SANY SY155U Operation And Maintenance Manual Download

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SANY Part Number

SSY005079291

SY155

Excavator

Operation and Maintenance Manual

Summary of Contents for SY155U

Page 1: ...service sanyamerica com SANY Part Number SSY005079291 SY155U Excavator Operation and Maintenance Manual ...

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

Page 3: ...ad and understand all safety precautions and instructions in this manual and the machine labels before operating or maintaining it Failure to follow safety messages could result in death or serious injury Keep this manual with the machine for reference SY155U Excavator ...

Page 4: ...ca com Phone 470 552 SANY 7269 Fax 770 632 7820 2019 by SANY All rights reserved No part of this publication may be reproduced used distributed or disclosed except for normal operation and maintenance of the machine as described herein All information included within this publication was accurate at the time of publication Product improvements revisions etc may result in differences between the ma...

Page 5: ...ication Plate 1 4 Frame Serial Number 1 4 Swing Motor Identification Plate 1 4 Engine Identification Plate 1 5 Hydraulic Pump Identification Plates 1 5 Travel Motor Identification Plate 1 5 SANY Contact Information 1 6 Record of Serial Number and Dealer Information 1 6 Correction Request Form 1 7 Glossary of Acronyms 1 8 Safety General Safety 2 2 Hazard Alerts in This Manual 2 2 Operator Safety In...

Page 6: ... 7 Avoid Backover Accidents 2 7 Dust and Chemical Hazards 2 7 Environmental Precautions 2 7 Precautions in High Voltage Areas 2 8 Machine Controls Machine Overview 3 4 Exterior Components 3 4 Controls 3 5 Hydraulic Lockout Control Lever 3 6 Travel Control Levers Pedals 3 6 Left Console 3 7 Right Console 3 7 Dozer Blade Control Lever 3 7 Throttle Control Dial 3 7 Windshield Washer Switch 3 8 Windsh...

Page 7: ...n Flow Selector Valve 3 18 Directional Arrow 3 18 Stop Valve 3 18 Sunlight Sensor 3 19 Climate Control System 3 20 Climate Control Panel 3 20 Climate Control System Operation 3 20 AUTO Button 3 20 OFF Button 3 20 Fan Speed Control 3 20 LCD Screen 3 20 Temperature Selection Control 3 20 Vent Mode Selection 3 20 Automatic Temperature Control AUTO 3 20 Air Conditioning AC Power 3 20 Fresh Air or Reci...

Page 8: ... Screen 3 35 Machine Configuration Screen 3 36 Tool Select Screen 3 37 Machine Operation Work Area 4 4 General Job Safety 4 4 Operator s Responsibilities 4 4 Seat Belt Usage 4 4 Operation and Maintenance Manual Check 4 4 Daily Maintenance Record Check 4 4 Cleaning the Machine 4 4 Cleaning the Machine Exterior 4 4 Cleaning the Cab Interior 4 5 Doors Panels Covers and Filler Cap 4 5 Cab Door 4 5 Eme...

Page 9: ...dshield 4 15 Cab Light 4 15 Mirrors 4 15 Check Fluid Levels 4 15 Starting the Engine 4 16 Cold Weather Engine Starting 4 17 Machine Warm up 4 18 Idling the Engine 4 18 Jump Start the Engine 4 19 New Machine Break In 4 20 Manual Regeneration 4 20 Engine Shutdown 4 21 Inspection after Engine Shutdown 4 21 Travel Operations 4 22 Machine Moving Precautions 4 22 Directional Arrow 4 22 Travel with Under...

Page 10: ... 4 30 One Track Stuck 4 30 Two Tracks Stuck 4 31 Recommended Operations 4 31 Backhoe Operation 4 31 Trenching Work 4 32 Vehicle Loading 4 32 Operation Precautions 4 32 Towing the Machine 4 32 Towing Point for a Light Load 4 33 Bucket Remove and Install 4 33 Remove the Bucket 4 33 Install the Bucket 4 34 Cold Weather Operation 4 35 Operation in Cold Weather 4 35 Engine Coolant in Cold Weather 4 35 ...

Page 11: ...ironments 5 7 Other Weather Environments 5 7 Check the Maintenance Log 5 7 Recommended Lubricants Fuel and Engine Coolant 5 8 Hydraulic Oil Description 5 8 Lubrication and Grease 5 8 Windshield Washer Fluid 5 8 Fuel 5 8 Engine Coolant 5 9 Engine Oil Viscosity Temperature Data 5 9 Lubricating Grease Temperature Data 5 9 Industrial Gear Oil Temperature Data 5 10 Hydraulic Oil Ambient Temperature Dat...

Page 12: ...pect and Clean the Radiator and Oil Cooler Fins 5 26 Drain the Charge Air Cooler 5 27 Inspect the Engine Coolant Pump 5 27 Heating and Air Conditioning System 5 28 Check the Air Conditioning System 5 28 Check the Air Conditioner Compressor Belt 5 29 Adjust the Air Conditioner Compressor Belt 5 29 Check Air Conditioner Fresh Air and Recirculation Filters 5 30 Fresh Air Filter 5 30 Recirculation Air...

Page 13: ...l Drive Oil 5 54 Swing Drive 5 55 Check and Add Swing Pinion Gear Grease 5 55 Check the Swing Drive Oil Level 5 55 Check the Swing Drive Mounting Fasteners 5 56 Change the Swing Drive Oil 5 56 Inspect the Swing Bearing Fasteners 5 57 Collect Oil Samples 5 57 Collect an Engine Oil Sample 5 57 Collect a Hydraulic Oil Sample 5 58 Collect a Final Drive Oil Sample 5 59 Collect a Swing Drive Oil Sample ...

Page 14: ...ons 6 2 Working Range 6 4 Technical Specifications 6 6 Lift Chart 6 7 Lift Chart Continued 6 8 Optional Equipment Optional Equipment Selection 7 2 Read Equipment Instructions 7 2 Removal and Installation Precautions 7 2 Operation Precautions 7 2 Install Optional Equipment 7 3 Remove Optional Equipment 7 4 ...

Page 15: ... 3 Maintenance 1 3 Specifications 1 3 Optional Attachment 1 3 Machine Applications 1 3 Machine Directions 1 3 Serial Number Location 1 4 Product Identification Plate 1 4 Frame Serial Number 1 4 Swing Motor Identification Plate 1 4 Engine Identification Plate 1 5 Hydraulic Pump Identification Plates 1 5 Travel Motor Identification Plate 1 5 SANY Contact Information 1 6 Record of Serial Number and D...

Page 16: ...ols and operation of the machine Point out 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...

Page 17: ...tailed prestart checks operating procedures end of day checks and storage information Maintenance This section provides routine maintenance procedures and fluid specifications Specifications This section provides general dimensions and weight of the machine and systems components performance information Optional Attachment This section provides information on operation of the attachments that can ...

Page 18: ...when ordering replacement parts or providing assistance for your machine Product Identification Plate 0003544 Figure 1 2 The identification plate is on the lower front of the cab Frame Serial Number 0003545 Figure 1 3 The frame serial number is stamped on the rear of the travel carriage frame Swing Motor Identification Plate 0003546 Figure 1 4 The identification plate is on the top of the swing mo...

Page 19: ...te is on the top of the engine Hydraulic Pump Identification Plates 0003548 Figure 1 6 The identification plate is on the top of the hydraulic pump Travel Motor Identification Plate 0003549 Figure 1 7 An identification plate is located on each travel motor Remove the cover plates to access the travel motors ...

Page 20: ...0 552 SANY 7269 Fax 770 632 7820 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 Swinging Drive Motor Serial No Hydraulic Pump Serial No Dealer Name Address Email Phone Numbers ...

Page 21: ...ge 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 22: ... HEST High Exhaust System Temperatures ISO International Organization for Standardization LCD Liquid Crystal Display OEM Original Equipment Manufacturer OSHA Occupational Safety and Health Administration PPE Personal Protective Equipment PQR Procedure Qualification Report ROPS Rollover Protective Structure SAE Society of Automotive Engineers SCA Supplemental Coolant Additive SDS Safety Data Sheet ...

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

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

Page 25: ...ng demolishing and trenching SANY assumes no responsibility for any consequence caused by use outside this specified range Unauthorized Use of This Machine Unauthorized uses include but are not limited to the following Transporting people on the machine or in the cab Attaching cables chains or other items to the machine to transport objects Overloading the machine beyond its capacity Unauthorized ...

Page 26: ...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 CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust ...

