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SANY SY50U, Operation And Maintenance Manual

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SY50U Excavator OMM   

Maintenance

SANY

      

Operation and Maintenance Manual — 0120

5-3

TABLE OF 

CONTENTS

INTRODUCTION

SAFETY

MACHINE

CONTROLS

MACHINE

OPERA

TION

MAINTENANCE

SPECIFICA

TIONS

OPTIONAL

 EQUIPMENT

 

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-32

Check the Engine Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-32
Change the Engine Coolant  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-33
Inspect the Engine Water Pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-34
Inspect and Clean the Cooling Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-35

Heating and Air Conditioning System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-36

Check Heating and Air Conditioning System Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-36
Clean or Replace the Ventilation Filter Screen  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-36
Check and Adjust the Air Conditioning Compressor Belt Tension. . . . . . . . . . . . . . . . . . . .  5-37

Two Methods of Checking Belt Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-37
Adjust the Air Conditioning Compressor Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . .  5-37

Air Conditioning Storage  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-38

Air Conditioning Components Inspection and Maintenance Schedule  . . . . . . . . . . . . .  5-38

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-39

Bleed the Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-39
Drain the Fuel Tank   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Replace the Fuel Filter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Drain and Clean the Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-41

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-43

Check the Battery  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-43
Remove the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-46

Check the Accumulator Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-46
Check the Hydraulic Hoses, Lines, and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-46
Relieve Hydraulic System Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-46
Check Hydraulic Oil Tank Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-47
Add Hydraulic Oil   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-47
Replace the Hydraulic Tank Breather Filter Element  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-48
Replace the Hydraulic Oil Pilot Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-49
Replace the Hydraulic Oil Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-50
Clean and Replace the Hydraulic Oil Suction Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-51
Change the Hydraulic Oil   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-53
Collect Hydraulic Oil Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-54

Track Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-55

Check the Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-55
Adjust the Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-55

Increase the Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-55
Decrease the Track Tension  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-56

Check and Add Final Drive Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-57
Change the Final Drive Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-58
Collect Final Drive Oil Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-59
Check the Final Drive Motor Mounting Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-59

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

Lubrication Points  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-60

Arm Cylinder Rod End Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-61
Boom-Arm Connecting Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-61
Arm Cylinder Base End Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-62
Boom Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
Swing Bearing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-62
Dozer Blade Linkage Pins and Dozer Blade Cylinder End Pins  . . . . . . . . . . . . . . . . . .  5-63
Boom Cylinder Base End Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-63

Summary of Contents for SY50U

Page 1: ...service sanyamerica com SANY Part Number SSY005082347 SY50U Excavator Operation and Maintenance Manual ...

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

Page 3: ...d Maintenance Manual WARNING Read and understand all safety precautions and instructions in this manual and on the machine labels before operating or maintaining it Failure to follow safety messages could result in death or serious injury Keep this manual with the machine for future reference ...

Page 4: ...9 www sanyamerica com Phone 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 resu...

Page 5: ...quipment 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 Plates 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: ...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 Monitor 3 4 Daily Maintenance Information Screen 3 4 Maintenance Information Screen 3 5 Home Screen 3 5 Function List Screen 3 7 System Information Screen ...

Page 7: ...tch 3 25 Power Outlet 12V 3 25 Dome Light Switch 3 26 Controls 3 27 Dozer Blade Control Lever 3 28 Return Flow Selector Valve 3 28 Joystick Controls 3 29 Joystick SAE Mode 3 29 Left Joystick SAE Mode 3 29 Right Joystick SAE Mode 3 29 Joystick BHL Mode 3 30 Left Joystick BHL Mode 3 30 Right Joystick BHL Mode 3 30 Pattern Change SAE BHL Valve 3 31 Hydraulic Lockout Control Lever 3 32 Directional Arr...

Page 8: ...een 3 13 Operating Mode Screen 3 13 Flow Rate Information Screen 3 14 Flow Rate Setting Screen 3 15 System Unlocked Screen 3 15 Reserved Function 3 15 Quick Coupler Control Screen 3 16 Date and Time Setup Screen 3 16 Diesel Particulate Filter DPF Screens 3 17 Switches 3 19 Joystick Switches 3 20 Left Joystick Switch 3 20 Right Joystick Switch 3 20 Horn Button 3 21 Throttle Control Dial 3 21 Key Sw...

Page 9: ...9 Air Outlets 3 39 Ventilation 3 39 Radio 3 40 Control Panel 3 40 Radio Operation 3 41 Presetting Radio Stations 3 41 Searching Radio Stations 3 42 Manual Tuning 3 42 Automatic Tuning 3 42 Sound Mode Adjustment 3 42 Time Adjustment 3 43 Escape Tool 3 44 Fire Extinguisher 3 44 Machine Operation Work Area 4 4 General Job Safety 4 4 Operator Responsibilities 4 4 Prestart Checks and Adjustments 4 5 Fl...

Page 10: ...t Control and Operation 4 26 Arm Control SAE Mode 4 26 Arm Control BHL Mode 4 26 Boom Control SAE Mode 4 26 Boom Control BHL Mode 4 27 Swing Control 4 27 Bucket Control 4 27 Boom Swing Control Pedal 4 28 Dozer Blade Control Lever 4 28 Restricted Operation 4 29 Never Operate with Bucket Force 4 29 Never Use Swing Force 4 30 Never Use Traveling Force 4 30 Never Operate Using Machine Weight 4 31 Do N...

Page 11: ...old Weather 4 47 After Cold Season 4 47 Long Term Storage 4 48 Before Long Term Storage 4 48 During Storage 4 48 Air Conditioner Storage 4 49 Removing from Storage 4 49 Starting the Engine After Long Term Storage 4 49 Transportation Information 4 50 Transportation Method 4 50 Loading and Unloading 4 50 Loading the Machine 4 51 Securing the Machine 4 54 Unloading the Machine 4 55 Lifting the Machin...

Page 12: ...e First 50 Hours 5 15 Weekly or Every 50 Hours 5 15 Every 100 Hours 5 15 After the First 150 Hours 5 15 Every 250 Hours 5 15 Every 3 Months or 500 Hours 5 15 Every 6 Months or 1000 Hours 5 16 Every 1500 Hours 5 16 Annually or Every 2000 Hours 5 16 Annually or Every 4000 Hours 5 17 After Maintenance is Completed 5 17 Hydraulic Breaker Maintenance Interval 5 17 Lubrication and Maintenance Charts 5 1...

Page 13: ...em 5 36 Check Heating and Air Conditioning System Operation 5 36 Clean or Replace the Ventilation Filter Screen 5 36 Check and Adjust the Air Conditioning Compressor Belt Tension 5 37 Two Methods of Checking Belt Tension 5 37 Adjust the Air Conditioning Compressor Belt Tension 5 37 Air Conditioning Storage 5 38 Air Conditioning Components Inspection and Maintenance Schedule 5 38 Fuel System 5 39 B...

Page 14: ...er End Pins 5 63 Boom Cylinder Base End Pin 5 63 Boom Cylinder Rod End Pin 5 63 Bucket Linkage Pins 5 64 Bucket Cylinder Rod End Pin 5 64 Bucket Cylinder Base End Pin 5 64 Boom Swing Cylinder Rod End Pin 5 65 Boom Swing Cylinder Base End Pin 5 65 Swing Gear 5 65 Boom Swing Pin 5 66 Cab Door 5 66 Inspect and Lubricate the Cab Door 5 66 Bucket 5 68 Replace the Bucket Teeth 5 68 Remove and Install th...

