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SANY SY135C, Operation And Maintenance Manual

The SANY SY135C Operation And Maintenance Manual is a comprehensive guide designed to assist users in effectively operating and maintaining their SY135C model. This manual provides step-by-step instructions and valuable tips for optimal handling, ensuring prolonged lifespan. Download the free manual from manualshive.com for expert assistance.

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Table of Contents

SY135C Excavator OMM

Operation and Maintenance Manual — 0120

SANY

Check the Accumulator Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-61

Check the Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-62
Add Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-63
Hydraulic Oil Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-66
Check the Hydraulic Lines and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-67
Check the Hydraulic System Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-68
Replace the Hydraulic Tank Breather Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-69
Replace the Hydraulic Tank Return Filter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-70
Clean the Hydraulic Oil Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-73
Relieve Hydraulic System Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-75
Change the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-77
Check the Hydraulic Pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-79
Check the Hydraulic Pump Mounting Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-80
Replace the Hydraulic Pilot Line Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-81
Replace the Case Drain Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-83

Collect Oil Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-84

Collect Engine Oil Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-84
Collect Hydraulic Oil Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-85
Collect Swing Drive Oil Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-87
Collect Final Drive Oil Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-87

Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-89

Check the Swing Drive Gearbox Mounting Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-89
Check the Swing Drive Gearbox Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-89
Change the Swing Drive Gearbox Oil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-90
Check the Swing Bearing Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-92
Check and Add the Swing Pinion Gear Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-93

Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-94

Check the Final Drive and Mounting Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-94
Check and Add Final Drive Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-95
Change the Final Drive Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-96

Track Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-97

Inspection and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-97
Check the Track Shoe Fasteners  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-98
Check the Carrier Roller  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-99
Check the Carrier Roller Mounting Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-99
Check and Adjust the Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-100
Increase the Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-101
Decrease the Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-102

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-103

Lubrication Points  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-103
Lubricate the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-104

Boom Cylinder Base Ends and Swing Bearing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-104
Dozer Blade Linkage Pins and Dozer Blade Cylinder End Pins  . . . . . . . . . . . . . . . . . .5-105
Boom Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-105
Arm and Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-106
Bucket Linkage Pin  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-107
Bucket  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-107

Miscellaneous Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-108

Operating Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-108
Check the Upper Structure and Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-110
Check the Operation and Maintenance Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-110

Summary of Contents for SY135C

Page 1: ...service sanyamerica com SANY Part Number SSY005078545 SY135C Excavator Operation and Maintenance Manual ...

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

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

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

Page 5: ...e Operation 1 4 Maintenance 1 4 Specifications 1 4 Optional Equipment 1 4 Machine Applications 1 5 Machine Directions 1 5 Serial Number Location 1 6 Product Identification Plate 1 6 SANY Contact Information 1 7 Record of Serial Number and Dealer Information 1 7 Correction Request Form 1 8 Glossary of Acronyms 1 9 Safety General Safety 2 3 Hazard Alerts in This Manual 2 3 Machine Decals 2 3 Operato...

Page 6: ...aces 2 12 Avoid Backover Accidents 2 13 Dust and Chemical Hazards 2 13 Environmental Precautions 2 13 Precautions in High Voltage Areas 2 14 Machine Controls Machine Overview 3 4 Doors Access Covers and Filler Cap 3 5 Cab Door 3 5 Fresh Air Filter Access Door 3 6 Left Rear Access Door 3 6 Right Rear Access Door 3 7 Engine Compartment Cover 3 8 Diesel Exhaust Fluid DEF Tank Access Door 3 9 Fuel Tan...

Page 7: ...n 3 22 Fan Speed Button 3 22 LCD Screen 3 22 Temperature TEMP Selection Button 3 22 Vent MODE Selection 3 22 Automatic AUTO Temperature Control 3 22 A C Power 3 22 Fresh Air or Recirculated Air Selection 3 22 Air Conditioning Faults 3 23 Radio 3 23 Radio Control Panel 3 23 Radio Operation 3 23 Automatic Scan Preset Station AS PS Button 3 23 Preset Station PRESET STATION Buttons 3 23 AM FM Selector...

Page 8: ...isplay 3 47 Diesel Exhaust Fluid DEF Level Gauge 3 47 System Time Calibration Screen 3 48 Main Menu Screen 3 49 Engine and Throttle Signals Screen 3 50 Selective Catalytic Reduction SCR Manual Regeneration 3 50 Pilot Pressure Signals Screen 3 52 Main Pump and Main Valve Signal Screen 3 53 Input Switch Signals Screen 3 54 Output Switch Signals Screen 3 55 Machine Configuration Screen 3 56 Failure C...

Page 9: ...ne 4 20 Directional Arrow 4 20 Machine Moving Precautions 4 20 Travel Controls 4 21 Right Turn 4 21 Left Turn 4 21 Straight Travel 4 22 Spot Turning 4 22 To the Left 4 22 To the Right 4 22 Operating on an Incline 4 22 Operating in Water 4 23 Releasing the Machine from Mud 4 23 One Track Stuck 4 23 Two Tracks Stuck 4 23 Work Equipment Control and Operation 4 25 SAE Control Pattern 4 25 Swing 4 25 A...

Page 10: ...ng the Machine 5 7 Weld Drill Cut or Grind on the Machine 5 7 Daily Inspection and Maintenance 5 8 Inspection and Maintenance in Adverse Environments 5 8 Mud Rain or Snow Conditions 5 9 Near Ocean Salt Air Environments 5 9 Dusty Environments 5 9 Cold Environments 5 9 Other Weather Environments 5 9 Maintenance Log 5 9 Recommended Lubricants Fuels and Coolant 5 10 Hydraulic Oil Description 5 10 Lubr...

Page 11: ... 29 Refrigerant Leak Test 5 30 Check and Adjust the Air Conditioner Compressor Belt 5 31 Check Air Conditioning Fresh Air and Recirculation Filters 5 32 Fresh Air Filter 5 32 Recirculation Air Filter 5 32 Engine 5 34 Engine Inspection 5 34 Check the Engine Primary Air Filter System 5 35 Change Engine Oil and Filter 5 37 Inspect Engine Serpentine Belt 5 40 Exhaust System 5 41 Check the Exhaust Syst...

Page 12: ...89 Check the Swing Drive Gearbox Mounting Fasteners 5 89 Check the Swing Drive Gearbox Oil Level 5 89 Change the Swing Drive Gearbox Oil 5 90 Check the Swing Bearing Fasteners 5 92 Check and Add the Swing Pinion Gear Grease 5 93 Final Drive 5 94 Check the Final Drive and Mounting Fasteners 5 94 Check and Add Final Drive Oil 5 95 Change the Final Drive Oil 5 96 Track Frame 5 97 Inspection and Lubri...

Page 13: ... 113 Inspect the Seat Belt 5 114 Check the Escape Tool 5 114 Check the Fire Extinguisher 5 114 Check the Windshield Washer Fluid Level 5 115 Bucket 5 116 Replace the Bucket Teeth 5 116 Specifications Machine Dimensions 6 2 Operating Ranges 6 4 Lift Chart 6 6 Lift Chart Continued 6 7 Optional Equipment Optional Equipment Safety 7 2 Optional Equipment Selection 7 2 Equipment Instructions 7 2 Removal...

Page 14: ...Table of Contents SY135C Excavator OMM Operation and Maintenance Manual 0120 SANY This Page Intentionally Left Blank ...

Page 15: ...ntenance Manual 1 3 Parts Manual 1 3 Maintenance Log 1 3 Organization of This Manual 1 4 Table of Contents 1 4 Introduction 1 4 Safety 1 4 Machine Controls 1 4 Machine Operation 1 4 Maintenance 1 4 Specifications 1 4 Optional Equipment 1 4 Machine Applications 1 5 Machine Directions 1 5 Serial Number Location 1 6 Product Identification Plate 1 6 SANY Contact Information 1 7 Record of Serial Number...

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

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

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

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

Page 20: ...dentification plates are located in various places on the excavator These list model and serial numbers that will be needed by a SANY dealer when ordering replacement parts or providing assistance for your machine Product Identification Plate The identification plate is on the right side of the cab Fig 1 2 0003544 ...

Page 21: ...318 Cooper Circle Peachtree City GA 30269 www sanyamerica com Phone 470 552 SANY 7269 Find a dealer go to www sanyamerica com find a dealer RECORD OF SERIAL NUMBER AND DEALER INFORMATION Use this table to record the product information related to this machine Machine Serial No Engine Serial No Right Travel Motor Serial No Left Travel Motor Serial No Swing Motor Serial No Hydraulic Pump Serial No D...

Page 22: ...make a copy of this page complete the form below and send it to SANY Correction Request Form Date of This Notification Your Name Company Name Department Street Address City State and ZIP Postal Code Phone E mail Machine Model and Serial No Description of Problem wrong information unclear or erroneous procedure etc Corrective Action Taken if any ...

Page 23: ...Diesel Particulate Filter ECM Engine Control Module GPS Global Positioning System HEST High Exhaust System Temperatures ISO International Organization for Standardization LCD Liquid Crystal Display OEM Original Equipment Manufacturer OSHA Occupational Safety and Health Administration PPE Personal Protective Equipment PQR Procedure Qualification Record ROPS Rollover Protective Structure SAE Society...

Page 24: ...Introduction SY135C Excavator OMM 1 10 Operation and Maintenance Manual 0120 SANY This Page Intentionally Left Blank ...

Page 25: ... Unauthorized Use of This Machine 2 5 Unauthorized Machine Modifications 2 5 Escape Tool 2 6 Fire Safety 2 6 Electrical Fires 2 6 Fire Extinguisher 2 6 In Case of Fire 2 7 Crushing Hazard 2 7 Diesel Engine Exhaust 2 7 Maintenance Safety 2 8 Lockout Tagout Procedure 2 8 Cleaning the Machine 2 9 Fluid Systems 2 9 Adding Fluids to the Machine 2 9 Refueling 2 9 High Pressure Fluid Lines 2 9 Accumulato...

Page 26: ...M 2 2 Operation and Maintenance Manual 0120 SANY Inclined Areas 2 12 Snow or Frozen Surfaces 2 12 Avoid Backover Accidents 2 13 Dust and Chemical Hazards 2 13 Environmental Precautions 2 13 Precautions in High Voltage Areas 2 14 ...

Page 27: ...amage personal injury or even death In this manual and on the machine decals signal words or illustrations are used to express the potential level of hazard This symbol is used within a graphic to alert the user not to do something Machine Decals All safety and warning decals must be in place undamaged and visible Become familiar with the location and content of all decals on the machine Walk arou...

Page 28: ...y All accident prevention guidelines operating instructions etc are based on the intended usage of the machine Read and understand this manual and any accompanying manuals before operating this machine This manual must be readily available to the operator at all times and must remain in the cab while the machine is in use Make sure all personnel in the working area around the machine are thoroughl...

Page 29: ...eps and deck for proper support Wear safety shoes with slip resistant soles Do not walk on any surface of the machine if its slip resistant material is missing or excessively worn Do not step on surfaces of the machine that are not approved for walking or working Keep all walking and working surfaces of the machine clean dry and slip resistant Always keep grab handles steps and walkway areas clean...

Page 30: ...achine daily for debris buildup Electrical Fires Short circuits damaged wiring or overcharging batteries can cause fires Observe the following Check the wiring on the machine for damage when doing a prestart check Contact a SANY dealer for repairs or replacement of any damaged wiring Make sure the battery is operating in its recommended range Never install aftermarket electrical equipment without ...

Page 31: ... base of the fire Crushing Hazard Keep your body inside the windows and door during operation or travel Keep all guards in place on the machine Never remove the side window of the machine If this window becomes damaged or broken replace it immediately Block off the area where the machine is being operated and keep all unnecessary personnel out of the work area Diesel Engine Exhaust WARNING CALIFOR...

Page 32: ...ked closed position and block the tracks to prevent the machine from moving before performing any maintenance or repairs Before disconnecting or removing components of the hydraulic system relieve the system pressure to prevent hydraulic fluid from spraying out See Relieve Hydraulic System Pressure on page 5 73 The engine coolant and oil in the machine may be hot even after the engine is stopped W...

Page 33: ...d hot Refueling When adding fuel shut down the machine before removing the fuel tank cap Fuel spills present a hazard if not cleaned up immediately Refuel only in a well ventilated area Never smoke or allow open flames nearby while refueling the machine Never mix gasoline with diesel fuel Gasoline is extremely flammable and could cause an explosion Do not top off the fuel tank High Pressure Fluid ...

Page 34: ... the system or cause intermittent system failures Battery Safety When working with batteries always work in a well ventilated area Batteries present a hazard especially when they have been in use for a long period of time The following are some basic precautions for working around batteries Always wear personal protective equipment PPE Battery gases are extremely explosive Smoking sparks or open f...

