7. Install a new filter element, gasket, and O-ring. Install the filter bowl and tighten securely.

8. To purge air from the system, start the engine and run it at low idle for 10 minutes. Check for leaks.

WARNING!

•

Allow the hydraulic system to cool before servicing. Hot oil may cause burns or other
serious injury.

•

The hydraulic tank may be under pressure, and hydraulic oil may be present at the filler
cap. Relieve any pressure to prevent injury.

Failure to follow these warnings could result in death or serious injury.

NOTICE!

Dispose of hydraulic oil and filters according to
all applicable environmental regulations. Failure
to do so could damage to environment.

Fig. 5-60

0003849

Fig. 5-61

0003787

Summary of Contents for SY35U

Page 1: ...service sanyamerica com SANY Part Number SSY005082353 SY35U Excavator Operation and Maintenance Manual ...

Page 2: ...This Page Intentionally Left Blank ...

Page 3: ...tor Operation and Maintenance Manual WARNING Read and understand all safety precautions and instructions in this manual before reading any other manuals provided with this machine and before operating or maintaining it Failure to do this could result in death or serious injury ...

Page 4: ...hone 470 552 SANY 7269 www sanyamerica com find a dealer 2020 by SANY All rights reserved No part of this publication may be reproduced used distributed or disclosed except for normal operation and maintenance of the machine as described herein All information included within this publication was accurate at the time of publication Product improvements revisions etc may result in differences betwe...

Page 5: ...Equipment 1 4 Machine Applications 1 5 Machine Directions 1 5 Serial Number Location 1 6 Product Identification Plate 1 6 Frame Serial Number 1 6 Swing Motor Identification Plate 1 7 Engine Identification Plate 1 7 Hydraulic Pump Identification Plate 1 8 Travel Motor Identification Plate 1 8 SANY Contact Information 1 9 Record of Serial Number and Dealer Information 1 9 Correction Request Form 1 1...

Page 6: ...d Operation Precautions 2 12 Inclined Areas 2 12 Snow or Frozen Surfaces 2 12 Avoid Backover Accidents 2 13 Dust and Chemical Hazards 2 13 Environmental Precautions 2 13 Precautions in High Voltage Areas 2 14 Machine Controls Machine Overview 3 3 Controls 3 4 Switches Cab Machine 3 4 Switches Canopy Machine 3 5 Joystick Buttons and Switches 3 6 Left Joystick Buttons 3 6 Right Joystick Switch 3 6 H...

Page 7: ... 24 Lower Front Windshield 3 25 Heating and Air Conditioning System 3 26 Control Panel 3 26 Heating and Air Conditioning System Operation 3 27 Air Outlets 3 28 Cab Ventilation 3 28 Radio 3 29 Radio Control Panel 3 29 Radio Operation 3 29 Auto Scan Preset Station AS PS Button 3 29 AM FM Selector Button 3 29 LCD 3 29 Sound Mode Adjustment Button SEL 3 30 Time Display Time Set Button 3 30 Power Butto...

Page 8: ...dd Engine Coolant 4 6 Engine Oil Level Check 4 7 Fuel Level Check 4 8 Add Fuel 4 8 Fuel Tank Filler Cap 4 9 Check and Drain the Primary Fuel Filter Water Separator 4 10 Check the Hydraulic Oil Level 4 11 Windshield Washer Fluid Check and Fill 4 11 Electrical Components Check 4 12 Horn Function Check 4 12 Seat and Seat Belt 4 13 Seat Position Adjustment 4 13 Seat Backrest Adjustment 4 13 Seat Weigh...

Page 9: ...4 31 Never Use Traveling Force 4 31 Never Operate Using Machine Weight 4 32 Do Not Operate a Cylinder at the Stroke End 4 32 Avoid Dozer Blade Impact 4 33 Avoid Shifting Travel Directions Suddenly 4 33 Support the Dozer Blade 4 33 Excavating Hard Ground 4 33 Travel 4 34 General Travel Instructions 4 34 Traveling at High Speed 4 35 Operating in Water 4 36 Traveling on an Incline 4 37 Precautions Wh...

Page 10: ...s After Maintenance or Repairs 5 5 Hour Meter Reading 5 5 Genuine SANY Parts 5 5 Approved SANY Lubricants 5 6 Oil and Filter Inspection 5 6 Collect Oil Sample 5 6 Fuel Tank Strainer 5 6 Preventing Contamination 5 6 Installation of Hydraulic Hoses 5 6 Securing Access Covers and Compartment Doors 5 6 Cleaning the Machine 5 7 Weld Drill Cut or Grind on the Machine 5 7 Inspection and Maintenance in Ad...

Page 11: ...nd Lubricate the Cab Door 5 23 Windshield 5 24 Inspect the Windshield Mechanisms 5 24 Engine Hood 5 25 Opening the Engine Hood 5 25 Closing the Engine Hood 5 25 Right Rear Access Door 5 26 Opening the Right Rear Access Door 5 26 Closing the Right Rear Access Door 5 26 Right Front Access Door 5 26 Unlocking Opening the Right Front Access Door 5 26 Closing Locking the Right Front Access Door 5 27 Fu...

Page 12: ...eplace the Secondary Fuel Filter 5 48 Replace the Primary Fuel Filter Water Separator Element 5 49 Check the Fuel Tank Strainer 5 51 Check the Fuel Lines 5 52 Battery 5 52 Check the Battery 5 52 Remove the Battery 5 54 Hydraulic System 5 56 Check the Accumulator Function 5 56 Relieve Hydraulic System Pressure 5 56 Check Hydraulic Oil Level 5 56 Add Hydraulic Oil 5 57 Replace the Hydraulic Tank Bre...

Page 13: ...er Base End Pin 5 79 Boom Swing Cylinder Rod End Pin 5 79 Boom Swing Cylinder Base End Pin 5 80 Boom Swing Pin 5 80 Swing Bearing 5 80 Swing Pinion Gear 5 81 Bucket 5 82 Replace the Bucket Teeth 5 82 Replace the Bucket 5 83 Check the Sheet Metal 5 83 Check Component Operating Functions 5 84 Check the Operation and Maintenance Manual 5 86 Check the Upper Structure and Undercarriage 5 87 Specificati...

Page 14: ...Table of Contents SY35U Excavator OMM Operation and Maintenance Manual 0120 SANY This Page Intentionally Left Blank ...

Page 15: ...s Manual 1 4 Introduction 1 4 Safety 1 4 Machine Controls 1 4 Machine Operation 1 4 Maintenance 1 4 Specifications 1 4 Optional Equipment 1 4 Machine Applications 1 5 Machine Directions 1 5 Serial Number Location 1 6 Product Identification Plate 1 6 Frame Serial Number 1 6 Swing Motor Identification Plate 1 7 Engine Identification Plate 1 7 Hydraulic Pump Identification Plate 1 8 Travel Motor Iden...

Page 16: ...int out possible hazardous situations when operation or maintaining the machine Increase machine efficiency during operation Prolong the service life of the machine Reduce maintenance costs Continuing improvements in the design of this machine can lead to changes which may not be covered in this manual Contact a SANY dealer for the latest available information on the machine or to answer any quest...

Page 17: ... the machine or be accessible to the operator at all times If the machine is sold a copy of this manual must be provided to the new owner A copy of the operation and maintenance manual should be made available to maintenance personnel when servicing the machine Parts Manual The parts manual consists of parts lists and matching drawings used for ordering parts as needed The parts manual must be mad...

Page 18: ...or this manual Machine Controls An overview of controls and the operating systems is provided in this section Machine Operation Detailed prestart checks operating procedures end of day checks general operating instructions and storage information Maintenance Provides routine maintenance procedures and fluid specifications Specifications General dimensions and weight of the machine and systems comp...

Page 19: ...t can also be used for grading slope trimming lifting breaking demolishing and trenching It can perform the functions of a bulldozer loader and a crane This excavator can also operate a variety of optional equipment SANY assumes no responsibility for any consequence caused by use outside this specified range Machine Directions In this manual the front back left and right directions indicate the mo...

Page 20: ...placement parts or providing assistance for your machine Product Identification Plate The machine identification plate is on the lower front of the cab or canopy Frame Serial Number The frame serial number is stamped on the front of the travel carriage frame East Huancheng Road Kunshan Development Zone Jiangsu China HYDRAULIC EXCAVATOR SANY HEAVY MACHINERY LIMITED MODEL TYPE OPERATING MASS kg ENGI...

Page 21: ...ECIFICATIONS OPTIONAL EQUIPMENT Swing Motor Identification Plate The swing motor identification plate is on top of the swing motor Engine Identification Plate The engine identification plate is on the top of the engine HYDRAULIC EQUIPMENT MODEL MFG No 7900158 20A P 9217A PCR 4B Fig 1 4 0003140 Fig 1 5 0003138 MODEL OUTPUT DISPLACEMENT MADE IN JAPAN kW min 1 ENGINE NO ...

Page 22: ...avel Motor Identification Plate An identification plate is on each travel motor Remove the cover plates to access the travel motors CN 100176 Beijing AL A10V 0 71 DFLR 31R VSC42N00 S4518 MNR R902481204 SN 60800000 vg 71 Made in China DR FR 17bar LR 29kW ROTA TION bar cm3 n 2100min 1 FD 17W33 CN30 Rexroth Fig 1 6 0003169 HYDRAULIC EQUIPMENT MODEL MFG No 7000073 70D PST 9793A PHV 4B Fig 1 7 0003188 ...

Page 23: ...18 Cooper Circle Peachtree City GA 30269 www sanyamerica com Phone 470 552 SANY 7269 Find a dealer go to www sanyamerica com find a dealer RECORD OF SERIAL NUMBER AND DEALER INFORMATION Use this table to record the product information related to this machine Machine Serial No Engine Serial No Right Travel Motor Serial No Left Travel Motor Serial No Swing Motor Serial No Hydraulic Pump Serial No De...

Page 24: ...make a copy of this page complete the form below and send it to SANY Correction Request Form Date of This Notification Your Name Company Name Department Street Address City State and ZIP Postal Code Phone E mail Machine Model and Serial No Description of Problem wrong information unclear or erroneous procedure etc Corrective Action Taken if any ...

Page 25: ...Diesel Particulate Filter ECM Engine Control Module GPS Global Positioning System HEST High Exhaust System Temperatures ISO International Organization for Standardization LCD Liquid Crystal Display OEM Original Equipment Manufacturer OSHA Occupational Safety and Health Administration PPE Personal Protective Equipment PQR Procedure Qualification Record ROPS Rollover Protective Structure SAE Society...

Page 26: ...Introduction SY35U Excavator OMM 1 12 Operation and Maintenance Manual 0120 SANY This Page Intentionally Left Blank ...

Page 27: ...Unauthorized Use of This Machine 2 5 Unauthorized Machine Modifications 2 5 Escape Tool 2 6 Fire Safety 2 6 Electrical Fires 2 6 Fire Extinguisher 2 6 In Case of Fire 2 7 Crushing Hazard 2 7 Diesel Engine Exhaust 2 7 Maintenance Safety 2 8 Lockout Tagout Procedure 2 8 Cleaning the Machine 2 9 Fluid Systems 2 9 Adding Fluids to the Machine 2 9 Refueling 2 9 High Pressure Fluid Lines 2 9 Accumulator...

Page 28: ... 2 2 Operation and Maintenance Manual 0120 SANY Inclined Areas 2 12 Snow or Frozen Surfaces 2 12 Avoid Backover Accidents 2 13 Dust and Chemical Hazards 2 13 Environmental Precautions 2 13 Precautions in High Voltage Areas 2 14 ...