Page 15: ... 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 Plates 1 8 Travel Motor Iden...

Page 16: ...possible hazardous situations when operating 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 questions reg...

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: ... 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 mov...

Page 20: ...excavator These list model and serial numbers that will be needed by a SANY dealer when ordering replacement parts or providing assistance for your machine Product Identification Plate The identification plate is on the lower front of the cab Frame Serial Number The frame serial number is stamped on the front of the travel carriage frame Fig 1 2 0003139 Fig 1 3 0003170 ...

Page 21: ...TRODUCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Swing Motor Identification Plate The identification plate is on the top of the swing motor Engine Identification Plate The identification plate is on the top of the engine Fig 1 4 0003140 Fig 1 5 0003138 ...

Page 22: ...20 SANY Hydraulic Pump Identification Plates The identification plate is on the bottom of the hydraulic pump Travel Motor Identification Plate An identification plate is on each travel motor Remove the cover plates to access the travel motors Fig 1 6 0003169 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 Report ROPS Rollover Protective Structure SAE Society...

Page 26: ...Introduction SY50U 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 6 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 9 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: ...e 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 around t...

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: ...d deck for proper support Wear safety 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 c...

Page 32: ...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 to repair or replace any damaged wiring Make sure the battery is operating in its recommended range Never install aftermarket electrical equipment without approval...

Page 33: ... base of the fire Crushing Hazard Keep your body inside the windows and door during operation or travel Keep all guards in place on the machine 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 the work area Diesel Engine Exhaust WARNING CALIFOR...

Page 34: ...n shut down the engine 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 46 The engine coolant and oil in the machine may be hot even after the engine is stoppe...

Page 35: ...ling 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 swelling in the hoses NOTE If there is any leakage from...

Page 36: ...Battery Safety When working with batteries always 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 batt...

Page 37: ...bility 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 the p...

Page 38: ...al 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 the inclined surface before ...

Page 39: ...resent 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 onto the g...

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: ...9 Switch Signals Screen 3 10 Joystick Screen 3 10 Machine Configuration Screen 3 11 Failure Information Screen 3 11 Global Positioning System GPS Information Screen 3 12 Language Selection Screen 3 12 Maintain Table Screen 3 13 Operating Mode Screen 3 13 Flow Rate Information Screen 3 14 Flow Rate Setting Screen 3 15 System Unlocked Screen 3 15 Reserved Function 3 15 Quick Coupler Control Screen 3...

Page 42: ...k BHL Mode 3 30 Right Joystick BHL Mode 3 30 Pattern Change SAE BHL Valve 3 31 Hydraulic Lockout Control Lever 3 32 Directional Arrow 3 33 Travel Control Levers Pedals 3 33 Boom Swing Control Pedal 3 34 Windshield 3 35 Opening the Windshield 3 35 Closing the Windshield 3 36 Lower the Windshield 3 37 Heating and Air Conditioning System 3 38 Control Panel 3 38 Heating and Air Conditioning System Ope...

Page 43: ...ION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT MACHINE OVERVIEW 1 Arm cylinder 10 Idler 2 Boom 11 Dozer blade 3 Boom swing cylinder 12 Dozer blade cylinder 4 Cab 13 Boom pivot 5 Carrier roller 14 Boom cylinder 6 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 11 15 14 16 17 13 5 12 ...

Page 44: ...achine See Prestart Checks and Adjustments on page 4 5 The eighth step reminds to warm up the engine and hydraulic system before normal operation of the machine See Prestart Checks and Adjustments on page 4 5 Start the machine and idle until its operating temperature is reached See Starting the Engine on page 4 17 Press the button below the check mark icon 1 to confirm all checks and procedures ha...

Page 45: ... 2 Press the button below the check mark icon 2 to confirm the completion of the maintenance information displayed on the screen NOTE When prompted to reset the maintenance icon on the home screen enter the password 53188 to clear the maintenance prompt This confirms that maintenance has been performed on this machine NOTE Return to the home screen by pressing the button below return icon 3 Home S...

Page 46: ... 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 Enter Function List screen 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 icon Displays...

Page 47: ...mation Screen on page 3 8 Operating Mode Designation of 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 To select the 1 Press the button...

Page 48: ...vious screen Main Menu Screen Fig 3 7 0003810 2 1 3 4 The Main Menu screen displays access to screens that offer access to the main signals to and from the system controller including real time running information machine configuration detailed failure information available languages and maintenance information Operation Information Displays real time engine operating values fuel level and load se...

Page 49: ... highlight the selected icon Press the button below the gear icon 2 to display the System Setup screen which is password protected for use by SANY only NOTE The gear icon selection is password protected for most of the Main Menu selections Press the button below the check mark icon 3 to access the selected icon screen if an active function of the machine Press the button below the return icon 4 to...

Page 50: ...h functions Press the button below the up down arrow icon 1 to scroll to the next page Press the button below the return icon 2 to return to the Main Menu screen Joystick Screen Fig 3 10 0003814 1 2 The Joystick screen displays real time joystick valve information Press the button below the up down arrow icon 1 to scroll to the next pages Press the button below the return icon 2 to return to the M...

Page 51: ...r and control system information Press the button below the return icon 1 to return to the previous screen NOTE This screen is password protected Failure Information Screen Fig 3 12 0003822 1 When a failure occurs the failure information icon on the home screen will change color to blue and the failure code will be displayed on the home screen The Failure Information screen displays failure codes ...

Page 52: ...revious screen Language Selection Screen Fig 3 14 0003820 3 2 1 The Language Selection screen is accessed through the Main Menu screen The Language Selection screen allows the selection of the language that will display on all screens To change the language setting Press the button below the up down arrow icon 1 to select the desired language Press the button below the check mark icon 2 to confirm...

Page 53: ...e bucket 1 as the default operation The auxiliary ports are used for hydraulic work tools Select the proper 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 Press the button below the left right arrow...

Page 54: ...left joystick left button and LR left joystick right button 2 settings are for the left joystick low pressure low flow circuit Press the button below the up down arrow icon 3 to select the hydraulic flow rate to adjust Press the button below the gear icon 4 to access the Flow Rate Setting screen Press the button below the check mark icon 5 to display a service screen that is password protected Pre...

Page 55: ...s 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 Press the button below the plus icon 2 to increase the length of the bar graph which will increase the flow rate Press t...

Page 56: ...cessed by selecting the Time Calibration icon on the Function List screen The Date and Time Setup screen allows changes to the date time and time zone Press the button below the up down icon 1 to increase the value of the selected position Press the button below the left right icon 2 to select the position for adjustment Press the button below the check mark icon 3 to confirm the time adjustment P...

Page 57: ... Start the engine and park in a safe location where the exhaust pipe will not face any combustible surface See Starting the Engine on page 4 17 3 Move the hydraulic lockout control lever to the locked closed position and run the engine at low idle See Hydraulic Lockout Control Lever on page 3 32 NOTE Make sure the DPF regeneration inhibit icon 1 is illuminated on the DPF Regeneration screen WARNIN...

Page 58: ...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 message will display on the DPF Regeneration screen with a caution message of high exhaust temperatures 6 When the...