Page 35: ...ibility of the operator s employer to conduct periodic safety training and familiarize all personnel with emergency procedures If pedestrians are in the area sound the horn and proceed slowly When working with another person on a job site make sure that all personnel involved understand all industry standard hand signals that are to be used The operator must respond to operating signals from the p...

Page 36: ...rom local authorities and follow their instructions Raise work equipment 8 in 12 in 20 cm 30 cm above the ground when traveling When traveling or operating in shallow water be aware of its depth and current Inclined Areas Traveling on an incline can be dangerous In order to prevent tipping loss of control or a rollover it is important to follow these rules Always check the firmness of the inclined...

Page 37: ...s present a serious danger when they are released or mishandled All workers involved should use approved personal protective equipment PPE and follow all environmental safety regulations Consult the Safety Data Sheet SDS for guidelines on personal protective equipment PPE proper handling and cleanup and correct reporting agencies if needed Environmental Precautions Oils and coolants poured onto th...

Page 38: ...ized and not insulated Be sure all underground utilities have been marked before excavating WARNING Overhead power lines carry high voltage electricity that can discharge to the ground through the machine even without direct contact with the machine s structure Avoid direct contact with high voltage power lines while operating High voltage contact could result in equipment damage death or serious ...

Page 39: ...p 3 10 Opening the Filler Cap 3 10 Closing the Filler Cap 3 11 Windshield 3 12 Opening the Windshield 3 12 Closing the Windshield 3 13 Lower Front Windshield 3 14 Emergency Escape Hatch 3 14 Battery Disconnect Switch 3 15 Cab 3 16 Controls 3 16 Seat and Seat Belt 3 17 Headrest Adjustment 3 17 Armrest Angle Adjustment 3 17 Backrest Angle Adjustment 3 17 Seat Forward Backward Position Lock 3 17 Seat...

Page 40: ...et Station AS PS Button 3 23 Preset Station PRESET STATION Buttons 3 23 AM FM Selector Button 3 24 Audio Selection SEL Button 3 24 Time Display Time Set TIME Button 3 24 Liquid Crystal Display LCD 3 24 Power Button 3 24 Volume Control Buttons 3 24 Tuning Buttons 3 24 Monitor Console 3 25 Sunlight Sensor 3 25 Monitor 3 25 Travel Alarm Switch 3 25 Power Outlet 12V 3 25 Right Console 3 26 Right Joyst...

Page 41: ...n Screen 3 46 System Time Display 3 47 Hours of Operation Display 3 47 Failure Code Display 3 47 Diesel Exhaust Fluid DEF Level Gauge 3 47 System Time Calibration Screen 3 48 Main Menu Screen 3 49 Engine and Throttle Signals Screen 3 50 Selective Catalytic Reduction SCR Manual Regeneration 3 50 Pilot Pressure Signals Screen 3 52 Main Pump and Main Valve Signal Screen 3 53 Input Switch Signals Scre...

Page 42: ...der 14 Track frame 2 Boom 15 Carrier roller 3 Work light boom 16 Track 4 Work lights cab 17 Track roller 5 Mirror 18 Idler 6 Cab 19 Dozer blade 7 Travel alarm 20 Door 8 Pattern change valve 21 Windshield wiper 9 Engine access cover 22 Boom cylinder 10 Battery disconnect switch 23 Bucket 11 Battery compartment access door 24 Bucket cylinder 12 Sprocket 25 Arm 13 Fresh air filter access door ...

Page 43: ...CATIONS OPTIONAL EQUIPMENT DOORS ACCESS COVERS AND FILLER CAP Cab Door 0004103 2 1 Fig 3 2 The cab door can be latched in the open position To latch the door in the open position release the door latch 1 swing the door open and firmly seat the latch into the door catch 2 To close the door push the latch 3 down and swing the door until it engages the latch Fig 3 3 0004102 3 ...

Page 44: ... Door Fig 3 4 0000524 1 Unlock and open the fresh air filter access door 1 Left Rear Access Door Fig 3 5 0004105 1 2 NOTE The cab door must be closed to open the left rear access door 1 Unlock and pull the latch 1 2 Open the access door 2 until the support rod 3 is seated in the bracket Fig 3 6 0000541 3 ...

Page 45: ...UCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Right Rear Access Door Fig 3 7 0000495 1 2 1 Unlock and pull the latch 1 2 Open the access door 2 3 Place the support rod 3 into the bracket to prevent the access door from closing unexpectedly Fig 3 8 0000542 3 ...

Page 46: ...cavator 3 8 Operation and Maintenance Manual 0120 SANY Engine Compartment Cover Fig 3 9 0000506 Fig 3 9 0000523 1 2 4 3 Release the latches 1 and lift the engine cover 2 until the support rod 3 is firmly seated in the bracket 4 ...

Page 47: ...S INTRODUCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Diesel Exhaust Fluid DEF Tank Access Door 1 Unlock and lift the latch 1 2 Lift the DEF tank access door 2 until the support rod 3 is engaged in the bracket Fig 3 10 0000525 1 2 Fig 3 11 0000543 3 ...

Page 48: ... the open position 4 Remove the filler cap NOTICE To prevent damage to the filler caps Make sure the O ring on the filler cap is clean If the O ring is contaminated by dirt or debris the O ring could be damaged and not seal improperly Inspect the O ring for wear or damage replace if necessary Make sure the filler cap is fully seated before turning the key to lock unlock the cap The key slot shield...

Page 49: ...TIONAL EQUIPMENT Closing the Filler Cap 1 Install the filler cap 2 onto the filler tube 2 Insert the key into the lock NOTE The key may break if it is turned before it is fully inserted into the lock 3 Turn the key from the open position 4 counterclockwise until the lock points to the lock position 3 Remove the key 4 Close the lock shield 1 to cover the lock Fig 3 13 0003017 3 4 2 1 ...

Page 50: ...the locked closed position 7 From the operator seat pull both windshield latches 2 This disengages the windshield latches from the locked position WARNING Avoid sudden movement of the machine or work equipment Always place the hydraulic lockout control lever in the locked closed position before opening or closing the windshield Failure to follow this warning could cause death or serious injury Fig...

Page 51: ...ndshield 1 Before closing the windshield park the machine on level ground lower the work equipment to the ground and stop the engine 2 Move the hydraulic lockout control lever 1 to the locked closed position CAUTION When open the windshield must be latched securely to the ceiling of the cab If it is not secured properly the windshield may slide down unexpectedly and result in personal injury or da...

Page 52: ...windshield See Opening the Windshield on page 3 12 NOTE Make sure the bottom of the lower front windshield and the seal are clean Accumulated dirt may make the windshield difficult to remove or install 2 Firmly hold the top of the lower front windshield 1 and lift upward for removal NOTE The lower front windshield is curved and will only install as removed Emergency Escape Hatch Use the emergency ...

Page 53: ...ne 1 Move the key switch to the OFF position NOTE The cab door must be closed to open the battery compartment access door 2 Open the battery compartment door See Left Rear Access Door on page 3 6 3 Turn the battery switch 1 to the OFF position The red battery disconnect switch handle can be removed in the OFF position to secure the machine 4 Close the battery compartment door NOTICE Never turn the...

Page 54: ...3 4 5 6 7 8 6 9 1 Footrests 6 Travel control pedals See page 3 35 2 Travel controls levers See page 3 35 7 Left control console See page 3 20 3 Monitor console See page 3 25 8 Hydraulic lockout control lever See page 3 19 4 Right joystick See page 3 26 9 Left joystick See page 3 20 5 Right control console See page 3 26 ...

Page 55: ...r comfort Backrest Angle Adjustment Fig 3 25 0004612 8 6 5 4 9 7 10 11 Pull up on the backrest adjustment lever 4 to adjust the angle of the backrest to the desired position Release the backrest adjustment lever to lock the seat backrest in position Seat Forward Backward Position Lock Move the position lock lever 5 to allow the seat to move forward and backward Move the position lever forward then...

Page 56: ...nterclockwise to decrease it Seat Belt Buckle the Seat Belt Fig 3 27 0005064 2 3 1 4 1 The seat belt 1 is provided to keep the operator securely in the operator s seat To buckle the seatbelt hold the latch plate 4 and pull upward to lengthen the belt Insert the latch plate into the buckle 2 until it locks Pull on the loose belt from the latch plate to tighten WARNING Inspect the seat belt Replace ...

Page 57: ... position 2 to disable hydraulic controls WARNING Keep belt slack to no more than 1 in 25 mm Belt slack beyond this amount could significantly reduce your protection in an accident Failure to follow this warning could result in death or serious injury WARNING Always move the hydraulic lockout control lever to the locked closed position before leaving the seat Failure to follow this warning and uni...

Page 58: ...joystick climate control panel and the radio control panel Left Joystick The function of the joystick 1 will vary depending on the operating mode selected See Joystick Modes on page 3 30 Climate Control System Panel The climate control panel 2 allows the operator to adjust the temperature inside the cab See Climate Control Panel on page 3 21 Radio Control Panel The radio control panel 3 allows the...

Page 59: ...er information OFF Button Press the OFF button 1 to shut off the fan the LCD and all heating and cooling functions NOTE The A C and heat functions will operate with the key switch on and the engine operating Press the fan speed or the AUTO button to turn on the heating and cooling functions 1 OFF button 6 Automatic AUTO temperature button 2 Fan speed button 7 Air Conditioning A C button 3 Liquid c...

Page 60: ...nt only Upper body vent only Upper body and rear window vents Foot vent under the operator seat upper body and rear window vents Foot vent only Windshield and foot vents Automatic AUTO Temperature Control Press AUTO 6 to activate the automatic temperature control system The climate control panel will automatically adjust fan speed outlet vents and air source to achieve and maintain the selected te...

Page 61: ...frequency blinking on the display Press the AS PS button once more to remain on the current station Press and hold the AS PS button for 2 seconds to activate the auto programming feature In auto programming the six radio stations with the strongest signals are stored in the six preset buttons 1 6 Preset Station PRESET STATION Buttons Press and hold any of the six preset station buttons 9 to assign...

Page 62: ...tton to display the set time for 5 seconds Time set While the time is being displayed press and hold the TIME button to enter the time set screen The hour numbers will flash Press the tuning arrow buttons 8 to set the desired hour To set the minutes press and release the TIME button again and the minute numbers will flash Press the tuning arrow buttons to set the desired minutes Press and release ...

Page 63: ... changes of temperature caused by direct sunlight Monitor The monitor 2 displays machine status information warnings and error messages The operator can access various screens to change machine settings See Monitor on page 3 38 Travel Alarm Switch Press the travel alarm switch 3 to turn the audible alarm and beacon light on top of the cab on and off Power Outlet 12V The 12V power outlet 4 can be u...

Page 64: ...ee Key Switch on page 3 28 Throttle Control Dial The Throttle Control Dial 4 adjusts engine speed and output power See Throttle Control Dial on page 3 28 Emergency Stop Switch When pressed the emergency stop switch 5 shuts off power to the engine s electronic control module ECM and the engine will shut down Right Joystick The function of the joystick 1 will vary depending on the operating mode sel...

Page 65: ...iper Switch Press the windshield wiper switch 7 to turn on the windshield wipers The windshield wiper switch has two operating positions In the center position the windshield wiper operates intermittently In the forward position the windshield wiper operates continuously Work Light Switch Press the work light switch 8 to turn on the work lights NOTICE Make sure that the windshield of the cab is cl...

Page 66: ...power to the electrical system is shut off and the key can be removed or inserted ON The ON position 3 allows the engine to remain running if already started The electrical system is energized when the key switch is turned to ON START When the key switch is turned to START 4 the starter motor will turn on and engage the engine flywheel Release the key after the engine has started and the key switc...

Page 67: ...nding on which operating mode is selected See Tool Select Screen on page 3 44 NOTE The two top buttons on the left joystick are used to operate the open and close functions of the quick coupler operating mode See Quick Coupler Screen on page 3 45 The bottom button 3 is not used at this time When the joystick is released it will return to the neutral position and machine movement will stop NOTE The...

Page 68: ...TE There are two operating modes available for the joystick controls the Society of Automotive Engineers SAE mode and the Backhoe Loader BHL mode The swing and bucket functions are the same for the SAE and BHL modes See Joystick Modes on page 3 30 Joystick Modes There are two operating modes available for the joysticks Society of Automotive Engineers SAE mode See SAE Mode on page 3 31 Backhoe Load...

Page 69: ...e Manual 0120 3 31 TABLE OF CONTENTS INTRODUCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT SAE Mode Front Swing Left Swing Right Left Front Right Bucket Dig Boom DOWN Bucket Dump Boom UP Arm IN Arm OUT Fig 3 38 0004112 ...

