SANY SY500H, Operation And Maintenance Manual

Page 1: ...service sanyamerica com SY500H Excavator Operation and Maintenance Manual SANY Part Number SSY005084272 ...

Page 2: ...Page Intentionally Blank ...

Page 3: ... and understand all safety precautions and instructions in this manual and on the machine labels before operating or maintaining the machine Failure to follow safety messages could result in death or serious injury Keep this manual with the machine for reference SY500H Excavator ...

Page 4: ... 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 between t...

Page 5: ...1 4 Engine Identification Plate 1 4 Main Control Valve Identification Plate 1 5 Hydraulic Pump Identification Plate 1 5 Travel Motor Identification Plate 1 5 SANY Contact Information 1 6 Glossary of Acronyms 1 6 Record of Serial Number and Dealer Information 1 7 Correction Request Form 1 8 Safety General Safety 2 2 Hazard Alerts in This Manual 2 2 Operator Safety Information 2 2 Mount and Dismount...

Page 6: ...ents 3 4 Seat and Seat Belt 3 5 Headrest 3 5 Seat Heater 3 5 Lumbar Adjustment 3 5 Armrest Angle Adjustment 3 5 Backrest Angle Adjustment 3 5 Seat Belt 3 5 Buckle the Seat Belt 3 5 Unbuckle the Seat Belt 3 5 Seat and Console Adjustment Lever 3 5 Weight Adjustment 3 6 Seat Forward and Backward Adjustment 3 6 Seat Cushion Adjustments 3 6 Emergency Stop Switch 3 6 Operator Controls 3 7 Left Control C...

Page 7: ...r Switch 3 15 Windshield Washer Switch 3 15 Headlight Switch 3 15 Battery Disconnect Switch 3 15 Batteries 3 16 Monitor Console 3 17 12V Power Supply Socket 3 17 Cup Ashtray 3 17 Airflow Vents 3 17 Sunlight Sensor 3 17 Joystick Controls 3 18 Left Joystick Buttons 3 18 Right Joystick Buttons Switch 3 18 SAE BHL Joystick Operating Modes 3 18 Pattern Change SAE BHL Valve 3 18 SAE Mode 3 19 BHL Mode 3...

Page 8: ...ation Screen 3 36 Tool Select Screen 3 36 Tool Icons 3 36 Bucket 3 36 Breaker 3 37 Shear Tool 3 37 Lifting Tool 3 38 Quick Coupler Tool 3 39 Machine Operation Work Area 4 4 General Job Safety 4 4 Operator Responsibilities 4 4 Seat Belt Usage 4 4 Operation and Maintenance Manual Check 4 4 Daily Maintenance Record Check 4 4 Cleaning the Machine 4 4 Cleaning the Cab Interior 4 5 New Machine Break in ...

Page 9: ...he Engine Access Door 4 10 Closing the Engine Access Door 4 11 Cab Door Windows 4 11 Windshield 4 11 Opening the Windshield 4 11 Closing the Windshield 4 12 Lower the Front Windshield 4 12 Cab Light 4 13 Mirrors 4 13 Backup Camera 4 13 Monitor Settings 4 14 First Time Setup 4 14 Access the Main Menu 4 14 Language Selection 4 14 System Clock Calibration 4 15 Data Unit Setting 4 15 Engine Start Proc...

Page 10: ...aintenance During Storage 4 28 Return to Service 4 28 Transportation Information 4 28 Counterweight Removal 4 28 Counterweight Installation 4 33 Lifting the Machine 4 34 Loading the Machine 4 34 Unloading the Machine 4 36 Maintenance Maintenance Information 5 4 Checks Before Maintenance 5 4 Checks After Maintenance or Repairs 5 4 Hour Meter Reading 5 4 Genuine SANY Replacement Parts 5 4 SANY Appro...

Page 11: ... Maintenance Interval 5 11 After Maintenance is Completed 5 11 Maintenance Procedures 5 12 Engine 5 12 Check the Crankcase Breather Tube 5 12 Check the Engine Air Precleaner 5 12 Check the Engine Air Filter System 5 12 Replace the Engine Air Filter 5 13 Check the Engine Oil Level 5 14 Collect an Engine Oil Sample 5 14 Replace the Engine Oil and Filter 5 15 Check the Engine Belts 5 17 Check the Alt...

Page 12: ...il 5 34 Replace Hydraulic Oil 5 35 Replace the Hydraulic Pilot Filter Element 5 37 Check the Hydraulic Pump 5 38 Replace the Hydraulic System Breather Filter 5 38 Check the Hydraulic Tank 5 40 Replace the Hydraulic Tank Return Filter 5 40 Clean the Hydraulic Suction Strainer 5 41 Check the Pump Mounting Fasteners 5 42 Electrical System 5 43 Check the Batteries 5 43 Replace the Battery 5 43 Check t...

Page 13: ...heet Metal 5 60 Structural Inspection 5 60 Clean and Check the Upper Structure and Undercarriage 5 60 Check the Windshield Washer Fluid 5 60 Windshield Wiper 5 61 Lubricate the Work Equipment 5 62 Machine Storage 5 63 Short Term Storage Less Than 30 Days 5 63 Long Term Storage Longer Than 30 Days 5 63 Specifications Machine Dimensions 6 2 Operating Ranges 6 4 Technical Specifications 6 5 Lift Char...

Page 14: ...5 10 SY500H Excavator OMM Page Intentionally Blank ...

Page 15: ... 1 3 Optional Equipment 1 3 Machine Applications 1 3 Machine Directions 1 3 Serial Number Locations 1 4 Product Identification Plate 1 4 Frame Serial Number 1 4 Swing Motor Identification Plate 1 4 Engine Identification Plate 1 4 Main Control Valve Identification Plate 1 5 Hydraulic Pump Identification Plate 1 5 Travel Motor Identification Plate 1 5 SANY Contact Information 1 6 Glossary of Acronym...

Page 16: ...e 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 questions regarding information in this manual Documentation Package This documentation applies only to this machine and should not be used with any other machine The documentation for th...

Page 17: ...eral dimensions and weight of the machine and systems components performance information Optional Equipment Provides general hydraulic installation and removal information for optional equipment Machine Applications This excavator is a multipurpose construction machine used primarily for digging or loading earth and stones It can also be used for lifting demolishing and trenching It can perform th...

Page 18: ...tion Plate 0004724 Figure 1 2 The product identification plate 1 with the machine s serial number is on the right side of the operator cab Frame Serial Number 0004794 Figure 1 3 A frame serial number 1 is stamped on the front of the travel carriage frame Swing Motor Identification Plate 0004796 Figure 1 4 The identification plates 1 are on the top and bottom of the swing motor Engine Identificatio...

Page 19: ...he hydraulic main control valve Hydraulic Pump Identification Plate 0004793 Figure 1 7 The identification plate 1 is on the side of the hydraulic pump Travel Motor Identification Plate 0000802 Figure 1 8 A travel motor identification plate 1 is on each travel motor Remove the cover plate to access the travel motor s identification plate 1 1 1 ...

Page 20: ...ckhoe Loader DEF Diesel Exhaust Fluid DPF Diesel Particulate Filter ECM Engine Control Module HEST High Exhaust System Temperatures LCD Liquid Crystal Display MSDS Material Safety Data Sheet OEM Original Equipment Manufacturer PPE Personal Protective Equipment OSHA Occupational Safety and Health Administration PQR Procedure Qualification Report SAE Society of Automotive Engineers SDS Safety Data S...

Page 21: ...ble to record the product information related to your machine Machine Serial Number Engine Serial Number Right Travel Motor Serial Number Left Travel Motor Serial Number Swing Drive Motor Serial Number Main Control Valve Serial Number Hydraulic Pump Serial Number Dealer Name Address Phone Numbers ...

Page 22: ...this page complete the form below and send it to SANY Date of This Notification Your Name Company Name Department Street Address City State and ZIP Postal Code Phone E mail Machine Model and Serial Number Description of Problem wrong information unclear or erroneous procedure etc Corrective Action Taken by You if any ...

Page 23: ...4 Diesel Engine Exhaust 2 4 Machine Decals 2 4 Maintenance Safety 2 4 Lockout Tagout Procedure 2 5 Clean the Machine 2 5 Fluid Systems 2 5 Adding Fluids to the Machine 2 5 Refueling 2 5 High Pressure Fluid Lines 2 5 Accumulator 2 5 Electrical System 2 5 Battery Safety 2 5 Disconnect the Battery 2 6 Job Safety 2 6 Personal Protective Equipment PPE 2 6 Hearing Protection 2 6 Travel and Operation Pre...

Page 24: ...g this machine Only qualified personnel who have been specifically trained on this machine are permitted to operate and or work on this machine The seat belt must be worn by the operator at all times Operator aids such as warning lights horns or buzzers along with displays on the monitors are designed to alert the operator to potential problems Sole reliance on these operator aids in place of good...

Page 25: ... can also be used for lifting breaking demolishing and trenching It can perform the functions of a loader and a crane SANY assumes no responsibility for any consequence caused by use outside this specified range Unauthorized Use of This Machine Unauthorized uses include but are not limited to the following Transporting riders on the machine or in the cab Towing or pushing other equipment Unauthori...