Page 59: ...HES 1 Left joystick switch page 3 20 7 Travel alarm switch page 3 22 2 Left joystick button Not used 8 Windshield washer switch page 3 23 3 Right joystick horn button page 3 21 9 Windshield wiper switch page 3 23 4 Right joystick switch page 3 20 10 Work light switch page 3 23 5 Throttle control dial page 3 21 11 Emergency stop switch page 3 24 6 Key switch page 3 22 Fig 3 22 0002975 11 10 8 7 5 6...

Page 60: ...the left auxiliary hydraulic lines Move the left joystick switch to the right 3 for medium flow and medium pressure of the right auxiliary hydraulic lines Right Joystick Switch Fig 3 24 0003277 1 3 2 Move the right joystick switch 2 to the left 1 for high flow and high pressure of the left auxiliary hydraulic lines Move the right joystick switch to the right 3 for high flow and high pressure of th...

Page 61: ...ton 1 is on the bottom of the right joystick Press the horn button to sound the horn Throttle Control Dial The throttle control dial 1 is used to adjust the 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 high idle Turn the throttle control dial fully clockwise Fig 3 2...

Page 62: ...y switch is turned to START When key is turned to START and released if ambient temperature is below a preset value the preheat cycle will begin The preheat icon on the home screen will turn on during preheat cycle When the preheat cycle is complete the preheat icon will turn off and the starter motor will engage to start the engine Release the key after the engine has started The key switch will ...

Page 63: ...0 0002978 1 Press the windshield wiper switch 1 to activate the windshield wiper The windshield wiper switch has two operating positions With the rocker switch in the center position the windshield wiper operates at low speed With the rocker switch in the rear position the windshield wiper operates at high speed Work Light Switch Fig 3 31 0002978 1 The work light switch 1 is used to turn the work ...

Page 64: ...om One work light 3 on the cab roof Emergency Stop Switch If a quick shutdown is required or the engine cannot be stopped normally push the emergency stop switch 1 Turn the switch clockwise to reset the switch NOTE This switch should not be used if the machine is operating normally Fig 3 32 0002979 2 Fig 3 33 0002980 3 Fig 3 34 0002974 1 ...

Page 65: ... or as needed for maintenance Power Outlet 12V The power outlet 12V 1 can be used to power various external devices A cigarette lighter is installed from the factory 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 machine shutdown wait at least 1 minute for the engine control m...

Page 66: ... Operation and Maintenance Manual 0120 SANY Dome Light Switch Fig 3 37 0002981 1 2 The dome light switch 1 is used to turn the dome light 2 on and off NOTE The cab light can be turned on only when the key switch is in the ON or START position ...

Page 67: ...IPMENT CONTROLS 1 Dozer blade control lever page 3 28 6 Hydraulic lockout control lever page 3 32 2 Right joystick page 3 29 7 Left travel control pedal page 3 33 3 Left joystick page 3 29 8 Right travel control pedal page 3 33 4 Right travel control lever page 3 33 9 Boom swing control pedal page 3 34 5 Left travel control lever page 3 33 10 Monitor page 3 4 Fig 3 38 0002973 10 2 3 6 4 5 8 7 9 1 ...

Page 68: ... neutral position when released Return Flow Selector Valve The return flow selector valve regulates the direction of hydraulic oil flow The return flow selector valve 1 has a one way or two way position for operating optional equipment being installed It is located behind the right rear access door A variety of optional one way and two way flow equipment is available for use on this machine A hydr...

Page 69: ...stick SAE Mode The SAE mode uses the left joystick to control the arm and upper structure Swing the upper structure to the left 1 Arm out 2 Swing the upper structure to the right 3 Arm in 4 Neutral N Right Joystick SAE Mode Fig 3 42 0003062 1 2 3 4 N The SAE mode uses the right joystick to control the boom and bucket Bucket curl 1 Boom down 2 Bucket uncurl 3 Boom up 4 Neutral N NOTE The joystick c...

Page 70: ...ructure Swing the upper structure to the left 1 Boom down 2 Swing the upper structure to the right 3 Boom up 4 Neutral N Right Joystick BHL Mode Fig 3 44 0003062 1 2 3 4 N The BHL mode uses the right joystick to control the arm and bucket Bucket curl 1 Arm out 2 Bucket uncurl 3 Arm in 4 Neutral N NOTE The joystick controls return to the neutral position automatically when released The functions of...

Page 71: ... engine off 2 Insert the key in the latch and open the fuse access door located below the operator seat See Fuse Access Door on page 5 23 3 Loosen the wing nut 1 until it is free of the threaded hole 4 Rotate the bar 2 to the desired mode position 5 Tighten the wing nut into the threaded hole 3 and tighten securely 6 Close the compartment access door and lock the door NOTICE Shut the engine down b...

Page 72: ...o the locked closed position 2 to disable all hydraulic controls Push the hydraulic lockout control lever to the unlocked open position 3 to enable 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 de...

Page 73: ...d and backward when you push them forward Left and right control directions are also reversed when the track frame faces backward Travel Control Levers Pedals NOTE The track frame faces the front if the drive motors are in the rear The travel control levers 3 and pedals 4 are used to change the machine s traveling direction Forward travel Push the travel control levers or pedals forward 1 Backward...

Page 74: ... the right footrest 1 to access the boom 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 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 injury Fig 3 50 0003019 1 Fig 3 51 0003018 1 2...

Page 75: ...the Windshield 1 Before opening the 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 WARNING Avoid sudden movement of the machine or work equipment Always place the hydraulic lockout control lever in the locked closed position before leaving the cab Failure to follow th...

Page 76: ...imilar 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 dam...

Page 77: ...eld 1 Open the windshield See Opening the Windshield on page 3 35 NOTE Sand or dust accumulated along the bottom of the lower windshield and the seal may make it difficult to remove or install NOTE Make sure the bottom of the lower front windshield and the seal are clean before removing or installing it 2 Rotate the latches 2 to clear the lower windshield 3 Firmly grasp the lower windshield knobs ...

Page 78: ...ases the temperature inside the cab Turn 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 Turn to the right 0 to 3 Increases the blower speed Turn to the left 3 to 0 Decreases the blower speed 4 Fresh air recirculation switch Press and release Indicator lamp on recircula...

Page 79: ... the air conditioning power switch to turn the air conditioning system off The indicator lamp will turn off Turn the temperature adjustment dial to the right to the desired position 3 Turn the blower speed adjustment dial to the right to positions 1 2 or 3 The blower will begin to deliver air to the cab 4 To switch off the air conditioning turn the blower speed adjustment dial to 0 and press the a...

Page 80: ...ng feature In auto programming the six radio stations with the strongest signals are stored in the six preset buttons 1 6 3 AM FM Press and release Selects the desired frequency band AM or FM 4 SEL Press and release Adjusts the base treble and balance functions See Sound Mode Adjustment on page 3 42 5 TIME Press and release Displays the current time for 5 seconds Press and hold 2 seconds Allows se...

Page 81: ... to the memory is completed The preset button number and the frequency will be displayed indicating the completion of the presetting operation After presetting the stations press one of the preset buttons for at least 1 5 seconds to tune in the preset station NOTE The AS PS button can be used to preset the stations automatically Press and hold the button to activate the auto programming feature In...