Page 70: ...ine Controls SY135C Excavator 3 32 Operation and Maintenance Manual 0120 SANY BHL Mode Fig 3 39 0004113 Front Boom DOWN Swing Left Swing Right Boom UP Left Front Right Bucket Dump Arm IN Bucket Dig Arm OUT ...

Page 71: ...ontrolled using the right joystick and the boom is controlled using the left joystick See BHL Mode on page 3 32 To switch the pattern change valve between SAE and BHL modes perform the following procedures 1 Shut down the engine See Engine Shutdown Procedure on page 4 16 2 Open the left rear access door See Left Rear Access Door on page 3 6 3 Loosen the wing nut 2 until it is free of the threaded ...

Page 72: ...Machine Controls SY135C Excavator 3 34 Operation and Maintenance Manual 0120 SANY 7 Position the SAE BHL pattern card 4 in the holder to match the current operating mode 0004111 Fig 3 42 4 ...

Page 73: ...f control levers 1 and control pedals 3 NOTE When the travel control levers pedals are released they return to the neutral position and machine movement stops The travel control levers and pedals change the travel direction of the machine Forward Travel Push the control lever pedal forward pedal tilts forward Backward Travel Pull the control lever pedal rearward pedal tilts backward Stop Release t...

Page 74: ...pedal The machine will move forward when you pull the control levers backward and backward when you push them forward Left and right control directions are also reversed when the track frame faces backward Fuses The fuse block 1 is on the left side of the cab behind the seat Remove the fuse block cover to access the fuses NOTICE A fuse should be replaced if it is blown corroded or becomes loose in...

Page 75: ...Amperage F1 GPS 10A F2 Travel and Swing Alarm 10A F3 Horn Cab Light Accessory Light 15A F4 Air Conditioner Control Panel 15A F5 Key Switch 30A F6 Windshield Wiper and Washer 10A F7 ECU Main Relay 30A F8 Motor Controller 20A F9 DCU 20A F10 Power Converter 15A F11 Engine Fuel Pump 15A F12 Fuel Tank Pump 15A F13 Charging Circuit 10A F14 Start Circuit 30A F15 ECU 10A F16 Work Light 15A F17 Not Used F1...

Page 76: ...display shows the operating states system information or programming information depending on the display status selected The displayed information appears as symbols or text When the key switch is in the ON position the monitor is energized The home screen is shown in the figure above 0004032 Fig 3 47 ...

Page 77: ...isplay panel 17 Working equipment configuration 4 Function Button display 18 System information 5 Function buttons F1 F5 19 Battery charging indicator 6 Direction buttons 20 Preheat indicator 7 Current date and time 21 System diagnostic trouble code 8 Selective catalytic reduction SCR warning indicator 22 Warning indicator 9 Machine lock indicator 23 Fuel level gauge 10 Engine warning lamp 24 Engi...

Page 78: ...buttons Function buttons can have different functions on different display screens Symbol Function Page up and down Select or enter Return to previous screen High speed travel Low speed travel Auto idle function Attachment select and setting Information menu H Heavy duty H mode 100 of the machine s rated power S Standard S mode 90 of the machine s rated power L Light L mode 80 of the machine s rat...

Page 79: ...nformation screen 1 will be displayed when the machine is turned on for the first time each day This screen reminds the operator of checks that should be performed before beginning work for the day See Prestart Checks and Adjustments on page 4 5 Start the machine and idle until operating temperature is reached See Starting the Engine on page 4 12 Press the enter function button 2 or the F1 functio...

Page 80: ...monitor screen The four work modes available are Heavy Duty H Provides 100 of the machine s rated power for excavating in hard or rocky ground Standard Duty S Provides 90 of the machine s rated power for normal excavating Light Duty L Provides 80 of the machine s rated power for light tasks such as digging in soft soil Breaker B Provides 70 of the machine s rated power and is used when operating w...

Page 81: ...ticks or travel controls are operated or if the throttle control dial is adjusted while the engine is idling at the lower factory set auto idle speed the engine speed automatically returns to its higher previously set level or the newly set level If the engine is shut down and then restarted the auto idle function is automatically re activated With the engine running and the auto idle function sel...

Page 82: ...l rabbit Tool Select Screen 0004117 Fig 3 53 1 8 6 5 4 2 3 7 Press the F4 function button 3 on the home screen to access the Tool Select screen which allows the operator to select the operation mode for the tool being used 1 Press the F1 function button 8 the up arrow 7 or the down arrow 6 button to access the desired menu item 1 Bucket Breaker Scissor Quick coupler 2 Press the Enter function butt...

Page 83: ...the quick coupler functions are selected an audible alarm will sound Once the quick coupler functions have been selected the icons for open and close can be activated The two top buttons on the left joystick are used to operate the open and close functions of the quick coupler To turn off the quick coupler controls the operator can use the quick coupler screen or press the F5 function button 3 Pre...

Page 84: ...to directly access the System Time Calibration screen without entering the password See System Time Display on page 3 47 To enter the password 3 1 Press the F1 function button 9 as needed to select the proper number 2 Use the F2 function button 10 the right arrow function button 7 or the left arrow function button 8 to index to the next position 3 Repeat steps 1 and 2 for each number 4 Press the E...

Page 85: ... See System Time Calibration Screen on page 3 48 to set the time Hours of Operation Display The hours of operation 3 for the machine is displayed using the format hhhhh mm Failure Code Display If an error occurs a red number the error code appears At the same time the warning lamp 2 and the symbol of the F4 function button 5 will light up red An audio warning alarm will sound Diesel Exhaust Fluid ...

Page 86: ...mation screen see page 3 46 NOTE When the System Time Calibration screen is accessed the cursor will automatically appear in the first time year field of calibration time 1 To set the time 1 Press the F1 function button 11 the up arrow button 10 or the down arrow button 8 to select the value 2 Press the F2 function button 12 the right arrow button 7 or the left arrow button 9 to change fields 3 Pr...

Page 87: ...sure Signals screen see Pilot Pressure Signals Screen on page 3 52 Main Pump and Main Valve Signals screen see Main Pump and Main Valve Signal Screen on page 3 53 Input Switch Signals screen see Input Switch Signals Screen on page 3 54 Output Switch Signals screen see Output Switch Signals Screen on page 3 55 Machine Configuration see Machine Configuration Screen on page 3 56 Failure Information s...

Page 88: ...nk yellow The F3 function button 3 can be pressed to activate the escape function 1 Press the F1 function button 5 to move to the next screen 2 Press the F2 function button 6 to start an SCR regeneration cycle 3 Press the F5 function button 4 to return to the Main Menu screen Selective Catalytic Reduction SCR Manual Regeneration To enable the manual stationary regeneration 1 Check the fuel level M...

Page 89: ...not engage The regeneration cycle requires approximately 30 minutes depending on the soot load 8 The SCR indicator will display a different color for each phase of the regeneration procedure Steady Green Auto regeneration Do not shut down the engine Blinking Yellow Manual regeneration is needed Start the regeneration cycle by accessing the Engine and Throttle Signals screen Steady Yellow Manual re...

Page 90: ...oom DOWN Kg 0 Bucket Kg 0 Breaker Kg 0 Swing Kg 0 Travel Left Kg 0 Travel Right Kg 0 Dozer Kg 0 Arm IN Kg 0 Arm OUT Kg 0 0004134 Fig 3 61 2 1 3 The Pilot Pressure Signals screen 1 enables the operator to monitor hydraulic pilot pressure at various hydraulic systems Press the F1 function button 3 to move to the next screen Press the F5 function button 2 to return to the Main Menu screen ...

Page 91: ...NAL EQUIPMENT Main Pump and Main Valve Signal Screen F1 F2 F3 Esc Enter F4 F5 18 01 11 11 03 31 00004H43M A B S1 0004135 Fig 3 62 1 2 3 The Main Pump and Main Valve Signal screen 1 enables the operator to monitor hydraulic signals that impact the main pump and valve Press the F1 function button 3 to move to the next screen Press the F5 function button 2 to return to the Main Menu screen ...

Page 92: ...Screen F1 F2 F3 Esc Enter F4 F5 18 01 11 11 03 31 00004H43M A B H1 0004138 Fig 3 63 1 2 3 The Input Switch Signals screen 1 enables the operator to monitor the input switch functions Press the F1 function button 3 to move to the next screen Press the F5 function button 2 to return to the Main Menu screen ...

Page 93: ...CE SPECIFICATIONS OPTIONAL EQUIPMENT Output Switch Signals Screen F1 F2 F3 Esc Enter F4 F5 18 01 11 11 03 31 00004H43M A B H1 0004136 Fig 3 64 3 2 1 The Output Switch Signals screen 1 enables the operator to monitor the output switch functions Press the F1 function button 3 to move to the next screen Press the F5 function button 2 to return to the Main Menu screen ...

Page 94: ...H43M A B H1 Machine Model SY135C9 Machine S N 167358 Engine Model ISUZU_IV Control System SYFCS V3 04 Hydraulic System KPM_P 0004137 Fig 3 65 1 2 The Machine Configuration screen 1 displays the following information Machine Model Engine Model Hydraulic System Control System Machine Serial Number Press the F5 function button 2 to return to the Main Menu screen ...

Page 95: ...TABLE OF CONTENTS INTRODUCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Failure Code Screen The Failure Code screen 1 displays failure codes recorded by the machine and is accessed from the Main Menu screen Press F1 function button 3 to scroll through the screen Press the F5 function button 2 to return to the home screen ...

Page 96: ...mation screen displays Longitude Latitude Altitude Velocity Number of satellites Indication Signal quality Press the F5 function button 2 to return to the Main Menu screen F1 F2 F3 Esc Enter F4 F5 18 01 11 11 03 31 00004H43M A B S1 GPS Information Longitude 0 000 E Latitude 0 000 N Altitude m 0 000 Velocity Km h 0 500 No of Sat 0000 Indication 0615 S N ratio 1 db 00 P S N ratio 2 db 00 S N ratio 3...

Page 97: ...nter F4 F5 18 01 11 11 03 31 00004H43M A B S1 Language Selection English Indonesia Deutsch 0004141 Fig 3 68 1 2 3 4 5 The Language Selection screen 1 enables the operator to select the language used to display information Press the F1 function button 5 to scroll through the language options Press the Enter button 4 or F4 function button 2 to select the desired language option Press the F5 function...

Page 98: ...ce or program updating When maintenance is required the maintenance prompt icon umbrella will be displayed on the home screen When service has been completed the service personnel must access the Maintenance History screen and reset the messages displayed by entering password 53188 The Maintenance History screen 1 displays a record of maintenance procedures performed Press the F1 function button 3...

Page 99: ... Cab 4 6 Mirrors Adjustment 4 7 Seat Belt Inspection 4 7 Operator Controls 4 8 Lights and Warning Devices 4 9 Fire Extinguisher 4 10 Escape Tool 4 10 Front Window Locks 4 10 Monitor Location 4 11 Engine Starting Procedures 4 12 Starting the Engine 4 12 Idling the Engine 4 14 Cold Weather Operation 4 15 Engine Shutdown Procedure 4 16 Warm up Operation 4 17 Travel Operations 4 18 Before Traveling 4 ...

Page 100: ...Boom 4 26 Bucket 4 26 BHL Control Pattern 4 27 Swing 4 27 Arm 4 27 Boom 4 28 Bucket 4 28 Recommended Applications 4 29 Backhoe Operation 4 29 Trenching Operation 4 30 Loading Operations 4 30 Bucket Replacement 4 31 Removal 4 31 Installation 4 32 End of Workday Checks 4 33 Parking and Storing the Machine 4 33 Overnight Storage 4 33 Short Term Storage 4 34 Long Term Storage 4 34 Maintenance During S...

Page 101: ...ty Become familiar with the work area and surroundings before beginning work Read and completely understand the instructions in this manual prior to operation Know and obey the operating procedures applicable laws and regulations Know and follow the requirements for safe operation Know and use the required safety precautions and protective devices Know and use the correct hand signals to communica...

Page 102: ...n at low idle until it reaches proper operating temperatures Do not move the controls 2 Avoid operating the machine under heavy loads or at high speeds during the break in period Operate as much as possible in the 1 2 to 3 4 throttle or load range Do not operate this machine with a full load during the break in period 3 Avoid sudden starts movements or stops 4 Monitor the instruments frequently es...

Page 103: ...been performed before operating the engine Check the machine for loose hardware fluid leaks or any other signs of damage Make repairs as necessary Make sure that all fluids are at operational levels Inspect the engine compartment for combustible debris that may come in contact with hot engine components Clear all debris from the engine and the engine compartment Check the undercarriage tracks spro...