Page 26: ...sed area use an exhaust pipe extension to vent the exhaust to the outdoors If an exhaust pipe extension is not available open doors and use fans to supply fresh air to the area 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 around the machine and review each of them Decals provide i...

Page 27: ...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 WARNING Never perform inspections or replace items while any system is under pressure Never use your hands to check or feel for leaks Always wear personal protect...

Page 28: ...s in good working condition Hearing Protection Prolonged exposure to loud noise can cause impairment or loss of hearing Wear suitable hearing protection to protect against loud noise Travel and Operation Precautions Confirm the relative positions of the undercarriage and operator before operating the machine Traveling with the machine may present hazards Always travel in a safe controlled manner a...

Page 29: ... 2 2 Oils and coolants poured onto the ground into bodies of water into storm drains or tossed into trash cans even in a sealed container can contaminate and pollute the soil groundwater streams and rivers Recycling used oil coolants and filters helps conserve natural resources and is good for the environment Obey all regulations when disposing of harmful items such as oil fuel filters batteries h...

Page 30: ...2 8 SAFETY SY500H Excavator OMM Page Intentionally Blank ...

Page 31: ...ystem Operation 3 10 OFF Button 3 10 Fan Speed Control Switch 3 10 Temperature Selection Control Switch 3 10 Vent Mode Selection Button 3 10 Automatic Temperature Control Selection Button 3 10 Air Conditioning Power Button 3 10 LCD Screen 3 10 Fresh Recirculated Air Selection Buttons 3 10 Radio Control Panel 3 11 Radio Operation 3 11 Universal Serial Bus USB Port 3 11 Auto Scan Preset Station AS P...

Page 32: ...2 Fuses and Relays 3 23 Accessory Light Outlet 24V 3 23 Fuse and Relay Locations 3 24 Monitor 3 25 Home Screen 3 25 Home Screen Display Icons 3 26 Date and Time 3 26 Hour Meter 3 26 Fault Icon 3 26 Periodic Maintenance Prompt 3 26 Installed Equipment 3 26 Engine Coolant Temperature Gauge 3 26 Function Icons 3 26 Function Buttons 3 26 Engine Speed Gauge Tachometer 3 26 Diesel Exhaust Fluid DEF Leve...

Page 33: ...avator OMM Time Format Setting Screen 3 34 System Language Setup Screen 3 35 Machine Configuration Screen 3 36 Tool Select Screen 3 36 Tool Icons 3 36 Bucket 3 36 Breaker 3 37 Shear Tool 3 37 Lifting Tool 3 38 Quick Coupler Tool 3 39 ...

Page 34: ...MM Exterior Components 0000002 Figure 3 1 1 Arm cylinder 7 Carrier rollers 2 Boom 8 Idler 3 Boom cylinders 9 Tracks 4 Counterweight removal system 10 Arm 5 Drive sprocket 11 Bucket 6 Track frame 12 Bucket cylinder 11 10 12 4 5 8 6 3 2 1 9 7 ...

Page 35: ... or cut if the buckle is damaged or malfunctions or if the mounting hardware is loose Replace according to the seat belt manufacturer s instructions Always keep the seat belt fastened during machine operation Never twist the seat belt when fastening Failure to follow these warnings could result in death or serious injury Buckle the Seat Belt Hold the seat belt latch plate 7 and pull upward to leng...

Page 36: ...er Seat Cushion Adjustments NOTE The total adjustable depth is 2 3 in 60 mm The cushion can be adjusted in 1 2 in 30 mm increments Pull the seat cushion depth adjustment lever 8 adjust the cushion angle and release the lever Pull the seat cushion adjustment lever 12 adjust the seat cushion forward or backward and release the lever Emergency Stop Switch 0004672 Figure 3 3 The emergency stop switch ...

Page 37: ...ge 3 13 12 Footrests 4 Throttle control dial page 3 13 13 Climate control panel page 3 10 5 Work light switch page 3 14 14 Radio control panel page 3 11 6 Windshield wiper switch page 3 15 15 Hydraulic lockout control lever page 3 8 7 Windshield washer switch page 3 15 16 Left joystick page 3 9 8 Headlight switch page 3 15 17 Travel control pedals page 3 21 9 Travel alarm silence switch page 3 14 ...

Page 38: ...ls when you move the hydraulic lockout control lever to an unlocked open or locked closed position Failure to follow these warnings could result in death or serious injury NOTICE If any part of the machine moves when the hydraulic lockout control lever is in the locked closed position shut down the engine immediately Contact a SANY dealer for assistance 0004670 Figure 3 6 The hydraulic lockout con...

Page 39: ...OMM 00004692 Figure 3 7 Move the hydraulic lockout control lever to the unlocked open position 3 to enable hydraulic controls Left Joystick 0004690 Figure 3 8 The left joystick 1 has three buttons See Left Joystick Buttons on page 3 18 3 1 ...

Page 40: ...lsius C temperature display Vent Mode Selection Button Press the vent MODE selection button 4 to select which vent or vents are used for airflow inside the cab Floor vent only Front and rear vents only All vents front rear and floor Automatic Temperature Control Selection Button Press the automatic temperature control selection button AUTO 5 to activate the automatic temperature control system The...

Page 41: ...und tones and speaker left right balance Each time the button is pressed the display will cycle to adjustment options as follows Press and hold the SEL button to access the bass adjustment Press and release the SEL button again to access the treble adjustment Press and release the SEL button again to adjust the cab speaker balance With the audio option selected use the VOL or the VOL button 8 to a...

Page 42: ...OL increase or decrease button 8 for volume Tuning Buttons Press the right or left arrow tuning buttons 9 to search for the next available radio station frequency within range Preset Station Buttons Press and hold any of the six preset station buttons 10 to assign the current radio station to that button When stations have been assigned to the buttons press and release a preset station button to s...

Page 43: ...any of the electrical system components except for work lights ON The ON position allows the engine to remain running if already started and provides electrical current to the electrical system components START Hold the key at the START position to start the engine then release it immediately after the engine has started The key returns to ON when released Throttle Control Dial 0004677 Figure 3 15...

Page 44: ...his switch is in the ON position an icon appears on the monitor screen Use the regeneration disable switch when high temperatures from automatic regeneration pose a risk due to the excavator s surroundings NOTICE Running the machine with automatic exhaust cleaning disable activated for an extended period of time will cause the soot level to increase and can damage the aftertreatment system Travel ...

Page 45: ...ndshield 0004691 Figure 3 23 Press the windshield washer switch 1 to spray windshield washer fluid Hold down the switch to continue spraying windshield washer fluid Release the switch to stop spraying windshield washer fluid Headlight Switch 0004691 Figure 3 24 The headlight switch 1 mounted in the right control console turns on the headlights 0004678 Figure 3 25 The headlights are on top of the c...

Page 46: ...east 2 minutes for the engine control module ECM to complete its shutdown before turning the battery disconnect switch to OFF Failure to follow this notice could damage the machine or cause it to operate improperly Batteries 0004716 Figure 3 27 There are two 12V batteries 2 connected in series to provide 24V power to the machine s electrical system The batteries are under a protective cover 1 behi...

Page 47: ...ay 3 is on the bottom of the console Airflow Vents Airflow vents 4 on the monitor console can be opened closed and rotated Sunlight Sensor NOTICE To make sure the automatic functions of the air conditioning function properly the sunlight sensor must be clean Never obstruct the sunlight sensor or it could malfunction If the control panel or sunlight sensor gets wet a failure may result Always keep ...

Page 48: ...the joysticks Society of Automotive Engineers SAE mode See SAE Mode on page 3 19 Backhoe Loader BHL mode See BHL Mode on page 3 20 Pattern Change SAE BHL Valve NOTICE Shut down the engine before adjusting the pattern change SAE BHL valve Failure to follow this notice could damage the machine or cause it to operate improperly The pattern change SAE BHL valve is behind the left access door below the...

Page 49: ...MACHINE CONTROLS 3 19 SY500H Excavator OMM SAE Mode 00001410 Figure 3 33 Front Swing Left Swing Right Left Front Right Bucket Curl Boom DOWN Bucket Uncurl Boom UP Arm IN Arm OUT ...

Page 50: ...3 20 MACHINE CONTROLS SY500H Excavator OMM BHL Mode 0000141 Figure 3 34 Front Boom DOWN Swing Left Swing Right Boom UP Left Front Right Bucket Uncurl Arm IN Bucket Curl Arm OUT ...

Page 51: ...ck is released it returns to the neutral position and machine movement stops 0000663 Figure 3 37 The travel control levers and pedals are used to change the travel direction of the machine Forward travel 1 Push the control lever forward pedal tilts forward Backward travel 2 Pull the control lever pedal tilts backward Neutral Position N The machine stops Auto idle The auto idle automatically activa...

Page 52: ...lve is shown in the closed position To open the valve turn the valve knob 2 counterclockwise until the stop 4 makes contact with the stop pin 3 Return Flow Selector Valve 0004988 Figure 3 40 The return flow selector valve 1 has a one way or a two way position for operating optional attachments It is on the left side of the hydraulic oil tank The return flow selector valve is adjusted as follows Mo...