Page 82: ...cally scan and stop at the next available station Sound Mode Adjustment The audio selector button SEL 1 adjusts the sound quality The sound mode adjustment option is displayed on the LCD 2 Each time the button is pressed the display will cycle adjustment options as follows Press and hold the button for the bass BAS level adjustment Pressing the button again will access the treble TRE level adjustm...

Page 83: ...o radio frequency after 5 seconds 2 To set the hours press and hold the time button down while the time is being displayed until the hour numbers flash and a beep is heard The hours and minutes change by one increment with each press of the tuning buttons 3 or 4 3 Press the tuning buttons to set the hours 4 To set the minutes press the time button again and the minute numbers flash 5 Press the tun...

Page 84: ...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 daily If it is damaged replace the extinguisher immediately Make sure the fire ext...

Page 85: ... 7 Fuel Level Check 4 8 Add Fuel 4 8 Fuel Tank Filler Cap 4 9 Check and Drain the Fuel Water Separator 4 10 Check the Hydraulic Oil Level 4 11 Windshield Washer Fluid Check and Fill 4 12 Electrical Components Check 4 13 Horn Function Check 4 13 Seat and Seat Belt 4 14 Seat Position Adjustment 4 14 Seat Backrest Adjustment 4 14 Seat Weight Suspension Adjustment 4 14 Seat Belt 4 14 Buckle the Seat B...

Page 86: ...Never Use Swing Force 4 30 Never Use Traveling Force 4 30 Never Operate Using Machine Weight 4 31 Do Not Operate a Cylinder to the Stroke End 4 31 Avoid Dozer Blade Impact 4 32 Avoid Shifting Travel Directions Suddenly 4 32 Support the Dozer Blade 4 32 Excavating Hard Ground 4 32 Travel 4 33 General Travel Instructions 4 33 Traveling at High Speed 4 34 Operating in Water 4 35 Traveling on an Incli...

Page 87: ...her 4 46 Battery in Cold Weather 4 46 After Daily Operation 4 46 Machine Storage in Cold Weather 4 47 After Cold Season 4 47 Long Term Storage 4 48 Before Long Term Storage 4 48 During Storage 4 48 Air Conditioner Storage 4 49 Removing from Storage 4 49 Starting the Engine After Long Term Storage 4 49 Transportation Information 4 50 Transportation Method 4 50 Loading and Unloading 4 50 Loading the...

Page 88: ... 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 89: ...eeded contact a SANY dealer 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 Clean and ...

Page 90: ... tank until 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 may be under pressure when the engine is hot Avoid contact with hot engine coolant Allow th...

Page 91: ...tained between the upper mark 2 and lower mark 3 of the dipstick 6 Add clean engine oil through the filler port 4 until the oil level is at the upper mark of the dipstick Always use SANY approved engine oil See Engine Oil Viscosity Temperature Data on page 5 12 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 29 7 Ins...

Page 92: ...TE Never overfill the fuel tank Stop fueling if the fuel spills over the fuel fill strainer Make sure the fuel nozzle does not damage the fuel fill strainer 3 Install the fuel filler cap after 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 flame or while smoking Clean up spilled fue...

Page 93: ...ler Cap 1 Open the right front access door See Unlocking Opening the Right Front Access Door on page 5 22 2 Turn the fuel filler cap 1 counterclockwise to remove 3 Add fuel See Add Fuel on page 4 8 4 Install the filler cap NOTICE Make sure the O ring in the filler cap is clean If the O ring is contaminated by dirt or debris the O ring will be damaged preventing the filler cap from sealing properly...

Page 94: ...ose 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 spil...

Page 95: ...lic tank decal See Figure 4 7 2 Prepare the machine for service See Maintenance Safety on page 2 8 3 The hydraulic oil level sight gauge can be seen through the opening 1 in the right side access panel 4 Check the hydraulic oil level in the hydraulic tank through the sight gauge 2 The hydraulic oil level should be between the H 3 and L 4 marks 5 If the level is below the L mark add hydraulic oil S...

Page 96: ...Open the engine hood and right rear access door See Opening the Engine Hood on page 5 21 and Opening the Right Rear Access Door on page 5 22 Check the windshield washer fluid level in the windshield washer fluid tank 1 Fill it with clean windshield washer fluid as necessary NOTE Keep dust and dirt out of the windshield washer fluid tank when adding windshield washer fluid Fig 4 10 0002769 1 ...

Page 97: ...d the battery of combustible materials For more information about faults in the electrical system contact a SANY dealer Horn Function Check 1 Turn the key switch to the ON position See Key Switch on page 3 22 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 26 NOTICE If fuses fail frequently the wiring harn...

Page 98: ...stment Use the seat weight adjustment lever 1 to select from one of three weight levels light medium or heavy that are indicated on the seat weight adjustment lever The seat will lock in the desired position each time the lever is pressed down and released Seat Belt NOTE A recoil assembly 3 is attached to the seat belt It removes slack from the seat belt and locks to restrain the operator It also ...

Page 99: ...nto place Pull on the latch plate end of the seat belt to make sure the seat belt is securely fastened Unbuckle the Seat Belt Press the red button on the buckle 1 to release the latch plate WARNING Keep seat belt slack to no more than 1 in 25 mm Seat belt slack beyond this amount could significantly reduce your protection in an accident Failure to follow this warning could result in death or serio...

Page 100: ... 1 2 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 When transporting or parking the machine in a building loosen the wing nut 1 and lower the antenna 2 to prevent damage Fig 4 14 0002780 1 2 1 ...

Page 101: ...tarting 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 Always start the engine from the operator seat Never start the engine by s...

Page 102: ...urned to the ON position 8 Sound the horn to warn personnel that the machine is being started See Horn Function Check on page 4 13 9 To start the engine turn the key switch to the START position When the engine starts release the key and it will return to the ON position NOTICE Never crank the engine for more than 15 seconds If the engine fails to start after 15 seconds stop and allow the starter ...

Page 103: ...ank the engine Release the key after the engine has started and the key switch will return to the ON position 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 obstruc...

Page 104: ...hrottle 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 monitor for normal operating readings NOTICE When the temperature is below 32 F 0 C and mud is built up on the tracks 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 f...

Page 105: ...tion before proceeding with the break in 1 Start and run the engine at low idle until it reaches proper operating temperatures Do not move the controls 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 or load range Do not operate this machine with a full load during the break in period 3 Avoid sudden...

Page 106: ...e exterior of the machine and the undercarriage 2 Check the engine coolant engine oil and hydraulic oil levels See Fluid Level Checks on page 4 6 3 Check for fluid leaks 4 Fill the fuel tank with diesel fuel See Add Fuel on page 4 8 5 To prevent fires clean the engine compartment of combustible debris 6 Clear the engine compartment of combustible debris and clean mud from the tracks and undercarri...

Page 107: ... when the track frame faces backward Machine Moving Precautions Check the direction of the track frame before operating the travel control levers pedals WARNING Check the surroundings and sound the horn before moving the machine Personnel are not allowed to approach the machine without operator approval The rear of the machine is a blind area Use the rearview mirrors and be extremely careful when ...

Page 108: ...ess the top of both foot pedals equally to move the machine forward Reverse Travel Pull both travel control levers backward or press the bottom of both foot pedals equally to move the machine in reverse Right Turn Fig 4 23 0002836 2 1 Push the left travel control lever 1 forward or press the top of the left pedal and leave the right travel control lever 2 in the neutral position to turn the machin...

