SANY Manual Shop

SY115C9/135C/155H Crawler Hydraulic Excavator
SY115C9/135C/155H
Crawler Hydraulic Excavator
Operation and Maintenance Manual
WARNING
Read and follow the safety precautions and instructions in this manual and on the ma-
chine decals. Failure to do can cause serious injury, death or property damage. Keep this
manual with the machine for reading and future reference.
Safety, Operation and Maintenance Manual - Sep 2012

SY115C9/135C/155H Crawler Hydraulic Excavator
Sany Group
Sany Heavy Machinery Limited
318A, Lianggang Avenue, Lingang Industrial Park,
Fengxian District, Shanghai, P. R. of China 201413
http://www.sanygroup.com
Tel: (86) 21 5700 8518

Service hotline: (86) 4006 098 318
E-mail: crd@sany.com.cn
2012 by Sany Group. All right reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as de-
scribed herein. All information included within this publication was accurate at the time
of publication. Product improvements ,revisions, etc., may result in differences between
your machine and what is presented here. Sany Group assumes no liability. For more in-
formation, Contact Sany Group.
Safety, Operation and Maintenance Manual - Sep 2012

SY115C9/135C/155H Crawler Hydraulic Excavator Table of Contents
Table of Contents
1 Introduction
1.1 Overview .................................................................................................................. 1-3
1.2 Your Documentation Package ................................................................................. 1-4
1.2.1 Recommendations on using the documentation ............................................ 1-5
1.2.2 Documentation storage .................................................................................. 1-5
1.2.3 Manual organization....................................................................................... 1-5
1.2.3.1 Introduction ........................................................................................... 1-6
1.2.3.2 Safety .................................................................................................... 1-6
1.2.3.3 System functions................................................................................... 1-6
1.2.3.4 Operation .............................................................................................. 1-6
1.2.3.5 Maintenance ......................................................................................... 1-6
1.2.3.6 Troubleshooting .................................................................................... 1-7
1.2.3.7 Specifications ........................................................................................ 1-7
1.2.3.8 Optional Equipment .............................................................................. 1-7
1.2.4 Page numbers................................................................................................ 1-7
1.3 Your Sany Machine .................................................................................................. 1-8
1.3.1 Machine applications ..................................................................................... 1-8
1.3.2 Machine directions ......................................................................................... 1-8
1.3.3 Breaking in a new machine ............................................................................ 1-9
1.3.4 Machine information....................................................................................... 1-9
1.3.4.1 Product identification plate .................................................................... 1-9
1.3.4.2 Engine identification plate ................................................................... 1-10
1.3.4.3 Right and left drive motors ...................................................................1-11
1.3.4.4 Swing motor .........................................................................................1-11
1.3.4.5 Hydraulic pump ....................................................................................1-11
1.3.4.6 Chassis serial number ........................................................................ 1-12
1.3.4.7 Machine monitor ................................................................................. 1-12
1.4 Table for serial number and distributor information................................................ 1-13
1.5 Correction Request Form - Technical Publications ................................................ 1-14
1.6 Contact Information ............................................................................................... 1-15
2 Safety
2.1 Safety Information.................................................................................................... 2-5
2.2 Safety Messages ..................................................................................................... 2-7
Safety, Operation and Maintenance Manual - Sep 2012 I
Table of Contents SY115C9/135C/155H Crawler Hydraulic Excavator
2.2.1 Hazard alert wording ...................................................................................... 2-8

2.2.2 Other alert wording ........................................................................................ 2-9
2.2.3 Safety decals ................................................................................................. 2-9
2.2.3.1 Textual safety decals........................................................................... 2-10
2.2.3.2 Graphical safety decals....................................................................... 2-10
2.2.3.3 Safety decal locations ..........................................................................2-11
2.3 General Precautions .............................................................................................. 2-19
2.3.1 Safety rules .................................................................................................. 2-19
2.3.2 Abnormalities ............................................................................................... 2-19
2.3.3 Personal protective equipment .................................................................... 2-19
2.3.4 Fire extinguisher and first aid kit .................................................................. 2-21
2.3.5 Safety equipment ......................................................................................... 2-21
2.3.6 Cleaning your machine ............................................................................... 2-22
2.3.7 Keeping the cab clean ................................................................................. 2-23
2.3.8 Engaging the hydraulic lockout control ........................................................ 2-23
2.3.9 Handholds and steps .................................................................................. 2-24
2.3.10 Overhead work........................................................................................... 2-25
2.3.11 No sitting on attachment ........................................................................... 2-25
2.3.12 Articulated parts ......................................................................................... 2-25
2.3.13 Preventing burns ....................................................................................... 2-25
2.3.13.1 Hot coolant ........................................................................................ 2-25
2.3.13.2 Hot oil ................................................................................................ 2-26
2.3.14 Preventing fire and explosion .................................................................... 2-26
2.3.14.1 Fire caused by fuel or oils ................................................................. 2-26
2.3.14.2 Fire caused by ammable materials ................................................. 2-27
2.3.14.3 Fire caused by electric lines.............................................................. 2-27
2.3.14.4 Fire caused by hydraulic lines .......................................................... 2-28
2.3.14.5 Fire caused by illumination equipment.............................................. 2-28
2.3.14.6 Fire caused by heat shield ................................................................ 2-28
2.3.15 In the event of fire ...................................................................................... 2-28
2.3.16 Windshield cleaning detergent ................................................................... 2-29
2.3.17 Preventing ejection of part ........................................................................ 2-29
2.3.18 Falling object protection ............................................................................. 2-30
2.3.19 Attachment installation ............................................................................... 2-30
2.3.20 Attachment combination ............................................................................ 2-31
2.3.21 Cab windows glasses ................................................................................ 2-31
II Safety, Operation and Maintenance Manual - Sep 2012

2.3.22 Unauthorized modification ......................................................................... 2-31

2.3.23 Job site investigation.................................................................................. 2-31
2.3.24 Operation on soft ground ........................................................................... 2-32
2.3.25 Overhead power cables ............................................................................. 2-33
2.3.26 Ensuring a good visibility ........................................................................... 2-34
2.3.27 Ventilating enclosed area ........................................................................... 2-35
2.3.28 Asbestos hazard ........................................................................................ 2-35
2.3.29 Alternate exit .............................................................................................. 2-36
2.4 Safe Operation Precautions................................................................................... 2-37
2.4.1 Safe starting ................................................................................................ 2-37
2.4.1.1 Safe mounting ..................................................................................... 2-37
2.4.1.2 Seat adjustment .................................................................................. 2-38
2.4.1.3 Seat belt .............................................................................................. 2-38
2.4.1.4 Before starting the engine ................................................................... 2-38
2.4.1.5 Engine starting rules ........................................................................... 2-39
2.4.1.6 Safe starting ........................................................................................ 2-39
2.4.1.7 Starting engine in cold season ............................................................ 2-40
2.4.1.8 Engine starting aid .............................................................................. 2-40
2.4.1.9 After starting the engine ...................................................................... 2-41
2.4.2 Operation ..................................................................................................... 2-42
2.4.2.1 Inspection before operation ................................................................ 2-42
2.4.2.2 Prior-operation precautions................................................................. 2-42
2.4.2.4 Travel directions .................................................................................. 2-43
2.4.2.3 Rules for steering safety ..................................................................... 2-43
2.4.2.5 Rules for traveling safety .................................................................... 2-45
2.4.2.6 Safe traveling ..................................................................................... 2-46
2.4.2.7 Operation on an incline ....................................................................... 2-47
2.4.2.8 Operation in snowy weather ............................................................... 2-48
2.4.2.9 Restricted operations .......................................................................... 2-48
2.4.3 Parking the machine .................................................................................... 2-51
2.4.3.1 Select a parking place......................................................................... 2-51
2.4.3.2 Machine shutdown .............................................................................. 2-51
2.4.4 Transportation .............................................................................................. 2-52
2.4.4.1 Loading and unloading the machine ................................................... 2-52
2.4.4.2 Transporting the machine ................................................................... 2-53
2.4.5 Battery.......................................................................................................... 2-54
Safety, Operation and Maintenance Manual - Sep 2012 III

2.4.6 Lifting objects with the machine ................................................................... 2-56

2.5 Precautions for Maintenance ................................................................................. 2-57
2.5.1 Prior-maintenance precautions .................................................................... 2-57
2.5.2 Select a working area .................................................................................. 2-57
2.5.3 Preparing the machine ................................................................................ 2-58
2.5.4 Preparing yourself ........................................................................................ 2-59
2.5.5 Lock-out and tag-out .................................................................................. 2-60
2.5.6 Using proper tools ........................................................................................ 2-60
2.5.7 Maintenance with engine running ................................................................ 2-61
2.5.8 Working under the machine ......................................................................... 2-61
2.5.9 Track maintenance....................................................................................... 2-62
2.5.10 Track tension adjustment precautions ....................................................... 2-63
2.5.11 Recoil spring .............................................................................................. 2-63
2.5.12 Welding operation ...................................................................................... 2-64
2.5.13 High-pressure hoses .................................................................................. 2-64
2.5.14 Pressurized uid ........................................................................................ 2-65
2.5.15 Hot cooling system..................................................................................... 2-66
2.5.16 Air-conditioning system ............................................................................. 2-66
2.5.17 High voltage precautions ........................................................................... 2-67
2.5.18 Accumulator ............................................................................................... 2-67
2.5.19 Avoiding fire and explosion ........................................................................ 2-68
2.5.20 Regular replacement of safety-related parts .............................................. 2-69
2.5.21 Maintenance operation ............................................................................. 2-70
2.5.22 Proper disposal of wastes .......................................................................... 2-71
3 System Functions
3.1 Machine Overview ................................................................................................... 3-5
3.2 Machine Controls ..................................................................................................... 3-6
3.3 Monitor ..................................................................................................................... 3-7
3.3.1 Monitor introduction ....................................................................................... 3-7
3.3.2 System information and operation ............................................................... 3-10
3.3.2.1 Main Page ........................................................................................... 3-10
3.3.2.2 System Information ............................................................................. 3-12
3.3.2.3 Time Setup .......................................................................................... 3-13
3.3.2.4 Main Menu .......................................................................................... 3-14
3.3.2.5 Engine & Throttle Signals .................................................................. 3-15
IV Safety, Operation and Maintenance Manual - Sep 2012

3.3.2.6 Main Pump Signals ............................................................................ 3-15

3.3.2.7 Input Switch Signals ........................................................................... 3-16
3.3.2.8 Output Switch Signals ........................................................................ 3-16
3.3.2.9 Machine Configuration ....................................................................... 3-17
3.3.2.10 Failure codes ................................................................................... 3-17
3.3.2.11 Maintenance Information................................................................... 3-18
3.3.2.12 Engine Speed Calibration ................................................................. 3-23
3.3.2.13 Language Selection .......................................................................... 3-25
3.3.2.14 GPS Monitoring Information.............................................................. 3-26
3.3.2.15 System Setup.................................................................................... 3-27
3.3.2.16 Machine configuration setup ............................................................. 3-28
3.3.2.17 Coolant Temperature ........................................................................ 3-29
3.3.2.18 Service Call ....................................................................................... 3-30
3.4 Switches ................................................................................................................ 3-31
3.4.2.1 Start switch ......................................................................................... 3-32
3.4.2.2 Fuel control dial................................................................................... 3-33
3.4.2.3 Work lamp switch ................................................................................ 3-33
3.4.2.4 Wiper switch........................................................................................ 3-35
3.4.2.5 Washer switch ..................................................................................... 3-36
3.4.2.6 Head lamp switch................................................................................ 3-36
3.4.2.7 Horn switch ......................................................................................... 3-37
3.4.2.8 Cab lamp ............................................................................................ 3-37
3.4.2.9 Cigar lighter......................................................................................... 3-37
3.4.2.10 Preheat switch (only for SY135C8M) ................................................ 3-38
3.4.2.11 Alternator indicator ............................................................................ 3-38
3.5 Control levers and pedals ...................................................................................... 3-39
3.5.1 Hydraulic lockout control .............................................................................. 3-40
3.5.2 Travel controls.............................................................................................. 3-41
3.5.3 Joystick controls........................................................................................... 3-42
3.6 Roof Hatch ............................................................................................................. 3-44
3.6.1 Opening the roof hatch ............................................................................... 3-44
3.6.2 Closing the roof hatch ................................................................................. 3-44
3.7 Windshield ............................................................................................................. 3-45
3.7.1 Opening the window ................................................................................... 3-45
3.7.2 Closing the window ..................................................................................... 3-48
3.7.3 Removing the lower window ...................................................................... 3-50
Safety, Operation and Maintenance Manual - Sep 2012 V

3.8 Alternate Exit.......................................................................................................... 3-51

3.9 Door Catch............................................................................................................. 3-52
3.10 Cover/cap with a Latch ........................................................................................ 3-52
3.10.1 Opening/closing the cover with lock........................................................... 3-53
3.10.2 Opening/closing the cap with lock.............................................................. 3-54
3.11 Cup Holder ........................................................................................................... 3-55
3.12 Storage Box ......................................................................................................... 3-56
3.13 Literature Bag ...................................................................................................... 3-56
3.14 Ashtray ................................................................................................................. 3-57
3.15 Air Conditioning System....................................................................................... 3-58
3.15.1 Control panel.............................................................................................. 3-58
3.15.2 Operation method ...................................................................................... 3-64
3.15.3 A/C operation precautions.......................................................................... 3-72
3.16 Radio ................................................................................................................... 3-74
3.16.1 Control panel.............................................................................................. 3-74
3.16.2 Radio operation.......................................................................................... 3-76
3.17 Auxiliary Power Supply ........................................................................................ 3-80
3.18 Fuses ................................................................................................................... 3-80
3.19 Fusible Link.......................................................................................................... 3-81
3.20 Controller ............................................................................................................. 3-82
3.21 Toolbox ................................................................................................................ 3-82
3.22 Grease pump frame ............................................................................................. 3-82
3.23 Fire extinguisher .................................................................................................. 3-83
4 Operation
4.1 Before Starting the Engine....................................................................................... 4-5
4.1.1 Routine checks ............................................................................................. 4-5
4.1.2 Checks before starting ................................................................................... 4-7
4.1.2.1 Fuel tank - check/drain.......................................................................... 4-7
4.1.2.2 Water separator - check/drain .............................................................. 4-7
4.1.2.3 Drain valve - regulate ............................................................................ 4-8
4.1.2.4 Hydraulic oil - check/refill ...................................................................... 4-9
4.1.2.5 Coolant - check/refill ........................................................................... 4-10
4.1.2.6 Oil in engine oil pan - check/refill .........................................................4-11
4.1.2.7 Electric wires - check .......................................................................... 4-12
4.1.2.8 Fuel tank - check/refuel....................................................................... 4-13
VI Safety, Operation and Maintenance Manual - Sep 2012

4.1.2.9 Work lamp switch - check ................................................................... 4-14

4.1.2.10 Horn - check...................................................................................... 4-15
4.1.3 Adjustment before operation ........................................................................ 4-15
4.1.3.1 Operator seat ...................................................................................... 4-15
4.1.3.2 Rear view mirrors ................................................................................ 4-17
4.1.3.3 Seat belt .............................................................................................. 4-19
4.1.4 Before Starting the Engine ........................................................................... 4-20
4.2 Engine Starting ...................................................................................................... 4-22
4.2.1 Engine Preheating ...................................................................................... 4-25
4.2.2 Warm-up operation ...................................................................................... 4-26
4.2.3 Selecting a working mode ........................................................................... 4-26
4.3 Engine Shutdown................................................................................................... 4-27
4.4 Machine Operation ................................................................................................ 4-28
4.4.1 Before moving the machine ......................................................................... 4-28
4.4.2 Moving the machine forward ........................................................................ 4-29
4.4.3 Moving the machine backward .................................................................... 4-30
4.5 Steering Operation................................................................................................. 4-32
4.5.4.1 Steering with travel controls ............................................................... 4-32
4.5.4.2 Steering with machine stopped ........................................................... 4-32
4.5.4.3 Steering during traveling ..................................................................... 4-33
4.5.4.4 Pivot turn ............................................................................................. 4-33
4.5.1 Swing operation ........................................................................................... 4-34
4.6 Work Equipment Control and Operation ................................................................ 4-35
4.7 Working mode........................................................................................................ 4-37
4.8 Restricted Operations ............................................................................................ 4-38
4.8.1 Operation with swinging force ...................................................................... 4-38
4.8.2 Operation with traveling force ...................................................................... 4-38
4.8.3 Operation when hydraulic cylinder reaches its stroke end ......................... 4-39
4.8.4 Operation with bucket landing force............................................................. 4-39
4.8.5 Operation with machine weight .................................................................... 4-40
4.8.6 Hard rocky ground ...................................................................................... 4-40
4.8.7 Sudden shift of travel speed during fast traveling ....................................... 4-41
4.9 General Operation ................................................................................................ 4-41
4.9.1 Traveling operation ...................................................................................... 4-41
4.9.2 High-speed travel ......................................................................................... 4-41
Safety, Operation and Maintenance Manual - Sep 2012 VII

4.9.3 Permissible depth of water........................................................................... 4-42

4.10 Traveling on Slope ............................................................................................... 4-42
4.10.1 Traveling downhill ..................................................................................... 4-44
4.10.2 Engine stalls on an incline ......................................................................... 4-44
4.10.3 Cab door on an incline ............................................................................... 4-44
4.11 Removing Machine from Mud .............................................................................. 4-44
4.11.1 One track trapped ...................................................................................... 4-44
4.11.2 Both tracks trapped .................................................................................... 4-45
4.12 Recommended Applications ................................................................................ 4-45
4.12.1 Backhoe operation ..................................................................................... 4-45
4.12.2 Trench work ............................................................................................... 4-46
4.12.3 Loading operation ...................................................................................... 4-46
4.13 Parking Operation ................................................................................................ 4-47
4.14 Checks after Each Workday ................................................................................ 4-49
4.15 Locking the Machine ............................................................................................ 4-50
4.16 Operation in Cold Weather .................................................................................. 4-50
4.16.1 Operation instruction .................................................................................. 4-50
4.16.1.1 Fuel and lubricant ............................................................................. 4-50
4.16.1.2 Battery............................................................................................... 4-51
4.16.2 After each workday .................................................................................... 4-52
4.16.3 After cold season ....................................................................................... 4-53
4.17 Long-Term Storage .............................................................................................. 4-54
4.17.1 Before storage ........................................................................................... 4-54
4.17.2 During storage ........................................................................................... 4-55
4.17.3 After storage............................................................................................... 4-56
4.17.4 Starting the engine after long-term storage ............................................... 4-56
4.18 Transportation Information ................................................................................... 4-57
4.18.1 Transport methods ..................................................................................... 4-57
4.18.2 Loading/unloading machine to/from a trailer .............................................. 4-57
4.18.2.1 Loading the machine......................................................................... 4-59
4.18.2.2 Securing the machine ....................................................................... 4-61
4.18.2.3 Rear view mirrors .............................................................................. 4-62
4.18.2.4 Unloading the machine ..................................................................... 4-63
4.18.3 Lifting the machine or its components ....................................................... 4-65
4.18.3.1 Lifting precautions ............................................................................. 4-65
4.18.3.2 Choosing a wire rope ........................................................................ 4-66
VIII Safety, Operation and Maintenance Manual - Sep 2012

4.18.3.3 Lifting the machine ............................................................................ 4-67
5 Maintenance
5.1 Maintenance Information ......................................................................................... 5-5
5.2 General Service ....................................................................................................... 5-9
5.2.1 Oil, fuel and coolant ....................................................................................... 5-9
5.2.1.1 Oil.......................................................................................................... 5-9
5.2.1.2 Fuel ..................................................................................................... 5-10
5.2.1.3 Coolant ................................................................................................5-11
5.2.2 Grease ......................................................................................................... 5-12
5.2.3 Oil and fuel storage ...................................................................................... 5-13
5.2.4 Filter element ............................................................................................... 5-13
5.2.5 Electrical system ......................................................................................... 5-14
5.2.6 Hydraulic system.......................................................................................... 5-14
5.3 Replacement Parts ................................................................................................ 5-16
5.4 Recommended Fluids ............................................................................................ 5-17
5.4.1 Fluid capacities ............................................................................................ 5-19
5.4.2 Recommended oils: .................................................................................... 5-20
5.5 Tightening Torque Specification ............................................................................. 5-22
5.6 Safety-Related Parts.............................................................................................. 5-24
5.7 Maintenance Schedule .......................................................................................... 5-25
5.7.1 List of maintenance schedule ...................................................................... 5-25
5.7.2 Hydraulic Breaker Service Interval............................................................... 5-27
5.8 Maintenance Procedures ....................................................................................... 5-28
5.8.1 Maintenance after initial 50 service hours.................................................... 5-28
5.8.1.1 Engine oil and filter - change/replace.................................................. 5-28
5.8.1.2 Fuel filter - replace ............................................................................. 5-28
5.8.2 When Required ............................................................................................ 5-29
5.8.2.1 Air cleaner - clean/replace .................................................................. 5-29
5.8.2.2 Cooling system - clean....................................................................... 5-37
5.8.2.3 Track shoe bolts - inspect/tighten ....................................................... 5-41
5.8.2.4 Track tension - inspect/adjust ............................................................. 5-42
5.8.2.5 Bucket tips (lateral pin) - replace ........................................................ 5-45
5.8.2.6 Bucket Replacement ........................................................................... 5-47
5.8.2.7 Bucket clearance - adjust.................................................................... 5-49
5.8.2.8 Window washer uid - check/refill ...................................................... 5-51
Safety, Operation and Maintenance Manual - Sep 2012 IX

5.8.2.9 Air conditioner - inspect/service .......................................................... 5-52

5.8.2.10 Gas spring - inspect .......................................................................... 5-54
5.8.2.11 Air in hydraulic system - purge .......................................................... 5-55
5.8.2.12 Hydraulic circuit internal pressure - release ...................................... 5-58
5.8.3 Checks before starting ................................................................................. 5-59
5.8.4 Every 100 service hours .............................................................................. 5-60
5.8.4.1 Lubrication .......................................................................................... 5-60
5.8.5.1 Compressor belt tension - inspect/adjust ............................................ 5-63
5.8.5.2 Oil in engine oil pan and oil filter - change/replace ............................. 5-65
5.8.5.3 Primary fuel filter - replace .................................................................. 5-67
5.8.5.4 Secondary fuel filter - replace ............................................................. 5-71
5.8.6.1 Swing bearing - lubricate .................................................................... 5-74
5.8.6.2 Swing pinion gear grease - check/refill ............................................... 5-75
5.8.6.3 Coolant tank and radiator fins - inspect/clean ..................................... 5-76
5.8.6.4 Air conditioner filters - clean ................................................................ 5-77
5.8.6.5 Swing drive oil - check/refill................................................................. 5-80
5.8.6.6 Final drive oil - check/fill ...................................................................... 5-81
5.8.7 Every 1000 service hours ............................................................................ 5-82
5.8.7.1 Hydraulic oil filter - replace.................................................................. 5-82
5.8.7.2 Swing drive oil - change ...................................................................... 5-84
5.8.7.3 Engine exhaust pipe clamps - check .................................................. 5-85
5.8.7.4 Fan belt tension - check/replace ......................................................... 5-85
5.8.7.5 Nitrogen pressure in accumulator (breaker) - check ........................... 5-85
5.8.8.1 Final drive oil - change ........................................................................ 5-86
5.8.8.2 Hydraulic tank filter screen - clean ...................................................... 5-88
5.8.8.3 Nitrogen pressure in accumulator (control oil circuit) - check ............. 5-89
5.8.8.4 Hydraulic circuit internal pressure - release ........................................ 5-92
5.8.8.5 Oil in hydraulic tank - change.............................................................. 5-93
5.8.8.6 Alternator - inspect .............................................................................. 5-95
5.8.8.7 Engine valve clearance - check/adjust................................................ 5-95
5.8.9.1 Coolant pump - inspect ....................................................................... 5-95
5.8.9.2 Start motor - check.............................................................................. 5-95
X Safety, Operation and Maintenance Manual - Sep 2012

5.8.9.3 Accumulator (control oil circuit) - replace ............................................ 5-96

5.8.9.4 High-pressure tube clamps and rubber - check .................................. 5-97
5.8.9.5 Compressor working condition - inspect ............................................. 5-97
5.8.10 Every 8000 service hours .......................................................................... 5-98
5.8.10.1 High-pressure tube clamps - replace ................................................ 5-98
5.8.11 Every 10000 service hours......................................................................... 5-98
6 Troubleshooting
6.1 Troubleshooting Preparation.................................................................................... 6-3
6.1.1 Checks before troubleshooting ...................................................................... 6-3
6.1.2 Troubleshooting procedure ............................................................................ 6-4
6.1.3 Troubleshooting precautions .......................................................................... 6-6
6.1.4 Electrical circuits troubleshooting precautions ............................................... 6-9
6.1.5 Hydraulic components handling precautions ............................................... 6-10
6.2 Pseudo Failures ..................................................................................................... 6-12
6.3 Towing the Machine ............................................................................................... 6-13
6.4 Towing Hook for Light Loads ................................................................................. 6-15
6.5 Severe Operating Conditions................................................................................. 6-15
6.6 Engine Failures ...................................................................................................... 6-16
6.6.1 Engine troubleshooting table ....................................................................... 6-16
6.6.2 Coolant temperature high ............................................................................ 6-19
6.6.3 Engine oil pressure low ................................................................................ 6-20
6.6.4 When fuel exhausts ..................................................................................... 6-22
6.6.5 When engine rotates reversely ................................................................... 6-24
6.7 Failures of the Electrical System ........................................................................... 6-25
6.7.1 Electrical system troubleshooting table........................................................ 6-25
6.7.2 Failure codes ............................................................................................... 6-28
6.8 Battery .................................................................................................................. 6-30
6.8.1 Battery removal and installation ................................................................... 6-30
6.8.2 Battery charging ........................................................................................... 6-31
6.8.3 Jump-starting the engine ............................................................................. 6-32
6.8.3.1 Connecting the jumper cables ............................................................ 6-33
6.8.3.2 Starting the engine .............................................................................. 6-34
6.8.3.3 Disconnecting the jumper cables ........................................................ 6-34
6.9 Failures of the Hydraulic System ........................................................................... 6-35
6.10 Other Common Failures ...................................................................................... 6-39
Safety, Operation and Maintenance Manual - Sep 2012 XI

7 Specifications
7.1 Machine Dimensions ............................................................................................... 7-3
7.2 Working Ranges ..................................................................................................... 7-4
8 Optional Equipment
8.1 General Safety ........................................................................................................ 8-3
8.1.1 Selection precautions..................................................................................... 8-3
8.1.2 Reading the instruction books........................................................................ 8-3
8.1.3 Removal and installation precautions ........................................................... 8-3
8.1.4 Operation precautions.................................................................................... 8-4
8.2 Hydraulic Control Elements and Oil Circuit ............................................................. 8-6
8.2.1 Location of the components ........................................................................... 8-6
8.2.1.1 Stop valve ............................................................................................. 8-6
8.2.1.2 Selector valve ....................................................................................... 8-7
8.2.1.3 Control pedal......................................................................................... 8-7
8.2.2 Hydraulic circuit.............................................................................................. 8-8
8.2.2.1 Hydraulic circuit switching ..................................................................... 8-8
8.2.2.2 Shifting to breaker / general optional equipment .................................. 8-8
8.2.2.3 Connecting hydraulic oil circuit ............................................................. 8-9
8.2.2.4 Hydraulic oil passage .......................................................................... 8-10
8.2.3 Optional equipment removal and installation ................................................8-11
8.2.3.1 Removal ...............................................................................................8-11
8.2.3.2 Optional equipment installation .......................................................... 8-13
8.2.4 Hydraulic oil and hydraulic tank filter - change/replace ............................... 8-15
8.2.5 Long-term storage........................................................................................ 8-16
8.2.6 Hydraulic specifications ............................................................................... 8-16
8.3 Optional equipment Guide ..................................................................................... 8-17
8.3.1 Work equipment combination ...................................................................... 8-17
8.3.2 Bucket tips selection .................................................................................... 8-19
8.3.2.1 Rockwork bucket tips .......................................................................... 8-19
8.3.2.2 Earthwork bucket tips.......................................................................... 8-19
8.4 Recommended Operations .................................................................................... 8-20
8.4.1 Hydraulic breaker ......................................................................................... 8-20
8.4.2 Hydraulic breaker operation ......................................................................... 8-21
8.6 Hydraulic Breaker Lubrication................................................................................ 8-25
XII Safety, Operation and Maintenance Manual - Sep 2012

8.7 Quick Coupler and Control System ....................................................................... 8-26

8.7.1 Quick coupler installation ............................................................................. 8-26
8.7.2 Operating precautions ................................................................................. 8-28
8.8 Refueling System.................................................................................................. 8-29
8.8.1 Introduction .................................................................................................. 8-29
8.8.2 Components................................................................................................. 8-30
8.9 Central Lubrication System.................................................................................... 8-31
8.9.1 Scheme and components ............................................................................ 8-31
8.9.2 System working principle ............................................................................. 8-33
8.9.3 Setting the lubrication time of electric grease pump .................................... 8-34
8.9.4 Technical description.................................................................................... 8-35
8.9.5 Adding grease with electric pump ................................................................ 8-36
Safety, Operation and Maintenance Manual - Sep 2012 XIII

XIV Safety, Operation and Maintenance Manual - Sep 2012

SY115C9/135C/155H Crawler Hydraulic Excavator Introduction
Introduction
1 Introduction
1.1 Overview .................................................................................................................. 1-3
1.2 Your Documentation Package ................................................................................. 1-4
1.2.1 Recommendations on using the documentation ............................................ 1-5
1.2.2 Documentation storage .................................................................................. 1-5
1.2.3 Manual organization....................................................................................... 1-5
1.2.3.1 Introduction ........................................................................................... 1-6
1.2.3.2 Safety .................................................................................................... 1-6
1.2.3.3 System functions................................................................................... 1-6
1.2.3.4 Operation .............................................................................................. 1-6
1.2.3.5 Maintenance ......................................................................................... 1-6
1.2.3.6 Troubleshooting .................................................................................... 1-7
1.2.3.7 Specifications ........................................................................................ 1-7
1.2.3.8 Optional Equipment .............................................................................. 1-7
1.2.4 Page numbers................................................................................................ 1-7
1.3 Your Sany Machine .................................................................................................. 1-8
1.3.1 Machine applications ..................................................................................... 1-8
1.3.2 Machine directions ......................................................................................... 1-8
1.3.3 Breaking in a new machine ............................................................................ 1-9
1.3.4 Machine information....................................................................................... 1-9
1.3.4.1 Product identification plate .................................................................... 1-9
1.3.4.2 Engine identification plate ................................................................... 1-10
1.3.4.3 Right and left drive motors ...................................................................1-11
1.3.4.4 Swing motor .........................................................................................1-11
1.3.4.5 Hydraulic pump ....................................................................................1-11
Safety, Operation and Maintenance Manual - Oct 2012 1-1

Introduction SY115C9/135C/155H Crawler Hydraulic Excavator
1.3.4.6 Chassis serial number ........................................................................ 1-12

1.3.4.7 Machine monitor ................................................................................. 1-12
1.4 Table for serial number and distributor information................................................ 1-13
1.5 Correction Request Form - Technical Publications ................................................ 1-14
1.6 Contact Information ............................................................................................... 1-15
1-2 Safety, Operation and Maintenance Manual - Oct 2012

1 INTRODUCTION
1.1 Overview
Sany-built machines offer high-quality per-
formance and star-grade, after-sales ser-
vice.
Sany-built machines are widely used
throughout the industry for various types of
applications.
Sany is a leading manufacturer of con-
struction equipment worldwide.
This operators manual provides safety, opera-
tion, maintenance, troubleshooting and techni-
cal specifications. In order to properly use your
equipment, it is important to read this manual
carefully before beginning any operations.
Items addressed in this manual are designed

to help you:
Understand the structure and performance

of your crawler hydraulic excavator.
Fig. 1-1
Reduce improper operation and point out
possible hazardous situations.
Increase equipment efficiency during op-
eration.
Prolong the service life of equipment.
Reduce maintenance costs.
Always keep this manual nearby and have all
personnel involved with any job-related proce-
dures read it periodically.
If you sell the machine, be sure to give this

manual to the new owner.
Continuing improvements in the design of this

machine can lead to changes in detail which
may not be covered in this manual. Always
consult your Sany distributor for the latest
available information or if you have questions
regarding information in this manual.

1.2 Your Documentation Package

The documentation for this machine includes
the following items:
Safety, Operation & Maintenance Manual

(SOMM) This manual is in the operator
cab seat pocket.
Parts Book This publication consists of
parts lists and matching drawings for or-
dering spare parts as-needed. If it was not
already shipped with your machine, the
parts book for your machine is available
directly from Sany.
CD A VCR on safety, operation and
maintenance of your excavator is delivered
with the machine.
CD system requirements
In order to use the Sany CD, be sure of the

following:
Hardware:
Intel Pentium II running at 500 MHz or

above
At least 128 MB RAM
CD-ROM drive
Minimum screen resolution of 800 x 600
pixels, high-color depth
Software:
Windows 2000, XP, Vista and Windows 7

operating systems
Internet Explorer 6.0 or later (pop-up block-
er disabled)
Acrobat Reader 7.0 or later version

1.2.1 Recommendations on using the

documentation
This documentation applies only to this

machine and should not be used with any
other machines.
To ensure that the documentation is always
complete and up to date:
Keep all pages inside its binder (if shipped
loose leaf).
Use the CD to print and replace any miss-
ing pages or those made unreadable due
to damage, grease, dirt, etc.
Insert Sany replacement pages immedi-
ately into the appropriate book; destroy old
versions of those pages.
Replace outdated CDs with new ones;
destroy the old ones to prevent any confu-
sion in the future.
1.2.2 Documentation storage
Always keep the operator manual and load

charts with the machine in the operator cab.
The parts book is best left either shelved in

the workshop area or office. It should always
be available to the maintenance and service
personnel as required.
These can be printed out from the CD.
1.2.3 Manual organization
The operators manual is designed for use

and maintenance of this machine. Each sec-
tion of this manual provides information you
should be familiar with before operating this
machine. Keep this manual with the machine
for your reference at all times. Replace it im-
mediately if it is damaged or lost. Due to im-
provement and updating of products, some
information may differ from your machine. If
you have any questions on the machine, con-
tact your Sany distributor before operating or

repairing the machine.
1.2.3.1 Introduction
This section provides an overview of what is

covered in the rest of this manual, including
machine label information and Sany contact
information.
1.2.3.2 Safety
This section covers basic safety information

relating to this equipment. Make sure you fully
understand all the precautions described in
this manual and the safety labels on the ma-
chine before operating or maintaining this ma-
chine. Failure to do so may result in serious
injury or death.
1.2.3.3 System functions
This section provides an overview of all the

controls, alerts and operating systems on the
machine. It is important to study and become
familiar with all systems before proceeding
with any operations.
1.2.3.4 Operation
This section provides some basic operating

procedures for this machine. Study and be-
come familiar with all operating procedures
before performing any job functions with the
machine.
1.2.3.5 Maintenance
This section provides all general maintenance

and repair procedures. (Detailed rebuild / re-
placement / repair information are covered in
a separate shop manual.) Study and become
familiar with all repair and maintenance proce-

dures before performing any repair or mainte-

nance operations.
1.2.3.6 Troubleshooting
This section includes common malfunctions

and fault diagnostics procedures for this crawl-
er hydraulic excavator operating system. Basic
mechanical, hydraulic and electrical system
troubleshooting is included.
1.2.3.7 Specifications
This section provides general required ma-

chine information for this crawler hydraulic
excavator. Some information may vary due to
design changes.
1.2.3.8 Optional Equipment
This section provides information regarding

optional equipment for the excavator as autho-
rized by Sany. If you will be using any optional
equipment, it is important to read the instruc-
tion manual for the optional equipment and the
general information related to optional equip-
ment in this manual.
1.2.4 Page numbers
The pages in this manual are numbered as the

following:
3-20
Page 20 of Chapter 3
Chapter 3

1.3 Your Sany Machine
1.3.1 Machine applications
Sany Hydraulic Excavators are designed for the following operations:
Excavating
Leveling
Digging
Loading
Demolishing
1.3.2 Machine directions
Fig. 1-2
(A) Front In this manual, the front, back, left or right di-
(B) Back rection indicates, when the cab faces the front
and the final drive is behind of the machine,
(C) Left
the moving direction that you could see from
(D) Right the cab.
(E) Operator Seat
(F) Sprocket

1.3.3 Breaking in a new machine
Your machine has been thoroughly adjusted and tested before shipment. However, initial opera-
tion of the machine under severe conditions can adversely affect the performance of the machine
or shorten the machine life. Therefore, Sany recommends that you allow a break-in period of 100
operating hours for a new machine.
During the break-in period:
Let the machine warm up before any operation.

Avoid operating with severe loads or at high speeds.
Avoid sudden starts or fast movements or stops.
Always let the system cool down at the end of the working day.
1.3.4 Machine information
The serial numbers and model numbers on the components are the only numbers that your Sany
distributor will need when ordering replacement parts or requiring assistance for your equipment.
It is a good idea to record this information in this manual for future use. Below are the locations of
the data plates.
1.3.4.1 Product identification plate
On the right side of the operator station on the bottom.
Fig. 1-3

1.3.4.2 Engine identification plate
On cover of engine cylinder head.
SY115C9/SY135C8/SY135C9/SY155H
Fig. 1-4
SY135C8(M)
Fig. 1-5

1.3.4.3 Right and left drive motors
On each drive motor:
Model: _____________________________
ID No.: _____________________________
Fig. 1-6
1.3.4.4 Swing motor
On top of swing motor:
Model: ______________________________
ID No.: ______________________________
Fig. 1-7
1.3.4.5 Hydraulic pump
On bottom of pump:
Model: ______________________________
ID No.: ______________________________
Fig. 1-8

1.3.4.6 Chassis serial number
An additional serial number is stamped on the

front part of the travel carriage frame.
Fig. 1-9
1.3.4.7 Machine monitor
Location of machine monitor is shown in the

right illustration.
Fig. 1-10

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

1.5 Correction Request Form - Technical Publications
If you find a problem with this manual, please make a copy of this page, fill out: the information
and send it to us attention Technical Publications. See Contact Information on next page.
Date of this request

Your Name
Company Name
Your Department
Street Address
City, State & ZIP
Phone
E-mail
Machine Model & Serial No.
Description of Problem (Wrong information, unclear or erroneous procedure, etc.)
Corrective Action by You (if any)

1.6 Contact Information

Thank you for purchasing a Sany machine. In the event that you should need to contact us for
any reason, you can reach us as follows:
Sany Heavy Machinery Limited

318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P. R. of China
201413
Tel: (86) 21 5700 8518
Service hotline: (86) 4006 098 318
E-mail: crd@sany.com.cn

E
G
PA
K
AN
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SY115C9/135C/155H Crawler Hydraulic Excavator Safety
Safety
2 Safety
2.1 Safety Information.................................................................................................... 2-5
2.2 Safety Messages ..................................................................................................... 2-7
2.2.1 Hazard alert wording ...................................................................................... 2-8
2.2.2 Other alert wording ........................................................................................ 2-9
2.2.3 Safety decals ................................................................................................. 2-9
2.2.3.1 Textual safety decals........................................................................... 2-10
2.2.3.2 Graphical safety decals....................................................................... 2-10
2.2.3.3 Safety decal locations ..........................................................................2-11
2.3 General Precautions .............................................................................................. 2-19
2.3.1 Safety rules .................................................................................................. 2-19
2.3.2 Abnormalities ............................................................................................... 2-19
2.3.3 Personal protective equipment .................................................................... 2-19
2.3.4 Fire extinguisher and first aid kit .................................................................. 2-21
2.3.5 Safety equipment ......................................................................................... 2-21
2.3.6 Cleaning your machine ............................................................................... 2-22
2.3.7 Keeping the cab clean ................................................................................. 2-23
2.3.8 Engaging the hydraulic lockout control ........................................................ 2-23
2.3.9 Handholds and steps .................................................................................. 2-24
2.3.10 Overhead work........................................................................................... 2-25
2.3.11 No sitting on attachment ........................................................................... 2-25
2.3.12 Articulated parts ......................................................................................... 2-25
2.3.13 Preventing burns ....................................................................................... 2-25
2.3.13.1 Hot coolant ........................................................................................ 2-25
2.3.13.2 Hot oil ................................................................................................ 2-26
Safety, Operation and Maintenance Manual - Sep 2012 2-1

Safety SY115C9/135C/155H Crawler Hydraulic Excavator
2.3.14 Preventing fire and explosion .................................................................... 2-26

2.3.14.1 Fire caused by fuel or oils ................................................................. 2-26
2.3.14.2 Fire caused by ammable materials ................................................. 2-27
2.3.14.3 Fire caused by electric lines.............................................................. 2-27
2.3.14.4 Fire caused by hydraulic lines .......................................................... 2-28
2.3.14.5 Fire caused by illumination equipment.............................................. 2-28
2.3.14.6 Fire caused by heat shield ................................................................ 2-28
2.3.15 In the event of fire ...................................................................................... 2-28
2.3.16 Windshield cleaning detergent ................................................................... 2-29
2.3.17 Preventing ejection of part ........................................................................ 2-29
2.3.18 Falling object protection ............................................................................. 2-30
2.3.19 Attachment installation ............................................................................... 2-30
2.3.20 Attachment combination ............................................................................ 2-31
2.3.21 Cab windows glasses ................................................................................ 2-31
2.3.22 Unauthorized modification ......................................................................... 2-31
2.3.23 Job site investigation.................................................................................. 2-31
2.3.24 Operation on soft ground ........................................................................... 2-32
2.3.25 Overhead power cables ............................................................................. 2-33
2.3.26 Ensuring a good visibility ........................................................................... 2-34
2.3.27 Ventilating enclosed area ........................................................................... 2-35
2.3.28 Asbestos hazard ........................................................................................ 2-35
2.3.29 Alternate exit .............................................................................................. 2-36
2.4 Safe Operation Precautions................................................................................... 2-37
2.4.1 Safe starting ................................................................................................ 2-37
2.4.1.1 Safe mounting ..................................................................................... 2-37
2.4.1.2 Seat adjustment .................................................................................. 2-38
2.4.1.3 Seat belt .............................................................................................. 2-38
2.4.1.4 Before starting the engine ................................................................... 2-38
2.4.1.5 Engine starting rules ........................................................................... 2-39
2.4.1.6 Safe starting ........................................................................................ 2-39
2.4.1.7 Starting engine in cold season ............................................................ 2-40
2.4.1.8 Engine starting aid .............................................................................. 2-40
2.4.1.9 After starting the engine ...................................................................... 2-41
2.4.2 Operation ..................................................................................................... 2-42
2.4.2.1 Inspection before operation ................................................................ 2-42
2.4.2.2 Prior-operation precautions................................................................. 2-42
2-2 Safety, Operation and Maintenance Manual - Sep 2012

2.4.2.4 Travel directions .................................................................................. 2-43

2.4.2.3 Rules for steering safety ..................................................................... 2-43
2.4.2.5 Rules for traveling safety .................................................................... 2-45
2.4.2.6 Safe traveling ..................................................................................... 2-46
2.4.2.7 Operation on an incline ....................................................................... 2-47
2.4.2.8 Operation in snowy weather ............................................................... 2-48
2.4.2.9 Restricted operations .......................................................................... 2-48
2.4.3.1 Select a parking place......................................................................... 2-51
2.4.3.2 Machine shutdown .............................................................................. 2-51
2.4.4 Transportation .............................................................................................. 2-52
2.4.4.1 Loading and unloading the machine ................................................... 2-52
2.4.4.2 Transporting the machine ................................................................... 2-53
2.4.5 Battery.......................................................................................................... 2-54
2.4.6 Lifting objects with the machine ................................................................... 2-56
2.5 Precautions for Maintenance ................................................................................. 2-57
2.5.1 Prior-maintenance precautions .................................................................... 2-57
2.5.2 Select a working area .................................................................................. 2-57
2.5.3 Preparing the machine ................................................................................ 2-58
2.5.4 Preparing yourself ........................................................................................ 2-59
2.5.5 Lock-out and tag-out .................................................................................. 2-60
2.5.6 Using proper tools ........................................................................................ 2-60
2.5.7 Maintenance with engine running ................................................................ 2-61
2.5.8 Working under the machine ......................................................................... 2-61
2.5.9 Track maintenance....................................................................................... 2-62
2.5.10 Track tension adjustment precautions ....................................................... 2-63
2.5.11 Recoil spring .............................................................................................. 2-63
2.5.12 Welding operation ...................................................................................... 2-64
2.5.13 High-pressure hoses .................................................................................. 2-64
2.5.14 Pressurized uid ........................................................................................ 2-65
2.5.15 Hot cooling system..................................................................................... 2-66
2.5.16 Air-conditioning system ............................................................................. 2-66
2.5.17 High voltage precautions ........................................................................... 2-67
2.5.18 Accumulator ............................................................................................... 2-67
2.5.19 Avoiding fire and explosion ........................................................................ 2-68
2.5.20 Regular replacement of safety-related parts .............................................. 2-69

2.5.21 Maintenance operation ............................................................................. 2-70

2.5.22 Proper disposal of wastes .......................................................................... 2-71

2 SAFETY
2.1 Safety Information

This Operation and Maintenance Manual is a
guide for you to operate your machine prop-
erly. It contains technical and safety informa-
tion necessary for operation of your machine.
Read and understand each section of the
manual.
Only eligible, experienced operators with an

official license (according to local laws) are al-
lowed to operate the machine.
Always operate your machine according to

national, provincial, prefectural and municipal
laws and regulations. The operation safety
information and description in this manual are
just suggestive and attentive.
Sany cannot anticipate every possible circum-

stance that might involve a potential hazard
during operation and maintenance. The Safety
messages in this manual and on the product
are, therefore, not all inclusive. If a procedure,
work method or operating technique that is not
specifically recommended in this manual is
used, you must be sure that it is safe for you
and for others. You should also ensure that
the product will not be damaged or be made
unsafe by the operation, lubrication, mainte-
nance or repair procedures that you choose.
Modifying or abusing the machine according

to your own will might impair the machine's
performance, or result in more serious poten-
tial hazard. For instance, the specific volume
of fuel exceeds set limit or the machine is
overloaded. Drive and operate the machine
carefully. Improper operation or application
may cause personal injury or machine dam-
age. Sany assumes no responsibility for such
losses.

Machines covered by this manual are used

for various operations under normal condi-
tions. Never use the machine in ammable or
explosive environment, or in areas containing
asbestos dust.
Select a Sany excavator that is suitable for

high-plateau operation when operating in
areas 2,000 m above the sea level.
This machine has gone through electromag-

netic capacity test according to EN 13309-
200C. All unapproved electronic attachments
(such as communication devices) are there-
fore to be tested before installation and ap-
plication. Make sure that the electromagnetic
attachments will not cause interference.
The information, specifications, and illustra-

tions in this publication are on the basis of
information that was available at the time that
the publication was written. Sany reserves the
right to change these information at any time
without prior notice. Consult your Sany dis-
tributor to obtain the latest information or if you
have any question on the information provided
in this manual.
Before starting operation and maintenance,

operator and service personnel shall observe
the following items:
Read and understand the whole manual.

Read and understand the safety notices
contained in this manual and the safety de-
cals on the machine.
Never apply or operate your machine un-
der any circumstances that are prohibited
by the manual.
If the amount of fuel added, content of par-
ticulates ,or latitude is beyond the speci-
fication of this type of machine, damage
could result and the warranty of your ma-
chine would become invalid.