Page 29: ...amage personal injury or even death In this manual and on the machine decals signal words or illustrations are used to express the potential level of hazard This symbol is used within a graphic to alert the user not to do something Machine Decals All safety and warning decals must be in place undamaged and visible Become familiar with the location and content of all decals on the machine Walk arou...

Page 30: ...rly All accident prevention guidelines operating instructions etc are based on the intended usage of the machine Read and understand this manual and any accompanying manuals before operating this machine This manual must be readily available to the operator at all times and must remain on the machine while it is in use Make sure all personnel in the working area around the machine are thoroughly f...

Page 31: ...shoes with slip resistant soles Do not walk on any surface of the machine if its slip resistant material is missing or excessively worn Do not step on surfaces of the machine that are not approved for walking or working Keep all walking and working surfaces of the machine clean dry and slip resistant Always keep grab handles steps and walkway areas clean and clear of mud oil grease or similar debr...

Page 32: ...eck the machine daily for debris buildup Electrical Fires Short circuits damaged wiring or overcharging batteries can cause fires Observe the following Check the wiring on the machine for damage when doing a prestart check Contact a SANY dealer for repairs or replacement of any damaged wiring Make sure the battery is operating in its recommended range Never install aftermarket electrical equipment...

Page 33: ... body inside the windows and door during operation or travel For canopy models keep your body inside the canopy during operation or travel Keep all guards in place on the machine For cab models never remove the side window of the machine If this window becomes damaged or broken replace it immediately Block off the area where the machine is being operated and keep all unnecessary personnel out of t...

Page 34: ...ed closed position and block the tracks to prevent the machine from moving before performing any maintenance or repairs Before disconnecting or removing components of the hydraulic system relieve the system pressure to prevent hydraulic fluid from spraying out See Relieve Hydraulic System Pressure on page 5 56 The engine coolant and oil in the machine may be hot even after the engine is stopped Wa...

Page 35: ...t fluid systems may be under pressure and hot Refueling When adding fuel shut down the machine before removing the fuel tank cap Fuel spills present a hazard if not cleaned up immediately Refuel only in a well ventilated area Never smoke or allow open flames nearby while refueling the machine Do not top off the fuel tank High Pressure Fluid Lines Check for cracks in the lines or hoses and for swel...

Page 36: ...work in a well ventilated area Batteries present a hazard especially when they have been in use for a long period of time The following are some basic precautions for working around batteries Always wear personal protective equipment PPE Battery gases are extremely explosive Smoking sparks or open flames could cause an explosion When opening a battery compartment always allow ample time for batter...

Page 37: ...sponsibility of the operator s employer to conduct periodic safety training and familiarize all personnel with emergency procedures If pedestrians are in the area sound the horn and proceed slowly When working with another person on a job site make sure that all personnel involved understand all industry standard hand signals that are to be used The operator shall respond to operating signals from...

Page 38: ...l from local authorities and follow their instructions Raise work equipment 8 in 12 in 20 cm 30 cm above the ground when traveling When traveling or operating in shallow water be aware of its depth and current Inclined Areas Traveling on an incline can be dangerous To prevent tipping loss of control or a rollover it is important to follow these rules Always check the firmness of an incline before ...

Page 39: ...emicals present a serious danger when they are released or mishandled All workers involved should use approved personal protective equipment PPE and follow all environmental safety regulations Consult the Safety Data Sheet SDS for guidelines on personal protective equipment PPE proper handling and cleanup and correct reporting agencies if needed Environmental Precautions Oils and coolants poured o...

Page 40: ...zed and not insulated Be sure all underground utilities have been marked before excavating WARNING Overhead power lines carry high voltage electricity that can discharge to the ground through the machine even without direct contact with the machine s structure Avoid direct contact with high voltage power lines while operating High voltage contact could result in equipment damage death or serious i...

Page 41: ...Switch 3 8 Windshield Washer Switch Cab Machine 3 9 Windshield Wiper Switch Cab Machine 3 9 Work Light Switch Cab Machine 3 10 Work Light Switch Canopy Machine 3 11 Emergency Stop Switch 3 12 Cigarette Lighter 12V Cab Machine 3 12 Power Outlet 12V Canopy Machine 3 13 Dome Light Switch Cab Machine 3 13 Operator Controls 3 14 Dozer Blade Control Lever 3 15 Joystick Controls 3 15 Joystick SAE Mode 3 ...

Page 42: ...rol Buttons 3 30 Tuning Buttons 3 30 Preset Station Buttons 3 30 Battery Disconnect Switch 3 31 Escape Tool cab 3 32 Fire Extinguisher Cab 3 32 Monitor 3 33 Daily Maintenance Information Screen 3 33 Maintenance Information Screen 3 34 Home Screen 3 34 Function List Screen 3 36 System Information Screen 3 37 Main Menu Screen 3 38 Operation Information Screen 3 39 Switch Signals Screen 3 39 Joystick...

Page 43: ...VERVIEW NOTE The illustration below shows a cab machine Canopy machines are similar for non cab related items 1 Arm cylinder 10 Idler 2 Boom 11 Dozer blade 3 Boom swing cylinder 12 Dozer blade cylinder 4 Cab or canopy 13 Boom pivot 5 Carrier roller 14 Boom cylinder 6 Drive sprocket 15 Bucket 7 Track rollers 16 Arm 8 Track 17 Bucket cylinder 9 Track frame Fig 3 1 0001462 1 3 2 4 6 7 8 9 10 15 14 16...

Page 44: ... machine has a canopy 1 Left joystick buttons page 3 6 6 Travel alarm switch page 3 8 2 Horn button page 3 7 7 Windshield washer switch page 3 9 3 Right joystick switch page 3 6 8 Windshield wiper switch page 3 9 4 Throttle control dial page 3 7 9 Work light switch page 3 10 5 Key switch page 3 8 10 Emergency stop switch page 3 9 Fig 3 2 0003776 10 9 7 6 4 5 2 3 8 1 ...

Page 45: ...NS OPTIONAL EQUIPMENT Switches Canopy Machine NOTE See Switches Cab Machine on page 3 4 if your machine has a cab 1 Left joystick buttons page 3 6 5 Key switch page 3 8 2 Horn button page 3 7 6 Travel alarm switch page 3 8 3 Right joystick switch page 3 6 7 Work light switch page 3 11 4 Throttle control dial page 3 7 8 Emergency stop switch page 3 9 Fig 3 3 0003777 8 2 4 5 6 7 1 3 ...

Page 46: ...ilar Left Joystick Buttons Fig 3 4 0003766 1 The two buttons 1 on the back of the left joystick are not used Right Joystick Switch Fig 3 5 0003277 1 3 2 Move the right joystick switch 2 to the left 1 for high flow and high pressure in the left side auxiliary hydraulic lines Move the right joystick switch to the right 3 for high flow and high pressure in the right side auxiliary hydraulic lines ...

Page 47: ...n button 1 is on the back of the right joystick Press the horn button to sound the horn Throttle Control Dial NOTE The illustration shows a cab machine Canopy machines are similar Use the throttle control dial 1 to adjust engine speed Turn the dial clockwise to increase engine speed and counterclockwise to decrease engine speed MIN low idle Turn the throttle control dial fully counterclockwise MAX...

Page 48: ... will determine if the engine preheat cycle will begin The engine preheat cycle will initiate when the engine coolant temperature is below the preset value See Home Screen on page 3 34 When the preheat cycle is complete preheat icon not illuminated the starter motor can be engage to start the engine Release the key after the engine has started The key switch will return to ON The engine will conti...

Page 49: ...r Switch Cab Machine Fig 3 11 0002978 1 When it is raining or if the front windshield is dirty press the windshield wiper switch 1 to activate the windshield wiper The windshield wiper switch has two operating positions In the center position the windshield wiper operates at low speed in the rear position the windshield wiper operates at high speed NOTICE Before cleaning a dry windshield press the...

Page 50: ...anual 0120 SANY Work Light Switch Cab Machine Use the work light switch 1 to turn the work lights on and off There are two work lights on a cab machine One work light 2 on the boom One work light 3 on the cab roof Fig 3 12 0002978 1 Fig 3 13 0003860 2 Fig 3 14 0002980 3 ...

Page 51: ...TION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Work Light Switch Canopy Machine Fig 3 15 0003768 1 Use the work light switch 1 to turn the work lights on and off There are three work lights on a canopy machine One work light 2 is mounted on the boom Two work lights 3 and 4 are mounted on the top of the canopy Fig 3 16 0003860 2 Fig 3 17 0003149 3 4 ...

Page 52: ...d normally push in the emergency stop switch 1 Turn the switch as indicated to reset the switch NOTE The emergency stop switch should not be used if the machine is operating normally Cigarette Lighter 12V Cab Machine Fig 3 19 0002977 1 Press the cigarette lighter 1 in to activate the lighter The lighter will pop out when ready to be used With the lighter removed the power outlet 12V can be used to...

Page 53: ...T Power Outlet 12V Canopy Machine Fig 3 20 0003769 1 Lift the access cover 1 up to use the power outlet 12V 1 to charge or operate 12V electronic devices Dome Light Switch Cab Machine Fig 3 21 0002981 1 2 Use the dome light switch 1 to turn the dome light 2 on and off NOTE The switch is shown in the OFF up position The cab light can be turned on only when the key switch is in the ON or START posit...

Page 54: ...er page 3 15 7 Monitor page 3 33 2 Right joystick page 3 16 8 Right travel control pedal page 3 21 3 Left joystick page 3 16 9 Left travel control pedal page 3 21 4 Hydraulic lockout control lever page 3 19 10 Left footrest 5 Left travel control lever page 3 21 11 Right footrest 6 Right travel control lever page 3 21 12 Boom swing control pedal page 3 22 0004645 2 3 4 6 5 8 12 1 10 9 11 7 Fig 3 22...

Page 55: ...kward 3 to raise the dozer blade NOTE The dozer blade control lever returns to the neutral position when released Joystick Controls NOTE There are two operating modes available for the joystick controls The Society of Automotive Engineers SAE mode and the Backhoe Loader BHL mode The swing and bucket functions are the same for SAE and BHL modes NOTE The illustrations in this section show a cab mach...

Page 56: ...g the upper structure to the right 3 Arm in 4 Neutral N NOTE The joystick controls return to the neutral position automatically when released The functions of the machine will stop Right Joystick SAE Mode The SAE mode uses the right joystick to control the boom and bucket Bucket dig 1 Boom down 2 Bucket dump 3 Boom up 4 Neutral N NOTE The joystick controls return to the neutral position automatica...

Page 57: ...om and upper structure Swing the upper structure to the left 1 Boom down 2 Swing the upper structure to the right 3 Boom up 4 Neutral N NOTE The joystick controls return to the neutral position automatically when released The functions of the machine will stop Right Joystick BHL Mode The BHL mode uses the right joystick to control the arm and bucket Bucket dig 1 Arm out 2 Bucket dump 3 Arm in 4 Ne...

Page 58: ...n 5 Tighten the wing nut into the threaded hole 2 and tighten securely 6 Close the fuse access door and lock the door Return Flow Selector Valve The return flow selector valve 1 has a one way position 3 or a two way position 2 for operating optional equipment It is located on top of the hydraulic tank A variety of optional one way and two way flow equipment is available for use on this machine A h...

Page 59: ...wing and travel control and optional equipment Move the hydraulic lockout control lever to the locked closed position 2 to disable all hydraulic controls WARNING Always place the hydraulic lockout control lever in the locked closed position before leaving the seat Failure to follow this warning and unintended movement of the joysticks or travel control levers pedals could result in death or seriou...