Page 109: ...travel control lever 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 to rotate the machine without traveling Stopping the Machine N Fig 4 26 0002839 Slowly move the travel control levers pedals to the neutral N position The travel brake will stop the machine a...

Page 110: ...ciety of Automotive Engineers SAE mode and 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 joystick To retract the arm pull the right joystick Boom Control SAE Mo...

Page 111: ...Fig 4 30 0003058 To raise the boom pull the left joystick To lower the boom push the left joystick Swing Control Fig 4 31 0002841 To swing the upper structure to the right move the left joystick to the right To swing the upper structure to the left move the left joystick to the left Bucket Control Fig 4 32 0002843 To uncurl the bucket move the right joystick to the right To curl the bucket move th...

Page 112: ... right of the travel controls The boom swing control pedal swings the boom to the right or left Press the right side of the pedal to swing the boom right Press the left side of the pedal to swing the boom left Dozer Blade Control Lever Fig 4 34 0003831 1 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 ...

Page 113: ...ct 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 increases the engine speed Avoid sudden stops when operating work equipment Hydraulic shock can damage the hydraulic system Avoid any working conditions that may cause the machine to tip over Avoid moving any control lever or pedal to abruptly chan...

Page 114: ...r 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 115: ...e Weight Fig 4 39 0002870 Never raise the front or rear 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 to the Stroke End Fig 4 40 0002848 Avoid operating the machine with any cylinder fully retracted or extended NOTE If the cylinder piston reaches the end of its stroke continued use of the work equi...

Page 116: ...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 Never quickly move the control levers from high speed to neutral Support the Dozer Blade Fig 4 43 0002876 When the dozer blade is used as a stabilizer never use one end of the blade to support the machine Excavating H...

Page 117: ... Select a flat travel surface and travel in a straight 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 p...

Page 118: ... 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 and cause rusting and peeling Wash these substances...

Page 119: ... water Move the machine to a different location if necessary Make sure that the swing bearing swing drive gear 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 w...

Page 120: ...0 cm 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 38 Before traveling up a steep slope allow the machine to warm up sufficiently so it can perform properly WARNING Operating the machine ...

Page 121: ...et to the downhill direction Build a platform 2 on an incline so the 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 grea...

Page 122: ...hen traveling downhill keep the bucket 11 in the traveling direction and 8 in 12 in 20 cm 30 cm above the ground 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 levers to the neutral position and restart the engine When the engine stalls ...

Page 123: ...off the ground Keep the boom arm angle between 90 and 110 1 with the back of the bucket on the ground 4 Remove 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 procedures to free...

Page 124: ...he boom over the front of the machine 3 Curl the bucket so the back 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 the arm as with normal excavating while driving the mach...

Page 125: ... can be used to tow a light load WARNING Make sure the wire ropes used for towing the machine are strong enough Never use a broken chain worn wire rope or a bent tow hook to tow the machine Never jerk the wire rope Failure to follow these warnings could result in death or serious injury WARNING Make sure the equipment used for towing has the correct capacity rating A shackle must be used Keep the ...

Page 126: ...ow any personnel within the work zone of the machine Be aware of all crush points on the machine and make sure 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 Fai...

Page 127: ... 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 slowly and retract the arm at the same time Once the arm passes the vertical position lower the boom slowly and keep the bucket moving paralle...

Page 128: ...oad 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 injury NOTICE Do not allow the arm to interfere with the tracks...

Page 129: ...se the windows and cab door 7 Turn the battery disconnect switch to the OFF position 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 the OFF position and ...

Page 130: ...e the following precautions 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 Battery acid ...

Page 131: ...her 1 Clean the machine 2 Check the engine coolant and engine oil levels and check for leaks The machine is normally pre filled to withstand a maximum low temperature of 40 F 40 C Change the fuel hydraulic oil and gear oil with new fluids that meet the air temperature requirements as necessary 3 Check the hydraulic motors hydraulic cylinders pumps circuits and swivels for leaks Check all cylinder ...

Page 132: ...attery 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 on a monthly ba...

Page 133: ...e that has been stored for a prolonged period of time Clean the grease from the cylinder piston rods Add oil and apply lubricant to all parts or components Check fluid levels Drain the water and sediment from the fuel water separator See Check and Drain the Fuel Water Separator on page 4 10 Starting the Engine After Long Term Storage 1 Insert the key and turn the key switch 1 to ON 2 Turn the thro...

Page 134: ...r 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 Use a signalman to alert the operator to any potential hazards Deact...

Page 135: ... strength The maximum angle of the ramps is 15 1 Never change 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 control levers when the machine is on a ramp Clean the loading platform ramps...

Page 136: ...se 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 keep it in a lower position Slowly swing the upper st...

Page 137: ...c lockout control lever in the locked closed position 9 Turn the key to the OFF position and remove it from the key switch 10 Close the cab window and door 11 Turn the battery disconnect switch to the OFF position 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 da...

Page 138: ...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 rearview 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 frame ...

Page 139: ...o match the distance between the tracks 3 Remove the chains or the wire ropes that secure the machine 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 prevent damage t...

Page 140: ...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 Unloading the machine with the arm retracted ...

Page 141: ...osed position 4 Turn the key to the OFF position and remove from the key switch 5 Close the cab window and door 6 Turn the battery disconnect switch to the OFF position 7 Lock all doors and hoods 8 Cover the exhaust opening to prevent contamination WARNING Make sure all lifting devices are in safe operating condition and with sufficient capacity rating to safely support the intended load Never lif...

Page 142: ... Use wire ropes and a container spreader bar that have adequate length to keep the machine free from damage 10 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 Fig 4 80 0002955 ...

Page 143: ...amination 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 8 Dusty Environments 5 8 Cold Environments 5 8 Other Weather Environments 5 8 Check the Maintenance Log 5 8 Dai...

Page 144: ...losing the Engine Hood 5 22 Right Rear Access Door 5 22 Opening the Right Rear Access Door 5 22 Closing the Right Rear Access Door 5 22 Right Front Access Door 5 22 Unlocking Opening the Right Front Access Door 5 22 Closing Locking the Right Front Access Door 5 23 Fuse Access Door 5 23 Unlocking Opening the Fuse Access Door 5 23 Closing Locking the Fuse Access Door 5 23 Windshield 5 24 Inspect the...

Page 145: ... Separator 5 41 Battery 5 43 Check the Battery 5 43 Remove the Battery 5 44 Hydraulic System 5 46 Check the Accumulator Function 5 46 Check the Hydraulic Hoses Lines and Connectors 5 46 Relieve Hydraulic System Pressure 5 46 Check Hydraulic Oil Tank Level 5 47 Add Hydraulic Oil 5 47 Replace the Hydraulic Tank Breather Filter Element 5 48 Replace the Hydraulic Oil Pilot Filter 5 49 Replace the Hydr...

Page 146: ...age Pins 5 64 Bucket Cylinder Rod End Pin 5 64 Bucket Cylinder Base End Pin 5 64 Boom Swing Cylinder Rod End Pin 5 65 Boom Swing Cylinder Base End Pin 5 65 Swing Gear 5 65 Boom Swing Pin 5 66 Cab Door 5 66 Inspect and Lubricate the Cab Door 5 66 Bucket 5 68 Replace the Bucket Teeth 5 68 Remove and Install the Bucket 5 69 ...