Page 27: ...When installing high pressure hoses make sure they are not twisted Damaged hoses are dangerous and should be replaced Take extreme caution when installing hoses for high pressure circuits Make sure fittings are correctly installed and tightened When assembling or installing parts always tighten them to the specified torque When installing protective parts such as guards or parts that vibrate or ro...

Page 28: ...sibility to replace any safety decals that are damaged or missing from the machine Never leave the machine running while it is unattended Always park the machine in a safe level area lower any work equipment to the ground lock the controls and secure the machine to prevent tampering by unauthorized personnel Shut down the engine before exiting the machine Before starting any work operations travel...

Page 29: ...ly affected The machine may not respond as expected when turning Avoid any rapid movement acceleration or quick stopping Always be aware of the increased stopping distance required on these surfaces Avoid deep snow or frozen bodies of water Even a slight incline may cause the machine to slip Be extra careful when working on an inclined surface covered with snow or ice When traveling or moving the ...

Page 30: ...en 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 injury Stay clear of overhead power lines they are an electrical hazard Treat all overhead power lines as being energized and not insulated Be sure all underground utilities have been marked before excavatin...

Page 31: ...ation Inhibit Switch 3 12 Auxiliary Flow Rate and Pressure Switches 3 12 Hydraulic Travel Motor Mode Switch 3 12 Engine Escape Mode Switch 3 12 Manual Regeneration Switch 3 12 Work Mode Switch 3 13 Auto Idle Switch 3 13 Auto Idle Function 3 13 Front Work Lights Switch 3 14 Travel Alarm Switch 3 14 Start Stop Switch 3 14 Cigarette Lighter 12V 3 14 Emergency Stop Switch 3 15 Battery Disconnect Switc...

Page 32: ...LCD 3 21 Sound Mode Adjustment Button SEL 3 21 TIME Button 3 21 Power Button 3 22 Volume Control Buttons 3 22 Tuning Buttons 3 22 Antenna 3 22 Fuse Location 3 22 Fuse Panel 3 22 Accessory Light Outlet 24V 3 22 Escape Tool 3 23 Fire Extinguisher 3 23 Monitor 3 24 Home Screen 3 24 Function Icons 3 26 Home Screen Functions 3 28 Work Accessory Selection 3 28 Tool Select Screen 3 28 Quick Coupler Opera...

Page 33: ...MACHINE CONTROLS 3 3 SY155U Excavator OMM Machine Configuration Screen 3 36 Tool Select Screen 3 37 ...

Page 34: ...1 Arm cylinder 13 Track 2 Boom 14 Track roller 3 Work lights 15 Door 4 Mirrors 16 Idler 5 Cab 17 Dozer blade 6 Beacon light 18 Dozer blade cylinders 7 Top engine compartment cover 19 Windshield wiper 8 Left rear access door 20 Boom cylinders 9 Fresh air filter access door 21 Bucket 10 Sprocket 22 Arm 11 Track frame 23 Stop valve 12 Carrier roller 24 Bucket cylinder ...

Page 35: ... page 3 6 2 Climate control panel page 3 20 9 Sunlight sensor page 3 19 3 Left console page 3 7 10 Monitor console page 3 15 4 Hydraulic lockout control lever page 3 6 11 Right console page 3 7 5 Emergency stop switch page 3 15 12 Dozer blade control lever page 3 7 6 Footrests 13 Right joystick page 3 9 7 Travel control pedals page 3 6 14 Radio page 3 21 ...

Page 36: ...tion 2 disables the hydraulic system The machine will not move even if the controls are moved Use the hydraulic lockout control lever when parking the machine leaving the cab or performing routine service procedures and inspections to prevent accidental movement of the machine 0003556 Figure 3 4 Moving the hydraulic lockout control lever up to the unlocked open position 3 enables the hydraulic sys...

Page 37: ...Console 0003669 Figure 3 7 The right control console contains the right joystick 1 dozer blade control lever 2 throttle control dial 3 windshield washer switch 4 windshield wiper switch 5 and the key switch 6 Dozer Blade Control Lever 0003635 Figure 3 1 The dozer blade control lever 1 is on the right side of the operator seat Move the lever forward 2 to lower the dozer blade Move the lever backwar...

Page 38: ...er operates at high speed Press the switch to the left to turn the windshield wiper off Key Switch 0003635 Figure 3 11 The key switch 1 is used to turn on the vehicle electrical system and start or stop the engine There are three positions on the start switch OFF When the key switch is turned to OFF the engine is shut down power to the electrical system is shut off and the key can be removed or in...

Page 39: ... side of left joystick is not used on this machine The left accessory button 3 located on the top left side of left joystick controls the accessory function Right Joystick Right Joystick Switches 0006346 Figure 3 13 WARNING Prevent unexpected movement of the machine Know the positions and functions of the joysticks before performing any machine operations Failure to follow this warning could resul...

Page 40: ...n system switch not equipped 10 Work mode switch 3 Rear work light switch not equipped 11 AUX pressure switch 4 Regeneration inhibit switch 12 AUX flow rate switch 5 AUX flow rate switch 13 Auto idle switch 6 AUX pressure switch 14 Front work lights switch 7 Hydraulic travel motor mode switch 15 Beacon light switch 8 Engine escape mode switch 16 Start Stop switch Item LED Indication LED Color Stat...

Page 41: ...sabled or off unless otherwise noted 10 Red Heavy duty work mode H Red Standard duty work mode S Red left and right alternate flashing Breaker work mode B None Light duty work mode L 11 Red Maximum Max pressure of AUX optional 12 Red Flow rate of AUX Red flashing AUX flow rate control valve error Red flashing AUX valve error 13 Red Auto idle disabled Red Auto idle enabled 14 Red LED indicator ligh...

Page 42: ...essure and are only to be used by a service technician Switch 5 decreases the hydraulic flow rate Switch 12 increases the hydraulic flow rate Switch 6 decreases the hydraulic pressure Switch 11 increases the hydraulic pressure Hydraulic Travel Motor Mode Switch Use the hydraulic travel motor mode switch 7 to select the fast travel mode When selected the LED status lights on the hydraulic travel mo...

Page 43: ... work mode S All three LED indicator lights heavy duty work mode H Auto Idle Switch The auto idle switch 13 enables or disables the auto idle function The auto idle switch LED lights are on or off to indicate system status LED lights off auto idle disabled LED lights on auto idle enabled Enable auto idle when using the machine with long pauses in work operations Auto idle reduces engine speed when...

Page 44: ...ible travel alarm will beep Turn on the travel alarm whenever the machine is being operated to increase jobsite safety Start Stop Switch Use the start stop switch 16 to start and stop the engine in addition to the key switch To start the machine with the start stop switch 1 Turn the key switch to ON 2 Press and hold the start stop switch until the engine starts then release the switch To stop the ...

Page 45: ... with a battery disconnect switch 1 When the switch is moved to the OFF position electrical power is disconnected from all machine systems Turn the power off when securing the machine for the day or as needed when performing service To disconnect the battery power from the machine 1 Move the key switch to OFF Wait for all systems to shut down 2 Open the left rear access door See Left Rear Access D...

Page 46: ...ange SAE BHL Valve on page 3 17 Left Joystick SAE Mode 0003645 Figure 3 25 In the SAE mode the left joystick controls the arm and upper structure as follows Swing the upper structure to the left 1 Arm out 2 Swing the upper structure to the right 3 Arm in 4 Neutral N Right Joystick SAE Mode 0003646 Figure 3 26 In the SAE mode the right joystick controls the boom and bucket as follows Bucket curl 1 ...

Page 47: ...ons will stop Pattern Change SAE BHL Valve The pattern change valve 1 is located inside the right front access door 0003667 Figure 3 29 SAE Mode 0004521 Figure 3 30 BHL Mode NOTICE Shut down the engine and relieve hydraulic system pressure before adjusting the pattern change SAE BHL valve Failure to follow this notice could result in damage to the machine or cause the machine to operate improperly...

Page 48: ... on the inside of each track frame indicates the forward direction of the undercarriage Check these arrows before using the travel control levers When possible face the cab in this direction NOTE When the operator cab faces backward the travel direction will be the reverse of the normal travel control functions The machine moves forward when you pull the control levers backward and the machine mov...

Page 49: ...nd the sunlight sensor and keep it clean to make sure the automatic functions of the climate control system operate properly The sunlight sensor 1 is on the front of the monitor console The sunlight sensor adjusts the climate control system airflow to match the changes of temperature caused by direct sunlight 1 ...