Page 53: ...er replace a fuse with one of a higher amperage Failure to follow these notices can damage the machine or cause it to operate improperly 0004687 Figure 3 41 The fuse and relay panel is behind the left front access door inside the electrical panel Open the electrical panel door 1 and remove the fuse and relay panel cover 2 to access the fuses and relays Accessory Light Outlet 24V 0004812 Figure 3 4...

Page 54: ...ay 24V 10A F5 Wiper washer 5A F21 DEF pump motor 10A R5 Power off relay 24V 10A F6 A C 20A F22 DEF heater relay 15A R6 Overload alarm relay 24V 5A F7 HCU power 20A F23 ECU power fuse 30A R7 Horn relay 24V 15A F8 Fuel 10A F24 Not used 10A R8 Alarm lamp relay 24V 10A F9 Power off delay 10A F25 Starter circuit 20A R9 Starter relay 24V 20A F10 Travel alarm 5A F26 Cab 5A R10 Starter cutoff relay 24V 20...

Page 55: ...Engine speed gauge tachometer 3 Fault icon 10 Diesel exhaust fluid DEF level gauge 4 Periodic maintenance prompt 11 Fuel level gauge 5 Installed equipment bucket tool shown 12 System service icons 6 Engine coolant temperature gauge 13 Work mode 7 Function icons 14 Throttle control dial setting F5 F4 F3 F2 F1 12 11 10 9 8 7 6 5 4 3 14 2 1 13 ...

Page 56: ...ant service Function Icons The function icons 7 are used for selecting and programming machine functions See Home Screen Function Icons and Buttons on page 3 27 Function Buttons The function buttons 8 are used for selecting and programming machine functions See Home Screen Function Icons and Buttons on page 3 27 Engine Speed Gauge Tachometer The engine speed gauge tachometer 9 indicates the revolu...

Page 57: ...ss travel speed is required Use the rabbit mode when more travel speed but less power is required 4 Press function button F4 5 to activate or deactivate the backup camera NOTE The icon illuminates red when the camera is deactivated 5 Press function button F5 4 to proceed to the Main Menu screen Main Menu Screen 1 High engine coolant temperature 9 Diesel exhaust fluid DEF alarm 2 High hydraulic oil...

Page 58: ... required See Maintenance Information Screen on page 3 29 Error Codes 3 displays specific codes if a fault condition occurs See Error Codes Screen on page 3 31 System Setting 9 allows for language units of measure time and date selection See System Setting Menu Screen on page 3 32 Machine Configuration 5 for factory use only Global Positioning System GPS Information 4 displays location velocity an...

Page 59: ...tween digits 4 Press function button F3 3 after entering the five digit password 5 Press function button F5 2 to return to the Main Menu screen without entering a password Work Parameters Screens These screens are for use by SANY technicians only and require a password Maintenance Information Screen 0004957 0005066 Figure 3 49 NOTE Use this screen to view procedures required for your machine when ...

Page 60: ...ance Information screen 3 There are a total of five Maintenance Information info screens designed for each interval of recommended maintenance 0005067 Figure 3 50 50 Hours 0005068 Figure 3 51 250 Hours 0005069 Figure 3 52 500 Hours 0005070 Figure 3 53 10000 Hours 0005071 Figure 3 54 2000 Hours ...

Page 61: ...hen turn the key switch to OFF and back to ON to confirm your selection and to clear the umbrella icon from the Home screen 5 Press function button F5 2 to return to the Main Menu screen without making any changes Error Codes Screen 0004957 0004711 Figure 3 55 NOTE Use this screen to view the specific error code s for your machine when the Machine Fault icon illuminates on the Home screen 1 Press ...

Page 62: ...etting and goes out when the fault condition is corrected In the example shown the error code is removed when fuel is added to the tank System Setting Menu Screen 0004957 0004709 Figure 3 56 NOTE Use this screen to access other screens to set various parameters 1 Press function button F1 4 three times at the Main Menu screen to navigate to the System Setting icon 1 then press F3 3 2 Press function...

Page 63: ...n turn the key switch to OFF and back to ON to confirm the selection NOTE Contact a SANY dealer if you do not have time zone information the number of time zones east or west of 0 degrees longitude 5 Press function button F5 5 to return to the System Setting screen without making any changes Data Unit Setting Screen 0004957 0004707 Figure 3 58 NOTE Use this screen to select which system of units o...

Page 64: ...light icon 1 on the System Setting screen then press function button F3 3 2 Press function button F1 5 to increase the screen brightness or function button F2 4 to decrease the screen brightness NOTES The number will change and the progress box will fill and empty to graphically indicate the screen brightness percentage 10 to 100 as set by the function buttons F1 5 and F2 4 3 Press function button...

Page 65: ...n defaults to highlight the 24 hour time format option even with the 12 hour time format in effect System Language Setup Screen 0004957 0004791 Figure 3 61 1 Proceed to the System Language Setup icon 1 on the System Setting screen 2 Press function button F1 5 or F2 4 to move up or down through the list to select the desired option 3 Press function button F3 3 then turn the key switch to OFF and ba...

Page 66: ... changes Tool Icons 0005075 Figure 3 63 0004711 0004957 Figure 3 64 1 Select one of five tool icons See Figure 3 63 NOTE The selected tool icon will illuminate on the Tool Select screen 3 See Figure 3 64 2 Press function button F1 2 to confirm the selection and proceed to the next screen 3 Press function button F5 1 to return to the Main Menu screen without making any selection Bucket 1 Select the...

Page 67: ... values for liters per minute Lpm and gallons per minute gpm will change and the progress box will fill or empty to indicate the chosen hydraulic oil flow rate 3 Press function button F4 3 then turn the key switch to OFF and back to ON to enable the rocker switch on the right joystick for one way flow work tool operation Confirm the hydraulic oil flow rate The Breaker icon will be displayed on the...

Page 68: ...ange and the progress box will fill or empty to indicate the chosen hydraulic oil flow rate 5 Press function button F3 3 then turn the key switch to OFF and back to ON to enable the joystick switches for two way flow tool operation Confirm the hydraulic oil flow rates The Shear icon will appear on the Tool Select screen 6 Press function button F5 1 to return to the Tool Select screen without makin...

Page 69: ...n to display the hydraulic oil pressures for this device and to operate the quick coupler for work tool attachment and removal 2 Press function button F2 3 to activate the quick coupler function 3 Press function button F1 4 to unlock the quick coupler to allow removal of the work tool 4 Press function button F3 2 to lock the quick coupler secures the work tool in place 5 Press function button F2 2...

Page 70: ...3 40 MACHINE CONTROLS SY500H Excavator OMM Page Intentionally Blank ...

Page 71: ...t Front Access Door 4 8 Right Rear Access Door 4 8 Opening the Right Rear Access Door 4 8 Closing the Right Rear Access Door 4 8 Left Rear Access Door 4 8 Opening the Left Rear Access Door 4 9 Closing the Left Rear Access Door 4 9 Left Front Access Door 4 9 Opening the Left Front Access Door 4 9 Closing the Left Front Access Door 4 9 Fuel Filler Cap 4 9 Opening the Fuel Tank Filler Cap 4 9 Closing...

Page 72: ...ne 4 18 Traveling Operations 4 19 Before Traveling 4 19 Track Direction 4 20 Traveling with the Undercarriage Reversed 4 20 Right Turn 4 20 Left Turn 4 20 Forward Travel 4 21 Backward Travel 4 21 Zero Degree Rotation 4 21 Left 4 21 Right 4 21 Operating on Inclines 4 21 Operating in Water 4 22 Releasing the Machine from Mud 4 22 One Track Stuck 4 22 Two Tracks Stuck 4 22 Work Equipment Controls 4 2...

Page 73: ...m Storage 4 27 Long Term Storage 4 27 Preparation 4 27 Maintenance During Storage 4 28 Return to Service 4 28 Transportation Information 4 28 Counterweight Removal 4 28 Counterweight Installation 4 33 Lifting the Machine 4 34 Loading the Machine 4 34 Unloading the Machine 4 36 ...

Page 74: ...w and use the required safety precautions and protective devices Know basic information about the systems of the machine Know and use the correct hand signals that will be used between the machine operator and a signal person Stop machine operations immediately if any defects endangering safety are found Maintain complete control of the machine at all times Before leaving the cab make sure all con...

Page 75: ... Avoid long periods of operation with the engine at idle or at continuous maximum horsepower levels Avoid sudden starts movements or stops Manage engine power to allow acceleration to the governed speed when conditions require more power Do not over rev the engine Monitor the instruments frequently especially the engine oil and coolant temperatures Shut down the machine at the first indication of ...

Page 76: ...ation about troubleshooting faults in the electrical system contact a SANY dealer Check the following electrical components Monitor operation Blown or loose fuses Make sure the fuses have the proper amperage rating for each circuit Make sure the battery terminal connectors are clean secure and free of dirt and debris Inspect the electrical wires and cables for worn or damaged insulation Make sure ...