Page 147: ...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 coming ...

Page 148: ...lled when fueling the machine The fuel tank strainer prevents larger dirt and other contaminates from entering the fuel system The fuel tank 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 ...

Page 149: ...operation add grease to the pins of the work equipment prior to each operation Cycle the operation of all working parts several times before filling with additional grease Mud Rain or Snow Conditions Before 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 NOTI...

Page 150: ...ture Data on page 5 12 SANY recommends fuels identified in Fuel on page 5 11for extremely cold environments Prior to starting the engine make sure the battery is fully charged and the battery 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 lubrica...

Page 151: ...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 152: ... 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 the machine Avoid using low viscosity grease...

Page 153: ...tant fluid that prevents engine overheating and freezing If using concentrated engine coolant use distilled water to dilute per instructions on engine coolant container Natural water such as river water and well water hard water contains large amount of minerals calcium magnesium etc which can form scale in the engine and radiator Mineral scale is not easily removed and can cause overheating Preca...

Page 154: ...hortened engine oil life Component or System Oil Type Ambient Temperature 22 F 4 F 14 F 32 F 50 F 68 F 86 F 104 F 122 F 30 C 20 C 10 C 0 C 10 C 20 C 30 C 40 C 50 C Engine Engine oil SAE 30 SAE 10W 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 ...

Page 155: ...s 1 Obtain an Oil Analysis Sample Kit from a SANY dealer 2 Operate the machine until the lubricant is at normal operating temperature 3 Prepare the machine for checks and inspections See Maintenance Safety on page 2 8 4 Send the sample for testing in accordance with the instructions packaged with the Oil Analysis Sample Kit NOTICE Commercially available service products may cause harm Use only the...

Page 156: ... the cab Check the seat belt and buckle for damage or wear Replace as necessary Check all controls for smooth operation and make sure they return to their 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 Lubricate the work equipment See page 5 18 Check the escape tool See page 3 44 Chec...

Page 157: ...50 Hours Initial replacement of the hydraulic oil return filter See page 5 50 Every 250 Hours Make sure all daily 50 hour and 100 hour maintenance tasks have been completed before proceeding with the 250 hour maintenance tasks Check the doors and hood See page 5 20 Check the track tension See page 5 55 Check and adjust air conditioning compressor belt tension See page 5 37 Change the engine oil an...

Page 158: ... the accumulator function See page 5 46 Replace the hydraulic tank breather filter element See page 5 48 Replace the hydraulic oil pilot filter See page 5 49 Replace the hydraulic oil return filter See page 5 50 Change the engine coolant See page 5 33 Every 1500 Hours Inspect the engine crankcase breather system See page 5 32 Annually or Every 2000 Hours Make sure all daily 50 hour 100 hour 250 ho...

Page 159: ...nually or Every 4000 Hours Inspect the engine water pump See page 5 34 After Maintenance is Completed Record the completion of all 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 eq...

Page 160: ...nts 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 lubrication chart See Lubrication Points on page 5 60 Fig ...

Page 161: ...erval Lubricant 50 hr 100 hr 250 hr 500 hr 1 Arm cylinder 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 pin 4 10 Boom swing cylinder pins 2 11 Swing gear 1 12 Boom swing pin 2 Replacement Item Intervals Replacement Items When Required 8 hr 50 hr 100...

Page 162: ... 0003204 1 An accessory light 12V outlet 1 located in the engine compartment for powering an accessory light DOORS AND HOOD NOTE 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 Engine hood 2 Fig 5 4 0002990 1 2 ...

Page 163: ...t using the cab door latch 1 Pull the door handle 2 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 located on the left side of the operator seat Engine Hood Opening the Engine Hood Fig 5 7 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...

Page 164: ... is no latch the door is secured by the engine hood 2 Secure the right rear access door in position by placing the support rod 3 into a slot on the right rear access door bracket 4 Closing the Right Rear Access Door Move the support rod 4 out of the right rear access door bracket 3 and close the right rear access door There is no latch the door is secured by the engine hood Right Front Access Door...

Page 165: ...nterclockwise to lock the door Remove the key Fuse Access Door Unlocking Opening the Fuse Access Door Fig 5 12 2 0003065 1 1 Insert the key into the fuse access door lock 2 NOTE Make sure the key is fully seated into the lock before turning 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 lower the door Closing Loc...

Page 166: ...ator OMM 5 24 Operation and Maintenance Manual 0120 SANY Windshield Inspect the Windshield Mechanism Fig 5 13 0003194 5 4 6 Check the windshield latches 4 linkages 5 and gas struts 6 inside the cab one mechanism on each side ...

Page 167: ...TS INTRODUCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Inspect and Tighten the Windshield Wiper Arm Nut Fig 5 14 0003196 8 7 Raise the nut cap 7 at the end of the wiper arm and check the nut 8 If the nut is loose tighten it to 26 33 lb ft 33 40 N m ...

Page 168: ...eplace a fuse with one of a higher amperage which could cause damage to the machine or cause the machine to operate improperly Fuse Amperage Circuit F1 25A Starting F2 10A Battery charging F3 15A Cab dome light horn and access light F4 25A Work light F5 15A Washer 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 A ...

Page 169: ... machine for service See Maintenance Safety on page 2 8 2 Shut the engine off and open the engine hood 3 Inspect the engine and engine compartment for Engine oil fuel and 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 open...

Page 170: ...ackaged with the sample kit Check the Engine Oil Level See Engine Oil Level Check on page 4 7 Prestart Check Reference Check the engine coolant level and add as necessary Engine Coolant Level on page 4 6 Check the engine oil level Engine Oil Level Check on page 4 7 Check the fuel level and add as necessary Fuel Level Check on page 4 8 Drain water and sediment from the fuel Check and Drain the Fuel...

Page 171: ...r housing mating surface as necessary to remove O ring residue and inspect the threads 7 Apply a thin layer of engine oil to the new oil filter O ring 8 Install the new oil filter by hand until the oil filter O ring touches the oil filter housing Tighten the oil filter 3 4 to 1 full turn by hand to securely install the oil filter NOTE Overtightening the oil filter may damage the O ring resulting i...

Page 172: ...t fastener 6 and tension adjuster locknut 7 4 Turn the tension adjuster 4 to achieve the specified belt tension 5 Tighten the adjusting plate fastener alternator bracket fastener and tension adjuster locknut 6 Check the fan belt tension to confirm correct adjustment Replace the Fan Belt Visually inspect the condition of the belt Fan belts that have been exposed to oil or engine coolant or show sig...

Page 173: ... valve should be closed if not replace the dust valve Replace 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Release the two latches 2 and remove the end cover 4 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 Chec...

Page 174: ...m has a spring backed diaphragm in the valve cover When the crankcase pressure 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 dia...

Page 175: ... and run it at low speed until the temperature reaches 194ºF 90ºC Run the engine for an additional 10 minutes 5 Stop the engine Allow the engine to cool and drain the water into an appropriately sized container 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...

Page 176: ...r 5 minutes and then at high speed for 5 minutes to bleed air from the cooling system Allow engine to cool 8 Top off the radiator and fill the overflow tank until the engine coolant is between the FULL and LOW marks 9 Install radiator cap Inspect the Engine Water Pump Prepare the machine for service See Maintenance Safety on page 2 8 If the fan pulley has play the bearings inside the engine water ...