Page 50: ...ature is reached LCD Screen The LCD screen 3 shows the preset temperature fan speed and vent selection during operation Temperature Selection Control Press the TEMP up or down arrow 4 to control the inside cab temperature between 63 F and 90 F 18 C and 32 C Press and hold both the up and down arrows for about 5 seconds to toggle between Fahrenheit F and Celsius C temperature display Vent Mode Sele...

Page 51: ...ode adjustment button 3 to adjust the sound tones and speaker balance Each time the SEL button is pressed the display will cycle to adjustment options as follows Press and hold the SEL button to access the bass adjustment Press and release the SEL button again to access the treble adjustment Press and release the SEL button again to access the speaker balance With the preferred sound mode option s...

Page 52: ... component If a fuse repeatedly blows the wiring harness must be inspected for broken or damaged wire insulation or a component placing a high electrical load on the system Contact a SANY dealer for repairs NOTICE A fuse should be replaced if it is blown corroded or becomes loose in the fuse block Before replacing a fuse make sure the key switch is in the OFF position and the battery disconnect sw...

Page 53: ...dow edge Fire Extinguisher 0003665 Figure 3 42 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 condition of the fire extinguisher daily If damaged replace the extinguisher immediately Make sure the fire extinguisher is within the listed inspection period Replace the fire extinguisher i...

Page 54: ... the battery is connected and the key switch is in the ON position Home Screen 0003699 Figure 3 43 1 2 9 7 5 4 6 10 8 3 11 Item Home Screen Display Function Description 1 Date and time Displays the current date and time Date YY MM DD and Time HH MM SS 2 Operating hours Displays the total number of machine operating hours 3 Function icons Displays information for machine systems ...

Page 55: ... indicates the number of revolutions per minute rpm that the engine is running 7 Engine rpm indication Digital rpm display 8 Engine load rate Indicates the hydraulic load percentage to the engine 9 Fuel level gauge Indicates the level of diesel fuel in the tank 10 Work mode indication Indicates the current work mode by letter designation L Light duty S Standard duty H Heavy duty B Breaker 11 Throt...

Page 56: ...e Engine power early warning Engine power final warning 3 Preheat icon illuminates when the engine is in the engine preheating mode Red Engine preheat is on 4 Not used 5 Maintenance prompt icon illuminates if any scheduled maintenance is due Yellow Green Fault code exists Internal circulation 6 Alarm silence icon illuminates when the audible alarm is off Red Alarm is silenced 7 High low speed icon...

Page 57: ...ngine oil pressure icon illuminates when the oil pressure is low or an oil change is required Yellow Red Engine oil change required Engine oil pressure low 17 Manual regeneration icon Yellow flashing Yellow steady Red Manual regeneration requested Manual regeneration on Diesel Particulate Filter DPF change required 18 High Exhaust System Temperature HEST icon Yellow Exhaust temperature is high Ite...

Page 58: ...oupler screen The icon for this button displays the current status of the quick coupler See Quick Coupler Screen on page 3 29 F4 button displays the output from the rearview camera F5 button opens the Main Menu screen Work Accessory Selection Tool Select Screen 0003697 Figure 3 46 Press F2 from the home screen to display the Tool Select screen with the following options Bucket Breaker Shear Quick ...

Page 59: ...lock quick coupler 4 Move the machine arm to the work equipment to be attached and align quick coupler with the work equipment 5 Press the F3 button below the Lock quick coupler icon 3 to lock the quick coupler 6 Press the F1 button below the Active quick coupler icon 1 to deactivate the quick coupler function 7 Press the F5 button below the return arrow icon 4 to return to the home screen Rearvie...

Page 60: ...gure 3 50 1 Press the F1 button below the up down arrow icon 1 from the Main Menu screen to highlight the Work Para Parameter icon then press the F3 button below the check mark icon 2 to accept the selection 2 Press the F1 button below the up down arrow icon to scroll through the work parameter screens to display the following signal screens Engine and throttle signals Input switch signals Output ...

Page 61: ...t screen or press the F5 button below the return arrow icon 2 to return to the Main Menu screen Input Switch Signals Screen The Input Switch Signals screen shows the inputs that are currently active This screen can be used to check for faulty switch inputs by a service technician 0003706 Figure 3 52 Press the F1 button below the up down arrow icon 1 to scroll to the next screen or press the F5 but...

Page 62: ... next screen or press the F5 button below return arrow icon 2 to return to the Main Menu screen Pilot Pressure Signals Screen The Pilot Pressure Signals screen shows the hydraulic pressures at hydraulic pilot lines on the main control valve This screen can be used to check for faulty hydraulic circuits by a service technician 0003708 Figure 3 54 Press the F1 button below the up down arrow icon 1 t...

Page 63: ...ump problems 0003709 Figure 3 55 Press the F1 button below the up down arrow icon 1 to scroll to the next screen or press the F5 button below the return arrow icon 2 to return to the Main Menu screen Maintenance Information Screen The Maintenance Information Screen is accessed through the Main Menu screen 0003710 Figure 3 56 NOTE The Maintenance Information Screen Maint Info screen is for SANY tec...

Page 64: ...een to highlight Error Codes 2 Press the F3 button below the check mark icon 2 to display the Fault Information screens NOTE Three Fault Information screens display electrical engine and hydraulic error code information 0003711 Figure 3 58 1 Press the F1 button below the up down arrow icon 1 to scroll to the next screen 2 Press the F5 button below the return arrow icon 3 to return to the Main Menu...

Page 65: ... Time Setting Backlight Setting Data Unit Setting Time Format Setting Language Selection 1 Press the F1 button below the up down arrow icon to highlight the setting to change 2 Press the F3 button below the check mark icon to accept the selection 3 After selecting the setting to be changed press the F1 button below the up down arrow icon to change values or press the F4 button below the left right...

Page 66: ...Main Menu screen to highlight Machine Config 2 Press the F3 button below the check mark icon 2 to open the Machine Configuration screen 0003713 Figure 3 62 The Machine Configuration screen displays the machine configuration information for installed operating systems You may need to provide this information when requesting vehicle information or talking with a service technician Press the F5 butto...

Page 67: ... screen to highlight Tool Select 2 Press the F3 button below the check mark icon 2 to open the Tool Select screen 0003697 Figure 3 64 1 Press the F1 button below the down arrow icon to select the tool to operate then press the F3 button below the check mark icon to accept it 2 Press the F5 button below the return arrow icon 3 to complete the change and return to the Main Menu screen NOTE The Tool ...

Page 68: ...3 38 MACHINE CONTROLS SY155U Excavator OMM Page Intentionally Blank ...

Page 69: ...the Right Rear Access Door 4 7 Closing the Right Rear Access Door 4 7 Left Rear Access Door 4 7 Opening the Left Rear Access Door 4 7 Closing the Left Rear Access Door 4 7 Fresh Air Filter Access Door 4 7 Engine Compartment Door 4 7 Opening the Engine Compartment Door 4 7 Closing the Engine Compartment Door 4 8 Fuel Tank Filler Cap 4 8 Opening the Fuel Tank Filler Cap 4 8 Closing the Fuel Tank Fil...

Page 70: ...4 24 Pattern Change SAE BHL Valve Operation 4 24 Arm Control SAE Mode 4 24 Arm Control BHL Mode 4 24 Boom Control SAE Mode 4 24 Boom Control BHL Mode 4 25 Bucket Control SAE BHL Mode 4 25 Swing Control SAE BHL Mode 4 25 Dozer Blade Control Lever 4 25 Restricted Operation 4 26 Never Operate with Bucket Force 4 26 Never Use Swing Force 4 26 Never Use Traveling Force 4 26 Excavating Hard or Rocky Gro...

Page 71: ...35 Engine Coolant in Cold Weather 4 35 Battery in Cold Weather 4 35 Track Cleaning in Cold Weather 4 35 After the Cold Season 4 35 Machine Storage in Cold Weather 4 35 After Daily Operation 4 35 Park the Machine 4 36 End of Workday Checks 4 36 Long Term Storage 4 36 Prepare for Long Term Storage 4 36 During Storage 4 37 Return to Service 4 37 Starting the Engine after Long Term Storage 4 37 Transp...

Page 72: ... endangering safety are found Maintain complete control of the machine at all times Before leaving the cab make sure that all control devices are set to the neutral or low idle position and that the engine is shut down Give warning signals when necessary Seat Belt Usage Always wear the seat belt when operating the machine WARNING The seat belt is designed to protect the operator from danger especi...