The manual must be kept in the operator cab

for reference at any time.
If the book delivery with machine is missing or

cannot be read, contact your Sany distributor
to obtain a new one.
This manual should be regarded as a perma-

nent component of your machine. If the ma-
chine is sold to a third party, give this manual
to new owner.
The machine provided by Sany to its buyer is

in line with all specifications and standards of
buyer's country. If the machine is purchased
from another country or someone of a third
country, it might be lacking of some safety
devices or technical requirements necessary
for using the machine in your country. In case
you question whether the machine is in accor-
dance with the standards and specifications of
your country, you may contact local Sany dis-
tributor before operating the machine.
2.2 Safety Messages

Safety precautions given in this manual and
on machine decals, both textual and graphical,
provide information of hazardous situations
and methods to avoid such situations.
Before performing operation and maintenance

on the machine, the operator and after-sale
service personnel must understand all warn-
ing signs or symbols on the machine decals,
strictly follow the safety rules and precautions
specified in this manual, and take positive
actions so as to reduce the possibility of per-
sonal injury or death, the damage of machine
caused by improper service, and the risk of
unsafe factors, to the minimum.

2.2.1 Hazard alert wording
Hazard alert words are used in this manual

and on some machine decals to inform the
operator of imminent or potential hazards that
lead to death, personal injury or property dam-
age.
Different alert words are used to indicate the

degree of hazard.
DANGER It indicates an imminently

hazardous situation which,
if not avoided, will result in
death or serious injury.
WARNING It indicates a potentially

if not avoided, could result
in death or serious injury.
CAUTION It indicates a potentially

if not avoided, may result
in minor or moderate in-
jury. It can also be used to
alert unsafe operation as
which may cause property
loss.
NOTICE It indicates a situation

which can cause damage
to the machine, personal
property and/or the en-
vironment, or cause the
equipment to operate im-
properly.
This is the safety alert symbol. It is used

to alert you to potential personal injury
hazards. Obey all safety messages that
follow this symbol to avoid possible injury
or death.

An example alert wording and alert text
WARNING
The hydraulic lockout control must be

placed in the LOCK position before you
leave the operator cab.
An unlocked hydraulic lockout control
lever can cause serious injury or death
if maneuvered unexpectedly.
2.2.2 Other alert wording
In addition to the safety-related alert words

above, the following words are used in this
manual to provide additional information to
which extra attention must be paid.
Note:
It is followed by information on how to avoid

reduction of machine service life.
Remark:
It is followed by very useful information.
2.2.3 Safety decals
Safety decals on the machine are used to

alert operator or maintenance personnel that
potential hazards might be involved when the
machine is being operated or serviced.
We use textual and graphical (or combined)

decals to indicate a hazardous situation and
how to avoid such situation.

2.2.3.1 Textual safety decals
Textual safety decals use brief text to indicate

hazardous situation and safety measures.
Fig. 2-1 is an example of textual safety decals.
Code
Fig. 2-1
2.2.3.2 Graphical safety decals
Graphical safety decals use images or sym-

bols to indicate a hazardous situation and how
to avoid it. Possible to fall
Fig. 2-2 is an example of graphical safety de-

cals.
The upper triangle indicates the type of haz-

ardous situation while the lower circle shows
Never step.
the way to avoid it.
Fig. 2-2 Code

2.2.3.3 Safety decal locations
Sany cannot anticipate every possible circum-

stance that might involve a potential hazard.
The warnings in this manual and on the prod-
uct are, therefore, not all inclusive. If a tool,
procedure, work method or operating tech-
nique that is not specifically recommended by
Sany is used, you must be sure that it is safe
for you and for others.
Application or operation not specified in this

manual shall not be performed at any time.
The following safety decals are used on the

machine.
Be sure to recognize the correct locations

and information on the decals.
To ensure that the decals can be read
and understood easily, they have to be at-
tached to the right locations and always
kept clean. The use of organic solution or
gasoline to clean the decals is not allowed.
There are also other decals besides those
for warning and safety. These messages
should be treated in the same way.
A new decal should be used for replace-
ment if the old one is broken or missing,
or cannot be read. See the manual or the
message for part number of the decal. You
may order a new one from your Sany dis-
tributor.

Fig. 2-3

(1) Read the manual
Warning!
Read the Manual before operation, main-
tenance, disassembly, reassembly and
transportation of your machine.
Fig. 2-4
(2) Lock the front window
Always lock the front window if it is open.

If the front window is unlocked in the open
position, it may fall and personal injury
could result.
Fig. 2-5
(3) Excavator control pattern
To prevent bodily injury or death, be aware

of the running condition and mode of your
machine. Pay attention to your surrounding
and operate your machine slowly.
Fig. 2-6

(4) High voltage
Electrocution hazard.
Keep a safe distance from power transmis-
sion lines.
Fig. 2-7
(5) Remove key after power-off
Before leaving your machine, lower the work

equipment to ground, engage the hydraulic
lockout control and remove the ignition key.
Fig. 2-8
(5) Alternate exit
Fig. 2-9

(7) Away from swinging range
This decal shows the possibility of being hit

by the machine. Be away from the swing-
ing range.
Keep a safe distance from the machine
when it is working.
Fig. 2-10
(8) Watch out work equipment
It is possible to be hurt by the work equip-

ment.
Keep a safe distance from the machine
when it is working.
Fig. 2-11
(9) Hot surface
Hot parts can cause burns. Never touch

any hot part.
Fig. 2-12

(10) Squirting hazard
Read the instruction before removing the

cap of any pressure vessel. To prevent
squirting, turn the cap slowly to release in-
ternal pressure before removing it.
Fig. 2-13
(11) Fan cutting hazard
A rotating part may cause injury. Keep a

safe distance from any rotating part.
Fig. 2-14
(12) Track tension adjustment warning
The regulator valve under high pressure

may eject and cause bodily injury. Never
loosen it over one turn.
Fig. 2-15

(13) Moving belt
A rotating belt is dangerous.

Stop the belt before maintenance.
Fig. 2-17
(14) Possible to fall
It is possible to fall.
Stay away from the edge.
Fig. 2-18
(15) Engine hood
It is possible to fall.
Never step here!
Fig. 2-16

(16) Not seating
Fig. 2-19
(17) Water separator draining precautions
A820601990962
Fig. 2-20
(18) Refill refrigerant
Fig. 2-21

2.3 General Precautions
2.3.1 Safety rules
Only trained personnel are allowed to op-

erate and service the machine.
All safety rules, precautions and instruc-
tions must be followed when operating and
servicing the machine.
Taking alcohol or drug could seriously im-
pair one's ability in operating or repairing
the machine, and it is hazardous for you
and other persons.
When working with another operator or job
site traffic signalman, be sure to make all
people understand all hand signals to be
used.
2.3.2 Abnormalities
In case of any abnormalities found during

operation and maintenance, such as noise, vi-
bration, odor, incorrect gauge display, smoke,
or oil leakage, contact your Sany distributor
and take necessary measures. Never operate
the machine before the faults are corrected.
2.3.3 Personal protective equipment
Wear proper work clothes and personal pro-

tective equipment (PPE) suitable for the envi-
ronment of the job site. You may need:
Hard hat
Safety shoes
Safety glasses, goggles or face shield
Protective gloves
Hearing protection
Reective protective clothing
Fig. 2-22
Rain gear

Dust mask
Wear all necessary PPEs as well as other
equipment required by your employer, local
government, and local laws and regulations.
Never take a risk.
WARNING
Observe the following items before per-

forming any operations. Failure to do so
could cause machine damage, personal
injury or death.
Never wear slack clothing and jewelry,

which may get caught by control levers
or other machine parts.
Long hair can be caught in moving
parts. Tie your hair if necessary to
avoid such hazard.
Always have your hard hat and safety
shoes on. Wear safety goggles, face
masks, gloves, hearing protection and
safety belt if necessary.
Make sure all PPEs are in good condi-
tion before use.
Never listen to radio or music with ear
plugs on during operation.

2.3.4 Fire extinguisher and first aid kit
To prevent injury or fire, observe the following

precautions:
First aid kit and fire extinguisher should be

available nearby.
Read and understand the instruction at-
tached to fire extinguisher. Use fire extin-
guisher properly.
Regular inspection and maintenance shall Fig. 2-23
be done to ensure proper functioning of fire
extinguisher at any time.
Check the first aid kit regularly and replen-
ish it when necessary.
Make emergency scheme to deal with fire
and accidents.
2.3.5 Safety equipment
To protect you and others around you, your

machine may be equipped with the following
safety equipment. Make sure that they are se-
cured in place and in good condition.
Falling object protective structure (FOPS)

Front guard
Lamps
Safety signs Fig. 2-24
Horn
Guards
Travel alarm
Mirrors
Fire extinguisher
First aid kit
Windshield wipers
Make sure the above equipment are opera-
tional. Never remove or disconnect any safety
equipment.

WARNING

forming any operations. Failure to do so
could cause machine damage, personal
injury or death.
Make sure all covers and caps are in

proper place. Repair or replace any of
them immediately once found dam-
aged.
Know how to use these facilities and
use them correctly.
Never remove the guard rail of the op-
erator cab (unless necessary) .
2.3.6 Cleaning your machine
Clean the windshields, mirrors and lights.

Make sure that the operating area, steps
and handholds are free from oil, grass,
snow, ice or mud, which can cause you
to slip and fall. Remove the mud on your
soles before getting on the machine.
If the machine is checked or serviced with
presence of mud or oil dirt, it may cause
you to slip or fall, or dirt may get into your
eyes. Keep the machine clean all the time. Fig. 2-25
If water has penetrated into the electri-
cal system, never rush to power on your
machine and start the engine, which can
cause machine failure or PC board dam-
age. Never flush the electrical system
(including sensors, connectors, etc.) with
water or steam.

2.3.7 Keeping the cab clean
Clean the mud and oil on your soles when

getting into the cab. Mud or oil under your
shoes can cause your foot to slip on the
pedal during operation, and serious acci-
dent could result.
Remove all loose personal items or other
objects from the operator's area. Secure
these items in the tool box or remove them
from the machine.
Never use cellular phone when operating
or driving the machine.
Never bring Hazardous articles, such as
flammable or explosive products, into the
cab.
2.3.8 Engaging the hydraulic lockout

control
Before you rise from the operator seat (e.g.

to open or close the front window or to
adjust the seat), lower work equipment to
ground, place hydraulic lockout control (1)
securely to the LOCK position, and then
stop the engine. If hydraulic lockout control
is FREE, accidental touching of control
levers can cause sudden machine move-
ment and serious injury, or machine dam-
age could result.
Fig. 2-26
Before leaving your machine, always lower
work equipment to ground, place hydraulic
lockout control (1) to the LOCK position,
and then shut down the engine. Lock all
lockable components and remove ignition
key.
Fig. 2-27

2.3.9 Handholds and steps
To avoid personal injury caused by slippery

handholds or steps, observe the following in-
structions:
Before mounting and dismounting, check

the handholds and steps (including tracks)
for oil, grease or mud. Always keep them
clean. Make necessary repairs and tighten
loose bolts if any.
When mounting and dismounting the
machine, use the handholds and steps
marked by the arrows.
Face the machine and maintain a 3-point
Fig. 2-28
contact with the handholds and steps (in-
cluding tracks) . A 3-point contact can be
both feet and one hand, or both hands and
one foot.
Never use any control lever as a handhold
when mounting or dismounting the ma-
chine.
Never carry tools when mounting or dis-
mounting the machine.
Never work on an engine hood or cover
with no non-slip mat on it.
Always face the machine when you mount Fig. 2-29
or dismount the machine.
Never jump onto/off the machine. Never
mount a moving machine. Never jump onto
the machine and try to stop it.
When you enter and exit the operator cab,
make sure the cab is on the central line of
undercarriage.
Fig. 2-30

2.3.10 Overhead work
When working on a overhead place, use a lad-

der or other support to ensure your safety.
2.3.11 No sitting on attachment
To avoid falling hazard, no one is allowed to sit

on work equipment or other machine attach-
ments.
2.3.12 Articulated parts
The space around work equipment changes

with movement of linkages. Serious personal
injury could result if one is stuck in between.
Never stay close to rotating or retracting/ex-
tending components.
2.3.13 Preventing burns
2.3.13.1 Hot coolant
To prevent burns caused by hot coolant or

steam when checking or discharging the
coolant, wait until the engine coolant is
cool enough before proceeding.
Never open the cap of radiator before the
engine cools down. Loosen the cap of the
radiator slowly before removing it. Internal
pressure of radiator must be relieved to
avoid serious burns.
Fig. 2-31

2.3.13.2 Hot oil
To prevent scalds caused by hot oil when

checking or discharging the oil, always wait
for the engine oil to cool down before you pro-
ceed.
When the engine has cooled down, loosen the

cover or screw plug slowly to relieve internal
pressure.
Fig. 2-32
Fig. 2-33
2.3.14 Preventing fire and explosion
2.3.14.1 Fire caused by fuel or oils
Engine oil and fuel must be stored in des-

ignated place, where unauthorized persons
cannot enter.
Never smoke or use fire near fuel or en-
gine oil.
Check for missing or loose pipe clamps,
twisted hoses, hoses rubbing against pipe-
line, damaged oil cooler, and loose bolts in
ange of oil cooler, so as to avoid oil leak-
age. Tighten, repair or replace any missing,
loose or damaged pipe clamps, pipelines, Fig. 2-34
hoses, oil coolers or other ange bolts.
Refuel or store oils in a place with good
ventilation.
Shut down the engine before refueling.

Never leave the machine when refilling the
fuel or engine oil.
Never let fuel overflow onto overheated
surface or electrical components.
Remove overowed fuel or engine oil after
refilling.
Store oily rags and any ammable materi- Fig. 2-35
als in protective containers in order to keep
the job site safe.
Screw on the caps of fuel tank and oil tank
tightly.
When oil is used to clean the parts, use
non-ammable oil. Never use diesel oil or
gasoline as they can easily catch on fire.
All flammable materials should be moved
to a safe place before carrying out grinding
or welding operation on the chassis.
Never weld or ame cut the lines contain-
ing ammable uid.
2.3.14.2 Fire caused by flammable materi-

als
Remove at any time dry leaves, wood

chips, paper pieces, dirt and other amma-
ble materials built up or stuck on engine,
exhaust manifold, battery or interior of en-
gine hood to prevent fire.
2.3.14.3 Fire caused by electric lines
Short circuit of electrical system can cause

fire.
Keep electric terminals clean and fastened.

Check power cables and electric lines for
looseness, entanglement, hardening or
break each day after operating for 8-10
hours. Check the presence or damage of
wiring terminal cover.

In case of slack or entangled power cables

or electric wires, tighten the connections
or wire clips, and repair or replace broken
wires.
2.3.14.4 Fire caused by hydraulic lines
Check the clamps, guards and gaskets of

all hoses and pipes to see whether they
are tightened in position.
In case of loosening, their vibration in op-
eration may lead to friction against other
components, resulting damage of hose,
ejection of high-pressure oil, disastrous fire
or serious injury.
2.3.14.5 Fire caused by illumination equip-

ment
Anti-blast illumination equipment shall be

used to avoid explosion when fuel, oil,
electrolyte, window cleaning detergent or
cooling uid is being checked.
Instructions in this manual must be fol-
lowed when power outlet on the machine
is used for illumination.
2.3.14.6 Fire caused by heat shield
Damage or missing of heat shield may

lead to fire.
In case of any abnormality, heat shield
must be repaired or replaced before opera-
tion of machine.
2.3.15 In the event of fire
When a fire breaks out, leave the machine im-

mediately by the following steps.
Turn start switch to the OFF position to

shut down the engine.
Leave the machine with the help of hand-
holds and steps.
2.3.16 Windshield cleaning detergent
Use alcohol based detergent. Never use meth-

anol based detergent as it irritates eyes.
2.3.17 Preventing ejection of part
The grease in track tensioning device is under

high pressure. Improper handling may result in
serious injury, blindness or death. Observe the
following instructions.
Never disassemble grease nozzle or valve

components. These parts may eject. Never
stay in front of the valve.
Travel reducer is under pressure.
Gear oil is hot liquid. Wait for it to cool Fig. 2-36
down before loosening the plug to release
pressure. To avoid injury, never face the
plug during operation.

2.3.18 Falling object protection
When the machine is operated in places

where the cab is likely to be hit or invaded
by falling objects, scattered materials or
foreign bodies, protective structure shall be
used to protect the operator.
In demolishing or breaking operation, a
front guard is necessary. In addition, a
transparent glass film shall be applied to
the windshield.
Fig. 2-37
In a coal mine or a quarry where falling ob-
jects are present, install falling object pro-
tective structure (FOPS) and front guard,
and apply a transparent glass film to the
windshield. The operator shall wear a hard
hat and goggles.
Keep the windshield shut in such condi-
tions and make sure other people are kept
a safe distance away from the operating
area.
Other guards may be necessary according
to different working conditions. In this case,
contact Sany distributor in advance.
2.3.19 Attachment installation
Installation of optional parts or attachments

may involve safety issues or be limited by
the law. In this case, contact your Sany
distributor in advance.
Sany assumes no responsibility for the in-
jury, accidents and product failure caused
by the use of unauthorized attachments
and parts.
Before installing and using machine attach-
ments, read related instructions regarding
the attachment and general precautions on
attachment in this manual.

2.3.20 Attachment combination
Different or combined work equipment may

collide with the cab or interfere with other
machine components. Before operating work
equipment you are not familiar with, check the
clearance between it and the machine and op-
erate it carefully.
2.3.21 Cab windows glasses
Broken cab windows at the side of the

work equipment may expose the operator
in direct contact with the work equipment.
In this case, stop operation immediately
and replace the glasses.
Broken or damaged window provides no
protection to the operator. When the roof
window is damaged, replace it immediately
with a new one.
2.3.22 Unauthorized modification
Any modification unauthorized by Sany may

lead to safety problems, personal injury or
death. Improper modification can affect ma-
chine's strength and operator's view. Contact
your Sany distributor before making any modi-
fication. Sany assumes no responsibility for
the accidents, failure or damage caused by
unauthorized modification.
2.3.23 Job site investigation
Machine operation near ammable materi-

als (e.g. dry tree leaves) poses a fire haz-
ard. Be careful during operation.
Check the terrain and ground condition and
use the safest operating method. Never
operate in areas with the risk of landslide
or falling stones.
Solidify the ground when operating beside
Fig. 2-38
a ditch or on road shoulders. Keep your

machine a safe distance away from the
ditch or road shoulder. Designate a signal
man, when necessary, to avoid accidental
injury.
When underground water mains, gas lines,
cables or high-voltage electric cables are
available on the job site, inform related
utilities providers and mark the area. Be
careful not to cut or damage any lines.
Prevent any unauthorized personnel from
entering the job site. Designate a signal
man and fence the job site when operating
your machine on a highway.
Be especially alert when operating on fro-
zen ground. Increase of ambient tempera- Fig. 2-39
ture may result in soft and slippery ground.
When traveling or operating in shallow wa-
ter or soft ground, check the type and con-
dition of rock bed as well as the depth and
water ow before operation.
2.3.24 Operation on soft ground
Avoid traveling or operating your machine

near cliffs, road shoulders or trenches. The
soft ground plus machine weight and vibra-
tion can cause your machine to sink or tip
over. The ground may become even softer
after heavy rain, explosion or earthquake.
When operating on a dam or near an exca-
vated ditch, vibration and machine weight
may trigger a landslide. Before operation,
take protective measures to prevent your
machine from tipping over or falling.

2.3.25 Overhead power cables
Never drive or operate your machine near

power cables, which may bring electrocution
hazard and cause machine damage, personal
injury or death. The following steps are to be
followed while working at where power cables
could be nearby.
Before operation in the vicinity of power

cables, inform local power company of the
coming operation and ask them to take
Fig. 2-40
necessary measures.
If your machine is too close to power
cable, electrocution is most likely to occur
and cause burns or death. A safe distance
must be kept between machine and power Cable Voltage Safe Distance
cable (See Table 2-1). Before operation, 100V-200V 2 m ( 7 ft) or above
communicate with local power company
6,600V 2 m ( 7 ft) or above
regarding safety measures.
22,000V 3 m ( 10 ft) or above
A signalman is to be designated to give
66,000V 4 m ( 14 ft) or above
signals if your machine is too close to pow-
154,000V 5 m ( 17 ft) or above
er cables.
187,000V 6 m ( 20 ft) or above
Nobody is allowed to approach the ma-
chine when it is operated near high-voltage 275,000V 7 m ( 23 ft) or above
cables. 500,000V 12 m ( 36 ft) or above
If your machine is too close to the cable Table 2-1

or touches the cable, to prevent electrocu-
tion, operator shall not leave the cab until
machine power is surely cut off. In addi-
tion, Nobody is allowed to approach the
machine.
To prevent accidents, wear rubber shoes
and rubber gloves during operation. Cover
the operators seat with rubber sheet and
pay attention to exposed part of body that
should not touch the lower part of machine.

2.3.26 Ensuring a good visibility
The machine is equipped with rearview mirrors

to improve the visibility of the operator. How-
ever, some areas cannot be seen from the
operator seat. When operating your machine
in a position that gives you poor visibility, un-
certainty of job site may cause machine dam-
age and personal injury. Observe the following
instructions when operating or driving your
machine in a place without a clear view.
Check rear view mirrors on each workday.

Remove debris and adjust the view to en-
sure good visibility.
Working in a darkened area requires turn- Fig. 2-41
ing on work lamps and head lamps of the
machine. Set up auxiliary illumination on a
job site if necessary.
Stop operation if you cannot have a clear
view in days with fog, snow, rain or sand
storm.
Road shoulder or soft ground should be
marked. In case of bad vision, a signalman
should be available if necessary. Operator
shall especially pay attention to the marks
and follow the instruction of the signalman.
Only one signalman is allowed to give sig-
nals.
Make sure all workers understand all sig-
nals and gestures before operation.

WARNING
Exposure to hazardous chemicals or dusts

pose a serious danger if released or mis-
handled. Performing demolition work or
handling hazardous materials often release
substances that could pose a hazard. Seri-
ous injury or death may result unless prop-
er precautions are observed while working
with these materials. All workers involved
in demolition or handling of hazardous
materials should use approved personal
protective equipment and follow all envi- Fig. 2-42
ronmental safety regulations.
2.3.27 Ventilating enclosed area
Engine exhaust gas can be fatal. If the engine

must be started, or if fuel, cleaning oil or paint
must be handled in an enclosed area, to pre-
vent gas poisoning, doors and windows shall
be opened to ensure sufficient ventilation.
2.3.28 Asbestos hazard
Inhalation of asbestos dust can cause lung

cancer. It is possible to inhale asbestos dust
when performing tear-down operation or han-
dling industrial wastes at job site. The follow-
ing rules must be followed.
Use water, instead of compressed air, to

remove the dust.
If the air contains asbestos dust, operate
the machine following the wind. All persons
shall wear acceptable filter mask.
Nobody is allowed to approach the ma-
chine during operation.
The regulations, rules and environment cri-
terion at job site shall be observed.
No asbestos is used in this machine. But after-

market parts could contain asbestos. There-

fore, use only the parts and components sup-
plied by Sany.
2.3.29 Alternate exit
If you are unable to open the cab door in

case of emergency, use the safety hammer
to break the rear window to escape.
Remove the pieces of glass from the win-
dow frame before escaping. Be careful not
to be cut by broken glass. Pay attention to
the broken glass on the ground, which may
cause you to slip and fall.
Fig. 2-43

2.4 Safe Operation Precautions
2.4.1 Safe starting
2.4.1.1 Safe mounting
When you mount or dismount the machine:
Always face the machine and maintain a

three-point contact (one hand and two feet
or two hands and one foot).
Fig. 2-44
Never jump on/off the machine. Never
mount a moving machine.
Never use any control lever as handhold.
Remove the mud, oil dirt and water from
the pedals, handholds and your soles at all
times.
The cab must be aligned with the under-
carriage centerline before you enter or exit
the cab.
An unattended machine is dangerous.
Fig. 2-45
Fig. 2-46

2.4.1.2 Seat adjustment
Uncomfortable seat position can easily lead to

operator fatigue and mistakes. The seat posi-
tion should be adjusted upon change of opera-
tor. Leaning against the back of seat, operator
shall be able to push the pedal to its limit with
his foot, and operate the control lever properly.
Otherwise, the seat should be readjusted by
moving it forward or backward.
Fig. 2-47
2.4.1.3 Seat belt
The operator may get seriously injured or

killed when the machine tips over. Before
operating the machine, check carefully your
seat belt, the buckles and the anchor point.
Replace the seat belt if damage or excessive
wear is observed. When the machine is being
operated, keep your seat belt buckled up.
The seat belt must be replaced every three

years regardless of its condition.
Fig. 2-48
2.4.1.4 Before starting the engine
Before starting your daily work, the following

items must be observed before starting the
engine.
Clean the windows to ensure a good vis-

ibility.
Clean the head lamps and work lamps,
and check if they are in good condition.
Check coolant level, fuel level and engine
oil level. Fig. 2-49
Check for blocked air filter and damaged
electrical wires.
Adjust the seat to a position easy for op-
eration; check seat belt and buckles for
damage and wear.

Check the instrument panel. Check if the

control levers are all in neutral position.
Check if the hydraulic lockout control is in
the LOCK position.
Adjust the rear view mirrors so as to see
clearly from the operator seat what is hap-
pening behind the machine.
2.4.1.5 Engine starting rules
Before starting the machine, make sure

nobody is on, under or around the ma-
chine. Sound the horn to warn people
around.
Always start and operate the machine from
the operator seat.
No one is allowed to stay on the machine
except the operator.
Never start the engine by shorting the start
motor circuit, which is dangerous and may
cause machine damage.
2.4.1.6 Safe starting
WARNING
Ample ventilation must be provided if

you have to start the engine or operate
the machine in an enclosed environ-
ment.
Excessive inhalation of exhaust gas can
be fatal.
If you do not know how to stop the ma-
chine, never start it.

To understand proper starting steps of the ma-

chine, see Engine Starting on page 4-22.
Being seated in the operator's position, ad-

just the seat so you can easily access all
controls from a seated position.
Familiarize all warning devices, gauges
and operation controls.
Place all controls to neutral/shutdown posi-
tion.
Nobody is allowed to stay in the working
area.
Start the engine as indicated in Operation
Section.
Fig. 2-50
2.4.1.7 Starting engine in cold season
When ambient temperature is blow 10C,

pre-heat the engine before start it. For de-
tailed information, see Engine Preheat-
ing on page 4-25.
When the machine is intended to work in
areas where temperature is always below
-15C, fuel heating system is recommend-
ed to improve engine startup performance.
Sufficient warm-up operation is necessary.
Incomplete warming up may result in slow
reaction and accidents.
Before starting, check the battery electro-
lyte. In case of frozen electrolyte, never
charge the battery or use alternative power
source to start the engine; instead, melt the
electrolyte first. Otherwise, fire may break
out on the battery.
2.4.1.8 Engine starting aid
Follow procedures in the Operation section

when using jumper cables to start the engine.

Improper handling may cause battery explo-

sion or loss of machine control, resulting in
personal injury and death. Never use jumper
cables to start the engine unless necessary.
Contact your Sany distributor before such an
attempt.
Using jumper cables to start the engine

needs two persons working together with
one seated in the operator seat and the
other handling the battery.
Wear goggles and rubber gloves before
starting the engine with jumper cables.
When connecting a normal machine with a
faulty machine with jumper cables, battery
voltage of the two machines shall be the
same. Be careful not to allow the two ma-
chines to contact with each other.
Turn both start switches to OFF position
when connecting the two machines. Oth-
erwise, the machine may move and cause
danger when it is powered on.
Start with the positive terminal when con-
necting the jumper cable. Start with the
ground or negative terminal when discon-
necting the jump cable.
When disconnecting the jumper cable, take
care not to allow the clips of jumper cable
to contact with each other or with the ma-
chine.
Ether is a liquid used for cold start, which is

extremely ammable and explosive. Read the
instructions on the ether container before ap-
plication.
Never use ether if the engine is equipped with

spark-plug preheater or other forms of pre-
heater.
2.4.1.9 After starting the engine
Run the engine at low idle for 3 to 5 minutes

after engine startup, and check the running
parameters and make sure they are normal

and all readings are within normal working

range.
2.4.2 Operation
2.4.2.1 Inspection before operation
When conducting inspection, move the

machine to a spacious area without barri-
ers and operate slowly. Any other person is
not allowed to approach the machine.
Be sure to buckle the seat belt.
Check the gauges and machine operation
for abnormality; check the bucket, arm,
boom, travel system, swivel system and
steering system for abnormal operation.
Check for abnormal noise, vibration, heat-
ing, odor or gauge reading; check oil or
fuel for leakage.
When the travel control level is in neutral
position, test the engine's speed control
device; operate each control lever and
confirm they work properly. Understand the
control mode of work equipment.
In case of any abnormality, stop operation
and take corrective measures immediately.
2.4.2.2 Prior-operation precautions
To prevent serious injury or death, follow the

items below before moving the machine.
It is dangerous to stay in the working range

during machine operation. Sound the horn
to warn people within the working range
before operating your machine.
Fig. 2-51
Nobody is allowed to stay on and near the
machine, or within the working range.
To improve the visibility in the travel direc-
tion, you may turn the cab if necessary.
Assign a signalman at where visibility is
poor.

2.4.2.4 Travel directions
WARNING
Improper operation of travel control lever/

pedal can cause serious injury or death.
Confirm the relative positions between the

undercarriage and operator before operat-
ing the machine.
If the motor is under the cab, pushing the
control lever/pedal forward will move the
machine backward.
If the guide roller is under the cab, push
the control lever/pedal to move machine
forward. Fig. 2-52
A sign for travel direction can be found on
internal side of undercarriage. When oper-
ator pushes control lever/pedal, the actual
travel direction is the direction indicated by
arrow.
Note:
In this manual, the forward, backward, left or

right direct is the direction seen from the cab
when the cab is straight forward and the driv-
ing wheels are in the rear.
Fig. 2-53
2.4.2.3 Rules for steering safety
Always drive and operate the machine in a

seated position.
Nobody is allowed in the cab except the
operator.
Check if the travel alarm works.
Always secure the cab door or windows,
either open or closed. At job site where y-
ing objects may get into the cab, check if
the doors and windows are properly shut.
Fig. 2-54
Assign a signalman if a blind area exists

at the rear of the machine. In turning or

swivel operation, be alert not to hit other
machines or personnel.
Sound the horn to warn personnel in the
area before traveling.
Check for the presence of personnel and/
or obstacles again in the machine sur-
roundings before traveling.
Before traveling, position the machine so Fig. 2-55
that the sprocket (1) is behind the operator
cab. If the sprockets are in front of the cab,
the machine will move in a direction oppo-
site to the move direction of control levers.
Special attention must be paid to opera-
tions under such circumstances.
If your vision is limited during reverse trav-
el, assign a signalman and keep him within
the range of your vision.
When a signalman is necessary on some
occasions, use hand signals specified in
local regulations. Fig. 2-56
The machine can only be moved when

both signalman and operator understand
the signals.
Understand all vocal, graphic and flag
signals used in work and decide who is to
give signals.
Keep the windows, rear view mirrors and
work lights clean and intact.
Dust, heavy rain and fog may reduce vis-
ibility. Drive slowly and use proper lights in Fig. 2-57
case of low visibility.
WARNING
During reverse or swivel operation, people

around the machine may get hit by the
counterweight or work equipment, result-
ing in serious injury or even death.

2.4.2.5 Rules for traveling safety
To prevent machine breakdown and avoid

damage of work equipment, never operate
the machine beyond its maximum load or
rated capacity.
When driving or operating the machine,
keep the machine a safe distance away
from people, building or other machine so
as to avoid collision.
When traveling on a highway, contact re-
lated departments in advance and follow
their instructions.
When traveling on flat ground, the work
equipment should be retracted and kept
20-30cm(8-12in) off the ground.
When traveling on rough ground, the ma-
chine shall move at a low speed and avoid
sudden change of direction, or the machine
may tumble down. If the work equipment
hits the ground, the machine will lose bal-
ance and get damaged. Fig. 2-58
When traveling on rough ground or on a
steep slope, the auto-deceleration switch (if
equipped) shall be switched off. If the auto-
idle switch is on, engine speed and travel
speed may drop suddenly.
Avoid traveling over a barrier if possible. If
you have to do that, lower the work equip-
ment close to the ground and drive slowly.
Never let the machine travel on a barrier
that would make it tilt sharply.
Check first the structural strength of a Fig. 2-59
bridge or a building before drive the ma-
chine on it.
Operate slowly when you are working in a
tunnel, under a bridge or power cables or
under where working height is limited. Take
care not to damage anything with work
equipment.

2.4.2.6 Safe traveling
Check the travel direction of the machine

before driving it. Make sure you know how
to operate the control levers and pedals.
Press the upper part of the control pedal or
push the control lever forward to move the
machine in the direction of the idlers.
Work equipment should be kept 20-30 cm
(8-12 in) off the ground when moving on a
slope. In case of an emergency, the work
equipment could be lowered to ground im- Fig. 2-60
mediately to help stop the machine.
WARNING
Driving the machine on a slope may cause

it to slip or tumble down, resulting in seri-
ous injury or death.
When driving the machine up a slope, face

the cab to the uphill direction; when driving
down a slope, face the cab to the downhill
direction.
Before traveling, always check the hard-
ness of ground before your machine.
Fig. 2-61
When driving the machine up a slope, ex-

tend the work equipment to keep balance.
Keep the work equipment 20-30 cm (8-
12in) off the ground and drive the machine
slowly.
When driving down a slope, lower the en-
gine speed, keep the travel control levers
close to neutral position and drive
slowly. Fig. 2-62

Drive straight up and down a steep slope.

It is very dangerous to turn on or drive
across a slope.
Fig. 2-63
To adjust the position of the machine on a

slope, drive it onto a flat surface, reposi-
tion it and driving the machine to the slope
again.
Drive at low speed on meadow, fallen
leaves or wet steel plate because even a
small grade could cause the machine to
slip.
If your engine stalls out when traveling on
a slope, place the control levers to neu- Fig. 2-64
tral position immediately and restart the
engine.
2.4.2.7 Operation on an incline
If you swing upper structure or operate work

equipment on an incline, you machine could
loose balance and tip over, causing serious
injury or damage. Therefore, such operations
must be performed carefully on a at platform.
When the bucket is fully loaded, never turn

work equipment from uphill to downhill.
Such operation is dangerous and your ma-
chine could tip over.
If you have to operate your machine on an Fig. 2-65
incline, always build an earth platform so
that your machine can work on a level sur-
face.

2.4.2.8 Operation in snowy weather
Snow-covered or frozen surfaces are slip-

pery. Never manipulate the control lever
suddenly when driving or operating the
machine. Extra attention should be paid to
operation on a slope because even small
inclination could cause the machine to slip.
The machine may tip over on frozen sur-
face which may become soft upon increase
of ambient temperature.
Avoid deep snow, which may cause your
machine to tip over or to be buried in
snow. Be noted that you shall never be
away from road shoulder and avoid being
trapped in snow.
When cleaning the snow, it is hard to see
the snow-covered road shoulder and ob-
jects near the road. There is danger for
your machine to tip over or hit the covered
objects. Therefore, please operate with ex-
treme caution.
2.4.2.9 Restricted operations
Never dig under an overhang, which may

lead to falling stones, collapse of overhang,
and accidents.
Fig. 2-66

Never dig too much under the machine,

which may cause the ground to collapse
due to cave-in, hence the accidents.
Fig. 2-67
In excavating operation, the track should

be adjusted vertical to road shoulder or
cliff, with sprockets behind the cab, so that
the machine can retreat easily in case of
an emergency.
Fig. 2-68
Never tear down under your machine,

which may cause your machine to destabi-
lize and roll over.
When operating on building or other
structures, strength of structure must be
checked to avoid collapse of building, thus
resulting injury or death.
Fig. 2-69

Never tear down any structure over your

machine. The falling of broken objects or
collapse of building could damage your
machine and cause personal injury or
death.
Fig. 2-70
Never break anything with the impact force

of work equipment as broken pieces could
lead to personal injury, the work equipment
could be damaged, and the counter-action
of impact force could roll over your ma-
chine.
Generally speaking, it is easier to tip over
with the work equipment at one side than it
is positioned in the front or rear.
Fig. 2-71
Lifting, moving or swinging the bucket shall

never pass over anybody or a truck's cab.
The falling of substances from the bucket
or collision of buckets could result in per-
sonal injury or machine damage.
The use of crusher or other heavy working
unit could cause your machine to lose bal-
ance and tip over. When operating on a at
surface or slope:
Fig. 2-72
Never lower, swing or stop the working unit
suddenly.
Never extend or retract the boom cylinder

suddenly as which may cause your ma-
chine to tip over due to impact.

2.4.3 Parking the machine
2.4.3.1 Select a parking place
Park your machine on a solid and at sur-

face.
Park the machine in an ares free of such
hazards as falling stones or landslide. If the
terrain is low, park it in a relatively higher
place.
If you have to park the machine on a slope,
observe the following instructions:
Fig. 2-73
Position the bucket in the downhill di-
rection and cut the bucket tips into the
earth.
Chock the tracks to prevent unexpected
movement.
Never park your machine on a road under-
going construction. If you have to park your
machine in such a place, flags are to be
used on daytime and signal lamps at night
to warn other people or vehicles according Fig. 2-74
to local regulations.
2.4.3.2 Machine shutdown
Follow the procedures below to shut down the

machine.
1. Stop the machine.
2. Position the machine properly.
3. Lower work equipment to ground or hold it

in a position.
4. Reduce engine speed to idle and keep it

running for 5 minutes.
5. Turn start switch to OFF position to stop Fig. 2-75

the engine.
6. Place hydraulic lockout control to the

LOCK position.
7. Remove ignition key.
8. Close the windows and the cab door.
9. Lock all access doors, boxes and cham-

bers.
When leaving your machine, face the machine

Fig. 2-76
and maintain a three-point contact with it. Nev-
er jump off the machine.
Be careful with slippery track, step and hand-

holds when dismounting the machine.
2.4.4 Transportation
2.4.4.1 Loading and unloading the machine
Improper loading and unloading of the ma-

chine may cause it to fall or tip over. Follow
the procedures below:
Load or unload the machine only on a solid

and flat surface. Keep it a safe distance
away from road sides or a cliff.
Keep on-lookers away.
Use an access ramp with enough strength.
Make sure that the width, length and thick-
ness of the access ramp is capable of pro-
viding a safe loading/unloading operation
(at an angle 15).
Make sure the access ramp is free from
grease, oil, water and debris. Clean the
track if necessary. Be extremely careful
when loading or unloading the machine in
rainy or snowy weather.
Never load or unload the machine using
the force of work equipment, which may
cause the machine to fall or tip over. Fig. 2-77
Run the engine at low speed and drive

slowly.
Place the work equipment straight forward.

Never operate any control levers other
than the travel control lever when the ma-
chine is driving up the ramp.
Never reposition the machine on the ac-
cess ramp. If necessary, drive it off the
ramp, reposition, and get on the ramp
again.
Gravity center of the machine may alter
when it passes the jointing area between
the ramp and the trailer. The machine may
tilt at this moment. Travel slowly when the
machine is on the joint area.
When loading or unloading the machine on
a platform, make sure the platform has ad-
equate width, strength and a proper grade.
The trailer may become less stable with
the machine on it. Retract the work equip-
ment and swing the upper structure slowly. Fig. 2-78
Once the machine is loaded, lock the cab
door. Otherwise, it may swing open during
transportation.
Secure the machine with chains and
chocks.
Secure all work equipment, lower the buck-
et, the arm and the boom, and place them
in position for transport.
2.4.4.2 Transporting the machine Fig. 2-79
Observe the following items when transporting

the machine:
Note the dimension of the trailer and the

machine, especially the height. Watch out
for barriers overhead and in narrow pas-
sages.
Check the structure and strength of a
bridge before crossing it. Obey local traf-
fic regulations and traffic police directions
when transporting the machine on high-
ways.

2.4.5 Battery
Electrolyte contains sulfuric acid, which gives

off ammable and explosive gases. Improper
handling may cause personal injury or fire.
Observe the instructions below when handling
battery:
Never smoke or use fire near a battery.

Turn the engine ignition key to the OFF po-
sition before working on the battery.
Wear safety glasses and rubber gloves Fig. 2-80
when handling battery.
Electrolyte is a strong acid. If electrolyte

contacts your clothing or skin, ush imme-
diately with plenty of water. Electrolyte may
cause blindness if it contacts your eyes.
Flush immediately with plenty of clean wa-
ter under such circumstances and seek
medical treatment.
Fig. 2-81
To avoid battery-induced explosion, observe
the following precautions:
Never allow tools and other metal parts to

contact with battery terminals. Keep tools
or metal parts away from batteries.
Stop the engine and wait for one minute
before you proceed. Always disconnect the
grounding terminal (negative(-) ) first. To
connect battery cables, always begin with
the positive (+) terminal, and then connect
the negative (-) terminal. Ensure all termi-
nals are securely connected.
Battery temperature rises when it is be-
ing charged. When battery temperature
exceeds 45C, stop charging and wait till
it is at ambient temperature. Reduce the
charging current by half and continue the

charging process.
A battery being charged may give off am-
mable gases. Before charging a battery,
remove it from the undercarriage, put it in
well-ventilated area and remove the cap.
If acid squirts out of battery vent during
charging, stop charging immediately.
Never smoke and keep flames or sparks
out when charging.
When the battery has been fully charged, a
green indicator will be on. Stop the charg-
ing process at this time.
Restore the battery cover after charging.
Fig. 2-82
Put the battery back to its original position.
When towing a damaged machine, improper
operation or use of unacceptable wire cable
could lead to serious accident:
Never tow the machine on a slope.

Wear protective gloves and a had hat
when using wire ropes.
Check the strength of wire cable and make
sure it could bear the weight of machine.
Never use ropes with broken wires (A), re-
duced diameter (B) and twisting (C). Such
ropes may break when towing.
Never stand between the towing machine
and the towed machine during towing op-
eration.
Operate the machine slowly. Never add
load to the wire cable suddenly.

2.4.6 Lifting objects with the machine
WARNING
Overload is dangerous and can cause

serious injury and death.
Make sure the load is within the loading
range and working radius of the ma-
chine.
Nobody is allowed to enter the working

area. Fig. 2-83
Confirm all signals to be used and assign a
signalman before operation.
Lift a load on a at surface to prevent the
machine from tilting or tipping over.
Never use chains, wire ropes, shackles
and slings that are damaged.
Anchor wire ropes or slings onto the desig-
nated lifting lug. Never attach the shackle
or sling onto the bucket tips. Loosened
bucket tips could cause the load to fall.
Fig. 2-84
Never leave the operator seat when lifting
is in progress.
To prevent the load from hitting any person
or building, inspect carefully the machine
surroundings before swinging or operating
the work equipment.
Never swing or operate the work equip-
ment suddenly. This may cause the load
to drift and the machine to tip over. Use a
drag rope if necessary.
Never use the work equipment or the
swing force to drag the load in any direc-
tion. The work equipment will jerk if the Fig. 2-85
shackle breaks and the load comes free,
resulting in serious personal injury.

2.5 Precautions for Maintenance
2.5.1 Prior-maintenance precautions
To prevent accidents:
Understand maintenance procedure before

operation.
Keep a clean and dry working area.
Never spray water or steam in the cab.
Never add lubricant and carry out other
maintenance work when your machine is
moving.
Keep your hands, feet and clothing away
from rotating parts.
2.5.2 Select a working area
For maintenance work, select a clean flat

area with plenty of space, ample sunlight
and good ventilation.
Clean the working area by removing fuel,
lubricant and water, and covering slippery
ground with sand or other absorptive mate-
rials.
Never leave your hammer or other tools at
the working area.
If a clean, tidy working area cannot be
guaranteed, there would be danger of tip-
ping, thus resulting in personal injury.

2.5.3 Preparing the machine
Before maintaining the machine:
Park the machine on solid and at ground.

Lower the bucket to the ground.
Place blocks under the tracks to prevent
movement of the machine. Fig. 2-86
Turn the fuel control dial to first gear. Run
the engine at low speed for 5 minutes.
Turn the start switch to OFF position and
stop the engine.
Turn the start switch to the ON position.
Operate the control levers 2 or 3 times in
all directions to relieve internal pressure of
the hydraulic system.
Remove the key from the switch.
Fig. 2-87
Place the hydraulic lockout control to the
LOCK position.
Fig. 2-88

2.5.4 Preparing yourself
Only approved personnel can maintain or

repair the machine. An observer may be as-
signed if necessary.
Wear protective clothing and shoes neces-

sary for the job.
Wear rubber apron and rubber gloves
when handling corrosive materials. Wear
heavy gloves when handling wooden ma-
terials, wire ropes or sharp-edged metals. Fig. 2-89
Wear a face shield when removing spring
or elastic parts, or adding acid to battery.
Wear safety hat and goggles when you
weld or cut with a torch.
Never carry out grinding, flame cutting or
welding without an aspirator and ventilation
equipment.
Loud noise may impair your hearing per-
manent or temporary. When maintaining
the engine, wear ear covers or ear plugs if
you have to work in loud noise for a long
Fig. 2-90
time.
When using a hammer to strike hard metal
parts such as pin, bucket teeth, cutting
edge or shaft, the ying of parts and metal
pieces may cause bodily injury. Therefore,
wear goggles and gloves and ensure the
surrounding area is clear of any other peo-
ple.
When compressed air is used for cleaning,
ying particles may cause personal injury.
In this case, wear goggles, dust-preventive
mask, gloves and other protective gear.
Fig. 2-91

2.5.5 Lock-out and tag-out
When maintenance is underway, starting

the engine or moving the control levers or
pedals could lead to serious accident.
Before maintenance, attach a Never OP-
ERATE tag or similar sign to the machine's
start switch or control levers to warn others
that this machine is under maintenance.
Attach other warning tags around the ma-
chine if necessary.
Fig. 2-92
Fig. 2-93
2.5.6 Using proper tools
Use proper tools and use them correctly. Us-

ing damaged, inferior, defective, temporary
tools or using the tools incorrectly could lead
to serious accidents.
Fig. 2-94

2.5.7 Maintenance with engine running
To prevent injury, no maintenance shall be car-

ried out when the engine is running. However,
if maintenance has to be done on a running
engine, at least two worker are needed to car-
ry out the maintenance.
One of the workers shall stay in the opera-

tor seat ready to shut down the engine at
any time. All the workers involved shall
keep in touch.
Fig. 2-95
Place the hydraulic lockout control to the
LOCK position to prevent movement of
work equipment.
Pay special attention to rotating parts like
fan and fan belt.
Never leave or insert any tool or other ob-
jects in the fan or the fan belt, which may
cause the parts to break or y.
Never touch any control lever. If one of the
control levers must be used, give signal
to other workers and warn them to move
quickly to a safe area.
Fig. 2-96
2.5.8 Working under the machine
Never carry out maintenance before the

machine is well supported.
Lower the work equipment to the ground
before maintaining the machine.
If the machine or work equipment has to
be lifted for maintenance, blocks or sup-
ports that are strong enough to support
the machine or work equipment should be
used. Never use slag bricks, empty tires
or stands to support the machine. These Fig. 2-97
things may collapse under continuing load.
Never use single jack to support the ma-
chine.

If the track shoes are lifted and the ma-

chine is solely supported by the work
equipment, it is very dangerous to work
under the machine. In case of failure of hy-
draulic pipe or accidental touch of control
lever, the work equipment or machine may
fall suddenly, causing injury or death. Nev-
er work under the machine if it is not firmly
supported with blocks or supports.
2.5.9 Track maintenance
WARNING
Never strike the recoil springs of the track.