Page 60: ... 1 on each of the track frames indicates forward movement of the machine Check these arrows before using the travel control levers pedals The drive sprocket is at the rear of the track frame If the track frame is facing backward the travel direction will be opposite the maneuvering direction of the travel control lever pedal The machine will move forward when you pull the control levers backward a...

Page 61: ... similar Use the travel control levers 3 or pedals 4 to change the machine s direction or travel Forward travel Push the control levers or pedals forward 1 Backward travel Pull the control levers or press pedals backward 2 Neutral position N The machine stops WARNING Take extra care when using the travel control pedals to steer the machine Never place your feet on the travel control pedals unless ...

Page 62: ... swing control pedal 2 Press the right side of the pedal to swing the boom right and press the left side of the pedal to swing the boom left Close the boom swing control pedal footrest 1 when boom swing operation is not used WARNING Do not place your foot on the boom swing control pedal except when using it for boom swing operation Failure to follow this warning could result in death or serious in...

Page 63: ...ning the Windshield 1 Before opening the front windshield park the machine on level ground lower the work equipment to the ground and stop the engine 2 Place the hydraulic lockout control lever 1 in the locked closed position CAUTION Avoid sudden movement of the machine or work equipment Always place the hydraulic lockout control lever in the locked closed position before opening the windshield Fa...

Page 64: ...milar Closing the Windshield 1 Before closing the windshield park the machine on level ground lower the work equipment to the ground and stop the engine 2 Move the hydraulic lockout control lever 1 to the locked closed position CAUTION When open the windshield must be secured to the roof of the cab If it is not secured the windshield may slide down unexpectedly and result in injury or machine dama...

Page 65: ... front windshield to engage the latches Lower Front Windshield 1 Raise the windshield to remove the lower front windshield 1 See Opening the Windshield on page 3 23 NOTE Sand or dust accumulated along the bottom of the lower front windshield and the seal may make it difficult to remove or install Make sure the bottom of the lower front windshield and the seal are clean before removing or installin...

Page 66: ...b Rotate to the left Decreases the temperature inside the cab 2 Air conditioning power switch Press and release Turns the air conditioning system on or off 3 Blower speed adjustment dial Rotate to the right 0 to 3 Increases the blower speed air volume output increases Rotate to the left 3 to 0 Decreases the blower speed air volume output decreases 4 Fresh air recirculation switch Press and release...

Page 67: ...r power button to turn on the air conditioning system The indicator light will illuminate Turn the temperature adjustment dial to the left to the desired position Heating mode Press the air conditioning power button to turn the air conditioning system off The indicator light will go out Turn the temperature adjustment dial to the right to the desired position 3 Turn the blower speed adjustment dia...

Page 68: ... the cab for operator comfort and windshield defrosting Windshield defrosting vent 1 Cab front vent 2 Cab rear vent 3 Cab Ventilation When the air conditioner is used for extended periods the fresh air recirculation switch should be switched to fresh air mode every hour to ventilate the cab 1 Fig 3 43 0003856 Fig 3 44 2 0003793 3 ...

Page 69: ...lay Press the AS PS button once more to remain on the current station Press and hold the AS PS button for 2 seconds to activate the auto programming feature In auto programming the six radio stations with the strongest signals are stored in the six preset buttons 1 6 AM FM Selector Button Press the AM FM selector button 2 to switch between AM1 AM2 FM1 FM2 and FM3 bands Each band can have six prese...

Page 70: ...utton to enter the time set screen The hour numbers will flash Press the tuning arrows 8 to set the desired hour To set the minutes press and release the TIME button again and the minute numbers will flash Press the tuning arrows to set the desired minutes Press and release the TIME button to leave the time set screen and return to time display for 5 seconds After 5 seconds the time display will r...

Page 71: ...e the battery from the electrical system when securing the machine for the day or as needed for maintenance NOTICE Never turn the battery disconnect switch to the OFF position while the engine is running This can damage the electrical system or cause the machine to operate improperly After machine shutdown wait at least 1 minute for the engine control module ECM to complete its shutdown before dis...

Page 72: ...ated on the rear pillar behind the seat of the cab The fire extinguisher must be at least a 2 5 lb Class ABC rated fire extinguisher National Fire Protection Association NFPA 10 Standard for Portable Fire Extinguishers NOTICE Always keep a fire extinguisher in the machine Read the instructions on the fire extinguisher carefully and know how to use it in an emergency Inspect the fire extinguisher d...

Page 73: ...nitor displays the Daily Maintenance Information screen The checklist steps 1 7 should be completed before starting the machine See Prestart Checks and Adjustments on page 4 5 1 Start the engine and idle until operating temperature is reached See Starting the Engine on page 4 16 2 Press the button below the check mark icon 1 to confirm all checks and procedures have been completed The display will...

Page 74: ...on page 3 34 2 Press the button below the pause icon 1 to pause or continue the display of maintenance information screens 3 Press the button below the check mark icon 2 to confirm the completion of the maintenance work displayed on the screen When prompted to reset the maintenance icon on the home screen enter the password 53188 to clear the maintenance prompt NOTE To return to the previous scree...

Page 75: ...n the coolant temperature is high the icon appears as a warning 11 Function list folder icon Press the button below the icon to access the function list screen See Function List Screen on page 3 36 12 High Low travel speed icon Press the button below the icon to select high low travel speed 13 Auto idle icon Press the button below the icon to enable or disable the auto idle function 14 Work mode i...

Page 76: ... work equipment and corresponding hydraulic flow control Quick Coupler Control Not equipped Time calibration Correct the year month day time and time zone System unlocked Factory and service only Reserved function Not used at this time Reserved for future function NOTE Access to some screens requires a password 1 Press the button below the left right arrow icon 1 to scroll to and illuminate the se...

Page 77: ...003812 2 1 3 4 Access to the Main Menu screen requires entering the password 31868 on the System Information screen 1 Press the button below the up down arrow icon 1 to scroll to the desired number 2 Press the button below the left right arrow icon 2 to move to the next number position 3 Press the button below the check mark icon 3 to confirm the selected icon NOTE To return to the previous screen...

Page 78: ...ed at this time in North America Language Selection Select the language that displays information on all screens Maintain Table Displays when the machine is due for maintenance If maintenance is not due the Maintain Table screen will not open The Maintain Table screen is also used to reset the service timer NOTE Access to some screens requires a password 1 Press the button below the left right arr...

Page 79: ...and load sense pressure with the engine running Press the button below the up down arrow icon 1 to scroll to the next pages NOTE To return to the Main Menu screen press the button below the return icon 2 Switch Signals Screen The Switch Signals screen enables the operator to monitor the input and output of switch functions Press the button below the up down arrow icon 1 to scroll to the next pages...

Page 80: ...e next pages NOTE To return to the Main Menu screen press the button below the return icon 2 Machine Configuration Screen Fig 3 59 0004624 1 Access the Machine Configuration screen from the Main Menu screen The Machine Configuration screen displays machine information such as model number serial number and control system information NOTE To return to the previous screen press the button below the ...

Page 81: ...he failure code will be displayed on the home screen The Failure Information screen displays failure codes recorded by the machine SPN and FMI codes are engine diagnostic failure codes Contact a SANY dealer for troubleshooting information NOTE To return to the previous screen press the button below the return icon 1 Global Positioning System GPS Information Screen Fig 3 61 0003821 1 The GPS Inform...

Page 82: ...all display screens To change the language setting 1 Press the button below the up down arrow icon 1 to select the desired language 2 Press the button below the check mark icon 2 to confirm the selected language NOTE To return to the previous screen press the button below the return icon 3 Maintain Table Screen Displays when the machine is due for maintenance If maintenance is not due the Maintain...

Page 83: ...ic work tool icon prior to operating it Bucket default 1 Breaker 2 Clamshell bucket 3 Tilt bucket 4 Auger 5 Rotary grapple 6 Grapple 7 Brush cutter 8 NOTE Check the work tool operator manual or contact a SANY dealer for hydraulic flow rate information 1 Press the button below the left right arrow icon 9 to scroll to and illuminate the selected work tool icon 2 Press the button below the informatio...

Page 84: ...ck left button and LR left joystick right button 2 settings are for the left joystick low pressure low flow circuit 1 Press the button below the up down arrow icon 3 to select the hydraulic flow rate to adjust 2 Press the button below the gear icon 4 to access the Flow Rate Setting screen 3 Press the button below the check mark icon 5 to display a service screen that is password protected NOTE To ...

Page 85: ...l the flow rate is at its maximum 100 When the bar graph has been set to its lowest level no bar is visible the flow is blocked and no hydraulic oil will flow Flow rate of the selected function in the Flow Rate Information screen can be adjusted in the bar graphic in the Flow Rate Setting screen 1 Press the button below the plus icon 2 to increase the length of the bar graph which will increase th...

Page 86: ...e date time and time zone 1 Press the button below the up down icon 1 to increase the value of the selected position 2 Press the button below the left right icon 2 to select the position for adjustment 3 Press the button below the check mark icon 3 to confirm the time adjustment NOTE To return to the previous screen press the button below the return icon 4 System Unlocked Screen For factory and se...

Page 87: ...clogged with soot 1 Park in a safe location where the exhaust pipe will not face any combustible surface prepare the machine for service See Maintenance Safety on page 2 8 2 Start the engine See Starting the Engine on page 4 16 3 Move the hydraulic lockout control lever to the locked closed position and run the engine at low idle WARNING The exhaust temperature during DPF regeneration can reach ap...

Page 88: ...rocess NOTE After the stationary regeneration process begins the failure lamp 6 and the amber warning lamp 7 turn off and simultaneously the DPF Regen Req lamp message 3 and the DPF Regen Ack lamp 4 message will flash The DPF Regen Req lamp message will go out and the DPF Regen Ack lamp message and exhaust gas temperature lamp message 5 will illuminate steadily NOTE A DPF regeneration in progress ...

Page 89: ...ck 4 8 Add Fuel 4 8 Fuel Tank Filler Cap 4 9 Check and Drain the Primary Fuel Filter Water Separator 4 10 Check the Hydraulic Oil Level 4 11 Windshield Washer Fluid Check and Fill 4 11 Electrical Components Check 4 12 Horn Function Check 4 12 Seat and Seat Belt 4 13 Seat Position Adjustment 4 13 Seat Backrest Adjustment 4 13 Seat Weight Suspension Adjustment 4 13 Seat Belt 4 13 Buckle the Seat Bel...

Page 90: ...0 Never Operate with Bucket Force 4 30 Never Use Swing Force 4 31 Never Use Traveling Force 4 31 Never Operate Using Machine Weight 4 32 Do Not Operate a Cylinder at the Stroke End 4 32 Avoid Dozer Blade Impact 4 33 Avoid Shifting Travel Directions Suddenly 4 33 Support the Dozer Blade 4 33 Excavating Hard Ground 4 33 Travel 4 34 General Travel Instructions 4 34 Traveling at High Speed 4 35 Operat...

Page 91: ...y in Cold Weather 4 47 Track Cleaning in Cold Weather 4 47 After Daily Operation 4 48 Machine Storage in Cold Weather 4 48 After Cold Season 4 48 Long Term Storage 4 49 Before Long Term Storage 4 49 During Storage 4 49 Air Conditioner Storage 4 50 Removing from Storage 4 50 Starting the Engine After Long Term Storage 4 50 Transportation Information 4 51 Transportation Method 4 51 Loading and Unloa...