Page 73: ...nd Escape Tool on page 3 23 Doors Panels Covers and Filler Cap Cab Door 0003620 Figure 4 2 The cab door 1 can be locked from the outside when closed using the cab door lock 3 To open the cab door from the outside unlock and pull the handle 2 Swing the cab door open until the catch 4 engages the cab door latch 5 securing it in the opened position 0003688 Figure 4 3 From inside the cab press down on...

Page 74: ...he fasteners 4 1 4 turn Door Support Rod 0003691 Figure 4 7 The access and top engine compartment doors use a support rod 1 and support bracket 2 to prevent it from closing unexpectedly Guide the support rod into the appropriate support bracket slot to secure the door in the open position NOTE Move the support rod out of the support bracket slot to allow the access door to close Right Front Access...

Page 75: ...place the access door support rod in the support bracket slot to prevent it from closing unexpectedly See Door Support Rod on page 4 6 Closing the Left Rear Access Door Move the support rod out of the slot in the support bracket to close the access door See Door Support Rod on page 4 6 Close the access door until latched Fresh Air Filter Access Door 0003625 Figure 4 11 Unlock and open the fresh ai...

Page 76: ...k 3 Turn the key from position 4 counterclockwise until the lock points to position 3 Remove the key 4 Close the lock shield 1 Prestart Checks and Adjustments CAUTION Perform inspections and have needed issues resolved before operation Failure to observe and follow this caution could result in injury Complete the following checks and adjustments before starting the engine each day Check the mainte...

Page 77: ...r rating for each circuit Make sure the battery terminal connectors are clean secure and free of dirt and debris Inspect the electrical wires and cables for worn or damaged insulation Make sure the vents on top of the batteries are free of any dirt or debris Check if the rear camera is operating if equipped Check for proper windshield wiper operation Lights and Warning Devices With the key switch ...

Page 78: ...F See Battery Disconnect Switch on page 3 15 3 Disconnect the negative battery cables from the batteries 4 The fuse panel 2 is located on the left side of the seat 0003581 Figure 4 15 5 Remove the fuse panel cover 1 and inspect for blown fuses Replace a blown fuse with a fuse of the same amperage rating 0003582 Figure 4 16 F1 F3 F5 F7 F9 F11 F13 F15 F2 F4 Horn Cab lamp Working light ECU power DCU ...

Page 79: ...ock it into position Seat Forward Backward Position Adjustment Lift and hold the forward and backward lever 7 to slide the seat 12 to the desired position Release the lever to lock the seat in position Seat Base Forward Backward Position Adjustment Lift and hold the seat base adjustment lever 10 to slide the seat base 11 and control consoles forward or backward Release the lever to lock the seat b...

Page 80: ...s damaged or malfunctions or if the mounting hardware is loose Replace according to seat belt manufacturer s instructions Always keep the seat belt fastened during machine operation Never twist the seat belt when fastening it Failure to follow these warnings could result in death or serious injury 0003636 Figure 4 19 Buckle the Seat Belt Hold the latch plate 2 and pull upward to lengthen the belt ...

Page 81: ...quipment 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 1 Before opening the front windshield park the machine on level ground lower the work equipment to the ground and stop the engine 2 Place the hydraulic lockout control lever 1 in the locked closed positio...

Page 82: ...ngers Failure to follow this caution could result in personal injury or machine damage 1 Before closing the windshield park the machine on level ground lower the work equipment to the ground and stop the engine 2 Move the hydraulic lockout control lever 1 to the locked closed position 0003685 Figure 4 26 3 Hold the left and right handles 2 and pull down on both windshield release latches 3 4 Move ...

Page 83: ...he cab light to operate properly Mirrors 0003683 Figure 4 29 The machine has two mirrors 2 and one convex mirror 3 for viewing around the machine To position the mirrors loosen the mounting fasteners 1 When positioned properly tighten the mounting fasteners securely NOTE The right mirror is shown The left side is similar Check Fluid Levels Complete the following procedures before starting the engi...

Page 84: ...ure 4 30 WARNING The engine should not start when the hydraulic lockout control lever is in the unlocked open position If it does contact a SANY dealer Failure to correct this could result in death or serious injury 5 Move the hydraulic lockout control lever 1 to the locked closed position 2 If the hydraulic lockout control lever is in the unlocked open position the engine will not start 6 Make su...

Page 85: ...ch is in the run position See Emergency Stop Switch on page 3 15 0003555 Figure 4 32 WARNING The machine should not start when the hydraulic lockout control lever is in the unlocked open position If it does contact a SANY dealer Failure to correct this could result in death or serious injury 5 Move the hydraulic lockout control lever 1 to the locked closed position 2 If it is in the unlocked open ...

Page 86: ...rational level Failure to follow this caution could damage the machine NOTICE In case of emergency irregular engine operation or other faults turn the key switch to the OFF position to stop the engine Insufficient warm up of the machine may cause slow response or abrupt movement during operation resulting in serious accidents Warm up is especially necessary in cold areas Operating the machine befo...

Page 87: ...follow this notice could damage the machine or cause improper machine operation 1 Make sure that the key switches of both machines are OFF NOTE Make sure that all jumper cables are securely clamped to their connections Failure to follow this notice could result in damage to the machine or cause the machine to operate improperly 2 Clamp one end of a jumper cable to the positive red terminal of the ...

Page 88: ... exhaust will be very hot Make sure the machine is not in a highly combustible area Failure to follow this warning could cause a fire or explosion resulting in death or serious injury A manual regeneration is required when the regeneration icon is flashing yellow See Function Icons on page 3 26 NOTICE If the flashing yellow regeneration icon is ignored for too long the regeneration icon remains on...

Page 89: ... allow the engine to idle for 5 minutes to cool down 4 Turn the key switch 2 to the OFF position and allow the engine to stop 0003555 Figure 4 35 5 Turn the key switch 2 to ON NOTE The hydraulic lockout control lever must be in the unlocked open position to relieve hydraulic system pressure 6 Operate all hydraulic controls to relieve hydraulic system pressure 7 Turn the key switch to the OFF posit...

Page 90: ...ontrol levers pedals If the sprockets are in the front the machine will move in the opposite direction of the travel control levers pedals 0003635 Figure 4 36 1 Adjust the throttle control dial 1 to MAX high idle 2 Raise work equipment a minimum of 16 in 20 in 40 cm 50 cm above the ground 3 Retract the boom to make sure good visibility is obtained Directional Arrow 0003364 Figure 4 37 The directio...

Page 91: ...th travel control levers equally or press the top of both foot pedals equally to move the machine forward Backward Travel Pull both travel control levers equally or press the bottom of both foot pedals equally to move the machine backward Right Turn 0003599 and 0004368 Figure 4 40 Push the left travel control lever 1 or press the top of the left foot pedal 2 with the right travel control lever and...

Page 92: ... BHL valve changes control of the boom and arm from one joystick to the other In SAE Society of Automotive Engineers mode the arm is controlled using the left joystick and the boom is controlled using the right joystick In BHL Backhoe Loader mode the arm is controlled using the right joystick and the boom is controlled using the left joystick To change the operating mode see Pattern Change SAE BHL...

Page 93: ...et move the right joystick to the right To curl the bucket move the right joystick to the left Swing Control SAE BHL Mode 0003609 and 0004008 Figure 4 48 To swing the machine to the right move the left joystick to the right To swing the machine to the left move the left joystick to the left Dozer Blade Control Lever 0003635 Figure 4 49 To raise to the dozer blade pull the dozer blade control lever...

Page 94: ...igure 4 50 Never use the landing force of the bucket for excavating digging breaking or pile driving operation Such operations may reduce the service life of the machine 0002869 Figure 4 51 To avoid hydraulic cylinder damage do not use the bucket to strike or compact the ground Never Use Swing Force 0002850 Figure 4 52 Never use the swing force to compact the ground or to break objects Such operat...

Page 95: ...Avoid operating the machine with any cylinder fully retracted or extended If the cylinder piston reaches its end of stroke continued use of the work equipment could damage that cylinder Avoid Dozer Blade Impact 0002875 Figure 4 56 Do not strike rocks or other hard objects with the dozer blade This can shorten the service life of the dozer blade or the hydraulic cylinder Support the Dozer Blade 000...

Page 96: ... the machine or cause the equipment to operate improperly Do not drive the machine into water where the water depth is above the carrier rollers Grease the parts that have been submerged until the old grease has been displaced from the bearings and the bucket pins Make sure that the job site surface is firm enough for the machine Continuously monitor the condition of the machine when operating in ...