Recoil springs are under immense pres-
sure and spring rupture may cause bodily
injury. Never remove any spring when it is
compressed.
Dry rubbing of pin against bushing may

produces extreme heat. Wear protective
gloves to avoid burns.
Maintain proper track tension. When work-
ing on mud- or snow-covered ground, mud
or snow may attach to track components
and causes over tension. Adjust track ten-
sion properly.
Check for loosened or broken track shoes.
Check the pins and bushings for wear or
damages. Check the track rollers and car-
rier rollers.

2.5.10 Track tension adjustment precautions
WARNING
Grease is injected into track tension ad-

justment system under high pressure. Fail-
ure to observe specified maintenance pro-
cedures may cause the grease discharge
plug to eject and cause serious injury and
damage.
Fig. 2-98
When loosening the grease discharge plug
(1) to reduce track tension, the plug shall
be unscrewed slowly for no more than one
turn.
Keep your face, hand, foot or any other
body part away from the grease discharge
plug.
2.5.11 Recoil spring
The recoil springs are used to reduce the im-

pact of tension rollers. It includes a high pres-
sure spring, which may y out and cause seri-
ous injury or death if removed improperly.
If it has to be removed, contact your Sany dis-

tributor.
Fig. 2-99

2.5.12 Welding operation

Welding operation may lead to fire or electro-
cution. Only qualified welders are allowed to
conduct welding operation using proper equip-
ment.
2.5.13 High-pressure hoses

If oil leaks from high-pressure hose, fault or
even fire may occur. If any bolt on hose is
loose, stop operation and tighten it to specified
torque. In case of hose damage, stop opera-
tion immediately and contact Sany HM autho-
rized dealer.
Replace the hose immediately in case of the

following problems:
Damage or leak of hydraulic hose fitting

Damage or break of outer cover, or ex-
posed steel wires of reinforcement layer
Ballooning outer cover in some places
Distortion or crushing of movable parts
Impurities in outer cover

2.5.14 Pressurized fluid

The hydraulic system is always under pres-
sure. Make sure pressure in hydraulic circuits
has been relieved before checking or replac-
ing the lines. Residual pressure in the circuit
may cause serious accidents.
Release system pressure before maintain-

ing the hydraulic system: 1) Remove the
butterfly nut of the vent valve and press
the venting button to release the internal
pressure of the hydraulic tank; 2) Turn the
start switch to ON position within 15 sec-
onds after engine shutdown and place the
hydraulic lockout control to FREE position.
Move the control levers to all directions to
release the pressure in the accumulator.
Open fire is not allowed around the hydrau-
lic system. Remove splashed hydraulic oil
as quickly as possible.
Diesel oil or pressurized hydraulic oil can
penetrate skin or eyes, causing serious
injury, blindness or death. It is hard to find
the leaking of hydraulic oil with naked eyes.
A cardboard or wooden board is necessary
for checking for leaks. Never touch leaking Fig. 2-100
liquid with bare hand. Wear face shield or
safety goggles to protect your eyes. If any
liquid penetrates your skin, ush with clean
water immediately and get medical atten-
tion as soon as possible.
The fuel lines are under high pressure
when the engine is running. When check-
ing or servicing the fuel system, shut down
the engine and wait for 30 seconds till in-
ternal pressure drops before operation.

2.5.15 Hot cooling system
WARNING
Touching hot high-pressure coolant may

cause serious injury.
When engine temperature rises, pressure of

the cooling system increases. Before remov-
ing the radiator cover, stop the engine and
let the system cool down. The radiator cover
could only be removed after the coolant in it
has cooled down.
Fig. 2-101
2.5.16 Air-conditioning system
WARNING
Refrigerant R134 a is a harmless gas

under room temperature. It will change
into highly toxic gas when burning.
Refrigerant getting into eyes may cause
blindness. It may cause frostbite if
splashed on your skin.
Keep fire source away when servicing air-

conditioning system.
In maintenance of air-conditioning system,
observe the instruction on the refrigerant
cylinder and use it correctly. The type of
refrigerant is R134a. Use of other refriger-
ants may damage the air-conditioning sys-
tem.
Obey local material disposal regulations.
Never discharge refrigerant directly into the Fig. 2-102
air.

2.5.17 High voltage precautions
When the engine is running or has just been

shut down, high voltage can occur in fuel in-
jector terminal and engine controller. Since
there is danger of electrocution, never touch
fuel injector or interior of engine controller.
Please contact Sany distributor if you have to

access fuel injector terminal or interior of en-
gine controller. Fig. 2-103
2.5.18 Accumulator
Accumulator contains highly pressurized ni-

trogen. Improper operation of accumulator
can cause explosion and serious accidents.
Therefore, the following precautions must be
observed:
Never disassemble the accumulator.

Never let the accumulator be near a fire
source or exposed in ame.
Fig. 2-104
Never punch, weld or flame-cut on accu-
mulator.
Never strike or roll the accumulator, or let it
bear any impact.
The gas must be released when disposing
of the accumulator. Contact Sany distribu-
tor for this disposal.

2.5.19 Avoiding fire and explosion
DANGER
Never smoke when handling the fuel or

maintaining the fuel system. The gases in
empty fuel tank can cause explosion eas-
ily. Never carry out flame-cutting or weld-
ing operation on fuel pipe, fuel tank or fuel
vessels, which can lead to fire, explosion,
injury or death.
Then engine must be shut down and elec-

trical equipment must be switched off when
refueling the tank. Be extremely care-
ful when adding fuel to a hot engine. No
sparks shall occur around the grounding
nozzle.
Handle all solvents and dry chemicals in a
place with good ventilation according to the
steps indicated on vessel.
Clean the machine of all dust and residu- Fig. 2-105
als. Never place greasy rag or other am-
mable materials on machine.
When cleaning the parts and components,
use nonammable solvents instead of gas-
oline, diesel oil or other ammable uids.
Store flammable liquids and materials in
suitable vessels as required by safety laws
and regulations.
Check fire extinguishers, fire-fighting sys-
tem and fire detectors (if equipment) and
make sure they are ready for use.

2.5.20 Regular replacement of safety-

related parts
WARNING
Safety-related parts are important for safe-

ty of you and your machine. Failure to re-
place them at specified intervals may lead
to personal injury, death or serious dam-
age.
Safety-related parts such as hoses and

seat belt must be replaced regularly for
the consideration of operating the machine
safely in a long term.
Materials of some parts may deteriorate
naturally when exceeding specific time
limit. Repeated use may lead to deteriora-
tion, wear and damage, hence the acci-
dents and serious injury. Through merely
visual inspection or feel it is hard to find out
how long the parts could serve. Therefore,
regular replacement is necessary.
Repair or replace any safety parts once
found defective regardless of its service
time.

2.5.21 Maintenance operation
Check all parts and replace the worn, bro-

ken and damaged parts during repairing
operation. Over-worn and over-damaged
parts may fail in operation and cause injury
and death. Replace damaged or illegible
signs and marks.
Tighten all fasteners and connectors to
specified torque.
Install all guards, covers and hoods after
repair and service. Replace or repair dam-
aged guards. Only the type of hydraulic oil
approved or recommended by Sany should
be used to make up the hydraulic system.
Start the engine and check for any leaks
(check the hydraulic system), and operate
all control devices to be sure of their prop-
er functioning. Make road test if necessary.
Shut down the engine and check the work
you have done (see if there are missing
pins, gaskets and nuts). Check again all
hydraulic oil levels before operation.

2.5.22 Proper disposal of wastes
Improper disposal of wastes harms the envi-

ronment and ecology. Consult local environ-
mental protection department or Sany dis-
tributors for methods of recycling and waste
disposal.
Potential harmful substances used in Sany

products include hydraulic oil, fuel, cooling
liquid, refrigerant, filter and batteries etc..
Use leak-proof vessels to hold discharged Fig. 2-106
uids. Never use food or beverage contain-
ers.
Never dump waste fluids directly to the
ground, sewage or water source.
Leaking of refrigerant from air conditioner
can spoil the atmosphere of the globe.
Related laws and regulations must be fol-
lowed to recover or regenerate the refriger-
ant.
Fig. 2-107

E
G
PA
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SY115C9/135C/155H Crawler Hydraulic Excavator System Functions
System Functions
3 System Functions
3.1 Machine Overview ................................................................................................... 3-5
3.2 Machine Controls ..................................................................................................... 3-6
3.3 Monitor ..................................................................................................................... 3-7
3.3.1 Monitor introduction ....................................................................................... 3-7
3.3.2 System information and operation ............................................................... 3-10
3.3.2.1 Main Page ........................................................................................... 3-10
3.3.2.2 System Information ............................................................................. 3-12
3.3.2.3 Time Setup .......................................................................................... 3-13
3.3.2.4 Main Menu .......................................................................................... 3-14
3.3.2.5 Engine & Throttle Signals .................................................................. 3-15
3.3.2.6 Main Pump Signals ............................................................................ 3-15
3.3.2.7 Input Switch Signals ........................................................................... 3-16
3.3.2.8 Output Switch Signals ........................................................................ 3-16
3.3.2.9 Machine Configuration ....................................................................... 3-17
3.3.2.10 Failure codes ................................................................................... 3-17
3.3.2.11 Maintenance Information................................................................... 3-18
3.3.2.12 Engine Speed Calibration ................................................................. 3-23
3.3.2.13 Language Selection .......................................................................... 3-25
3.3.2.14 GPS Monitoring Information.............................................................. 3-26
3.3.2.15 System Setup.................................................................................... 3-27
3.3.2.16 Machine configuration setup ............................................................. 3-28
3.3.2.17 Coolant Temperature ........................................................................ 3-29
3.3.2.18 Service Call ....................................................................................... 3-30
3.4 Switches ................................................................................................................ 3-31
3.4.2.1 Start switch ......................................................................................... 3-32
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator
3.4.2.2 Fuel control dial................................................................................... 3-33

3.4.2.3 Work lamp switch ................................................................................ 3-33
3.4.2.4 Wiper switch........................................................................................ 3-35
3.4.2.5 Washer switch ..................................................................................... 3-36
3.4.2.6 Head lamp switch................................................................................ 3-36
3.4.2.7 Horn switch ......................................................................................... 3-37
3.4.2.8 Cab lamp ............................................................................................ 3-37
3.4.2.9 Cigar lighter......................................................................................... 3-37
3.4.2.10 Preheat switch (only for SY135C8M) ................................................ 3-38
3.4.2.11 Alternator indicator ............................................................................ 3-38
3.5 Control levers and pedals ...................................................................................... 3-39
3.5.1 Hydraulic lockout control .............................................................................. 3-40
3.5.2 Travel controls.............................................................................................. 3-41
3.5.3 Joystick controls........................................................................................... 3-42
3.6 Roof Hatch ............................................................................................................. 3-44
3.6.1 Opening the roof hatch ............................................................................... 3-44
3.6.2 Closing the roof hatch ................................................................................. 3-44
3.7 Windshield ............................................................................................................. 3-45
3.7.1 Opening the window ................................................................................... 3-45
3.7.2 Closing the window ..................................................................................... 3-48
3.7.3 Removing the lower window ...................................................................... 3-50
3.8 Alternate Exit.......................................................................................................... 3-51
3.9 Door Catch............................................................................................................. 3-52
3.10 Cover/cap with a Latch ........................................................................................ 3-52
3.10.1 Opening/closing the cover with lock........................................................... 3-53
3.10.2 Opening/closing the cap with lock.............................................................. 3-54
3.11 Cup Holder ........................................................................................................... 3-55
3.12 Storage Box ......................................................................................................... 3-56
3.13 Literature Bag ...................................................................................................... 3-56
3.14 Ashtray ................................................................................................................. 3-57
3.15 Air Conditioning System....................................................................................... 3-58
3.15.1 Control panel.............................................................................................. 3-58
3.15.2 Operation method ...................................................................................... 3-64
3.15.3 A/C operation precautions.......................................................................... 3-72
3.16 Radio ................................................................................................................... 3-74
3.16.1 Control panel.............................................................................................. 3-74

3.16.2 Radio operation.......................................................................................... 3-76

3.17 Auxiliary Power Supply ........................................................................................ 3-80
3.18 Fuses ................................................................................................................... 3-80
3.19 Fusible Link.......................................................................................................... 3-81
3.20 Controller ............................................................................................................. 3-82
3.21 Toolbox ................................................................................................................ 3-82
3.22 Grease pump frame ............................................................................................. 3-82
3.23 Fire extinguisher .................................................................................................. 3-83


3 SYSTEM FUNCTIONS
3.1 Machine Overview
Fig. 3-1
(1) Bucket (6) Boom cylinder

(2) Bucket cylinder (7) Sprocket
(3) Arm (8) Track frame
(4) Arm cylinder (9) Track shoe
(5) Boom (10) Track idler

3.2 Machine Controls
Fig. 3-2
(1) Air conditioner control panel (11) Indicator lights

(2) Radio control panel (12) Start switch
(3) Hydraulic lockout control (13) Fuel control dial
(4) Left joystick control (14) Work lamp switch
(5) Foot rest (15) Wiper switch
(6) Travel control pedals (16) Washer switch
(7) Travel control levers (17) Head lamp switch
(8) Monitor (18) Cigar lighter
(9) Horn button (19) Cab lamp switch
(10) Right joystick control (20) Preheat switch (only for SY135C8M)

3.3 Monitor
When the start switch is turned to the ON position, the monitor is energized by the battery and
initializes.
An operating monitor looks like below:
Alert indicator
Alert and signal indicators Signal indicator
Page heading
Screen Screen display
Function icons
Function keys
Operation keys
Navigation keys
Fig. 3-3
3.3.1 Monitor introduction
Alert indicator (1)
The indicator is on when machine controller

detects any fault, warning the user that the
machine has a problem.
Signal indicators (2)
These indicators are designed for power indi-

cation, CAN indication and other signal indi-
cation. It is the users choice to use any of
them or not. Fig. 3-4

LCD display
The LCD display allows you to view system

information like operating parameters, time,
and function icons. As shown in Fig. 3-5, the
following information will be displayed on the
monitor.
1. Working mode (S, H, L or B)
2. Coolant temperature (C)
3. Fuel level (%)
4. Fuel control dial position (1-11)

Fig. 3-5
5. Failure code (refreshed every 2s)
6. Engine total operating hours (h/m)
7. Maintenance prompt, if any
8. GPRS signal, indicating whether the com-

munication signal is 1023.
9. System calendar (Y/M/D)
10. System clock (h:m:s)
Operation keys
The operation keys include function keys and

navigation keys.
1. Function keys
F1, F2, F3, F4, F5. See Fig. 3-6. Function

of each key is defined by the icon displayed
above it.
Function of each key is defined by the icon

above it.
The key becomes invalid when no icon is Fig. 3-6
displayed above it.

Common icons and function keys
Function key Icon Function Range
F1 Select a working mode SHLB
F2 Switch to idle/non-idle Idle/non/idle
F3 Switch to high/low speed Lo Hi
F4 Access an option/setup Same as the Enter key
View information
F5
Return to previous page Same as the Esc key
Table 3-1
Default setup after starting the engine
Working mode: S
Full speed/auto idle: auto idle
High/Low travel speed: low
Auto idle switch
The auto idle switch is on as default. If no operation is performed within 5s, the engine will en-
ter auto idle (the controller changes engine speed to idle) in order to reduce fuel consumption
and noise.
If the controller detects any operation or gear position change under idling state, the engine
will restore its original speed automatically.
Auto idle function is disabled under L mode.

2. Navigation keys
Navigation key Function
Enter an option/setup item.
Return to previous page.
Select previous item (select the last item after the first one).
Select next item (select the first item after the last one).
Select the left item (select the right most item after the left most one).
Select the right most item (select the left most item after the right most one).
Table 3-2
3.3.2 System information and operation
3.3.2.1 Main Page
Normally, the monitor displays the working

mode, current date, throttle position, coolant
temperature, fuel level, operating hours, warn-
ing information, maintenance prompt, GPRS
signal, real time, etc. The user can set up the
operating conditions of the machine.
Screen output
1. Working mode (S, H, L or B)

2. Coolant temperature (C)
3. Fuel level (%)
4. Engine total operating hours (h/m)
5. Press [F1] to select a working mode:
S H L B S Fig. 3-7
6. Press [F2] to switch on/off auto idle:

OFF ON OFF
7. Failure code, if any, is refreshed every 2s.
8. Press [F3] to change travel speed:
Hi Lo Hi
9. The icon appears if some maintenance is

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

3.3.2.2 System Information
Pass code is required to access system infor-

mation.
Screen output
1. A 5-digit pass code is required to access

system information, with each indicated by
an asterisk (*) standing for a value from 0
to 9. A numeral appears at the digit where
the cursor is located while the other four
digits are in asterisk.
2. Press [F1 to increase/decrease the digit
value at where the cursor is located.
3. Press [F2] to move the cursor the left/right
digit.
4. System clock setup
5. P r e s s [ F 4 ] t o a c c e s s U n l o c k t h e
System. Fig. 3-8
6. Press [F5] to return to the Main Page.
Keypad input
[ ] [ ]: Increase/decrease the value at the

digit where the cursor is located.
[ ] [ ]: Move the cursor to the left/right
digit.
[F1]: Increase the value at where the cursor is
located.
[F2]: Move the cursor to the left/right digit.
[F3]: Access "System Clock Setup".
[F4]: Acdess "Unlock the System".
[F5]: Return to the "Main Page".
[ESC]: Return to the "Main Page".
[Enter]: Check the validity of pass code. If the
pass code is valid, you are allowed to access
the "Main Menu".

3.3.2.3 Time Setup
Set up the time of system clock.
Screen output
1. Date and time.

2. Enter time setup.
3. Return to "System Information".
Keypad input
[ ] [ ]: Increase/decrease the value by 1.

[ ] [ ]: Move the cursor.
[F1]: Enter time setup
[F5]: Return to the "System Information".
Fig. 3-9

3.3.2.4 Main Menu
A list of system functions that can be selected

to access different options.
Screen output
1. Menu of system functions.

2. A short description of the item selected, in-
cluding: a) operating parameters of engine,
main pump and main valve; b) Information
of major components; c) Failure code and
explanation; d) Maintenance information
of the engine, hydraulic system, etc.; e)
Auto setup of fuel control dial positions (1-
11) and engine speed; f) System language
setup; g) GPS information.
3. Press [F1] to scroll through the Main
Menu.
4. Press [F2] to access item selected. Fig. 3-10
5. Press [F4] to access System Setup.
Keypad input
[ ] [ ]: Scroll through the "Main Menu".

[F2]: Access the item selected.
[F4]: Acdess "System Setup".

3.3.2.5 Engine & Throttle Signals
Displaying operating parameters of engine.
Screen output
1. Real-time display of engine signals col-

lected by the controller.
2. Press [F1] to view "Main Pump Signals" on
a positive ow machine.
3. Press [F5] to return to the "Main Menu".
Keypad input
[F1]: View Main Pump Signals on a posi-

tive ow machine.
[F5]: Return to the "Main Menu".
Fig. 3-11
3.3.2.6 Main Pump Signals
Displaying parameters of the main pump.
Screen output
1. Real-time display of main pump signals

collected by the controller.
2. Press [F1] to view "Input Switch Signals" .
Keypad input
[F1]: View Input Switch Signals.

[ESC]: Return to the "Main Menu".
Fig. 3-12

3.3.2.7 Input Switch Signals
Displaying input switch signals.
Screen output
1. Real-time display of input switch signals.

2. Press [F1] to view "Output Switch Signals".
Keypad input
[F1]: View Output Switch Signals.

Fig. 3-13
3.3.2.8 Output Switch Signals
Displaying output switch signals.
Screen output
1. Real-time display of output switch signals.

2. Press [F1] to view "Engine & Throttle
Signals".
Keypad input
[F1]: View Engine & Throttle Signals.

Fig. 3-14

3.3.2.9 Machine Configuration
Displaying major components of the machine.
Screen output
1. Machine configuration information.

Keypad input

Fig. 3-15
3.3.2.10 Failure codes
Displaying failure codes and explanation.
Screen output
1. All failure codes and corresponding infor-

mation.
2. Press [F1] to browse failure information.
3. Press [F5] to return to the "Main Page".
4. Number of failures.
5. Failure code.
Keypad input
[F1]: Browse failure information.

Fig. 3-16

3.3.2.11 Maintenance Information
Every 50 service hours
Screen output
1. Maintenance interval.
2. Maintenance items.
3. Press [F1] to call System Setup. Enter
the pass code and confirm that mainte-
nance is done.
4. Press [F4] to start/pause rolling mainte-
nance:
Keypad input
[F1]: Maintenance is OK.

Fig. 3-17
[F4]: Start/Pause rolling maintenance informa-
tion.
[Enter]: Maintenance is OK.

Screen output
nance is done.
nance information:
Keypad input

tion.
Fig. 3-18

Screen output
nance is done.
nance:
Keypad input

tion. Fig. 3-19

Screen output
nance is done.
nance:
Keypad input

tion.
Fig. 3-20

Screen output
nance is done.
nance:
Keypad input

tion.
Fig. 3-21

3.3.2.12 Engine Speed Calibration
Auto setup of gear positions and correspond-

ing engine speed.
Screen output
1. Press [F1] to select a working mode:

S H L B S
2. Press [F2] to switch on/off auto decelera-
tion: OFF ON OFF
3. Press [F3] to start/stop auto gear position
setup.
4. Press [F4] to start/stop auto speed setup.
5. Press [F5] to return to the Main Menu.
Keypad input
[F1]: Select a working mode (S, H, L or B). Fig. 3-22
[F2]: Select auto idle/full speed.

[F3]: Start/stop auto gear position setup.
[F4]: Start/stop auto speed setup.
[ ]: Increase the allowable deviation by 1.
[ ]: Decrease the allowable deviation by 1.
[ ]: Increase the allowable deviation by 5.
[ ]: Decrease the allowable deviation by 5.

Remark:
Gear position calibration

1. Gear position calibration can be performed without running the engine.
2. Auto gear position calibration procedure:
1) Press [F1] to select working mode H.

2) Turn the fuel control dial to position 0. (The monitor displays 0 for gear position.)
3) Press the calibration start key [F3] to activate auto calibration mode. The blue icon for gear
position calibration will turn red.
4) Turn the fuel control dial to position 1. After 2 seconds, the monitor shows 1 for current
gear position. The calibration of gear position 1 is done.
5) Turn the fuel control dial to the next position. After 2 seconds the monitor shows the value
for current gear position. The calibration of this gear position is done.
6) After setting up the 11 gear positions, the red gear position calibration icon turns blue,
meaning the calibration is done successfully.
7) Press [F5] or [ESC] to exit gear position calibration.
3. Failure to follow the above steps will fail the calibration.
Speed calibration
1. Auto speed calibration requires running the engine.
2. Auto speed calibration procedure:
1) Press [F1] to select working mode H. Press [F2] to enable full speed.
2) Turn the fuel control dial to position 1.
3) Press the speed calibration start key [F4] to enter auto speed calibration mode. The blue
icon for auto speed calibration will turn red.
4) After setting up the speed for the 11 gear positions, the red speed calibration icon turns
blue, meaning the calibration is done successfully.
5) Auto speed calibration is not applicable to gear position 0.

3.3.2.13 Language Selection
Selecting a system language.
Screen output
1. List of language options.

2. Press [F1] to scroll down the list.
3. Press [F2] to select a language.
Keypad input
[F1]: Scroll down the list of system languages.

[F2]: Select a system language.
Fig. 3-23
[ ] [ ]: Move up or down the list.

3.3.2.14 GPS Monitoring Information
Displaying GPS monitoring information.
Screen output
1. Real-time display of GPS monitoring

information.
Keypad input
Fig. 3-24
Remark:
1. In this section the letter E stands for East Longitude and W for West Longitude.
2. The letter N stands for North Latitude and S for South Latitude.
3. The letter P stands for the height above the seal level and N for the height below the
seal level.
4. The signal-to-noise ratio ranges from 0 to 99, which is indicated by a bar. The value on the
right of the bar is real S/N ratio.
5. If the elevation value is not zero and no value is displayed for the longitude and latitude, GPS
data are being received but the location has not been precisely defined yet.
6. When the communication signal is 1023, GPRS communication is regular. When it is 615, the
GPRS communication is abnormal.
7. When the communication signal changes from 7 to 0, the SIM card or the antenna has a bad
connection.
8. When the communication signal changes from 15 to 0, GPRS service is not available, the SIM
card has insufficient fund, or GPRS network is abnormal.
9. When the communication signal changes from 31 to 0, the monitoring center is closed.

3.3.2.15 System Setup
Access to Machine Setup requires a pass

code.
Screen output
1. A 5-digit pass code is required to access

Machine Setup, with each indicated by
an asterisk (*) standing for a value from 0
to 9. A numeral appears at the digit where
the cursor is located while the other four
digits are in asterisk. Press [F3] to change
all digits into asterisks.
2. Press [F1 to increase/decrease the digit
value at where the cursor is located.
3. Press [F2] to move the cursor the left/right
digit.
Fig. 3-25
4. Press [F3] to check the validity of pass
code. If it is correct, you are able to access
System Setup; if wrong, you will be
prompted by Pass code invalid, try
again!
Keypad input
[F1]: Increase/decrease the value at where the cursor is located.

[F2]: Move the cursor to the left/right digit.
[F3]: Check the validity of pass code. If it is correct, you are able to access the System Set-
up.
[Enter]: Check the validity of pass code. If the pass code is valid, you are allowed to access "Ma-
chine Setup".
Remark:
The pass code is only revealed to related commissioning or service personnel.

3.3.2.16 Machine configuration setup
Setting up serial number of the machine.
Screen output
1. Machine serial number and operating

hours.
2. Select an item to set up.
3. Setup is OK.
4. Return to the Main Menu.
Keypad input
[ ] [ ]: Increase/decrease machine serial

number by 100.
[ ] [ ]: Increase/decrease machine se-
rial number by 1. Depress the key to quickly Fig. 3-26
increase/decrease machine serial number by
10.
[F1]: Select an item to set up.
[F2]: Setup is OK.
[F5]: Return to the "Main Menu" and save the
setup.
[ESC]: Return to the "Main Menu" and save
the setup.

3.3.2.17 Coolant Temperature
Displaying the coolant temperature.
Screen output
1. Coolant temperature.
Keypad input
Remark:
To access the Coolant Temperature page,

you need to enter the pass code on the Sys-
tem Setup page.
Fig. 3-27

3.3.2.18 Service Call
Sending a call to machine service center.
Screen output
1. Call state.
2. Call command.
3. Operator phone number.
Keypad input
[ ] [ ]: Increase/decrease the value. De-

press the key to quickly increase/decrease
machine serial number by 10.
[ ] [ ]: Move the cursor through the digits
of operator phone number.
Fig. 3-28
[Enter]: Call the service center.
Remark:
If the call fails to be connected through, it will

be hold: Calling...... Please wait!
A successful call will have such a feedback

that "The service center has received your
trouble information. We will contact you as
soon as possible!"

3.4 Switches
Fig. 3-29
(1) Start switch (6) Head lamp switch

(2) Fuel control dial (7) Horn switch
(3) Work lamp switch (8) Cab lamp switch
(4) Wiper switch (9) Cigar lighter
(5) Washer switch (10) Preheat switch (only for SY135C8M)

3.4.2.1 Start switch
NOTICE
If the engine does not stop at low idle

speed, the service life of engine will be
reduced. Except for emergency, never
shut off the engine while it is running at
high speed, which may otherwise cause
troubles like fatigue cracking on cylinder
cap and damage to bearing of the turbo-
charger.
Start switch is used to turn on or turn off the

engine.
(A): OFF
It allows you to insert or remove the key. All

switches of the electrical system (except out-
door lights) are off and the engine is shut
down.
(B): ON
The charging and lamp circuits are energized.

Keep the start switch in ON position when
operating the engine.
Fig. 3-30
(C): START
This is engine starting position. When starting,

keep the key staying in the position. Release
the key immediately after the engine is started.
The key will return to ON position (B) automat-
ically.
(D): HEAT
This is engine preheating position. Insert the

key and turn it counterclockwise to HEAT posi- Fig. 3-31
tion. Keep the key in this position to preheat
the engine. Releasing the key, it will return to
OFF position (A) automatically and stops pre-
heating.
3.4.2.2 Fuel control dial
Fuel control dial is used to adjust engine

speed and output power. Turn the dial clock-
wise to increase engine speed; turn it counter-
clockwise to decrease engine speed.
(a) - Low Idle (MIN): Turn it counterclockwise

to MIN position.
(b) - Full Speed (MAX): Turn it clockwise to

MAX position.
Fig. 3-32
3.4.2.3 Work lamp switch
The switch is used to turn on or turn off the

work lamp.
WARNING
An exposed harness or loose plugging of

harness could cause short circuit between
power supply positive wire and work lamp
Fig. 3-33
internal grounding wire during excavator
operation, which may burn the work lamp
or the entire chassis harnesses, or cause
personal injury or death.
1. Work lamp locations
a. One(1) work lamp on the chassis
Fig. 3-34

b. Two(2) work lamps on the boom
2. Work lamp external structure
(1) Work lamp seat

(2) Two-wire socket jacket
(3) Nut
(4) Work lamp screw
3. Work lamp internal wiring

Fig. 3-35
(5) Power supply grounding wire
(6) Internal power supply positive socket
(7) Bulb power supply positive plug
(8) Bulb
Note:
The bulb is connected with power supply posi-

tive harness plug.
Fig. 3-36
4. Replacing the bulb
1) Remove work lamp screw and open the

work lamp.
2) Remove the bulb and pull out the plug

(7) from the socket (6).
3) Install a new bulb and insert the power

supply positive plug into the socket (6).
Fig. 3-37
4) If the harness is exposed after wiring,
use insulation tape to wrap it properly.

3.4.2.4 Wiper switch
NOTICE
When you use the wiper, press the washer

switch to spray some detergent in order
to prevent damaging the wiper due to fric-
tion.
Fig. 3-38
When it is raining or the windshield is dirty,

you can press the wiper switch to activate the
windshield wiper.
Fig. 3-39
Fig. 3-40

3.4.2.5 Washer switch
CAUTION
Before pressing the button, make sure that

the windshield of cab is closed.
Press washer switch to spray cleaning deter-

gent.
With the switch depressed, the washer keeps

spraying detergent.
Releasing the switch, it goes back to its origi-

nal position automatically and stops spraying.
Fig. 3-41
3.4.2.6 Head lamp switch
Head lamp switch is used to switch on or

switch off the lamps on top of the cab.
Fig. 3-42
Fig. 3-43

3.4.2.7 Horn switch
The horn switch is located on top of right joy-

stick. Press the switch to sound the horn.
Depress the switch to keep the horn hooting.
Fig. 3-44
3.4.2.8 Cab lamp
The cab lamp is mounted inside the cab. Tog-

gle the cab lamp switch to turn on/ off the cab
lamp.
(a) - ON
(b) - OFF
Note:
The cab lamp can be switched on even if the Fig. 3-45

start switch is in the OFF position.
3.4.2.9 Cigar lighter
The cigar lighter is used to light a cigarette.
Pushing in the lighter, it returns to its original

position after a few seconds. Pull it out to light
a cigarette.
The socket of cigar lighter can be used as a

power source for devices rated not more than
240 W (24V10A). Fig. 3-46
Note:
The cigar lighter is 24V.

3.4.2.10 Preheat switch (only for SY135C8M)
This is engine preheat switch, which will be

used together with the preheat start switch.
Pressing the preheat switch (6) and turning

the key counterclockwise to HEAT position,
the engine will start to preheating.
Maintaining the key in this position, the en-
gine keeps preheating.
After releasing the key, the key will return
to OFF position (A) automatically and the
engine will stop preheating.
Fig. 3-47
3.4.2.11 Alternator indicator
The alternator indicator is illuminated when the

start switch is energized; the indicator goes off
while the engine is running and the alternator
is working regularly; check the generator for
any fault if the indicator is on all the time.
Fig. 3-48

3.5 Control levers and pedals
Fig. 3-49
(1) Hydraulic lockout control (3) Left joystick control

(2) Travel controls (4) Right joystick control

3.5.1 Hydraulic lockout control
WARNING
Always place the hydraulic lockout

control securely in the LOCK position
before you leave the operator cab. If
the hydraulic lockout control is left un-
locked, unintended touching of it could
cause serious injury or death.
If the hydraulic lockout control is not
in the LOCK position, move of control
lever can cause serious accidents.
Check the hydraulic lockout control as
shown in Fig. 3-50.
Be careful not to touch the joysticks
when you engage or disengage the hy-
draulic lockout control.
Hydraulic lockout control (1) is a device used

to lock out control levers of work equipment,
swing system, travel system and attachment (if
equipped).
LOCK position: Push down the hydraulic

lockout control to engage it. The machine
will not move even if you maneuver the
controls.
FREE position: The machine moves ac-
cording to operation of control levers. Fig. 3-50
This lever is a hydraulic lockout control. When
it is engaged, maneuver of control lever or
pedal would therefore lead to no movement of
the machine.
With all controls in neutral position, if any part

of the machine tends to move or moves when
you disengage the hydraulic lockout control,
it indicates a failure in your machine. In this
case, immediately engage the hydraulic lock-
out control and stop the engine. Contact your
Sany distributor to solve this problem.

3.5.2 Travel controls
WARNING
Do not put your foot on any pedal during operation, except for travel. Unintended ped-
aling could lead to sudden move of your machine and cause severe accidents.
Take extra care when driving or steering the machine with pedals. Do not put your foot
on any pedal when they are not used.
Control levers are used to change travel direc-

tion of your machine. Description in brackets
is given for pedal operation.
a - Forward travel:
Push the control lever.
(Pedal tilts forward. )
b - Backward travel:
Pull the control lever.
(Pedal tilts backward. )
N - (Neutral Position): Machine stops.
Remark:
When track frame faces backward direction,

travel direction is opposite to maneuvering di-
rection of travel control lever. (Machine moves
Fig. 3-51
forward when you pull control levers and back-
ward when you push them. The left and right directions are reversed too.)
Check direction of track frame before you maneuver travel control levers. (If the sprocket is in the
rear, the track frame faces the front.)
With automatic deceleration function, travel control levers can be used to change engine speed
through the following ways.
When travel control levers and joystick controls are in neutral position, engine speed will drop
to medium level even if fuel control dial is set above medium speed. If you maneuver any con-
trol, engine speed will rise to the level set by fuel dial control.
If travel control levers and joystick controls are in neutral position, engine speed will decrease
by 100 rpm. About four seconds later engine will drop to the level (about 1,400 rpm) set for
automatic deceleration.

3.5.3 Joystick controls
WARNING
Never expose any part of your body

outside the window, which may other-
wise put you in danger of being hurt by
the boom if the joystick is moved un-
expectedly. If the window is broken or
missing, replace it immediately.
It is important to know the positions
and functions of each joystick control.
Unexpected movement of machine
could cause personal injury.
As shown in the following illustrations, oper-

ating the joysticks diagonally can realize two
functions in combined operation.
Left joystick control
Left joystick operation

Forward Arm OUT
Backward Arm IN
Left Left swing
Right Right swing Fig. 3-52
Table 3-3
Fig. 3-53

Right joystick control
Right joystick operation

Forward Boom DOWN
Backward Boom UP
Left Bucket DIG
Right Bucket DUMP
Table 3-4
Fig. 3-54
Remark: Fig. 3-55
When travel control levers and joystick con-

trols are in neutral position, engine speed will
drop to medium level even if fuel control dial
is set above medium speed. If you maneuver
any control, engine speed will rise to the level
set by fuel dial control.
If travel control levers and joystick controls are

in neutral position, engine speed will decrease
by 100 rpm. About four seconds later engine
will drop to the level (about 1,400 rpm) set for
automatic deceleration.
Releasing control lever or joystick, it goes

back to neutral position automatically and ma-
chine function stops.

3.6 Roof Hatch
WARNING
Secure the lockout control to the LOCK

position when leaving the operator's seat.
Serious accidents can be caused if any
control lever or pedal is maneuvered by
mistake when the lockout control is in
FREE position.
3.6.1 Opening the roof hatch
1. Place hydraulic lockout control (1) to the

LOCK position.
Fig. 3-56
2. Push upward the locks (B) at both sides of

grip (A). Hold the grip (A) and push upward
the roof hatch.
Fig. 3-57
3.6.2 Closing the roof hatch
Hold grip (A) to pull downward the roof hatch.

The locks (B) will be engaged automatically. If
the locks are not engaged properly, open the
roof hatch and try to close it again.

3.7 Windshield
Front window can be pulled up onto the cab
roof.
WARNING
Always leave the lockout control in the

LOCK position when opening or closing
the windshield, bottom window or cab
door. Serious accidents can be caused if
any control lever or pedal is maneuvered
by mistake when the lockout control is in
FREE position.
Before opening or closing any window,

park your machine on a level ground, lower
the work equipment to ground, and stop
the engine.
When opening the windshield, hold tight
the grip with both hands and pull the win-
dow upward. Never stop before the auto-
matic catch is engaged.
When closing the windshield, the window
moves quickly under its weight. Be sure to
hold the grip tightly with both hands when
closing the window.
3.7.1 Opening the window
1. Park your machine on a level ground,

lower the work equipment to ground, and
stop the engine.
2. Place hydraulic lockout control (1) to the

LOCK position.
Fig. 3-58

3. Check the wiper blade, which shall be

stored in the right bracket.
Fig. 3-59
4. Hold the left and right handholds (A) of

the windshield and pull the two levers
(B) in order to release the locks on top
of the windshield. The windshield will be
unlocked.
Fig. 3-60
Fig. 3-61

5. In the cab, hold the lower handhold (C)

with your left hand and the upper handhold
(D) with your right hand, and push the win-
dow upward. Continue to push the window
toward the latch (E)in the rear of the cab till
it is locked securely.
Fig. 3-62
Fig. 3-63
Fig. 3-64

6. Check the lever (B), which shall be secured

in locked position.
Check the arrow on the catch (F), which

should be aligned with the arrow on lever
(B). The lock is engaged.
If the arrow on the catch (F) is not aligned
with the arrow on lever (B), the lock is not
engaged. Repeat step 5 to engage the
Fig. 3-65
lock.
3.7.2 Closing the window
CAUTION
Close the windshield slowly and never get

your hand pinched by the window.
1. Park your machine on a level ground,

lower the work equipment to ground, and
stop the engine.
2. Secure the hydraulic lockout control (1) to

LOCK position.
Fig. 3-66
3. Hold the left and right handholds (A) and

pull the lever (B) downward to release the
lock.
Fig. 3-67

4. Hold the lower handhold (C) with your left

hand and upper handhold (D) with your
right hand, push the window forward and
lower the window slowly.
Fig. 3-68
Fig. 3-69
5. When the bottom of windshield reaches

the top of bottom window, push forward the
top of windshield in order to engage both
the left and right latches (G) of the locks.

6. Check the lever (B), which should be

secured in locked position.
Check the arrow on the catch (F), which

should be aligned with the arrow on lever
(B). The lock is engaged.
If the arrow on the catch (F) is not aligned
with the arrow on lever (B), the lock is not
engaged. Repeat step 5 to engage the
Fig. 3-70
lock.
3.7.3 Removing the lower window
Open the windshield, hold the grip (1) to pull

upward in order to remove the lower wind-
shield.
Fig. 3-71
It will be difficult to remove the windshield

in case of sand or dust building up at the
bottom of the windshield. Moreover, the
sand or dust may be brought into the cab
along with the glass when storing the win-
dow. To prevent this from happening, the
area (A) is to be cleaned before removing
the window.
Fig. 3-72

3.8 Alternate Exit
If you are unable to open the cab door in case

of emergency, use the hammer to break the
rear window and escape.
Never use the hammer for other purposes.
CAUTION
Broken glass can cut. Be careful not to

be hurt by broken glass when you escape
from a broken window. Fig. 3-73
Fig. 3-74

3.9 Door Catch
CAUTION
Park your machine on a level ground

before unlocking the cab door.
Never unlock the door on a slope. The
door may shut suddenly and cause in-
jury.
Never expose your body or hand out
of the cab or lay your hand on the door
frame before unlocking the door. The
door may shut suddenly and cause in-
jury.
Lock the door to its position after opening it.
1. Push the cab door toward the catch (1) so

as to lock the door by engaging the catch
(1).
2. Before closing the door, press the joystick

(2) to the left of the operator seat to
release the catch (1).
Secure the door firmly on its catch (1) after the Fig. 3-75
door is opened.
3.10 Cover/cap with a Latch

Use the start switch key to open/close the cap
or cover.
Insert the key to its shoulder (A).
The key could be broken if turned before it is

fully inserted.
Fig. 3-76

3.10.1 Opening/closing the cover with lock
NOTICE
Make sure to turn the cover (1) to shield

the key hole after removing the key.
Otherwise, invasion of foreign bodies
could make the switch sluggish or fail-
ing.
A longer travel distance is required to
tighten the cover with lock. Make sure
the cover is turned in position before
you turn the key to lock the cover. If
the key is turned when the cover is not
in position, the lock plate will press
against inner wall of filler opening and
cause damage to lock cylinder.
Be sure to have a clean O-ring seal in
lock cover. If the seal is contaminated
by iron scraps, stone pieces or other
foreign bodies, it would be damaged
during tightening and improper sealing
of lock cover could result.
Opening the cover
1. Turn to open the key hole cover(1).
2. Insert the key into the key hole.
3. Turn clockwise the key to align the key

notch to the mark (A) on the cover. Open
the cover(2).
Position (A): unlocked
Position (B): Locked Fig. 3-77

Closing the cover
1. Screw on the cover(2) and insert the key

into the key hole.
2. Turn the start switch key to locked posi-

tion (B), and remove the key.
3. Turn the cover (1) to shield key hole.
Fig. 3-78
3.10.2 Opening/closing the cap with

lock
Opening the cap
1. Insert the key.
2. Turn the key counterclockwise and open

the cap with its lever.
Position (A): unlocked

Fig. 3-79
Position (B): locked
Closing the cap
1. Close the cap properly and insert the key.
2. Turn the key clockwise and remove the

key.

3.11 Cup Holder
A cup holder has been designed and installed

to the left side of operator in order to hold bev-
erage.
Fig. 3-80
As shown in the illustration, the cup holder

can be folded to prevent damage when it is
not used.
Fig. 3-81

3.12 Storage Box

Located to the rear right of operator seat,
the storage box is used to keep your drinks
warm in winter and cool in summer.
Cool or warm air is sent into the storage
box according to the setting of air-condi-
tioner.
Fig. 3-82
Fig. 3-83
3.13 Literature Bag

The bag is located on the back of the op-
erator seat.
The "safety, operation and maintenance
manuals" can be stored in this bag for you
to refer to at any time.
Fig. 3-84

3.14 Ashtray
The ashtray is above the cigar lighter.
Make sure that the cigarette is extin-
guished before closing the ash tray.
Fig. 3-85
Fig. 3-86

3.15 Air Conditioning System
3.15.1 Control panel
Fig. 3-87
Remark: (1) Power-off switch

(2) Fan switch
After the automatic control switch (5), fresh (3) Temperature switch
air/recirculation switch (6) and air conditioner
(4) Air outlet selector switch
switch (8) are switched on, the indicator above
the corresponding switch will be illuminated. (5) Automatic control switch
(6) Fresh air/Recirculation switch
(7) LCD panel
(8) Air conditioner switch
(9) Sunlight sensor
(1) Power-off switch
This switch (1) is used to stop the fan and air-

conditioner.
When the power-off switch (1) is pressed,

the temperature and air ow displayed on the
LCD panel disappear, the indicators above the
automatic control switch and air conditioner
switch go out, and the operation stops. Fig. 3-88

(2) Fan control switch
The switch (2) is used to regulate the volume

of air ow, which can be set to any of six lev-
els.
The amount of air flow is displayed on the

LCD panel.
Press to increase the air ow.

Press to decrease the air ow.
The air flow changes automatically in the Fig. 3-89
automatic control mode.
LCD panel and air flow
a: Low
b: Moderate -1
c: Moderate - 2
d: Moderate - 3
e: Moderate - 4
f: High
Table 3-5
(3) Temperature switch
This switch (3) is used to control the tempera-

ture inside the operator cab.
The temperature can be set between 18

(64.4 ) and 32 (89.6 ).
Press to increase the preset tempera-

ture.
Press to decrease the preset tempera-
ture.
The temperature is generally set at 25 Fig. 3-90
(77 ).
The temperature can be set with an incre-
ment of 0.5 (0.9 ).

LCD display and function
LCD display ( ) Set Temperature

18.0 Maximum cooling
18.5 ~ 31.5 Adjust temperature inside operator cab to selected temperature
32.0 Maximum heating
Table 3-6
(4) Air outlet selector switch
This switch (4) is used to select the position of

each air outlet.
When the switch (4) is pressed, the LCD

panel will display the mode selected. The
air will come out of the outlet displayed.
The outlet is switched automatically in au- Fig. 3-91
tomatic control mode.
(A): Air outlet for back (4)
Fig. 3-92
(B): Air outlet for face (1)
(C): Air outlet for defrosting (1)
Fig. 3-93

(D): air outlet for feet (1)
Fig. 3-94
Air Outlet
LCD Display Air Outlet Mode Remark
A B C D
Front outlet for face Auto operation disabled

Front and back outlets for

face
Front and back outlets for

face and feet
Air outlet for feet
Air outlet for feet and de-
Auto operation disabled
froster
Air outlet for defroster Auto operation disabled
Table 3-7
Remark:
Air comes out of the outlet identified with .

(5) Automatic control switch
This switch (5) can be used to set air ow, out-

lets and fresh air or circulation automatically
according to the preset temperature.
Pressing the automatic control switch (5),

the indicator above the switch comes on.
Fig. 3-95
Generally, pressing this switch and setting
with the Temperature Switch (3) to a suit-
able temperature, the air conditioner will
run automatically.
Changing from automatic control to manual
control requires only resetting the air ow,
outlets and fresh air/recirculation mode.
The indicator above the switch goes out.
Remark:
When automatic control is selected, the air

ow may remain at HIGH if the temperature is
set at 18 (64.4 ) or 32 (89.6 ). But
this is not a fault.
(6) Fresh air/recirculation switch
This switch (6) is used to open or close the

fresh air inlet.
After the switch is pressed, the indicator

above the switch is illuminated to indicate
a state of taking in fresh air.
Fresh air and recirculation modes toggle
automatically in automatic control. Fig. 3-96
The air inlet is closed. The air will recirculate in the operator cab.
Recirculate It is suitable for rapid cooling or heating of the operator cab. It is also used
when the external air is contaminated.
Fresh air is taken into the operator cab.
Fresh Air Intake
It is used to take in fresh air and defog.

(7) LCD display
LCD display (7) shows the preset temperature

(a), air flow (b) and outlet position (c) during
operation.
By pressing the OFF switch (1), the display

of preset temperature (a), air ow (b) and
outlet position (c) disappears, and the op-
eration stops.
(8) Air conditioner switch

Fig. 3-97
The air conditioner switch (8) is used to switch
on/off the air conditioner or its operation (cool-
ing, dehumidifying and heating).
When the fan is working (the LCD

displays(b)), press the air conditioner
switch (8) to activate the air conditioner.
The indicator above the switch will be illu-
minated. Press this switch again to deacti- Fig. 3-98
vate the air conditioner. The indicator goes
out.
The air conditioner is disabled when the
fan is switched off (outlet position disap-
pears from the LCD display).
(9) Sunlight sensor
The sunlight sensor will adjust the air ow of

air outlet to match the strength of sunlight. In
addition, it can detect automatically the varia-
tion of the temperature in the operator cab due
to the strength of sunlight. And it can control
temperature automatically.
Fig. 3-99

3.15.2 Operation method
You can control the air conditioner automati-

cally or manually. Select a control manner you
want.
Automatic operation
1. Turn on the automatic control switch (5).
The LCD panel will display the temperature

(a) and air flow (b). The indicators above
the automatic switch (5) and air conditioner
switch (8) will be illuminated.
Fig. 3-100
Fig. 3-101
2. Use the temperature switch (3) to set a

comfortable climate. By setting the tempera-
ture, the air conditioner will change auto-
matically its air ow, air outlet position and
fresh air/recirculation air in order to achieve
the preset temperature.
Fig. 3-102

Remark:
When air outlet (c) is in (d) or (e) mode and

the temperature of engine coolant is low, the
air ow will be restricted to prevent blowing the
cooling air.
Fig. 3-103
Stopping AUTO operation
Press the OFF switch (1) in order to stop auto-

matic operation.
Fig. 3-104
Manual operation
1. Press fan switch (2) to regulate air flow.