Page 92: ... perform the following Reject the job site if there are doubts regarding safety Become familiar with the work area and surroundings before beginning work Read and completely understand the instructions in this manual prior to operation Know and obey all operating procedures applicable laws and regulations Know and follow the requirements for safe operation Know and use the required safety precauti...

Page 93: ...aler Inspect the engine compartment for combustible debris that may come in contact with hot engine components Clear all debris from the engine and engine compartment Check the undercarriage tracks sprockets rollers and guards for damage wear loose fasteners and oil leaks If repairs are needed contact a SANY dealer Check the bucket or optional equipment for damage Lubricate work equipment as neces...

Page 94: ...the engine coolant is at the FULL mark 3 Install the filler cap after refilling WARNING Engine coolant is toxic Avoid inhaling or ingesting engine coolant If eyes or skin are contaminated by coolant wash the affected area with plenty of water and seek medical treatment immediately Engine coolant is under pressure when the engine is hot Avoid contact with hot engine coolant Allow the engine to cool...

Page 95: ...il through the filler port 3 until the oil level is at the upper mark of the dipstick 2 Always use SANY approved engine oil See Recommended Lubricants Fuels and Engine Coolant on page 5 10 6 Install the dipstick NOTE If the oil level is above the upper mark on the dipstick drain the excess oil See Change the Engine Oil and Filter on page 5 33 WARNING Hot oil and engine components may cause burns o...

Page 96: ...nk Filler Cap on page 4 9 2 Fill the machine with clean diesel fuel as necessary WARNING Fuel or fuel vapors that come into contact with hot surfaces or electrical components can cause a fire Never service the fuel system near an open flame or while smoking Clean up spilled fuel immediately Failure to follow these warnings could result in death or serious injury NOTICE Contaminated fuel can cause ...

Page 97: ...nstall the fuel filler cap after refueling Fuel Tank Filler Cap 1 To remove the filler cap 1 turn it counterclockwise 2 To install the filler cap place the cap on the filler neck and turn it clockwise NOTICE To prevent damage to the fuel filler cap Make sure the O ring on the fuel filler cap is clean If the O ring is contaminated by dirt or debris the O ring could be damaged and not seal improperl...

Page 98: ... hose 2 into a suitable container 4 Open the drain valve 1 and drain the water and sediment 5 When only clean fuel flows through the drain valve close and tighten the valve 6 Start the engine and check for leaks WARNING Fuel or fuel vapors that come into contact with hot surfaces or electrical components can cause a fire Never service the fuel system near an open flame or while smoking Clean up sp...

Page 99: ...il level in the hydraulic tank through the sight gauge 2 The hydraulic oil level should be between the H 3 and L marks 4 4 If the level is below the L mark add hydraulic oil See Add Hydraulic Oil on page 5 57 Windshield Washer Fluid Check and Fill Fig 4 10 0003781 1 Prepare the machine for service See Maintenance Safety on page 2 8 Check the windshield washer fluid level in the windshield washer r...

Page 100: ...about faults in the electrical system contact a SANY dealer Horn Function Check 1 Turn the key switch to ON 2 The horn sounds when the horn button 1 on the right joystick is pressed If the horn does not sound check the horn fuse See Fuses on page 5 28 NOTICE If fuses fail frequently the wiring harness must be inspected for broken or damaged wire insulation or a component placing a high electrical ...

Page 101: ...backward Seat Weight Suspension Adjustment Use the seat weight adjustment lever 3 to select from one of three weight levels that are indicated on the seat weight adjustment lever light medium or heavy The seat will lock in the next position each time the lever is pressed down and released Seat Belt NOTE A recoil assembly 4 is attached to the seat belt It removes slack from the seat belt and locks ...

Page 102: ... the seat belt to make sure the seat belt is securely fastened Unbuckle the Seat Belt Press the red button on the buckle 3 to release the latch plate WARNING Keep belt slack to no more than 1 in 25 mm Belt slack beyond this amount could significantly reduce your protection in an accident Failure to follow this warning could result in death or serious injury WARNING Contact a SANY dealer if the sea...

Page 103: ... this section show a cab machine Canopy machines are similar 1 Loosen the fasteners 1 that secure the mirror 2 to the arm and rail 2 Adjust the mirror for the best visibility to the rear of the machine and tighten the fasteners ANTENNA The antenna receives radio signals For best reception keep the antenna in a vertical position When transporting or parking the machine in a building loosen the wing...

Page 104: ...eely and return to the neutral position when released WARNING Before starting the engine or leaving the operator seat make sure the hydraulic lockout control lever is in the locked closed position If the hydraulic system is not locked unintentional machine operation may occur Confirm that the surrounding area is clear of personnel and obstructions and sound the horn before starting the engine Alwa...

Page 105: ...is turned to ON 9 Sound the horn to warn personnel that the machine is being started See Horn Function Check on page 4 12 10 Turn the key switch to START and the starter motor will crank the engine Release the key after the engine has started and the key switch will return to ON NOTICE Before starting the engine make sure that the throttle control dial is at MIN low idle Starting the engine with t...

Page 106: ...If the hydraulic system is not locked unintentional machine operation may occur Confirm that the surrounding area is clear of personnel and obstructions and sound the horn before starting the engine Always start the engine from the operator seat Never start the engine by shorting the starter solenoid or starter relay Never use ether starting fluid to start the engine Ether is highly flammable and ...

Page 107: ...chine warm up 1 Deactivate the auto idle mode after starting the engine and adjust the throttle so the engine runs unloaded at 1400 rpm for 5 minutes 2 Adjust the throttle so the engine runs at 1600 rpm then slowly operate the bucket for 5 minutes 3 Adjust the throttle so the engine runs at max rpm then operate the boom arm and bucket five to ten times Repeat all movements several times Check the ...

Page 108: ...s Work in a well ventilated area If battery acid contacts your skin or eyes flush the area immediately with fresh water and seek medical attention Always jump start the engine with equal voltages The starting system voltage and the battery voltage in the boosting machine should be no more than 12V Never use a welder or equipment with a higher voltage system to jump start the machine Using a higher...

Page 109: ...al or an unpainted part of the structure of the machine with the drained battery 7 Start the engine of the machine with the charged battery and run it at medium speed 8 Attempt to start the engine of the machine with the drained battery Retry every 3 minutes if the engine will not start NOTE Contact a SANY dealer if the engine will not start after five attempts 9 Disconnect the jumper cables from ...

Page 110: ...n at low idle until it reaches proper operating temperatures Do not move the controls or the throttle 2 Avoid operating the machine under heavy loads or at high speeds during the break in period Operate as much as possible in the 1 2 to 3 4 throttle range Do not operate this machine with a full load during the break in period 3 Avoid sudden starts movements or stops 4 Monitor the instruments frequ...

Page 111: ...ttle control dial 1 to MIN low idle position and allow the engine to idle for 5 minutes to cool down 4 Turn the key switch 2 to the OFF position and remove the key Pull the hydraulic lockout control lever 3 back to the locked closed position NOTICE Stopping the engine before it cools can accelerate engine component wear Never abruptly shut down the engine except in an emergency Never stop the engi...

Page 112: ...neuvering direction of the travel control lever pedal The machine will move forward when you pull the control levers backward and backward when you push them forward Left and right control directions are also reversed when the track frame faces backward Auto Idle Function The auto idle function automatically activates when the engine is started and acts to reduce fuel consumption and noise levels ...

Page 113: ...achine without operator approval If the travel motors are in the front of the machine the travel control pedals will operate in reverse Check the position of the travel direction arrows on the track frame before traveling The rear of the machine is a blind area Use the mirror and be extremely careful when backing up the machine Use a signalman as needed Failure to follow these warnings could resul...

Page 114: ...the left travel control lever 2 in the neutral position to turn the machine to the left Spot Turning Fig 4 25 0002838 Simultaneously push one travel control lever forward and pull the other travel control lever backward or press the top of one travel pedal and the bottom of the other to rotate the machine without traveling Stopping the Machine N Fig 4 26 0002839 Slowly move the travel control leve...

Page 115: ...wo operating modes available for the joystick controls the Society of Automotive Engineers SAE mode and the Backhoe Loader BHL mode The swing and bucket functions are the same for the SAE and BHL modes Arm Control SAE Mode Fig 4 27 0002840 To extend the arm push the left joystick To retract the arm pull the left joystick Arm Control BHL Mode Fig 4 28 0003057 To extend the arm push the right joysti...

Page 116: ... machine to the left move the right joystick to the left Bucket Control SAE BHL Mode Fig 4 32 0002843 To uncurl the bucket move the right joystick to the right To curl the bucket move the right joystick to the left Boom Swing Pedal Fig 4 33 0003793 The boom swing control pedal is mounted on the cab floor to the right of the travel controls The boom swing control pedal swings the boom to the right ...

Page 117: ...CHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Dozer Blade Control Lever NOTE Illustration shows a cab machine Canopy machines are similar Push the dozer blade control lever 1 forward to lower the dozer blade Pull the dozer blade control lever backward to raise the dozer blade Fig 4 34 0003063 1 ...

Page 118: ...compact the ground WARNING Use caution when operating work equipment while the machine is traveling When the engine auto idle is on moving any control lever will increase the engine speed Do not operate the machine on any ground that lacks sufficient support Do not attempt work operations with the hydraulic cylinder fully extended When the machine is traveling keep the bucket 8 in to 12 in 20 cm t...

Page 119: ...IONAL EQUIPMENT Never Use Swing Force Fig 4 37 0002846 Never use swing force to compact the ground or to break objects Such operation is very dangerous and may reduce the service life of the machine Never Use Traveling Force Fig 4 38 0002864 Never use the machine s traveling force to cut the bucket into the ground to excavate Such an operation may damage the machine or the work equipment ...

Page 120: ...of the machine to use the machine s weight to excavate Operating while using the machine s weight may damage the machine Do Not Operate a Cylinder at the Stroke End Fig 4 40 0002848 Avoid operating the machine with any cylinder fully retracted or extended NOTE If a cylinder piston reaches its end of stroke continued use of the work equipment could damage the cylinder ...

Page 121: ...inder Avoid Shifting Travel Directions Suddenly Never jerk the control levers Jerking the control levers can cause travel motor strain and shorten the service life Avoid moving the control levers quickly from forward travel to reverse travel Avoid moving the control levers quickly from high speed to neutral Support the Dozer Blade Fig 4 43 0002876 When the dozer blade is used as a stabilizer never...

Page 122: ...ight line If possible turn the machine slowly and gradually Never let the machine make contact with power lines or bridges 2 WARNING Check the surroundings and sound the horn before moving the machine Personnel are not allowed to approach the machine without operator approval If the travel motors are in the front of the machine the travel control pedals will operate in reverse Check the position o...

Page 123: ...even ground A lower speed reduces the possibility of machine damage Do not operate the machine on a surface covered by small stones that could cause track skidding or damage Avoid premature track wear or damage Do not operate the machine on new asphalt or other hot surfaces Do not allow fuels oils salt or chemical solvents to make contact with the tracks These substances will erode the track links...

Page 124: ...ear and swivel do not become submerged in water NOTE If the swing bearing swing drive gear or swivel have been submerged in water they must be cleaned Lubricate the swing drive gear and swing bearing NOTICE Operate the machine slowly when traveling through water Check the depth of the water with the bucket Do not operate the machine in a marine environment Salt in seawater can damage the track lin...

Page 125: ... direction and 8 in to 12 in 20 cm to 30 cm off the ground Travel at low speed Do not attempt to change direction on a slope or the machine may slip and tip over Only perform a direction change on an even and solid surface If the engine stalls on a slope see Engine Stalls on an Incline on page 4 39 Before traveling up a steep slope allow the machine to warm up sufficiently so it can perform proper...