Page 97: ...to warm up to operating temperature Avoid crossing inclines as much as possible Slipping or rolling over may occur 0002891 Figure 4 59 Do not swing the upper structure to the downhill direction the machine may tip over If such an operation is necessary carefully swing the upper structure and the boom Do not swing a loaded bucket to the downhill direction Build a platform 1 on an incline so the mac...

Page 98: ...rain could cause wide tracks with wide shoes to bend or come loose and damage other track components Wide track hoes are intended for operation on soft ground Inspect the track shoe fasteners on a regular basis Choose the proper tracks when operating the machine on soft ground Soft ground could cave in and cause the machine to roll over Place steel plates on soft ground to support the machine The ...

Page 99: ... keep clear of these areas to prevent injury To prevent injuries avoid moving any travel control lever or pedal to abruptly change the direction of the machine and avoid stopping the machine suddenly by releasing the lever or pedal while traveling at high speed NOTICE Avoid sudden stops when lowering the boom Hydraulic shock can damage the hydraulic system Avoid extending the arm cylinder while in...

Page 100: ...he job site Operate the machine on a hard level surface When working in a ditch or on a road shoulder keep the tracks perpendicular to the work face and the travel motors at the rear of the machine Placing the machine in this position helps facilitate escape if a collapse occurs When working under a cliff or high embankment make sure the work area is secure Do not allow the arm to interfere with t...

Page 101: ...juries Make sure the surrounding area is clear of all personnel and wear goggles a hard hat protective gloves and other personal protective equipment PPE during these operations Do not stand behind the bucket when removing pins Keep hands and feet clear of the underside of the bucket during removal Do not use hands or fingers to aid in bore alignment Failure to follow this caution could result in ...

Page 102: ...et attachment pin bore 3 Apply a light coat of grease to the attachment pins 000229S Figure 4 73 4 Install the shims 1 as noted during the removal and install attachment pins 2 securing the bucket 3 to the arm 4 and link assembly 5 000228S Figure 4 74 5 Install the retaining fastener and nuts 6 securing the link attachment pin 7 to the bucket 000227S Figure 4 75 6 Install the retaining fastener an...

Page 103: ...e coolant is used as an alternative drain and flush the cooling system completely Add new ethylene glycol engine coolant to the cooling system Machine Storage in Cold Weather Clean the machine Check the engine coolant and engine oil levels and check for leaks The machine is normally filled to withstand a maximum low temperature of 40 F 40 C Change the fuel hydraulic oil and gear oil with new fluid...

Page 104: ...and cab door 8 Turn the battery disconnect switch to OFF 9 Close and lock all doors End of Workday Checks 1 Collect any trash or debris from the cab and deposit it into a proper disposal container 2 Remove all built up mud or debris on the undercarriage and machine exterior 3 Inspect the machine work equipment machine exterior and undercarriage for signs of fluid leaks or damage 4 In oceanic salt ...

Page 105: ...just the throttle control dial 2 to MAX high idle for 3 seconds 3 Adjust the throttle control dial to MIN low idle and start the engine See Starting the Engine on page 4 16 4 Run the engine for 5 minutes after the engine and all components have reached normal operating temperature Transportation Information Transportation Method Applicable laws and regulations must be observed when transporting th...

Page 106: ...latform ramps and trailer floor before loading or unloading Grease mud or ice on the trailer landing platform and ramps can cause the machine to slide and tip over Loading the Machine NOTE Do not load or unload the machine without a landing platform or ramps 0000723 Figure 4 80 Use a landing platform or ramps when loading or unloading the machine When loading the excavator with work equipment inst...

Page 107: ...inute for the Engine Control Module ECM to complete its shutdown before turning the battery disconnect switch to OFF Failure to follow this notice could cause damage to the machine or cause improper machine operation 11 Turn the battery disconnect switch to OFF See Battery Disconnect Switch on page 3 15 12 Lock all doors and hoods 13 Cover the exhaust opening to prevent contamination NOTICE To avo...

Page 108: ...ngth The maximum angle of the ramps is 15 4 Remove the chains or wire ropes that secure the machine 5 Start the engine 6 Turn the hydraulic lockout control lever to the unlock open position 0000731 Figure 4 86 7 Raise the work equipment and retract the arm toward the boom Drive the machine slowly 8 Stop the machine when it travels over the rear wheels of the trailer and toward the ramps 9 Adjust t...

Page 109: ...he machine see Technical Specifications on page 6 6 1 Park the machine on firm level ground raise the dozer blade and swing the upper structure to the rear of the machine 2 Fully extend the arm cylinder and the bucket cylinder Raise the boom 3 Move the hydraulic lockout control lever to the locked closed position 4 Turn the key to OFF and remove it from the switch 5 Close the cab window and door 6...

Page 110: ...4 42 MACHINE OPERATION SY155U Excavator OMM Page Intentionally Blank ...

Page 111: ...ironments 5 7 Check the Maintenance Log 5 7 Recommended Lubricants Fuel and Engine Coolant 5 8 Hydraulic Oil Description 5 8 Lubrication and Grease 5 8 Windshield Washer Fluid 5 8 Fuel 5 8 Engine Coolant 5 9 Engine Oil Viscosity Temperature Data 5 9 Lubricating Grease Temperature Data 5 9 Industrial Gear Oil Temperature Data 5 10 Hydraulic Oil Ambient Temperature Data 5 10 Capacities 5 11 Other Ap...

Page 112: ...26 Inspect and Clean the Radiator and Oil Cooler Fins 5 26 Drain the Charge Air Cooler 5 27 Inspect the Engine Coolant Pump 5 27 Heating and Air Conditioning System 5 28 Check the Air Conditioning System 5 28 Check the Air Conditioner Compressor Belt 5 29 Adjust the Air Conditioner Compressor Belt 5 29 Check Air Conditioner Fresh Air and Recirculation Filters 5 30 Fresh Air Filter 5 30 Recirculati...

Page 113: ...e Final Drive Oil 5 54 Swing Drive 5 55 Check and Add Swing Pinion Gear Grease 5 55 Check the Swing Drive Oil Level 5 55 Check the Swing Drive Mounting Fasteners 5 56 Change the Swing Drive Oil 5 56 Inspect the Swing Bearing Fasteners 5 57 Collect Oil Samples 5 57 Collect an Engine Oil Sample 5 57 Collect a Hydraulic Oil Sample 5 58 Collect a Final Drive Oil Sample 5 59 Collect a Swing Drive Oil S...

Page 114: ...5 4 MAINTENANCE SY155U Excavator OMM Check the Operation and Maintenance Manual 5 66 ...

Page 115: ...ing on the monitor home screen on a daily basis Confirm hour meter readings with the required maintenance intervals listed in this manual See Monitor on page 3 24 Genuine SANY Parts Use genuine SANY replacement parts when repairing or replacing machine components Failure to do so may result in premature system or part failure SANY Approved Lubricants Always use SANY approved lubricants and engine ...

Page 116: ... operation Perform daily service as necessary Inspect the machine for loose or missing fasteners and components Clean the cab Check all controls for smooth operation and make sure they return to the neutral position Make sure all safety decals are in place and are legible Check for fluid leaks With the engine running check the following operations Monitor the control panel for normal machine opera...

Page 117: ...ther Weather Environments NOTE If there is evidence of overheating of bearings or bushings loose parts or rust during regular inspection increase the frequency of lubrication Based on experience and suggestions by lubricating oil suppliers the lubricating intervals listed in the Maintenance Schedule on page 5 12 apply only to normal operating conditions In harsh environments including those with d...

Page 118: ...extreme pressure EP grease when greasing the machine Avoid using low viscosity greases SANY recommends EP 2 or equivalent grease designed for heavy duty plain and rolling element bearings operating under severe conditions including shock loading in wet environments Windshield Washer Fluid Only use clean automotive windshield washer fluid Do not mix concentrates into the washer fluid In cold weathe...

Page 119: ... before refilling engine coolant NOTE See the engine manual or contact a SANY dealer for the recommended engine coolant Engine Oil Viscosity Temperature Data NOTE Due to its comparatively better lubricating characteristics including improved oil consumption engine operation in frigid climates and continued lubrication in high temperatures SAE 15W 40 is recommended for most climates In some circums...