Page 77: ...b door or windshield cannot be opened during an emergency To open the emergency escape hatch press the left and right latches 4 and push up The emergency escape hatch is supported in the open position by two pneumatic cylinders 3 To close the emergency escape hatch pull the handle 2 until right and left latches lock into place Access Door Support Rod 0004821 Figure 4 6 The access doors use a suppo...

Page 78: ...ss Door Pull the door down hook the door latch onto the door and secure by locking the door latch Right Rear Access Door 004738 Figure 4 9 Opening the Right Rear Access Door To open the right rear access door 1 unlock and pull the door latch 2 When fully open place the access door support rod in the support bracket slot to prevent the door from closing unexpectedly See Access Door Support Rod on p...

Page 79: ...cess Door Move the support rod out of the slot in the support bracket to close the access door See Access Door Support Rod on page 4 7 Close the access door To secure the door close the left rear access door See Closing the Left Rear Access Door on page 4 9 Fuel Filler Cap NOTICE Make sure the O ring on the filler cap is clean If the O ring is contaminated by dirt or debris it could be damaged and...

Page 80: ...ock 2 and turn the key clockwise Closing the Fresh Air Access Door With the key in the lock push and hold the door in closed position and turn the key counterclockwise to secure Engine Access Door Opening the Engine Access Door 0004825 Figure 4 15 To open the engine access door 1 unlock the latches and pull the top of latch assembly arms 2 away from the access door and unhook the latches 0004826 F...

Page 81: ... windows press the window latch 1 and slide the rear or forward door window open NOTE Rear window latch shown Front window latch is similar Windshield 0004783 Figure 4 19 The windshield 1 can be opened and stored on the ceiling of the cab Opening the Windshield WARNING Avoid sudden movement of the machine or work equipment Always place the hydraulic lockout control lever in the locked closed posit...

Page 82: ... avoid pinching hands or fingers Failure to follow this caution could result in injury or machine damage 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 to the locked closed position See Hydraulic Lockout Control Lever on page 3 8 0005179 Figure 4 21 3 Pull both windshield latch r...

Page 83: ...ttery disconnect switch and the key switch must be in the ON position for the cab light to operate Mirrors 0000453 Figure 4 25 The machine has two standard mirrors 1 and one convex mirror 2 for viewing around the machine To position the mirrors loosen the mounting fasteners When positioned properly tighten the mounting fasteners securely Backup Camera 0004742 Figure 4 26 1 Turn the key switch to t...

Page 84: ... First Time Setup 0004717 Figure 4 28 Access the Main Menu 1 Press function button F5 11 to access Main Menu screen displays 2 Press function button F1 12 to move to and highlight the System Setting icon 13 3 Press function button F3 14 to activate System Setting Language Selection See System Language Setup Screen on page 3 35 1 15 17 16 18 ...

Page 85: ...n page 3 5 5 Check that the emergency stop switch is in the run position See Emergency Stop Switch on page 3 6 WARNING The engine should not start when the hydraulic lockout control lever is in the unlocked open position If it does contact a SANY dealer Failure to follow this warning could result in death or serious injury 6 Move the hydraulic lockout control lever to the locked closed position If...

Page 86: ...e the throttle control dial is at MIN low idle Starting with the throttle control dial at MAX high idle will accelerate the engine and could damage the engine Failure to follow this notice could damage the machine or cause it to operate improperly 7 Set the throttle control dial to MIN 8 Turn the key switch to ON and check the monitor If all readings are normal and no fault codes are present the d...

Page 87: ...s NOTE Except for emergencies never shut down the engine while it is running at high speed Stopping the engine at high speed can damage the machine personal property and the environment or cause the equipment to operate improperly 4 Turn the key switch to OFF and remove the key 5 Turn the battery disconnect switch to OFF Cold Weather Operation The following recommendations are for operating SANY m...

Page 88: ...cons on page 3 26 6 When the regeneration is complete the engine will return to idle speed and the HEST and regeneration lamps will turn off Jump Start the Engine WARNING Before proceeding with any battery maintenance procedure observe the following precautions Battery gases are explosive Never smoke around batteries or expose them to sparks or open flames Work in a well ventilated area Wear perso...

Page 89: ...rt after five attempts 8 Perform steps 2 through 5 in reverse order to disconnect the jumper cables from the machine with the drained battery and from the machine with the charged battery Traveling Operations WARNING Never allow any personnel to be in the work area while the machine is being operated Avoid moving any control lever or pedal to abruptly change the direction of the machine Be aware o...

Page 90: ... are also reversed when the track frame faces backward Traveling with the Undercarriage Reversed CAUTION Traveling with the undercarriage reversed could pose a hazard resulting in injury When the cab faces the opposite direction of the arrows on the undercarriage the machine moves forward when the control levers are pulled and backward when they are pushed SANY does not recommend traveling with th...

Page 91: ...t foot pedal 3 and pull the right travel control lever 1 or press the bottom of the right foot pedal 2 to rotate the machine to the right Operating on Inclines WARNING Operating on an incline may cause the machine to become unstable Use caution when operating the machine on inclines and use a lower engine speed Operate the machine slowly and monitor machine movement Do not travel on an incline wit...

Page 92: ...rop without warning Failure to follow this warning could result in death or serious injury One Track Stuck 1 Position the boom and arm at an angle between 90 and 110 2 Pivot the upper structure to position the boom over the track that is stuck 3 Curl the bucket so the back of the bucket touches the ground 4 Lower the boom to raise the track NOTE Use cribbing to provide a firm surface if necessary ...

Page 93: ... swing the work equipment to the right move the left joystick to the right Arm 0000699 Figure 4 42 To extend the arm move the left joystick forward To retract the arm move the left joystick to the rear Boom 0000700 Figure 4 43 To lower the boom move the right joystick forward To raise the boom move the right joystick to the rear Bucket 0000701 Figure 4 44 NOTE The bucket function is the same for S...

Page 94: ... swing the work equipment to the right move the left joystick to the right Arm 0000699 Figure 4 46 To extend the arm move the right joystick forward To retract the arm move the right joystick to the rear Boom 0000700 Figure 4 47 To lower the boom move the left joystick forward To raise the boom move the left joystick to the rear Bucket 0000701 Figure 4 48 NOTE The bucket function is the same for S...

Page 95: ...g at high speed Failure to follow these warnings could result in death or serious injury Backhoe Operation 0000703 Figure 4 49 Backhoe operation is used for digging an area lower than the machine The digging range of the arm is between 30 and 45 The angle may vary according to the digging depth 0000704 Figure 4 50 Maximum digging force can be obtained when the angle between the boom and the arm an...

Page 96: ...ower the work equipment to the ground 3 Run the engine at idle speed 1050 rpm for 5 minutes to allow the engine to cool down Extend this cool down time in hot weather 4 Turn the key switch to the OFF position NOTE Always remove the key and take it with you even if you are leaving the machine for only a moment Keep it with you to prevent unauthorized operation of the machine 0004670 Figure 4 53 5 M...

Page 97: ...e ground 2 Run the engine at low idle speed for 5 minutes to avoid increasing internal temperatures and to allow for heat dissipation Extend this cool down time in hot weather 3 Shut down the engine and remove the key from the key switch 4 Move the hydraulic lockout control lever to the locked closed position See Hydraulic Lockout Control Lever on page 3 8 5 Close and lock the windows 6 Exit the c...

Page 98: ...or replace as necessary 3 Start the machine and test all operations Transportation Information Applicable laws and regulations must be observed when transporting the machine When transporting the machine on a trailer confirm the length width height and weight capacity of the trailer before loading Investigate the road conditions in advance for example dimension restrictions weight restrictions and...

Page 99: ... OMM 0004739 Figure 4 59 The SY500H excavator is equipped with a built in counterweight removal system 1 Figure 4 60 There are two parts to the SY500H counterweight assembly the lift 2 and the counterweight 3 1 0000711 Lift Counterweight 3 2 ...

Page 100: ... to level the counterweight Replace the shims exactly the same way when reattaching the counterweight 2 Remove the eight fasteners 6 and spacers 5 that secure the counterweight to the machine frame 3 Start the machine and set the throttle to low idle 4 Access the Tool Select screen See Tool Select Screen on page 3 36 5 Press function button F4 6 Move the hydraulic lockout control lever to the unlo...

Page 101: ...or OMM 000715 Figure 4 63 8 Push the right handle 8 of the control valve to raise the counterweight 9 off the frame 0000716 Figure 4 64 9 Pull the left handle 10 of the control valve and tilt the counterweight away from the machine 8 9 10 ...

Page 102: ... cannot support its weight The counterweight is heavy and could possibly break through surfaces that are not strong enough to support it which could result in death or serious injury NOTE Make sure the ground is firm under the counterweight Do not let the counterweight sink more than 1 ft 32 cm into the ground or the machine may not be able to pick up the counterweight 11 ...

Page 103: ...the engine Counterweight Installation NOTE Make sure that all shims are replaced in the same locations and are the same type thickness as noted during removal 1 Install the counterweight in the reverse order of removal 2 Tighten the mounting fasteners to 2249 2545 ft lb 3050 3450 N m 0000719 Figure 4 67 3 With the counterweight 1 on the ground the distance between the machine and the counterweight...