Check the temperature (a) and the air ow
(b) displayed on the LCD display (7).
Fig. 3-105
Fig. 3-106

2. Turn on the air conditioner switch (8).
Fig. 3-107
3. Press the temperature switch (3) to set the

internal temperature of the operator cab.
Fig. 3-108
4. Press the air outlet selector switch (4) to

set it to the desired mode. The display at (c)
on the LCD panel (7) will change accord-
ingly.
Fig. 3-109
Fig. 3-110

5. Press the fresh air/recirculation switch (6)

to select the recirculation or fresh air intake
mode of the operator cab.
Fig. 3-111
Stopping manual operation
Press the switch OFF (1) to stop the manual

operation.
Fig. 3-112
Cooling air for face and warm air for feet
In order to direct cooling air to your face and

warm air to your feet, observe the following
procedures:
1. Press the fan switch (2) to adjust the air

flow. Check the LCD screen (7) for the
temperature (a) and air ow (b).
Fig. 3-113
Fig. 3-114

2. Press the air outlet selector switch (4) in

order to display on the LCD panel the im-
age as shown in the right illustration.
Fig. 3-115
3. Turn on the air conditioner switch (8).
Fig. 3-116
4. Press the fan switch (2), temperature

switch (3) and fresh air/recirculation switch
(6) as desired.
Fig. 3-117

Defroster operation
1. Press the fan switch (2) to regulate the air

flow. Meanwhile, check the temperature
(a) and air flow (b) displayed on the LCD
panel (7).
Fig. 3-118
Fig. 3-119
2. Press the air outlet selector switch (4) and

set the air outlet mode on the LCD panel
as shown the right illustration (f) or (g).
Fig. 3-120
Fig. 3-121

3. Press the fresh air/recirculation switch (6)

to open the air inlet.
Fig. 3-122
4. Press the temperature switch (3) and set

the temperature on the LCD panel (7) to
the maximum (32 ).
Fig. 3-123
5. Adjustment:
Rear air outlet (A)
Fig. 3-124

Air outlet for face (B)

Defrosting outlet (C)
Fig. 3-127
The air outlet (D) toward feet is fixed and

nonadjustable.
Fig. 3-125
Turn on the air conditioner switch (8) when

operating in rainy season, defogging the
windows or carrying out dehumidifying op-
eration.
Fig. 3-126

3.15.3 A/C operation precautions
Remark:
When running the air conditioning system,

always start with the engine running at a
low speed. Avoid starting the air condi-
tioner when the engine is running at a high
speed, or possible damage to the air con-
ditioner may result .
If water should get on control panel or sun-
light sensor, an unexpected failure may
result. Always keep these components
clear and free from water. In addition, keep
these components away from naked ame.
For the auto function of the air conditioner
to work properly, always keep the sunlight
sensor clean and free from debris, or it will
inuence the function of sunlight sensor.
Ventilation
When the air conditioner has been operat-

ing for hours, the fresh air/recirculation
mode shall be switched to fresh air mode
every hour for ventilation.
If you smoke when air conditioner is run-
ning, the smoke may hurt your eyes. In
this case, the fresh air/recirculation mode
shall be switched to fresh air mode in
order to eliminate the smoke through con-
tinuous cooling.
Temperature control
When the compressor is working, set the

temperature (5 or 6 (9 or 10.8 ) above
outdoor temperature) that just makes you feel
cool after entering the cab. This temperature
difference is considered as the most healthy
temperature. Therefore, the temperature shall
be adjusted properly.
Inspection and maintenance of air condi-

tioned machine
When checking and maintaining the air

conditioned machine, it is important to

follow the graph for inspection and main-
tenance. For more information see Air
Conditioner - Inspect/Service (Maintenance
Section), Compressor Belt Tension - In-
spect/Adjust (Maintenance Section) and
Air Filter Element - Inspect/Clean/Replace
(Maintenance Section).
When the air conditioner has not been
used for a long time, it is necessary to of-
ten run the engine at low speed and con-
duct cooling, dehumidifying and heating
operations for several minutes in order to
prevent loss of oil film on each component.
The air conditioner will not work if the in-
ternal temperature of cab is low. You can
circulate fresh air into the cab so as to in-
crease the temperature. Switch on the air
conditioner again to make it work.
In case that any device or sensor of the air
conditioner is found abnormal, A/C con-
troller failure will be displayed on the air
conditioner control penal. Please contact
Sany distributor to investigate and repair it.

3.16 Radio
3.16.1 Control panel
Fig. 3-128
(1) Power switch (6) Preset stations (1, 2, 3, 4, 5, 6)

(2) Sound effect switch (7) LCD
(3) Time display (8) Tuning buttons
(4) FM/AM selector (9) Time adjusting buttons
(5) AS/PS button (10) Volume control
Power switch
Press the power switch (1) in order to turn on the radio. The frequency is shown on the LCD dis-
play (7). Press the power switch again in order to turn off the radio.
Sound effects conversion
Pressing the switch (2) each time, the sound effects will be displayed in turn: VOL BAS
TRE Balance.
The host machine will return to frequency display in terms of no operation within 5 seconds.
The state of sound effects will be displayed on the LCD display (7).
Time display
Pressing the switch (3) will display frequency in priority.

When the frequency is displayed, pressing the switch (3) will display the present time for 5
seconds. The display will resume displaying frequency after 5 seconds.

Depress the button (4) for more than 5 seconds in order to display the region: ASIA: EU.
FM/AM band selector
Press the switch (4) to select the desired band. Pressing the button each time toggles the band
between FM and AM.
AS/PS button
The button (5) is used to auto scan and preset stations.
Auto Scan:
When tuning in the radio, pressing the button AS/PS (5) allows you to scan each preset sta-
tion, which will be played for 10 seconds, while the number of the preset station scanned is
blinking on the display. If you want to tun in some station, press the button (5) again.
Preset Stations:
When tuning in the radio, depressing the button AS/PS (5) for more than 2 seconds will acti-
vate the auto scanning of current stations. Six radio stations that have the strongest signal will
be stored in turn to the 6 buttons (1-6). Now you can play any of the preset stations.
Tuning in preset stations (1, 2, 3, 4, 5 and 6)
If the buttons (6) have been preset with some stations, you can press any of the buttons to play
the preset station.
LCD display
The band, radio frequency, preset number and time will be displayed on the display (7).
Tuning button
Press the button (8) to change frequency.
Time set button
Press the button (9) to reset the time.
H: Hour
M: Minute
ADJ: Set to 00 minute
Volume control
Press the button + (10) in order to increase the sound volume. The maximum volume is 40.
Press the button - in order to decrease the sound volume. The minimum volume is 0.
In case of no operation within 5 seconds, the display returns to show the frequency.

3.16.2 Radio operation
Presetting radio station
1. Press the power switch (1) in order to show

the frequency on display (7).
2. Press one of the tuning buttons (8) to locate

the desired frequency. There are two tuning
ways: manual and automatic.
3. When desired frequency is shown on the

display (7), depress one of the preset but-
tons for at least 1.5 seconds. The voice will
disappear. But the voice will come back Fig. 3-129
when the presetting operation (storing to the
memory) is completed. The preset button
number and the frequency will be displayed,
indicating the completion of presetting op-
eration. After presetting the stations, press
one of the preset buttons (6) for at least 1.5
seconds in order to tune in the preset sta-
tion.
Remark:
The AS/PS button can be used to preset the stations automatically.
Searching radio station
1. Press the power switch (1) in order to show the frequency on display (7).
2. Press one of the tuning buttons (8) to locate the desired frequency. There are two tuning
ways: manual and automatic.
Manual tuning
Press one of the tuning buttons (8) till the frequency appears on the display (7).
key: Decrease the frequency.
key: Increase the frequency.
When the frequency reaches its maximum or minimum limit, it will cycle in the order of max-min
or min -max.
Automatic tuning
Depress one of the tuning buttons (8) will activate automatic scanning of radio stations. When
any station is found, the tuning stops. To scan next station, depress one of the tuning buttons (8)
again.

key: Decrease the frequency.
key: Increase the frequency.
If this button is pressed during automatic tun-

ing, automatic tuning will be cancelled. The
setting returns to the previous frequency be-
fore the button is pressed.
Sound effect conversion methods:
VOL - Volume: Press + in order to in-

crease the volume, which can be increased
to 40. Press - in order to decrease the
volume, which can be decreased to 0.
BAS - Bass: Press the SEL key (2) in or-
der to access sound effect and select BAS.
Press VOL key (10) within 5 seconds in
order to change the bass level between +7
and -7.
TRE - Treble: Press the SEL key (2) in or-
der to access sound effect and select TRE.
Press VOL key (10) within 5 seconds in or-
der to change the treble level between +7
and -7.
BAL - Balance: Press the SEL key (2) in
order to access sound effect and select
BAL. Press VOL key (10) within 5 seconds
in order to change the balance of the left
and right audio channels between L9 and
R9. BAL.0 means that both audio channels
are kept balanced.
Remark:
For any mode, the display will return to show

previous setting if no operation is done within
5 seconds.

Setting the time correctly
3. Press the button (3) to display the time.

The display will return to show radio
frequency after 5 seconds and the time
cannot be reset. In this case, press the
time display button (3) again.
4. Press one of the time adjustment keys (9)

in order to select hours or minutes.
H key: Hour adjustment
(Pressing this key once will increase 1 hour.) Fig. 3-130
M key: Minute adjustment
(Pressing this key once will increase 1 min-

ute.)
by pressing the H key or the M key, the hours

or minutes will keep going till the key is re-
leased.
ADJ key: When pressing the ADJ key, the

time will be preset as following:
When it displays 00-05 minutes,the time

will return to 00 minute and 00 second.
(The hours remain unchanged.)
When it displays 55 - 59 minutes, the time
will advance to 00 minute and 00 second.
(The hours will be more.)
When it displays 06 - 54 minutes, the
time can not be preset. (Time remains the
same).
For Example:
10:05 10:00
10:59 11:00
10:26 10:26
Use the H, M and ADJ keys to set the time

correctly.

Antenna
Before moving your machine into any build-

ing, it is necessary to put away the antenna
in order to prevent intervention. Put away the
antenna by the following steps:
1. Loosen the antenna's mounting bolt (1) in

order to place the antenna in position (A).
2. Tighten the bolt (1) after storing the an-

tenna.
Radio operation precautions Fig. 3-131
To be safe, the volume should be kept at a

level that you could hear the outside sound
during operation.
The penetration of water into the loud-
speaker or radio may lead to unexpected
trouble. In this case, be careful of not get-
ting the device wet.
Never use benzol, diluent or other solvent
to clean the control panel or buttons. Soft
dry cloth shall be used for cleaning. If the
device is too dirty, wipe it with alcohol.
When disconnecting or replacing the bat-
tery, the preset stations and the clock will
be cleared. Therefore, the settings should
be readjusted.

3.17 Auxiliary Power Supply

24V Power
Remove the cigar lighter. Its socket can be

used as auxiliary power supply.
Max applicable power supply is 240W

(24V10A).
Remark:
Fig. 3-132
Never use this power supply for 12V devices.
3.18 Fuses
Remark:
Before replacing a fuse, make sure that the

start switch is in OFF position.
The fuse panel is located at the right rear

of operator's seat .
Fuses can protect electrical devices and
wires from burning.
The fuse should be replaced if it is eroded,
produces white powder or becomes loose
in the fuse panel.
Replace the fuse with one of the same ca-
pacity. Fig. 3-133

Fuse capacity and corresponding circuit
No. Capacity Circuit

F1 20A Start circuit
F2 10A Charging indicator
F3 5A Horn circuit
F4 15A Work lamp
F5 5A Wiper & washer
F6 10A Radio
F7 10A Cab lamp
F8 20A Air conditioner
F9 5A Access lamp
F10 5A Monitor
F11 15A Controller
F13 15A Head lamp
F14 10A GPS
F15 15A Cigar lighter
Table 3-8 Fig. 3-134
3.19 Fusible Link

The fusible link (1) could possibly fail if the
starter motor does not work with the start
switch in ON position. Open the fuse compart-
ment cover to access the fusible link on the
back side of the seat in order to check and re-
place it.
Remark:
The fusible link is the large-size fuse applied

to high current circuit in order to protect elec- Fig. 3-135
trical component and wire from burning, in the
way operating as a common fuse.

3.20 Controller
Be careful not to get the controller contami-
nated by water, mud or juice, which can cause
failure.
Never disassemble the controller in case of

any failure. Please contact Sany distributor for
repair.
Fig. 3-136
3.21 Toolbox
Store your tools in this box.
Fig. 3-137
3.22 Grease pump frame

The grease pump frame is inside the access
door at the left rear part of the machine. When
the grease pump is not in service, place it on
the frame.
Fig. 3-138

3.23 Fire extinguisher

Fire extinguisher is equipped in the rear of op-
erator cab.
The following precautions must be observed in

order to deal with unexpected fire.
Read instruction label on fire extinguisher

and know how to use fire extinguisher in
event of fire.
Check fire extinguisher regularly in order
to make sure it is in the guarantee period.
If your extinguisher has expired, replace it
immediately.
Fig. 3-139

E
G
PA
K
AN
BL

SY115C9/135C/155H Crawler Hydraulic Excavator Operation
Operation
4 Operation
4.1 Before Starting the Engine....................................................................................... 4-5
4.1.1 Routine checks ............................................................................................. 4-5
4.1.2 Checks before starting ................................................................................... 4-7
4.1.2.1 Fuel tank - check/drain.......................................................................... 4-7
4.1.2.2 Water separator - check/drain .............................................................. 4-7
4.1.2.3 Drain valve - regulate ............................................................................ 4-8
4.1.2.4 Hydraulic oil - check/refill ...................................................................... 4-9
4.1.2.5 Coolant - check/refill ........................................................................... 4-10
4.1.2.6 Oil in engine oil pan - check/refill .........................................................4-11
4.1.2.7 Electric wires - check .......................................................................... 4-12
4.1.2.8 Fuel tank - check/refuel....................................................................... 4-13
4.1.2.9 Work lamp switch - check ................................................................... 4-14
4.1.2.10 Horn - check...................................................................................... 4-15
4.1.3 Adjustment before operation ........................................................................ 4-15
4.1.3.1 Operator seat ...................................................................................... 4-15
4.1.3.2 Rear view mirrors ................................................................................ 4-17
4.1.3.3 Seat belt .............................................................................................. 4-19
4.1.4 Before Starting the Engine ........................................................................... 4-20
4.2 Engine Starting ...................................................................................................... 4-22
4.2.1 Engine Preheating ...................................................................................... 4-25
4.2.2 Warm-up operation ...................................................................................... 4-26
4.2.3 Selecting a working mode ........................................................................... 4-26
4.3 Engine Shutdown................................................................................................... 4-27
4.4 Machine Operation ................................................................................................ 4-28
4.4.1 Before moving the machine ......................................................................... 4-28
Operation SY115C9/135C/155H Crawler Hydraulic Excavator
4.4.2 Moving the machine forward ........................................................................ 4-29

4.4.3 Moving the machine backward .................................................................... 4-30
4.5 Steering Operation................................................................................................. 4-32
4.5.4.1 Steering with travel controls ............................................................... 4-32
4.5.4.2 Steering with machine stopped ........................................................... 4-32
4.5.4.3 Steering during traveling ..................................................................... 4-33
4.5.4.4 Pivot turn ............................................................................................. 4-33
4.5.1 Swing operation ........................................................................................... 4-34
4.6 Work Equipment Control and Operation ................................................................ 4-35
4.7 Working mode........................................................................................................ 4-37
4.8.1 Operation with swinging force ...................................................................... 4-38
4.8.2 Operation with traveling force ...................................................................... 4-38
4.8.3 Operation when hydraulic cylinder reaches its stroke end ......................... 4-39
4.8.4 Operation with bucket landing force............................................................. 4-39
4.8.5 Operation with machine weight .................................................................... 4-40
4.8.6 Hard rocky ground ...................................................................................... 4-40
4.8.7 Sudden shift of travel speed during fast traveling ....................................... 4-41
4.9 General Operation ................................................................................................ 4-41
4.9.1 Traveling operation ...................................................................................... 4-41
4.9.2 High-speed travel ......................................................................................... 4-41
4.9.3 Permissible depth of water........................................................................... 4-42
4.10 Traveling on Slope ............................................................................................... 4-42
4.10.1 Traveling downhill ..................................................................................... 4-44
4.10.2 Engine stalls on an incline ......................................................................... 4-44
4.10.3 Cab door on an incline ............................................................................... 4-44
4.11 Removing Machine from Mud .............................................................................. 4-44
4.11.1 One track trapped ...................................................................................... 4-44
4.11.2 Both tracks trapped .................................................................................... 4-45
4.12 Recommended Applications ................................................................................ 4-45
4.12.1 Backhoe operation ..................................................................................... 4-45
4.12.2 Trench work ............................................................................................... 4-46
4.12.3 Loading operation ...................................................................................... 4-46
4.13 Parking Operation ................................................................................................ 4-47
4.14 Checks after Each Workday ................................................................................ 4-49

4.15 Locking the Machine ............................................................................................ 4-50

4.16 Operation in Cold Weather .................................................................................. 4-50
4.16.1 Operation instruction .................................................................................. 4-50
4.16.1.1 Fuel and lubricant ............................................................................. 4-50
4.16.1.2 Battery............................................................................................... 4-51
4.16.2 After each workday .................................................................................... 4-52
4.16.3 After cold season ....................................................................................... 4-53
4.17 Long-Term Storage .............................................................................................. 4-54
4.17.1 Before storage ........................................................................................... 4-54
4.17.2 During storage ........................................................................................... 4-55
4.17.3 After storage............................................................................................... 4-56
4.17.4 Starting the engine after long-term storage ............................................... 4-56
4.18 Transportation Information ................................................................................... 4-57
4.18.1 Transport methods ..................................................................................... 4-57
4.18.2 Loading/unloading machine to/from a trailer .............................................. 4-57
4.18.2.1 Loading the machine......................................................................... 4-59
4.18.2.2 Securing the machine ....................................................................... 4-61
4.18.2.3 Rear view mirrors .............................................................................. 4-62
4.18.2.4 Unloading the machine ..................................................................... 4-63
4.18.3 Lifting the machine or its components ....................................................... 4-65
4.18.3.1 Lifting precautions ............................................................................. 4-65
4.18.3.2 Choosing a wire rope ........................................................................ 4-66
4.18.3.3 Lifting the machine ............................................................................ 4-67


4 OPERATION
4.1 Before Starting the Engine
4.1.1 Routine checks
Before starting the engine, it is necessary to

inspect your machine carefully and completely.
Check for any loose bolts or nuts. Check for
any leaks of oil, fuel or coolant. Check the con-
ditions of the work equipment and hydraulic
system. It is also necessary to check for loose
wires, any spaces or dust buildup at where it
is close to high temperature.
Remove flammable materials from the sur-

rounding of battery, engine, muffler, turbo-
charger, or other hot components. The leak of
oil or fuel may cause the machine to catch on
fire. Careful inspection is necessary. Contact
your Sany distributor if any fault of your ma-
chine must be corrected.
Check and clean the following items each day

before starting the engine:
1. Check the work equipment, cylinders, arms

and hoses for cracks, excessive wear or
loosening. Repair it in case of any problem.
2. Remove the dirt and debris around the

engine, battery and radiator.
Check the surrounding of engine and ra-

diator for buildup of dirt. Check the sur-
rounding of mufer, turbo charger or other
hot components for flammable materials
like dry leaves and thin branches. Remove
them if any dirt or ammable materials are
found.
For method of removing dirt from radiator,

see Coolant tank and radiator fins -
inspect/clean on page 5-76 .

3. Check for any leaks of coolant or oil

around the engine.
Check the engine for leak of oil. Check the

cooling system for leak of coolant. Repair it
in case of any problem.
4. Check the hydraulic unit, hydraulic tank,

hoses and joints for any leaks of oil.
Check for oil leaks. Repair the leaks if any.
5. Check the undercarriage (track, sprockets,

tension rollers and guards) for damage,
wear, loose bolts or roller leakage.
Correct the problem if any.
6. Check the handholds and step for any

problem like loose bolts.
Repair it in case of any problem. Tighten

the loose bolts.
7. Check the gauges and monitor.
Check the gauges and monitor in the cab.

Change the parts or components in case
of any problem. Clean their surfaces.
8. Clean and check rear mirrors
Clean and check the rear mirrors for any

damage. Repair it in case of any damage.
Clean the mirrors and adjust their positions
so that the area behind the machine could
be seen clearly from operators seat.
9. Check the safety belt and holds for dam-

age or wear. Replace it with a new one in
case of any damage.
10. Check the bucket with hook (if equipped)

for any damage.
Check the hoisting hook, guide plate and

hook seat for any damage. Contact Sany
distributor for repair in case of any prob-
lem.

4.1.2 Checks before starting
The items in this section must be checked ev-

ery day before starting the engine.
4.1.2.1 Fuel tank - check/drain
1. Remove lower cover plate of fuel tank.
2. Place a vessel under drain valve (1) to

contain drained fuel.
3. Turn drain valve (2) to OPEN position (O)

to drain sediment, water and fuel from
tank.
4. When clean fuel is seen, turn the drain

valve (2) to CLOSE position (S).
Fig. 4-1
5. Reinstall the lower cover plate.
4.1.2.2 Water separator - check/drain
1. Open the pump compartment door on the

right side of the machine.
Water separator is integrated with fuel pre-

filter (1).
SY115C9SY135C8/C9SY155H
2. Through transparent cover (2) you can
Fig. 4-2
observe water level and volume of sedi-
ment. In case of water or sediment built up
at bottom, place a vessel under drain hose
(4) to receive drainage.
3. Open drain valve (3) to discharge water.
4. Immediately close drain valve (3) when

fuel is seen coming out of drain hose (4).
Remark: SY135C8(M)
Clean transparent cover (2) when replac- Fig. 4-3

ing the additional fuel filter (1) if the trans-

parent cover (2) is dirty or it is hard to see
the interior through it.
When drain valve (3) has been removed
during cleaning, its O-ring must be greased
and the valve must be tightened till it con-
tacts the bottom.
4.1.2.3 Drain valve - regulate
If the drain valve (3) does not work smoothly,

the part with O-ring shall be greased to make
it move smoothly.
1. Place a vessel under the additional fuel

filter cartridge (1).
2. Open the drain valve (3) and drain all
water and sediment behind the transparent Fig. 4-4
cover (2), and drain the fuel accumulated
in cartridge (1).
3. Remove the drain valve (3) after confirming

that nothing is coming out of the drain hose
(4).
4. Apply suitable amount of grease to the

O-ring (5). Pay attention to not greasing
the drain valve outlet (6) or its threads (7).
SY135C8(M)
5. Tighten drain valve (3) with hand till it
contacts bottom of transparent cover (2). Fig. 4-5
6. Remove the fuel vessel.
Fig. 4-6

4.1.2.4 Hydraulic oil - check/refill
WARNING
Components and oil art still hot and can cause burns after the engine has been just
shut down. Wait for them to cool down before working on them.
When removing the cap for oil injection, turn it slowly to release internal pressure be-
fore removing it.
1. Adjust the work equipment to the attitude

shown by the right illustration. Check oil
level. Add oil if necessary.
For the type of hydraulic oil used on the
machine see Recommended Fluids
on page 5-17.
2. If the work equipment is not in the illus-

trated position, start the engine and run it
at low speed. Properly retract the arm and Fig. 4-7
bucket cylinders, lower the boom to rest
the arm front end on the ground, and stop
the engine.
3. Within 15 seconds after stoppage, operate
work equipment joystick controls and travel
control levers in all directions in order to
release internal pressure.
4. Open the pump chamber door on the right
in order to check the oil level gauge (G).
Oil level should be maintained between H
and L marks. Fig. 4-8
Note:
Never add oil to a level above the H mark,
which may ruin hydraulic devices and cause
oil to squirt. If the oil level is above the H mark,
stop the engine and wait for the oil to cool
down. Place a container under the drain plug
(P) beneath the hydraulic tank and discharge
excessive oil from the tank via the drain plug.
5. If the oil level is below the L mark, add
oil through filler opening (F) on top of the
tank.
Fig. 4-9
Remark:
The oil level may change as the oil tempera-
ture varies. (Refer to the following ranges.)
Before operation: L+12.5~L+32.5

(Oil temperature: 10 - 30C (50 - 86F))
During operation: higher than the mid-
mark.
(Oil temperature: 50 - 80C (122 -176F))
4.1.2.5 Coolant - check/refill
WARNING
The coolant is hot and the radiator is

under high pressure upon shutdown of
the engine. It is possible to be burned if
you remove the radiator cap (1) to check
coolant level at the moment. In this case,
before removing the cap (1), you have to
wait for the temperature to cool down, and
then slowly turn the cap to release internal
pressure.
1. The level of coolant must remain between Fig. 4-10

the upper and lower limits marked on the
tank when the engine is running. If water
level is below the lower limit, it is neces-
sary to add coolant to radiator and coolant
to auxiliary tank.
2. Open the rear door to the left side of

machine and check the coolant in auxiliary
tank (2) to see whether its level is between
the marks of FULL and LOW. If the coolant
level is low, refill coolant to FULL position
through the injection opening of auxiliary
tank (2). Fig. 4-11
3. Tighten the cap after refilling the coolant.
4. If auxiliary tank (2) is empty, the coolant

might leak. Correct the fault immediately

after inspection. If no problem is found,

check coolant level in radiator. Add coolant
to auxiliary tank (2) if its level is low.
5. If auxiliary tank (2) is dirty inside and the

level cannot be seen clearly, clean the tank
by following the steps specified inCooling
system - clean on page 5-37.
4.1.2.6 Oil in engine oil pan - check/refill
WARNING
After shutting off the engine, the compo-

nents and oil are still hot, which can lead
to severe burns. Wait for the oil to cool
down before operation.
1. Open the engine's hood.

2. Take out oil dipstick (G) and wipe the oil off
Fig. 4-12
the dipstick with cloth.
3. Insert the dipstick (G) to bottom and then

pull it out.
SY135C8(M)
Fig. 4-13
4. Oil level should be between the H and

L marks on dipstick (G). Add oil through
opening (F) if oil level is below the L mark.
Fig. 4-14

5. If oil level is above H mark, the drain

valve (P) on the bottom of oil pan is to be
opened to discharge extra oil. Check oil
level again.
6. Tighten the filler cap and properly close the

engine hood if oil level is normal.
Remark:
If you need to check oil level after operation Fig. 4-15

of the engine, shut off the engine and wait at
least for 15 minutes before checking.
If your machine is on a slope, move it to a
level ground before inspection.
For the type of engine oil used on the machine
see Recommended Fluids on page 5-17.
4.1.2.7 Electric wires - check
NOTICE
If any fuse burns frequently or any wire

shows the sign of short circuit, contact
your Sany distributor to find the cause
and eliminate the trouble.
Keep battery surface clean and check
the vent on battery cover. Flush the
cover to clean the vent if the vent is
plugged by dirt or dust.
Check whether the fuse is damaged; whether

the fuse with proper capacity is used; whether
any wire connection is off; whether wire sheath
is broken.
Check for loose terminals. Fix it if any.
Moreover, pay special attention to electric

wires when checking battery, engine, start
motor and alternator. Make sure to check for
flammable materials around battery. Immedi-
ately remove them if any.
4.1.2.8 Fuel tank - check/refuel
WARNING
Never make fuel splash or overflow

during refueling, which can cause fire.
Clean the fuel completely in case of
splashing. Remove the fuel if it flows
onto ground or sand.
Fuel is flammable and dangerous. No
open fire is allowed in the vicinity of
fuel.
1. Turn the engine start switch to ON position

and check the fuel level on display (1).
Return the switch to OFF position after
checking.
Fig. 4-16
2. In case of low fuel level, unscrew the filler

cap (F) on fuel tank and add fuel to the
tank till the float level meter (G) reaches
the highest point.
Fuel tank capacity: 240L

When the fuel tank is full, top (a) of the float
level meter (G) is positioned at about 50mm.
Fig. 4-17

3. Add fuel and press down the float level

meter (G) with the filler cap (F). Pay atten-
tion to not letting the level meter (G) be
stuck on the cover plate of filler cap (F).
Screw on the cap (F) tightly.
Remark:
Pressure of fuel tank may drop and fuel does

not ow if the vent (2) on the cap is blocked.
Clean the vent whenever necessary.
A longer travel distance is required to tighten Fig. 4-19

the cover with lock. Make sure the cover is
turned in position before you turn the key to
lock the cover. If the key is turned when the
cover is not in position, the lock plate will press
against inner wall of filler opening and cause
damage to lock cylinder.
Be sure to have a clean O-ring seal in lock

cover. If the seal is contaminated by iron
scraps, stone pieces or other foreign bodies, it
would be damaged during tightening and im-
proper sealing of lock cover could result. Fig. 4-20
4.1.2.9 Work lamp switch - check
Check the work lamps for normal functioning.
Check for any dirt or damage.
If any lamp does not work, the bulb may be

burned or broken circuit may be present.
Please contact Sany distributor for repair.
1. Turn the start switch to the ON position.

Fig. 4-18
2. Switch on the work lamp and check if it
lights up.

4.1.2.10 Horn - check
1. Turn the start switch to the ON position.
2. The horn sounds immediately when the

horn button is pressed. Make sure that the
horn sounds normally. In case of dead horn
or abnormal sound, please contact Sany
distributor for repair.
Fig. 4-21
4.1.3 Adjustment before operation
It is necessary to adjust seat position be-

fore operating or after changing operator.
Adjust the seat so as to enable operator to
easily manipulate the control levers, ped-
als and switches from the seat.
4.1.3.1 Operator seat
(A) Forward and backward adjustment
Pull the lever (1) upward, slide the seat to de-

sired position, and release the lever.
Adjustment space: 200mm (10mm for each

adjustment)
Fig. 4-22

(B) Backrest adjustment
Lift lever (2), move the backrest to an optimum

position at where operation can be easily con-
ducted, and release the lever.
Make sure the backrest does not interferes

with the cover plate of the air conditioner at
rear when adjusting the inclination of backrest.
Be careful with the control levers, which shall
not be touched by armrest.
Fig. 4-23
(C) Height adjustment
The seat can be raised by 30 mm when you

hear a "click" sound, and another 30 mm at
the second "click". The seat can be lowered to
the minimum height if you continue to raise it.
Adjustable height: 60mm (30mm for each ad-

justment)
(D) Armrest angle adjustment
Turning the plate (4) beneath armrest (3) can

adjust the angle of armrest to desired position.
The armrest can be placed vertically so that

the operator could leave the seat easily.
Adjustable angle: 40
Fig. 4-24

(E) Adjust the seat forward and backward

as a whole
Pull the lever (5), slide the seat to desired po-

sition, and release the lever. In this case, the
operator seat moves along with both armrest
boxes and pilot hydraulic lockout control.
(F) Suspension adjustment (if equipped)
Turning the lever (6) counterclockwise will

bring you a hard suspension which is suitable
for heavy operator; turning the lever (6) clock-
wise will bring you a soft suspension which is
suitable for light operator.
Remark:
To achieve the best adjustment, adjust the

reading (kg) on dial (7) to weight of operator.
Fig. 4-26
4.1.3.2 Rear view mirrors
WARNING
The rear mirrors must be adjusted before

operation. Without proper adjustment,
a good visibility cannot be ensured and
which may lead injury.
Fig. 4-25

Rear mirror (A)
Adjust installation of rear mirror (A) so that

people to rear left of machine can be seen
clearly.
Install rear mirror (A) to the position as shown

in the right illustration.
Turn the rod (1) around rod (4) to a suitable

position and fix rod (1).
Fig. 4-27
When adjusting mirror angle, if the mirror can-
not move smoothly, you may loosen bolt (2)
and bolt (3) to release the mirror.
Torque of bolt (2):
4.0~5.4 Nm (0.41~0.55 kgfm)
Adjustment of rear mirror is accomplished

when side of machine can be seen in the mir-
ror, as shown in the right illustration.
Fig. 4-28
Rear mirror (B)
Adjust installation of rear mirror (B) so that

people to rear right of machine can be seen
clearly.
Install rear mirror (B) to the position as shown

in the right illustration.
M: 120 mm
Fig. 4-29

When adjusting mirror angle, if the mirror can-

not move smoothly, you may loosen bolt (5)
and bolt (6) to release the mirror.
Torque of bolt (5): 4.0~5.4 Nm
(0.41~0.55 kgfm)
Adjustment of rear mirror is accomplished

when side of machine can be seen in the mir-
ror, as shown in the right illustration.
Fig. 4-30
4.1.3.3 Seat belt
Check the condition of the seat belt and

the buckle before you fasten it. Replace
the belt if excessive wear or damage is
observed.
Replace the seat belt every 3 years re-
gardless of its condition. See the produc-
tion date on the back of the belt.
Be sure to fasten your seat belt during ma-
chine operation.
Never twist the seat belt.
Buckle up and release
The seal belt has a coiler, and belt length

needs no adjustment.
1. Buckle up
Hold clip (2) and pull the belt out of coiler

(1). Check that there is no twist on the belt
and insert catch (3) into buckle (4).
Check if the belt has been fastened by

pulling it slightly.
2. Release
Press button (5) on buckle (4) to release

catch (3). The belt will retract into the coil-
er automatically.
Hold clip (2) so that the belt retract slowly

into the coiler. Fig. 4-31

4.1.4 Before Starting the Engine
WARNING
Before starting the engine, check the

hydraulic lockout control whether it is
secured in "locked" position.
If the hydraulic lockout control is not
secured in position, accidental touch-
ing of control lever or pedal when start-
ing the engine may lead to unexpected
movement of machine, which could
cause serious accident.
When rising from operator seat, make
sure the hydraulic lockout control is in
LOCK position, regardless of that the
engine is running or not.
1. Check if the hydraulic lockout control (1) is

in the LOCK position (L).
2. Check if all control levers and pedals are in

a NEUTRAL position. They should remain
in NEUTRAL position if left touched.
Fig. 4-32
Fig. 4-33

3. Insert your key into start switch (2), turn

the key to ON position (B), and then check
the following:
Fig. 4-34
Two seconds after the key is turned to ON po-

sition, default screen will be displayed under
normal condition, as shown in the right illustra-
tion.
Engine coolant temperature gauge (3)

Fuel level gauge (4)
Failure code (5)
Fig. 4-35

4.2 Engine Starting
WARNING
Always start the engine from the opera-

tor seat.
Never start the engine in a way that
may cause short circuit, which can lead
to serious injury or fire.
Sound the horn and start the engine
after you have confirmed that the sur-
rounding area is clear of personnel or
barriers.
Never use start-assisting solution as
which may cause explosion.
Exhaust gas is poisonous. Pay special
attention to keeping a good ventila-
tion when starting the engine in an en-
closed space.
Note:
Before starting the engine, check that the

fuel control dial (2) is in MIN position for
low idling speed. If the knob is in MAX po-
sition, starting the engine can lead to sud-
den acceleration and damage to its parts.
Never keep the ignition key in START
position for more than 20 seconds.
If the engine fails to start, wait at least two
minutes before restarting it.
After the engine is started, operation is not
allowed until oil pressure stays in the nor-
mal range. Never manipulate any control Fig. 4-36
lever or pedal in case of abnormal oil pres-
sure.

1. Check if the hydraulic lockout control (1)

is in the LOCK position (L). If it remains in
FREE position (F), the engine cannot be
started.
Fig. 4-37
2. Turn the fuel control dial (2) to MIN posi-

tion.
Fig. 4-38
3. Turn the ignition key to ON position (B).
Fig. 4-39

4. Turn the ignition key to START position (C).
Fig. 4-40
5. Release the key (3) after starting the

engine. The key will be back to the ON
position (B) by itself.
Remark:
When ambient temperature is low, the engine

may fail to start after the start switch is kept at
START position for more than 10 seconds. In
this case, wait at least for 1 minute before re-
starting the engine. Fig. 4-41
6. Wait until engine oil pressure alarm is

reset even if the engine is started. Never
maneuver any control lever or pedal when
engine oil is abnormal.
Note:
If oil pressure remains abnormal after 4-5

seconds, immediately shut down the engine,
check oil level and check for oil leak. Take
necessary actions in case of abnormality.

4.2.1 Engine Preheating
When ambient temperature is below 10C, it is

necessary to preheat the engine before start-
ing.
1. For model SY135C8M
Turn the fuel control dial to MIN position (b),

and turn the ignition key to HEAT position
(a). At the same time, switch on the pre-
heat switch. When preheating indicator (c)
lights, engine preheating begins. See the
following table for preheating period.
Temperature (C) 0~10 -10~0 <-10

Preheating period 10s 20s 30s
2. For models SY115C9, SY135C8, SY

135C9 and SY155H
Turn fuel control dial to the MIN position (b).

Turn ignition key to the HEAT position (a).
The preheat indicator (c) will be on and the
engine begins preheating. The preheat in-
dicator (c) will be off after preheating. The
engine is now ready to start up.
After preheating, turn the ignition key to

the START position (C) to start the en-
gine.
If the engine fails to start, wait at least
one(1) minute before re-preheating and
restarting the engine.

4.2.2 Warm-up operation
WARNING
In case of emergency, abnormal running of engine, or other faults, turn the start switch
to OFF position and shut off the engine.
Never operate any control lever or pedal suddenly when temperature of hydraulic oil is
low. Make sure to preheat the machine till temperature of hydraulic oil rises to a suit-
able point.
Failure code 37 will be displayed when hydraulic oil becomes abnormal in tempera-
ture.
If the machine has not been preheated completely, it may fail to respond or move sud-
denly and quickly during operation, and cause serious accidents. Complete warming-
up is especially necessary in cold region.
Never accelerate your machine suddenly before finishing preheat operation. Never
continuously run the engine at low or high speed for more than 20 minutes, which
may cause leaks in oil supply pipe of turbo charger. If the engine has to be run at idle
speed, it is necessary to add load to it or run it at a moderate speed.
Never enter into operation immediately after starting the engine. Proceed and check the following
items:
1. Adjust fuel control dial to make the engine run unloaded at low speed (about 1,100 rpm) for
about five minutes.
2. Adjust fuel control dial to make the engine run at moderate speed (about 1,400 rpm), and then
slowly operate the bucket for five minutes.
3. Adjust fuel control dial to make the engine run at high speed, and operate the boom, arm and
bucket for 5-10 minutes.
4. Cycle each action of excavator for several times before ending the preheat operation.
5. Check all gauges for normal display after preheating the machine.
Continue to preheat the machine if coolant temperature (see display) and hydraulic oil tem-
perature (50~80 ) fail to reach normal values.
6. Check exhaust color, noise or vibration for abnormality. Repair it if any.
4.2.3 Selecting a working mode

Press the working mode selection key F1 on machine monitor to choose a mode you want.
For more information see Working mode on page 4-37.

4.3 Engine Shutdown

Remark:
Shutting off the engine suddenly may con-

siderably reduce service life of its compo-
nents.
Never shut off the engine suddenly except
for emergency.
Never shut off the engine suddenly if the
engine is too hot. Run the engine at low
CZ215-1103061
idle in order to let it cool down gradually.
Stop the engine. Fig. 4-42
1. Run the engine at idle speed for about five
minutes to cool it down gradually.
2. Turn the start switch key (1) to OFF posi-

tion (A) to shut off the engine.
3. Remove the key (1) from the start switch.
Fig. 4-43

4.4 Machine Operation
WARNING
Check the surrounding of machine for safety and sound the horn before moving the
machine.
Nobody is allowed to enter the area around the machine.
Remove any barriers from the travel route.
There is a blind area behind the machine. Therefore, pay special attention to reverse
travel.
Check alarm devices for normal functioning before moving the machine.
Check the correct travel direction before operating travel control lever or pedal. If the track frame
faces the rear (behind the sprockets), the machine will move in a direction opposite to the operat-
ing direction of travel control lever or pedal (Both the forward and backward travels are reversed,
and the leftward and rightward travels as well).
4.4.1 Before moving the machine
(1) Fuel control dial

(2) Hydraulic lockout control
(3) Travel control levers
(4) Travel control pedals
Fig. 4-44
Turn the fuel control dial in the MAX direction

to the desired position in order to increase en-
gine speed.
Fig. 4-45

4.4.2 Moving the machine forward
1. Place the hydraulic lockout control to the

FREE position (F), and retract the work
equipment till it is 40-50 cm above the
ground, as shown in the right illustration.
If you never have a good visibility to the

right, raise the boom to ensure a good vis-
ibility.
Fig. 4-46
2. Operate the left and right travel control

levers or the left and right travel pedals
according to the following instruction:
When the sprocket (A) is under the rear

part of machine:
Slowly push the control lever or slowly
push down the front part of pedal to move
the machine. Fig. 4-47
When the sprocket (A) is under the front

part of machine:
Slowly pull the control lever or slowly push
down the rear part of pedal to move the
machine.
Fig. 4-48
Remark:
Fully preheat your machine if its travel speed

is abnormal in cold weather. In addition, if the
undercarriages is stuck with mud and the ma-
chine's travel speed becomes irregular, it is
necessary to remove the mud from the under-
carriage.

4.4.3 Moving the machine backward

FREE position (F), and retract the work
equipment till it is 40-50 cm above the
ground, as shown in the right illustration.
If you never have a good visibility to the

right, raise the boom to ensure a good vis-
ibility.
Fig. 4-49
2. Operate the left and right travel control

levers or the left and right travel pedals as
the following:
When the sprocket (A) is under the rear

part of machine:
Slowly pull the control lever or slowly push
down the rear part of pedal to move the
machine backward.
Fig. 4-50
When the sprocket (A) is under the front

part of machine:
Slowly push the control lever or slowly
push down the front part of pedal to move
the machine backward.
Fig. 4-51
Remark:
Fully preheat your machine if its travel speed

is abnormal in cold weather. Moreover, if the
tracks are stuck by mud and the machine's
travel speed becomes irregular, it is necessary
to remove the mud from the tracks.

4.4.4 Parking the machine
Never park your machine suddenly.
Before parking your machine, leave yourself

enough space so that you could leave the ma-
chine easily.
Place the left and right travel control levers

(1) to neutral position before parking your ma-
chine.
Fig. 4-52
Fig. 4-53

4.5 Steering Operation

Check the direction of track frame (position of
sprocket) before maneuvering the travel con-
trols. When the operator faces the sprockets,
moving direction of travel controls is opposite
to travel direction of machine.
4.5.4.1 Steering with travel controls
Avoid changing travel direction suddenly if

possible. Stop your machine before making a
turn, especially before a pivot turn.
Operate travel controls (1) according to the

following instructions.
Fig. 4-54
4.5.4.2 Steering with machine stopped
When turning to the left side:
Push the right travel control lever to turn the

machine to the left side in forward travel.
Pull the right travel control lever to turn the

machine to the left side in backward travel.
(A) Turning left in forward travel
(B) Turning left in backward travel
Remark:
Operate the left travel control lever in the

same way to turn your machine to the right
side.
Fig. 4-55

4.5.4.3 Steering during traveling
When turning to the left side:
Place the left travel control lever in the neutral

position to turn your machine to the left side
during traveling.
(A) Turning left during forward travel
(B) Turning left during backward travel
Remark:
Operate the right travel control lever in the

same way to turn your machine to the right
side during traveling.
Fig. 4-56
4.5.4.4 Pivot turn
Pull the left travel control lever and push the

right one to make a pivot turn to the left side.
Remark:
Pull the right travel control lever and push the

left one to make a pivot turn to the right side.
Fig. 4-57

4.5.1 Swing operation
When the rear part of the machine is posi-

tioned away from the track, check whether
the surrounding area of the machine is
safe before carrying out swinging opera-
tion.
When the engine's speed decreases due
to automatic idling function, the engine's
speed could increase abruptly if any con-
trol lever is maneuvered. Be careful with
the operation of control levers.
Maneuver the left joystick (1) in the illustrated

directions to swing the turntable of upper
structure.
(A) Swing to left
(B) Swing to right
CZ215-1103064
Fig. 4-58
Fig. 4-59

4.6 Work Equipment Control and

Operation
CAUTION
Operation of the control levers while the

engine is idling may cause engine speed
to increase abruptly. Be careful with the
operation of joystick controls.
Work equipment is controlled through the joy-

sticks.
Note that joystick control will return to neutral

position when released and movement of work
equipment will be held.
Arm control
Push or pull the left joystick to control arm op-
eration.
Fig. 4-60
Swing control
Move the left joystick left or right to control
swing operation.
Fig. 4-61

Boom control
Push or pull the right joystick to control boom
operation.
Fig. 4-62
Bucket control
Move the right joystick left or right to control
bucket operation.
When joystick control is in the neutral position,

the auto deceleration system will be activated
to lower engine speed to a moderate level if
no operation is performed within 5 seconds.
This will happen even if you turn the fuel con-
trol dial to the MAX position.
Fig. 4-63
Remark:
This machine includes an energy accumulator

installed in oil control lines. Turning the start
switch key to ON position and placing the hy-
draulic lockout control to the FREE position,
within 15 minutes after shutting off the engine,
allows you to maneuver the control levers to
lower the work equipment to ground.
This method can also be used to release the

remaining pressure of hydraulic system, or to
lower the boom after the machine has been
loaded onto a trailer.

4.7 Working mode

The working modes selection switch (1) is
used to select a mode suitable for your work-
ing condition and purpose. In this way, effec-
tive operation can be achieved.
Select the most effective working modes

through the following steps:
Default working modes H will be displayed

when the start switch is ON.
Working modes selection key F1 is used to
set the optimum mode according to operat-
ing practices.
When pressing down the working modes
selection key (1), the working modes will be
cycled (H S L B) at (2) on the screen.
Fig. 4-64
Mode Suitable Operations

Heavy-loaded operation for such
H
as ore excavation
Standard operation for such as
S
earth removing
Breaking operation performed
B
with breaker
Light-loaded operation for level-

L
ing ground or trimming a slope.
Note:
If breaking operation is performed in a mode

other than mode B, the hydraulic unit could be
damaged.
Never perform breaking operation in a mode Fig. 4-65

other than mode B.

4.8 Restricted Operations

Never maneuver the control levers of the
work equipment when the machine is trav-
eling. Stop the machine before maneuver-
ing any control lever.
The engine's speed could increase abrupt-
ly if you maneuver any control lever when
the automatic idling function is active.
4.8.1 Operation with swinging force
Never use the swinging force to compact the

ground or break objects. Doing this is danger-
ous. In addition, the service life of machine
would be reduced considerably.
Fig. 4-66
4.8.2 Operation with traveling force
Never cut your bucket into ground and use the

traveling force to excavate, which could dam-
age your machine or work equipment.
Fig. 4-67
4.8.3 Operation when hydraulic cylin-

der reaches its stroke end
If the cylinder's piston reaches its end of

stroke, using the work equipment under ex-
ternal impact could damage hydraulic cylinder
and cause personal injury. Avoid operating the
machine when its hydraulic cylinder is fully re-
tracted or extended.
Fig. 4-68
4.8.4 Operation with bucket landing

force
1. Never use the bucket's landing force for

excavating, digging, breaking or pile-driving
operation, which may otherwise reduce the
service life of the machine considerably.
2. To avoid damage of hydraulic cylinders,

never use the bucket to strike or compact
the ground while its cylinder is fully ex-
tended or retracted.
Fig. 4-69

4.8.5 Operation with machine weight
Never use the weight of machine to excavate.
Fig. 4-70
4.8.6 Hard rocky ground
Never try to directly excavate hard rocky

ground. Perform excavation after breaking the
rocks through other means. By doing so, dam-
age to your machine could be minimized, in
addition to cost reduction.