Page 120: ...tenance Do not use any additives in the hydraulic oil Change the hydraulic oil that has been subjected to overheating or damaged components Change the hydraulic filter as recommended Keep the hydraulic oil tank filled Keep the oil cooler free of dust and debris Cap and plug all openings after removing components for service or repair NOTE Selection of the proper hydraulic oil is based on local ope...

Page 121: ...age the machine and cause it to operate improperly Approved lubricants include Any anaerobic sealant thread locking compound having properties that offer high temperature performance and oil tolerance to prevent the loosening of fasteners Any lithium grease based spray lubricant Mineral spirits Type II odorless and or Class 1 high flash point Capacities Fuel DEF Engine Oil Hydraulic Tank Swing Dri...

Page 122: ... See page 5 22 Check the air conditioner compressor belt See page 5 28 Check the diesel exhaust fluid DEF level See page 5 16 Check the seat belt and buckle See page 4 12 Check the escape tool See page 3 23 Check the fire extinguisher See page 3 23 Check the electrical system See page 5 36 Check the fuel level See page 5 16 Check the climate control system See page 3 20 Check the operation and mai...

Page 123: ...heck the fuel tank strainer See page 5 35 Inspect the fuel lines See page 5 33 Check the aftertreatment exhaust piping See page 5 30 Replace the hydraulic pilot line filter element See page 5 41 Check the accumulator function See page 5 38 Replace the Diesel Exhaust Fluid DEF tank filter See page 5 32 Replace the Diesel Exhaust Fluid DEF pump filter See page 5 31 Replace the hydraulic tank return ...

Page 124: ...nt WARNING Engine coolant is toxic Avoid inhaling or ingesting engine coolant If eyes or skin are contaminated by engine coolant wash the affected area with plenty of water and seek medical treatment immediately Do not remove the expansion tank cap while the engine is hot Engine coolant may be under pressure when the engine is hot Avoid contact with hot engine coolant Allow the engine to cool befo...

Page 125: ...5 4 5 Install the dipstick If engine oil is needed see Add Engine Oil on page 5 15 Add Engine Oil 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 injury NOTICE Do not overfill the engine with oil This could result i...

Page 126: ...s needed until the tank is full The fuel float gauge 3 will rise when the tank is nearly full Check the Diesel Exhaust Fluid DEF Level 1 Prepare the machine for checks and inspections See Maintenance Safety on page 2 5 0003695 Figure 5 8 2 Turn the key switch to the ON position and check the DEF level display 1 on the system monitor Add Diesel Exhaust Fluid DEF 1 Prepare the machine for checks and...

Page 127: ...n counterclockwise to the OFF position NOTES Avoid draining the fuel filter completely Air could enter the fuel system 7 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 8 Close the drain valve when the flow from th...

Page 128: ...e Battery Disconnect Switch on page 3 15 0003566 Figure 5 14 4 Check the washer fluid level inside the windshield washer reservoir 1 NOTE Use washer fluid appropriate for use in cold or winter climates as required NOTICE Never use tap water dirty water or fluids that could freeze clog or damage the windshield washer system Using these fluids could cause damage to the windshield washer system or ca...

Page 129: ...aintenance Failure to follow this caution could result in injury 1 Prepare the machine for checks and inspections See Maintenance Safety on page 2 5 2 Open the appropriate access covers or compartment doors See Doors Panels Covers and Filler Cap on page 4 5 3 Turn the battery disconnect switch to OFF See Battery Disconnect Switch on page 3 15 0003573 Figure 5 15 4 Check the crankcase breather tube...

Page 130: ... 9 Clean the inside of the air filter housing 5 with a clean cloth before replacing the secondary air filter 6 10 Install the air filter housing end cap on the housing making sure that the dust valve is pointing down Secure the end cap to the housing using the latches 11 Close the battery and air filter access door Change the Engine Oil and Filter Replace the engine oil after the initial 50 hours ...

Page 131: ...ttach a drain hose 6 to the drain valve NOTE The drain tube must have a special connector that opens the spring loaded engine oil drain valve Contact a SANY dealer for more information 10 Open the drain valve by turning the valve counterclockwise until oil begins to flow through the drain tube NOTICE Dispose of used engine oil and filter in accordance with all applicable environmental regulations ...

Page 132: ... at any moment Heat age and stress are the primary contributors Pulling Belt material is sheared 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 i...

Page 133: ...appropriate access covers or compartment doors See Doors Panels Covers and Filler Cap on page 4 5 3 Turn the key switch to the START position and listen for abnormal noise and operation Some symptoms that may indicate a faulty starter High pitched screeching sounds Grinding noise Intermittent whirring sound starter not engaging engine flywheel Starter turns engine over slowly Burning smell or smok...

Page 134: ... Open the radiator drain valve 5 and allow the engine coolant to drain into the container 10 Close the radiator drain valve after the engine cooling system is empty 11 Secure the radiator drain access plate with the six fasteners Tighten securely 0003568 Figure 5 32 12 Add new engine coolant into the engine coolant expansion tank filler neck 6 until the engine coolant level is between the low and ...

Page 135: ... the air conditioner condenser fins 3 with compressed air 7 Inspect the area below the radiators and remove any debris that has accumulated during operations 8 Install the screen and secure with two wing nut fasteners 9 Close the left rear access door Inspect and Clean the Radiator and Oil Cooler Fins 1 Prepare the machine for checks and inspections See Maintenance Safety on page 2 5 2 Open the ap...

Page 136: ...ssed air 0003680 Figure 5 38 6 Place a suitable catch container under the end of drain hose 3 7 Open the drain valve 4 and allow any accumulated oil in the charge air cooler 5 to drain NOTICE Dispose of oil in accordance with all applicable environmental regulations Failure to follow this notice could damage the environment 8 Close the drain valve install the screen with the two wing nut fasteners...

Page 137: ...ge 2 5 4 Open the appropriate access covers or compartment doors See Doors Panels Covers and Filler Cap on page 4 5 5 Turn the battery disconnect switch to OFF See Battery Disconnect Switch on page 3 15 0003603 Figure 5 41 6 Check the air conditioner condenser 4 for leaks 0003613 Figure 5 42 7 Check the air conditioner compressor 6 for Refrigerant leaks at the hose and line connections 5 Loose wor...

Page 138: ...or signs of damage 6 Press down on the belt between the air conditioner compressor pulley and the drive pulley The belt should deflect 0 20 in 0 31 in 5 mm 8 mm when pressed with a force of 43 lb ft 58 3 N m 7 Adjust belt tension if necessary See Adjust the Air Conditioner Compressor Belt on page 5 28 8 Install the shroud and secure it in place Adjust the Air Conditioner Compressor Belt CAUTION Do...

Page 139: ...rn the battery disconnect switch to OFF See Battery Disconnect Switch on page 3 15 4 Remove two fasteners 2 and the retaining plate 3 that secure the fresh air filter 4 5 Remove the fresh air filter 6 Clean the fresh air filter with compressed air NOTE After cleaning the fresh air filter five times or if the filter cannot be cleaned replace it with a new one 7 Install the filter retaining plate an...

Page 140: ...ty on page 2 5 2 Open the appropriate access covers or compartment doors See Doors Panels Covers and Filler Cap on page 4 5 3 Turn the battery disconnect switch to OFF See Battery Disconnect Switch on page 3 15 0003652 Figure 5 50 4 Remove seven fasteners 1 and remove the exhaust system cover 2 0003656 Figure 5 51 5 Remove nine fasteners 3 and remove the panel 4 0003658 Figure 5 52 6 Check the con...

Page 141: ...stem cover and close the appropriate access covers or compartment doors Replace the Diesel Exhaust Fluid DEF Pump Filter 1 Prepare the machine for checks and inspections See Maintenance Safety on page 2 5 2 Open the appropriate access covers or compartment doors See Doors Panels Covers and Filler Cap on page 4 5 3 Turn the battery disconnect switch to OFF See Battery Disconnect Switch on page 3 15...

Page 142: ...covers or compartment doors See Doors Panels Covers and Filler Cap on page 4 5 3 Turn the battery disconnect switch to OFF See Battery Disconnect Switch on page 3 15 0003576 Figure 5 59 4 Tag and disconnect the four DEF hoses 1 Cap and plug all openings 5 Disconnect the DEF sending unit wiring harness connector 3 6 Remove two fasteners 2 from the DEF sending unit cover 4 0000158 Figure 5 60 7 Remo...

Page 143: ...o OFF See Battery Disconnect Switch on page 3 15 NOTE For capacity of the fuel tank Capacities on page 5 11 0003583 Figure 5 61 4 Place a suitable container under the end of drain hose 1 to collect the drained fuel NOTICE Dispose of fuel in accordance with all applicable environmental regulations Failure to follow this notice could damage the environment 5 Open the drain valve 2 to drain water and...