Page 104: ...on both sides of the machine Loading the Machine 1 Clean the undercarriage 2 Start the machine and allow it to reach operating temperature 3 Position the machine so the centerline of the machine matches the centerline of the trailer 0004938 0004957 Figure 4 70 4 Press function button F2 1 on the Main screen to set the auto idle to OFF 5 Press function button F3 2 on the Main screen to set the trav...

Page 105: ...oid hitting the trailer or truck 0000726 Figure 4 74 8 Swing the machine so the work equipment faces the back of the trailer 0000727 Figure 4 75 9 Place a support block 3 on the trailer under the work equipment 10 Fully extend the bucket cylinder arm and arm cylinder 11 Lower the work equipment onto the support block 12 Shut down the machine and remove the key from the key switch 13 Close and lock...

Page 106: ...eign material from entering during transport 0000729 Figure 4 79 19 Secure the machine to the trailer with suitable tie downs in accordance with all applicable laws and regulations Unloading the Machine WARNING To prevent the machine from tipping over select 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 movemen...

Page 107: ...ors so the operator has a clear view to the front and rear of the machine 5 Start the machine and allow it to warm up to operating temperature 0004938 0004957 Figure 4 81 6 Press function button F2 1 to set the auto idle to OFF 7 Press function button F3 2 to set the travel speed to low 8 Move the hydraulic lockout control lever to the unlocked open position See Hydraulic Lockout Control Lever on ...

Page 108: ...ately 1050 rpm for 5 minutes 14 Move the hydraulic lockout control lever to the locked closed position See Hydraulic Lockout Control Lever on page 3 8 15 Shut down the engine remove the key from the key switch and turn the battery disconnect switch to OFF NOTICE If disconnecting the battery wait at least 1 minute before disconnecting the battery cables so the machine s ECM can complete its updatin...

Page 109: ...nts 5 5 Fluids and Lubricants 5 6 Location Capacity and Type 5 6 Collect Oil Samples 5 6 Engine Oil Viscosity Temperature Data 5 7 Lubricating Grease Temperature Data 5 7 Industrial Gear Oil Temperature Data 5 7 Hydraulic Oil Ambient Temperature Data 5 8 Diesel Exhaust Fluid DEF 5 8 Engine Coolant 5 8 Lubricants 5 8 Grease 5 8 Fuel 5 9 Windshield Washer Fluid 5 9 Hydraulic Oil Description 5 9 Main...

Page 110: ...eck the Aftertreatment Exhaust Piping 5 23 Check the Engine Exhaust Pipe Clamps 5 23 Replace the Diesel Exhaust Fluid DEF Pump Filter 5 24 Check the Diesel Exhaust Fluid DEF 5 25 Fill the Diesel Exhaust Fluid DEF Tank 5 25 Replace the Diesel Exhaust Fluid DEF Tank Filter 5 26 Stationary Regeneration 5 27 Fuel System 5 28 Check the Fuel Level 5 28 Check the Fuel Lines 5 28 Drain the Fuel Tank 5 28 ...

Page 111: ...icate the Swing Bearing 5 53 Check the Swing Bearing Fasteners 5 53 Check the Swing Drive 5 53 Collect a Swing Drive Oil Sample 5 54 Replace the Swing Drive Oil 5 54 Check the Swing Grease Bath Level 5 55 Bucket 5 56 Replace the Bucket 5 56 Replace the Bucket Teeth 5 57 Miscellaneous Procedures 5 58 Check the Cab Door Doors and Locks 5 58 Check the Cooling Fan 5 58 Check the Decals 5 58 Check the ...

Page 112: ... the machine Hour Meter Reading Record the hour meter reading on a daily basis Compare meter readings with the required maintenance intervals listed in this manual Genuine SANY Replacement Parts Use genuine SANY replacement parts when repairing or replacing a part on the machine Failure to do so may result in premature system or part failure SANY Approved Lubricants Always use SANY approved lubric...

Page 113: ... Clean or replace the following components Immediately service the air filter and air filter housing if the air filter alarm indicates service is required Clean the fins and other cooling system parts on a regular basis to avoid overheating Replace the fuel filter on a regular basis or as required Clean the electrical components including the starter motor and the alternator to prevent dust buildu...

Page 114: ...e are absolutely clean Failure to adhere to this warning can cause equipment damage and contaminate the sample 3 Prepare the machine for service See Maintenance Safety on page 2 4 4 Obtain and send the oil sample for testing in accordance with the instructions included with the sample kit Location Approx Capacity Lubricant Coolant Engine 8 7 gal 33 L See Engine Oil Viscosity Temperature Data on pa...

Page 115: ... In some circumstances short term use of low viscosity engine oil in cold temperatures below 23 F 5 C is acceptable however long term use can reduce engine life Grease Type Temperature Summer Winter NGLI 2 molybdenum disulfide lithium based grease NGLI 1 molybdenum disulfide lithium based grease NOTE Always use clean extreme pressure EP grease when greasing the machine Avoid using low viscosity gr...

Page 116: ...leetguard ES Compleat coolant Lubricants NOTICE Use only lubricants recommended in this manual Using other lubricants can damage the machine and could cause improper machine operation Contact a SANY dealer for assistance if the machine will be operated in subzero temperatures where the use of an auxiliary heating device is required Grease Always use clean extreme pressure EP grease when greasing t...

Page 117: ... fuel Take appropriate precautions to prevent fuel contamination during refueling Windshield Washer Fluid Only use clean automotive windshield washer fluid Do not mix concentrates into the washer fluid In cold weather areas use washer fluid with a low temperature rating Hydraulic Oil Description Hydraulic oil is an important part of the hydraulic system Hydraulic oil lubricates hydraulic system co...

Page 118: ...eld washer fluid See page 5 60 Replace the bucket teeth See page 5 57 Replace the bucket See page 5 56 Check the air filter if a restriction warning is displayed See page 3 26 After the First 50 Hours Initial change of the engine oil and filter See page 5 15 Lubricate the swing bearing See page 5 53 Drain sediment and water in fuel filter See page 5 30 Check air cleaner and connection of air intak...

Page 119: ...the hydraulic tank return filter See page 5 40 Replace the hydraulic oil pilot filter element See page 5 37 Replace the hydraulic case drain filter element See page 5 32 Annually or Every 2000 Hours NOTE Make sure all daily 50 hour 100 hour 250 hour and 1000 hour maintenance tasks have been completed before proceeding with the 2000 hour maintenance tasks Check the alternator See page 5 17 Check th...

Page 120: ...triction Material deterioration General damage NOTE If any of the above conditions exist replace the crankcase breather tube 3 Close the engine access door See Closing the Engine Access Door on page 4 11 Check the Engine Air Precleaner 0004989 Figure 5 3 1 Check the engine air precleaner annually 2 Remove the cover inspect and remove any debris Check the Engine Air Filter System 0004769 Figure 5 4...

Page 121: ... the air filter housing with a clean cloth 5 Install the air filters 6 Close the air filter housing 7 Close the left front access door See Closing the Left Front Access Door on page 4 9 Replace the Engine Air Filter 0004769 Figure 5 6 1 Locate the engine air filter housing 1 behind the left front door See Opening the Left Front Access Door on page 4 9 0004770 Figure 5 7 2 Open the air filter housi...

Page 122: ...stick 8 Close and secure the engine access door See Closing the Engine Access Door on page 4 11 NOTICE Do not overfill the engine with oil This could result in machine damage and improper machine operation Collect an Engine Oil Sample 1 Prepare the machine for service See Maintenance Safety on page 2 4 2 Start the engine and operate the machine for all systems to reach normal operating temperature...

Page 123: ... Wait for the engine to cool before proceeding 1 Prepare the machine for service See Maintenance Safety on page 2 4 2 Remove the machine bottom cover 1 under the engine compartment 0004771 Figure 5 13 3 Open the engine access door 2 See Engine Access Door on page 4 10 0004768 Figure 5 14 4 Loosen either of the two engine oil filler caps 3 0000738 Figure 5 15 NOTE For engine oil capacity see Locati...

Page 124: ...r mount then tighten the filter by hand an additional 3 4 of a turn 17 Remove the engine oil filler cap NOTE Do not overfill the engine with oil Overfilling of oil could result in machine damage or improper machine operation 18 Add oil as needed See Location Capacity and Type on page 5 6 for engine capacity 0004775 Figure 5 17 19 Install the engine oil filler cap 7 0004772 Figure 5 18 20 Remove th...

Page 125: ...ndicate a faulty starter High pitched screeching sounds Grinding noise Intermittent whirring sound starter not engaging engine flywheel Starter turns engine over slowly Burning smell or smoke coming from the starter If the starter is malfunctioning contact a SANY dealer for additional information Check the Air Intake and the Charge Air Piping 0004826 Figure 5 1 1 Prepare the machine for service Se...