Page 104: ...ris from inside the cab to prevent interference with machine operation Cab Remove all debris from inside the cab to prevent interference with machine operation Make sure that the Operation and Maintenance Manual is in the cab CAUTION Never allow passengers to ride on or inside the machine Never bring objects into the operator area that could restrict movement or vision Appoint a signalman when dri...

Page 105: ...ted 3 and the right side mirror 1 is attached to the right side grab handle 4 Seat Belt Inspection 1 Check the seat belt by fastening it tightly around your waist 2 Make sure the latch plate 1 and the buckle 2 connect and click WARNING Inspect the seat belt Replace the seat belt immediately if the webbing is frayed or cut if the buckle is damaged or malfunctions or if the mounting hardware is loos...

Page 106: ...out excessive play The control levers and pedals should return to neutral when released NOTE See Travel Controls on page 3 35 for controls information WARNING Keep belt slack to no more than 1 in 25 mm Belt slack beyond this amount could significantly reduce your protection in an accident Failure to follow this warning could result in death or serious injury WARNING Contact a SANY dealer if the se...

Page 107: ...l 0120 4 9 TABLE OF CONTENTS INTRODUCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Lights and Warning Devices Fig 4 7 0004022 1 2 3 With the key switch 2 set to ON check the following for proper operation Work lights 3 Horn 1 ...

Page 108: ...t belt buckle cannot be released Front Window Locks Fig 4 9 0000433 2 1 1 Push up on the handles 2 to make sure that the front window locks 1 are fully engaged Make sure the window does not move while operating the machine NOTICE Always keep the fire extinguisher in the cab and read the instructions carefully to know how to use it in an emergency Check the condition of the pull pin and housing of ...

Page 109: ...120 4 11 TABLE OF CONTENTS INTRODUCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Monitor Location The monitor 1 is mounted in the front right of the cab NOTE See Monitor on page 3 38 for additional information Fig 4 10 0000430 1 ...

Page 110: ...arting the Engine Perform the following steps to start the engine NOTE See Cold Weather Operation on page 4 15 for additional information 1 Set the hydraulic lockout control lever 1 to the locked closed position NOTE See Hydraulic Lockout Control Lever on page 3 19 WARNING Never attempt to start the machine if it has been locked out by maintenance personnel this could result in death or serious in...

Page 111: ...the throttle control dial 3 to MIN 3 Turn the key switch 2 to ON NOTE The monitor 4 displays the Home Screen 2 seconds after the key switch is turned to ON WARNING The machine should not move when the hydraulic lockout control lever is in the locked closed position If it does contact a SANY dealer Failure to follow this warning could result in death or serious injury Fig 4 12 0004022 2 3 Fig 4 13 ...

Page 112: ...own on the display screen NOTE See Monitor on page 3 38 for additional information Idling the Engine Idling the engine for long periods wastes fuel and causes carbon formation oil dilution formation of lacquer or gummy deposits on the valves pistons and rings and rapid accumulation of sludge in the engine Allow the engine to idle until it reaches normal operating temperatures before beginning oper...

Page 113: ...iscosity Temperature Data on page 5 13 and Other Approved Lubricants on page 5 14 This machine must have appropriate hydraulic oil lubricants and other auxiliary items required for operation in subzero temperatures Individual machine functions should be operated to make sure they are sufficiently warmed prior to performing work NOTE See Location Capacity and Type on page 5 12 Cold weather operatio...

Page 114: ...peed for 5 minutes 4 Turn the key switch 1 to OFF 5 Turn the key switch to ON Operate all functional controls to relieve pressure on the systems 6 Turn the key switch to OFF and remove the key 7 Place the hydraulic lockout control lever 2 in the locked closed position See Hydraulic Lockout Control Lever on page 3 19 NOTICE Except for emergencies never shut down the engine while it is running at hi...

Page 115: ...he throttle so the engine runs at high rpm then operate the boom arm and bucket for 5 to 10 minutes Repeat all movements several times 6 Continue the warm up process until the engine coolant temperature reaches the normal operating range displayed on the monitor See Monitor on page 3 38 WARNING In case of emergency irregular engine operation or other faults turn the key switch to OFF or press the ...

Page 116: ... lever or pedal to abruptly change the direction of the machine Failure to follow these warnings could result in death or serious injury CAUTION Never allow passengers to ride on or inside the machine Never bring objects into the operator area that could restrict movement or vision Appoint a signalman when driving or operating the machine in confined areas Use standard hand signals before starting...

Page 117: ...trol lever in the unlocked open position 2 See Hydraulic Lockout Control Lever on page 3 19 3 Retract the boom to make sure there is good visibility to the operator s right See Work Equipment Control and Operation on page 4 25 4 Retract the work equipment until it is 16 in 20 in 40 cm 50 cm above the ground dimension 3 See Work Equipment Control and Operation on page 4 25 5 Raise the dozer blade F...

Page 118: ...rows on the undercarriage the travel direction WARNING Check the surroundings and sound the horn before moving the machine Personnel are not allowed to approach the machine without operator approval The rear of the machine is a blind area Use the rearview mirrors and be extremely careful when backing up the machine Use a signalman as needed Failure to follow these warnings could result in death or...

Page 119: ...he undercarriage reversed Travel Controls Right Turn Fig 4 23 0000457 Move the left travel control lever pedal to cause the left track to move forward or backward depending on which direction the control is moved The farther the control is moved in either direction the faster the left track moves Left Turn Fig 4 24 0000458 Move the right travel control lever pedal to cause the right track to move ...

Page 120: ...he left travel control lever pedal forward and pull the right travel control lever pedal rearward to cause a right spot rotation of the machine Operating on an Incline Observe the following when operating the machine on an incline Do not travel on an incline exceeding 15 26 8 side to side or 35 70 forward and backward The hydraulic tank must be at the proper operating level Avoid holes rocks extre...

Page 121: ...1 Position the boom and arm at an angle between 90 and 110 2 Pivot the upper structure to position the boom over the track that is stuck 3 Curl the bucket so that the back of the bucket touches the ground 4 Lower the boom to raise the track 5 Place cribbing under the track to provide a firm surface if necessary 6 Raise the boom to lower the track onto the cribbing 7 Drive the machine out of the mu...

Page 122: ...ket so that the back of the bucket touches the ground 4 Lower the boom to lift the front of the tracks 5 Place cribbing under the track to provide a firm surface if necessary 6 Raise the boom to lower the tracks onto the cribbing 7 Cut the bucket into the ground in front of the machine Retract the arm as with normal excavating while driving the machine forward out of the mud ...

Page 123: ... the Society of Automotive Engineers SAE mode and the Backhoe Loader BHL mode The swing and bucket functions are the same for the SAE and BHL modes SAE Control Pattern See SAE Mode on page 3 31 for additional information Swing Fig 4 27 0000588 NOTE The swing function is the same for Society of Automotive Engineers SAE and backhoe loader BHL modes To swing the upper structure to the left move the l...

Page 124: ...0 To lower the boom push the right joystick forward To raise the boom pull the right joystick back Bucket 0000591 Fig 4 30 NOTE The bucket function is the same for SAE and BHL operating modes To curl the bucket move the right joystick to the left To uncurl the bucket move the right joystick to the right ...

Page 125: ...See BHL Mode on page 3 32 for additional information Swing Fig 4 31 0000593 NOTE The swing function is the same for SAE and BHL operating modes To swing the upper structure to the left move the left joystick to the left To swing the upper structure to the right move the left joystick to the right Arm Fig 4 32 0000594 To extend the arm push the right joystick forward To retract the arm pull the rig...

Page 126: ... To lower the boom push the left joystick forward To raise the boom pull the left joystick to the rear Bucket Fig 4 34 0000591 NOTE The bucket function is the same for SAE and BHL operating modes To curl the bucket move the right joystick to the left To dump the bucket move the right joystick to the right ...

Page 127: ...ging force can be obtained when the angle between the boom and the arm and the angle between the bucket cylinder and the bucket bracket are both at 90 WARNING Contact the site supervisor before any digging to make sure that all underground hazards have been located Never allow any personnel within the work area of the machine while it is being operated Avoid moving any control lever or pedal to ab...

Page 128: ...75 Trenching can be done efficiently by using a suitable bucket and positioning the tracks parallel to the trench line When digging a wider trench excavate the sides first then remove the middle Loading Operations Fig 4 38 0004376 Loading material from the rear of the truck is more efficient than loading from the side ...

Page 129: ...emove the fasteners on the plate that retains the arm pin 2 and link pin 4 4 Remove the arm pin and link pin and then remove the bucket NOTE Clean the pins of mud and sand after removal Inspect seals and bushings Replace as necessary CAUTION Keep fingers and other body parts away from pinch points to prevent crushing injuries while removing or installing the bucket Never put your finger into the p...

Page 130: ...rease is squeezed out from around the pins Wipe off excess grease upon completion NOTICE Replace damaged seals when replacing a bucket Broken seals could allow sand or dust to penetrate into the bore and cause abnormal wear This can damage the machine or cause it to operate improperly NOTICE Replace damaged seals when replacing a bucket Broken seals could allow sand or dust to penetrate into the b...

Page 131: ...t is found and perform maintenance on electrical components to prevent corrosion Parking and Storing the Machine Overnight Storage 1 Park the machine on a flat level stable surface 2 Lower the work equipment to the ground 3 Run the machine at low idle for 5 minutes to allow the engine to cool Extend this cool down time in hot weather 4 Turn the key switch to OFF and remove the key 5 Set the hydrau...

Page 132: ...storage is defined as a period of more than 30 days Proper preparation for long term storage will reduce the chances of machine damage and deterioration 1 Park the machine in a secure location and position the work equipment with the arm and bucket fully extended 2 Run the engine at low idle for 5 minutes to avoid increasing internal engine temperatures and to allow for heat dissipation Extend thi...

Page 133: ...ocation 10 Turn both of the outside mirrors inward so they are within the perimeter of the machine NOTE The left mirror is cab mounted The right mirror is attached to the right side grab handle see Mirrors Adjustment on page 4 7 for mirror locations 11 Fill the fuel tank 12 Make sure the following items are secured and locked Cab door 1 Engine cover 2 Left rear access panel 3 Air conditioner fresh...

Page 134: ...itional information 5 Turn on the air conditioner for 3 to 5 minutes to lubricate the compressor and related parts 6 Return the machine to the proper storage location and condition 7 Check the fuel for water contamination Drain the fuel and replace the filters as necessary See Drain Sediment Water From the Primary Fuel Filter Water Separator on page 5 25 8 Check the engine oil for water contaminat...

Page 135: ...proper cab protection for use during transportation of the machine 1 Clean the tracks 1 2 Position the machine so the centerline of the machine matches the centerline of the trailer WARNING To prevent the machine from tipping over observe the following precautions when loading or unloading Select a firm and level location that is a safe distance from any road or structure Make sure the trailer is ...

Page 136: ... to the machine the equipment should be positioned in front of the machine during loading NOTE If no work equipment is attached back the machine onto the trailer NOTE The machine may lean forward when it passes over the trailer wheels 5 Move the machine slowly until the tracks make full contact with the trailer 6 Slowly raise the work equipment until high enough to avoid hitting the trailer or tru...

Page 137: ...the bucket cylinder and arm cylinder 10 Lower the work equipment onto the support block 11 Shut down the machine and remove the key from the key switch NOTE Wait 2 minutes before turning the battery disconnect switch to OFF 12 Turn battery disconnect switch to OFF 13 Close and lock the windows 14 Exit the cab 15 Turn both of the outside mirrors inward so they are within the perimeter of the machin...

Page 138: ... SANY 16 Make sure the following items are secured and locked Cab door 7 Engine cover 8 Left rear access panel 9 Air conditioner fresh air inlet door 10 Right rear access panel 11 Hydraulic tank filler cover 12 Fuel tank cap 13 Fig 4 54 0000466 7 8 10 9 Fig 4 55 0003745 11 12 13 ...

Page 139: ...NE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT 17 Cover the exhaust opening 14 to prevent foreign material from entering during transport 18 Secure the machine to the trailer with suitable tie downs 15 in accordance with all applicable laws and regulations Fig 4 56 0000624 14 Fig 4 57 0000726 o 15 ...

Page 140: ... the machine WARNING To prevent the machine from tipping over select a firm and level location that is a safe distance from any road or structure Make sure the trailer is properly chocked to prevent any movement Use an access ramp with enough length strength and width to properly support the machine The ramp grade should not exceed 15 Drive slowly at the junction of the ramp and the trailer The ma...