Page 126: ...machine can be operated on a level surface When traveling down a grade greater than 15 the work equipment should be positioned in front of the cab with the travel motors 3 at the rear of the machine Keep the boom arm angle 4 between 90 and 110 and the bucket 5 8 in 12 in 20 cm 30 cm above the ground When traveling up a grade greater than 15 the work equipment should be positioned with the travel m...

Page 127: ...raveling uphill keep the travel motors 10 at the rear of the machine When traveling downhill keep the bucket in the traveling direction and 8 in to 12 in 20 cm to 30 cm above the ground 11 Lower the bucket immediately if the machine slips or loses balance Engine Stalls on an Incline If the engine stalls when the machine is on an incline lower the bucket to the ground immediately move all control l...

Page 128: ...emove mud buildup by rotating the lifted track backward and forward 5 Raise the boom to lower the track to the ground Removing a Stuck Machine Be careful when operating on soft terrain to avoid becoming stuck If your machine becomes stuck in soft terrain perform the following procedure to free the machine One Track Stuck NOTICE Rugged terrain could cause damage to track components Wide track shoes...

Page 129: ...en 90 and 110 2 Pivot the upper structure to position the boom over the front the machine 3 Curl the bucket so the bottom of the bucket touches the ground 4 Lower the boom to raise the front of the tracks 5 Place cribbing under the tracks to provide a firm surface if necessary 6 Raise the boom to lower the tracks onto the cribbing 7 Cut the bucket into the ground in front of the machine Retract th...

Page 130: ...ing the machine has the correct capacity rating Never use a broken chain worn wire rope or a bent hook to tow the machine Never jerk the wire rope Failure to follow these warnings could result in death or serious injury NOTICE Make sure the equipment used for towing has the correct capacity rating A shackle must be used Keep the wire ropes slings horizontal and parallel to the tracks Drive the mac...

Page 131: ...all personnel keep clear of these areas to prevent injury To prevent injuries avoid moving any travel control lever or pedal to abruptly change the direction of the machine Avoid stopping the machine suddenly by releasing the travel control lever or pedal while traveling at high speed Failure to follow these warnings could result in death or serious injury NOTICE Avoid sudden stops when lowering t...

Page 132: ...ture Fig 4 59 0002917 The boom swing feature allows this excavator to perform trench work close to a wall Vehicle Loading Fig 4 60 0002919 To increase efficiency load the dump truck from behind instead of from the side Leveling Operation Fig 4 61 0002921 1 Choose the light load mode when performing a leveling operation Roll the bucket out and hold it slightly ahead of the arm 2 Raise the boom slow...

Page 133: ... a hard and level surface When working in a ditch or on a road shoulder keep the tracks perpendicular to the work face and the travel motors at the rear of the machine Placing the machine in this position helps facilitate escape if a collapse occurs When working under a cliff or high embankment make sure the work area is secure Failure to follow these warnings could result in death or serious inju...

Page 134: ... battery disconnect switch to OFF 8 Close and lock all doors Parking the Machine on a Grade If it is necessary to park the machine on a grade 1 Face the machine uphill 2 Firmly set the bucket teeth and dozer blade into the ground 3 Move the hydraulic lockout control lever to the locked closed position 4 Turn the key switch to OFF and remove the key 5 Turn the battery disconnect switch to OFF 6 Clo...

Page 135: ...s swing the upper structure 90 and raise the machine so that one track is off the ground Rotate the track forward and backward to remove the mud from the sprocket track rollers and idlers Repeat for the other side WARNING Before proceeding with any battery maintenance procedure observe the following precautions The top of the battery must be kept clean to prevent plugging of the battery vents Regu...

Page 136: ...hange the fuel hydraulic oil and gear oil with new fluids that meet the air temperature requirements as necessary 3 Check the machine for leaks Check all cylinder rods for scratches and corrosion Apply grease to exposed cylinder rods 4 Remove and charge the battery When the battery is fully charged store it indoors 5 Clean the battery terminals as necessary Apply a coat of dielectric grease to the...

Page 137: ... the negative battery cable or remove the battery and store it 7 If the ambient temperature is expected to drop below 32 F 0 C check the engine coolant mixture ratios and add concentrated engine coolant to the cooling system if necessary 8 Place the hydraulic lockout control lever in the locked closed position 9 Close and lock all doors During Storage During the storage period operate the machine ...

Page 138: ...ll parts or components Check fluid levels Drain the water and sediment from the fuel water separator See Check and Drain the Primary Fuel Filter Water Separator on page 4 10 Starting the Engine After Long Term Storage NOTE The illustration shows a cab machine Canopy machines are similar 1 Insert the key and turn the key switch 1 to ON 2 Turn the throttle control dial 2 to the MAX high idle positio...

Page 139: ...t a firm and level location that is a safe distance from any road or structure Make sure the trailer is properly chocked to prevent any movement Use an access ramp with enough length strength and width to properly support the machine The ramp grade should not exceed 15 Drive slowly at the junction of the ramp and the trailer The machine may shift suddenly due to a change in its center of gravity U...

Page 140: ...hange direction on the access ramp If repositioning the machine is necessary back up re orient the machine and drive up or down the ramps Use care when driving over the joints 2 between the trailer and the ramps Never operate any control levers other than the travel levers when the machine is on a ramp Clean the landing platform ramps and trailer floor before loading or unloading Loading the Machi...

Page 141: ... up the ramps The ramp grade should not exceed 15 1 Use the following procedures during loading 1 Align the centerline of the machine with that of the trailer 2 Slowly drive the machine up the ramps 3 When the machine tilts toward the trailer side lower the bucket close to the trailer floor Drive slowly until the tracks are completely on the trailer 4 Slightly raise the bucket Retract the arm and ...

Page 142: ...ion 9 Turn the key to OFF and remove it from the key switch 10 Close the cab window and door 11 Turn the battery disconnect switch to OFF 12 Lock all doors and the engine hood 13 Cover the exhaust opening to prevent contamination NOTICE Never turn the battery disconnect switch to OFF while the engine is running This can damage the electrical system or cause the machine to operate improperly After ...

Page 143: ...sure to secure the machine firmly in place to prevent it from sliding NOTICE To prevent damage to the machine during transportation Lower the radio antenna and position the mirror inward towards the cab Secure any removed parts to the trailer Put a wood block between the bucket cylinder and the trailer floor to help prevent damage to the bucket cylinder Secure chains and wire ropes to the machine ...

Page 144: ...4 Start the engine 5 Push the hydraulic lockout control lever to the unlocked open position 6 Raise the work equipment and retract the arm toward the boom Drive the machine slowly 7 Stop the machine when it travels over the rear wheels of the trailer and toward the ramps NOTICE To avoid damage to the machine during unloading Use extreme care when the machine drives over the joint area between the ...

Page 145: ... the ramps 9 Operate the boom and the arm slowly when the machine is on the ramps Allow the machine to descend slowly until it comes in contact with the ground NOTICE Use extreme care when the machine drives over the joint area between the trailer and the ramps Avoid damage caused by unexpected movement of the work equipment Maintain the boom arm between an angle of 90 and 110 Avoid unloading the ...

Page 146: ...t contamination 7 Use wire ropes and a spreader bar that have adequate length to keep the machine free from damage 8 Lift the machine 10 in 12 in 25 cm 30 cm and check its balance If it is not balanced lower the machine to the ground and adjust the boom or dozer blade positions WARNING Make sure all lifting devices are in safe operating condition and with sufficient capacity rating to safely suppo...

Page 147: ...n 5 6 Installation of Hydraulic Hoses 5 6 Securing Access Covers and Compartment Doors 5 6 Cleaning the Machine 5 7 Weld Drill Cut or Grind on the Machine 5 7 Inspection and Maintenance in Adverse Environments 5 7 Mud Rain or Snow Conditions 5 7 Near Ocean Salt Air Environments 5 7 Dusty Environments 5 8 Cold Environments 5 8 Other Weather Environments 5 8 Check the Maintenance Log 5 8 Daily Inspe...

Page 148: ...ing the Engine Hood 5 25 Closing the Engine Hood 5 25 Right Rear Access Door 5 26 Opening the Right Rear Access Door 5 26 Closing the Right Rear Access Door 5 26 Right Front Access Door 5 26 Unlocking Opening the Right Front Access Door 5 26 Closing Locking the Right Front Access Door 5 27 Fuse Access Door 5 27 Unlocking Opening the Fuse Access Door 5 27 Closing Locking the Fuse Access Door 5 27 F...

Page 149: ...ediment 5 46 Replace the Secondary Fuel Filter 5 48 Replace the Primary Fuel Filter Water Separator Element 5 49 Check the Fuel Tank Strainer 5 51 Check the Fuel Lines 5 52 Battery 5 52 Check the Battery 5 52 Remove the Battery 5 54 Hydraulic System 5 56 Check the Accumulator Function 5 56 Relieve Hydraulic System Pressure 5 56 Check Hydraulic Oil Level 5 56 Add Hydraulic Oil 5 57 Replace the Hydr...

Page 150: ...Cylinder Rod End Pin 5 78 Bucket Linkage Pins 5 78 Bucket Cylinder Rod End Pin 5 79 Bucket Cylinder Base End Pin 5 79 Boom Swing Cylinder Rod End Pin 5 79 Boom Swing Cylinder Base End Pin 5 80 Boom Swing Pin 5 80 Swing Bearing 5 80 Swing Pinion Gear 5 81 Bucket 5 82 Replace the Bucket Teeth 5 82 Replace the Bucket 5 83 Check the Sheet Metal 5 83 Check Component Operating Functions 5 84 Check the O...

Page 151: ...red Always use the proper tools when performing any maintenance procedures Checks After Maintenance or Repairs Before starting the machine after maintenance or repairs verify the following If necessary have a coworker inspect your work for correct and proper completion Complete the Maintenance Log Check for leaks in the system that had maintenance or repairs Verify there are no abnormal sounds com...

Page 152: ...k strainer does not filter out very small or non solid impurities Preventing Contamination Clean dirt dust and debris from the hydraulic tank filler cap or cover before opening Make sure objects do not fall into the tank and contaminate fluids during servicing If any object falls into any tank remove it immediately Failure to do so could result in component malfunction damage to the machine or imp...

Page 153: ... operating the machine inspect each connector for looseness After operating the machine clean the machine and inspect for missing or loose fasteners Add oil and lubricating grease as needed Near Ocean Salt Air Environments Before operating the machine inspect for any signs of corrosion Apply grease where rust is found After operating the machine thoroughly wash away the salt residue apply grease w...

Page 154: ...ttery case and the cables have not cracked Other Weather Environments NOTE If there is evidence of overheating of bearings or bushings loose parts or rust during regular inspection increase the frequency of lubrication Based on experience and suggestions by lubricating oil suppliers the lubricating intervals listed in the Maintenance Schedule on page 5 14 apply only to normal operating conditions ...

Page 155: ...s for smooth operation and make sure they return to the neutral position Make sure all safety decals are in place and are legible Make sure safety equipment is in place and in operating condition Check for fluid leaks Check the following during operation with the engine running Monitor the control panel for normal machine operating parameters Make sure that the machine operates normally Check for ...

Page 156: ...ent Temperature 22 F 4 F 5 F 32 F 50 F 68 F 86 F 104 F 122 F 30 C 20 C 15 C 0 C 10 C 20 C 30 C 40 C 50 C Engine Yanmar 3TNV88F Engine oil SAE 40W SAE 5W 40 SAE 5W 30 SAE 10W 30 SAE 15W 40 Swing machinery case Idler Final drive Gear oil SAE 30 SAE 15W 40 Hydraulic system Hydraulic oil SAE 10W SAE 10W 30 SAE 15W 40 ISO VG32 ISO VG46 ISO VG68 Fuel tank Diesel fuel ASTM D 975 No 2 GB252 Super 20 diese...