Page 144: ...l system may cause engine starting failure or abnormal running Make sure trapped air is released after water and sediment in the water separator have been drained the filter has been changed the priming pump filter has been cleaned and or the fuel tanks have been drained 13 Start the engine and allow it to run at idle speed See Starting the Engine on page 4 16 14 Check for leaks in the fuel system...

Page 145: ... the fuel shutoff valve 1 1 4 turn clockwise to the ON position 14 Start the engine and allow it to run at idle speed See Starting the Engine on page 4 16 15 Check for leaks in the fuel system 16 Shut down the engine 17 Close the right rear access panel Check the Fuel Tank Strainer 0003578 Figure 5 65 1 Prepare the machine for checks and inspections See Maintenance Safety on page 2 5 2 Open the ap...

Page 146: ...x The fuse box is located on the left behind the operator s seat NOTE See Fuse Location on page 3 22 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 electrical system Inspect all electrical equipment If necessary remove and replace items including loose connectors worn or degraded wiring cables...

Page 147: ...e battery compartment 7 Install the cover 8 Close the access panel Replace the Batteries NOTICE Dispose of batteries in accordance with all applicable environmental regulations Failure to follow this notice could damage the environment 1 Prepare the machine for checks and inspections See Maintenance Safety on page 2 5 2 Open the appropriate access covers or compartment doors See Doors Panels Cover...

Page 148: ...ator Function WARNING The accumulator contains pressurized nitrogen Improper handling is extremely dangerous Do not drill holes in the accumulator or place it close to fire or a high heat source Do not weld any part on the accumulator Air in the accumulator must be released upon disposal See Accumulator on page 2 6 for special precautions that need to be taken when working with or around the accum...

Page 149: ... the machine for checks and inspections See Maintenance Safety on page 2 5 4 Turn the key switch to ON 0003556 Figure 5 76 5 Set the hydraulic lockout control lever to the unlocked open position 1 NOTE See Hydraulic Lockout Control Lever on page 3 6 for additional information 6 Fully cycle each joystick and travel control lever pedals two to three times within 15 seconds to release hydraulic press...

Page 150: ...oil level is between the level marks as shown on the decal 2 0003557 Figure 5 81 4 If it is necessary to add hydraulic oil remove the vent cap 3 0003558 Figure 5 82 5 Press the vent button 4 to relive any pressure in the hydraulic tank 6 Remove the four fasteners and washers 5 and remove the breather 6 from the machine NOTE See Hydraulic Oil Ambient Temperature Data on page 5 10 for oil specificat...

Page 151: ...ther filter element 8 Install the breather filter cover 9 Install the vent cap Replace the Hydraulic Pilot Line Filter Element NOTE Perform this procedure after the first 250 hours every 1000 service hours or at least once a year whichever occurs first 1 Prepare the machine for checks and inspections See Maintenance Safety on page 2 5 2 Open the appropriate access covers or compartment doors See D...

Page 152: ...draulic Tank Return Filter WARNING Allow the hydraulic system to cool before servicing Hot oil may cause burns or other serious injury The hydraulic tank may be under pressure and hydraulic oil may be present at the filler cap Relieve pressure to prevent injury Failure to follow these warnings could result in death or serious injury 0003551 Figure 5 88 1 Park the machine in a secure location and p...

Page 153: ...ilter housing 11 Remove all debris from inside the filter housing 12 Install a new return filter and O ring with the solid end down 13 Install the return filter in the filter housing 14 Install the filter spring on top of the filter housing 15 Hold the filter cover down to secure with the four fasteners NOTE If not changing the hydraulic oil fill the tank at this time See Add Hydraulic Oil on page...

Page 154: ...ilter cover to move up while the fasteners are being removed Press down on the cover while removing the fasteners When the cover is removed cover the filter opening to prevent dirt and debris from falling into the hydraulic tank 0003586 Figure 5 98 7 Remove the four fasteners 3 and the plate 4 0003587 Figure 5 99 8 Clean the top of the hydraulic tank and remove contaminants from around the suction...

Page 155: ...re to follow this notice could damage the environment Check the Hydraulic Hoses 0003614 Figure 5 101 1 Prepare the machine for checks and inspections See Maintenance Safety on page 2 5 2 Open the appropriate access covers or compartment doors See Doors Panels Covers and Filler Cap on page 4 5 3 Turn the battery disconnect switch to OFF See Battery Disconnect Switch on page 3 15 4 Check all lines a...

Page 156: ...t down the engine 5 Turn the battery disconnect switch to OFF See Battery Disconnect Switch on page 3 15 6 Relieve System pressure See Relieve Hydraulic System Pressure on page 5 39 7 Collect a hydraulic oil sample before replacing the hydraulic oil See Collect a Hydraulic Oil Sample on page 5 57 0003591 Figure 5 102 8 Remove four fasteners 1 and remove the panel 2 from under the hydraulic tank NO...

Page 157: ...enance Safety on page 2 5 2 Open the appropriate access covers or compartment doors See Doors Panels Covers and Filler Cap on page 4 5 3 Start the engine NOTE Contact a SANY dealer if any abnormality is found 4 Inspect the hydraulic pump 1 for leaks noise and function Repair as needed 5 Shut down the engine 6 Close the right rear access panel Check the Hydraulic Pump Mounting Fasteners 1 Prepare t...

Page 158: ...repair replacement 6 Check the sprocket 3 for wear and proper operation If damaged contact a SANY dealer for repair replacement 7 Make sure the track groove is fully engaged over the idler 6 8 Check for visible damage to final drive 4 and its cover mounting bolts 9 Remove as much accumulated dirt as possible from the undercarriage Excess dirt requires more energy to operate the tracks and causes s...

Page 159: ... or looseness NOTE Use anaerobic thread lock compound when tightening and installing fasteners 4 Replace any damaged or defective fasteners and tighten any loose fasteners Check and Adjust the Track Tension 1 If the track tension is noticeably loose operate the machine with the engine at idle speed 2 Travel forward about 13 ft 4 m on a flat level and stable surface 3 Stop the machine 4 Shut down t...

Page 160: ...rack tension grease fitting is under extreme pressure Grease can exit the grease valve and cause serious injury Wear safety goggles gloves and other personal protective equipment PPE to prevent serious injury Do not stand directly in front of the track tension grease fitting valve when loosening the valve Failure to follow these warnings could result in death or serious injury 1 Prepare the machin...

Page 161: ...ore pressure is released Failure to follow these precautions could result in injury 11 Drive the machine forward at low idle speed for a distance equivalent to one full revolution of the track 12 Park the machine 13 Check the track tension again Adjust if it is still out of the acceptable range Final Drive Check the Final Drive Hoses 1 Prepare the machine for checks and inspections See Maintenance...

Page 162: ...d Final Drive Oil 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 the plugs slowly to prevent injury Failure to follow these precautions could result in injury 0003598 Figure 5 120 1 Position the mac...

Page 163: ... doors See Doors Panels Covers and Filler Cap on page 4 5 4 Turn the battery disconnect switch to OFF See Battery Disconnect Switch on page 3 15 5 Collect a final drive oil sample before changing the final drive oil See Collect a Final Drive Oil Sample on page 5 58 0003598 Figure 5 121 6 Place a suitably sized container under the final drive drain plug 2 7 Loosen the final drive drain plug slowly ...

Page 164: ...w add grease through the inspection filler hole as needed See Lubrication and Grease on page 5 8 for additional information on grease type 7 Check the grease color to see if it is milk white NOTE Milk white grease indicates that the grease has been contaminated Contact a SANY dealer for information on changing the grease 8 Install the cover on the inspection filler hole Check the Swing Drive Oil L...

Page 165: ... could be hot Be sure to use personal protective equipment PPE Failure to follow this caution could result in injury 1 Start the engine 2 In an open area rotate the upper structure 90 in both directions five times to warm the oil In cold weather conditions below 0 F 18 C rotate the upper structure 90 in both directions 10 times 3 Shut down the engine 4 Prepare the machine for checks and inspection...

Page 166: ... cap Inspect the Swing Bearing Fasteners 1 Prepare the machine for checks and inspections See Maintenance Safety on page 2 5 0003593 Figure 5 131 2 Inspect the swing bearing mounting fasteners 1 for damage 3 Start the engine and rotate the upper structure 90 to the right to gain access to the remaining fasteners See Starting the Engine on page 4 16 4 Shut the engine down See Engine Shutdown on pag...