Page 177: ...t dirt buildup clean the cooling package with compressed air Do not exceed 90 psi 621 kPa For heavy dirt buildup clean the cooling package using a high pressure washer with soap and water Do not exceed 290 psi 2000 kPa 4 Check the fins for deformation corrosion and cracks after cleaning Repair the component immediately if damaged cooling fins are found 5 Check the hose clamps Tighten them as neces...

Page 178: ...ing power switch function Clean or Replace the Ventilation Filter Screen 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Lift the right side of the front floor mat 2 3 Remove the two fasteners 3 and the ventilation filter screen cover 1 WARNING Do not allow compressed air pressurized water or steam to come into contact with skin Always wear goggles gloves and other personal ...

Page 179: ... air conditioning compressor belt A new belt should be tightened to 143 lbf 637 N and a used belt should be tightened to 99 lbf 441 N Check the air conditioning compressor belt tension by pressing down on the belt between the fan pulley 1 and the alternator pulley 2 The belt must deflect 3 0 28 in 0 39 in 7 mm 10 mm Adjust the Air Conditioning Compressor Belt Tension Fig 5 30 0003097 1 2 1 Prepare...

Page 180: ...ance Schedule Item Description Service Interval Refrigerant R134a Check for leaks in lines fittings and components Daily Condenser Check if condenser fins are plugged When required Compressor Check the compressor for function and leaks Every 4000 service hours V belt Check tension Every 250 service hours Check for damage wear and deterioration Blower speed adjustment dial Check fan motor and fan o...

Page 181: ...pacity 2 Locate the fuel drain valve 1 under the right side of the machine Place a suitable container under the valve to collect the drained fuel 3 Open the valve to drain water and sediment accumulated on the bottom of the tank Do not allow the fuel to splash out of the container 4 Close the valve when only clean fuel drains from the fuel tank 5 If the fuel tank is completely drained the system m...

Page 182: ...ng in a fuel leak 6 Bleed trapped air from the fuel system See Bleed the Fuel System on page 5 39 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 flame or while smoking Fuel that comes into contact ...

Page 183: ...ckwise to the OFF position 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 flame or while smoking Fuel that comes into contact with hot surfaces or electrical components can cause a fire Clean up any fuel spills immediately Failure to follow these warni...

Page 184: ... and filter element 3 from the filter housing 7 Clean the filter housing with clean fuel 8 Replace the filter element and make sure it is securely seated within the filter housing and fill the filter housing with clean fuel 9 Install the filter housing and turn the fuel shutoff valve 1 1 4 turn clockwise to the ON position 10 Bleed trapped air from the fuel system See Bleed the Fuel System on page...

Page 185: ...enance 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 Ba...

Page 186: ...fore proceeding with any battery maintenance 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 equipm...

Page 187: ...2 5 Remove the fasteners 3 securing the battery hold down Remove the battery hold down 4 6 Check that all cables and parts are out of the way then lift the battery out of the battery compartment 7 Clean the battery and terminals See Check the Battery on page 5 43 8 Clean the battery tray with a mixture of baking soda and warm water 9 Installation is in the reverse order of removal Connect the posi...

Page 188: ...ance between all hydraulic lines and hoses and high temperature engine components Make sure all hydraulic lines and hoses do not come in contact with each other Relieve Hydraulic System Pressure NOTE Hydraulic system 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 O...

Page 189: ...osition the work equipment as shown on the hydraulic tank decal See Check the Hydraulic Oil Level on page 4 11 2 Relieve system pressure See Relieve Hydraulic System Pressure on page 5 46 3 Prepare the machine for service See Maintenance Safety on page 2 8 WARNING Allow the hydraulic system to cool before servicing Hot oil may cause burns or other serious injury The hydraulic tank may be under pre...

Page 190: ...lter Element 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Open the right front access door 3 Clean around the hydraulic tank breather assembly 4 4 Remove the wing nut cover 1 and press the relief valve button 2 to release pressure in the hydraulic tank 5 Remove and clean the cover 3 WARNING Allow the hydraulic system to cool before servicing Hot oil may cause burns or oth...

Page 191: ... 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 NOTICE Dispose of the hydraulic oil and filters in accordance with all applicable environmental regulations Failure to do so could result in damage to the environment WARNING Allow the hydraulic system to cool before servicing Hot oil may cause burns or other serio...

Page 192: ...draulic oil leaks Use a piece of cardboard or paper Hydraulic oil leaking under pressure can penetrate the skin Failure to follow this warning could result in death or serious injury 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 breather Relieve any pressur...

Page 193: ...k the hydraulic oil level and add hydraulic oil as needed See Check the Hydraulic Oil Level on page 4 11 Clean and Replace the Hydraulic Oil Suction Strainer NOTICE Dispose of the hydraulic oil and filters in accordance with all applicable environmental regulations Failure to do so could result in damage to the environment WARNING Never use hands to search for hydraulic oil leaks Use a piece of ca...

Page 194: ...d suction strainer 5 6 Clean the suction strainer of any contaminants Inspect and replace if damaged 7 Install the suction strainer rod and spring 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 Che...

Page 195: ...ty on page 2 8 3 Relieve system pressure See Relieve Hydraulic System Pressure on page 5 46 4 Remove the four fasteners 2 that secure 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 breather Relieve an...

Page 196: ... 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 47 5 Insert the oil sample tube into the hydraulic tank and collect a sample of hydraulic oil Install the hydraulic...

Page 197: ... 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 tracks If the track sag is outside of this range the track tension must be adjusted Adjust the Track Tension Increase the Track Tension NOTICE Remove gravel or mud buildup between the sprocket and the track before checking track tension WARNING The track tension grease fitting is under extreme pressure and grease ...

Page 198: ...vement 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 grease valve to 44 lb ft 59 lb ft 60 N m 80 N m 5 Rotate the track one full revolution Check the track tension to confirm adjustment WARNING The tra...

Page 199: ... 2 to relieve any internal pressure 5 The oil should be at or near the lower edge of the oil level plug opening 6 Remove the fill plug 1 and add oil if necessary 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 The final driv...

Page 200: ... capacity 7 Remove the drain plug and allow the oil to drain 8 Install the drain plug and tighten to 12 5 lb ft 17 N m 9 Add new gear oil through the fill plug opening Fill until the gear oil is at the lower edge of the level plug opening 10 Install the oil level plug and fill plug Tighten to 12 5 lb ft 17 N m 11 Repeat this procedure on the other final drive CAUTION Allow the final drive to cool ...

Page 201: ... Send the sample for testing in accordance with the instructions packaged with the sample kit Check the Final Drive Motor Mounting Fasteners 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Remove the travel motor cover 3 Inspect all of the final drive mounting fasteners for rust damage or looseness 4 Replace any damaged or defective fasteners and tighten any loose fasteners ...

Page 202: ... page 5 61 10 Bucket linkage pins page 5 64 3 Arm cylinder base end pin page 5 62 11 Bucket cylinder rod end pin page 5 64 4 Boom pin page 5 62 12 Bucket cylinder base end pin page 5 64 5 Swing bearing page 5 62 13 Boom swing cylinder rod end pin page 5 65 6 Dozer blade linkage pins page 5 63 14 Boom swing cylinder base end pin page 5 65 7 Dozer blade cylinder end pins page 5 63 15 Swing gear page...