4.8.7 Sudden shift of travel speed dur-

ing fast traveling
1. Never maneuver any control lever or pedal

abruptly to change the action of machine.
2. Never suddenly change the position of

control lever or pedal from forward (A) to
reverse (B), or vice versa.
3. Never stop the machine by suddenly

releasing the control lever or pedal while
traveling at high speed.
Fig. 4-71
4.9 General Operation
4.9.1 Traveling operation
Traveling over road shoulders, stumps or other

barriers could bring strong impact on the chas-
sis (especially the tracks), and cause damage
to the machine. In this case, remove the bar-
riers or bypass them. You can also take other Fig. 4-72
actions to avoid barriers.
If there is no way to avoid traveling over barri-

ers, drive your machine slowly while keeping
its work equipment close to ground and run-
ning the track over barriers along the track's
centerline.
4.9.2 High-speed travel
Run your machine slowly on rough surfaces

with rocky bed or large stones. Place the ten-
sion wheel in forward direction while traveling
at high speed.
Press F3 (1) to change the travel speed.

The travel speed (Hi or Lo) will be dis-
played at (2) above the F3 key.
Fig. 4-73
4.9.3 Permissible depth of water
Note:
When driving your machine out of water, an

inclination of slope exceeding 15 would have
the rear of its upper turntable immersed in
water, thus the fan could be damaged due to
water.
Pay special attention to your machine when

driving it out of water.
Don not drive your machine into water

Fig. 4-74
where water level could reach the center of
carrier roller (1).
Add grease to parts that have been soaked
long in water, till old grease is completely
squeezed out of the bearing (especially the
area around the pin of bucket).
Never operate your machine in water un-
less the foundation of job site is strong
enough so that the level of water could not
reach the center of carrier roller.
If the swing bearing, swing gear and cen- Fig. 4-75
tral swing joint are soaked in water, the
drain plug should be opened to remove
mud and water. Clean the swinging area
and reinstall the plug. Lubricate the mesh
gear and swing bearing inside the swing
unit.
4.10 Traveling on Slope

When operating your machine on a slope,
never turn your machine or operate the
work equipment as that would cause your
machine to loose balance.
It is dangerous to swing downward on a
slope when your bucket is loaded. If such
operation is necessary, you have to pile
up a platform on the slope with earth so
that your machine could be kept on a level
ground.
Fig. 4-76
Never travel on a steep slope, which could

cause your machine to tip over.
The bucket must be lifted 20-30 cm above
the ground during traveling.
Never travel reversely down a slope.
Never turn your machine on a slope or tra-
verse a slope.
The above operations must be carried out
on a level ground. You might have to travel
a long distance for the sake of safety.
The operations must be performed in this
way because the machine can be stopped
safely at any time when it skids or be- Fig. 4-77
comes instable.
If the track shoes skid or the power of
tracks is unable to help your machine run
up a slope, never use the pulling force of
arm to run up the slope as that could dam-
age your machine.
1. The travel control lever and fuel control dial

are used to keep your machine traveling at
a low speed when running down a steep
slope. When angle of the slope is more
than 15, adjust your work equipment to
an attitude as shown in the right illustration
and lower engine speed.
2. When running up a steep slope, it is

necessary to move your work equipment
Fig. 4-78
to the forward direction. Maintain the work
equipment at about 20-30 cm above the
ground and travel at a low speed.
Fig. 4-79

4.10.1 Traveling downhill
Place the travel control levers to the neutral

position, which can make the brake function
automatically.
4.10.2 Engine stalls on an incline
If the engine stops while traveling on a slope,

place the travel control lever to its neutral po-
sition, lower the bucket to the ground and park
the machine before restarting the engine.
4.10.3 Cab door on an incline
If the engine stalls out on a slope, never

perform swinging operation with the left
joystick. The upper turntable will swing
naturally under its weight.
When your machine is on a slope, never
open or close the cab door, which can
change suddenly the force on machine.
Always keep the cab door in an opening or
closing position.
4.11 Removing Machine from Mud

Be careful with operation and avoid being
trapped in the mud. If your machine is trapped
in the mud, drive it out according to the follow-
ing method.
4.11.1 One track trapped
Note:
When the boom or arm is used to lift your ma-

chine, make sure that the bottom of bucket
contacts the ground. The boom and arm shall
form an angle between 90 and 110.
This is also applicable to a reversely-mounted

bucket.
When one of the tracks is trapped in the mud,

use the bucket to lift the track, place wood
planks or logs under the track and then drive
your machine out of the mud.
4.11.2 Both tracks trapped

Fig. 4-80
When both tracks are trapped in the mud and
the machine cannot move due to skidding, use
wood planks as described in the above meth-
od and cut your bucket into the ground in front
of your machine. Retract the arm as you do
in normal excavation, place the travel control
lever in "FORWARD" position, and drive your
machine out.
Fig. 4-81
4.12 Recommended Applications
Besides the following applications, the scope
of application could be expanded by using
various additional attachments.
4.12.1 Backhoe operation
Backhoe operation is suitable for digging an

area which is lower than your machine.
When your machine is in a state shown in the

right illustration (the angle between (bucket
cylinder and link) and (bucket cylinder and
arm) is 90), maximum digging force can be
obtained through the thrusting force of each
hydraulic cylinder.
Fig. 4-82
When digging, using this angle effectively can
help you achieve the maximum working effi-
ciency.

The digging range of arm is from 30 to 45, as

relative to the machine.
The angle may vary according to digging

depth, but it is better to keep it within the
above range if possible. Never operate the hy-
draulic cylinders to their full stokes.
Fig. 4-83
4.12.2 Trench work
You can dig a trench efficiently by installing

a bucket suitable for this job and adjust your
tracks to parallel the to-be-dug trench line.
When digging a wider trench, excavate first

both sides of the trench and then remove the
middle part.
Fig. 4-84
4.12.3 Loading operation
In a place where the swinging angle is small,

working efficiency can be improved by parking
the dump truck at where the operator could
see easily.
It is more convenient to load more material if

the truck is loaded from rear rather than from
its sides.
Fig. 4-85

4.13 Parking Operation

Park your machine on a hard, level ground
that is free from dangers. If you have to park
your machine on a slope, chock the tracks
with blocks. You can also penetrate the bucket
into ground as additional safety support.
If any of the control levers is moved unexpect-

edly, the machine may move suddenly and
cause serious accidents. Make sure that the
hydraulic lockout control has been placed in Fig. 4-86
"locked" position before you leave the cab.
1. Place both right and left travel control

levers (1) in neutral position to stop your
machine.
CZ215-1103065
Fig. 4-87
Fig. 4-88

2. Turn fuel control dial to low idle (MIN) posi-

tion in order to reduce engine speed.
Fig. 4-89
3. Lower the bucket horizontally until its bot-

tom is in contact with ground.
Fig. 4-90
4. Place hydraulic lockout control in LOCK

position (L).
Fig. 4-91

5. Check engine coolant temperature and oil

pressure on machine monitor.
If red segments appear on coolant tem-

perature gauge (2), cool down the engine
until red segments disappear. Shut down
the engine.
If alert indicator (1) is on and you are sure
it is caused by abnormal oil pressure, shut
down the engine immediately.
6. Shut down the engine. For engine shut-
down steps see Engine Shutdown
on page 4-27.
Fig. 4-92
4.14 Checks after Each Workday

1. Inspect your machine and check the work
equipment, the exterior of machine, and
the undercarriage. Check for leaks of oil or
coolant. Repair it in case of any problem.
2. Refuel the tank to maximum level.
3. Check the engine compartment for any

paper or other debris. Remove them, if
any, in order to prevent fire.
4. Remove mud built up on the undercar-

riage.
5. If the ambient temperature is below -35C,

make sure to drain the coolant of radiator
and engine (Sany uses the type of anti-
freeze liquid that freezes at -35C. )

4.15 Locking the Machine

The following locations must be locked.
(1) Cab door

Close the windows properly.
(2) Injection cap of fuel tank
(3) Engine hood
(4) Battery cover (Battery is mounted behind
left access door on some models.)
(5) Left door of machine Fig. 4-93
(6) Right door of machine

(7) A/C fresh air inlet
Remark:
Use start switch key to lock and open these

locations.
Fig. 4-94
4.16 Operation in Cold Weather
4.16.1 Operation instruction
The engine possibly fails to start and the cool-

ant may freeze under low temperature. In this
case, the following instructions must be fol-
lowed.
4.16.1.1 Fuel and lubricant
Fuel and lubricant with low viscosity shall be

used for all components.
For more information on specification of vis-

Recommended Fluidson page 5-17.
cosity see

WARNING
Antifreeze liquid is poisonous. Pay at-

tention to not letting it contaminate
your eyes or skin. If it contaminates
your eyes or skin, flush with large
amount of clean water and See medical
care immediately.
When replacing the coolant or dispos-
ing the coolant containing antifreeze
liquid, which is drained when repairing
the radiator, contact your Sany dis-
tributor or a professional company to
dispose it. Since the antifreeze liquid
is poisonous, never drain it to sewage
system or leave it on the ground.
Antifreeze liquid is flammable, so no
naked fire is allowed to approach it.
Never smoke while disposing antifreeze
liquid.
Note:
Please use Sany genuine, efficient anti-freeze

liquid as the coolant. In principle, we never
recommend you choosing any other type of
coolant.
SeeCooling system - cleanon page 5-37

for more information about the mixing ratio of
anti-freeze liquid when changing the coolant.
4.16.1.2 Battery
Battery capacity decreases as the ambient

temperature drops. It is important to keep bat-
tery capacity at 100% level. Never let the bat-
tery stay long under low temperature so as to
avoid the difficulty in starting your machine.
Since the battery's capacity will decrease un-

der low temperature, it is important to cover
the battery or remove it from your machine.
Store your battery in a warm place and rein-
stall it before operating your machine.

4.16.2 After each workday
CAUTION
Rotating track can cause severe injury.

Always keep a safe distance from rotating
track.
Observe the following precautions to prevent

the machine from being immobilized the next
day due to frozen mud and ice on the under-
carriage.
Remove all mud and water from your ma-

chine. Clean especially the piston rods of
hydraulic cylinders in order to prevent mud,
dirt or water from penetrating the cylinders
and spoiling the seals.
Park your machine on a hard, level ground.
Park your machine on planks if possible.
The planks can prevent your machine from
freezing with the ground and you can move
your machine the next day.
Open the drain valve to discharge accu-
mulated water of the fuel system so as to
prevent it from freezing.
Refill the fuel tank to the maximum level. In
this way, when ambient temperature drops,
the condensate in the tank could be mini-
mized.
After operation in water or mud, remove
the water on the undercarriage according
to the following instruction so as to extend
its service life.
1. When the engine is running at idle speed,
swing the upper structure by 90 in order
to maintain the work equipment at the track
side.
2. Lift one side of your machine just above

the ground, as shown in the illustration,
and run the track freely. Cycle this opera-
tion between the left and right tracks.
Fig. 4-95
4.16.3 After cold season
When the season changes and the weather

gets warm, perform as described below.
The fuel or lubricant of any components

shall be replaced with the one of specified
viscosity.
For more information see Recommended
Fluids on page 5-17 .

4.17 Long-Term Storage
4.17.1 Before storage
Note:
When storing your machine for more than one

month, adjust your machine to the attitude as
shown in the right illustration in order to pro-
tect cylinder piston rod against rusting.
When storing your machine for more than a

month, perform as described below:
Clean all parts of your machine and then

store your machine indoors. If you have
to store your machine outdoors, choose a Fig. 4-96
level ground and cover your machine with
canvas.
Refill your fuel tank to its maximum level in
order to avoid accumulation of water.
Lubricate your machine and change its oil
before storing it.
Apply grease to the exposed part of the
piston rod of hydraulic cylinder.
Disconnect the battery's negative terminal
and reinstall its cover, or remove the bat-
tery from your machine and store it in a
separate place.
For machines equipped with additional
equipment, the control pedal of additional
equipment shall be placed to LOCK posi-
tion.
To prevent rusting, please use Sany genu-
ine, efficient anti-freeze liquid as coolant of
the engine.

4.17.2 During storage
WARNING
When your machine is stored indoors, it is

important to prevent it from rusting, Open
the doors and windows to allow good ven-
tilation. This can also prevent gas poison-
ing.
During storage, it is important to operate

your machine and drive it for a short dis-
tance once a month. This can help apply
a new oil film on parts and components.
Meanwhile, charge the battery of your ma-
chine. The storage temperature of this ma-
chine is between -25C and 75C.
Before operating the work equipment, wipe
off all the grease from the piston rod of hy-
draulic cylinder.
If your machine is equipped with air condi-
tioner, switch on the air conditioner for 3-5
minutes once a month, which can lubricate
all parts of its compressor. The engine shall
run at low idle speed when air conditioner
is working. In addition, check its refrigerant
twice a year.

4.17.3 After storage
Note:
If your machine has been stored for a long pe-

riod but no rusting prevention had been made
each month, please contact Sany distributor
before operating your machine again.
Before using your machine again after a long-

term storage, perform as described below:
Wipe off the grease from the piston rod of

hydraulic cylinder.
Apply lubricant or grease to all necessary
locations.
The moisture of air can mix with oils when
your machine has been stored for a long
time. Check the oils before and after start-
ing the engine. If the oil contains water, re-
move the water timely.
4.17.4 Starting the engine after long-

term storage
Before starting a machine that has been

stored for a long period of time, it is important
to fully warm up the engine.
For more information see Warm-up opera-

tion on page 4-26.

4.18 Transportation Information

Related laws and regulations must be ob-
served when transporting the machine. Safety
must be ensured.
4.18.1 Transport methods
Choose a method that is suitable for the

weight and dimension provided in the
sectionSpecification.
The weight and dimension provided in
"Specification" can vary due to different
type of track shoe, arm or other additional
equipment.
For transport of the machine installed with
cab protection housing, please contact
Sany distributor for more information.
4.18.2 Loading/unloading machine to/

from a trailer
The following instruction must be followed
when loading/unloading the machine.
Choose a hard, level ground to load and

unload your machine. Keep a safe dis-
tance to sides of road.
Auto idle must be switched off. If the auto
idle switch is activated, the machine may
move suddenly.
The travel speed must be set to low (Lo).
Run the engine at idle speed and operate
your machine slowly when loading or un-
loading. Fig. 4-97
In a cold region, it is important to fully pre-
heat your machine and ensure a stable
rpm of the engine before loading or un-
loading.
Never reposition your machine on the ac-
cess ramp, which may otherwise cause
your machine to tip over. If necessary, re-
position your machine on a level ground or
on the trailer.
It is dangerous to load or unload your ma-
chine with the work equipment. The use of
an access ramp is necessary.
On an access ramp, never maneuver any
other control lever except the travel control
lever.
At the junction of the access ramp and
trailer, the machine's center of gravity may Fig. 4-98
change suddenly and it is possible to loose
balance. Drive slowly when passing the
junction.
If you have to swing the work equipment
on the trailer, be extra careful with your
machine, which may tip over due to insta-
ble base.
If the work equipment has been installed
on the machine, it must be retracted slowly
to avoid the machine loosing balance.
Considering operating safety, a signal man

shall be assigned to alert preventing the
machine from falling off the ramp.
The following items must be carefully ob-
served:
Use an access ramp with enough width,

length, thickness and strength. Ramp
grade shall not exceed 15.
When piling the earth to build a platform,
the platform must be fully compacted to
prevent landslide.
To prevent the machine from skidding
on the ramp, clean its track shoes and
the ramp before loading and unloading.
The machine has the danger to skid when
the access ramp is contaminated with wa-
ter, snow, grease or ice.

4.18.2.1 Loading the machine
1. The machine shall only be loaded and

unloaded on a hard, level ground.
It is necessary to keep a safe distance to

roadside.
2. Choke the trailer and put blocks under its

wheels to prevent its moving.
Use two access ramps (2) and place them

at the left and right sides respectively. The
two ramps shall parallel each other and
have equal distance to trailer centerline (3).
Ramp grade (4) shall not exceed 15. If the
ramps bend too much under the weight of
machine, supports must be placed under
the ramps to prevent their bending.
Fig. 4-99
3. Set the travel speed selector switch to low

speed (Lo).
Press travel speed button (6) to change

travel speed (Lo, Hi), which will be dis-
played at (5) on the display screen.
4. Press button (8) to turn off auto decelera-
tion. Use the fuel control dial to set engine
speed to low idle.
When machine is running in auto idle

mode, the screen displays at (7).
Press the button (8) again to cancel auto
idle. The screen will display at (5).
Auto idle is the default mode after the ma-
chine is started. Press the button (8) to
toggle between auto-idle and non auto-idle
.
Fig. 4-100

5. If the machine is installed with work equip-

ment, the work equipment must be placed
in front of the machine. Move the machine
straight forward up the ramp. Without the
work equipment, reverse the machine up
the ramp.
Lower the bucket on the trailer to sup-

port the machine immediately after getting
aboard. Fig. 4-101
Instruction and signals from a commander

must be followed, in especially reverse
travel.
6. Align your machine with the ramp before

driving up the ramp. The centerline of ma-
chine shall match the centerline of trailer.
Align your machine with the ramp and trav-

el slowly.
Lower the work equipment as low as pos-

sible if it causes no trouble.
Fig. 4-102
On an access ramp, only the travel lever
can be maneuvered. Never maneuver any
other control levers.
7. Drive the machine slowly forward till all

tracks are on the trailer and have full
contact with trailer oor.
8. When the machine passes the rear wheels

of the trailer, the machine could lean
forward. So drive the machine slowly and
carefully in order to avoid impact with the
trailer.
9. Slightly raise the bucket, retract the arm

and maintain it in lower position, and slowly
swing the upper structure by 180.
Fig. 4-103

10. Fully extend the bucket cylinder and arm

cylinder, and slowly lower the boom.
11. Place a wood block under the end of the

bucket cylinder in order to prevent it from
touching the trailer oor, which could result
in damage to the cylinder.
Fig. 4-104
4.18.2.2 Securing the machine
Note:
Reinstall the rear view mirrors in order to

enable them to be within the sphere of ma-
chine width.
To prevent damage to the bucket cylinder
during transit, place a wood block under
the top end of the bucket linkage so as to
prevent the bucket cylinder from touching
the trailer oor.
Check if the engine hood is locked. Seize
the grip of engine hood and lift it slightly.
If it is not open, it indicates that the hood
catch is engaged. If the hood is not locked,
it might be swung open during transit.
Secure the machine to the trailer through the

following steps:
1. Fully extend the bucket cylinder and arm

cylinder, and slowly lower the boom.
Fig. 4-105


LOCK position (L).
3. Stop the engine and remove the key from

the start switch.
4. Close all doors, windows and covers

properly.
Lock the covers, caps and doors.

Fig. 4-106
5. Chock the tracks on both ends in order to

prevent the machine from moving during
transportation. Tie down the machine
with chains or wire ropes with sufficient
strength.
It is important to keep the machine in a

proper position in order to ensure that the
machine could not slip to the sides.
Fig. 4-107
4.18.2.3 Rear view mirrors
The rear view mirror is located in the position

shown in the right illustration.
If the rear view mirror is broken or it is nec-

essary to reinstall the mirror after disas-
sembling for shipping purpose, the follow-
ing procedure must be observed.
The rear view mirror must be readjusted
after installation. For more information
seeRear view mirrors on page 4-17.
Fig. 4-108

Removal
1. Loosen bolt (2) and remove the rear view

mirror (1) from the bar (3).
2. Loosen bolt (4) and remove the bar (3) and
the clasp (5).
Fig. 4-109
Installation
1. Install the bar (3) and the clasp (5) to the

handhold, and tighten bolt (4).
2. Install the rear view mirror (1) to the bar (3),
and tighten the bolt (2).
4.18.2.4 Unloading the machine
1. Load and unload the machine only on

a hard, level ground, and keep a safe
distance from roadside as well.
2. Apply braking to the trailer and chock the

trailer under its wheels to prevent moving.
Use two access ramps (2) and place them

at the left and right sides respectively. The
Fig. 4-110
two ramps shall parallel each other and
have equal distance to trailer centerline (3).
Ramp grade (4) shall not exceed 15. If the
ramps bend too much under the weight of
machine, supports must be placed under
the ramps to prevent their bending.
3. Remove the chains and wire ropes fasten-

ing the machine.
4. Start the engine and warm it up fully.

Fig. 4-111
5. Move the hydraulic lockout control to FREE
position (F).

6. Set the travel speed selector switch to low

speed (Lo).
Press travel speed button (6) to change

travel speed (Lo, Hi), which will be dis-
played at (5) on the display screen.
7. Press button (8) to turn off auto decelera-
tion. Use the fuel control dial to set engine
speed to low idle.
When machine is running in auto idle

mode, the screen displays at (7).
Press the button (8) again to cancel auto
idle. The screen will display at (5).
Auto idle is the default mode after the ma-
chine is started. Press the button (8) to
toggle between auto-idle and non auto-idle
.
Fig. 4-112
8. Raise the work equipment, retract the arm

below the boom, and drive the machine
slowly.
9. Stop the machine when it comes to the

rear wheels of the trailer and is positioned
horizontally.
Fig. 4-113
Remark:
Make sure to keep an angle of 90 - 110

between the arm and the boom when un-
loading the machine.
The machine could be damaged if it is un-
loaded with retracted arm.
When the machine runs on the access
ramp, never penetrate the bucket into
ground, which could damage the hy-
draulic cylinder. Fig. 4-114
10. While the machine is on the ramp, it is

important to keep an angle of 90 - 110

between the arm and the boom. Lower
the bucket to the ground and move the
machine slowly.
11. When the machine is going down the

ramp, slowly operate the boom and arm,
and carefully drive the machine off the
ramp. Fig. 4-115
4.18.3 Lifting the machine or its com-

ponents
WARNING
Using a single rope to lift an object is pos-

sible to cause turning of the load and un-
fastening or slipping of the rope. Serious
accidents could result.
4.18.3.1 Lifting precautions
1. Put wire rope on the middle of hook.
If wire rope is hooked near hook end, the

rope may slide off the hook, causing seri-
ous accident. The middle part of hook is
stronger than the rest parts.
Fig. 4-116
2. Never lift an object when wire rope forms

a bigger sling angle with the hook. If two
or more ropes are used, the load on each
rope increases with sling angle. The fol-
lowing table shows variation of allowable
load kN(kg) with different angles when
two ropes are used to lift a load. If a single
rope is capable of lifting 9.8 kN(1000 kg)
in vertical position, two ropes will be able
to lift 19.6 kN(1000 kg) perpendicularly.
However, when the two ropes forms a sling
angle of 120 degrees, its lifting capacity
becomes 9.8 kN(1000 kg). On the other Fig. 4-117

hand, if the sling angle is 150 degrees, to lift a load of 19.6 kN(1000 kg), each rope has to
bear 39.2 kN(1000 kg).
3. Never use a single rope to lift an object. Its better to bind the object with two or more rope
symmetrically.
4.18.3.2 Choosing a wire rope
Select a suitable wire rope according to the object to be lifted. See the table below.
Wire Rope
(Standard bright wire rope Z)
JISG3525No.66X37-A type
Wire Rope
Allowable Load
Nominal Diameter
mm kN Ton
10 8.8 0.9
12 12.7 1.3
14 17.3 1.7
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
Table 4-1
Note:
The allowable load equals to one sixth of the breaking force of wire rope. (Safety factor: 6)

4.18.3.3 Lifting the machine
WARNING
Only eligible, experienced operator with official license (according to local laws) is al-
lowed to operate a crane.
Never lift the machine when someone is riding on it.
Nobody shall be allowed to enter the area below or around the lifted machine.
Make sure that the wire cables used for lifting the machine are strong enough to bear
the weight of machine. Never use damaged or aged wire cable or sling.
Never lift the machine when its upper structure has swung aside. Before lifting, it is
important to move the work equipment to the final drive end and keep the longitudinal
centerlines of the upper structure and the lower structure parallel.
Before lifting, the lockout control must be put to "locked" position in order to prevent
unexpected movement of the machine.
Keep the machine parallel to the ground during lifting.
Never lift the machine at fast speed, which may otherwise overload the wire cables or
slings and result in rupture.
Besides the attitudes recommended in the following procedure, never use any other at-
titudes to lift the machine. Never use the type of lifting equipment other than the ones
specified in the following procedure. Otherwise it may have the danger to loose balance.
Note:
The lifting procedure is applicable to machines of standard dimension.
The lifting methods may vary according to actual additional and optional components installed.
Contact Sany distributor for suitable lifting methods.
For more information on the weight of machine see the section "Specification".
When lifting the machine, operate on a level ground according to the following steps.

Machine of standard dimension
1. Start the engine and swing the upper

structure in order to position the work
equipment at the side of the sprocket (1).
2. Fully extend the bucket cylinder and the

arm cylinder, and use the boom cylinder to
lower the work equipment to the ground,
as shown in the right illustration.
Fig. 4-118
3. Move the hydraulic lockout control to

"locked" position (L).
4. Shut off the engine. Check the surrounding

of the cab before leaving the machine.
Close the cab door and windows properly.
Fig. 4-119
5. Run a wire rope between the first two track

rollers and between the last two track
rollers. For machines installed with roller
guard, the ropes shall go through under
the tracks.
6. Adjust the wire rope lifting angle (A) to 30 -

40, and lift the machine slowly.
7. When the machine is above the ground,

make sure that the hook condition and
the lifting condition are normal, and lift the
machine slowly.
Fig. 4-120

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SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance
Maintenance
5 Maintenance
5.1 Maintenance Information ......................................................................................... 5-5
5.2 General Service ....................................................................................................... 5-9
5.2.1 Oil, fuel and coolant ....................................................................................... 5-9
5.2.1.1 Oil.......................................................................................................... 5-9
5.2.1.2 Fuel ..................................................................................................... 5-10
5.2.1.3 Coolant ................................................................................................5-11
5.2.2 Grease ......................................................................................................... 5-12
5.2.3 Oil and fuel storage ...................................................................................... 5-13
5.2.4 Filter element ............................................................................................... 5-13
5.2.5 Electrical system ......................................................................................... 5-14
5.2.6 Hydraulic system.......................................................................................... 5-14
5.3 Replacement Parts ................................................................................................ 5-16
5.4 Recommended Fluids ............................................................................................ 5-17
5.4.1 Fluid capacities ............................................................................................ 5-19
5.4.2 Recommended oils: .................................................................................... 5-20
5.5 Tightening Torque Specification ............................................................................. 5-22
5.6 Safety-Related Parts.............................................................................................. 5-24
5.7 Maintenance Schedule .......................................................................................... 5-25
5.7.1 List of maintenance schedule ...................................................................... 5-25
5.7.2 Hydraulic Breaker Service Interval............................................................... 5-27
5.8 Maintenance Procedures ....................................................................................... 5-28
5.8.1 Maintenance after initial 50 service hours.................................................... 5-28
5.8.1.1 Engine oil and filter - change/replace.................................................. 5-28
5.8.1.2 Fuel filter - replace ............................................................................. 5-28
5.8.2 When Required ............................................................................................ 5-29
Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator
5.8.2.1 Air cleaner - clean/replace .................................................................. 5-29

5.8.2.2 Cooling system - clean....................................................................... 5-37
5.8.2.3 Track shoe bolts - inspect/tighten ....................................................... 5-41
5.8.2.4 Track tension - inspect/adjust ............................................................. 5-42
5.8.2.5 Bucket tips (lateral pin) - replace ........................................................ 5-45
5.8.2.6 Bucket Replacement ........................................................................... 5-47
5.8.2.7 Bucket clearance - adjust.................................................................... 5-49
5.8.2.8 Window washer uid - check/refill ...................................................... 5-51
5.8.2.9 Air conditioner - inspect/service .......................................................... 5-52
5.8.2.10 Gas spring - inspect .......................................................................... 5-54
5.8.2.11 Air in hydraulic system - purge .......................................................... 5-55
5.8.2.12 Hydraulic circuit internal pressure - release ...................................... 5-58
5.8.3 Checks before starting ................................................................................. 5-59
5.8.4.1 Lubrication .......................................................................................... 5-60
5.8.5.1 Compressor belt tension - inspect/adjust ............................................ 5-63
5.8.5.2 Oil in engine oil pan and oil filter - change/replace ............................. 5-65
5.8.5.3 Primary fuel filter - replace .................................................................. 5-67
5.8.5.4 Secondary fuel filter - replace ............................................................. 5-71
5.8.6.1 Swing bearing - lubricate .................................................................... 5-74
5.8.6.2 Swing pinion gear grease - check/refill ............................................... 5-75
5.8.6.3 Coolant tank and radiator fins - inspect/clean ..................................... 5-76
5.8.6.4 Air conditioner filters - clean ................................................................ 5-77
5.8.6.5 Swing drive oil - check/refill................................................................. 5-80
5.8.6.6 Final drive oil - check/fill ...................................................................... 5-81
5.8.7.1 Hydraulic oil filter - replace.................................................................. 5-82
5.8.7.2 Swing drive oil - change ...................................................................... 5-84
5.8.7.3 Engine exhaust pipe clamps - check .................................................. 5-85
5.8.7.4 Fan belt tension - check/replace ......................................................... 5-85
5.8.7.5 Nitrogen pressure in accumulator (breaker) - check ........................... 5-85
5.8.8.1 Final drive oil - change ........................................................................ 5-86
5.8.8.2 Hydraulic tank filter screen - clean ...................................................... 5-88

5.8.8.3 Nitrogen pressure in accumulator (control oil circuit) - check ............. 5-89
5.8.8.4 Hydraulic circuit internal pressure - release ........................................ 5-92
5.8.8.5 Oil in hydraulic tank - change.............................................................. 5-93
5.8.8.6 Alternator - inspect .............................................................................. 5-95
5.8.8.7 Engine valve clearance - check/adjust................................................ 5-95
5.8.9.1 Coolant pump - inspect ....................................................................... 5-95
5.8.9.2 Start motor - check.............................................................................. 5-95
5.8.9.3 Accumulator (control oil circuit) - replace ............................................ 5-96
5.8.9.4 High-pressure tube clamps and rubber - check .................................. 5-97
5.8.9.5 Compressor working condition - inspect ............................................. 5-97
5.8.10 Every 8000 service hours .......................................................................... 5-98
5.8.10.1 High-pressure tube clamps - replace ................................................ 5-98
5.8.11 Every 10000 service hours......................................................................... 5-98


5 MAINTENANCE
5.1 Maintenance Information

Never conduct any inspection and mainte-
nance work other than the scope specified in
this manual.
Hour meter reading

Keep track of the hour meter reading on a
daily basis. Make sure whether it is time to
perform the required maintenance.
Genuine Sany replacement parts

Always use genuine Sany replacement parts
listed in the Parts Manual.
Genuine Sany lubricants

Always use genuine Sany engine oil and
grease. Select engine oil and grease of suit-
able viscosity according to ambient tempera-
ture.
Window washer fluid

Use automotive windshield washer fluid only,
which shall not be contaminated by foreign
substances.
Oil and lubricants

Always use clean oils and greases. Keep the
oil reservoir and grease reservoir clean, which
shall be free from any impurities.
Drained oil and used filter element

After changing the oil and replacing the filter
element, check the used oil and filter element
for signs metal particles and foreign mate-
rial. If large amount of metal particles and/or
impurities are found in the used oil and filter
element, report to the personnel in charge and
take proper measures.

Primary fuel filter

Primary Fuel Filter must be installed before fill-
ing the fuel.
Welding instruction
Turn off the engine start switch and wait for
1 minute before disconnecting the negative
(-) terminal of the battery.
Connect the ground cable of the welder at
least 1 m (3.3 ft.) away from the place be-
ing welded.
If the ground cable is connected to any
electrical components (instrument, con-
nector, etc.), the instrument will be out of
function. If there are any seals or bearings
between the weld and the grounding point,
choose another grounding point away from
these parts.
Never use a grounding point in the vicinity
of the work equipment pin or hydraulic cyl-
inder .
Never apply more than 200V continuously.
Preventing things from falling into machine

When opening the access window or tank
filler for inspection, make sure that the
nuts, bolts or tools are not left inside the
machine. Failure to do so could result in
unexpected failure or damage to the ma-
chine, or accidents. In case that any mate-
rials fall into the machine, remove it imme-
diately.
Never carry unnecessary items in your
pockets except those necessary for inspec-
tion.
Dusty work site

Observe the following items before working in
a dusty place.
When inspecting your machine or chang-

ing the oil, park your machine in a dust-

free place in order to prevent dust from

getting into the oil.
Clean the air filter cartridge immediately if
the filter's alarm indicates clogging.
Clean the fins and other heat exchanger
parts frequently to avoid them being
clogged.
Clean and replace the fuel filter frequently.
Clean the electrical components, espe-
cially the start motor and the alternator, to
prevent dust from building up on them.
Lubricants of different brands

Never mix lubricants of different brands and/or
grades together. If you need to use the lubri-
cant of another brand or grade, drain the old
lubricant completely and replace with the new
brand.
Securing access cover

When servicing the machine with the access
covers open, use a locking lever to secure the
cover to certain position. Otherwise, the cover
can be swung close by wind and cause bodily
injury.
Purging air from hydraulic system

When any hydraulic units have been repaired
or replaced or any hydraulic lines have been
removed or installed, always bleed the air from
the system. For more information see "Air in
hydraulic system - purge."
Connecting hydraulic hoses

In removal of parts with O-rings or gaskets,
clean the installation surfaces and replace
with new parts. Remember to install the O-
rings or gaskets.
Never twist or bend the hydraulic hoses
when assembling. Failure to do so could
cause damage to the hoses and consider-
ably reduce their service life.

After inspection and maintenance

If no checks have been made after inspection
and maintenance, unexpected failure may oc-
cur, causing severe injury or damage. The fol-
lowing items must be observed:
Checks when machine is running.

For more information on checks during
engine operation see "Maintenance dur-
ing Engine Running." Be alert to your
safety in the meantime.
Whether the checked or maintained
parts work normally.
Whether oil leakage occurs when the
engine speed increases and the oil is
under pressure.
Checks after the operation (when the en-
gine has been shut down)
Whether you have missed the items to
be checked or maintained.
Whether all the checks and mainte-
nance have been performed correctly.
Whether any tools and parts are left in
the machine. It is very dangerous to
have a foreign object blocked in the link-
age.
Whether leakage of water or oil occurs;
whether all the bolts have been screwed
tightly.
Closing engine hood properly

When the engine hood is closed after inspec-
tion and maintenance, hold the lever and lift
the engine hood slightly in order to check
whether the lock is securely engaged. An un-
locked hood may be opened and cause acci-
dents.

5.2 General Service

Use genuine Sany replacement parts,
grease and oil.
Never change or refill oil with a different
type. When different oil is to be used, the
used oil must be drained completely before
filling the fresh oil. Meanwhile, the oil filter
must be replaced. (A small amount of used
oil remaining in the lines would affect noth-
ing.)
Unless specified otherwise, your machine
contains the following oils and coolants
when delivered from the factory.
Item Type
Engine Oil Pan Diesel Oil CH-4 15W-40
Swing Drive
Gear Oil 85W/140
Final Drive
Hydraulic System Caltex HDZ46
Radiator TEEC-L35 antifreeze
Table 5-1
5.2.1 Oil, fuel and coolant
5.2.1.1 Oil
The oils in engine and hydraulic units keep

deteriorating when operating your machine
under extreme conditions, such as high
pressure and high temperature.
Always use the type of oil recommended
in the "Maintenance Section", which shall
also be applicable under extreme ambient
temperatures.
Within the specified oil change interval, the
oil must be changed even if it is not dirty.
Like the blood in human body, lubricant
shall be handled carefully in order to pre-
vent impurities such as water, metal par-
ticles and dust.

Most troubles of the machine are caused

by impurities.
Pay special attention to the prevention of
any impurities when storing or filling the oil.
Fill the amount of oil as specified. Failure
to do so could result in abnormality.
Never mix oils of different grades or brands
together.
Contact your Sany distributor when the oil
in your work equipment has been contami-
nated by water or air.
To know the condition of your machine,
regular oil quality analysis is recommend-
ed. Contact your Sany distributor if you
need such service.
Related filter elements must be replaced
when changing the oil. In replacement of
engine oil filter element, acceptable clean
oil shall be filled into the new filter element
prior to installation.
Use the oils approved by Sany.
Never use the hydraulic oil that has not
been approved by Sany, which can block
filter cartridge.
Remove the remaining oil as much as pos-
sible from the lines and cylinders when
changing the hydraulic oil. A small amount
of different residual is acceptable.
5.2.1.2 Fuel
To prevent the moisture in air from con-

densing in the fuel tank, the tank must be
fully refueled after each workday.
The fuel injection pump is a precise com-
ponent, which may not work normally if the
fuel contains water or other foreign sub-
stances.
The sediment and water in the fuel tank
must be drained before starting the engine
or after 10 minutes since injection of oil.

Flush the fuel tank and the fuel system

in case of any impurities found in the fuel
tank.
The air in fuel path must be eliminated in
case that the engine runs out of fuel or the
filter cartridge has been replaced.
Always use the type of fuel specified in the
"Maintenance Section."
The fuel can freeze below the speci-
fied temperature (especially lower than
-15C (5F)).
When the fuel is used above the speci-
fied temperature, its viscosity and out-
put power will decrease .
Pay special attention to prevention of
impurities when storing or refilling the
fuel.
Note:
Always use diesel oil as the fuel.
To ensure favorable consumption and exhaust

of the fuel, the engine installed to your ma-
chine uses high-pressure oil injection unit with
mechanical control. The unit contains high-
precision components that require high-quality
lubrication. Therefore, the use of low-viscosity
fuel with low lubricating capability will consid-
erably reduce the service life of the unit.
5.2.1.3 Coolant
The coolant is also an important fluid

against corrosion and freezing.
Anti-freezing coolant is also necessary in
regions where freezing prevention is un-
necessary.
Sany machines are prefilled with TEEC-

L35 antifreeze, which has excellent perfor-
mance in anticorrosion, anti-freezing and
cooling, and can last for 1 year or 2000

hours.
As a basic principle, we do not recommend

you using coolants other than TEEC-L35
antifreeze. The use of other coolants is
possible to cause serious problems, such
as corrosion of the light metal parts of the
engine and cooling system.
Use distilled water or tap water (softened

water) to dilute anti-freezing coolant.
Natural water, such as river water and well
water (hard water), contains large amount
of minerals (calcium, magnesium, etc.),
which can easily scale in the engine and
radiator. The scale is hardly removed once
formed in the engine and radiator. Over-
heat can occur due to unfavorable heat
exchange. The water with overall hardness
lower than 10 PPM is recommended when
diluting the coolant.
Precautions in this manual must be fol-

lowed when using antifreeze.
Anti-freezing coolant is ammable. There-
fore, it must be kept away from naked fire.
If the engine is overheating, wait for the
engine to cool down before refilling cool-
ant.
Overheat can be caused if the coolant
level is low. In addition, the air trapped in
coolant can result in corrosion problem.
5.2.2 Grease
Grease is used to prevent distortion and

noise of joints.
It is necessary to add grease to any com-
ponent that appears inexible or noisy after
operation for a long period.
Always use the recommended greases.
Select the grease according to change
interval and ambient temperature recom-

mended in this manual.

Wipe off the used grease that has been
squeezed out when greasing. Make sure
to wipe off the used grease that has been
contaminated by sand or debris, which can
otherwise lead to wear of rotating compo-
nents.
5.2.3 Oil and fuel storage
Store the oils and fuel indoors in order to

keep them free from water, dust and other
foreign substances.
To store the barrel of oil or fuel for a
long period, it is necessary to place the
barrel with its opening facing the side
in order to prevent intake of moisture.
If you have to place the barrels outdoors,
cover them properly with waterproof can-
vas or take other protective measures.
To prevent deterioration of oil or fuel during
long-term storage, use the oil or fuel that
has been stored earlier than others.
5.2.4 Filter element
Filter element is extremely important for

safety. It can prevent failures by keep-
ing important devices free from impurities
coming from oil path or air path. All filter el-
ements must be replaced regularly. When
operating in unfavorable conditions, the
filter elements shall be replaced more fre-
quently according to the sulfur content in
lubricant and fuel.
Never use an element that has been
cleaned. Replace it with a new one.
In replacement of filter element, check the
element for attached metal particles. Con-
tact your Sany distributor if metal particles
are found.
Never open the package of a spare ele-
ment when it is in storage.

Use genuine Sany elements.
5.2.5 Electrical system
Humid electrical devices or damaged wire

can cause short circuit and machine fail-
ure. Never flush the interior of your cab
with water. When flushing your machine,
be careful with water, which shall not pen-
etrate into the electrical components.
Electrical system maintenance correlates
to checking the tension, damage or wear of
fan belt.
Never install any other electrical compo-
nents except those specified by Sany.
External electromagnetic interference can
cause failure of system controller. Contact
your Sany distributor before installing radio
receiver or other wireless devices.
Operating on beach requires cleaning the
electrical system thoroughly in order to
prevent corrosion.
When installing an electrical device,
connect it to dedicated power source.
Never connect other power sources to the
fuse, start switch or battery relay.
5.2.6 Hydraulic system
During operation and immediately after opera-

tion is ended, the temperature of the hydraulic
system still remains high.
In addition, high hydraulic pressure is applied

to the system. Take care when inspecting and
maintaining the hydraulic system.
Stop the machine on lever ground; lower the

bucket to the ground, then set so that there is
no pressure applied to the cylinder circuit.
Always stop the engine Immediately after op-

erations, the hydraulic oil and lubricating oil

are at high temperature and high pressure, so

wait for the oil temperature to go down before
starting maintenance.
Even when the temperature goes down, the

circuit may still be under internal pressure, so
when loosening the plug or screw, or the hose
joint, do not stand in front of the part. Loosen it
slowly to release the internal pressure before
removing it.
When carrying out inspection or maintenance

of the hydraulic circuit, always bleed the air
from the hydraulic tank to remove the internal
pressure.
Periodic maintenance includes the inspection

of the hydraulic oil lever, replacement of the
filter and refilling of hydraulic oil.
When the high pressure hose, etc. Is removed,

check the O-ring for damage. If necessary, re-
place it.
After the hydraulic filter element and strainer

are cleaned or replaced, or after the hydraulic
system is repaired of replaced or the hydraulic
piping is removed, bleed air from the hydraulic
circuit.
The accumulator is charged with high-pres-

sure nitrogen gas. Incorrect handling may be
dangerous.
For the handling procedure Accumulator

on page 2-67.

5.3 Replacement Parts

Replacement parts, such as filter element and bucket tips, should be replaced according to
maintenance schedule or before the wearing limits are reached.
Replacement parts shall be replaced properly in order to use your machine economically.
Select Sany genuine quality parts for replacement.
Check the part number in the Parts Manual when ordering a part.
Also replace the part in brackets.
Component Part Number Part Qty Interval
Fuel filter, pri- 60064761(SY115C9, SY135C8/C9, SY155H)

Filter element 1 Every 250 hours
mary 60033346(SY135C8(M))
B222100000453(SY115C9, SY135C8/C9,
Fuel filter, sec-
SY155H) Filter 1 Every 250 hours
ondary
B222100000415(SY135C8(M))
B222100000488(SY115C9, SY135C8/C9,
Oil filter SY155H) Filter 1 Every 250 hours
B222100000386(SY135C8(M))
Filter element 1
Pilot filter B229900000063 Every 500 hours
(O-ring seal) (1)
Filter element,
Hydraulic oil 60101257 oil suction 1
Every 1000 hours
filter 60101256 Filter element, (1)
oil return
Air filter, main B222100000500 Filter element 1
Air filter, safety B222100000501 Filter element 1
Breather valve
60174894 Filter element 1 Every 1500 hours
filter element
Lateral pin
60102737 Bucket tips 5
(60102738) (Pin group) (5)
Bucket
A229900007131 Left cutter 1
(SY115C)
A229900007130 Right cutter 1
(A210111000301) (Bolt) (8)
(A210307000006) (Nut) (8)
Lateral pin
(10143975) (Pin) (4)
Bucket
(SY135C8)
(A210111000301) (Bolt) (8)
(A210307000006) (Nut) (8)

Component Part Number Part Qty Interval

Lateral pin
(10143975) (Pin) (4)
A229900005244 Tip adaptor 4
Bucket
A229900005241 Tip pin 4
(SY135C9)
A210111000301 (Bolt) (8)
60012073 (Nut) (8)
Lateral pin
(A229900005241) (Pin) (4)
Bucket
(SY155H)
(A210111000301) (Bolt) (8)
(A210307000006) (Nut) (8)
5.4 Recommended Fluids

To keep your machine at the maximum state for a long period of time, it is necessary follow
the oil instructions described in this manual. Failure to do so can cause overwear and service
life reduction of the engine, power train, cooling system and other components.
The additives available in market could benefit your machine, but they could impair your ma-
chine as well. We do not recommend any lubricant additives.
The specific capacity refers to the overall oil volume in tanks and lines. Supplementary vol-
ume refers to the amount of oil used to make up the system in inspection and maintenance.
The use of multigrade oils is strongly recommended when starting the engine at temperatures
below 0C (32F), even if the daytime temperatures rise above 0C(32F).
Use the recommended oils according the ambient temperatures given in the following table.
When the sulfur content of fuel is less than 0.5%, change the fuel according to the required
maintenance interval given in this manual. If the sulfur content is more than 0.5%, change the
fuel according to the following table:
Sulfur Content in Fuel Oil-Change Interval - Engine Oil Pan

0.5 - 1.0% 1/2 of standard interval
More than 1.0% 1/4 of standard interval
Table 5-2

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

5.4.1 Fluid capacities
Engine Oil Hydraulic Cooling Sys-

Swing Drive Final Drive Fuel Tank
Pan* System tem
L 13.2(*) 3.0 2.5 150 16 240
US gal 3.5 0.79 0.66 39.62 4.23 63.4
Note:
* Capacity of engine oil pan on SY135C8M is 15 L (3.98 US gal).
Always use diesel oil as the fuel.
To ensure favorable consumption and exhaust of the fuel, the engine installed to your machine
uses high-pressure oil injection unit with mechanical control. The unit contains high-precision
components that require high-quality lubrication. Therefore, the use of low-viscosity fuel with low
lubricating capability will considerably reduce the service life of the unit.
Note 1: The HTHS (high-temperature high-shear viscosity at 150C) required by ASTM D4741
must be equal to or more than 3.5 mPa-S. Sany strongly recommend the use of engine
oil 15W-40.
Note 2: Coolant
1) The coolant is also an important uid against corrosion and freezing.

Antifreezing coolant is also necessary in regions where freezing prevention is unnecessary.
Sany machines are prefilled with TEEC-L35 antifreeze, which has excellent performance in
anticorrosion, antifreezing and cooling.
2) For more information on diluting TEEC-L35 antifreeze with water see Cooling system -
clean on page 5-37.
3) The proper concentration of coolant must be kept in order to ensure the coolant's performance
against corrosion.
Recommended brands and quality of recommended products besides Sany genuine oils
Consult your Sany distributor before using any oils other than those recommended by Sany.