Page 157: ...e hydraulic oil Replace hydraulic oil that has been subjected to overheating or damaged components Change the hydraulic oil filter as recommended Keep the hydraulic oil tank filled to the full level Keep the oil cooler free of dust and debris Cap and plug all openings after removing components for service or repair Lubrication and Grease Always use clean extreme pressure EP grease when greasing th...

Page 158: ...n the fuel system If fuel waxing or bacterial growth occurs in the fuel system contact a SANY dealer Make sure that there is no water or foreign material in the fuel Take appropriate precautions to prevent fuel contamination during refueling WARNING Fuel or fuel vapors that come into contact with hot surfaces or electrical components can cause a fire Never service the fuel system near an open flam...

Page 159: ...m open fire If the engine is overheating wait for the engine to cool before refilling the engine coolant Other Approved Lubricants Approved lubricants include Any anaerobic sealant thread locking compound having properties that offer high temperature performance and oil tolerance to prevent the loosening of fasteners Any lithium grease based spray lubricant Mineral spirits Type II odorless and or ...

Page 160: ...estriction indicator See page 5 36 Check the windshield washer fluid See page 4 11 Check the track tension See page 5 67 Replace the bucket teeth See page 5 82 Replace the bucket See page 5 83 Drain the water and sediment from the fuel tank See page 5 46 Daily or Every 10 Hours Lubricate the work equipment See page 5 75 Drain the primary fuel filter water separator See page 4 10 Check for fluid le...

Page 161: ...d locks on cab machines See page 5 23 Check the mirrors See page 4 15 Check the electrical system See page 4 12 Check the fuel level See page 4 8 Check component operating functions See page 5 84 Check the air conditioner on cab machines See page 3 27 Check the Operation and Maintenance Manual See page 5 86 After the First 50 Hours Initial change of the engine oil and filter See page 5 33 Weekly o...

Page 162: ...hood See page 5 21 Check the track tension See page 5 67 Check the track assembly See page 5 67 Check the fuses See page 5 28 Initial change of the final drive oil See page 5 73 With a breaker operating above 50 replace the hydraulic oil return filter See page 5 60 Otherwise see Hydraulic Breaker Maintenance Interval on page 5 18 Clean replace ventilation filter screen on cab machines See page 5 4...

Page 163: ...e 5 74 Every 6 Months or 1000 Hours Make sure all daily 50 hour 250 hour and 500 hour maintenance tasks have been completed before proceeding with the 1000 hour maintenance tasks Check the exhaust system mounting hardware See page 5 37 Check the fuel tank strainer See page 5 51 Check the fuel lines See page 5 52 Check the accumulator function See page 5 56 Change the engine coolant See page 5 39 R...

Page 164: ... the completion of all of the maintenance tasks in the Maintenance Log If authorized remove all lockout tagout warnings and machine securing elements and fully activate the machine Return the machine to operation Hydraulic Breaker Maintenance Interval Hydraulic oil breaks down faster on machines equipped with a hydraulic breaker than on machines equipped with a bucket Follow the steps below to set...

Page 165: ...ion will lead to excessive wear and damage to components Engine oil is critical for engine operation Never use lubricants that are not SANY approved Clean grease fittings before applying grease Use a grease gun to pump grease into the fitting until old grease begins to escape Clean off any grease that has escaped Shown below are the lubrication points that must be maintained according to the lubri...

Page 166: ...r pins 2 Grease 2 Boom arm connecting pin 1 3 Boom pin 2 4 Swing bearing 2 5 Dozer blade linkage pins 2 6 Dozer blade cylinder pins 2 7 Boom cylinder pins 2 8 Bucket linkage pins 3 9 Bucket cylinder pins 4 10 Boom swing cylinder pins 2 11 Swing gear 1 12 Boom swing pin 2 Replacement Item Intervals Replacement Items When Required 10 hr 50 hr 100 hr 250 hr 500 hr 1000 hr 2000 hr Engine oil and filte...

Page 167: ... 3 0003786 1 An accessory light 12V outlet 1 is located in the engine compartment and is used for operating an accessory light DOORS WINDSHIELD AND HOOD NOTE Illustrations show a cab machine Canopy machines are similar for non cab related items The following can be locked using the machine key to prevent unauthorized access Fuel tank filler cap See Fuel Tank Filler Cap on page 4 9 Cab door 1 Engin...

Page 168: ...aintenance SY35U Excavator OMM 5 22 Operation and Maintenance Manual 0120 SANY Right rear access door 3 Right front access door 4 Fuse access door 5 Fig 5 5 0003770 3 Fig 5 6 0002991 4 Fig 5 7 0004629 5 ...

Page 169: ...g the cab door latch 1 Pull the door handle 2 to open and push the cab door open until the catch 3 engages the latch 4 2 To release the cab door from the catch push down on the release lever 5 on the left side of the operator seat Inspect and Lubricate the Cab Door Fig 5 10 0004630 1 1 Check the body 1 of the cab door lock for loose or damaged components Make sure the cab door closes tightly and l...

Page 170: ...door hinges 3 until grease comes out of the hinges Wipe off excess grease Windshield Inspect the Windshield Mechanisms Fig 5 13 0003194 5 4 6 1 Check the windshield latches 4 linkages 5 and struts 6 inside the cab for loose or damaged components 2 Make sure the windshield closes tightly and latches securely NOTE The left side is shown The right side is similar Fig 5 11 0003193 2 Fig 5 12 0003195 3...

Page 171: ...4 0002992 2 1 1 Insert the key into the lock 1 and turn the key clockwise to unlock the hood 2 2 Press the lock button to release the latch and open the engine hood Closing the Engine Hood Fig 5 15 0003770 1 2 3 1 Close the right rear access 2 door before closing the engine hood 1 2 Close the engine hood and make sure it is firmly seated in the latch 3 3 Insert the key into the lock and turn count...

Page 172: ...support rod 4 into a slot on door bracket 3 Closing the Right Rear Access Door Move the support rod 4 out of the door bracket 3 and close the door There is no latch The door is secured by the engine hood Right Front Access Door Unlocking Opening the Right Front Access Door 1 Insert the key into the right front access door lock 1 NOTE Insert the key all the way into the lock The key may break if tu...

Page 173: ...o lock Remove the key Fuse Access Door NOTE The illustration shows a cab machine Canopy machines are similar Unlocking Opening the Fuse Access Door Fig 5 19 0004629 1 2 1 Insert the key into the fuse access door lock 2 NOTE Insert the key all the way into the lock The key may break if turned before it is fully inserted 2 Turn the key clockwise to unlock the fuse access door 1 Remove the key and lo...

Page 174: ...Fuse Access Door on page 5 27 3 Remove the transparent fuse cover 3 by gently pulling out on the bottom of one of the four latches 4 while lifting up the adjacent corner of the cover Repeat for the other three tabs to release the cover NOTICE A fuse should be replaced if it is blown corroded or becomes loose in the fuse block Before replacing a fuse make sure the key switch is in the OFF position ...

Page 175: ...ntact a SANY dealer for troubleshooting electrical problems with the machine Fuse Amperage Circuit F1 25A Starting F2 10A Battery charging F3 15A Cab dome light horn and accessory light F4 25A Work light F5 15A Washer beacon wiper and radio F6 5A HVAC control panel F7 10A Global positioning system GPS F8 20A HVAC system fan F9 10A Power outlet 12V F10 10A AC compressor F11 25A Monitor controller F...

Page 176: ...the engine hood See Opening the Engine Hood on page 5 25 3 Inspect the engine and engine compartment for Oil fuel and engine coolant leaks Loose fasteners and connections Worn or loose belts Damaged hoses and wiring harnesses WARNING Maintenance and service must be performed with the engine off unless otherwise indicated Shut off the engine before opening or removing the engine cover Remove the ke...

Page 177: ...ick 6 Send the sample for testing according to the instructions packaged with the sample kit Prestart Check Reference Check the engine coolant level and add engine coolant as necessary Check the Engine Coolant Level on page 4 6 Check the engine oil level and add engine oil as necessary See Engine Oil Level Check on page 4 7 Check the fuel level and add fuel as necessary See Fuel Level Check on pag...

Page 178: ...stick Add clean engine oil until the oil level is at the upper mark of the dipstick 6 Add engine oil through the filler port 4 as required Always use SANY recommended engine oil NOTE If the oil level is above the upper mark on the dipstick drain the excess oil See Change the Engine Oil and Filter on page 5 33 WARNING Hot oil and engine components may cause burns or other serious injury Allow the e...

Page 179: ...machine for service See Maintenance Safety on page 2 8 2 Remove the four fasteners 1 and oil drain cover 2 3 Place a suitable container under the engine oil drain plug 4 4 Remove the engine oil drain plug and allow the oil to completely drain 5 Install and tighten the engine oil drain plug 6 Install oil drain cover and fasteners NOTICE Dispose of used oil and filters in according to all applicable...

Page 180: ... filter 3 4 to 1 full turn by hand to securely install the oil filter NOTE Overtightening the filter may damage the O ring resulting in an oil leak 13 Remove oil filler cap 5 NOTE See Fluid Capacities on page 5 11 for the engine oil capacity and Recommended Lubricants Fuels and Engine Coolant on page 5 10 for the proper engine oil 14 Add engine oil until the oil level is at the upper mark on the d...

Page 181: ...e of specification 4 Loosen the adjusting plate fastener 4 and alternator bracket fastener 5 5 Use a lever between the alternator and adjusting plate bracket to properly tension the belt 6 Hold the alternator in this position and tighten the adjusting plate fastener 7 Tighten the alternator bracket fastener 8 Check the fan belt tension to confirm adjustment Replace the Fan Belt Visually inspect th...

Page 182: ...ce the Engine Air Filters 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Release the two latches 4 and remove the end cover NOTE Clean the interior of the housing before removing the primary filter element 3 Remove the primary filter element 6 and then the secondary filter element 5 4 Installation is in the reverse order of removal Check the Alternator Prepare the machine f...

Page 183: ...he engine hood 1 See Opening the Engine Hood on page 5 25 NOTE A cab is shown Canopy machines are similar 2 Remove four fasteners 2 and the left rear panel 3 3 Inspect the muffler 4 and its mount for leaks or signs of damage 4 Make sure the exhaust pipe 5 is clear and not restricted 5 Check the connection to the expansion pipe to be sure there are no signs of leakage NOTE If any abnormality is fou...

Page 184: ...ressure reaches a predetermined level the diaphragm opens a passage that allows crankcase fumes to be routed to the intake manifold To inspect the diaphragm and spring 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Remove the fasteners and diaphragm cover 1 3 Remove the spring 2 diaphragm plate 3 and diaphragm 4 4 Inspect the diaphragm for damage and the spring for distorti...

Page 185: ...diator cap 1 WARNING Never operate a machine with a damaged or defective exhaust system exhaust leaks or restrictions Failure to follow this warning could result in death or serious injury WARNING Engine coolant is toxic Avoid inhaling or ingesting engine coolant If eyes or skin are contaminated by coolant wash the affected area with plenty of water and seek medical treatment immediately Do not re...

Page 186: ...riate container under the drain hose Open the drain valve and allow the engine coolant to drain 6 Close the drain valve Add clean water to fill the radiator Start the engine and run it at low speed until the temperature reaches a normal operating temperature Run the engine for an additional 10 minutes 7 Stop the engine Allow the engine to cool and drain the water into an appropriately sized contai...