Page 126: ...door See Engine Access Door on page 4 10 0004828 Figure 5 2 4 Open the expansion tank access door 1 See Expansion Tank Access Door on page 4 10 5 Slowly open the filler cap 2 on top of the expansion tank to release the cooling system pressure 6 Remove the cap when all pressure has been relieved 0004777 Figure 5 3 NOTE For engine cooling system capacity See Location Capacity and Type on page 5 6 7 ...

Page 127: ...could result in death or serious injury Avoid inhaling or ingesting engine coolant CAUTION Do not remove the radiator cap while the engine is hot Engine coolant is under pressure when hot and will spray out which could result in burns or serious injury Always wait for the engine to cool to outdoor ambient temperatures before removing the radiator cap NOTICE Dispose of the coolant in accordance wit...

Page 128: ...Charge Air Cooler and Air Conditioner Condenser Fins 1 Prepare the machine for service See Maintenance Safety on page 2 4 2 Open the engine access door See Engine Access Door on page 4 10 3 Open the left rear access door See Left Rear Access Door on page 4 8 0004780 Figure 5 9 4 Remove the fasteners 2 that secure the protection screens 1 mounted in front of the radiator 5 Remove the protection scr...

Page 129: ... Figure 5 13 3 Press on the belt 2 between the compressor pulley and the drive pulley The belt should deflect 0 20 in 0 31 in 5 mm 8 mm NOTE If using a tension meter to check the belt tension of the compressor the tension should measure 143 lbf 637 N 4 Adjust belt tension as necessary 5 Close and secure the engine access door Adjust the Air Conditioner Compressor Belt NOTE Do not perform any air c...

Page 130: ...to be readjusted after the first hour of operation 7 Close and secure the engine access door Replace the Fresh Air Filter 0004817 Figure 5 15 1 Unlock and open the fresh air filter door 1 0004733 Figure 5 16 2 Remove the three fasteners 2 that secure the fresh air filter 3 in place 3 Remove the fresh air filter 4 Clean the fresh air filter using compressed air NOTE The fresh air filter can be clea...

Page 131: ...ponents have cooled until they can be touched without burning Hot engine and exhaust components can cause burns and injury 1 Open the engine access door See Engine Access Door on page 4 10 0004752 Figure 5 18 2 Locate the exhaust system 1 next to the engine 3 Inspect the exhaust system and its mount for leaks or signs of damage 4 Check the connection to the expansion pipe 2 for leaks or signs of d...

Page 132: ...id DEF Pump Filter Perform this procedure every 4500 hours of operation or 3 years whichever comes first 1 Open the right front access door See Right Front Access Door on page 4 8 0004754 Figure 5 20 2 Locate the DEF pump 1 3 Remove the DEF pump filter housing 2 from the bottom of the pump 0000757 Figure 5 21 4 Remove the old filter element 3 and replace it with a new one 5 Install a new DEF pump ...

Page 133: ...monitor Home screen Fill the Diesel Exhaust Fluid DEF Tank 0004869 Figure 5 23 1 Open the DEF tank compartment door 1 on the right front side of the machine See Right Front Access Door on page 4 8 0004755 Figure 5 24 2 Remove the DEF tank cap 2 then add DEF through the filler neck as needed 3 Install the DEF tank cap and close the right front access door F5 F4 F3 F2 F1 1 1 2 ...

Page 134: ... sending unit and mark the hose locations 5 Remove the DEF sending unit fasteners 4 then lift the DEF sending unit from the tank 0000762 Figure 5 27 6 Remove and replace the DEF suction filter 7 7 Install the DEF sending unit 6 into the tank 0004755 Figure 5 28 8 Install the fasteners 14 to secure the DEF sending unit 11 to the tank 12 9 Connect the two DEF lines 10 and two DEF coolant hoses 9 10 ...

Page 135: ...so could result in engine damage 1 Make sure the machine is in a safe location where the exhaust pipe outlet will not face any combustible materials CAUTION The engine exhaust will be very hot Make sure that the machine is not in a combustible area Otherwise it could cause a fire or explosion resulting in injury 0004902 Figure 5 30 2 Make sure that both the DEF 5 and fuel tank 6 are full as shown ...

Page 136: ...ing those on the engine CAUTION Failure to perform this procedure as directed could result in a fire during operation which could result in death or serious injury Drain the Fuel Tank 1 Prepare the machine for service See Maintenance Safety on page 2 4 2 Open the right rear access door See Right Rear Access Door on page 4 8 0004767 Figure 5 35 3 Locate the drain valve 1 for the fuel tank behind th...

Page 137: ...and replace if damaged 8 Remove the primary fuel filter NOTICE Dispose of contaminated fuel or water in accordance with all applicable environmental regulations Failure to do so could damage the environment 9 Install the new filter on the primary filter housing 2 NOTE Follow the manufacturer s instructions on the fuel filter body when installing the filter 10 Install the plastic housing to the bot...

Page 138: ...e fuel filter drain the fuel tank 6 Check for fuel leaks 7 Repair fuel leaks if found 8 Close and secure the right rear access door Hydraulic System Check the Accumulator Function WARNING The accumulator contains pressurized nitrogen Improper handling is extremely dangerous Do not drill holes in the accumulator or place it close to fire or a high heat source Do not weld any part on the accumulator...

Page 139: ...ller cap Relieve pressure to prevent injury Failure to follow these warnings could result in death or serious injury 0000709 Figure 5 42 1 Park the machine in a secure location and position the work equipment with the arm and bucket fully extended 1 2 Shut down the engine 3 Prepare the machine for service See Maintenance Safety on page 2 4 4 Turn the key switch to ON 0004692 Figure 5 43 5 Set the ...

Page 140: ... 5 31 5 Remove the hydraulic suction strainer cover See Add Hydraulic Oil on page 5 34 6 Insert the oil sample tube into the hydraulic oil tank 7 Collect a sample of hydraulic oil 8 Remove the oil sample tube 9 Replace the hydraulic suction strainer cover 10 Follow the instructions included with the sample kit to send the sample for testing Replace the Case Drain Filter CAUTION Hydraulic oil may b...

Page 141: ...personal protective equipment PPE and use a piece of cardboard or paper to search for suspected leaks 13 Check for leaks and repair as necessary 14 Close and secure the right rear access door 15 Shut down the engine Check the Hydraulic Oil Level NOTE Park the machine on a level surface 1 Prepare the machine for maintenance See Maintenance Safety on page 2 4 2 Open the right rear access door See Ri...

Page 142: ... a hose if it is cracked damaged or worn 3 Check fittings at both ends of all lines and flexible hoses 4 Inspect all fasteners Tighten any loose fasteners NOTE Replace any damaged fasteners Add Hydraulic Oil CAUTION Hydraulic oil may be hot and under pressure which could result in injury Always wait for the machine to cool before attempting to open the hydraulic system 1 Position the machine as in...

Page 143: ...r the breather valve when the hydraulic oil level is correct 19 Check for leaks 20 Tighten connections if leaks are found Replace Hydraulic Oil 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 filter cover Relieve any pressure to prevent injury Failure to foll...

Page 144: ...5 58 8 Remove the bottom cover 3 0000780 Figure 5 59 9 Place a suitable container with a minimum capacity of 127 gal 480 L under the hydraulic tank drain plug 4 to collect the drained hydraulic oil 10 Clean the area around the hydraulic tank drain plug of dust and debris 11 Remove the drain plug and allow the hydraulic tank to drain completely NOTICE Dispose of drained hydraulic oil in accordance ...

Page 145: ...east once each year whichever occurs first NOTE Make sure the machine is on firm level ground before proceeding 1 Position the work equipment as shown on the hydraulic tank decal 2 Prepare the machine for service See Maintenance Safety on page 2 4 3 Relive hydraulic system pressure See Relieve Hydraulic System Pressure on page 5 31 0004735 Figure 5 63 4 Open the right rear access door See Right Re...

Page 146: ... Wear gloves eye protection and other personal protective equipment PPE and use a piece of cardboard or paper to search for suspected leaks Failure to follow this warning could result in death or serious injury CAUTION Hydraulic oil may be hot and under high pressure which could result in injury Always wait for the machine to cool and relieve hydraulic pressure before attempting to open the hydrau...

Page 147: ...ress the hydraulic tank vent button 3 0000791 Figure 5 70 5 Unscrew and remove the filter element cover 4 from the filter 5 6 Pull the filter up and remove it from the valve body NOTICE Dispose of the filter in accordance with all applicable environmental regulations Failure to do so could damage the environment 0000790 Figure 5 71 7 Install the new breather filter 8 Install the breather filter co...

Page 148: ...aulic Oil on page 5 34 6 Check and tighten all hydraulic fittings as necessary 7 Close and secure the right rear access door Replace the Hydraulic Tank Return Filter WARNING Allow the hydraulic system to cool before servicing Hot hydraulic 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 pressure to prev...

Page 149: ...bleed any air from the hydraulic system 0004692 Figure 5 79 15 Move the hydraulic lockout control lever 10 to the unlocked open position 11 16 Check for leaks If any are located repair as needed 17 Check the hydraulic fluid level See Add Hydraulic Oil on page 5 34 Clean the Hydraulic Suction Strainer CAUTION Allow the hydraulic system to cool before servicing Hot hydraulic oil may cause burns or o...