5.4.2 Recommended oils:
1. Engine oil
Select the oil of proper viscosity according

to the temperature range given in the oil
change schedule.
Engine oil grade: Above API CF-4
Recommended engine oil brand and type:
Caltex CH-4 15W-40
2. Engine fuel
Light diesel oil (GB252.81)
In most cases, the use of fuel ASTH2

and the diesel oil (minimum cetane
number is 40) can achieve the best
economic result and operating perfor-
mance. At where the elevation is high or
the ambient temperature is too low, it is
necessary to use the fuel whose cetane
number is more than 40 in order to pre-
vent ameout and too much smoke.
When the fuel of low sulfur content is
used, its cloud point shall be at lease
10C lower than the expected minimum
fuel temperature. Cloud point is the
temperature at which the waxy crystals
begin to form.
The universal diesel fuel of commercial
brands shall contain sulfur that is less
than 0.5%.
Clean fuel free from water and/or impu-
rities shall be ensured before refueling.
3. Hydraulic oil
The hydraulic system uses Caltex HDZ46

hydraulic oil (code B420106000036).
When the ambient temperature is below

0C, the following items have to be fol-
lowed to heat the hydraulic system in order

to ensure the safety of the hydraulic sys-

tem.
Run the engine at idle speed for 7-10

minutes before increasing its rpm to
1000 - 1200. Never operate your exca-
vator except running the engine unload-
ed for 30-40 minutes or longer in order
to heat the hydraulic oil to a tempera-
ture above 20C.
Now your machine can be used for
normal construction operation after the
hydraulic oil temperature rises above
20C. However, the heating time shall
be adjusted according to ambient tem-
perature. In normal construction work,
the joystick controls and pedals shall be
maneuvered slowly while paying close
attention to the system's running condi-
tion. Operating your machine with the
hydraulic oil temperature being below
20C could damage the hydraulic ele-
ments.
Anti-friction hydraulic oil L-HM46 is
widely used in temperate zones.
Low-temperature, anti-friction hydraulic
oil L-HV32, whose pour point is -42C,
is used in extremely cold regions (below
-30C) such as Russia and Northeast
China.
Anti-friction hydraulic oil L-HM68 is gen-
erally used in torrid regions such as the
Middle East and India.
Select proper hydraulic oil according to
the region where your machine is to be
operated. The machine has been filled
with hydraulic oil of suitable brand and
type before it is delivered. User is re-
sponsible to change the oil after the ma-
chine is delivered. You may consult our
after-sale service personnel to obtain
correct brand and type of the hydraulic
oil.

5.5 Tightening Torque Specification
NOTICE
The nuts, bolts or other parts having not been tightened to specific torque values can
lead to loose or damaged parts, hence resulting in machine failure and operating trou-
bles.
Special attention shall be paid when tightening any parts.
Unless specified otherwise, the metric nuts

and bolts shall be tightened to the values giv-
en in the following table.
The tightening of torque is determined by the

width of screw cap or nut.
In replacement of the bolts or nuts, use Sany

genuine parts of equivalent size. Fig. 5-1
Thread Square Tightening Torques

Diameter Size
Target Values Torque Limits
a b
(mm) (mm) Nm kgfm lbft Nm kgfm lbft
6 10 13.2 1.35 9.8 11.8 - 14.7 1.2 - 1.5 8.7 - 10.8
8 13 31 3.2 23.1 27 - 34 2.8 - 3.5 20.3 - 25.3
10 17 66 6.7 48.5 59 - 74 6.0 - 7.5 43.4 - 54.2
12 19 113 11.5 83.2 98 - 123 10.0 - 12.5 72.3 - 90.4
14 22 177 18 130.2 157 - 196 16.0 - 20.0 115.7 - 144.7
16 24 279 28.5 206.1 245 - 309 25.0 - 31.5 180.8 - 227.8
18 27 382 39 282.1 343 - 425 35.0 - 43.5 253.2 - 314.6
20 30 549 56 405 490 - 608 50.0 - 62.0 361.7 - 448.4
22 32 745 76 549.7 662 - 829 67.5 - 84.5 488.2 - 611.2
24 36 927 94.5 683.5 824 - 1030 84.0 - 105.0 607.6 - 759.5
27 41 1320 135 976.5 1180 - 1470 120.0 - 150.0 868.0 - 1085.0
30 46 1720 175 1265.8 1520 - 1910 155.0 - 195.0 1121.1 - 1410.4
33 50 2210 225 1627.4 1960 - 2450 200.0 - 250.0 1446.6 - 1808.3
36 55 2750 280 2025.2 2450 - 3040 250.0 - 310.0 1808.3 - 2242.2
39 60 3280 335 2423.1 2890 - 3630 295.0 - 370.0 2133.7 - 2676.2
Table 5-4

Hydraulic hoses are tightened according to the

torques given below.
Fig. 5-2
Nominal Thread Tightening Torques

Square Size
Number Target Values Permissible Range
(b)(mm)
(a) Nm kgfm lbft Nm kgfm lbft
9/16-18UNF 19 44 4.5 32.5 35-63 3.5-6.5 25.3-47
11/16-16UN 22 74 7.5 54.2 54-93 5.5-9.5 39.8-68.7
13/16-16UN 27 103 10.5 75.9 84-132 8.5-13.5 61.5-97.6
1-14UNS 32 157 16.0 115.7 128-186 13.0-19.0 94-137.4
13/16-12UN 36 216 22.0 159.1 177-245 18.0-25.0 130.2 -180.8
1 -7/16 - 12UN
41 215 22.0 159.1 176-234 18.0-24.0 130.2-180.8
- 2B
Table 5-5
Note: The item marked with is used for tightening the hose on top of the swivel joint.

5.6 Safety-Related Parts

To ensure your safety during operating or driving the machine, user shall carry out regular main-
tenance on the machine. In addition, user shall also replace the parts listed in the table in order to
further improve the safety condition. These parts are closely related to safety and fire prevention.
Since the safety-related parts may become easily worn or deteriorated due to material changing
along with the time, it is hard to judge their conditions through regular maintenance. These parts
shall be replaced as scheduled regardless of their conditions, which can effectively guarantee the
functions of these parts.
If any safety-related part becomes abnormal before its scheduled replacement, it must be re-
paired or replaced immediately.
If any hose deteriorates, such as deforming or cracking, the hose clamps shall also be replaced
while replacing the hose.
O-ring, gasket and other similar parts shall also be replaced while replacing a hose.
Consult your Sany distributor to replace the following safety-related parts on a regular basis.
No. Safety-related parts subject to regular replacement Quantity Frequency

1 Fuel hose (fuel tank - water separator) 1
2 Fuel hose (water separator - primary filter) 1
3 Fuel return hose (engine - fuel tank) 1
4 Fuel hose (primary filter - engine) 1
5 Pump outlet hose (pump - control valve) 2
6 Work equipment hose (boom cylinder oil inlet) 4
7 Work equipment hose (Bucket cylinder line - boom root) 2 Every 2 years
8 Work equipment hose (bucket cylinder oil inlet) 2 or 4000 hours,
9 Work equipment hose (arm cylinder line - boom root) 2 whichever occurs
10 Work equipment hose (arm cylinder oil inlet) 2 first.
11 Swing drive hose (swing motor oil inlet) 2

12 Main oil suction hose 1
13 Travel control hose (control valve - swivel joint) 4
14 Travel control hose (swivel joint - travel motor) 4
15 Pump pressure hose 1
16 Accumulator (control oil) 1
17 High-pressure tube clamps 1
Every 8000 hours
18 Cover - fuel squirt prevention 1
19 Seat belt 1 Every 3 years
Table 5-6

5.7 Maintenance Schedule

If your machine is equipped with hydraulic breaker, the maintenance schedule for some parts
may vary. For more information and proper maintenance see "Hydraulic Breaker Maintenance
Schedule."
5.7.1 List of maintenance schedule
Maintenance after initial 50 service hours ............................................................................ 5-28
Engine oil and filter - change/replace ........................................................................................ 5-28

Fuel filter - replace .................................................................................................................... 5-28
When Required ........................................................................................................................ 5-29
Air cleaner - clean/replace ......................................................................................................... 5-29

Cooling system - clean ............................................................................................................. 5-37
Track shoe bolts - inspect/tighten .............................................................................................. 5-41
Track tension - inspect/adjust .................................................................................................... 5-42
Bucket tips (lateral pin) - replace ............................................................................................... 5-45
Bucket Replacement ................................................................................................................. 5-47
Bucket clearance - adjust .......................................................................................................... 5-49
Window washer uid - check/refill ............................................................................................ 5-51
Air conditioner - inspect/service................................................................................................. 5-52
Gas spring - inspect................................................................................................................... 5-54
Air in hydraulic system - purge .................................................................................................. 5-55
Hydraulic circuit internal pressure - release .............................................................................. 5-58
Checks before starting............................................................................................................ 5-59
Every 100 service hours ......................................................................................................... 5-60
Lubrication ................................................................................................................................. 5-60
Compressor belt tension - inspect/adjust .................................................................................. 5-63

Oil in engine oil pan and oil filter - change/replace .................................................................... 5-65
Primary fuel filter - replace......................................................................................................... 5-67
Secondary fuel filter - replace .................................................................................................... 5-71

Swing bearing - lubricate ........................................................................................................... 5-74

Swing pinion gear grease - check/refill ...................................................................................... 5-75
Coolant tank and radiator fins - inspect/clean ........................................................................... 5-76
Air conditioner filters - clean ...................................................................................................... 5-77
Swing drive oil - check/refill ....................................................................................................... 5-80
Final drive oil - check/fill ............................................................................................................ 5-81
Every 1000 service hours ....................................................................................................... 5-82
Hydraulic oil filter - replace ........................................................................................................ 5-82

Swing drive oil - change ............................................................................................................ 5-84
Engine exhaust pipe clamps - check ......................................................................................... 5-85
Fan belt tension - check/replace................................................................................................ 5-85
Nitrogen pressure in accumulator (breaker) - check ................................................................. 5-85
Final drive oil - change .............................................................................................................. 5-86

Hydraulic tank filter screen - clean ............................................................................................ 5-88
Nitrogen pressure in accumulator (control oil circuit) - check .................................................... 5-89
Hydraulic circuit internal pressure - release .............................................................................. 5-92
Oil in hydraulic tank - change .................................................................................................... 5-93
Alternator - inspect .................................................................................................................... 5-95
Engine valve clearance - check/adjust ...................................................................................... 5-95
Coolant pump - inspect.............................................................................................................. 5-95

Start motor - check .................................................................................................................... 5-95
Accumulator (control oil circuit) - replace .................................................................................. 5-96
High-pressure tube clamps and rubber - check......................................................................... 5-97
Compressor working condition - inspect.................................................................................... 5-97
High-pressure tube clamps - replace......................................................................................... 5-98
Every 10000 service hours ..................................................................................................... 5-98

5.7.2 Hydraulic Breaker Service Interval
For machines equipped with a hydraulic

breaker, the hydraulic oil deteriorates faster
than that of machines operating with a bucket.
In this case, the following steps shall be fol-
lowed in order to adjust the service intervals.
Change hydraulic filter element

For a new machine, the filter element is to
be replaced after the first 100-150 service
hours. Subsequent replacement shall be
carried out according to the right chart.
Change the oil of hydraulic tank

Change the oil according to the right chart.
Replace the additional filter element (if

equipped) of the breaker
Replace the pilot filter element (if
equipped).
Fig. 5-3
The filter element is to be replaced accord-
ing the right chart when the breaker has
served for 250 hours (breaker operating
proportion more 50%).
Remark:
100% breaker operation means that the break-

er is used all the time, while 0% means that
the breaker never used.

5.8 Maintenance Procedures
5.8.1 Maintenance after initial 50 ser-

vice hours
The following maintenance is to be carried out

after initial 50 service hours.
Consult your Sany distributor for special tools

used for checks and maintenance.
5.8.1.1 Engine oil and filter - change/

replace
For the procedures of changing engine oil and

replacing oil filter see Oil in engine oil pan
and oil filter - change/replaceon page 5-65.
5.8.1.2 Fuel filter - replace
For the procedures of replacing fuel filters see

Primary fuel filter - replaceon page 5-67
and Secondary fuel filter - replace on
page 5-71.

5.8.2 When Required
5.8.2.1 Air cleaner - clean/replace
WARNING
If you check, clean and replace the filter

when the engine is running, dust may
invade the engine and cause damage.
Shut down the engine before doing this
job.
The sealing rubber of the end cap must
be held tightly against the filter.
The use of compressed air could cause
debris to fly out and result in personal
injury.
Always wear goggles, dust-proof mask
or other protective gear.
It is dangerous to pull out the outer filer
element with force. When you work on a
overhead place or at where you cannot
stand firmly, be careful that the counter-
acting force resulted from pulling of the
outer filter element could cause you to
fall.
Always prepare your machine as required

and lock/tag it out before proceeding. See
Preparing the machine on page 2-58 and
Lock-out and tag-out on page 2-60.

Replacement
Replace filter elements.

If the filter has been used for more than a
year or cleaned for more than six times, re-
place the outer filter element (5) and inner
filter element (6) together.
Replace vacuum valve.

If rubber seal is broken or deformed con-
siderably, replace the vacuum valve (4).
Fig. 5-4
Cleaning the outer filter element
Note:
Never place the filter under direct sunlight be-

fore and after cleaning.
1. Open the left rear door of the machine and

loosen the four latches (2) to remove the
cover (3).
Fig. 5-6
Note:
Never disassemble the secondary air

cleaner element (6), which will allow dirt to
pass through and cause engine failure.
Never use a screwdriver or other tools.
Fig. 5-5

2. Hold the primary air cleaner element (5),

shake it slightly and turn it in both direc-
tions in order to pull it out.
3. After removing the primary air cleaner ele-

ment (5), check the secondary air cleaner
element to see if it displaces or tilts. Push
it back to position in case of displacement
or tilting.
4. After removal of the primary air cleaner

element (5), use clean cloth or tape to
cover the secondary air cleaner element (6)
in order to prevent entering of dirt.
5. Wipe or brush off the dirt from the cover (3)

and the inside of air cleaner housing (1).
6. Wipe off the dirt built up on the cover (3)

and the vacuum valve (4).
Fig. 5-7
Note:
Never tap the air filter with any object when

cleaning it.
7. Use dry compressed air (less than 0.69

MPa (7kgf/cm2) 99.4 PSI)) to blow along
the inside of the pleats toward the primary
air cleaner element, and then direct the
compressed air along the outside of the
pleats to blow from interior to exterior.
1) Replace the primary air cleaner ele-

ments that have been cleaned six times
or used for more than a year. Replace Fig. 5-8
the secondary air cleaner element at the
same time.
2) Remove one of the tags from the filter

after each cleaning.

8. Use a light to illuminate the whole primary

air cleaner element. Replace the primary
air cleaner element in case of holes or
reduced thickness found in the filter mate-
rial.
9. Remove the cloth or tape covering the

inner filter element (6).
Note: Fig. 5-9

Never use air cleaner elements with dam-
aged pleats, gaskets or seals.
Using a filter that has been used for more
than a year or an O-ring that has been
cleaned could result failure. Never use
them again.
10. Check the new filter or the cleaned filter for
dirt or oil stains on the sealing area. Wipe
off the dirt or oil stains.
11. Push the primary air cleaner element

straight forward into the air cleaner hous-
ing. You can hold the primary air cleaner
element and shake it slightly in order to
insert the primary air cleaner element eas-
ily.
Note:
The air cleaner must be reinstalled correctly.

Make sure that the air cleaner cartridge's bot-
tom (the end without opening) (B) (C) faces
the cover (3). Incorrect installation could result
in air filter damage and engine damage.
Fig. 5-10

Note:
The latches (2) and housing of air cleaner

could be damaged when you insert filter ele-
ment with expanded rubber on the top or you
did not push it in vertically but latch the cover
(3) with force. So be careful when you reas-
semble filter element.
Fig. 5-11
12. Install the cover (3) according to the follow-

ing steps.
1) Align the cover (3) with the filter.
2) Let the end of latch (2) catch the ange

of the air cleaner housing.
3) To lock the latches (2), engage the

latches in a diagonal sequence (top -
bottom - left - right) like tightening the Fig. 5-12
bolts.
4) The vacuum valve (4) shall face toward

the ground (A) when installing the cover
(3).
5) When the cover (3) is installed, inspect

the air cleaner housing shall not have
a larger clearance with the cover (3).
Reinstallation is necessary in case of
larger clearance.

Replacing filter elements
1. Open the left rear door of the machine and

loosen the four latches (2) before removing
the cover (3).
Fig. 5-14
2. Hold the outer filter element (5), shake

it slightly and turn it in both directions in
order to pull it out. Never remove the inner
filter element (6).
3. After removing the outer filter element (5),

check the inner filter element to see if it
displaces or tilts. Push it back to position in
case of displacement or tilting.
Fig. 5-15
4. Wipe or brush off the dirt from the cover (3)

and the inside of air filter housing (1).
5. Wipe off the dirt built up on the cover (3)

and the vacuum valve (4).
Fig. 5-13

Note:
Never use the inner filter element after

cleaning it. Replace the inner filter element
while the outer filter element is replaced.
When the outer filter element and the cover
have been installed, improper installation
of the inner filter element could damage
the outer filter element.
Fake parts will allow dirt to pass through
and damage the engine due to insufficient
precision in the sealing area. Therefore,
fake parts shall not be used under any cir-
cumstances.
6. Remove the secondary air cleaner element
(6) and install a new secondary air cleaner
element immediately.
Insert the secondary air cleaner element

securely.
7. Push the primary air cleaner element (5)

straightly into the air cleaner housing.
When pushing the primary air cleaner ele-

ment, you may hold the primary air cleaner
element and shake it slightly in order to
make the insertion easily.
Note:
The air cleaner must be reinstalled correctly.

Make sure that the air cleaner cartridge's bot-
tom (the end without opening) (B) (C) faces
the cover (3). Incorrect installation could result
in air filter damage and engine damage.
Fig. 5-16

Note:
The latches (2) and housing of air cleaner

could be damaged when you insert filter ele-
ment with expanded rubber on the top or you
did not push it in vertically but latch the cover
(3) with force. So be careful when you reas-
semble filter element.
Fig. 5-17
8. Install the filter cover (3) through the fol-

lowing steps.
1) Align the cover (3) with the filter.
2) Let the end of latch (2) catch the ange

of the air cleaner housing.
3) To lock the latches (2), engage the

latches in a diagonal sequence (top -
bottom - left - right) like tightening the Fig. 5-18
bolts.
4) The vacuum valve (4) shall face toward

the ground (A) when installing the cover
(3).
5) When the cover (3) is installed, inspect

the air cleaner housing shall not have
a larger clearance with the cover (3).
Reinstallation is necessary in case of
larger clearance.
9. Use a new sticker to replace sticker (7) on

cover (3).
Fig. 5-19

5.8.2.2 Cooling system - clean
WARNING
The radiator coolant is still hot under high pressure when the engine has just been
shut down. It is possible to burn if you remove the radiator cap to drain the coolant.
Remove the cap slowly to relieve pressure only when the cap is cool enough to touch
with your bare hand.
When you start the engine for cleaning purpose, the hydraulic lockout control should
be placed in the LOCK position in order to prevent movement of the machine.
For more information on startup of the engine See related sections in this manual.
When disassembling the outer filter element, it is dangerous to pull it out with force.
Be careful when you are doing this job on an overhead surface or at where you are un-
able to stand firmly. Take care that the counter-acting force of pulling the outer filter
element could cause you to fall.
Always prepare your machine as required and lock/tag it out before proceeding. See Preparing
the machine on page 2-58 and Lock-out and tag-out on page 2-60.
Clean the inside of the cooling system and change the coolant according to the following table.
Interval for cleaning the inside of the cooling system and

Anti-freezing coolant
changing anti-freezing coolant
TEEC-L35 antifreeze Every years or 2000 hours, whichever occurs first
Table 5-7
The coolant is also an important uid against corrosion and freezing.
Anti-freezing coolant is also necessary in regions where freezing prevention is unnecessary.
Sany recommends TEEC-L35 antifreeze, which has excellent performance in anticorrosion, anti-
freezing and cooling, and can last for one year or 2000 hours.
We do not recommend you using other coolants. The use of other coolants is possible to erode
the engine and cooling system parts that made of light metal such as aluminum.

Sany recommends TEEC-L35 antifreeze. This antifreeze has a concentration of 50% and needs
no dilution.
If you buy antifreeze from the market, make sure that the antifreeze's concentration is within the
range 30-68% in order to ensure its performance against corrosion.
The ratio of mixing antifreeze with water is determined by the minimum ambient temperature, as
shown in the following table.
It is better to estimate 10 (18 ) lower than the actual temperature when selecting a mixture
ratio.
The mixture ratio is determined by ambient temperature. The mixture ratio shall not be lower than
30% (antifreeze/total volume of coolant 100) in even the regions where freezing prevention is
unnecessary in order to prevent corrosion of the cooling system.
The undiluted antifreeze will freeze at -15 (5 ). Do not store the undiluted antifreeze in an
environment where is lower than -15 (5 ).
Minimum -10 -15 -20 -25 -30 -35 -40

atmospheric
14 5 -4 -13 -22 -31 -40
temperature
L 6.75 8.1 9.23 10.35 11.25 12.15 13.05
Antifreeze
US gal 1.79 2.15 2.45 2.75 2.98 3.22 3.46
L 15.75 14.4 13.3 12.15 11.25 10.35 9.45
Water
US gal 4.18 3.82 3.53 3.22 2.98 2.75 2.51
Volume ratio (%) 30 36 41 46 50 54 58
Table 5-8

WARNING
Antifreeze is flammable. Naked fire

should be kept away from antifreeze.
Antifreeze is poisonous. Be careful
when opening the drain valve in order
to prevent skin contract of the water
containing antifreeze. In case of con-
tact with your eyes, flush with large
amount of clean water and refer to
medical care immediately.
To change the coolant or drain the ra-
diator coolant when repairing your ma-
chine, consult professional company
or your Sany distributor to dispose the
coolant containing antifreeze. Never
drain the coolant to sewage or onto
ground since the antifreeze is poison-
ous.
Use suitable water to dilute the antifreeze. (For

more information seeCoolanton page 5-11.)
Density meter is recommended to control the

mixture ratio.
Prepare a container to hold the drained cool-

ant. The container's capacity should be larger
than the specific volume of coolant.
Prepare a hose to transfer anti-freezing cool-

ant and water.
1. Park your machine on a level ground and

then shut off the engine. Lock out and tag
out your machine before proceeding. See
2. Remove slowly the radiator cap (1) to

relieve pressure only when the coolant is
cool enough for you to touch the radiator
cap with your bare hand.
Fig. 5-20

3. Remove the bottom cap and place a con-

tainer to hold the coolant under the drain
valve (2).
Open the radiator bottom drain valve (2) to

drain the coolant.
4. Close the drain valve (2) after draining

the coolant. Add tap water to the radiator.
When the radiator is full, start the engine
at low speed in order to heat up to 90
Fig. 5-21
(194 )at minimum. Continue to run the
engine for about 10 minutes.
5. Stop the engine and open the drain valve

(2) to discharge water.
6. Use detergent to clean the radiator after

draining the water. Refer to the detergent
instruction for cleaning method.
7. Close the drain valve (2).
8. Reinstall the bottom cap.
9. Fill the coolant containing antifreeze till the Fig. 5-22

uid overows from the filler opening. The
mixture ratio of antifreeze and water is to
be determined according to the chart of
mixing values of antifreeze and coolant.
10. Run the engine at low speed for about five

minutes and then at high speed for five
minutes in order to eliminate the air from
the coolant. (The radiator cap (1) shall be
left open at the moment.)
11. Clean the auxiliary reservoir (3) after

completely draining the coolant from it. Add
water till the coolant level reaches a level
between the high and the low marks.
Replace the auxiliary tank with a new one

if the old one is hard to clean.
12. Stop the engine. Wait about three minutes

before adding water through the filler open-
ing. Screw on the radiator cap tightly.

5.8.2.3 Track shoe bolts - inspect/tighten
If your machine is operated with loose track

shoe bolts (1), the bolts can break. Tighten
any loose bolts immediately.

Tightening Fig. 5-23
Three-grouser track shoe
1. Tighten the bolts to torque values of

600Nm - 680Nm (61.2kgf - 69.4kgf or
441Ibft - 500Ibft). Make sure that the nuts
and track shoe are in close contact with
the link mating surface.
2. Inspect and tighten again by 12010.
Tightening sequence
Tighten the bolts in the sequence shown in the

right illustration. After tightening, make sure
that the nuts and track shoe are in close con-
tact with the link mating surface.
Fig. 5-24

5.8.2.4 Track tension - inspect/adjust
The wear of undercarriage pin rolls and pin

bushings may vary according to operating
condition and soil type. Therefore, the ten-
sion of track shall be checked often in order to
maintain standard tension.

Inspection
1. Run the engine at low idle speed. Travel

the machine forward a distance that is
equivalent to the length of an unfolded
track. Park your machine.
2. Place a straight edge on top of the track

grousers between the idler (1) and the
carrier roller (2), as shown in the right
illustration.
3. Measure the maximum amount of sag in Fig. 5-25

the track. The sag is measured from the
highest point of the track grouser to the
bottom of the straight edge.
The standard value of sag (a) should be10

- 30 mm (0.4 -1.2in).

If the track tension is beyond the standard

range, adjust the track tension through the fol-
lowing procedure.
Adjustment
CAUTION
The screw plug (1) is possible to fly out

under high-pressurized grease. Never
loosen the screw plug (1) over one
turn.
Never loosen any other components
except the screw plug (1). Never face
the installation direction of the screw
plug (1).
If the track does not loosen with the
following method, contact your Sany Fig. 5-26
distributor.
Increasing track tension
To increase the track's tension, prepare a

grease gun.
1. Add grease with the grease gun through

the grease fitting (2). (The grease fitting (2)
and the screw plug (1) are integral.)
2. Slowly travel the machine forward (7-8 m

(23 ft - 26 ft 3 in)) in order to check whether Fig. 5-27
the track tension is suitable.
3. Check the track tension again. Readjust

the tension if it is still beyond the standard
range.
4. Continue to add grease till the distance

(S) becomes null (0). If the tension is still
loose, it is probably because the pin roll
and bushing are overworn. The pin rolls or
bushings must be swapped or replaced.
Fig. 5-28
Contact your Sany distributor for repair.

Reducing track tension
WARNING
Never loosen the valve (1) quickly or

excessively. The grease under pres-
sure can squirt out of the track tension-
ing cylinder. Carefully loosen the valve
(1) and keep your body and face away
from the valve (1).
Never loosen the grease fitting (2).
The grease is to be released through
the following steps. If the tension of
track is still tight, contact your Sany Fig. 5-29
distributor for repair.
If gravels or mud falls between the sprock-

et and track link, remove it before you re-
duce track tension.
To reduce track tension, slowly turn valve
(1) counterclockwise with a long socket
wrench. The grease will come out of the
grease fitting.
Loosening valve (1) only one turn is
enough to reduce track tension.
Fig. 5-30
If grease does not come out smoothly,
drive your machine back and forth for a
short distance.
When suitable sag of track is achieved,
turn valve (1) clockwise to 78.4 Nm (8
kgfm).
To check if you have got desired track
tension, run the engine at low idle speed,
drive your machine forward (at a distance
that is equivalent to the length of an un-
folded track), and then park the machine. Fig. 5-31
Check track tension again. Readjust the
tension if it is still beyond the standard
range.

5.8.2.5 Bucket tips (lateral pin) - replace
Replace the bucket tip before the tip adapter

is worn.
WARNING
Place the work equipment firmly before

replacing the bucket tips. Stop the en-
gine and engage the hydraulic lockout
control. If the hydraulic lockout control
is free, unexpected movement of the
work equipment could cause sever ac-
cident.
If you drive the pin with great force, the
pin may fly out and cause an accident.
Keep irrelevant people a safe distance
from the area.
Debris may fly out during replacement.
Always wear safety goggles, gloves
and other necessary protective gear.

1. Place a block beneath the bucket in order

to remove the pin and keep the bucket
bottom leveling.
Fig. 5-32
2. Make sure the work equipment is stable

and the hydraulic lockout control is in
LOCK position.
Fig. 5-33
3. Place a metal stick against one end of the

pin (1) and hammer the metal stick in order
to drive the pin (1) out and remove the
bucket tip (2).
Remark:
The metal stick shall have a smaller diam-

eter than the pin.
If the tip cannot be removed safely in this
Fig. 5-34
way, consult Sany distributor for replace-
ment.
4. Remove the tip and check the latch for
any damage. Replace it if necessary.
The latches and tips worn short must be
replaced with new ones.
5. Clean the installation surface. Mount the

new bucket tip (2) to its adapter. Push part
of the pin (1) into the tip and hammer it in
completely in order to lock the bucket tip
onto its adapter. Fig. 5-35
No. Item No. Item

1 Bucket 8 Latch
2 Plate 9 Bush
3 Plate 10 Bolt
4 Plate 11 Washer
5 Adaptor 12 Spacer
6 Tip 13 Side cutter (left)
7 Pin 14 Side cutter (right)
Table 5-9 Fig. 5-36

5.8.2.6 Bucket Replacement
CAUTION
Driving a pin shaft with a hammer can

cause flying metal pieces that could
lead to severe injury. Wear goggles,
safety hat, protective gloves and other
protective gear during such an opera-
tion.
If the pin shaft is tapped with strong
force, it could fly out and cause per-
sonal injury. Make sure that the sur-
rounding area is clear of people before
doing the job.
Never stand behind the bucket when
removing the pin shaft; pay special at-
tention to not placing your foot under
the bucket when working at one of the
sides.
Never get your finger pinched while re-
moving or installing the pin shaft.
Never put your finger into the pin bore
during alignment.
Park your machine on a hard, level ground.
Designate a commander and follow his in-

structions when carrying out the connection
work.


1. Place the bucket on a level ground.
Remark:
Before removing the pin roll, slowly lower the

bucket to a level where it just contacts the
ground.
If a larger force is used to lower the bucket to Fig. 5-37

the ground, resistance could increase on the
pin roll, causing difficulties while removing it.
Note:
Make sure the pin roll is free from mud or sand

after removal.
Both ends of the bushing are installed with

seals against dust. Be careful not to damage
Fig. 5-38
them.
2. Remove the nuts and screws on the plate

retaining arm pin (A) and link pin (B), take
out arm pin (A) and link pin (B), and then
remove the bucket.
3. Align arm (5) with the bore for bucket

replacement and the link (6) with bore (2).
Insert the greased pin rolls (A) and (B) into
bore (1) and bore (2) respectively.
Fig. 5-39

Remark:
When mounting the bucket, place the O-ring

(3) of bucket (4) to the position, as shown in
the right illustration, corresponding to the arm
pin (A). After the pin roll is inserted, align it to
the standard notch.
4. Reinstall the nuts and bolts onto the plate

retaining the pin rolls. Add grease to the
pin rolls.
Remark: Fig. 5-40
Inject sufficient amount of grease till the

grease is squeezed out of the end face.
Replace any broken seals when replacing
a bucket. The use of broken seals could
allow sand or dust to penetrate through to
the pin roll and cause its abnormal wear.
5.8.2.7 Bucket clearance - adjust
The bucket linking clearance must be readjust-

ed after your machine has been operated for
a period of time. When the linking clearance
is excessively large or small, it is necessary to
install or remove the spacer.
WARNING
Place the work equipment firmly before ad-

justing bucket clearance. Stop the engine
and engage the hydraulic lockout control.
If the hydraulic lockout control is free,
unexpected movement of the work equip-
ment could cause severe accident.

1. Park your machine on a level ground.

Lower the bucket to the ground, in an at-
titude shown in the right illustration.
2. Run the engine at low speed. Fix the

bucket on the ground. Slowly turn the
upper structure counterclockwise till the
inside of the left side of the bucket contact
closely with the left end surface of the arm.
3. Shut off the engine. Lock out and tag out Fig. 5-41
your machine before proceeding. See
Lock-out tag-out on page 2-60.
4. Move the O-ring (1) and measure the

clearance (a). It is easy to obtain accurate
result with a feeler gauge.
5. Loosen the four plate-mounting bolts (2) in

order to detach the plate (3). The spacer
has an opening, so it is unnecessary to
remove the bolt when making adjustment.
6. Remove the spacer equivalent to the

measured clearance (a).
Fig. 5-42
(For example)
If the clearance is 3 mm (0.118 in), remove

two 1.0 mm (0.039 in) spacers and one 0.5
mm (0.02 in) spacer, or one 2.0 mm (0.078
in) spacer and one 0.5 mm (0.02 in) spac-
er. The clearance is reduced to 0.5 mm
(0.02 in). The spacers (4) include three
types, 2.0 mm (0.078 in), 1.0 mm (0.039 in)
and 0.5 mm (0.02 in). When the clearance
(a) is less than one spacer, no adjustment
shall be made.
7. Tighten the four bolts (2).
If it is difficult to tighten the bolts (2), re-

move the pin-retaining bolt (5) before tight-
ening the bolts (2).

5.8.2.8 Window washer fluid - check/refill

If the washer uid contains air, check the uid

level in the reservoir (1). Add washer fluid if
necessary.
To prevent dirt from entering the reservoir, be

careful when filling the washer uid. Fig. 5-43
Select a mixture ratio according to ambient

temperature. Therefore, the detergent is to be
diluted with water according the ratios listed
below.
Operating Regions Mixture Ratio Anti-Freezing Temperature
Detergent 1/3:
General - 10 (14F)
Water 2/3
Detergent 1/2:
Cold regions in winter - 20 (- 4F)
Water 1/2
Frigid regions in winter Pure detergent - 30 (- 22F)
Table 5-10
There are two types of detergent: one for -10 (4F) (common) and one for -30 (-22F) (frigid
regions), which can be selected according to the operating region.

5.8.2.9 Air conditioner - inspect/service

Checking refrigerant (gas) level
WARNING
The refrigerant getting into your eyes

or on your skin can cause blindness
or freezing injury. Never touch the re-
frigerant. Never loosen any parts of the
refrigerant lines.
Keep any naked fire away from the
leaking position of refrigerant gas.
Insufficient refrigerant (R134a) will severely

impair the cooling performance.
When the engine is running at high speed, op-

erate the air conditioner for strong refrigeration
and observe through the sight glass (1) on the
condenser reservoir (2) in order to inspect the
condition of refrigerant gas owing to the tube.
The refrigerant flows without bubble: per-

fect
The refrigerant ow contains bubbles that Fig. 5-44
pass continuously: refrigerant level low
Colorless and transparent: no refrigerant
Remark:
The appearance of bubbles indicates low re-

frigerant level. Please consult Sany distributor
to add refrigerant. Running the air conditioner
with low refrigerant level could damage its
compressor.
Inspection during idle period Fig. 5-45

When the air conditioner will not be used for a long period of time, the air conditioner
shall be operated for 3-4 minutes each month in order to lubricate the compressor com-
ponents.
Components Description Service Interval
Twice a year (spring and au-

Refilling
tumn)
Refrigerant (gas)
Tube connections and internal leakage of parts
Daily
and components
Condenser Radiator fins plugged Every 500 hours
Compressor Function Every 4000 hours
Loose and bent Every 250 hours
V-belt Deterioration, wear, scratch and cracking Every 250 hours
Noise, odor smell or abnormal heat When required
Fan motor and fan Function (check for abnormal noise) When required
Air conditioner air

Air ow control switch and switching function Daily
ow switch
Control unit Function (make sure the function is normal) When required
Loose connections and loose or detached nuts

Joining bolts Every 6 months
and bolts
Installation condition, loose connections, air

Connection tubes When required
leakage or any damage
Reservoir dryer
Temperature difference indicates a blocked
temperature differ- Every year
dryer.
ence
Table 5-11

5.8.2.10 Gas spring - inspect
WARNING
The Gas Spring contains high-pressurized

nitrogen. Wrong operation can cause ex-
plosion and result in machine damage and
personal injury or death. The following
items shall be observed when dealing with
the Gas Spring.
Be away from naked fire.

Never drill or weld the Gas Spring.
Never hammer the Gas Spring or ex-
pose it under any impact.

The air springs are located on top of the cab (at

both the left and right sides).
Contact your Sany distributor for inspection,

repair and replacement in case of the following
conditions.
The cab roof hatch cannot be opened eas-

ily.
The cab roof hatch cannot be kept open. Fig. 5-46
Oil or air leaks from the air spring.

5.8.2.11 Air in hydraulic system - purge

1. Purging air from the pump
1) Loosen air vent plug (1) and check for

oil leak.
2) If no oil leaks, disconnect drain hose

from hydraulic pump and add hydraulic
oil to hydraulic pump through drain port
(2).
Well secure the disconnected hose. To

prevent overow, hose opening must be
higher than oil level in hydraulic tank.
3) Tighten the plug (1) and reconnect the

drain hose after purging the air. Fig. 5-47
Note:
If drain hose is reconnected before tightening

the plug (1), oil will squirt out of the plug (1).
If the pump is operated when it is not fully filled

with hydraulic oil, extra heat will be generated
and pump damage could result.
2. Starting the engine
See Engine Starting on page 4-22.
After starting the engine run it at low speed

for 10 minutes before you perform any op-
eration.
3. Purging air from hydraulic cylinders
1) Run the engine at low idle speed.

Extend and retract oil cylinder 4-5 times.
Note that the piston shall not reach its

stroke end. Keep it 100 mm (3.9 in)

from stroke end.
2) Operate each cylinder 3-4 times to its

stroke end.
3) Operate each cylinder 4-5 times to its

stroke end in order to purge air com-
pletely.
Note:
If you instantly run the engine at high speed or

operate a cylinder to its stroke end, air in cylin-
der could damage piston seal.
4. Purging air from swing motor
1) Run the engine at low speed. Loosen

the hose (3) at the port S. Check if oil
comes out of the hose (3) from the port
S.
Note:
Do not operate the swing drive under any cir-

cumstances.
2) If no oil is seen, shut off the engine.

Remove the hose (3) from the port S
and add hydraulic oil to the motor shell.
Fig. 5-48
3) Tighten the hose (3) at the port S after
purging the air from the swing motor.
4) With the engine running at low idle

speed, swing evenly and slowly to the
left side and the right side at least two
times. The air will be expelled from the
swing drive oil path.
Note:
The air in the swing motor could damage

the motor bearing.
To replace the relief valve of the travel mo-
tor, consult Sany distributor for replace-

ment and air elimination.
5. Eliminate air from the travel motor (only

when the oil has been discharged from the
travel motor shell)
1) Run the engine at low speed. Loosen

the air vent screw plug (4). Tighten the
screw plug if oil is seen.
2) Run the engine at low speed. Swing the

work equipment 90 degrees in order to
place it at the track side.
3) Raise the machine with the force of the Fig. 5-49

work equipment. With the track lifted
just above the ground, run the track
unloaded for two minutes. Repeat this
operation for both tracks and run the
tracks back and forth uniformly.
6. Eliminate air from attachment (if equipped)
If a breaking hammer or other attachment

has been installed, run the engine at low
idle speed and operate the attachment
control pedal repeatedly (about 10 times)
Fig. 5-50
till the air is expelled from the oil path com-
pletely.
Note:
If manufacturer of the attachment has pro-

vided instruction on eliminating air from
the attachment, the instruction shall be fol-
lowed to eliminate the air.
Turn off the engine after air elimination.

Wait five minutes before operation in order
to eliminate the bubbles in hydraulic cylin-
der.
Check for oil leakage and wipe off the oil

overowed.
Check the oil level after purging the air.

Add oil if the oil level is low.

5.8.2.12 Hydraulic circuit internal pressure - release
WARNING
The hydraulic circuit is always under

pressure. In this case, the pressure in
hydraulic circuit is to be released when
checking or replacing the hoses or fit-
tings. Without doing so, the pressur-
ized oil will squirt out and cause seri-
ous personal injury.
After the engine is stopped, the com-
ponents and oil are still hot and can
cause serious burn. Wait until the tem-
perature comes down before operating.
The oil may squirt out when remov-
ing the oil filler cap. Therefore, slowly
remove the cap in order to release the
internal pressure.
1. Park your machine on a hard, level ground.
2. Within 15 minutes since the engine is shut

off, turn the start switch to ON position and
cycle the work equipment control lever and
the travel control lever in all directions in
order to release the internal pressure.
3. Lock/tag it out before proceeding. See

Lock-out tag-out on page 2-60.
Fig. 5-51
4. Slowly loosen the oil filler cap on top of
the hydraulic tank in order to release the
internal pressure.
Fig. 5-52

5.8.3 Checks before starting
For more information about the following items

see Checks before starting on page 4-7.
Drain water and sediment from fuel tank.

Check water separator and drain water
and sediment.
Check oil level in hydraulic tank and refill
the tank.
Check coolant level and add coolant.
Check oil level in engine oil pan and add
oil.
Check electric wires.
Check fuel level and refuel the tank.
Check work lamp switch.
Check the function of horn.
Check engine lower exhaust pipe and keep
it clean. (Check exhaust pipe at any time in
earthwork.)

5.8.4 Every 100 service hours
5.8.4.1 Lubrication
NOTICE
If the lubricated components produce abnormal noise, additional lubrication is re-

quired besides regular maintenance.
A new machine shall be greased every 10 hours within the initial 50 hours.
After operating in water, the machine's wet pin rolls are to be greased.
1. Adjust your machine to a to-be-greased attitude shown in the illustration below, lower the work
equipment to the ground and then turn off the engine.
2. Lock/tag it out before proceeding. See Lock-out tag-out on page 2-60.
3. Use a grease gun to inject grease through the greasing points indicated in Fig. 5-53.
4. Finally, wipe off the used grease that has been squeezed out.
Fig. 5-53

(1) Boom cylinder root pin (2)
Fig. 5-54
(2) Boom root pin (2)
(3) Boom cylinder piston rod end (2)
(4) Arm cylinder root pin (1)
Fig. 5-55
(5) Boom-arm joining pin (2)
Fig. 5-56

(6) Arm cylinder piston rod end (1)
(7) Bucket cylinder root pin (1)
Fig. 5-57
(8) Arm-Bucket joining pin (1)
Fig. 5-58
(9) Rod joining pin (2)
(10) Bucket cylinder piston rod end (1)
(11) Bucket-rod joining pin (1)
Fig. 5-59

5.8.5.1 Compressor belt tension - inspect/

adjust

Inspection
With a force of about 58.8N (6kgf), press with

your finger the middle section of the belt be-
tween the drive pulley (1) and the compressor
pulley (2) in order to check the deection (A),
which should be 5-8mm (0.20in-0.31in). Fig. 5-60
Adjustment
1. Loosen the bolts (1) and (2).
2. Move the compressor (3) and its bracket (4)

in order to adjust belt tension.
3. Tighten the bolt (1) and (2) after positioning

the compressor (3).
4. Check again the belt tensioning device

after adjustment.
Fig. 5-61
Reference
Use a tension meter to check the belt tension

of the compressor.
New Belt Used Belt
637108 (N) 44188.2 (N)
(6511 (kgf)) (459 (kgf))
Table 5-12

Note:
Check for damaged pulleys and worn V-

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

5.8.5.2 Oil in engine oil pan and oil filter -

change/replace
WARNING
When the engine has just been stopped,

the parts and oil are still hot and can
cause serious burn. Wait until they are
cool enough before doing the job.

Prepare as the following:

Fig. 5-62
Capacity of engine oil pan: See Fluid
capacities on page 5-19.
Filter wrench
1. Remove the bottom cover of the machine.

Place a container under the drain valve.
(Choose a container of a proper size ac-
cording to the capacity table). The oil will
be drained into the container through a
piece of clean cloth.
2. To avoid splashing of the oil, slowly open Fig. 5-63

the drain valve to discharge oil, and close
the valve after drainage.

3. Open the right door and turn the filter

(1) leftward with filter spanner in order to
disassemble the filter.
4. Clean the filter seat (2). Fill the new filter

with clean engine oil. Apply engine oil (or a
film of grease) to the filter sealing surface
and the threads before installing the filter
to its seat.
Fig. 5-64
Remark:
Check the filter seat (2) for presence of used

seal. The presence of used seal in the filter
seat (2) can cause oil leakage.
5. The installation requires contact of the

sealing surface with that of the filter seat
(2). Turn the filter 3/4-1 turn.
6. After replacement of the filter, open the

engine's hood and fill engine oil through
the filler to a level between the H and L
marks of the dipstick. Fig. 5-65
7. Run the engine idly for a short time and

then turn off the engine. Check again the
oil level, which shall be between the H and
L marks of the dipstick. For more informa-
tion see Oil in engine oil pan and oil
filter - change/replace on page 5-65.
8. Reinstall the bottom cover.

Fig. 5-66
NOTICE
Contact your Sany distributor to obtain

genuine engine oil in order to guarantee
oil quality and ensure 250 service hours.

5.8.5.3 Primary fuel filter - replace
WARNING
Never replace the filter immediately af-

ter the engine is shut down, as all parts
are still hot. Wait for the parts to cool
enough before replacement.
High pressure is created in the fuel
system when the engine is running.
Before replacing the filter, wait at least
30 seconds since engine stoppage. The
replacement work shall be carried out
after the internal pressure drops to a
safe level.
Be away from fire sources.
Note:
Sany genuine fuel filter is a special filter

of effective filtration. The filter must be re-
placed with a genuine one.
The use of other parts may allow dirt or de-
bris to get into the fuel system and cause
the injection system failure. Therefore,
avoid using any substitutes.
It is more important to prevent dirt from
getting into the fuel system during inspec-
tion and service. In case of any parts con-
taminated by dust, flush them clean with
diesel fuel.
Prepare a container to hold the fuel
drained.
Prepare a filter wrench.


1. Open the door on the right side of machine.
2. Place a fuel container under the filter.
3. Loosen the drain valve (1) to discharge

water and sediment in the bowl (2). Also
drain the fuel in filter (3).
4. Use a filter wrench to turn counterclock-

wise the bowl (2) in order to remove it. (The
bowl can be reused.)
5. Use the filter wrench to turn counterclock-

wise the filter (3) in order to remove it.
6. Install the bowl (2) to the bottom of new

filter. Always replace the O-ring seal (4). Fig. 5-67
7. Apply oil to seal surface during installa-

tion. Make the seal and filter have a close
contact before further tightening the filter
by 1/4 - 1/2 turn.
If the bowl (2) was over-tightened, the

O-ring seal might be damaged and fuel
leak could result. If the bowl (2) was not
tightened enough, fuel will leak through
the gap with O-ring seal. To prevent such
problems, always tighten it to the specified
torque.
8. Clean the filter seat. Add clean fuel to new

filter. Apply a thin layer of oil to the seal
surface and install the filter to the filter
seat.

Note:
Never remove the cover (B) while filling the

fuel. Always fill fuel via the eight(8) external
holes (A).
Remove the cover (B) after filling. Install
the fuel filter.
Always fill clean fuel. Take care to keep
the fuel free from dust or dirt. Be especially
careful that the central part is clean and
never remove the cover (B) during filling.
Always keep the central part free from con-
Fig. 5-68
tamination.
9. Tighten the filter until the seal contacts

the filter seat. Further turn it by 3/4 turn.
If the filter cartridge was over-tightened,
the seal might be damaged and fuel leak
could result. If the filter cartridge was not
tightened enough, fuel will leak through
the gap with seal. Always tighten it to the
specified torque.
10. Check drain valve (1) to see if it is tight-

ened properly.
11. Release the air after replacing filter (3).
Air-purging steps:
12. Fill fuel into the fuel tank until the float
reaches the maximum level.
13. Use a transfer pump (5) to pump the fuel in

and out until heavy resistance is felt.
Remark:
It is unnecessary to remove the plug on the

primary fuel filter and the secondary fuel
filter.
When fuel exhausts, operate the transfer
pump (5) to purge air.