Page 141: ...lock and start the machine Allow the machine to warm up to operating temperature 6 Press function key F2 2 on the home screen to set the auto deceleration to OFF 7 Press function key F3 3 on the home screen to set the travel speed function to low 8 Put the hydraulic lockout control lever 4 in the unlocked open position 9 Raise the work equipment to clear the trailer Fig 4 59 0000627 3 2 Fig 4 60 0...

Page 142: ... machine in the desired location 13 Run the engine at low idle for 5 minutes 14 Shut down the engine remove the key from the switch and turn the battery disconnect switch to OFF NOTICE If disconnecting the battery wait at least 2 minutes before disconnecting the battery cables so the machine s electronic control module ECM can complete its updating procedure Failure to follow this notice can damag...

Page 143: ...n 5 6 Installation of Hydraulic Hoses 5 6 Securing Access Covers and Compartment Doors 5 7 Cleaning the Machine 5 7 Weld Drill Cut or Grind on the Machine 5 7 Daily Inspection and Maintenance 5 8 Inspection and Maintenance in Adverse Environments 5 8 Mud Rain or Snow Conditions 5 9 Near Ocean Salt Air Environments 5 9 Dusty Environments 5 9 Cold Environments 5 9 Other Weather Environments 5 9 Main...

Page 144: ...ter Water Separator 5 25 Check the Hydraulic Oil Level 5 27 Check Add Windshield Washer Fluid 5 27 Climate Control System 5 29 Check the Air Conditioning System 5 29 Refrigerant Leak Test 5 30 Check and Adjust the Air Conditioner Compressor Belt 5 31 Check Air Conditioning Fresh Air and Recirculation Filters 5 32 Fresh Air Filter 5 32 Recirculation Air Filter 5 32 Engine 5 34 Engine Inspection 5 3...

Page 145: ...asteners 5 80 Replace the Hydraulic Pilot Line Filter Element 5 81 Replace the Case Drain Filter 5 83 Collect Oil Samples 5 84 Collect Engine Oil Sample 5 84 Collect Hydraulic Oil Sample 5 85 Collect Swing Drive Oil Sample 5 87 Collect Final Drive Oil Sample 5 87 Swing Drive 5 89 Check the Swing Drive Gearbox Mounting Fasteners 5 89 Check the Swing Drive Gearbox Oil Level 5 89 Change the Swing Dri...

Page 146: ...nd Undercarriage 5 110 Check the Operation and Maintenance Manual 5 110 Check the Sheet Metal 5 111 Left Side Sheet Metal 5 111 Right Side Sheet Metal 5 112 Check the Machine Decals 5 113 Check the Doors Covers and Locks 5 113 Check the Grab Handles and Steps 5 113 Inspect the Seat Belt 5 114 Check the Escape Tool 5 114 Check the Fire Extinguisher 5 114 Check the Windshield Washer Fluid Level 5 11...

Page 147: ...lways use the proper tools when performing any maintenance procedures Checks After Maintenance or Repairs Before starting the machine after maintenance or repairs verify the following If necessary have a coworker inspect your work for correct and proper completion Complete the Maintenance Log Check for leaks in the system that had maintenance or repairs Verify there are no abnormal sounds coming f...

Page 148: ...aler Fuel Tank Strainer The fuel tank strainer should always be installed when fueling the machine The fuel tank strainer prevents larger dirt and other contaminates from entering the fuel system The fuel tank strainer does not filter out very small or non solid impurities Preventing Contamination Clean dirt dust and debris from the hydraulic tank filler cap or cover before opening Make sure objec...

Page 149: ...d or pressure wash the inside of the cab Use only nonflammable cleaning solvents Never use flammable liquids to clean parts or systems Weld Drill Cut or Grind on the Machine NOTICE Contact a SANY dealer before beginning any welding repairs Any welding repairs on the machine must be performed by personnel who are certified to perform repairs that require welding Owners are responsible for the struc...

Page 150: ...nel for normal machine operating parameters Make sure that the machine operates normally Check for fluid leaks Check the following after operation with the engine off and cool Check service points for wear or damage Clean the cab Check for fluid leaks Check for loose or missing fasteners and components Inspection and Maintenance in Adverse Environments If the machine will be operating under advers...

Page 151: ...y Cold Environments In cold environments 32 F 0 C or below lubricate only with the oils shown in Engine Oil Viscosity Temperature Data on page 5 13 SANY recommends fuels identified in Fuel on page 5 11 for extremely cold environments Prior to starting the engine make sure the battery is fully charged and the battery case and the cables have not cracked Other Weather Environments NOTE If there is e...

Page 152: ...onents Change the hydraulic filter as recommended Keep the tank filled to the full level of hydraulic oil Keep the oil cooler free of dust and debris Cap and plug all openings after removing components for service or repair Lubrication and Grease Always use clean extreme pressure EP grease when greasing the machine Avoid using low viscosity greases SANY recommends EP 2 or equivalent grease designe...

Page 153: ...nti freezing engine coolant is also necessary in regions where freezing protection is unnecessary If using concentrated engine coolant use distilled water to dilute per instructions on engine coolant container Natural water such as river water and well water hard water contain large amounts of minerals calcium magnesium etc which can form scale in the engine and radiator Mineral scale is not easil...

Page 154: ...nt 6 2 gal 23 6 L See the engine manual or contact a SANY dealer for the recommended engine coolant Swing drive gearbox 1 gal 4 0 L See Industrial Gear Oil Temperature Data on page 5 13 for additional information Final drive 1 5 gal 5 5 L each side Hydraulic oil 61 gal 230 L See Hydraulic Oil Ambient Temperature Data on page 5 14 for additional data Swing bearing 75 lb 34 kg See Lubricating Grease...

Page 155: ...e life Lubricating Grease Temperature Data Industrial Gear Oil Temperature Data Oil Type Temperature F C 22 30 4 20 5 15 32 0 50 10 68 20 86 30 104 40 122 50 SAE 15W 40 SAE 10W 30 SAE 5W 30 SAE 5W 40 SAE 40W Grease Type Summer Winter NGL1 2 molybdenum disulfide lithium based grease NGL1 1 molybdenum disulfide lithium based grease NOTE Always use clean EP extreme pressure grease when greasing the m...

Page 156: ...50 10 68 20 86 30 104 40 122 50 ISO VG 46 anti wear hydraulic oil ISO VG 32 low temperature anti wear hydraulic oil NOTE Selection of the proper hydraulic oil is based on local operating climate and conditions Use ISO VG 46 anti wear hydraulic oil in general operating climates of 14 F 10 C and 122 F 50 Use ISO VG 32 low temperature anti wear hydraulic oil pour point is 43 6 F 42 C in generally arc...

Page 157: ...50 Check the track tension See page 5 96 Replace the bucket teeth See page 5 112 Check the windshield washer fluid See page 5 111 Daily or Every 10 Hours Lubricate the work equipment See page 5 99 Drain the primary fuel filter water separator See page 5 25 Check the engine air filter See page 5 34 Check the decals See page 2 3 Check the sheet metal See page 5 107 Check the hydraulic pump mounting ...

Page 158: ... the carrier roller and fasteners both See page 5 95 Check the track shoe fasteners See page 5 94 Check the exhaust system See page 5 40 Check the hydraulic system See page 5 60 Check the hydraulic hoses for wear or damage See page 5 65 Monthly or Every 250 Hours NOTE Make sure all daily and 50 hour maintenance tasks have been completed before proceeding with the 250 hour maintenance tasks Check t...

Page 159: ...conditioner condenser fins See page 5 48 Check the air conditioning fresh air and recirculation filters See page 5 31 Check the final drive oil level See page 5 91 Check the hydraulic hoses for wear or damage See page 5 65 Change the engine oil and filter See page 5 36 Check the swing drive bearing fasteners See page 5 89 Change the swing drive oil See page 5 87 Check add swing pinion gear grease ...

Page 160: ...t Fluid DEF tank filter See page 5 43 Replace the Diesel Exhaust Fluid DEF pump filter See page 5 45 Replace the hydraulic oil tank return filter See page 5 68 Clean and inspect the hydraulic oil suction strainer See page 5 71 Replace the hydraulic oil pilot filter element See page 5 79 Replace the Case Drain Filter See page 5 80 Annually or Every 2000 Hours NOTE Make sure all daily 50 hour 250 ho...

Page 161: ...nce Interval Hydraulic oil breaks down faster on machines equipped with a hydraulic breaker than on machines equipped with a bucket Change the hydraulic oil and filters every 400 hours on breaker equipped machines See Change the Hydraulic Oil on page 5 75 NOTICE The hydraulic oil filter must be replaced after 250 hours with a breaker operating rate above 50 Failure to follow this notice could resu...

Page 162: ...y tank sight glass 2 Start the engine and run it at low idle for 5 minutes 3 Shut down the engine 4 Check the coolant level Add more coolant if necessary 5 Close the engine compartment cover WARNING Engine coolant is toxic Avoid inhaling or ingesting engine coolant If eyes or skin are contaminated by coolant wash the affected area with plenty of water and seek medical treatment immediately Do not ...

Page 163: ...the engine and note the oil level NOTE The oil level should be within the etched area 2 4 Install the dipstick If engine oil is needed see Add Engine Oil on page 5 22 CAUTION Do not perform engine maintenance when the engine is hot Hot engine oil or engine components may cause severe burns Allow the engine to cool before performing engine maintenance Failure to follow this caution could result in ...

Page 164: ...ee Maintenance Safety on page 2 8 2 Open the engine compartment cover See Engine Compartment Cover on page 3 8 3 Remove the oil filler cap 1 and add oil as necessary 4 Check the engine oil level See Check the Engine Oil Level on page 5 21 5 Install the oil filler cap 6 Close the engine compartment cover NOTICE Do not add engine oil past the upper mark on the dipstick as this may result in engine d...

Page 165: ...5 66 0004114 1 Turn the key switch to ON Check the fuel level display 1 on the monitor system home screen Add Fuel Fig 5 67 0004153 2 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Remove the fuel tank filler cap 2 See Fuel Tank Filler Cap on page 3 10 NOTE See Other Approved Lubricants on page 5 14 for fuel specifications 3 Add fuel as needed until the tank is full 4 Insta...

Page 166: ... ON and check the DEF level display 1 on the monitor Add Diesel Exhaust Fluid DEF Fig 5 69 0004114 1 2 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Open the DEF tank access door 1 See Diesel Exhaust Fluid DEF Tank Access Door on page 3 9 3 Remove the DEF tank cap 2 and add DEF until full NOTE See Recommended Lubricants Fuels and Coolant on page 5 10 4 Install the DEF tank...

Page 167: ...en the engine is stopped and may cause severe burns Wait until components and oil are cool before you proceed Never service the fuel system near an open flame or while smoking Fuel that comes into contact with hot surfaces or electrical components can cause a fire Clean up any fuel spills immediately Failure to follow these warnings could result in death or serious injury NOTICE Cleanliness is imp...

Page 168: ...ould enter the fuel system 5 Open the drain valve 3 to allow all water and or contaminated fuel to drain from the filter NOTE If an excessive amount of water or contaminant is found while draining the fuel filter SANY recommends draining the fuel tank completely 6 Close the drain valve when the flow from the primary fuel filter water separator is free of water and contamination 7 Turn the fuel shu...

Page 169: ...the oil level is between the level marks shown on the sight glass decal 2 6 Shut down the engine 7 If necessary add hydraulic oil to the system See Add Hydraulic Oil on page 5 62 8 Check tightness of the hydraulic fittings 9 Replace any fittings that are damaged or worn Check Add Windshield Washer Fluid 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Open the left rear acces...

Page 170: ...is manual NOTICE Do not operate the windshield wiper on a dry window Doing so could result in machine damage and improper machine operation Climate Control System Assembly Component Symptom Cause Hose and line assembly Check hoses and lines for cracks and leaks Loose connection loose fasteners Connecting fastener Connection is loose fastener is loose or damaged Air conditioner compressor belt Dete...

Page 171: ... See Engine Compartment Cover on page 3 8 3 With the engine running press the air conditioner fan button 1 inside the cab to check startup airflow and fan speed control 4 Shut down the engine 5 Check the air conditioner condenser 2 for leaks See Refrigerant Leak Test See page 5 30 6 Check the air conditioner compressor 3 for Refrigerant leaks at the line and hose connections 4 Loose worn or twiste...

Page 172: ...artment cover See Engine Compartment Cover on page 3 8 3 Use a tensioning gauge to check the tension of the air conditioner compressor belt Press down on the belt halfway between the drive belt pulley and the compressor belt pulley Apply 143 lbf 637 N of force on a new belt and 99 lbf 441 N on a used belt The belt must deflect 0 20 in 0 31 in 5 mm 8 mm NOTE Contact a SANY dealer for belt replaceme...