Page 150: ... level is midway in the sight glass 4 NOTICE Do not overfill the hydraulic tank This could result in machine damage and improper machine operation 10 Reinstall the suction strainer cover 11 To purge air from the system start the engine and run at low idle for 10 minutes Check the hydraulic oil level and add hydraulic oil as needed See Check the Hydraulic Oil Level on page 5 33 Check the Pump Mount...

Page 151: ...left rear access door See Left Rear Access Door on page 4 8 2 Wait several minutes to allow any accumulated battery gases to clear before servicing the batteries 3 Turn the battery disconnect switch to the OFF position See Battery Disconnect Switch on page 3 15 NOTICE If performing a battery disconnect wait for at least 1 full minute before disconnecting the battery cables so the machine s engine ...

Page 152: ...mproperly 4 Turn the battery disconnect switch to the OFF position See Battery Disconnect Switch on page 3 15 0004716 Figure 5 86 5 Remove the battery cover 1 0004807 Figure 5 87 NOTE Battery terminals are protected by plastic covers lift covers to gain access to the terminals do not remove covers 6 Disconnect the black ground battery cables first 2 then disconnect the red positive battery cables ...

Page 153: ...nnectors worn or degraded wiring etc Identify and repair any electrical faults Use only genuine SANY parts and fuses Shut down the engine immediately if a fault with the power supply occurs Check the Operating Functions 1 Turn the key switch to ON do not start the engine to provide power to the machine and verify that all functions in the cab work correctly NOTE Make sure any damaged or inoperable...

Page 154: ...service See Maintenance Safety on page 2 4 0004960 Figure 5 93 2 Remove six fasteners 1 and remove final drive motor cover 2 0000802 Figure 5 94 3 Inspect the final drive motor 3 and make sure all hoses are connected tightly 4 Make sure all fasteners are present and tight NOTE Replace any damaged or defective fasteners and tighten any loose fasteners Use thread lock compound when reinstalling loos...

Page 155: ...tions could result in death or serious injury 0004729 Figure 5 95 1 Position the machine on a firm level surface Make sure the oil level line 2 is parallel with the ground and the arrow is pointed up 2 Prepare the machine for service See Maintenance Safety on page 2 4 3 Turn the battery disconnect switch to OFF See Battery Disconnect Switch on page 3 15 4 Remove dirt and debris from around the fil...

Page 156: ...ut with extreme force which could result in injury Slowly loosen the plug to gradually release the pressure Failure to follow these precautions could result in death or serious injury 0004729 Figure 5 98 1 Position the machine on a firm level surface making sure the oil level line 1 is parallel with the ground 2 Prepare the machine for service See Maintenance Safety on page 2 4 3 Remove any dirt a...

Page 157: ...operate improperly Overfilling the final drive case may damage the case seals resulting in machine damage and improper machine operation 11 Add new oil through the filler hole 2 until the oil level is within 0 4 in 10 mm of the bottom of the check plug hole 12 Check for external leaks NOTICE If oil leaks are found during the inspection stop the inspection and locate and repair the cause of the oil...

Page 158: ...xcessive debris requires more energy to operate the tracks and causes the moving parts to wear rapidly Check the Track Fasteners 0004869 Figure 5 102 NOTE Replace any damaged or defective fasteners 1 Make sure all track fasteners are installed for each track shoe 1 and are not broken bent loose or damaged NOTE Tighten the fasteners in a crisscross sequence shown starting at the number 2 position a...

Page 159: ...and the idler as shown 4 Measure the gap at location A from the top of the track to the string or straightedge Figure 5 105 5 Hold a taut string or straightedge between the centers of the rear top roller and the sprocket as shown 6 Measure the gap at location B from the top of the grouser to the string or straightedge 7 Add dimensions A and B NOTE The specified range must be within 3 in 4 in 76 2 ...

Page 160: ...specified range Decrease the Track Tension WARNING Do not loosen the grease fitting The grease fitting is under extreme pressure and can exit the grease valve quickly and forcefully which could result in death or serious injury Do not stand directly in front of the grease valve when loosening the valve Wear suitable personal protective equipment PPE in the form of protective clothing gloves safety...

Page 161: ...he Swing Bearing Figure 5 110 1 Lubricate the fittings 1 on the swing bearing with grease until grease seeps out of the seal 2 2 Check the condition of the seal NOTE If the seal is leaking replace it immediately 3 Start the engine 4 Lift the arm off the ground 5 Rotate the upper structure 90 and repeat steps 1 and 2 6 Rotate the upper structure until a full 360 rotation has been made 7 Shut down t...

Page 162: ...all systems to reach normal operating temperatures 3 Shut down the machine 4 Remove the dipstick from the swing drive See Replace the Swing Drive Oil on page 5 54 5 Insert the oil sample tube into the dipstick tube 6 Collect a sample of swing drive oil 7 Remove the oil sample tube 8 Replace the dipstick 9 Follow the instructions included with the sample kit to send the sample for testing Replace t...

Page 163: ... the swing drive oil fill cap 6 11 Fill the swing drive with clean oil NOTICE Do not overfill the swing gearbox with oil This could result in damage to the swing drive 12 Check the swing gearbox oil level using the swing drive dipstick 5 0000814 Figure 5 118 NOTE The oil level must be within the etched area 7 Add clean oil as necessary 13 Install and tighten the oil fill cap NOTICE If oil leaks ar...

Page 164: ...any of the pins The pins could fly out and cause personal injury Do not stand behind the bucket when removing pins Keep hands and feet clear of the underside of the bucket during removal to avoid injury To avoid injury do not use hands or fingers to aid in bore alignment 1 Prepare the machine for service See Maintenance Safety on page 2 4 Figure 5 121 2 Lower the bucket 1 to where it just touches ...

Page 165: ...moved Do not allow anyone to stand in front of the pins during pin removal Metal fragments from roll pins and tools may break off during roll pin removal and installation Wear safety goggles gloves and other personal protective equipment PPE to prevent serious injury Failure to follow these warnings could result in death or serious injury NOTE Bucket teeth must be replaced before the bucket tooth ...

Page 166: ...n for any damage and replace as necessary 2 Make sure the cooling fan is securely mounted 3 Tighten the fasteners if necessary Check the Decals All safety decals should be visible and complete NOTE See Operator Safety Information on page 2 2 Check the Escape Tool 0004669 Figure 5 3 NOTE Inspect the escape tool periodically Replace it if it appears damaged or unable to break the cab window or cut t...

Page 167: ...ever allow loose items to remain on the machine Collect Oil Samples 1 Acquire an oil analysis sample kit from a SANY dealer 2 Collect the following oil samples Engine oil See Collect an Engine Oil Sample on page 5 14 Hydraulic oil See Collect a Hydraulic Oil Sample on page 5 32 Swing drive oil See Collect a Swing Drive Oil Sample on page 5 54 Final drive oil See Collect a Final Drive Oil Sample on...

Page 168: ... damage loose connections or missing fasteners Structural Inspection 1 Thoroughly wash the machine 2 Inspect the entire structure of the machine for signs of damage or excessive wear Clean and Check the Upper Structure and Undercarriage The machine consists of two major component groups The undercarriage with its various components and assemblies The upper structure with its various components and...

Page 169: ...tice could result in machine damage or improper machine operation 3 Check the operation of the windshield washer nozzle 1 and wiper 2 to make sure there is no smearing across the windshield during operation Replace the wiper blade with a new one if smearing does occur 4 If necessary adjust the spray nozzle to make sure the fluid spray is properly directed 2 1 ...

Page 170: ... with lines leading to the bearings 1 Grease the arm cylinder head end pin fitting 1 2 Grease the two boom foot pin fittings 2 3 Grease the two boom cylinder rod end pin fittings 3 0004731 Figure 5 13 4 Grease the two boom cylinder head end pin fittings 4 1 Boom pin 7 H link 2 Boom cylinder rod end 8 Bucket pin 3 Arm cylinder head end 9 Arm pin 4 Arm cylinder rod end 10 Boom cylinder head end 5 Bu...

Page 171: ...er rod end fitting 10 Figure 5 18 11 Grease the two arm pin fittings 11 one on each side Machine Storage Store the machine in a secure area free of public access If your storage area is near the ocean or other saltwater environment it is important to be aware of salt damage Contact a SANY dealer for additional storage procedures if this is the case Short Term Storage Less Than 30 Days See Short Te...

Page 172: ...5 64 MAINTENANCE SY500H Excavator OMM Page Intentionally Blank ...

Page 173: ...6 1 SY500H Excavator OMM Specifications Machine Dimensions 6 2 Operating Ranges 6 4 Technical Specifications 6 5 Lift Chart 6 6 Lift Chart Continued 6 7 Chapter 6 ...

Page 174: ...6 2 SPECIFICATIONS SY500H Excavator OMM Machine Dimensions 0000837 Figure 6 1 1 2 3 4 5 6 7 8 9 10 11 ...