Page 187: ... minutes to bleed air from the cooling system 12 Top off the radiator and fill the expansion tank until the engine coolant is between the FULL and LOW marks 13 Install the radiator cap Inspect the Engine Coolant Pump Prepare the machine for service See Maintenance Safety on page 2 8 The engine coolant pump 1 is behind and connected to the engine fan 2 by a fan pulley 3 1 Check if the engine fan pu...

Page 188: ...the opposite direction of the airflow through the cooling package 5 Check the fins for deformation corrosion and cracks after cleaning Repair the component immediately if damaged cooling fins are found 6 Check the hose clamps Tighten as necessary WARNING Do not allow compressed air pressurized water or steam to come into contact with skin Always wear goggles gloves and other personal protective eq...

Page 189: ...al to the left and check if the air temperature decreases 4 Check the fresh air recirculation switch function 5 Check the air conditioning power switch function Clean or Replace the Ventilation Filter Screen Cab 1 Prepare the machine for service See Maintenance Safety on page 2 8 WARNING Do not allow compressed air pressurized water or steam to come into contact with skin Always wear goggles glove...

Page 190: ...pressor Belt Tension Check the Air Conditioner Compressor Belt Tension Prepare the machine for service See Maintenance Safety on page 2 8 Check the air conditioner compressor belt tension using one of the following two methods Check the tension of the compressor belt using a tensioning gauge A new belt should be tightened to 143 lbf 637 N and a used belt should be tightened to 99 lbf 441 N Press d...

Page 191: ...ompressor components and air conditioning system seals Air Conditioner Components Inspection and Maintenance Schedule NOTICE Check the pulleys and V belt for damage and wear Make sure that the V belt does not rub against the bottom groove of the pulleys A newly installed V belt must be readjusted after operating the machine for 1 hour Item Description Service Interval Refrigerant R134a Check for l...

Page 192: ...uel tank Never use trichloroethane to clean the fuel tank Perform this procedure only if an excessive amount of water or contaminants is found while draining the primary fuel filter water separator 1 Prepare the machine for service See Maintenance Safety on page 2 8 WARNING Fuel or fuel vapors that come into contact with hot surfaces or electrical components can cause a fire Never service the fuel...

Page 193: ...an attach a drain hose to the valve by removing the right side panel 2 NOTE See Other Approved Lubricants on page 5 13 for fuel tank capacity 4 Open the valve 3 to drain water and sediment accumulated on the bottom of the tank Do not allow the fuel to splash out of the container 5 Close the valve when only clean fuel drains from the fuel tank 6 If the fuel tank is completely drained the system mus...

Page 194: ... leak 6 Turn the key switch to the ON position for 2 3 minutes before attempting to start the engine The lift pump will bleed air from the system 7 Start the engine and check the fuel filter for leaks WARNING Components and oil remain hot when the engine is stopped which may cause severe burns Wait until components and oil are cool before you proceed Never service the fuel system near an open flam...

Page 195: ... and Drain the Primary Fuel Filter Water Separator on page 4 10 WARNING Components and oil remain hot when the engine is stopped and may cause severe burns Wait until components and oil are cool before you proceed Never service the fuel system near an open flame or while smoking Fuel that comes into contact with hot surfaces or electrical components can cause a fire Clean up any fuel spills immedi...

Page 196: ... filter and make sure it is securely seated within the filter body 11 Fill the filter housing with clean fuel 12 Install the filter housing 13 Place the fuel shutoff valve in the ON position 14 Turn the key switch to the ON position for 2 to 3 minutes before attempting to start the engine The lift pump will bleed air from the system 15 Start the engine and allow it to run at idle speed See Startin...

Page 197: ...ght front access door See Unlocking Opening the Right Front Access Door on page 5 26 2 Remove the fuel filler cap 1 NOTE Fuel filler cap may be a locking type cap 3 Lift the fuel tank strainer 2 out of the fuel filler tube 4 Clean and inspect the fuel tank strainer NOTE Replace a damaged or missing fuel tank strainer with a new one 5 Install the new or cleaned fuel tank strainer and the fuel fille...

Page 198: ...ntenance procedure observe the following The top of the battery must be kept clean to prevent plugging of the battery vents Regularly wash the top of the battery to prevent the battery vents from plugging Battery gases are explosive Never smoke around batteries or expose them to sparks or open flames Work in a well ventilated area Wear personal protective equipment PPE when working with batteries ...

Page 199: ...everal minutes for any accumulated battery gases to clear before servicing the battery 4 Turn the battery disconnect switch 3 to the OFF position 5 Check the positive 1 and ground 2 terminals for corrosion or loose connections under the protective covers Clean the area with a mixture of baking soda and warm water and tighten fasteners as needed 6 Wipe down the battery and terminals with a clean cl...

Page 200: ...n to prevent plugging of the battery vents Regularly wash the top of the battery to prevent the battery vents from plugging Battery gases are explosive Never smoke around batteries or expose them to sparks or open flames Work in a well ventilated area Wear personal protective equipment PPE when working with batteries Battery acid can cause burns or injury If battery acid makes contact with your sk...

Page 201: ...the positive terminal 1 6 Remove the fastener 3 securing the battery hold down 4 Remove the battery hold down 7 Check that all cables and parts are out of the way then lift the battery out of the battery compartment 8 Clean the battery and terminals See Check the Battery on page 5 52 9 Clean the battery tray 10 Installation is in the reverse order of removal Connect the positive terminal first the...

Page 202: ...tem pressure must be relieved before disconnecting or servicing hydraulic system components 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Turn the key switch to the ON position Do not start the engine 3 Set the hydraulic lockout control lever to the unlocked open position 4 Fully cycle each pedal joystick and travel control two or three times to release pressure remaining ...

Page 203: ...ean around the hydraulic tank breather assembly 1 6 Remove the four fasteners 2 and the hydraulic tank breather assembly 7 Slowly add hydraulic oil through the breather assembly opening of the hydraulic tank Monitor the oil level as it is added See Check the Hydraulic Oil Level on page 4 11 8 Reinstall the hydraulic tank breather assembly WARNING Allow the hydraulic system to cool before servicing...

Page 204: ...tton 3 to release pressure in the hydraulic tank 5 Remove and clean the cover 1 6 Inspect the filter element 5 Replace the filter element as needed 7 Install the filter Tighten the cover and wing nut cover securely WARNING Allow the hydraulic system to cool before servicing Hot oil may cause burns or other serious injury The hydraulic tank may be under pressure and hydraulic oil may be present at ...

Page 205: ...ilter element from the housing Clean the interior of the housing and bowl 7 Install a new filter element gasket and O ring Install the filter bowl and tighten securely 8 To purge air from the system start the engine and run it at low idle for 10 minutes Check for leaks WARNING Allow the hydraulic system to cool before servicing Hot oil may cause burns or other serious injury The hydraulic tank may...

Page 206: ...ause burns or other serious injury The hydraulic tank may be under pressure and hydraulic oil may be present at the filler cap Relieve any pressure to prevent injury Failure to follow these warnings could result in death or serious injury NOTICE Examine the return filter for metal chips and debris An excessive amount of bronze and steel chips indicates that the hydraulic pump or a hydraulic motor ...

Page 207: ...e fasteners Remove the cover 5 Discard the used spring 3 and return filter 4 Install a new return filter and spring 6 Install a new O ring for the return filter cover Tighten the fasteners securely 7 To purge air from the system start the engine and run it at low idle for 10 minutes 8 Check the hydraulic oil level and add hydraulic oil as needed See Check the Hydraulic Oil Level on page 4 11 NOTIC...

Page 208: ...er to the boss 6 of the hydraulic tank 8 Install a new O ring for the suction strainer cover Tighten the fasteners securely NOTE Use the extrusion on the bottom of the cap to hold the spring in place 9 To purge air from the system start the engine and run it at low idle for 10 minutes 10 Check the hydraulic oil level See Check the Hydraulic Oil Level on page 4 11 WARNING Allow the hydraulic system...

Page 209: ...m pressure See Relieve Hydraulic System Pressure on page 5 56 4 Remove the two fasteners 2 securing the hydraulic oil drain access panel and remove the panel WARNING Allow the hydraulic system to cool before servicing Hot oil may cause burns or other serious injury The hydraulic tank may be under pressure and hydraulic oil may be present at the filler cap Relieve any pressure to prevent injury Fai...

Page 210: ...lic oil samples are taken every 3 months or every 250 operating hours 1 Obtain an oil analysis sample kit from a SANY dealer 2 Operate the machine until the hydraulic oil is up to normal operating temperature 3 Prepare the machine for service See Maintenance Safety on page 2 8 4 Remove the hydraulic tank breather assembly See Add Hydraulic Oil on page 5 57 5 Insert the oil sample tube into the hyd...

Page 211: ...ump lines or connectors connected to the engine compartment must be replaced if damaged Make sure there is sufficient clearance between all hydraulic lines and hoses and the high temperature engine components Make sure there is no friction between them and that no hydraulic lines and hoses contact each other Check the Hydraulic Pump and Fasteners NOTE This section shows a cab Canopy machines are s...

Page 212: ...ct hydraulic pump 3 for loose broken or missing pump mounting fasteners 4 and leaks or cracking at these mounting fastener locations NOTE Not all pump mounting fasteners are visible Be sure to inspect all pump mounting fastener locations 4 Tighten any loose fasteners 0003853 3 Fig 5 70 4 ...

Page 213: ...e between 90 and 110 1 with the bottom of the bucket on the ground 2 Rotate the track one full revolution 3 Prepare the machine for service See Maintenance Safety on page 2 8 4 Use a straightedge to measure the track sag 2 between the tread of the track roller and the rail surface of the track 5 Normal track sag is 0 4 in 0 8 in 10 mm 20 mm for rubber tracks and 0 6 in 1 0 in 15 mm 25 mm for steel...

Page 214: ... sure that the grease valve 1 is closed tightly 4 Using a grease gun pump grease into the grease fitting 2 while observing idler movement 5 Rotate the track one full revolution Check the track tension to confirm adjustment WARNING The track tension grease fitting is under extreme pressure and grease can exit the grease valve and cause serious injury Wear safety goggles gloves and other personal pr...

Page 215: ...round 2 Prepare the machine for service See Maintenance Safety on page 2 8 3 Slowly open the grease valve 1 1 to 1 1 2 turns while observing idler movement Grease should come out from behind the grease valve NOTE If grease does not come out slowly rotate the track in both directions When grease begins to flow stop and continue the adjustment 4 When the track sag is within specification tighten the...

Page 216: ...is shown The left side is similar Replace any damaged or defective fasteners and tighten any loose fasteners NOTE Use thread lock compound when tightening loose fasteners or installing new fasteners Check the Idler Check the idler 1 for cracks and distortion NOTE The left side is shown The right side is similar Contact a SANY dealer for replacement if damage is found 1 Fig 5 77 0003852 Fig 5 78 00...

Page 217: ...ve the final drive motor cover 2 The left side is shown the right side is similar 3 Inspect the final drive to make sure all hoses 3 are connected tightly The right side is shown the left side is similar 4 Inspect all of the final drive mounting fasteners 4 for rust damage or looseness 5 Replace any damaged or missing fasteners and tighten any loose fasteners NOTE Use thread lock compound when rei...

Page 218: ...on page 5 10 for the recommended final drive oil 6 If necessary remove the fill plug 1 and add oil 7 Install the oil level and fill plugs and tighten to 12 5 lb ft 17 N m 8 Repeat this procedure on the other final drive CAUTION Allow the final drive to cool before servicing Hot oil may cause burns or other serious injury Wear safety goggles gloves and other personal protective equipment PPE to pre...