Page 173: ...71 2 1 3 1 Unlock and open the fresh air filter access door 1 See Fresh Air Filter Access Door on page 3 6 2 Remove the three fasteners 2 that secure the fresh air filter 3 3 Remove the fresh air filter 4 Install a new fresh air filter using the three fasteners 5 Close and lock the access door Recirculation Air Filter Fig 5 80 0000472 5 4 4 NOTE The recirculation filter is behind the seat near the...

Page 174: ...aintenance Manual 0120 SANY 2 Remove the two fasteners 6 that secure the recirculation filter 7 3 Remove the recirculation filter 4 Install a new recirculation filter using the two fasteners 5 Install the filter cover and fasteners Fig 5 81 0000473 6 7 6 ...

Page 175: ...enance Safety on page 2 8 2 Open the engine compartment cover See Engine Compartment Cover on page 3 8 3 Inspect the engine and engine compartment for the following Oil fuel and coolant leaks Loose fasteners and connections Worn or loose drive belts Damaged hoses and wiring harnesses Damage dampness or dust in the primary engine air filter system WARNING Maintenance and service must be performed w...

Page 176: ...eeze the dust evacuator 1 mounted on the end cap 2 of the filter housing to release any dust or debris 4 Check the condition of the dust evacuator and replace if required NOTE If the dust evacuator is cracked torn remains open or is missing dust particles that are normally expelled can collect on the filter and will shorten air filter service life 5 Release three latches 3 and remove the air filte...

Page 177: ...if any are noted 8 Clean the inside of the air filter housing 5 with a clean cloth before installing the primary air filter 9 Install the air filter housing end cap on the housing making sure that the dust evacuator is pointing down Secure the end cap to the housing using the latches 10 Close the left rear access door NOTICE Do not attempt to clean the air filter Failure to replace a damaged damp ...

Page 178: ... compartment cover See Engine Compartment Cover on page 3 8 3 Remove four fasteners 1 and remove the belly plate 2 below the engine compartment CAUTION Do not perform this task when the engine is hot Hot engine oil or engine components may cause severe burns Allow the engine to cool before performing engine maintenance Failure to follow this caution could result in injury Fig 5 86 0004121 1 1 2 ...

Page 179: ...ON SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT 4 Loosen the engine oil filler cap 3 NOTE The engine has an oil capacity of 5 8 gal 22 L 5 Place an appropriately sized container under the drain valve 4 6 Remove the drain valve cap Fig 5 87 0004119 3 Fig 5 88 0000518 4 ...

Page 180: ...y is found 9 Open the right rear access door See Right Rear Access Door on page 3 7 10 Place a container under the engine oil filter 6 11 Remove the oil filter Make sure old O ring is removed 12 Clean the engine oil filter mount 7 and oil filter mounting surface 13 Apply a thin film of clean engine oil to the new oil filter O ring 14 Install the new oil filter on its mount until the filter gasket ...

Page 181: ... off from the ribs Lack of tension misalignment worn pulleys or a combination of these factors can cause the following Uneven rib wear The belt shows damage to the side with the possibility of breaks in the tensile cord or jagged edged ribs A thumping grinding noise may also be heard when running Improper installation A belt rib begins separating from the strands If left unattended the cover will ...

Page 182: ...ee per side fasteners 2 and remove the diesel oxidation catalyst selective catalytic reduction DOC SCR cover 1 WARNING Never operate a machine with a damaged or defective exhaust system exhaust leaks or restrictions Failure to follow this warning could result in death or serious injury CAUTION Make sure that the engine is off and that the exhaust components have cooled so they can be touched witho...

Page 183: ... SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT 4 Remove four fasteners 3 and remove panel 4 5 Check the connection to the expansion pipe 5 for leaks or signs of damage If any abnormality is found contact a SANY dealer for repairs Fig 5 93 0000526 4 3 3 Fig 5 94 000017S 5 ...

Page 184: ...ged components 7 Check all electrical 9 and fluid connectors 10 for loose connections Tighten as needed 8 Inspect the diesel oxidation catalyst selective catalytic reduction DOC SCR assembly 8 and its mount for leaks or signs of damage 9 Be sure the exhaust outlet 7 is clear and not restricted 10 Install the panel 11 Install the exhaust system cover and close the engine cover Fig 5 95 0000531 9 9 ...

Page 185: ...esel Exhaust Fluid DEF Tank Access Door on page 3 9 3 Disconnect engine coolant hoses 2 and DEF hoses 3 Cap and plug all openings 4 Remove the fasteners 6 from the DEF sending unit cover 4 5 Disconnect the DEF sending unit wiring harness connector 5 NOTICE It is critical that all materials used when working with the DEF system are absolutely clean Dispose of the DEF pump filter in accordance with ...

Page 186: ...ding unit from the tank 7 Remove the DEF suction filter 7 8 Replace the DEF suction filter with a new one 9 Install the DEF sending unit into the tank using fasteners 10 Connect the DEF hoses 11 Connect the engine coolant hoses 12 Connect the DEF sending unit wiring harness connector Fig 5 99 0000158 7 ...

Page 187: ...and tank from the bottom of the machine 3 Remove the DEF pump filter housing 1 from the bottom of the pump 2 4 Replace the DEF pump filter element with a new one 5 Replace the filter housing O ring with a new one and install the filter housing NOTICE It is critical that all materials used when working with the DEF system are absolutely clean Dispose of the DEF pump filter in accordance with all ap...

Page 188: ...ng system pressure Remove the cap when all pressure has been relieved 6 Unscrew four fasteners 2 and remove the lower radiator access panel 3 WARNING Engine coolant is toxic Avoid inhaling or ingesting engine coolant If eyes or skin are contaminated by coolant wash the affected area with plenty of water and seek medical treatment immediately Do not remove the radiator cap while the engine is hot E...

Page 189: ...y into the expansion tank filler neck 6 until the coolant level reaches the bottom of the filler neck Install the filler cap 11 Start the engine and run it at idle speed for about 5 minutes and allow the coolant level to drop 12 Shut down the engine and allow to cool 13 Check the coolant level 14 Add new coolant to the expansion tank until it is between the L and H marks on the sight gauge 7 15 In...

Page 190: ...essure water or steam can damage the cooling fins if the nozzle is too close to the fins To prevent cooling fin damage keep the nozzle at a safe distance while cleaning Damaged cooling fins may lead to leaks and overheating In dusty environments inspect the cooling fins daily regardless of the maintenance schedule Failure to follow this notice could result in damage to the machine or cause it to o...

Page 191: ...prevent cooling fin damage keep the nozzle at a safe distance while cleaning Damaged cooling fins may lead to leaks and overheating In dusty environments inspect the cooling fins daily regardless of the maintenance schedule Failure to follow this notice could result in damage to the machine or cause it to operate improperly NOTE Maintain a minimum distance of 12 in 30 cm from the cooling fins duri...

Page 192: ...k to collect drained fuel 4 Open the shutoff valve 1 to drain water and sediment accumulated on the bottom of the tank Do not allow fuel to splash out of the container 5 Close the shutoff valve when clean fuel drains from the fuel tank 6 Add fuel to the fuel tank as necessary 7 Start the engine and allow it to run at idle speed 8 Check the fuel shutoff valve for leaks Contact a SANY dealer if repa...

Page 193: ...nt Water From the Primary Fuel Filter Water Separator on page 5 25 WARNING Components and oil remain hot when the engine is stopped and may cause severe burns Wait until components and oil are cool before you proceed Never service the fuel system near an open flame or while smoking Fuel that comes into contact with hot surfaces or electrical components can cause a fire Clean up any fuel spills imm...

Page 194: ... housing 3 9 Remove the filter 4 from the filter body 5 10 Replace the filter and make sure it is securely seated within the filter body 11 Fill the filter housing with clean fuel 12 Install the filter housing 13 Turn the fuel shutoff valve 1 4 turn clockwise to the ON position 14 Start the engine and allow it to run at idle speed See Engine Starting Procedures on page 4 12 15 Check for leaks in t...

Page 195: ...ectric fuel feed pump 7 to operate as needed 8 Open the fuel bleeder plug 2 Do not remove the plug 9 Turn the primer plunger 1 counterclockwise until it can be pulled out 10 Press and release the primer plunger more than 20 times to fill the filter with fuel WARNING Components and oil remain hot when the engine is stopped and may cause severe burns Wait until components and oil are cool before you...

Page 196: ...ngine on page 4 12 15 Check for leaks in the fuel system 16 Shut down the engine 17 Close the right rear access door Check the Fuel Tank Strainer 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Unlock and remove the fuel tank filler cap 1 3 Lift the fuel tank strainer 3 out of the tank filler neck 2 4 Clean and inspect the fuel tank strainer Replace a damaged or missing fuel...

Page 197: ...ion wear damage or leaks Contact a SANY dealer for repairs on the fuel system Electrical System The electrical system should be inspected starting with the fuse box The fuse box is on the left behind the operator s seat See Fuses on page 3 36 for fuse location and other data If a fuse is corroded or if a white powder can be seen on it contact a SANY dealer for repair information regarding the elec...

Page 198: ... battery cover WARNING Before proceeding with any battery maintenance procedure observe the following The top of the battery must be kept clean to prevent plugging of the battery vents Regularly wash the top of the battery to prevent the battery vents from plugging Battery gases are explosive Never smoke around batteries or expose them to sparks or open flames Work in a well ventilated area Wear p...

Page 199: ...enance Safety on page 2 8 2 Open the left rear access door See Left Rear Access Door on page 3 6 3 Remove the four fasteners 1 that secure the battery cover 2 WARNING Before proceeding with any battery maintenance procedure observe the following The top of the battery must be kept clean to prevent plugging of the battery vents Regularly wash the top of the battery to prevent the battery vents from...

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

Page 201: ...3 first then disconnect the red positive cable 4 5 Remove the jumper cable 5 6 Remove the fasteners 6 from the retaining fasteners and lift the battery hold down bracket 7 off the batteries 7 Remove the failed battery or batteries 8 Install the new battery or batteries 9 Connect the red positive cables first then connect the black negative cables NOTE The two 12 volt batteries are attached in seri...

Page 202: ...the right joystick forward to move the boom down 7 The boom moving down to the ground indicates proper operation 8 If the boom does not move down to the ground contact a SANY dealer 9 Start the engine and run it at low idle for about 5 minutes to repressurize the accumulator WARNING The accumulator contains pressurized nitrogen Improper handling is extremely dangerous Do not drill holes on the acc...

Page 203: ...n the right rear access door See Right Rear Access Door on page 3 7 4 Check the hydraulic tank for leaks exterior rust and other damage 5 Check the hydraulic oil level using the sight glass 2 on the side of the hydraulic tank Make sure the oil level is between the level marks shown on the sight glass decal 2 6 Shut down the engine See Engine Shutdown Procedure on page 4 16 7 If necessary add hydra...

Page 204: ...locked closed position WARNING Allow the hydraulic system to cool before servicing Hot hydraulic oil may cause burns or other serious injury The hydraulic tank may be under pressure and hydraulic oil may be present at the filler cap Relieve hydraulic system pressure to prevent injury Failure to follow these warnings could result in death or serious injury NOTICE Filling the hydraulic tank past the...

Page 205: ...g nut 2 from the breather valve 5 Press the vent button 3 to relieve hydraulic system pressure in the hydraulic oil tank 6 Install the wing nut 7 Open the right rear access door See Right Rear Access Door on page 3 7 8 Check the oil level using the sight glass 4 on the side of the hydraulic tank Make sure the hydraulic oil level is between the level marks Fig 5 122 0004158 2 Fig 5 123 0004159 3 Fi...

Page 206: ...5 14 for oil specifications 10 Add hydraulic oil as needed 11 Install the filler cover and fasteners 12 Start the engine See Starting the Engine on page 4 12 13 Move the hydraulic lockout control lever 7 to the unlocked open position 14 Run the engine at low idle for 10 minutes to vent the air from the hydraulic system 15 Shut down the engine See Engine Shutdown Procedure on page 4 16 Fig 5 125 00...

Page 207: ...re engine components for example the exhaust system and that there is no friction between them Examine lines and hoses for the following Cracked or loose couplings Inspect for damage cuts or abrasions in the external rubber layer Hardening chapping or burning of the hose Cracks damage or serious corrosion on the couplings Leaks at the couplings Twisting flattening distortion or broken Blisters or ...

Page 208: ... hydraulic pump for cracks damage or abnormal wear NOTE Replace the hose if it is cracked damaged or worn 4 Check the fittings at both ends of all hoses 2 NOTE The fasteners at each end of the hoses may loosen due to vibration 5 Inspect all fasteners for tightness NOTE Do not use thread lock compound when reinstalling loose fasteners or installing new fasteners 6 Replace any damaged or missing fas...