Page 175: ... height 12 ft 4 in 3 76 m 4 Upper width 10 ft 10 in 3 29 m 5 Cab height 11 ft 3 in 3 42 m 6 Track shoe width standard 2 ft 11 in 0 9 m 7 Track gauge 9 ft 2 74 m 8 Minimum ground clearance 1 ft 10 in 0 56 m 9 Tail swing radius 12 ft 8 in 3 85 m 10 Track length on ground 14 ft 6 in 4 41 m 11 Track length 17 ft 11 in 5 45 m Boom length 22 ft 11 in 6 99 m Arm length 12 ft 9 in 3 88 m ...

Page 176: ... 2 Item Dimensions 1 Maximum digging height 36 ft 5 in 11 11 m 2 Maximum dumping height 25 ft 9 in 7 84 m 3 Maximum digging depth 27 ft 1 in 8 25 m 4 Maximum vertical wall digging depth 22 ft 1 in 6 72 m 5 Maximum digging reach 41 ft 1 in 12 54 m 6 Maximum swing radius 17 ft 2 in 5 24 m ...

Page 177: ...h park brake Travel pressure maximum 4975 psi 34 3 MPa Travel speed high low High speed 3 2 mph 5 2 kph Low speed 2 1 mph 3 4 kph Travel effort maximum 48 109 lb ft 214 0 kN Grade capability maximum 35 Swing motor Axial piston with swing brake Swing pressure maximum 3989 psi 27 5 MPa Swing speed maximum 8 rpm Undercarriage standard Steel track Track shoe width standard 2 ft 7 in 800 0 mm Track rol...

Page 178: ...22 035 39 244 17 801 32 256 14 631 31 127 14 119 23 869 10 827 0 0 ft 0 0 m 49 362 22 390 49 362 22 390 42 366 19 217 31 109 14 111 33 296 15 103 23 104 10 480 4 9 ft 1 5 m 33 268 15 090 33 268 15 090 58 930 26 730 46 421 21 056 43 557 19 757 30 618 13 888 34 326 15 570 22 710 10 301 9 8 ft 3 0 m 50 658 22 978 50 658 22 978 56 531 25 642 46 782 21 220 42 726 19 380 30 657 13 906 33 797 15 330 22 7...

Page 179: ...45 23 027 10 445 18 889 8 568 15 684 7 114 9 8 ft 3 0 m 24 766 11 234 19 226 8 721 22 842 10 361 15 285 6 933 18 931 8 587 14 894 6 756 4 9 ft 1 5 m 26 495 12 018 18 609 8 441 23 647 10 726 14 991 6 800 19 579 8 881 14 643 6 642 0 0 ft 0 0 m 27 818 12 618 18 148 8 232 21 914 9 940 14 950 6 781 4 9 ft 1 5 m 28 307 12 840 17 932 8 134 21 914 9 940 14 950 6 781 9 8 ft 3 0 m 27 172 12 325 18 071 8 197...

Page 180: ...6 8 SPECIFICATIONS SY500H Excavator OMM Page Intentionally Blank ...

Page 181: ...ructions 7 2 Removal and Installation Precautions 7 2 Operation Precautions 7 2 Equipment Control Valves 7 3 Stop Valves 7 3 Return Flow Selector Valve 7 4 Optional Equipment Controls 7 4 Right and Left Joystick 7 4 Monitor 7 4 Install Optional Equipment 7 5 Remove Optional Equipment 7 6 Chapter 7 ...

Page 182: ...ons 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 handling objects weighing more than 55 lb 25 kg Never stand under a suspended load Make sure the machine is well balanced and supported whenever installing or removing optional equipment For additional information about removal and installation of...

Page 183: ...SANY dealer for hydraulic flow and pressure adjustment needed for the attached equipment Stop Valves 0004953 Figure 7 1 The stop valves 1 control the flow of the hydraulic oil to optional equipment when mounted to the arm NOTE A stop valve is mounted on each side of the arm The right side is shown 0004809 Figure 7 2 In the open position 2 the line in the stop valve is in line with the oil flow Thi...

Page 184: ... two way flow attachments is available for use on this machine A breaker is an example of a one way flow attachment and a shear is an example of a two way flow attachment Optional Equipment Controls WARNING Do not operate the joystick control buttons when you are not operating the attachments Accidental operation of an attachment could result in death or serious injury Right and Left Joystick 0000...

Page 185: ...ment 3 Place a suitably sized container under the stop valve to catch any hydraulic oil NOTE Replace the O rings 4 Remove four fasteners 1 and plate 2 from the end of the stop valve to allow any residual hydraulic oil to drain into the container NOTE Right side shown Repeat for the left side 5 Connect the optional equipment to the machine in accordance with the manufacturer s instructions 6 Connec...

Page 186: ...do so could damage the environment 3 Place a suitably sized container under the hydraulic connection to catch any residual hydraulic oil 4 Disconnect the optional equipment hydraulic lines in accordance with the manufacturer s instructions 0004809 Figure 7 8 5 Turn both stop valves to the closed position 1 NOTICE Dispose of hydraulic oil in accordance with local environmental regulations Failure t...

Page 187: ...ck 3 18 Vent Mode Selection 3 10 C Cab Cab Light 4 13 Climate Control Panel 3 10 Hydraulic Lockout Control Lever 3 8 Joystick Controls 3 18 Left Control Console 3 8 Left Joystick 3 9 Left Joystick Button 3 18 Monitor 3 25 Monitor Console 3 17 Right Control Console 3 12 Right Control Console Buttons 3 12 Right Control Console Switches 3 12 Right Joystick 3 13 Right Joystick Button Switch 3 18 Clean...

Page 188: ...st Piping 5 23 Fill DEF Tank 5 25 Manual Regeneration 4 17 Replace DEF Pump Filter 5 24 Replace DEF Tank Filter 5 26 Stationary Regeneration 5 27 F Fire Extinguisher 2 4 Fluids and Lubricants Diesel Exhaust Fluid DEF 5 8 Engine Coolant 5 8 Fuel 5 9 Hydraulic Oil 5 9 Location Capacity and Type 5 6 Lubricants 5 8 Windshield Washer Fluid 5 9 Form Correction Request 1 8 Serial Number 1 7 Frame Serial ...

Page 189: ...ick Controls 3 18 K Key Switch 3 13 L Left Control Console 3 8 Air Conditioning Power Button 3 10 Automatic Temperature Control 3 10 Climate Control Panel 3 10 Fan Speed Control Switch 3 10 Hydraulic Lockout Control Lever 3 8 LCD Screen 3 10 Left Joystick 3 9 Left Joystick Button 3 18 Off Button 3 10 Radio Control Panel 3 11 Recirculated Fresh Air Selection 3 10 Temperature Selection Control Switc...

Page 190: ...0 Swing Bearing Fasteners 5 53 Swing Drive 5 53 Swing Grease Bath Level 5 55 Windshield Washer Fluid 5 60 Windshield Wiper 5 61 Maintenance Procedures Add Hydraulic Oil 5 34 Adjust AC Compressor Belt 5 21 Check and Add Final Drive Oil 5 47 Clean or Replace AC Fresh Air Filter 5 22 Clean or Replace AC Recirculation Filter 5 23 Collect Oil Samples 5 59 Decrease Track Tension 5 52 Drain the Fuel Tank...

Page 191: ...e 5 47 Hydraulic 5 32 Swing Drive 5 54 Operating Ranges 6 4 Operator Controls 3 7 Operator Safety Information 2 2 Optional Equipment Installation 7 5 Removal 7 6 Optional Equipment Controls See Work Equipment Controls P Plate Engine Identification 1 4 Hydraulic Pump Identification 1 5 Main Control Valve Identification 1 5 Product Identification 1 4 Swing Motor Identification 1 4 Travel Motor Ident...

Page 192: ...ation 1 4 Log 1 7 Record 1 7 Specifications Lift Chart 6 6 Machine Dimensions 6 2 Operating Ranges 6 4 Technical Specifications 6 5 Stop Valve 3 22 Storing the Machine Long Term 4 27 Maintenance During Storage 4 28 Overnight 4 26 Return to Service 4 28 Short Term 4 27 Sunlight Sensor 3 17 Swing Motor Identification Plate 1 4 Switch Battery Disconnect 3 15 Emergency Stop 3 6 Fan Speed Control 3 10 ...

Page 193: ... 4 12 Windshield Open 4 11 Wiper 5 61 Wiper Switch 3 15 Work Equipment Controls 4 22 Arm 4 23 4 24 Backhoe Operation 4 25 Boom 4 23 4 24 Bucket 4 23 4 24 Digging a Trench 4 25 Loading Operations 4 25 Monitor 7 4 Right and Left Joystick 7 4 Swing 4 23 4 24 Numerics 12V Power Supply Socket 3 17 ...

Page 194: ...I 8 SY500H Excavator OMM Page Intentionally Blank ...

Page 195: ...Page Intentionally Blank ...

Page 196: ... Part Number SSY005084272 318 Cooper Circle Peachtree City Georgia 30269 www sanyamerica com find a dealer Sales E mail sales sanyamerica com Service E mail service sanyamerica com Service Hotline 470 552 SANY 7269 sanyamerica com ...