14. After purging the air, push in the knob of

pump (5) and tighten it.
15. After replacing the filter, start the engine

and run the engine at low idle for 10 min-
utes.
Check the filter seal and the cover for fuel

leak. Check the tightening degree of the
filter when fuel leak is found.
If fuel leak still exists, repeat step 1

through step 7 to remove the filter. If the
seal is found damaged or cut by foreign
substance, replace filter cartridge. Repeat
step 8 through step 14 to install a new fil-
ter cartridge.

5.8.5.4 Secondary fuel filter - replace
WARNING
Never replace the filter immediately af-

ter the engine is shut down, as all parts
are still hot. Wait for the parts to cool
enough before replacement.
High pressure is created in the fuel
system when the engine is running.
Before replacing the filter, wait at least
30 seconds since engine stoppage. The
replacement work must be carried out
after the internal pressure drops to a
safe level.
Note:
Sany genuine fuel filter is a special filter

of effective filtration. The filter must be re-
placed with a genuine one.
The use of other parts may allow dirt or de-
bris to get into the fuel system and cause
the injection system failure. Therefore,
avoid using any substitutes.
It is more important to prevent dirt from

getting into the fuel system during inspec-
tion and service. In case of any parts con-
taminated by dust, flush them clean with
diesel fuel.
Prepare a container to hold the fuel
drained.
Prepare a filter wrench.


1. Open engine hood.
2. Place a fuel container under the filter.
3. Use filter wrench to turn counterclockwise

the filter (1) in order to remove it.
4. Clean the filter seat. Apply a thin layer of

oil to sealing surface of filter cartridge and
install filter cartridge to filter seat.
Replace internal seal (2) with a new one. Fig. 5-69
Fig. 5-70
Note:
Never add fuel to new filter cartridge.

Remove cap (B) and install filter cartridge.
Fig. 5-71

5. Tighten filter cartridge until the seal con-

tacts filter seat. Further turn it by 3/4 turn.
If filter cartridge was over-tightened, the

seal might be damaged and fuel leak could
result. If filter cartridge was not tightened
enough, fuel will leak through the gap
of seal. Always tighten it to the specified
torque.
6. Remove air after replacing the filter.
Air-purging steps:
7. Refill fuel tank until the float reaches the

maximum level.
8. Loosen plug (3) of fuel filter.
9. Turn counterclockwise the handle (4) of Fig. 5-72

start priming pump.
10. Push and pull the handle (4) to pump fuel.
11. Tighten plug (3) when fuel coming out of

plug of fuel filter contains no foam.
Tightening torque: 9.82.0 Nm {1.00.2

kgfm}
12. Operate the priming pump 5-6 times and

turn handle (4) clockwise to tighten it.
Fig. 5-73
13. Completely remove overflowed fuel after
purging the air. Start the engine and run it
at low idle for 10 minutes.
Check filter cartridge for fuel leak. Check

the tightening of filter cartridge if fuel leak
is found.
If fuel leak still exists, repeat step 1 through

step 3 to remove the cartridge. If seal dam-
age or impurities are found, repeat step 4
through step 13 to install a new cartridge.
Fig. 5-74
Also perform maintenance for every 100 and

250 service hours is in the meantime.
5.8.6.1 Swing bearing - lubricate
1. Lower work equipment to ground, stop

the engine and engage hydraulic lockout
control.
2. Add grease through two grease fittings

while the upper structure is kept static.
3. Start the engine, disengage hydraulic

lockout control and raise the bucket 20-30
mm off ground. Swing upper structure by
45 degrees and add grease through steps
1 and 2. Fig. 5-75
4. Repeat step 3 twice to accomplish greas-

ing.
Note:
The grease is used to prevent distortion

and noise of joints.
It is necessary to add grease to any com-
ponent that appears inexible or noisy after
operation for a long period.
Wipe off the used grease that has been
squeezed out when greasing.
Make sure to wipe off all used grease in
different locations. Using a grease that has
been contaminated by sand or debris can
lead to wear of rotating components.

5.8.6.2 Swing pinion gear grease - check/refill

Prepare a dipstick.
1. Remove the two bolts (1) from the swing
frame. Remove the cover (2).
2. Insert the dipstick (3) into the grease

through the hole for inspection and
adjustment. Check the grease level, which
should be 14 mm (0.6 in) at minimum, at
where the pinion gear passes.
3. Check the grease to see whether it is milk-

white. Milk-white grease indicates that the
grease has been contaminated. Consult Fig. 5-76
Sany distributor in order to change the
grease.
Total grease volume: 15 L (3.97 US gal)
Fig. 5-77
4. Use the bolts (1) to reinstall the cover (2).
Fig. 5-78

5.8.6.3 Coolant tank and radiator fins - inspect/clean
WARNING
If you are directly impacted by compressed air, pressurized water or steam, or you use
them to purge dirt or debris, personal injury could result. Make sure you are well protect-
ed by wearing goggles, dust-proof mask or other protective gear.
Note:
When compressed air is used for cleaning, it

is important to use the air at certain distance
in order to avoid damaging the radiator fins.
Damage of radiator fins will lead to water
leakage and overheating. Working in a dusty
place, the fins shall be inspected on each
workday despite of the service schedule.
Always prepare your machine as required Fig. 5-79

1. Open engine hood (1).
2. Loosen screws (3) and (8). Pull up screens

(2) and (9).
3. Clean the screens.
4. Inspect the coolant tank (4), intercooler

fins (5), A/C condenser fins (6) and the Fig. 5-80
hydraulic oil radiator fins (7). Compressed
air can be used to remove dirt and leaves
sticking to the fins.
Steam or water can also be used to clean

the fins.
However, a safe distance to the machine

shall be kept when cleaning the heat ex-
changers (of radiator, oil cooler, intercooler
Fig. 5-81

and air conditioner condenser) with power-

ful steam (from high-pressure ushing ma-
chine). With steam cleaning (high-pressure
machine flushing) at a near distance, the
heat exchanger could deform and early
plugging and cracking could be resulted.
5. Inspect rubber hoses. Replace the hoses

in case of cracking or aging. Check hose
clamps for looseness.
6. Remove bottom cover (10). Remove dirt,

debris and tree leaves that have been
swept to the outside.
7. Reinstall cleaned screens (2) and (9) and

tighten them with screws (3) and (8). Fig. 5-82
5.8.6.4 Air conditioner filters - clean
WARNING
The dust blown by compressed air could

cause personal injury. Make sure you are
protected by goggles, dust-proof mask
and other protective gear.
Note:
The filter shall be cleaned every 500 hours,

but operating your machine in a dusty place
requires cleaning the filter more frequently.
Remark:
An air filter plugged with dust will reduce air

ow and cause the air-conditioning unit to pro-
duce noise.


Cleaning the filter screen
1. Remove the screw (1) from the access

window located on the left rear bottom of
the cab, loosen the locking nut (2) and
remove the air recirculation filter (3).
2. Use compressed air to clean the filter. If

the filter bears oil or too much dirt, clean it
with moderate detergent. After the filter has
been flushed with water, it must be dried
completely before reuse. This filter shall
be replaced every year with a new one. If
a plugged air filter cannot be cleaned with
compressed air or ushing water, replace it
immediately.
Fig. 5-83
Fig. 5-84

Cleaning the fresh air filter
1. Unlock the rear cover (4) on the left side

of the cab with the start switch key. Open
the cover (4) with your hand, remove the
locking nut (5) and take out the fresh air
filter (6).
2. Use compressed air to clean the filter. If

the filter bears oil or too much dirt, clean it
with moderate detergent. After the filter has
been flushed with water, it must be dried
completely before reuse. This filter shall
be replaced every year with a new one. If
a plugged air filter cannot be cleaned with Fig. 5-85
compressed air or ushing water, replace it
immediately.
3. After cleaning, restore the filter (6), tighten

the nut (5) and close the cover. Lock the
cover with your start switch key and then
remove the key.
Fig. 5-86
Remark:
The fresh air filter must be installed correctly.

To install the filter, the long end (L) of the filter
(6) must be inserted first into the filter box. By
inserting the short end (S), the cover (4) will
not be closed.
Fig. 5-87

5.8.6.5 Swing drive oil - check/refill
WARNING


1. Remove the dipstick (G) and wipe off the

oil.
2. Insert the dipstick (G) completely into the

filter tube.
3. Take out the dipstick (G) and check Fig. 5-88

whether the oil level is between the H and
L marks.
4. If the oil level is lower than the L mark on

the dipstick (G), remove the filler cap and
add oil.
5. If the oil level is higher than the H mark on

the dipstick (G), loosen the drain valve (P)
to drain excessive oil.
Fig. 5-89
If the oil level is too high, consult Sany
distributor for inspection.
Place a container under the drain valve
before draining the oil.
6. After checking the oil level or refilling the
oil, insert the dipstick (G) into the hole and
restore the filler cap.
Fig. 5-90

5.8.6.6 Final drive oil - check/fill
WARNING
When the engine is shut down, the oil is still hot. Wait until the oil is cool enough be-
fore operation.
Remaining pressure in the tank can cause oil to squirt out or the screw plug to fly out.
Slowly loosen the screw plug in order to release the pressure.
When the screw plug is loosen, do not stand in front of the screw plug.

Refilling volume: 5.5 L (1.45 US gal)
Prepare a 10 mm wrench.
1. Adjust the filler cap screw (F) to the upper
position in order to make the line through
the oil inspection screw plug (L) and the
drain screw plug (P) perpendicular to the
ground.
2. Use a proper screwdriver to eliminate the

dirt from the hexagonal socket of screw
plug in order to avoid damage to the bolt.
3. Use a spanner to remove the screw plug

(L). When the oil level reaches the point 10
mm (0.4 in) below the bottom of the screw
plug (L) opening, the amount of oil added
is just perfect.
4. If the oil level is too low, reinstall the screw

plug (L), operate the travel level and slowly
travel your machine forward or backward in Fig. 5-91
order to run the sprocket one turn. Repeat
step 2 and check again.
5. If the oil level is low, fill oil through the

opening of the screw plug (F) till the oil
overows through the opening of the screw
plug (L).
6. When the oil level is too high, consult Sany

distributor for inspection.
7. Restore the screw plugs (F) and (L) after

check and tighten them to: 58.819.6N.m.
Also perform maintenance for every 100, 250

and 500 service hours in the meantime.
5.8.7.1 Hydraulic oil filter - replace
WARNING

the parts and oil are still hot and can cause
serious burn. Wait for the temperature to
cool down before doing the job.
Note:

For more information see Hydraulic Break-
er Service Interval on page 5-27.


Adjust the work equipment to an attitude
ready for service, as shown in the right
illustration. Lower the work equipment to
ground and turn off the engine.
2. Lock out and tag out your machine before

proceeding. See Lock-out tag-out on
page 2-60. Fig. 5-92
3. Turn the buttery nut on the breather valve

and press the venting button.
4. Loosen the four bolts and remove the cap

(1). When the cap is removed, it may fly
out due to the action of the spring (2). In
this case, hold down the cap when remov-
ing the bolts.
5. Remove the spring (2), valve (3) and

strainer (4) before disassembling the filter
(5).
Check the bottom of the filter box and Fig. 5-93

remove the dirt if any. Keep the hydrau-
lic oil free from any dirt.
6. Clean the disassembled parts with clean-
ing oil.
7. Install a new filter.
8. Restore the valve (3), strainer (4) and

spring (2).
9. Install the cap (1) to its position. Hold down

the cap and tighten the bolts.
10. In order to vent the air, start the engine Fig. 5-94
(see "Engine Starting" in the Operation
Section) and run the engine at low idle for
10 minutes.
11. Stop the engine.

5.8.7.2 Swing drive oil - change
WARNING


Tank capacity:
3.5 L (1.06 US gal)
1. Place a container under the drain valve (P)

in order to contain the gear oil drained.
2. Loosen the drain valve (P) beneath the

machine to drain the gear oil. Tighten the
drain valve upon completion of the drain-
ing.
Fig. 5-95
Remark:
If the gear oil ows out in a thin thread pat-

tern, you can end the draining operation.
When the temperature is low, you can
swing the work equipment to slightly in-
crease the oil temperature before draining
the oil. However, the work equipment shall
not be swung during draining, which may
otherwise damage the swing unit.

3. Remove the filler cap (F) and fill the oil as

required through the filler opening (F).
4. Check the oil level. For more information

see Swing drive oil - check/refill on
page 5-80.
5. For information on selection of oil and tem-

perature see Recommended Fluids
on page 5-17.
Fig. 5-96
5.8.7.3 Engine exhaust pipe clamps - check
Consult Sany distributor to check the fastening

conditions of the air cleaner - turbocharger -
post cooler - engine clamps.
5.8.7.4 Fan belt tension - check/replace
Check the tension of fan belt. Replace the fan

belt in case of cracks or damage. Contact your
Sany distributor if you have any troubles.
5.8.7.5 Nitrogen pressure in accumulator

(breaker) - check
(If equipped)
Special tools will be used in order to check the

accumulator and inject nitrogen.
Please consult Sany distributor, if possible, to

conduct related inspection and inating opera-
tion.

Also perform maintenance for every 100, 500

and 1000 service hours in the meantime.
5.8.8.1 Final drive oil - change
WARNING
When the engine is just shut down, the

oil and components are still hot and
can cause burn. Wait until the oil is cool
enough before servicing.
Remaining pressure in the tank can
cause oil to squirt out or the screw plug
to fly out. Personal injury could result.
Slowly loosen the screw plug in order
to release the pressure. Never stand in
front of the screw plug.

Refilling capacity:
See Fluid capacities on page 5-19.
Prepare a wrench.
1. Adjust the filler cap screw (F) to the upper
position in order to make the line through
the oil inspection screw plug (L) and the
drain screw plug (P) perpendicular to the
ground.
2. Use a proper screwdriver to eliminate the

dirt from the hexagonal socket of screw
plug in order to avoid damage to the bolt.
3. Place under the drain plug (P) a container

used to contain the oil.
Fig. 5-97
4. Use the spanner to remove the drain plug
(P) in order to drain the oil.
Remark:
Check the O-ring on screw plug and replace

the O-ring if broken.
5. Tighten the plug (P) and remove the plugs

(F) and (L).
6. Fill oil through the opening of the plug (F).
7. When the oil is seen coming out of the

opening (L), reinstall the plug (F) and (L)
and tighten them to: 58.819.6N.m.

5.8.8.2 Hydraulic tank filter screen - clean
WARNING

the parts and oil are still hot and can cause
serious burn. Wait until they are cool
enough before doing the job.

1. Turn the buttery nut on the breather valve

and press the venting button.
2. Loosen the four bolts and remove the cap

(1). When the cap is removed, it may fly
out due to the action of the spring (2). In
this case, hold down the cap when remov-
ing the bolts.
3. Hold the top end of the rod (3) and pull it

upward in order to remove the spring (2) Fig. 5-98
and the screen (4).
4. Clean the screen (4) of all dirt. Flush it with

cleaning oil. Replace the screen if dam-
aged.
5. During installation, fix the screen (4) to

the bigger part (5) of the oil tank before
assembling.
6. When assembling, take advantage of the

bulged part of the cap (1) to hold the spring
(2) before tightening the bolts.
Fig. 5-99

5.8.8.3 Nitrogen pressure in accumulator (control oil circuit) - check
WARNING
The accumulator contains pressurized nitrogen, which may explode due to improper op-
eration, thus resulting in machine damage and personal injury. The following items must
be observed when handling the accumulator:
Some pressure remains in the hydraulic circuit. Never face the opening from which oil
may squirt when disassembling a hydraulic device. In addition, loosen the bolts slowly.
Never dismantle the accumulator.
Never punch or weld the accumulator.
Never bump or roll the accumulator. Keep it free from any impacts.
Vent the air completely when handling the accumulator. Consult your Sany distributor
to do this job.
Note:
In continuous operation with low nitrogen pres-

sure in the accumulator, the remaining pres-
sure in hydraulic circuit will not be released
once failure occurs to your machine.
Functions of the accumulator
The accumulator stores the pressure of the

control circuit. Even if the engine is turned off,
the control oil circuit allows you to achieve the
following operations:
Operate the control lever to lower the work

equipment. The work equipment will fall
due to gravity.
The pressure in hydraulic circuit can be re-
leased.
The installation location of the accumulator is
Fig. 5-100

Checking the functions of accumulator
NOTICE
During inspection, make sure the sur-

rounding area is clear without personnel
or any barriers.
Check the nitrogen pressure through the fol-

lowing steps:
2. Keep the work equipment 1.5m (4ft 11in)

above the ground at maximum reach (with
the arm fully extended and the bucket fully
turned outward.
Fig. 5-101
The step 3 through step 5 shall be conducted
within 15 seconds.
The accumulator's pressure drops gradu-

ally since stoppage of the engine. Therefore,
check the accumulator immediately after the
engine is shut down.
3. Keep the work equipment at its maximum

operating radius, turn the start switch to
OFF position (A) and stop the engine.
Fig. 5-102

4. Turn the start switch to ON position (B).
Fig. 5-103
5. Place the lockout control to FREE position

(F). Operate the control lever to lower the
work equipment. Check the work equip-
ment whether it reaches the ground.
Fig. 5-104
6. A work equipment lowering and touching

the ground under gravity indicates that the
accumulator functions normally.
In case that the work equipment is unable

to lower or is held half way, the pressure in
the hydraulic circuit accumulator may have
dropped already.
Fig. 5-105
Consult Sany distributor for such inspec-
tion.
7. After checking through the a.m. steps,

place the hydraulic lockout control to LOCK
position and turn the start switch to OFF
position.

5.8.8.4 Hydraulic circuit internal pressure - release
1. Low the work equipment to ground.
2. Place the work equipment lockout control

to the LOCK position (L).
The step 4 through step 6 shall be carried

out within 15 seconds.
Pressure of the accumulator will drop grad-

ually after the engine is stopped. There-
fore, the pressure can only be released
Fig. 5-106
when the engine has just be turned off.
3. Turn off the engine.
4. Turn the start switch to ON position (B).
Fig. 5-107
5. Place the lockout control to FREE position

(F) and then cycle the work equipment
control lever in all directions in order to
release the pressure in control circuit.
6. Place the lockout control to the LOCK

position (L) and then turn the start switch
to "OFF" position.
Fig. 5-108

5.8.8.5 Oil in hydraulic tank - change
WARNING

Press the breather valve venting button
to release the internal pressure before
removing the oil filler cap.
Note:

For more information see Hydraulic Break-
er Service Interval on page 5-27.
For refilling capacity seeFluid capaci-

ties on page 5-19.
Prepare a lever (used for 36 mm socket
wrenches)
1. Unscrew the bolts of the bottom cover
plate and remove the cover plate.
2. Swing the upper structure in order to posi-

tion the drain plug beneath the hydraulic
tank between the tracks.
Fig. 5-109
3. Retract the arm and bucket cylinders and
lower the boom in order to enable the
bucket tips to touch the ground.
4. lace the hydraulic lockout control to the

LOCK position and turn off the engine.

5. Remove the cap of the oil filler (F) .
6. Place a container under the drain plug.

Remove the drain plug (P) with the lever
in order to drain the oil. Check the O-ring
on the drain plug (P) and replace it timely if
broken. Tighten the plug (P) after draining.
Tightening torque: 927103Nm (94.6

10.5 kgfm or 683.5 76.0lbft)
Do not get oil on your body when re-
moving the drain plug (P).
7. Fill the hydraulic oil as required through the
filler (F). Check the oil level, which shall be Fig. 5-110
between the H and L marks of dipstick.
For more information on applicable hy-

draulic oil see Recommended Flu-
ids on page 5-17.
For more information on oil level inspec-
tion see Cooling system - clean
on page 5-37.
8. Eliminate air from the hydraulic circuit.
For more information on elimination of air

from the hydraulic circuit see Hydraulic
Breaker Service Interval on page 5-27.

5.8.8.6 Alternator - inspect
Contact your Sany distributor to inspect the al-

ternator.
Check the engine every 1000 service hours if

the engine is started frequently.
5.8.8.7 Engine valve clearance - check/

adjust
Special tools are necessary for inspection and

maintenance. Consult Sany distributor to do
this job.
Also perform maintenance for every 100,

250, 500, 1000 and 2000 service hours in the
meantime.
5.8.9.1 Coolant pump - inspect
Check coolant pump for leak of water or oil. In

case of any problem, contact your Sany dis-
tributor for disassembly, repair or replacement.
Fig. 5-111
5.8.9.2 Start motor - check
Consult Sany distributor to check the start mo-

tor. Check it every 1000 service hours if the
engine is started frequently.

5.8.9.3 Accumulator (control oil circuit) - replace
WARNING
The accumulator contains pressurized

nitrogen, which may explode due to im-
proper operation, thus resulting in machine
damage and personal injury. The following
items must be observed when handling the
accumulator:
Some pressure remains in the hydrau-

lic circuit. Never face the opening from
which oil may squirt when disassem-
bling a hydraulic device. In addition,
loosen the bolts slowly.
Never dismantle the accumulator. Fig. 5-112
Never punch or weld the accumulator.
Never bump or roll the accumulator.
Keep it free from any impacts.
Vent the air completely when handling
the accumulator. Consult your Sany dis-
tributor to do this job.
If your machine is kept operating when the

performance of accumulator decreases, the
pressure in the hydraulic system will not be re-
leased. Consult Sany distributor to replace the
accumulator.
The accumulator's installation location is


5.8.9.4 High-pressure tube clamps and rubber - check
Fig. 5-113
Always prepare your machine as required and lock/tag it out before proceeding. See Preparing
the machine on page 2-58 and Lock-out and tag-out on page 2-60.
Check, through visual inspection and feel, for any loose bolts on the five mounting clamps of
high-pressure tubes between feed pump and injection nozzle. Check for any aged rubber. Con-
tact your Sany distributor to replace any part that fails.
5.8.9.5 Compressor working condition - inspect
The following two items are to be inspected:
1. Whether the compressor and the magnetic clutch are switched on/off when switching on/off
the air conditioner.
2. Whether the clutch or compressor produces abnormal noise.
In case of any problem, Contact your Sany distributor for disassembly, repair or replacement
of the parts.

Also perform maintenance for every 100, 250,

500, 1000, 2000 and 4000 service hours in the
meantime.
5.8.10.1 High-pressure tube clamps - re-

place
Contact your Sany distributor to replace the

high-pressure tube clamps on the engine.
Contact your Sany distributor for an overall

maintenance if your machine has worked for
10,000 hours.

E
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SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting
Troubleshooting
6 Troubleshooting
6.1 Troubleshooting Preparation.................................................................................... 6-3
6.1.1 Checks before troubleshooting ...................................................................... 6-3
6.1.2 Troubleshooting procedure ............................................................................ 6-4
6.1.3 Troubleshooting precautions .......................................................................... 6-6
6.1.4 Electrical circuits troubleshooting precautions ............................................... 6-9
6.1.5 Hydraulic components handling precautions ............................................... 6-10
6.2 Pseudo Failures ..................................................................................................... 6-12
6.3 Towing the Machine ............................................................................................... 6-13
6.4 Towing Hook for Light Loads ................................................................................. 6-15
6.5 Severe Operating Conditions................................................................................. 6-15
6.6 Engine Failures ...................................................................................................... 6-16
6.6.1 Engine troubleshooting table ....................................................................... 6-16
6.6.2 Coolant temperature high ............................................................................ 6-19
6.6.3 Engine oil pressure low ................................................................................ 6-20
6.6.4 When fuel exhausts ..................................................................................... 6-22
6.6.5 When engine rotates reversely ................................................................... 6-24
6.7 Failures of the Electrical System ........................................................................... 6-25
6.7.1 Electrical system troubleshooting table........................................................ 6-25
6.7.2 Failure codes ............................................................................................... 6-28
6.8 Battery .................................................................................................................. 6-30
6.8.1 Battery removal and installation ................................................................... 6-30
6.8.2 Battery charging ........................................................................................... 6-31
6.8.3 Jump-starting the engine ............................................................................. 6-32
6.8.3.1 Connecting the jumper cables ............................................................ 6-33
6.8.3.2 Starting the engine .............................................................................. 6-34
Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator
6.8.3.3 Disconnecting the jumper cables ........................................................ 6-34

6.9 Failures of the Hydraulic System ........................................................................... 6-35
6.10 Other Common Failures ...................................................................................... 6-39

6 TROUBLESHOOTING
6.1 Troubleshooting Preparation
6.1.1 Checks before troubleshooting
Item Judgement value Remedy
1. Check fuel level and type of fuel Add fuel

2. Check for impurities in fuel Clean, drain
3. Check hydraulic oil level Add oil
4. Check hydraulic oil strainer Clean, drain
Lubricating 5. Check swing drive oil level Add oil
oil, coolant 6. Check engine oil level (in oil pan) Add oil
7. Check coolant level Add water
8. Check dust indicator for clogging Clean or replace
9. Check hydraulic filter Replace
10. Check final drive oil level Add oil

1. Check for looseness and corrosion of battery termi-
Tighten or replace
nal and wiring

E l e c t r i c a l 2. Check for looseness and corrosion of alternator ter-
Tighten or replace
equipment minal and wiring
3. Check for looseness and corrosion of start motor
Tighten or replace
terminal and wiring
H y d r a u l i c , 1. Check for abnormal noise and smell Repair

mechanical 2. Check for oil leakage Repair
equipment 3. Carry out air bleeding Bleed air
1. Check battery voltage (engine stopped) 20-30V Replace

2. Check battery electrolyte level Add or replace
3. Check for discolored, burnt, exposed wiring Replace
4. Check for missing wiring clamps and hanging wiring Repair
5. Check for water leaking on wiring (be particularly
Electrics, Disconnect con-
careful attention to water leaking on connectors or
electrical nector and dry
terminals)
equipment
6. Check for blown or corroded fuses
Replace
7. Check alternator voltage (engine running at 1/2 After running for
Replace
throttle or above) several minutes:
8. Check operating sound of battery relay 27.5~ 29.5V
Replace
(when switch is turned ON/OFF)
Table 6-1

6.1.2 Troubleshooting procedure
1. Check and determine failure symptom.
Ask for the following information upon ser-

vice request of a client.
Name of client
Model and serial number of machine
Detailed information on job site, etc.
Obtain general information through ques-

tions.
Failure encountered
Working condition when failure occurs
Working environment
Repair and maintenance history
2. Determine possible locations of failure.
Refer to Troubleshooting Section in this

manual in order to find possible locations
of the failure.
3. Prepare tools for troubleshooting.
Tools required:
T-connector
Hydraulic gauge, etc.
Refer to the Parts Book and prepare
necessary replacement parts.
4. Go to job site.
5. Ask operator for more information on the

failure.
Is there any abnormality before the fail-

ure occurred?
Does the failure occurred suddenly?

Did you do any repair when the failure

occurred?
6. Play back the failure.
7. Start the engine and operate the machine

to make sure that the symptom does exist.
Simply determine location of failure and

make repair before performing trouble-
shooting.
Checks before starting

Other checking items
Refer to Troubleshooting Section in this

manual and choose troubleshooting pro-
cedure according to machine symptom be-
fore performing the service work.
8. Work out a service plan.
Repair in work shop.

Repair on job site.

6.1.3 Troubleshooting precautions
WARNING

forming any troubleshooting operations.
Failure to do so can cause machine dam-
age, personal injury or death.
Park your machine on a hard, level

ground. Make sure that the safety pins,
blocks and machine brake are effective.
Co-workers must use the same signal
system. Keep irrelevant people a safe
distance from the machine.
If the radiator cap is removed when the
engine is hot. Hot coolant may squirt
out and cause burns, wait for the engine
to cool down before troubleshooting.
Take care not to touch any hot parts or
be caught by any rotating parts.
Before disconnecting any electrical wir-
ing, always disconnect the negative ()
post of battery.
Before removing the plug or cap from
any vessel that contains pressurized
oil, water or air, release the internal
pressure. When installing a measuring
equipment, be sure to connect it prop-
erly.
The aim of troubleshooting is to pinpoint the

basic cause of the failure, to carry out repairs
swiftly, and to prevent reoccurrence of the fail-
ure.
When carrying out troubleshooting, it is impor-

tant to understand the structure and function.
However, a short cut to effective troubleshoot-

ing is to ask the operator various questions
to form some idea of possible causes of the
failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not

hurry to disassemble the components.
If components are disassembled immedi-

ately any failure occurs:
Parts that have no connection with the

failure or other unnecessary parts will
be disassembled.
It will become impossible to find the

cause of the failure.
It will also cause a waste of man-hours,

parts, or oil or grease, and at the same
time, will also lose the confidence of the
user or operator.
For this reason, when carrying out trouble-

shooting, it is necessary to carry out thor-
ough prior investigation and to carry out
troubleshooting in accordance with the
fixed procedure.
2. Points to ask user or operator:
1) Have any other problems occurred

apart from the problem that has been
reported?
2) Was there anything strange about the

machine before the failure occurred?
3) Did the failure occur suddenly, or were

there problems with the machine condi-
tion before this?
4) Under what conditions did the failure

occur?
5) Had any repairs been carried out before

the failure? When were these repairs
carried out?

6) Has the same kind of failure occurred

before?
3. Check before troubleshooting
1) Check the oil level.
2) Check for any external leakage of oil

from the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve

spool.
5) O t h e r m a i n t e n a n c e i t e m s c a n b e
checked externally, so check any item
that is considered to be necessary.
4. Confirming failure
Confirm the extent of the failure your-

self, and judge whether to handle it as
a real failure or as a problem with the
method of operation, etc.
When operating the machine to reenact

the troubleshooting symptoms, do not
carry out any investigation or measure-
ment that may make the problem worse.
5. Troubleshooting
Use the results of the investigation

and inspection in Items 2 4 to narrow
down the causes of failure, then use the
troubleshooting flowchart to locate the
position of the failure exactly.
The basic procedure for troubleshooting

is as follows.
1) Start from the simple points.
2) Start from the most likely points.

3) Investigate other related parts or

information.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root

cause of the failure is not repaired, the
same failure will occur again. To prevent
this, always investigate why the problem
occurred. Then, remove the root cause.
6.1.4 Electrical circuits troubleshooting

precautions
1. Always turn the power off before discon-

necting or connect connectors.
2. Before carrying out troubleshooting, check

that all the related connectors are properly
inserted.
Disconnect and connect the related con-

nectors several times to check.
3. Always connect any disconnected connec-

tors before going on to the next step.
If the power is turned ON with the con-

nectors still disconnected, unnecessary
abnormality displays will be generated.
4. When carrying out troubleshooting of

circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
If there is any change, there is probably

defective contact in that circuit.

6.1.5 Hydraulic components handling precautions
With the increase in pressure and precision

of hydraulic equipment, the most common
cause of failure is dirt (foreign material) in the
hydraulic circuit. When adding hydraulic oil, or
when disassembling or assembling hydraulic
equipment, it is necessary to be particularly
careful.
1. Be careful of the operating environment
Avoid adding hydraulic oil, replacing filters,

or repairing the machine in rain or high
winds, or places where there is a lot of
dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is

carried out on hydraulic equipment in the Fig. 6-1
field, there is danger of dust entering the
equipment. It is also difficult to confirm the
performance after repairs, so it is desir-
able to use unit exchange. Disassembly
and maintenance of hydraulic equipment
should be carried out in a specially pre-
pared dust-proof workshop, and the per-
formance should be confirmed with special
test equipment.
3. Do not let any dirt or dust get in during

refilling operations.
Be careful not to let any dirt or dust get

in when refilling with hydraulic oil. Always
keep the oil filler and the area around it
clean, and also use clean pumps and oil
containers. If an oil cleaning device is
used, it is possible to filter out the dirt that
has been collected during storage, so this
is an even more effective method.
Fig. 6-2

4. Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it

flows easily. In addition, the sludge can
also be drained out easily from the circuit
together with the oil, so it is best to change
the oil when it is still warm. When changing
the oil, as much as possible of the old hy-
draulic oil must be drained out. (Drain the
oil from the hydraulic tank; also drain the
oil from the filter and from the drain plug in
the circuit.) If any old oil is left, the contam-
inants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic
oil.
5. Flushing operations
After disassembling and assembling

the equipment, or changing the oil, use
flushing oil to remove the contaminants,
sludge, and old oil from the hydraulic cir-
cuit. Normally, ushing is carried out twice:
primary ushing is carried out with ushing
oil, and secondary flushing is carried out
with the specified hydraulic oil.
Fig. 6-3
6. Cleaning operations
After repairing the hydraulic equipment

(pump, control valve, etc.) or when run-
ning the machine, carry out oil cleaning to
remove the sludge or contaminants in the
hydraulic oil circuit. The oil cleaning equip-
ment is used to remove the ultra fine (about
3) particles that the filter built into the hy-
draulic equipment cannot remove, so it is
an extremely effective device.
Fig. 6-4

6.2 Pseudo Failures

Note that the following failures are pseudo
ones:
The arm speed may drop suddenly when

retracting the arm with the work equipment
lowering unloaded and the arm in a nearly
vertical position.
Fig. 6-5
When the bucket tips are nearly parallel

to the ground, the bucket speed may drop
suddenly.
Fig. 6-6
The brake valve produces noise when

starting or stopping swinging operation.
The travel motor produces noise when the
machine travels downhill at low speed.

6.3 Towing the Machine
WARNING
Towing the machine improperly or using

wire cables beyond the specification could
lead to serious injury or death.
Make sure that the wire cables used for

towing the machine are strong enough,
which may otherwise result in acci-
dents.
While towing the machine, do not use
wire cables with broken wires (A), re-
duced diameter (B) or knot (C) in order
to prevent rupture of the wire cables.
Always wear protective gloves when
handling wire cables.
Fig. 6-7
Never tow the machine on a slope.
Never stand between the towing ma-
chine and the towed machine when
performing towing operation.
Operate the machine slowly and avoid
imposing sudden load on wire cable.
Note:
The towing operation must be performed with-

in the maximum towing capacity.

If the machine is trapped in mud and can-

not move out of the mud with its own force,
or the towing force of excavator is occu-
pied by heavy object, wire cables can be
used as shown in the right illustration.
Place wood blocks or other protective
materials between where the wire cable
contacts the machine in order to prevent
friction between the wire cable and the ma-
Fig. 6-8
chine.
Keep the wire cable parallel to the ground
and align its direction with that of the track
frame.
Move at a speed of 1Km/h when towing
the machine. Tow the machine to a place
suitable for repair. Never tow the machine
over a long distance.
Towing of the machine is only allowed in
case of emergency.
Fig. 6-9

6.4 Towing Hook for Light Loads
WARNING
Towing the machine improperly could

cause severe accidents. The following
items must be observed when towing
the machine.
Shackle must be used.
Keep the wire cable parallel to the
ground and align its direction with that
of the track frame.
Move the machine slowly and avoid im-
posing sudden load on wire cable.
The track frame has an eye, which can be

hooked when towing a light object.
Fig. 6-10
6.5 Severe Operating Conditions
When performing excavation in water, if the
installation pins of work tool go below wa-
ter surface, it is necessary to add grease
to the pins before each operation.
For heavy-loaded operation and deep ex-
cavation, it is necessary to add grease to
the installation pins of the work tool before
each operation. Cycle the operation of the
boom, stick and bucket for several times
before refilling the grease.

6.6 Engine Failures
6.6.1 Engine troubleshooting table
Check the engine according to the following table if any failure occurs to it. Contact your Sany
distributor to repair the engine.
Failure Causes Remedy

Recharge/replace the bat-
Battery low
tery.
Engine start switch internal failure
Replace
Pilot switch failure
Repair/replace
Start motor failure
Repair/replace
Unable to start the en- Open circuit of wire harness
Check/repair
gine Fuse failure (F1)
Replace
Short circuit of wire (grounding failure)
Check/repair
Alternator internal failure
Repair/replace
Start relay failure
Replace
Brake failure
Repair/replace
Open circuit of wire harness Check/repair
Sensor internal failure Replace
Rough engine speed
Short circuit of wire (grounding failure) Check/repair
Unable to power off the Battery relay failure Replace
machine Breakdown of surge diode Replace
Boom-up signal failure Check/repair
Boom-down signal failure Check/repair
Arm-in signal failure Check/repair
Arm-out signal failure Check/repair
Bucket-dig signal failure Check/repair
Auto idle fails.
Bucket-dump signal failure Check/repair
Swing signal failure Check/repair
Travel signal failure Check/repair
Attachment signal failure Check/repair
Controller failure Replace
Preheat fuse failure Replace
Preheat relay failure Replace
Preheating function fails.
Preheat controller failure Replace
Hydraulic lockout control failure Repair/replace
All devices fail. Short circuit of wire (grounding failure) Check/repair
Failure of internal coil of pilot lockout valve Replace
Sensor failure Replace
Short circuit of harness (grounding failure) Check/repair
Boom slow and weak
Open circuit of harness Check/repair


Arm slow and weak
Bucket slow and weak Open circuit of harness Check/repair
Bucket conuence solenoid valve failure Replace
Travel slow and weak
Fuse failure Replace
Open circuit of wire Check/repair
Monitor black-out
Monitor failure Replace
Resistor failure Replace
Monitor displays nothing.
Monitor or controller failure Replace
Dual travel speed solenoid valve failure Replace
Dual-travel speed failure Open circuit of wire Check/repair
Coolant temperature sensor failure Replace
Engine coolant tempera- Open circuit of wire Check/repair
ture reading incorrect Short circuit of wire (grounding failure) Check/repair
Wire short-circuited with 24V Check/repair
Fuel level sensor failure Replace
Fuel level reading incor- Open circuit of wire Check/repair
rect Short circuit of wire (grounding failure) Check/repair
Wiper motor internal failure Repair/replace
Wiper failure Open circuit of wire Check/repair
5V power supply failure Repair/replace
Arm-in pilot pressure Open circuit of signal line Check/repair
reading incorrect Short circuit of signal line Check/repair
Arm-out pilot pressure Open circuit of signal line Check/repair


Boom-up pilot pressure Open circuit of signal line Check/repair
Boom-down pilot pres- Open circuit of signal line Check/repair
sure reading incorrect Short circuit of signal line Check/repair
Bucket-dig pilot pressure Open circuit of signal line Check/repair
Bucket-dump pilot pres- Open circuit of signal line Check/repair
Swing pilot pr essure Open circuit of signal line Check/repair
Travel pilot pressure Open circuit of signal line Check/repair
Table 6-2

6.6.2 Coolant temperature high
CAUTION
Never remove the radiator cap when the

coolant is still hot. Hot water or steam
may squirt and cause burns.
Wait the coolant to cool down before re-
moving the radiator cap.
NOTICE
Do not stop the engine immediately.

sudden rise of coolant temperature can
cause engine parts to burn.
Refill the coolant slowly in several
times. Quick filling of low-temperature
coolant can cause engine cracks.
When the coolant temperature gauge shows

a temperature higher than 100C, the coolant
temperature alert indicator will be on. Stop op-
erating your machine and keep engine running
at a speed a little higher than idle in order to
reduce temperature. When the pointer of cool-
ant temperature gauge returns to the middle
position, the alert indicator is off. Now, stop the
engine and perform the following steps.

Always prepare your machine as required and

lock out/tag out your machine before proceed-
ing. See Preparing the machine on page
2-58 and Lock-out and tag-out on page
2-60.
1. Check radiator hoses for coolant leak.
2. Check V-belt for rupture. Check the belt

tension.
3. Check coolant level. Refill coolant if neces-

sary. Fig. 6-11
Remove the radiator cap (1) and refill

coolant to the opening. Tighten the cap
properly.
Open the reservoir (2) and refill coolant
to the FULL mark. Tighten the cap prop-
erly.
4. Check the front of radiator for any contami-
nants.
5. If your machine has coolant leak or often

encounters higher coolant temperature, the
cooling system has a problem. Fig. 6-12
6.6.3 Engine oil pressure low
NOTICE
When oil pressure low alert indicator is on,

shut down the engine immediately. Dam-
age could occur to the engine if leave it
running.
When the engine is just started, the oil pres-

sure gauge indicates high pressure before the
engine is preheated. Check oil pressure after
the engine is fully preheated.
When engine oil pressure gauge shows a val-

ue lower than the one given in the following ta-

ble, the low oil pressure alert indicator and oil

filter alert indicator will be on at the same time,
altering that oil pressure is abnormal. Stop
operating your machine, shut down the engine
immediately, and proceed as the following.
Always prepare your machine as required and

lock out/tag out your machine before proceed-
ing. See Preparing the machine on page
2-58 and Lock-out and tag-out on page
2-60.
1. Check for oil leak.
2. Check engine oil level. Refill oil when

required.
Remove the dipstick (1). Wipe off the oil

on dipstick(1) with cloth.
Fully insert the dipstick into oil and then
slowly pull it out.
If oil level between the marks L and H,
the amount of oil is good.
If oil level is low, refill it immediately. If Fig. 6-13
engine oil is contaminated, change the
oil immediately.
Replace the dipstick(1) after checking.
3. If engine oil level is normal but abnormal

pressure of engine oil is altered, contact
your Sany distributor in time to solve the
problem.
Fig. 6-14

6.6.4 When fuel exhausts
When fuel exhausts, it is necessary to refuel

the engine and purge air from the fuel system
before restarting it.
WARNING
Never use a lighter, smoke, or use other

fire sources when purging the air. A fire
source can cause fire.
Completely remove engine oil or fuel
splashed onto the exhaust pipe and
other places. These oil and fuel can
cause fire or slipping accident.
The space for air-purging operation is
limited. Take care not to be cut by the
edges.
1. Turn counterclockwise the handle (1) of

manual pump to release it.
Fig. 6-15
2. Loosen air vent plug (2) on fuel filter and

cover it with cloth.
Fig. 6-16
3. Repeatedly push the pump to transfer fuel

until no foam is seen at the vent.
Fig. 6-17
4. Retighten plug (2) when you are sure no

foam is seen.
Plug tightening torque
9.82.0Nm {10.2 kgfm}
Fig. 6-18
5. Continue to operate the manual pump until

heavy resistance is felt.
Resistance of pump operation may not rise

when fuel temperature is low. It is neces-
sary to operate the pump continuously and
repeatedly.
Fig. 6-19
6. After purging the air, completely remove

WARNING
splashed fuel before starting the engine.
7. Make sure no fuel leaks. Make sure no fuel leaks from filter and its
housing. Fuel leak could cause fire.

6.6.5 When engine rotates reversely
WARNING
Reverse rotation of engine can burn the

engine within several minutes or cause
severe injury. Shut down the engine imme-
diately once reverse rotation is found. The
exhaust gas from air cleaner is possible to
cause fire.
The following symptoms can be used to iden-

tify reverse rotation of engine.
High colliding sound produced after start-

ing
Heavy smoke coming out air cleaner
Tachometer and oil pressure gauge giving
no response
Low oil pressure alert indicator on
Check and clean the air cleaner and intake
hoses after shutting down the engine. Replace
any defective air cleaner or hose immediately.

6.7 Failures of the Electrical System
6.7.1 Electrical system troubleshooting table
Trouble-shoot the electrical system according to the following tables. Contact your Sany distribu-
tor solve the problem.
Recharge/replace the bat-

Battery low
tery.
Engine start switch internal failure
Replace
Pilot switch failure
Repair/replace
Start motor failure
Repair/replace
Unable to start the en- Open circuit of wire harness
Check/repair
gine Fuse failure (F1)
Replace
Short circuit of wire (grounding failure)
Check/repair
Alternator internal failure
Repair/replace
Start relay failure
Replace
Brake failure
Repair/replace
Open circuit of wire harness Check/repair
Rough engine speed
Unable to power off the Battery relay failure Replace
machine Breakdown of surge diode Replace
Boom-up signal failure Check/repair
Boom-down signal failure Check/repair
Arm-in signal failure Check/repair
Arm-out signal failure Check/repair
Bucket-dig signal failure Check/repair
Auto idle fails.
Bucket-dump signal failure Check/repair
Swing signal failure Check/repair
Travel signal failure Check/repair
Attachment signal failure Check/repair
Preheat fuse failure Replace
Preheat relay failure Replace
Preheating function fails.
Preheat controller failure Replace
Hydraulic lockout control failure Repair/replace
All devices fail. Short circuit of wire (grounding failure) Check/repair
Failure of internal coil of pilot lockout valve Replace
Boom slow and weak


Arm slow and weak
Bucket slow and weak Open circuit of harness Check/repair
Bucket conuence solenoid valve failure Replace
Travel slow and weak
Fuse failure Replace
Monitor black-out
Monitor failure Replace
Resistor failure Replace
Monitor displays nothing.
Monitor or controller failure Replace
Dual travel speed solenoid valve failure Replace
Dual-travel speed failure Open circuit of wire Check/repair
Coolant temperature sensor failure Replace
Engine coolant tempera- Open circuit of wire Check/repair
ture reading incorrect Short circuit of wire (grounding failure) Check/repair
Fuel level sensor failure Replace
Fuel level reading incor- Open circuit of wire Check/repair
rect Short circuit of wire (grounding failure) Check/repair
Wiper motor internal failure Repair/replace
Wiper failure Open circuit of wire Check/repair
Arm-in pilot pressure Open circuit of signal line Check/repair
Arm-out pilot pressure Open circuit of signal line Check/repair


Boom-up pilot pressure Open circuit of signal line Check/repair
Boom-down pilot pres- Open circuit of signal line Check/repair
Bucket-dig pilot pressure Open circuit of signal line Check/repair
Bucket-dump pilot pres- Open circuit of signal line Check/repair
Swing pilot pr essure Open circuit of signal line Check/repair
Travel pilot pressure Open circuit of signal line Check/repair
Table 6-3

6.7.2 Failure codes
The failure code(1) displayed on the monitor

can be used to make failure analysis.
Fig. 6-20
Failure
Symptom Alarm Trigger Condition
Code
Oil pressure lower than 200 and engine speed higher than
3 Engine oil pressure low
800 for 15s
4 Fuel level low Fuel level lower than 10% for 10s
Coolant temperature higher than 105C or coolant tempera-
5 Coolant temperature high
ture over-high pressure switch off
6 Air cleaner plugged Air cleaner plugging pressure switch off
Engine speed lower than 800 rpm but higher than 400 rpm
7 Engine speed low
for 3s
8 Engine speed high Engine speed higher than 2500 rpm
10 Hydraulic oil temperature high Hydraulic oil temperature higher than 90C for 10s
Motor feedback voltage lower than 0.25V or higher than 4.75V
12 Motor working range irregular
for 3s
Front pump pressure sensor Front pump pressure collecting volt lower than 0.25V or
20
abnormal higher than 4.75V for 3s
Rear pump pressure sensor Rear pump pressure collecting volt lower than 0.25V or high-
21
abnormal er than 4.75V for 3s
Bucket-dig pilot pressure sen- Bucket-dig pilot pressure collecting volt lower than 0.25V or
22
sor abnormal higher than 4.75V for 3s
Bucket-dump pilot pressure Bucket-dig pilot pressure collecting volt lower than 0.25V or
23
sensor abnormal higher than 4.75V for 3s
Arm-in pilot pressure sensor Arm-in pilot pressure collecting volt lower than 0.25 and
24
abnormal higher than 4.75 for 3s
Arm-out pilot pressure sensor Arm-out pilot pressure collecting volt lower than 0.25 and
25

Failure
Symptom Alarm Trigger Condition
Code
Boom-up pilot pressure sensor Boom-up pilot pressure collecting volt lower than 0.25 and
26
Boom-down pilot pressure sen- Boom-down pilot pressure collecting volt lower than 0.25 and
27
sor abnormal higher than 4.75 for 3s
Left travel pilot pressure sensor Left travel pilot pressure collecting volt lower than 0.25 and
28
Right travel pilot pressure sen- Right travel pilot pressure collecting volt lower than 0.25 and
29
sor abnormal higher than 4.75 for 3s
Swing pilot pressure sensor Swing pilot pressure collecting volt lower than 0.25 and high-
30
abnormal er than 4.75 for 3s
Front pump proportional valve Front pump proportional valve current higher than 1300mA
34
overcurrent for 3s
Rear pump proportional valve Rear pump proportional valve current higher than 1300mA for
35
overcurrent 3s
Front pump proportional valve Front pump proportional valve current lower than 200mA for
36
undercurrent 3s and controller PWM output higher than 10V
Rear pump proportional valve Rear pump proportional valve current lower than 200mA for
37
undercurrent 3s and controller PWM output higher than 10V
Front pump proportional valve feedback current lower than
38 Front pump proportional valve 150mA or higher than 1350mA for 3s and controller PWM
duty output higher than 10V
Rear pump proportional valve feedback current lower than
39 Rear pump proportional valve 150mA or higher than 1350mA for 3s and controller PWM
duty output higher than 10V
Hydraulic oil temperature sen- Hydraulic oil temperature collecting volt lower than 0.25V or
40
sor abnormal higher than 4.75V for 3s
Coolant temperature collecting resistance lower than 10 or
41 Coolant sensor abnormal higher than 120 for 3s after 30 minutes since engine start-
ing
Fuel level collecting resistance lower than 10 or higher than
42 Fuel level sensor abnormal
120 for 3s
43 Speed sensor abnormal Speed collecting frequency lower than 100 for 3s under load
Fuel control dial collecting volt lower than 0.25V or higher
44 Fuel control dial abnormal
than 4.75V for 3s
CAN communication monitoring component overtime or reset
45 CAN bus abnormal
characters changed for 3s
Table 6-4

6.8 Battery
WARNING
It is dangerous to charge a battery

while it is installed on the machine. Re-
move the battery before charging it.
Stop the engine and turn the start
switch key to OFF position before
checking or handling the battery.
Wear goggles and rubber gloves when
handling the battery.
Disconnect first the grounding cable
(negative terminal (-)) before removing
the battery. Connect first the positive
terminal (+) while installing the bat-
tery. Be especially careful with your
tools, which may produce sparks when
touching the positive terminals and the
chassis.
A loose terminal can result in improper
contact, which may cause sparks and
Fig. 6-21
explosion.
Check that which terminal is positive
(+) and which one is negative (-) when
removing or installing the terminals.
6.8.1 Battery removal and installation
Disconnect the grounding cable (generally

the one in connection with the negative ter-
minal (-)) before removing the battery.
Sparks can occur if your tool touches the
positive terminal and the chassis.
Secure the battery with clamping plates
when changing the battery.