Page 209: ... Clean the top of the hydraulic oil tank around the breather valve 3 Remove the wing nut 1 and spacer from the top of the breather valve 4 Press the vent valve 3 to relieve the hydraulic tank pressure 5 Unscrew and remove the hydraulic tank breather filter element cover 2 6 Remove the breather filter element 4 from the valve body 7 Install the new breather filter element 8 Install the breather fil...

Page 210: ... the wing nut 1 from the breather valve 4 Press the vent button 2 5 Install the wing nut WARNING Allow the hydraulic system to cool before servicing Hot hydraulic oil may cause burns or other serious injury The hydraulic tank may be under pressure and hydraulic oil may be present at the filler cap Relieve hydraulic system pressure to prevent injury Failure to follow these warnings could result in ...

Page 211: ...he filler cover is removed to prevent dirt and debris from falling into the hydraulic oil tank 6 Remove the four fasteners 3 from the filter cover 4 and remove the filter cover 7 Remove the spring 5 and inner filter 6 8 Remove the filter element 7 and the O ring 8 9 Remove all debris from inside the filter housing 10 Install a new O ring NOTICE Dispose of the hydraulic oil and filters in accordanc...

Page 212: ...ith four fasteners NOTE If not changing the hydraulic oil fill the hydraulic oil tank at this time See Add Hydraulic Oil on page 5 62 14 Move the hydraulic lockout control lever to the locked closed 10 position NOTE See Hydraulic Lockout Control Lever on page 3 19 for additional information 15 Start and run the engine at low idle for 10 minutes to vent the air from the hydraulic system 16 Shut dow...

Page 213: ...ce See Maintenance Safety on page 2 8 3 Remove the wing nut 1 from the breather valve 4 Press the vent button 2 to release any pressure 5 Install the wing nut WARNING Allow the hydraulic system to cool before servicing Hot hydraulic oil may cause burns or other serious injury The hydraulic oil tank may be under pressure and hydraulic oil may be present at the filler cap Relieve hydraulic system pr...

Page 214: ...strainer of any contaminants 12 Install the suction strainer to the boss of the hydraulic oil tank 13 Install a new O ring for the suction strainer cover 14 Tighten the cover fasteners securely NOTE Use the extrusion on the bottom of the cap to hold the spring in place 15 To purge air from the system start the engine and run it at low idle for 10 minutes 16 Check the hydraulic oil level and add hy...

Page 215: ...e See Maintenance Safety on page 2 8 4 Turn the key switch 1 ON 5 Fully cycle both joysticks 2 and 3 and travel levers pedals 4 two to three times within 15 seconds to release hydraulic pressure remaining in the hydraulic system WARNING Allow the hydraulic system to cool before servicing Hot hydraulic oil may cause burns or other serious injury The hydraulic oil tank may be under pressure and hydr...

Page 216: ...lic lockout control lever 5 to the locked closed position 7 Turn the key switch OFF and remove the key 8 Remove the wing nut 6 from the breather valve 9 Press the vent button 7 to relieve pressure in the hydraulic system 10 Install wing nut Fig 5 146 0004608 5 Fig 5 147 0004158 6 Fig 5 148 0004159 7 ...

Page 217: ...the access panel 8 Place a suitable container under the drain plug 2 See Location Capacity and Type on page 5 12 for hydraulic oil capacity 9 Remove the hydraulic oil drain plug and allow the hydraulic oil tank to completely drain 10 Replace the O ring 11 Install and tighten the drain plug WARNING Allow the hydraulic system to cool before servicing Hot hydraulic oil may cause burns or other seriou...

Page 218: ...c Oil on page 5 62 NOTE See Hydraulic Oil Ambient Temperature Data on page 5 14 15 Start the engine See Engine Starting Procedures on page 4 12 16 Move the hydraulic lockout control lever to the unlocked open position NOTE See Hydraulic Lockout Control Lever on page 3 19 for additional information 17 Run the engine at low idle for 10 minutes to purge air from the hydraulic system 18 Shut down the ...

Page 219: ...art the engine See Engine Starting Procedures on page 4 12 4 Inspect the hydraulic pump 1 for leaks abnormal noise and function Contact a SANY dealer for additional information 5 Shut down the engine 6 Close the right rear access door WARNING Allow the hydraulic system to cool before servicing Hot hydraulic oil may cause burns or other serious injury The hydraulic tank may be under pressure and hy...

Page 220: ... pump mounting fasteners are shown 3 Inspect the hydraulic pump for loose broken or missing pump mounting fasteners 1 Replace any missing or damaged fasteners and tighten any loose fasteners Inspect the pump for leaks or cracking at the mounting fastener locations Contact a SANY dealer if any damage is found 4 Close the right rear access door NOTICE Do not overtighten the mounting fasteners This c...

Page 221: ...e filter element housing 1 to catch any hydraulic oil that may leak out 5 Use a wrench on the hex end 2 at the bottom of the filter housing to loosen the pilot filter housing 6 Remove the pilot filter housing 2 WARNING Allow the hydraulic system to cool before servicing Hot hydraulic oil may cause burns or other serious injury The hydraulic tank may be under pressure and hydraulic oil may be prese...

Page 222: ...ed 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Relieve hydraulic system pressure See Relieve Hydraulic System Pressure on page 5 73 3 Place a suitable container under the case drain filter 4 See Change the Hydraulic Oil on page 5 75 for the steps to drain the hydraulic oil tank 5 Remove the fasteners that secure the case drain filter cover to the case drain filter housin...

Page 223: ...r testing in accordance with the instructions packaged with the sample kit Collect Engine Oil Sample 1 Obtain an oil analysis sample kit from a SANY dealer 2 Start the engine and operate the machine until engine oil reaches normal operating temperature 3 Prepare the machine for service See Maintenance Safety on page 2 8 4 Shut down the engine See Engine Shutdown Procedure on page 4 16 5 Turn the b...

Page 224: ...s sample kit from a SANY dealer 2 Start the engine and operate the machine until the hydraulic oil reaches normal operating temperature 3 Shut down the engine See Engine Shutdown Procedure on page 4 16 4 Prepare the machine for service See Maintenance Safety on page 2 8 5 Clean the top of the hydraulic oil tank 6 Remove the wing nut 1 from the breather valve NOTICE It is critical that all material...

Page 225: ...nd remove the hydraulic suction strainer cover 4 10 Insert the oil sample tube into the hydraulic oil tank 11 Collect a sample of hydraulic oil 12 Remove the oil sample tube 13 Install the hydraulic suction strainer cover 14 Follow the instructions included with the sample kit to send the sample for testing NOTICE It is critical that all material used to collect the sample is absolutely clean Fail...

Page 226: ...be into the dipstick tube 7 Collect a sample of swing drive oil 8 Remove the oil sample tube and install the swing drive dipstick 9 Follow the instructions included with the sample kit to send the sample for testing Collect Final Drive Oil Sample 1 Obtain an oil analysis sample kit from a SANY dealer 2 Start the engine and operate the machine to reach normal operating temperatures See Starting the...

Page 227: ...wly loosen the check plug to relieve pressure within the final drive 6 Remove the oil level check plug 7 Insert the oil sample tube into the oil check plug hole 8 Collect a sample of oil from the final drive 9 Remove the oil sample tube 10 Replace the oil check plug NOTE Repeat preceding steps for the other final drive as needed 11 Follow the instructions included with the sample kit to send the s...

Page 228: ... tighten any loose fasteners Contact a SANY dealer for additional information Check the Swing Drive Gearbox Oil Level Fig 5 162 0000490 1 2 3 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Inspect the swing drive gearbox 1 for leaks or damage Contact a SANY dealer if any damage is found 3 Remove the dipstick 2 The oil level should be within the etched area 4 4 Install the d...

Page 229: ...TE This procedure allows the hydraulic oil to drain easier 3 Shut down the engine See Engine Shutdown Procedure on page 4 16 4 Prepare the machine for service See Maintenance Safety on page 2 8 5 Loosen the swing drive gearbox oil fill cap 1 CAUTION Allow the swing drive gearbox to cool before servicing Hot oil may cause burns or other serious injury Wear safety goggles gloves and other personal p...

Page 230: ...gearbox access panel 11 Remove the swing drive gearbox oil fill cap 12 Fill the swing drive gearbox with clean oil through the oil fill tube NOTE See Industrial Gear Oil Temperature Data on page 5 13 for oil specifications 13 Check for correct oil level See Check the Swing Drive Gearbox Oil Level on page 5 86 14 Install and tighten the oil fill cap NOTICE Do not overfill the swing drive gearbox wi...

Page 231: ...y fasteners are missing or damaged contact a SANY dealer Check and Add the Swing Pinion Gear Grease 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Remove two fasteners 1 and remove the cover to open the inspection filler hole 3 Check the grease level by inserting a ruler into the grease through the inspection filler hole The minimum level is 3 4 in 19 mm NOTE See Lubricatin...

Page 232: ...cover 2 3 Inspect the final drive to make sure all hoses 3 are connected tightly Check for leaks 4 Inspect all of the final drive mounting fasteners 4 for rust damage or looseness 5 Replace any damaged or missing fasteners and tighten any loose fasteners NOTE Use anaerobic thread lock compound when installing loose fasteners and installing new fasteners NOTE Contact a SANY dealer if any abnormalit...

Page 233: ...evel is within 0 4 in 10 mm of the oil level check hole 5 Replace the O ring on each plug 6 Install and tighten the plugs 7 Check for external leaks CAUTION Allow the final drive to cool before servicing Hot oil may cause burns or other serious injury Wear safety goggles gloves and other personal protective equipment PPE to prevent serious injury The final drive oil may be under pressure Remove th...

Page 234: ...w the oil to drain NOTE The oil capacity of the final drive is 1 5 gal 5 5 L 6 Replace the O ring on the drain plug 7 Install and tighten the drain plug 8 Remove the oil filler plug 1 and add oil until the level is within 0 4 in 10 mm of the oil level check hole WARNING Allow the hydraulic system to cool before servicing Hot hydraulic oil may cause burns or other serious injury The hydraulic oil t...

Page 235: ...e Maintenance Safety on page 2 8 NOTE Use a pry bar to shift and or lift the track shoes as needed to perform this procedure 2 Check the track 1 for damage wear unevenness looseness raised sections tightening of track shoes or any other abnormalities Replace track shoes as necessary 3 Check the idler 6 carrier roller 2 and track rollers 5 for wear and proper operation If any are damaged contact a ...

Page 236: ... as much accumulated dirt as possible from the undercarriage Excess dirt requires more energy to operate the tracks and causes severe wear of moving parts Check the Track Shoe Fasteners Prepare the machine for service See Maintenance Safety on page 2 8 1 Check that all fasteners 1 are properly in place at each pair of track shoes 2 2 Check for broken bent loose or damaged fasteners 3 Replace any f...

Page 237: ...roller If the carrier roller is cracked or distorted contact a SANY dealer Check the Carrier Roller Mounting Fasteners 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Inspect the four mounting fasteners 1 that secure each of the carrier rollers to the track frame for rust damage or looseness NOTE Use anaerobic thread lock compound when tightening and installing fasteners 3 R...

Page 238: ...e 4 Prepare the machine for checks and inspections See Maintenance Safety on page 2 8 5 Turn the battery disconnect switch to OFF See Battery Disconnect Switch on page 3 15 6 Place a straightedge 1 on the track above the carrier roller 2 7 Measure the track sag value 3 the distance between straightedge and the track using a ruler NOTE The acceptable track sag range is 0 4 in 1 2 in 10 mm 30 mm 8 I...

Page 239: ... swing the access panel 3 up 4 Tighten the upper access panel screw to hold the access panel in place 5 Add grease through the grease fitting 4 This will move the idler and increase the track tension 6 Slowly move the machine forward 23 ft 26 ft 7m 8 m and stop the machine 7 Shut the engine down See Engine Shutdown Procedure on page 4 16 8 Check the track tension 9 Add grease until an acceptable r...

Page 240: ...TE The grease will come out from behind the grease valve 7 If the grease does not come out smoothly move the machine back and forth for a short distance 8 Check the track tension When it is correct turn the grease valve clockwise 9 Drive the machine forward at low idle speed for a distance equivalent to one full revolution of the track 10 Shut the engine down See Engine Shutdown Procedure on page ...