Page 203: ...ine to expel any water from the lubrication 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 Fig 5 54 0003171 1 2 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 Wi...

Page 204: ...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 Swing Bearing Fig 5 58 0003175 1 1 Grease the two fittings on the swing bearing 1 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 groun...

Page 205: ... pins and the dozer blade linkage pins grease fittings NOTE Wipe excess grease from around the grease fittings 3 Install the grease fitting caps Boom Cylinder Base End Pin Fig 5 60 0003177 1 2 1 Remove the grease fitting cap 1 from the boom cylin der base end pin grease fitting 2 2 Grease the boom cylinder base end pin grease fitting NOTE Wipe excess grease from around the grease fitting 3 Install...

Page 206: ...Rod End Pin Fig 5 63 0003179 1 1 2 2 1 Remove the grease fitting caps 1 from the bucket cyl inder rod end pin grease fittings 2 2 Grease the bucket cylinder rod end pin grease fittings NOTE Wipe excess grease from around the grease fittings 3 Install the grease fitting caps Bucket Cylinder Base End Pin Fig 5 64 0003180 1 2 1 Remove the grease fitting cap 1 from the bucket cyl inder base end pin gr...

Page 207: ...2 Grease the boom swing cylinder rod end pin grease fitting NOTE Wipe excess grease from around the grease fitting 3 Install the grease fitting cap Boom Swing Cylinder Base End Pin Fig 5 66 0003182 1 Grease the boom swing cylinder base end pin grease fitting 1 NOTE Wipe excess grease from around the grease fitting Swing Gear Fig 5 67 0003183 1 2 1 Remove the grease fitting cap 1 from the swing gea...

Page 208: ...ngs 2 2 Grease the boom swing pin grease fittings NOTE Wipe excess grease from around the grease fitting 3 Install the grease fitting cap Cab Door Inspect and Lubricate the Cab Door Fig 5 69 0003192 1 1 Check the body 1 of the cab door lock for loose or broken components Make sure the cab door closes tightly and latches securely 2 Check that the lock catch 2 of the cab door lock is secure and has ...

Page 209: ...tenance Manual 0120 5 67 TABLE OF CONTENTS INTRODUCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT 3 Grease the two cab door hinges 3 until grease comes out of the hinges Wipe off excess grease Fig 5 71 0003195 3 ...

Page 210: ...sition Keep 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 lock out the control levers Roll pins may eject with extreme force ...

Page 211: ...e 6 Install the bucket pins Install the mounting fasteners and pins into the bucket pins 7 Grease the bucket pins 8 Start the engine and run it at low idle Operate the bucket slowly in both directions to check for binding CAUTION Keep fingers and other body parts away from pinch points to prevent crushing injuries while removing or installing the bucket Never put your finger into the pin bore duri...

Page 212: ...Maintenance SY50U Excavator OMM 5 70 Operation and Maintenance Manual 0120 SANY This Page Intentionally Left Blank ...

Page 213: ...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 5 Lift Chart Blade Down 6 6 Lift Chart Blade Up 6 7 ...

Page 214: ...mum ground clearance 1 ft 1 in 325 mm 4 Upper structure width 5 ft 9 in 1760 mm 5 Track gauge 5 ft 1 in 1560 mm 6 Standard track width 1 ft 4 in 400 mm 7 Transport width 6 ft 5 in 1960 mm 8 Track ground length 6 ft 6 in 1990 mm 9 Track length 8 ft 3 in 2510 mm 10 Transport length 17 ft 8 in 5390 mm 11 Dozer blade height 1 ft 1 in 330 mm 12 Maximum lowering depth of dozer blade 1 ft 1 in 330 mm 13 ...

Page 215: ...pecifications SANY Operation and Maintenance Manual 0120 6 3 TABLE OF CONTENTS INTRODUCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT WORKING RANGES 1 5 3 2 4 6 Fig 6 1 0003762 ...

Page 216: ...Maximum digging height 17 ft 11 in 5450 mm 3 Maximum dumping height 12 ft 6 in 3805 mm 4 Maximum digging depth 11 ft 3 in 3420 mm 5 Maximum vertical wall digging depth 8 ft 1 in 2460 mm 6 Maximum reach at ground level 19 ft 3 in 5880 mm Maximum height at minimum swing radius 13 ft 8 in 4155 mm Boom length 8ft 10 in 27700 mm Arm length 4 ft 11 in 1500 mm ...

Page 217: ... 2400 rpm Maximum engine torque 133 3 lb ft 144 9 N m 1500 rpm Engine displacement 133 8 cu in 2 191 L Main pump flow 29 1 gal 110 Lpm Swing speed 10 rpm Travel speed 2 5 1 7 mph 4 0 2 7 kph Tractive effort 9150 lb ft 40 7 kN Arm digging force ISO 5148 lb ft 22 9 kN Bucket breakout force ISO 7306 lb ft 32 5 kN Number of upper rollers 1 per side Number of lower rollers 4 per side Fuel tank capacity...

Page 218: ...r the side 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 16 4 5 0 Lift capacity at max reach End Side End Side End Side End Side End Side 13 1 4 0 1085 2387 845 1859 9 8 3 0 1050 2310 815 1793 1050 2310 655 1441 6 6 2 0 1545 3399 1190 2618 1190 2618 790 1738 1055 2321 580 1276...

Page 219: ...e in compliance with ISO 10567 2007 Least stable position is over the side 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 16 4 5 0 Lift capacity at max reach End Side End Side End Side End Side End Side 13 1 4 0 1025 2255 845 1859 9 8 3 0 985 2167 815 1793 790 1738 655 1441 6 6...

Page 220: ...Specifications SY50U Excavator OMM 6 8 Operation and Maintenance Manual 0120 SANY This Page Intentionally Left Blank ...

Page 221: ...TION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Optional Equipment Optional Equipment Selection 7 2 Read Equipment Instructions 7 2 Installation and Removal Precautions 7 2 Equipment Operation Precautions 7 3 Install Optional Equipment 7 4 Remove Optional Equipment 7 6 ...

Page 222: ...nual is missing or damaged contact the manufacturer of the optional equipment to obtain a replacement Installation and Removal Precautions NOTICE The following precautions must be strictly observed when selecting installing and operating optional equipment Failure to observe and follow this notice can cause damage to the machine or cause the machine to operate improperly Prepare the machine for se...

Page 223: ... 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 224: ...ording to the manufacturer s instructions 6 Connect the optional equipment hydraulic lines and operate the optional equipment according to the manufacturer s instructions WARNING Do not release the optional equipment unless it is on the ground or on a solid supportive surface Block or support the equipment to prevent rolling or tipping Hydraulic systems operate under high pressure Hydraulic oil es...

Page 225: ...t rear access door It regulates the direction of hydraulic oil flow There are one way or two way 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 8 Select the correct operating mode fr...

Page 226: ...acturer s instructions 7 Adjust the return flow selector valve as necessary See Return Flow Selector Valve on page 3 28 8 Select the correct operating mode from the monitor See Operating Mode Screen on page 3 13 9 Check the hydraulic oil level See Check the Hydraulic Oil Level on page 4 11 WARNING Do not release the optional equipment unless it is on the ground or on a solid supportive surface Blo...

Page 227: ...This Page Intentionally Left Blank ...

Page 228: ...ca com SANY Part Number SSY005082347 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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