Page 219: ...ieve any internal pressure NOTE See Other Approved Lubricants on page 5 13 for the final drive capacity 6 Remove the drain plug and allow the oil to drain 7 Install the drain plug and tighten to 12 5 lb ft 17 N m NOTE Refer to Recommended Lubricants Fuels and Engine Coolant on page 5 10 for the recommended final drive oil 8 Add new gear oil through the fill plug opening Fill until the gear oil is ...

Page 220: ...Remove the final drive check plug See Check and Add Final Drive Oil on page 5 72 5 Insert the oil sample tube into the final drive and collect a sample of final drive oil Install the final drive check plug 6 Send the sample for testing according to the instructions packaged with the sample kit NOTICE It is critical that all material used to collect the sample is absolutely clean Failure to follow ...

Page 221: ...ge 5 78 2 Boom arm connecting pin page 5 76 11 Boom cylinder rod end pin page 5 78 3 Arm cylinder base end pin page 5 77 12 Bucket linkage pins page 5 78 4 Cab door lock page 5 23 13 Bucket cylinder rod end pin page 5 79 5 Boom pin page 5 77 14 Bucket cylinder base end pin page 5 79 6 Cab door hinges page 5 23 15 Boom swing cylinder rod end pin page 5 79 7 Swing bearing page 5 80 16 Boom swing cyl...

Page 222: ...ubrication points 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Using a grease gun pump grease into the grease fittings 3 Clean off all excess grease Arm Cylinder Rod End Pin 1 Remove the grease fitting cap 1 from the arm cylin der rod end pin grease fitting 2 2 Grease the arm cylinder rod end pin grease fitting NOTE Wipe excess grease from around the grease fitting 3 Inst...

Page 223: ...e the grease fitting cap 1 from the boom pin grease fitting 2 2 Grease the boom pin grease fitting NOTE Wipe excess grease from around the grease fitting 3 Install the grease fitting cap Dozer Blade Linkage Pins and Dozer Blade Cylinder End Pins NOTE Only one dozer blade linkage pin grease fitting cap is shown 1 Remove the grease fitting caps 1 from the dozer blade cylinder end pins 2 and the doze...

Page 224: ...inder Rod End Pin 1 Remove the grease fitting cap 1 from the boom cylin der rod end pin grease fitting 2 2 Grease the boom cylinder rod end pin grease fitting NOTE Wipe excess grease from around the grease fitting 3 Install the grease fitting cap Bucket Linkage Pins 1 Remove the grease fitting caps 2 from the bucket linkage pin grease fittings 1 2 Grease the bucket linkage pin grease fittings NOTE...

Page 225: ...Install the grease fitting caps Bucket Cylinder Base End Pin 1 Remove the grease fitting cap 1 from the bucket cyl inder base end pin grease fitting 2 2 Grease the bucket cylinder base end pin grease fitting NOTE Wipe excess grease from around the grease fitting 3 Install the grease fitting cap Boom Swing Cylinder Rod End Pin 1 Remove the grease fitting cap 1 from the boom swing cylinder rod end p...

Page 226: ...in grease fittings NOTE Wipe excess grease from around the grease fitting 3 Install the grease fitting cap Swing Bearing 1 Remove the grease fitting cap 1 and grease the two fittings on the swing bearing 2 NOTE Only one fitting is shown The fittings are 180 offset from each other 2 Start the engine and raise the bucket 0 8 in 1 2 in 20 mm 30 mm above the ground Swing the upper structure 45 degrees...

Page 227: ...ound as shown 1 Turn the throttle to MIN and run the machine unloaded at low speed for five minutes 2 Turn the machine off 3 Grease the swing pinion gear using the top grease fitting 3 4 Start the engine and raise the bucket 0 8 in 1 2 in 20 mm 30 mm above the ground Swing the upper structure 45º 1 8 turn in each direction 5 Add grease to the swing bearing until grease appears from the swing beari...

Page 228: ...ep the bottom of the bucket level on a wooden block 3 4 Remove the roll pins and worn bucket teeth 5 Install new bucket teeth and roll pins in the reverse order of removal WARNING Unexpected machine movement can be dangerous when replacing the bucket teeth Place the bucket on a stable work surface Shut down the engine and relieve the hydraulic system pressure Roll pins may eject with extreme force...

Page 229: ...at low idle Operate the bucket slowly in both directions to check for binding Check the Sheet Metal Fig 5 103 0002925 NOTE Repair or replace sheet metal as needed using SANY approved parts Check for missing or damaged sheet metal panels doors and covers Check for loose connections or missing fasteners Replace panels doors covers or fasteners as needed CAUTION Keep fingers and other body parts away...

Page 230: ...t Switch Cab Machine on page 3 10 or See Work Light Switch Canopy Machine on page 3 11 Check the work light 2 on top of the cab for proper operation or damage See Work Light Switch Cab Machine on page 3 10 Check the work lights 3 on top of the canopy for proper operation or damage See Work Light Switch Canopy Machine on page 3 11 Fig 5 104 0003860 1 Fig 5 105 0002980 2 Fig 5 106 0003149 3 ...

Page 231: ...o smearing across the windshield during operation See Windshield Wiper Switch Cab Machine on page 3 9 Replace the wiper blade with a new one if smearing does occur Check for proper operation of the windshield washer nozzle 5 See Windshield Washer Switch Cab Machine on page 3 9 Check the windshield washer fluid level in the windshield washer tank 6 behind the right rear access door Fill with clean ...

Page 232: ...20 SANY Check the horn 7 for proper operation See Horn Button on page 3 7 Check the Operation and Maintenance Manual Make sure the Operation and Maintenance Manual is in the cab If this manual is damaged or missing contact a SANY dealer for a replacement Fig 5 109 0003827 7 ...

Page 233: ...jor component groups The undercarriage with its various components and assemblies The upper structure with its various components and assemblies Check all structural components identified below for cracks or distortion Notify a SANY dealer if any cracks or distortion are found NOTE The illustration below shows a cab machine Canopy machines are similar for non cab related items 1 Boom 4 Track 2 Cab...

Page 234: ...Maintenance SY35U Excavator OMM 5 88 Operation and Maintenance Manual 0120 SANY This Page Intentionally Left Blank ...

Page 235: ...anual 0120 6 1 TABLE OF CONTENTS INTRODUCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Specifications Machine Dimensions 6 2 Working Ranges 6 3 Technical Specifications 6 4 Lift Chart Blade Down 6 5 Lift Chart Blade Up 6 6 ...

Page 236: ... width 3 ft 1 in 950 mm 5 Track width standard shoe 12 in 300 mm 6 Track gauge 4 ft 8 in 1420 mm 7 Transport width 5 ft 8 in 1720 mm 8 Ground clearance minimum 12 in 300 mm 9 Transport height 8 ft 3 in 2515 mm 10 Engine rear panel height 5 ft 1 in 1550 mm 11 Platform clearance 1 ft 11 in 590 mm 12 Track length on ground 5 ft 6 in 1670 mm 13 Track length 7 ft 1 in 2155 mm 14 Blade maximum digging d...

Page 237: ...TIONS OPTIONAL EQUIPMENT WORKING RANGES Item Description Dimensions 1 Minimum swing radius 8 ft 1 in 2475 mm 2 Maximum digging height 15 ft 11 in 4855 mm 3 Maximum dumping height 11 ft 4 in 3460 mm 4 Maximum digging depth 10 ft 2 in 3105 mm 5 Maximum vertical wall digging depth 8 ft 10 in 2700 mm 6 Maximum reach at ground level 17 ft 11 in 5465 mm Fig 6 2 0003762 1 2 3 4 5 6 ...

Page 238: ...ers 4 Fuel tank capacity 10 6 gal 40 0 L Hydraulic tank capacity 10 6 gal 40 0 L Cooling system capacity 1 7 gal 6 5 L Engine oil capacity 1 8 gal 6 7 L Ground pressure 4 6 psi 32 0 kPa Boom length 8 ft 4 in 2 54 m Stick arm length 4 ft 7 in 1 40 m Grade capability maximum 35 Hydraulics Load sensing with pilot control Main hydraulic pump Axial piston with variable displacement Main hydraulic pump ...

Page 239: ...e a bucket and are in compliance with ISO 10567 2007 NOTE Least stable position is over the side NOTE The load point is the centerline of the bucket pivot mounting pin on the arm Load Point Height ft m Rated Capacity lb kg Load Point Radius ft m 6 6 2 0 9 8 3 0 13 1 4 0 Lift capacity at max reach End Side End Side End Side End Side 13 1 4 0 1767 803 1452 660 9 8 3 0 1800 818 1107 503 1514 688 1008...

Page 240: ...NOTE Least stable position is over the side NOTE The load point is the centerline of the bucket pivot mounting pin on the arm Load Point Height ft m Rated Capacity lb kg Load Point Radius ft m 6 6 2 0 9 8 3 0 13 1 4 0 Lift capacity at max reach End Side End Side End Side End Side 13 1 4 0 1549 704 1452 660 9 8 3 0 1175 534 1107 503 1069 486 1008 458 6 6 2 0 1797 817 1676 762 1148 522 1080 491 904 ...

Page 241: ...TION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Optional Equipment Optional Equipment Selection 7 2 Read Equipment Instruction 7 2 Removal and Installation Precautions 7 2 Equipment Operation Precautions 7 3 Install Optional Equipment 7 4 Remove Optional Equipment 7 6 ...

Page 242: ...ns for maximum flow and pressure of optional equipment If the optional equipment manual is missing or damaged contact the manufacturer of the optional equipment to obtain a replacement Installation and Removal Precautions Follow the instructions in this manual and in the optional equipment manual Remove and install equipment only on a firm level surface Use an appropriate lifting device when handl...

Page 243: ... and working range may change Make sure the machine is well balanced Maintain a safe distance from all surrounding barriers during machine operations To prevent the machine from tipping over never swing lower or stop the machine suddenly To prevent impact that may cause the machine to tip over never raise or lower the boom suddenly Install front guards on the machine as necessary per the nature of...

Page 244: ...Connect the optional equipment to the machine in accordance with the manufacturer s instructions 7 Connect the optional equipment hydraulic lines and operate the optional equipment according to the manufacturer s instructions 8 Turn the left and right stop valves to the open position WARNING Do not release the optional equipment unless it is on the ground or on a solid supportive surface Block or ...

Page 245: ...e hydraulic tank It regulates the direction of hydraulic oil flow There are one way 4 or two way 5 positions for operating optional equipment NOTE A variety of optional one way and two way flow equipment is available for use on this machine A hydraulic breaker is an example of one way flow equipment a bucket thumb or shear are examples of two way flow equipment 10 Select the correct operating mode...

Page 246: ...e with the manufacturer s instructions 8 Adjust the return flow selector valve as necessary See Return Flow Selector Valve on page 3 18 9 Select the correct operating mode from the monitor See Operating Mode Screen on page 3 43 10 Check the hydraulic oil level See Check Hydraulic Oil Level on page 5 56 WARNING Do not release the equipment unless it is on the ground or on a solid supportive surface...

Page 247: ...This Page Intentionally Left Blank ...

Page 248: ...ca com SANY Part Number SSY005082353 318 Cooper Circle Peachtree City Georgia 30269 Find a Dealer sanyamerica com find a dealer Sales E mail sales sanyamerica com Service E mail service sanyamerica com Service Hotline 470 552 SANY 7269 ...

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SANY SY35U, Operation And Maintenance Manual

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