Page 241: ...9 8 NOTE Items 2 3 and 10 are lubricated through the grease manifold 4 1 Arm cylinder rod end 9 Boom cylinder base end 2 Arm cylinder base end 10 Boom pivot pin 2 3 Boom cylinder rod end 2 11 Boom to arm pin 2 4 Grease manifold 12 Arm to bucket pin 5 Swing bearing 13 Bucket linkage pin 6 Dozer blade cylinder base end 2 14 Bucket cylinder rod end 7 Dozer blade cylinder rod end 2 15 Bucket linkage t...

Page 242: ... left 4 and right 2 boom cylinder base end pin grease fittings Grease the two boom cylinder base end grease fittings Install the grease fitting caps 2 Remove the grease fitting cap from the swing bearing fitting 3 Grease the swing bearing fitting Install the grease fitting cap 3 Check the seal condition If it leaks replace the seal immediately Contact a SANY dealer 4 Start the engine See Starting ...

Page 243: ...ot pin grease fitting Grease the dozer pivot pin grease fitting 4 Install the grease fitting cap NOTE The right dozer blade cylinder is shown The left side is similar Boom Manifold Fig 5 185 0000505 1 4 5 2 6 3 1 Remove the grease fitting cap 1 from the left 5 and right 6 boom pivot grease fittings Grease the left and right boom pivot grease fittings Install the grease fit ting caps 2 Remove the g...

Page 244: ...cap 2 Remove the grease fitting cap 1 from the boom to arm pivot pin fitting Grease the boom to arm pivot pin fitting 3 Install the grease fitting cap 3 Remove the grease fitting cap 1 from the bucket cylinder base end grease fitting Grease the bucket cylinder base end grease fitting 4 Install the grease fitting cap 4 Remove the grease fitting cap 1 from the arm to bucket grease fitting Grease the...

Page 245: ... grease fitting cap Bucket Fig 5 189 0000502 1 1 1 3 3 2 4 1 Remove the grease fitting cap 1 from the bucket cyl inder rod end fitting Grease the bucket cylinder rod end grease fittings 2 Install the grease fitting cap 2 Remove the grease fitting cap 1 from the bucket linkage to bucket cylinder rod end pin grease fittings Grease the bucket linkage to bucket cylinder rod end pin grease fittings 3 I...

Page 246: ...ontact a SANY dealer 1 Prepare the machine for service See Maintenance Safety on page 2 8 2 Turn the key switch to ON but do not start the engine to provide power to the machine and check that all functions in the cab work correctly 3 Make sure that the following lights and other devices work properly Work light 1 Horn 2 Headlights 3 Fig 5 190 0003744 1 2 Fig 5 191 0003744 3 ...

Page 247: ... Maintenance Manual 0120 5 105 TABLE OF CONTENTS INTRODUCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Boom work light 4 Windshield washer 5 and windshield wiper 6 Fig 5 192 0000466 4 Fig 5 193 0003744 5 6 ...

Page 248: ...e with its various components and assemblies Check all structural components identified below for cracks or distortion Notify a SANY dealer if any cracks or distortion are found Check the Operation and Maintenance Manual Make sure the Operation and Maintenance Manual is in the cab If this manual is damaged or missing contact a SANY dealer for a replacement 1 Cab 4 Swing bearing 2 Engine compartmen...

Page 249: ...e Sheet Metal Fig 5 195 0004014 1 2 3 4 5 NOTE Repair or replace sheet metal as needed using SANY approved parts Check for missing or damaged sheet metal panels doors and covers and for loose connections or missing fasteners Replace panels doors covers or fasteners as needed 1 Cab door page 3 5 4 Machine decals page 5 108 2 Engine compartment cover page 3 8 5 Fresh air filter access door page 3 6 ...

Page 250: ...ir locks to be sure they close and lock properly NOTE Properly operating doors and covers are important for the security and operation of the machine 2 Repair or replace any damaged doors covers or locks immediately 1 Right rear access door page 3 7 4 Fuel tank filler cap page 3 10 2 Exhaust system cover page 5 40 5 Diesel Exhaust Fluid DEF tank access door page 3 9 3 Hydraulic oil tank filler cov...

Page 251: ...eners 3 Remove any tool lubricants or debris from the upper structure step 2 4 Remove any tools lubricants or debris from the track frame steps 3 the right side is shown the left side is similar NOTE Never allow loose items to remain on the machine Inspect the Seat Belt Fig 5 199 0003046 1 Inspect the seat belt Replace the seat belt immediately if the webbing is frayed or cut if the buckle is dama...

Page 252: ...ast a 2 5 lb type ABC rated fire extinguisher National Fire Protection Association NFPA 10 Standard for Portable Fire Extinguishers NOTICE Always keep a fire extinguisher on the machine Read the instructions on the fire extinguisher carefully and know how to use it in an emergency Inspect the fire extinguisher daily If damaged replace the extinguisher immediately Make sure the fire extinguisher is...

Page 253: ...ndshield washer fluid reservoir 1 NOTE Use washer fluid approved for use in cold or winter climates as required 4 Remove the cap 2 and add windshield washer fluid as necessary 5 Check the operation of the windshield washer nozzle 3 and wiper 4 to make sure there is no smearing across the windshield during operation Replace the wiper blade if smearing occurs 6 If necessary adjust the spray nozzle t...

Page 254: ... worn bucket teeth 2 NOTE New bucket teeth and roll pins must be installed in the reverse order of removal WARNING Unexpected machine movement can be dangerous when replacing the bucket teeth Place the bucket on a stable work surface Shut down the engine and lock out the control levers Roll pins may eject with extreme force when removed Do not allow anyone to stand in front of the pins during pin ...

Page 255: ...nd Maintenance Manual 0120 5 113 TABLE OF CONTENTS INTRODUCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT 5 Install new bucket teeth 4 and roll pins 5 in the reverse order of removal Fig 5 206 0002352 4 5 ...

Page 256: ...Maintenance SY135C Excavator OMM 5 114 Operation and Maintenance Manual 0120 SANY This Page Intentionally Left Blank ...

Page 257: ...n and Maintenance Manual 0120 6 1 TABLE OF CONTENTS INTRODUCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Specifications Machine Dimensions 6 2 Operating Ranges 6 4 Lift Chart 6 6 Lift Chart Continued 6 7 ...

Page 258: ...Specifications SY135C Excavator OMM 6 2 Operation and Maintenance Manual 0120 SANY MACHINE DIMENSIONS Fig 6 1 1 9 11 10 4 3 2 5 6 7 8 0004570 ...

Page 259: ...n 2 65 m 3 Transport height 9 ft 3 in 2 815 m 4 Upper structure width 8 ft 2 in 2 49 m 5 Cab height 9 ft 2 74 m 6 Track shoe width standard 2 ft 0 6 m 7 Track gauge 6 ft 6 in 1 99 m 8 Minimum ground clearance 1 ft 5 in 0 425 m 9 Tail swing radius 7 ft 3 in 2 205 m 10 Center idler to center sprocket length 9 ft 7 in 2 93 m 11 Track length 12 ft 3 665 m Boom length 15 ft 1 in 4 6 m Arm length 8 ft 2...

Page 260: ...Specifications SY135C Excavator OMM 6 4 Operation and Maintenance Manual 0120 SANY OPERATING RANGES Fig 6 2 6 1 2 3 4 5 0004571 ...

Page 261: ... OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Dimensions Standard Arm 1 Maximum digging height 28 ft 4 in 8 645 m 2 Maximum dumping height 20 ft 3 in 6 175 m 3 Maximum digging depth 18 ft 1 in 5 5 m 4 Maximum vertical wall digging depth 15 ft 11 in 4 85 m 5 Maximum digging reach 27 ft 2 in 8 29 m 6 Minimum swing radius 8 ft 2 in 2 5 m ...

Page 262: ...Specifications SY135C Excavator OMM 6 6 Operation and Maintenance Manual 0120 SANY LIFT CHART Fig 6 3 0003678 ...

Page 263: ...MM Specifications SANY Operation and Maintenance Manual 0120 6 7 TABLE OF CONTENTS INTRODUCTION SAFETY MACHINE CONTROLS MACHINE OPERATION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Lift Chart Continued 0003679 Fig 6 1 ...

Page 264: ...Specifications SY135C Excavator OMM 6 8 Operation and Maintenance Manual 0120 SANY This Page Intentionally Left Blank ...

Page 265: ...ION MAINTENANCE SPECIFICATIONS OPTIONAL EQUIPMENT Optional Equipment Optional Equipment Safety 7 2 Optional Equipment Selection 7 2 Equipment Instructions 7 2 Removal and Installation Precautions 7 2 Optional Equipment Precautions 7 3 Tool Select Screen 7 3 Adjust the Auxiliary Hydraulic Flow 7 4 Install Optional Equipment 7 6 Remove Optional Equipment 7 9 ...

Page 266: ...ation Precautions Prepare the machine for service See Maintenance Safety on page 2 8 When removing or installing optional equipment observe the following Follow the instructions in this manual and in the manual provided with the optional equipment Remove and install equipment only on a firm level surface Use an appropriate lifting device when handling heavy objects Never stand under a suspended lo...

Page 267: ...ce from all surrounding structures during machine operations To prevent the machine from tipping over never swing lower or stop the machine suddenly except in an emergency To prevent impact that may cause the machine to tip over never raise or lower the boom suddenly Install the necessary front guard on the machine Tool Select Screen 0004117 Fig 7 4 1 7 5 4 3 2 6 Press the F4 function button on th...

Page 268: ...me screen press the F1 button to select B breaker work mode 5 4 Press the F2 button to enable auto idle 4 5 Press F3 to select the high speed rabbit travel mode 3 See Travel Speed on page 3 44 6 Turn the throttle dial until B3 2 appears in the upper right corner of the monitor screen 7 Press the F5 button to select the folder icon Use the arrow buttons to enter password 31868 Press the Enter butto...

Page 269: ... F1 button to scroll to the Pilot Pressure Signals screen 6 See Main Menu Screen on page 3 49 9 Raise the boom off the ground so the bucket has full range of movement 10 On the right joystick push and hold the slide switch 7 forward to curl the bucket and decrease hydraulic oil flow Move and hold the slide switch backward to uncurl the bucket and increase the hydraulic oil flow The hydraulic flow ...

Page 270: ...aulic pressure 6 Turn the key switch to OFF 7 Move the hydraulic lockout control lever to the locked closed position 2 WARNING Do not remove equipment unless it is on the ground or on a solid supportive surface Block or support equipment to prevent rolling or tipping that could result in death or serious injury Hydraulic systems operate under extremely high pressure Always relieve hydraulic system...

Page 271: ...0 Install the wing nut 11 Place an appropriately sized container under the hydraulic connection to catch any hydraulic oil 12 Remove the hydraulic hose caps and plugs and allow any residual hydraulic oil to drain into the container 13 Connect the optional equipment hydraulic lines and operate equipment according to the manufacturer s instructions NOTICE Dispose of the hydraulic oil in accordance w...

Page 272: ...t the one way direction flow Turn the valve counterclockwise to select the two way direction flow NOTE A variety of optional one way and two way flow equipment is available for use on this machine A hydraulic breaker is an example of one way flow equipment a bucket thumb or shear are examples of two way flow equipment 15 Check the hydraulic oil level in the sight glass 6 mounted on the side of the...

Page 273: ...lly cycle each pedal joystick and control lever two to three times to release hydraulic pressure 6 Turn the key switch to OFF 7 Move the hydraulic lockout lever to the locked closed position 2 WARNING Do not remove equipment unless it is on the ground or on a solid supportive surface Block or support equipment to prevent rolling or tipping that could result in death or serious injury Hydraulic sys...

Page 274: ...opriately sized container under the hydraulic connection to catch any hydraulic oil 12 Disconnect the optional equipment hydraulic lines Close all openings using caps and plugs 13 Disconnect the optional equipment on the machine following the manufacturer s instructions NOTICE Dispose of the hydraulic oil in accordance with local environmental regulations Failure to do so could result in damage to...

Page 275: ...wise to select the one way flow setting Turn the valve counter clockwise to select the two way flow setting 15 Set the monitor to the correct work mode following the optional equipment manufacturer s instructions See Work Mode on page 3 42 16 Set the flow rates and pressures as required following the optional equipment manufacturer s instructions 17 Check the hydraulic oil level in the sight glass...

Page 276: ...Optional Equipment SY135C Excavator OMM 7 12 Operation and Maintenance Manual 0120 SANY This Page Intentionally Left Blank ...

Page 277: ...This Page Intentionally Left Blank ...

Page 278: ...ca com SANY Part Number SSY005078545 318 Cooper Circle Peachtree City Georgia 30269 Find a Dealer sanyamerica com find a dealer Sales E mail sales sanyamerica com Service E mail service sanyamerica com Service Hotline 470 552 SANY 7269 ...

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