Page 167: ...Insert the oil sample tube into the dipstick tube and collect a sample of engine oil Install the dipstick 8 Send the sample for testing in accordance with the instructions packaged with the sample kit Collect a Hydraulic Oil Sample 1 Obtain an oil analysis sample kit from a SANY dealer 2 Start the engine and operate the machine for the hydraulic oil system to reach normal operating temperatures 3 ...

Page 168: ...g to relieve pressure within the final drive 6 Remove the check plug 7 Insert the oil sample tube into the check plug hole 8 Collect a sample of oil from the final drive 9 Remove the oil sample tube 10 Install the check plug NOTE Repeat preceding steps for the other final drive as needed 11 Send the sample for testing in accordance with the instructions packaged with the oil analysis sample kit Co...

Page 169: ...connect switch to OFF See Battery Disconnect Switch on page 3 15 1 Arm cylinder rod end 11 Boom cylinder base end 2 Arm cylinder base end 12 Boom pivot pin 2 3 Boom cylinder rod end 2 13 Boom to arm pin 2 4 Grease manifold 14 Arm to bucket pivot pin 5 Door hinges 15 Bucket to bucket linkage pin 6 Swivel bearing 2 16 Bucket cylinder rod end 7 Dozer blade cylinder base end 2 17 Bucket linkage to buc...

Page 170: ...f it leaks replace the seal immediately Contact a SANY dealer 5 Start the engine 6 Lift the arm off the ground 7 Rotate the upper structure 90 and repeat steps 1 and 2 8 Repeat until a full 360 rotation has been made 9 Shut down the engine Swing Gear 0003572 Figure 5 142 Grease the swing gear through grease fitting 1 Boom Manifold 0003567 Figure 5 143 At the grease manifold for the boom grease the...

Page 171: ...4 Grease the two arm to bucket pivot grease fittings 4 Bucket 0000502 Figure 5 146 1 Grease the bucket rod pin grease fittings 1 2 Grease the bucket cylinder rod end grease fitting 2 3 Grease the bucket to bucket linkage pin grease fitting 3 Dozer Blade Cylinder Ends and Pivot Pins 0000515 Figure 5 147 1 Grease the dozer blade cylinder rod end 1 and base end 2 grease fittings 2 Grease the dozer li...

Page 172: ... and inspections See Maintenance Safety on page 2 5 2 Check the mounting fasteners on the grab handles 1 3 Replace any missing or damaged mounting fasteners and tighten any loose fasteners 4 Remove any tools lubricants or debris from the steps 2 Never allow loose items to remain on the machine Check the Cab Door Access Doors Covers and Locks 1 Prepare the machine for checks and inspections See Mai...

Page 173: ...e to make sure the fluid spray is properly directed 5 Lift the cover 3 and make sure the wiper arm nut 4 is tight If the wiper arm nut is loose tighten it to 26 lb ft 33 lb ft 35 N m 40 N m Check Locks Doors and Metal Panels Check the Sheet Metal 0003550 Figure 5 152 1 Prepare the machine for checks and inspections See Maintenance Safety on page 2 5 2 Open the appropriate access covers or compartm...

Page 174: ...ols may break off during roll pin removal and installation Wear safety goggles gloves and other personal protective equipment PPE to prevent serious injury Failure to follow these warnings could result in death or serious injury NOTE Bucket teeth must be replaced before the bucket tooth adapter wears out 1 Prepare the machine for checks and inspections See Maintenance Safety on page 2 5 2 Turn the...

Page 175: ...oils and filters for contamination may damage the machine or cause improper operation Always inspect drained engine and hydraulic oil along with the used filter for metal particles and impurities A small amount of metal particles may be expected with normal wear A sample of the drained oil should be sent out for testing to verify An excessive amount of metal particles or large debris may be an ind...

Page 176: ...5 66 MAINTENANCE SY155U Excavator OMM Page Intentionally Blank ...

Page 177: ...6 1 SY155U Excavator OMM Specifications Machine Dimensions 6 2 Working Range 6 4 Technical Specifications 6 6 Lift Chart 6 7 Lift Chart Continued 6 8 Chapter 6 ...

Page 178: ...6 2 SPECIFICATIONS SY155U Excavator OMM Machine Dimensions 0003676 Figure 6 1 5 11 1 2 3 4 6 10 8 7 9 ...

Page 179: ...cket length 9 ft 7 in 2 93 m 4 Track length 12 ft 3 665 m 5 Upper structure width 8 ft 2 in 2 49 m 6 Transport height 9 ft 9 in 3 022 m 7 Track shoe width standard 2 ft 0 6 m 8 Transport width 8 ft 6 in 2 59 m 9 Track gauge 6 ft 6 in 1 99 m 10 Minimum ground clearance 1 ft 5 in 0 425 m 11 Cab height 9 ft 3 in 2 82 m Boom length 15 ft 1 in 4 6 m Arm length 8 ft 2 in 2 5 m ...

Page 180: ...6 4 SPECIFICATIONS SY155U Excavator OMM Working Range 0003677 Figure 6 2 2 1 6 7 4 5 3 ...

Page 181: ...s 22 ft 1 7 in 6 749 m 3 Maximum dumping height 22 ft 1 in 6 755 m 4 Minimum swing radius 6 ft 10 1 in 2 086 m 5 Maximum digging reach 27 ft 4 2 in 8 338 m 6 Maximum vertical wall digging depth 12 ft 9 in 3 888 m 7 Maximum digging depth 17 ft 11 in 5 469 m Maximum dozer raising height 1 ft 7 8 in 504 mm Maximum dozer lowering depth 1 ft 1 8 in 350 mm ...

Page 182: ...6034 kg Standard bucket capacity 21 19 ft 3 0 6 m3 Blade width and height 102 in x 18 89 in 2590 mm x 480 mm Travel speed high low High speed 3 3 mph 5 3 km h slow speed 1 9 mph 3 1 km h Grade ability 35 Swing speed 20 5 26 5 seconds Engine model ISUZU AR 4JJ1XASC Rated power kW rpm 105 2 hp 78 5 kW at 2000 rpm ...

Page 183: ...SPECIFICATIONS 6 7 SY155U Excavator OMM Lift Chart 0004398 Figure 6 3 ...

Page 184: ...6 8 SPECIFICATIONS SY155U Excavator OMM Lift Chart Continued 0004399 Figure 6 4 ...

Page 185: ...hine standing on a firm uniform supporting surface The user shall make allowances for job conditions such as soft or uneven ground The operator should be fully acquainted with the operator s manual and the operating safety manual furnished by the manufacturer before operating the machine The least stable position is over the side Lift capacities apply only to the machine as originally manufactured...

Page 186: ...6 10 SPECIFICATIONS SY155U Excavator OMM Page Intentionally Blank ...

Page 187: ...MM Optional Equipment Optional Equipment Selection 7 2 Read Equipment Instructions 7 2 Removal and Installation Precautions 7 2 Operation Precautions 7 2 Install Optional Equipment 7 3 Remove Optional Equipment 7 4 Chapter 7 ...

Page 188: ...stall optional equipment only on a firm level surface Use an appropriate lifting device when handling objects weighing more than 55 lb 25 kg Never stand under a suspended load Make sure the machine is well balanced and supported whenever installing or removing optional equipment For additional information on removing and installing optional equipment consult a SANY dealer Operation Precautions NOT...

Page 189: ...h local environmental regulations Failure to do so could damage the environment 4 Place an appropriately sized container under the hydraulic connection to catch any residual hydraulic oil 5 Remove the fitting plug 2 if installed 6 Connect the optional equipment to the machine in accordance with the manufacturer s instructions 7 Connect the optional equipment hydraulic lines and bleed the hydraulic...

Page 190: ...e of hydraulic oil in accordance with local environmental regulations Failure to follow this notice could damage the environment 4 Place a suitably sized container under the hydraulic connection to catch any residual hydraulic oil 5 Disconnect the optional equipment hydraulic lines in accordance with the manufacturer s instructions 6 Install both fitting plugs 2 7 Disconnect the optional equipment...

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Page 192: ...ice sanyamerica com SANY Part Number SSY005079291 318 Cooper Circle Peachtree City Georgia 30269 Fax 770 632 7820 Sales E mail sales sanyamerica com Service E mail service sanyamerica com Service Hotline 470 552 SANY 7269 ...

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SANY SY155U, Operation And Maintenance Manual

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