6.8.2 Battery charging
Improper handling can result in explosion

when the battery is charged. Follow the in-
struction, seeBatteryon page 6-30 and the
instruction of charger, and proceed the proce-
dure below:
Regulate the charger to the voltage appli-

cable to the battery. Incorrect voltage can
over heat the charger and cause explo-
sion.
Fig. 6-22
Connect the charger's positive clip (+) to
the battery's positive terminal (+). Connect
the charger's negative clip (-) to the bat-
tery's negative terminal (-). The wire clips
must be fixed.
Regulate the charging current to 1/10 of
the rated capacity of battery. In case of
quick charging, regulate the charging cur-
rent to a level below the rated capacity of
battery. Larger charging current may cause
leakage or evaporation of electrolyte,
hence fire and explosion.
If the battery electrolyte freezes, do not
charge the battery, or use an alternate
power supply to start the engine. Charging
a frozen battery may cause electrolyte to
catch on fire and the battery to explode.

6.8.3 Jump-starting the engine
WARNING
Never let the positive terminal (+) con-

tact with the negative terminal (-) when
connecting the cable.
Keep a normal machine away from
the faulty machine in order to prevent
sparks around the battery from burning
the hydrogen released from the battery.
Avoid mistakes in connection of the
jumper cable. Its final connection with
upper structure of the machine can Fig. 6-23
produce sparks. In this case, the bat-
tery shall be connected to a location
that is far enough from the battery. (But
the work tool shall be excluded as the
work tool is not a good conductor.)
When removing the jumper cables, pay
extra attention to the cables, whose
clips shall not contact with each other
or with the chassis.
Note:
The start system of the machine is sup-

plied with a 24V power source. Two 12V
batteries are connected serially to supply
power to a normally-operating machine.
The sizes of jumper cables and clips shall
match the size of battery.
Generally, the batteries of the machine
shall have the same capacity with the en-
gine to be started.
Check the cables and clips for damage or
corrosion.
Make sure that the cables and clips are
connected securely.
Check both machines whether their lock-
out controls and brake levers are in the

"LOCKED" position.
Check the control levers whether they are
in the neutral position.
6.8.3.1 Connecting the jumper cables
Turn the start switches of the normal machine

and the faulty machine to the OFF position.
Connect the jumper cables in the numbered

sequence, as shown in the diagram.
1. Connect the clip of jumper cable (A) to the

positive terminal (+) of battery (C) of the
faulty machine.
2. Connect the clip on the other end of jumper

cable (A) to the positive terminal (+) of bat-
tery (D) of the normal machine.
3. Connect the clip of jumper cable (B) to the

negative terminal of battery (D) of the nor-
mal machine.
4. Connect the clip on the other end of jumper

cable (B) to the swivel frame (E) of the faulty Fig. 6-24
machine.

6.8.3.2 Starting the engine
WARNING
Check the lockout control, which must

be in the "LOCKED" position regardless
of that the machine is operating normally
or has trouble. Check all control levers,
which shall be in the "retaining" or neutral
position.
1. Make sure the clips are securely connected

with terminals of the battery.
2. Start the engine of the good machine and

run it at high idle.
3. Turn the start switch of the faulty machine

to "START" position and start the engine.
If the engine fails to start, wait for two minutes

before attempting to restart it.
6.8.3.3 Disconnecting the jumper cables
After the engine is started, disconnect the

jumper cables in steps reversed to their con-
nection.
1. Disconnect the clip of the jumper cable (B)

from the swivel frame (E) of the faulty ma-
chine.
2. Disconnect the clip of the jumper cable (B)

from the negative terminal (-) of battery (D)
of the normal machine.
3. Disconnect the clip of jumper cable (A) from

the positive terminal (+) of battery (D) of the
Fig. 6-25
normal machine.
4. Disconnect the clip of jumper cable (A) from

the positive terminal (+) of battery (C) of the
faulty machine.

6.9 Failures of the Hydraulic System

Trouble-shoot the hydraulic system according to the following tables. Contact your Sany dis-
tributor solve the problem.
Set the working mode to S and the fuel control dial to position 10 before troubleshooting
Bad adjustment or failure of main relief valve Replace

Pilot relief valve failure Replace
Work equipment moving
Regulator failure Repair/replace
slowly, or travel and swing
Plunger pump failure Check/repair
speed slow
Failure of pilot proportional solenoid valve of Repair/replace
right joystick
Pilot safety valve failure Repair/replace
Work equipment, final drive
Pilot pump relief valve failure Replace
or swing drive not function-
Hydraulic pump failure Check/repair
ing
Coupling failure Check/repair
Hydraulic oil level low Refill hydraulic oil
Bad hydraulic oil Use suitable hyd oil
Abnormal noise in hydraulic
Hydraulic tank cap vent plugged Clean/replace
pump
Hydraulic tank filter screen plugged Clean/replace
Plunger pump failure Check/repair
Auto idle not functioning Pilot valve failure Replace
Controller failure Repair/replace
Right pilot valve (boom circuit) failure Check/repair
Pressure sensor failure Replace
Boom control valve (spool) failure Repair/replace
Boom speed slow Boom control valve (retaining valve) failure Repair/replace
Boom control valve (Safety valve and feed Repair/replace
valve) seal failure
Boom cylinder failure Check/repair
Left pilot valve (arm circuit) failure Check/repair
Arm control valve (spool) failure Repair/replace
Arm speed slow Arm control valve (regeneration valve) failure Repair/replace
Arm control valve (Safety valve and feed valve) Repair/replace
or seal failure
Arm cylinder failure Check/repair
Check/repair
Right pilot valve (bucket circuit) failure
Replace
Pressure sensor failure
Repair/replace
Bucket control valve (spool) failure
Repair/replace
Bucket speed slow Bucket control valve (regeneration valve) failure

Bucket control valve (Safety valve and feed
Repair/replace
valve) or seal failure

Bucket cylinder failure
Check/repair

Pilot valve failure Check/repair

One cylinder of work equip-
ment not working
Work equipment control valve (spool) failure Repair/replace
Work equipment cylinder failure Repair/replace
Retaining valve (of boom or arm) failure Repair/replace
Work equipment cylinder
Work equipment control valve (safety valve and Repair/replace
drifting excessively
feed valve) seal failure
Work equipment valve spool failure Repair/replace
Arm regeneration valve failure
Repair/replace
Work equipment sluggish Control valve (safety valve and feed valve) fail-
Repair/replace
ure
Other work equipment
moves when single cylinder Control valve seal failure Replace
is in relief.
Travel speed drops remark-
ably during swing or travel Straight travel valve failure Repair/replace
operation.
Travel pilot valve failure Repair/replace
Regulator failure Repair/replace
Machine runs out during Proportional solenoid valve sluggish Repair/replace
travel Travel valve spool sluggish Repair/replace
Central swivel joint sluggish Repair/replace
Travel motor failure Repair/replace
Travel pilot pressure sensor failure Replace
Travel speed slow
Travel control valve (spool) failure Repair/replace
Travel control valve (feed valve) failure Repair/replace
Travel motor failure Check/repair
Travel pilot pressure sensor failure Replace
Machine steering difficult or Travel control valve (spool) failure Repair/replace
power insufficient Travel control valve (feed) failure Repair/replace
Travel motor (safety valve) failure Repair/replace
Travel motor (check valve) failure Repair/replace
High/low travel speed shift valve failure Repair/replace
Unable to shift travel speed
Travel control valve (feed valve) seat failure Repair/replace
Travel motor (safety valve) seat failure Repair/replace
Travel fails (on one side) Travel motor (feed valve) seat failure Repair/replace
Pilot pressure sensor failure Replace

Swing motor (parking brake) failure Check/repair

Bad adjustment or failure of swing motor (safety Adjust/replace
Unable to swing
In both directions valve)

Swing motor failure Check/repair
Swing drive failure Check/repair
Pilot valve failure Repair/replace

In one direction Swing control valve (spool) failure Repair/replace
Swing motor (feed valve) seal failure Replace
Swing motor (parking brake) failure Check/repair
valve)
Acceleration perfor-
Swing speed slow
mance bad
Brake control line blocked Remove obstruction
or replace the pipe-
line.
B a d a c c e l e r a t i o n Swing motor (pressure compensation valve) fail- Repair/replace
performance on one ure
side or swing speed Swing motor (feed valve) seal failure Replace
slow Leak on one side the shuttle valve of swing pilot Repair/replace
pressure sensor
Too much overrun in swing stoppage
In both directions valve)


In one direction Swing control valve (spool) failure Repair/replace
Swing motor (feed valve) seal failure Replace
Swing pilot valve failure Repair/replace

Too much jerk in swing
Swing anti-jerk valve failure Repair/replace
stoppage
Swing relief valve failure Repair/replace
Back pressure valve failure Repair/replace
High abnormal noise in Swing motor (safety valve) failure Repair/replace
swing stoppage Swing motor (feed valve) failure Repair/replace
Swing system mechanical failure Check/repair


Excessive hydraulic drift of swing
When swing brake Swing brake control line failure Check/repair

engaged Swing motor (parking brake) failure Repair/replace
Swing control valve (spool) failure Repair/replace

When swing brake
Swing motor (relief valve) failure Repair/replace
disengaged
Swing motor (feed valve) failure Repair/replace
Table 6-5

6.10 Other Common Failures
Loose fastener Check and retighten.

Structure member
noise loud Bigger clearance between arm and buck- Reduce the clearance to a value that
et end faces due to wear is smaller than 1mm.
Spring deformed and weak due to re-
Bucket tip falls off dur- peated use of bucket tip pin Replace bucket tip pin
ing operation.
Bucket tip pin not matching the adaptor
Loose track Tighten the track
Track kinks. Traveling at high speed on rough road in Travel slowly on rough road in the
the direction of sprocket direction of idler.
Improper electrical connection or con-
nector contact
Fan not working Air ow control switch, relay or tempera- Repair/replace.
ture control switch damaged
Fuse exploded or battery voltage low
Air intake side blocked
Fan running but pro- Evaporator or condenser fin plugged,
Clean/replace.
ducing less air ow giving ineffective heat conduction
Fan vane seized or damaged
Compressor clutch not picking up due to Repair
wire break or defective contact of electri-
cal circuit
Compressor not work- Loose compressor belt Adjust the tension of compressor
ing or working with diffi- belt
culty Wire break or failure of compressor Replace clutch coil
clutch coil
Insufficient or excessive refrigerant Refill/drain the refrigerant to a suit-
able level
Refrigerant leaks. Eliminate the leaking point.
Refrigerant insufficient
Insufficient refilling Refill suitable amount of refrigerant.
High/low pressure Ambient temperature30 50

reading in normal op- High pressure gauge: 1.47 1.67MPa15 17kgf/cm2
eration Low pressure gauge: 0.13 0.20MPa1.4 2.11kgf/cm2
Low pressure gauge
Expansion valve opening excessively. Replace expansion valve.

Low pressure Defective contact of expansion valve Install thermo-bulb correctly.
reads higher.
tube surface thermo-bulb

frosted Excessive refrigerant in the system Drain refrigerant to the specified
level.

Both high and

low pressure
gauge read- Refill refrigerant to the specified
Low pressure gauge reads
Refrigerant insufficient
ings lower level.
the standard
value.
Low pressure
Low pressure hose blocked; expansion Repair the system. Replace reser-
gauge could
valve blocked by ice or contaminants. voir in case of ice blockage.
read negative.
lower.
Evaporator
Thermostat failure Replace thermostat.
frozen
Expansion valve inlet
Expansion valve blocked. Clean/replace expansion valve.
felt cool and frosted.
Expansion valve outlet

is not felt cool. Low Expansion valve thermo-tube or bulb Replace expansion valve.
pressure could be leaks.
negative.
Both high/
low pressure Air trapped in circulation system.
High pressure gauge reads higher.
Empty the system and vacuate to

gauges read refill refrigerant.
higher than Excessive refrigerant refilled. Drain refrigerant to the specified
standard level.
value.
Bad condens- Condenser blocked by dust and debris Clean the condenser.
ing effect of
condenser. Condenser fan damaged Check/replace condenser fan.
Both high and

low pressure Refrigerant insufficient Refill refrigerant as required.
gauges read
lower.
High
pressure Low pres-
gauge sure could be Low pressure line blocked/damaged Clean/replace faulty component.
reads negative.
lower.
Condenser
and high
pressure tube Compressor internal failure Replace compressor.
hot
Bad refrigerating effect
Hot water valve damaged and left open Replace hot water valve.
due active heater
Table 6-6

E
G
PA
K
AN
BL

E
G
PA
K
AN
BL

SY115C9/135C/155H Crawler Hydraulic Excavator Specifications
Specifications
7 Specifications
7.1 Machine Dimensions ............................................................................................... 7-3
7.2 Working Ranges ..................................................................................................... 7-4

Specifications SY115C9/135C/155H Crawler Hydraulic Excavator

7 SPECIFICATIONS
7.1 Machine Dimensions
Fig. 7-1
Item Unit SY115C9 SY135C8/C9 SY135C8(M) SY155H

Operating weight kg 12400 13,500 14,100
3
Bucket capacity m 0.48 0.54 0.6
Engine model 4BG1-TABGC-03-C2 4D34-TLE2A BB-4BG1TRP
Engine power kW/rpm 72.7 / 2200 70 / 2050 72.7 / 2200
A Shipping length mm 7280 7700 7700
B Total width mm 2550 2550 2550
C Shipping height mm 2810 2815 2815
D Top width mm 2480 2490 2580
E Total height to top of cab mm 2810 2740 2740
Standard width of track
F mm 500 500 500
shoe
G Gauge mm 1990 1990 1990
Min. ground clearance
H mm 422 425 425
Excluding grouser
I Tail swing radius mm 2325 2240 2240
J Track grounding length mm 2680 2930 2930
K Track length mm 3360 3665 3665
Ground clearance of upper
L structure (excluding grous- mm 915 870 870
er)
Travel speed (high/low) km/h 3.5/5.5 3.5 / 5.5 3.5 / 5.5
Swing speed rpm 12 12 12
Table 7-1

7.2 Working Ranges
Fig. 7-2

Item Unit SY115C9 SY135C8/C9 SY155H

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

E
G
PA
K
AN
BL

SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment
Optional Equipment
8 Optional Equipment
8.1 General Safety ........................................................................................................ 8-3
8.1.1 Selection precautions..................................................................................... 8-3
8.1.2 Reading the instruction books........................................................................ 8-3
8.1.3 Removal and installation precautions ........................................................... 8-3
8.1.4 Operation precautions.................................................................................... 8-4
8.2 Hydraulic Control Elements and Oil Circuit ............................................................. 8-6
8.2.1 Location of the components ........................................................................... 8-6
8.2.1.1 Stop valve ............................................................................................. 8-6
8.2.1.2 Selector valve ....................................................................................... 8-7
8.2.1.3 Control pedal......................................................................................... 8-7
8.2.2 Hydraulic circuit.............................................................................................. 8-8
8.2.2.1 Hydraulic circuit switching ..................................................................... 8-8
8.2.2.2 Shifting to breaker / general optional equipment .................................. 8-8
8.2.2.3 Connecting hydraulic oil circuit ............................................................. 8-9
8.2.2.4 Hydraulic oil passage .......................................................................... 8-10
8.2.3 Optional equipment removal and installation ................................................8-11
8.2.3.1 Removal ...............................................................................................8-11
8.2.3.2 Optional equipment installation .......................................................... 8-13
8.2.4 Hydraulic oil and hydraulic tank filter - change/replace ............................... 8-15
8.2.5 Long-term storage........................................................................................ 8-16
8.2.6 Hydraulic specifications ............................................................................... 8-16
8.3 Optional equipment Guide ..................................................................................... 8-17
8.3.1 Work equipment combination ...................................................................... 8-17
8.3.2 Bucket tips selection .................................................................................... 8-19
8.3.2.1 Rockwork bucket tips .......................................................................... 8-19
Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator
8.3.2.2 Earthwork bucket tips.......................................................................... 8-19

8.4 Recommended Operations .................................................................................... 8-20
8.4.1 Hydraulic breaker ......................................................................................... 8-20
8.4.2 Hydraulic breaker operation ......................................................................... 8-21
8.6 Hydraulic Breaker Lubrication................................................................................ 8-25
8.7 Quick Coupler and Control System ....................................................................... 8-26
8.7.1 Quick coupler installation ............................................................................. 8-26
8.7.2 Operating precautions ................................................................................. 8-28
8.8 Refueling System.................................................................................................. 8-29
8.8.1 Introduction .................................................................................................. 8-29
8.8.2 Components................................................................................................. 8-30
8.9 Central Lubrication System.................................................................................... 8-31
8.9.1 Scheme and components ............................................................................ 8-31
8.9.2 System working principle ............................................................................. 8-33
8.9.3 Setting the lubrication time of electric grease pump .................................... 8-34
8.9.4 Technical description.................................................................................... 8-35
8.9.5 Adding grease with electric pump ................................................................ 8-36

8 OPTIONAL EQUIPMENT
8.1 General Safety

It is important to be safe when an optional
equipment is used. Read the following precau-
tions before selecting, installing and operating
an optional equipment.
8.1.1 Selection precautions
Consult your Sany distributor before install-

ing an optional equipment to your machine.
Front guard, top guard or other protective
structures may be required according to
the type of optional equipment to be used.
Only Sany-approved optional equipment
can be installed. Sany assumes no re-
sponsibility to accidents, losses or failures
caused by any attachment that has not
been approved by Sany.
8.1.2 Reading the instruction books
Read and understand the instruction books

of your machine and of attachment or op-
tional equipment before installation and
operation.
If the instruction book is missing or dam-
aged, ask the manufacturer or your Sany
distributor to obtain a new one.
8.1.3 Removal and installation precau-

tions
To be safe, the following items must be ob-

served before you remove or install an attach-
ment or optional equipment.
The removal or installation procedure must

be performed on a hard, level ground.

If the job has to be done by two or more

persons, appoint a chief and follow his in-
struction.
Use a crane if you handle an object that
weighs over 25 kg. (Only eligible, experi-
enced personnel with official license are
allowed to operate a crane.)
Never stay under an object that is being
lifted by a crane.
Do not operate your machine when an
object is being lifted with crane during re-
moval or installation. Support can be used
to prevent falling from the object when nec-
essary.
When a heavy part is to be removed, it is
necessary to consider the impact to ma-
chine balance after removal. To prevent the
machine from tipping over, support your
machine, if necessary, before removing the
heavy component.
Before or after the optional equipment has
been installed or removed, make sure that
it is stable without the danger to tip.
For more information about removal and
installation please consult Sany distributor.
8.1.4 Operation precautions
Keep the following procedures in mind when

installing a larger or heavy optional equipment.
Before the operation, move your machine to a
safe ground for trial operation. Make sure that
you know very well the movement, center of
gravity, and working range of your machine.
If the machine stays inclined, swinging op-

eration is not allowed in order to prevent
tipping of the machine.
Keep a safe distance to surrounding barri-
ers during operation.
Pay attention to the following points when
installing a heavy optional equipment.

Heavy optional equipment probably re-

quires a larger space for swinging op-
eration. There might be the danger of
impacting other objects if the swinging
range has not been calculated accu-
rately. A larger space must be prepared
before performing the swinging opera-
tion.
When the lifting of heavy optional

equipment is held, the distance mov-
ing downward is relatively longer due
to gravity. In this case, it should be
lowered to the ground instead of being
held in air.
Never swing, lower or stop your ma-

chine suddenly in order to prevent it
from tipping over.
Never extend or retract the boom cylin-

der suddenly in order to prevent impact
that may cause the machine to tip.

8.2 Hydraulic Control Elements and Oil Circuit
8.2.1 Location of the components
Fig. 8-1
(1) Stop valve

(2) Selector valve
(3) Control pedal
8.2.1.1 Stop valve
Stop valve stops hydraulic oil ow.
(a) Unlocked position allows flow of the hy-

draulic oil.
(b) Locked position stops ow of the hydraulic

oil.
Switch the valve to locked position when re-

moving or installing an optional equipment. Fig. 8-2

8.2.1.2 Selector valve
Selector valve changes owing direction of hy-

draulic oil.
The change of direction is made according to

the working mode selected. The working mode
must be applicable to the installed optional
equipment. For changing the working mode,
seeHydraulic circuit on page 8-8.
Fig. 8-3
8.2.1.3 Control pedal
WARNING
Do not operate when placing your foot on

the pedal. If the pedal is pushed mistaken-
ly, the optional equipment will move sud-
denly and cause severe accidents.
Control pedal is used to control the optional

equipment.
When the front, center, or rear of the pedal is

pushed down, the optional equipment will op-
erate as the following.
Hydraulic breaker
Front (A): Operate
Center (N): Stop Fig. 8-4
Rear (B): Stop
For other optional equipment, consult its man-

ufacturer for installation in order to confirm the
operation of pedal and optional equipment be-
fore operating your machine.

8.2.2 Hydraulic circuit
Note:
When the breaker is mounted, the oil return line must be connected directly to the return filter.
Therefore, do not use the return line except for mode B.
In the stand-by valve, the safety valve's standard pressure was set at the factory before the
machine was delivered. When mode B is selected, the pressure is set to 20.6MPa (210kgf/
cm2, 2980PSI); when the mode of hydraulic shear is chosen, the pressure is set to 27.4MPa
(280 kgf/cm2, 3980PSI). Readjustment may be necessary according to the type of optional
equipment. In this case, please contact Sany distributor for adjustment.
8.2.2.1 Hydraulic circuit switching
Set the working mode on the monitor according to the following standards according to the
type of optional equipment.
The pressures set for the safety valve in the stand-by valve and for the switch of hydraulic line
are determined by the working mode selected.
Optional equipment Mode Hydraulic line Safety Valve Pressure Setting

Hydraulic path forms
automatically at the When delivered from factory:
One-way hydraulic optional
B control valve where the
equipment, such as breaker
return oil does not pass 20.6Mpa (210kgf/ cm2 2980PSI)
through.
Hydraulic path forms
Dual-action hydraulic optional automatically at the When delivered from factory:
equipment, such as hydraulic S control valve where
shear the return oil passes 27.4MPa (280kgf/cm2, 3980PSI)
through.
8.2.2.2 Shifting to breaker / general optional equipment
When installing an optional equipment with working mode B

(a) Breaker hydraulic path (one-way hydraulic path) has been formed.
(b) The overow valve is set to low pressure.
When delivered from the factory: 20.6MPa (210kgf/cm2, 2980PSI)
When installing an optional equipment with working mode S

(a) Shear hydraulic path (dual-action hy-

draulic path) has been formed.
(b) The overow valve is set to high pres-

sure.
When delivered from the factory:

27.4MPa 280kgf/cm2, 3980PSI
8.2.2.3 Connecting hydraulic oil circuit
Connect the hydraulic lines to the optional

equipment according to the following steps.
1. Check the stop valve, which should be in

the locked position (b).
(a) unlocked: allows flow of the hydrau-

lic oil (the arrow-indicated direction is
parallel to the longitudinal direction of
arm).
Fig. 8-5
(b) locked: stops flow of the hydraulic oil
(the arrow-indicated direction is per-
pendicular to the longitudinal direction
of arm).
2. Remove the screw plug (3) from the end of

the stop valve line.
Note:
The disassembled parts should not be lost or Fig. 8-6

damaged.
3. The optional equipment manufacturer is

responsible to connect the line (4) of the
optional equipment after the screw plug (3)
has been removed.
Connection sizes and additional accumula-

tor may vary according to different optional
equipment manufacturers. Please consult
Sany distributor in this regard.
Fig. 8-7

8.2.2.4 Hydraulic oil passage
The operating directions of the pedal and hydraulic path are shown below.
Fig. 8-8
By pushing the front of the pedal, the hydraulic oil flows to the left of the work equipment; by
pushing the rear, the hydraulic oil ows to the right. (Only the front part of the pedal can be oper-
ated upon the installation of breaker.)

8.2.3 Optional equipment removal and installation
8.2.3.1 Removal
1. Lower the work equipment to the ground

and shut down the engine.
2. Turn the start switch to ON position (B),

and place the lockout control to FREE
position (F).
Fig. 8-9
3. After finishing step 2, fully cycle each

control level and control pedal for 2-3 times
within 15 seconds in order to release the
internal pressure remained in the hydraulic
lines.
Fig. 8-10
4. Place the lockout control to LOCK position

(L).
Fig. 8-11

5. The breather valve (F) on top of the

hydraulic tank can be used to release the
internal pressure of the hydraulic lines.
To release the pressure completely, turn

and open the buttery nut on the breather
valve (F) and press the relief button to re-
lease the pressure.
Fig. 8-12
6. Check the temperature of hydraulic oil,

which should be cooled to a safe tempera-
ture, and then turn the rotor of the stop
valve (mounted to the inlet and outlet lines
to the side of the arm) to locked position (b).
(a) unlocked: allows flow of the hydraulic

oil (the arrow-indicated direction is
parallel to the longitudinal direction of
arm).
(b) locked: stops flow of the hydraulic oil Fig. 8-13

(the arrow-indicated direction is per-
pendicular to the longitudinal direction
of arm).
7. Disconnect the hose at the side of the

optional equipment. Install the screw plugs
to the two outlets.
The screw plugs are used to prevent that

the invasion of foreign materials could lead
to the malfunction of the optional equip-
ment. Put the optional equipment in stor-
age after the screw plugs have been in-
stalled properly.
Fig. 8-14
8. Remove the two installation pins, disas-
semble the optional equipment, and install
the bucket.
For more information on the bucket instal-

lation procedures seeBucket Replace-
ment on page 5-47.

9. Check the oil level in the hydraulic tank af-

ter the bucket has been installed properly.
8.2.3.2 Optional equipment installation
1. Remove the bucket.
2. Place the optional equipment to a flat

surface. Install the optional equipment to
the arm with the pin (A) followed by the pin
(B).
Fig. 8-15
3. Lower the equipment to the ground and

shut down the engine.
4. Turn the start switch to ON position (B),

and place the lockout control to FREE
position (F).
5. After finishing step 2, fully cycle each

control level and optional equipment con-
trol pedal for 2-3 times within 15 seconds Fig. 8-16
in order to release the internal pressure
remained in the hydraulic lines.
Fig. 8-17

6. Place the lockout control to LOCK position

(L).
7. The breather valve (F) on top of the

hydraulic tank can be used to release the
internal pressure of the hydraulic lines.
To release the pressure completely, turn

and open the buttery nut on the breather
valve (F) and press the relief button to re-
lease the pressure.
Fig. 8-18
8. Check the temperature of the hydraulic

oil, which should be cooled down to a safe
temperature. Remove the two screw plugs
from the inlet and outlet. Be careful not to
contaminate the hose connections with any
dirt or soil.
If the O-ring is broken, replace it with a

new one.
9. Connect the hose to the side of the op-

Fig. 8-19
tional equipment.
When connecting the hose, check the oil

flow direction and be careful not to make
any mistakes.
10. Turn the rotor of the stop valve (mounted

to the inlet and outlet lines to the side of
the arm) to FREE position (a).
(a) unlocked: allows ow of the hydraulic oil

(the arrow-indicated direction is parallel
to the longitudinal direction of arm).
(b) locked: stops ow of the hydraulic oil (the

arrow-indicated direction is perpendicu-
lar to the longitudinal direction of arm).
Fig. 8-20
11. Check the oil level in hydraulic tank after
installation of the optional equipment.

8.2.4 Hydraulic oil and hydraulic tank filter - change/replace
The operation of hydraulic breaker could contaminate the hydraulic system and deteriorate the
hydraulic oil. In this case, the hydraulic oil and hydraulic tank filter should be changed more of-
ten, as compared with the machine installed with bucket. Otherwise, damage could occur in the
hydraulic breaker, hydraulic pump and other hydraulic components. The recommended replace-
ment intervals are shown below. (For information about how to change oil and replace a filter, see
related items in the Maintenance Section.)
Table 8-1 Change interval (hours)
Machine with Hydraulic Breaker Machine with Common Bucket

Hydraulic oil 600 1500 or 2500 or 4000
Filter cartridge 100 1000
Note:
The figures in the above table are determined at 100 percent operation with hydraulic breaker. As
the operating hours of hydraulic breaker reduce, the change intervals could be prolonged corre-
spondingly as shown in the following illustration.
The filter cartridge must be replaced after the breaker has been operated for 100 hours.
Fig. 8-21

8.2.5 Long-term storage
The following procedures shall be followed

when the equipment is to be stored for a long
period of time.
Turn the stop valve to locked position.

Screw the plug on the valve.
Place the latch pin to locked position.
Operating the pedal without installing the
breaker or general optional equipment may
cause overheating or other problems.
8.2.6 Hydraulic specifications
Max. combined ow 263 L/min

The overow pressure of the safety valve
in the stand-by valve has been set to
27.4MPa (280 kgf/cm2, 3980PSI) (except
mode B).
The pressure to activate the safety valve
24.5MPa (250 kgf/cm2, 3550PSI) (except
mode B).
The overflow pressure of the safety valve
in the stand-by valve has been set to 15-
17MPa (153-174 kgf/cm2, 2178-2469 PSI)
(mode B).
The pressure to activate the safety valve
15.2MPa (155kgf/cm2, 2200PSI) (mode B).
Besides the valves listed above, we also of-
fer valves in which the overflow pressure of
safety valve can be set to 24.5MPa (250kgf/
cm2, 3550PSI) and its activating pressure can
be set to 20.1MPa (205 kgf/cm 2, 2911PSI).
Please consult Sany dealer in your locality.

8.3 Optional equipment Guide
WARNING
Read the optional equipment instruction

manual and related sections about option-
al equipment.
Safety issue will be involved when in-

stalling any optional equipment. There-
fore, please consult Sany distributor
before the installation.
Installing an optional equipment with-
out approval from Sany distributor
could lead to safety problems which
may impair the operation and service
life of your machine.
Sany assumes no responsibility for
any injuries, accidents or damage re-
sulted from the installation of unauthor-
ized optional equipment.
8.3.1 Work equipment combination
WARNING
There is the danger of impacting the

cab or machine body due to the type or
combination of work equipment.
Operating a work equipment for the
first time requires to check for the dan-
ger of any intervention before starting.
Operate your machine carefully.

Note:
In excavation, the boom may intervene with the undercarriage when the boom is fully low-
ered. Be careful with the operation of the boom.
For excavating or loading hard soil or soft soil containing gravels, reinforced rock-digging
bucket with higher strength and abrasion resistance is recommended.
It is recommended using high-strength and high-antiwearing rockwork bucket when you dig or
load hard soil or soft soil containing stone pieces.
Capacity Outer Width Weight Stand Arm

Bucket Type m3 mm Kg m Remark
cu.yd ft in lb ft in
Rockwork 0.48 882 405 2.36 Standard
SY115C9 0.64 2ft 10in 893 7 ft 9 in Rockwork
0.53 880 480 2.5
Standard
Earthwork 0.71 2ft 10in 1058 8 ft 2 in
SY135C8 0.53 946 478 2.5
Rockwork
0.71 3 ft 1 in 1052 8 ft 2 in
0.54 860 484 2.5
Standard
Earthwork 0.71 2ft 10in 1058 8 ft 2 in
SY135C9 0.6 950 960 2.5
Optional
0.71 3 ft 1 in 1052 8 ft 2 in
0.53 946 479.6 2.5
Rockwork
Earthwork 0.71 3 ft 1in 1057 8 ft 2 in
SY155H 0.6 986 489 2.5
Standard
0.80 3 ft 3 in 1078 8 ft 2 in
Table 8-2
Digging or loading materials of specific gravity 1.8 t/m3

8.3.2 Bucket tips selection
Bucket tips may break off the adapter due to the working condition. In this case, suitable bucket
tips must be determined. Currently, we offer bucket tips with a lateral pin. So the following types
of bucket tips are recommended according to different working conditions.
8.3.2.1 Rockwork bucket tips
Would be used at where the bucket tips service life could be impaired, such as loading hard
rocks.
Would be used at where the bucket tips will not penetrate into the soils, such as handling
gravels after blasting or loosening the soils.
Would be used at where heavy load operation is carried out, such as tapping or pulling the
rock with bucket tips.
8.3.2.2 Earthwork bucket tips
Would be used at where the bucket tips will penetrate into the soils, such as excavating and
loading sand or clay.
Applicable Worksite
Rocks Gravel Sandstone Clay and loose sand
Excavation during
Light Heavy
pile-driving
Work Condition
Scraping the earth Rockwork Tips Earthwork Tips
General Excavation
Loading
Table 8-3

8.4 Recommended Operations

The following instruction must be followed
when operating an excavator with optional
equipment.
Note:
Select the optimum model of optional equip-

ment for your hydraulic excavator.
The type of optional equipment to be in-

stalled and the model of special optional
equipment may vary according to the mod-
el of your hydraulic cylinder. In this case,
for selecting the optimum optional equip-
ment, please consult Sany distributor.
8.4.1 Hydraulic breaker
Major applications:
Crushing rocks
Demolition
Road Engineering
This optional equipment can be used widely
for, such as demolishing buildings, breaking
road surface or slag, tunneling, crushing rocks,
and breaking operation at quarry.
Fig. 8-22

8.4.2 Hydraulic breaker operation
1. Press the breaker chisel vertically and

firmly onto the object to be broken during
breaking operation.
2. Press the breaker chisel tightly onto the

working surface when striking and slightly
raise the front of the undercarriage about 5
mm (0.2 in) from the ground, as shown in
the right illustration. This clearance above
ground shall not exceed 5 mm (0.2 in).
Fig. 8-23
Note:
The excavator shall not be raised too much.
Fig. 8-24
3. If the same surface cannot be penetrated

or broken by the chisel within one minute
under continuous striking, change the
struck position and try to break it near the
edge.
Fig. 8-25

4. The chisel's penetrating direction will devi-

ate gradually to the working direction of
breaking hammer. It is important to align
them by readjusting the bucket cylinder.
Fig. 8-26
5. Always press the chisel properly on the

working surface in order to prevent striking
without resistance.
Fig. 8-27
8.5 Restricted Operations

Do not operate your machine in any of the fol-
lowing manners in order to ensure a longer
service life and safe operation.
Do not operate any of the oil cylinders to

its full stroke. A distance of 5 cm (2 in) is to
be reserved for backup.
1. Accumulating rocks with the breaker.
Fig. 8-28

2. Breaking with swinging force.
Fig. 8-29
3. Moving the chisel during striking operation.
Fig. 8-30
4. Keep the chisel level or upward during

striking operation.
Fig. 8-31

5. Swing the chisel when the rock has been

penetrated.
Fig. 8-32
6. Pecking operation.
Fig. 8-33
7. Raise your machine above ground by fully

extending the bucket cylinder and by the
pushing force.
Fig. 8-34

8.6 Hydraulic Breaker Lubrication

Grease the breaker at the correct point.
Fig. 8-35
Note:
Greasing in an improper manner could add

grease more than desired. As a result, soil and
sand may enter the hydraulic system, which
can damage the hydraulic components when
using the breaker.
Fig. 8-36
Fig. 8-37

8.7 Quick Coupler and Control System

8.7.1 Quick coupler installation
1. Remove the safety pin of quick coupler, as

Fig. 8-38
2. Depress the quick coupler operation button

(1) (auto reset) on the left joystick in order
to slowly reduce the opening of the exible
jaws and the fixed jaws of quick coupler.
Fig. 8-39
3. Make the quick coupler's fixed jaws to

slowly grip the bucket's support pin (2), as
Fig. 8-40

4. Extend the bucket cylinder to slowly move

the flexible jaws of quick coupler toward
the bucket's support pin (3).
Fig. 8-41
5. Make sure that the jaws of quick coupler

grip completely the support pin (3) of the
bucket.
Fig. 8-42

6. Release the operation button of quick

coupler in order to enable the quick cou-
pler to grip the bucket's support pin before
conducting other operations.
7. Insert the safety pin after installation.
Fig. 8-43
8.7.2 Operating precautions
1. After installation of the quick coupler, the

bucket and other optional equipment will
make the swing diameter longer during the
operation. In this case, they could possibly
impact the cab or boom of your excavator.
So be careful with the operation. After the
quick coupler has been installed, retract
the bucket to its position (the bucket
cylinder is fully extended) before retracting
the arm when carrying out retracting the
operation. To avoid damaging the boom, Fig. 8-44
never retract the arm to its position (the
arm cylinder is fully extended) before
operating the bucket.
2. Overloaded preparation may impair your

machine and its optional equipment, thus
reducing their service life.
Fig. 8-45

3. Do not apply pressure when the quick cou-

pler touches the ground. Use the coupler
only when it is connected with the bucket
or optional equipment.
Fig. 8-46
4. It is very dangerous to move a heavy

object with the quick coupler. Meanwhile,
the service life of quick coupler could be
reduced.
Note:
Consult Sany local authorized dealer if you

need to install a quick coupler. Make sure that
you are using an optional equipment that has
been approved by Sany. Sany assumes no re- Fig. 8-47
sponsibility for any failure and accident result-
ed from installation of any optional equipment
that has not been approved by Sany.
8.8 Refueling System
8.8.1 Introduction
Sany excavators are equipped with a fueling

system, which uses a refueling pump assem-
bly. The refueling pump assembly is intended
specially for large mobile off-the-road machin-
ery, vehicles and vessels. It uses on-board
battery as the power source and is not limited
by terrain and power supply, which makes it
very suitable for construction side and field.
For information regarding refueling amount,

seeFluid capacities on page 5-19.

8.8.2 Components
The fueling system of Sany excavators in-

cludes mainly: a refueling pump assembly
(including relevant piping and valves), a
control switch and a fuel level control relay.
Open the battery cover (1) and you can
see the control switch and the refueling
pump (2).
Fig. 8-48
The main structure of the refueling pump 2)

is shown in the right illustration.
Technical specifications of the refueling
pump:
Pump ow rate: 46L/min
Rated voltage: 24V
Rate speed: 2800 rpm
Coupling thread: 3/4G
Fig. 8-49
Weight: 3.5kg
Packing dimension: 215120160mm
The fuel level control relay (3) is shown in
the right illustration.
This relay is installed in front of the fuel
tank filler opening and is connected with
the refueling pump control switch and re-
lay. Its signaling position is 100mm from
the tank top surface.
Fig. 8-50

8.9 Central Lubrication System
8.9.1 Scheme and components
1. Models SY115C9, SY135C8/9 and SY155H adopt a 18-point lubrication scheme.
A sketch on distribution of excavator lubricating points is shown below:
Fig. 8-51
2. System components
Electric grease pumping section

It is composed of the pump-mounting
base, the electric pump, the pumping unit,
the safety valve and the filter.
Fig. 8-52

Distributor section
System distributor is mainly composed of:
Main distributor (1)

MX-F3/3
Secondary distributors (3)
MX-F510
MX-F3/5
MX-F3/4
Fig. 8-53
The main distributor (A) and the secondary

distributor (B) installed to the boom root
are shown in the right illustration.
Secondary distributor (C) mounted to the

arm.
Fig. 8-54
Secondary distributor (D) mounted to the

inside of the linking rod.
Major lines configuration

The system's major lines include high-
pressure hoses, straight connectors, el-
bows, straight expansion core, bent expan-
sion core, steel wire protection sleeves,
hose protection sleeves, bucket distributor
protection plates, etc.
Fig. 8-55

8.9.2 System working principle
As Sany SY series excavators have a relatively central distribution of lubricating points that are
close to each other, we choose to use a progressive central lubrication system which is shown in
the illustration below.
Operating principle: The pressurized grease from the electric plunger pump goes through the
pumping unit, safety valve and filter to the main distributor, where the grease is sent through the
tubes to three secondary distributors and then supplied in turn to each lubricating point according
to a certain proportion.
Fig. 8-56
8.9.3 Setting the lubrication time of electric grease pump
The electronic controller built in the electric grease pump can realize related control over the
time or cycle of the central lubrication system. When the time programming control is applied,
the cab's central lubrication system indicator ashes after the excavator is powered on; the yel-
low LED indicator of the electronic controller will be illuminated for 25 seconds, indicating that the
system is ready for lubrication.
By pressing the start button on the motor's shell or instrument panel, the lubrication cycle begins.
Upon completion of the lubrication cycle, the motor of lubricating pump stops and the shutdown
cycle begins. Subsequent lubrication will start according to the predetermine time schedule. If the
engine is shut off during shutdown period or lubrication cycle, the cycle will be terminated and the
time period will be recorded. When the engine is started again, the lubrication cycle will continue
counting the time from when the previous cycle is terminated. For the suspended lubrication cy-
cle, pressing the forcible start button allows you to activate the lubricant pump. Once the control
unit is energized, a lubrication cycle will be activated. The following illustration shows the panel of
electronic controller of the grease pump.
Fig. 8-57
Setting the parameters

The interval can be set to 0.5 - 8 hours; the lubrication cycle can be set to 1 - 16 minutes, as
shown in the illustration below. If you need to adjust the time, use a at-headed screw driver
to disassemble the red edge frame, loosen the four cross-headed screws, and remove the
transparent covers in turn. If any of the covers is not shut properly, water could penetrate into
the control unit and damage may result in.
Fig. 8-58
8.9.4 Technical description
1. The system will lubricate for 10 minutes every half an hour, which was set at the factory
before delivery.
2. After operating for 100 hours, you can adjust (increase or decrease) the lubricating time ac-
cording to actual condition. The lubricating interval, however, shall not be changed.
3. Clean lithium base grease NLG12# is recommended for the lubrication.
4. Electric lubricant pump (24V/DC, 19 kg) with built-in electronic controller is used.

8.9.5 Adding grease with electric pump
The electric grease pump of the central lubrication system lubricates your machine in the follow-
ing three ways.
1. Standard Method:
Manual or pneumatic grease gun is used to add grease through the ball-type nozzle (1), as
shown in the following illustration.
Fig. 8-59
2. Add grease through the connector, as shown in the illustration below.
Fig. 8-60

Fig. 8-61
3. Add grease through the grease gun, as shown in the illustration below.
Fig. 8-62
Note:
Please consult Sany distributor if you need to install the central lubrication system. Make sure
that you are using accessories specified by Sany. Sany assumes no responsibility for failures and
accidents caused by the installation of any accessories that have not been approved by Sany.

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SY115C9/135C/155H Crawler Hydraulic Excavator

Safety, Operation and Maintenance Manual - Sep 2012

Tel: (86) 21 5700 8518

Safety, Operation and Maintenance Manual - Sep 2012

2.2.1 Hazard alert wording ...................................................................................... 2-8

II Safety, Operation and Maintenance Manual - Sep 2012

2.3.22 Unauthorized modification ......................................................................... 2-31

Safety, Operation and Maintenance Manual - Sep 2012 III

2.4.6 Lifting objects with the machine ................................................................... 2-56

IV Safety, Operation and Maintenance Manual - Sep 2012

3.3.2.6 Main Pump Signals ............................................................................ 3-15

Safety, Operation and Maintenance Manual - Sep 2012 V

3.8 Alternate Exit.......................................................................................................... 3-51

VI Safety, Operation and Maintenance Manual - Sep 2012

4.1.2.9 Work lamp switch - check ................................................................... 4-14

Safety, Operation and Maintenance Manual - Sep 2012 VII

4.9.3 Permissible depth of water........................................................................... 4-42

VIII Safety, Operation and Maintenance Manual - Sep 2012

4.18.3.3 Lifting the machine ............................................................................ 4-67

Safety, Operation and Maintenance Manual - Sep 2012 IX

5.8.2.9 Air conditioner - inspect/service .......................................................... 5-52

X Safety, Operation and Maintenance Manual - Sep 2012

5.8.9.3 Accumulator (control oil circuit) - replace ............................................ 5-96

Safety, Operation and Maintenance Manual - Sep 2012 XI

XII Safety, Operation and Maintenance Manual - Sep 2012

8.7 Quick Coupler and Control System ....................................................................... 8-26

Safety, Operation and Maintenance Manual - Sep 2012 XIII

XIV Safety, Operation and Maintenance Manual - Sep 2012

Safety, Operation and Maintenance Manual - Oct 2012 1-1

1.3.4.6 Chassis serial number ........................................................................ 1-12

1-2 Safety, Operation and Maintenance Manual - Oct 2012

Items addressed in this manual are designed

Understand the structure and performance

If you sell the machine, be sure to give this

Continuing improvements in the design of this

Safety, Operation and Maintenance Manual - Oct 2012 1-3

1.2 Your Documentation Package

Safety, Operation & Maintenance Manual

In order to use the Sany CD, be sure of the

Intel Pentium II running at 500 MHz or

Windows 2000, XP, Vista and Windows 7

1-4 Safety, Operation and Maintenance Manual - Oct 2012

1.2.1 Recommendations on using the

This documentation applies only to this

1.2.2 Documentation storage

Always keep the operator manual and load

The parts book is best left either shelved in

These can be printed out from the CD.

1.2.3 Manual organization

The operators manual is designed for use

tact your Sany distributor before operating or

This section provides an overview of what is

This section covers basic safety information

1.2.3.3 System functions

This section provides an overview of all the

This section provides some basic operating

This section provides all general maintenance

1-6 Safety, Operation and Maintenance Manual - Oct 2012

dures before performing any repair or mainte-

This section includes common malfunctions