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SANY HEAVY MACHINERY LIMITED
www.sanygroup.com
Quailty Changes the World
Crawler Hydraulic
Excavator
SY115C9
SY135C8
SY135C9
SY155H
Safety, Operation and Manitenance Manual
318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District,
Shanghai, P.R. of China 201413
Tel: (86) 21 5700 8518
Service hotline:(86) 4006 098 318
E-mail: [email protected]
Documentation No.: B06T01ENAM1-SY115C9/135C/155H
11644389
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SY115C9/135C/155H
Crawler Hydraulic Excavator
Read and follow the safety precautions and instructions in this manual and on the machine decals. Failure to do can cause serious injury, death or property damage. Keep this
manual with the machine for reading and future reference.
WARNING
Operation and Maintenance Manual
Safety, Operation and Maintenance Manual - Aug 2012
SY115C9/135C/155H Crawler Hydraulic Excavator
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2012 by Sany Group. All right reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as described herein. All information included within this publication was accurate at the time
of publication. Product improvements ,revisions, etc., may result in differences between
your machine and what is presented here. Sany Group assumes no liability. For more information, Contact Sany Group.
©
Sany Group
Sany Heavy Machinery Limited
318A, Lianggang Avenue, Lingang Industrial Park,
Fengxian District, Shanghai, P. R. of China 201413
http://www.sanygroup.com
Tel: (86) 21 5700 8518
Service hotline: (86) 4006 098 318
E-mail: [email protected]
Safety, Operation and Maintenance Manual - Aug 2012
SY115C9/135C/155H Crawler Hydraulic Excavator
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Table of Contents
Safety, Operation and Maintenance Manual - Aug 2012 I
SY115C9/135C/155H Crawler Hydraulic Excavator
1 Introduction
1.1 Overview .................................................................................................................. 1-3
1.2 Your Documentation Package ................................................................................. 1-4
1.2.1 Recommendations on using the documentation ............................................ 1-5
1.2.2 Documentation storage .................................................................................. 1-5
1.2.3 Manual organization....................................................................................... 1-5
1.2.3.1 Introduction ........................................................................................... 1-6
1.2.3.2 Safety .................................................................................................... 1-6
1.2.3.3 System functions ................................................................................... 1-6
1.2.3.4 Operation .............................................................................................. 1-6
1.2.3.5 Maintenance ......................................................................................... 1-6
1.2.3.6 Troubleshooting .................................................................................... 1-7
1.2.3.7 Specifi cations ........................................................................................ 1-7
1.2.3.8 Optional Equipment .............................................................................. 1-7
1.2.4 Page numbers................................................................................................ 1-7
1.3 Your Sany Machine .................................................................................................. 1-8
1.3.1 Machine applications ..................................................................................... 1-8
1.3.2 Machine directions ......................................................................................... 1-8
1.3.3 Breaking in a new machine ............................................................................ 1-9
1.3.4 Machine information....................................................................................... 1-9
1.3.4.1 Product identifi cation plate .................................................................... 1-9
1.3.4.2 Engine identifi cation plate ................................................................... 1-10
1.3.4.3 Right and left drive motors ...................................................................1-11
1.3.4.4 Swing motor .........................................................................................1-11
1.3.4.5 Hydraulic pump ....................................................................................1-11
1.3.4.6 Chassis serial number ........................................................................ 1-12
1.3.4.7 Machine monitor ................................................................................. 1-12
1.4 Table for serial number and distributor information ................................................ 1-13
1.5 Correction Request Form - Technical Publications ................................................ 1-14
1.6 Contact Information ............................................................................................... 1-15
2 Safety
2.1 Safety Information.................................................................................................... 2-5
2.2 Safety Messages ..................................................................................................... 2-7
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Safety, Operation and Maintenance Manual - Aug 2012II
SY115C9/135C/155H Crawler Hydraulic Excavator
2.2.1 Hazard alert wording ...................................................................................... 2-8
2.2.2 Other alert wording ........................................................................................ 2-9
2.2.3 Safety decals ................................................................................................. 2-9
2.2.3.1 Textual safety decals ........................................................................... 2-10
2.2.3.2 Graphical safety decals ....................................................................... 2-10
2.2.3.3 Safety decal locations ..........................................................................2-11
2.3 General Precautions .............................................................................................. 2-19
2.3.1 Safety rules .................................................................................................. 2-19
2.3.2 Abnormalities ............................................................................................... 2-19
2.3.3 Personal protective equipment .................................................................... 2-19
2.3.4 Fire extinguisher and fi rst aid kit .................................................................. 2-21
2.3.5 Safety equipment ......................................................................................... 2-21
2.3.6 Cleaning your machine ............................................................................... 2-22
2.3.7 Keeping the cab clean ................................................................................. 2-23
2.3.8 Engaging the hydraulic lockout control ........................................................ 2-23
2.3.9 Handholds and steps .................................................................................. 2-24
2.3.10 Overhead work........................................................................................... 2-25
2.3.11 No sitting on attachment ........................................................................... 2-25
2.3.12 Articulated parts ......................................................................................... 2-25
2.3.13 Preventing burns ....................................................................................... 2-25
2.3.13.1 Hot coolant ........................................................................................ 2-25
2.3.13.2 Hot oil ................................................................................................ 2-26
2.3.14 Preventing fi re and explosion .................................................................... 2-26
2.3.14.1 Fire caused by fuel or oils ................................................................. 2-26
2.3.14.2 Fire caused by fl ammable materials ................................................. 2-27
2.3.14.3 Fire caused by electric lines .............................................................. 2-27
2.3.14.4 Fire caused by hydraulic lines .......................................................... 2-28
2.3.14.5 Fire caused by illumination equipment .............................................. 2-28
2.3.14.6 Fire caused by heat shield ................................................................ 2-28
2.3.15 In the event of fi re ...................................................................................... 2-28
2.3.16 Windshield cleaning detergent ................................................................... 2-29
2.3.17 Preventing ejection of part ........................................................................ 2-29
2.3.18 Falling object protection ............................................................................. 2-30
2.3.19 Attachment installation ............................................................................... 2-30
2.3.20 Attachment combination ............................................................................ 2-31
2.3.21 Cab windows glasses ................................................................................ 2-31
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SY115C9/135C/155H Crawler Hydraulic Excavator
2.3.22 Unauthorized modifi cation ......................................................................... 2-31
2.3.23 Job site investigation.................................................................................. 2-31
2.3.24 Operation on soft ground ........................................................................... 2-32
2.3.25 Overhead power cables ............................................................................. 2-33
2.3.26 Ensuring a good visibility ........................................................................... 2-34
2.3.27 Ventilating enclosed area ........................................................................... 2-35
2.3.28 Asbestos hazard ........................................................................................ 2-35
2.3.29 Alternate exit .............................................................................................. 2-36
2.4 Safe Operation Precautions................................................................................... 2-37
2.4.1 Safe starting ................................................................................................ 2-37
2.4.1.1 Safe mounting ..................................................................................... 2-37
2.4.1.2 Seat adjustment .................................................................................. 2-38
2.4.1.3 Seat belt .............................................................................................. 2-38
2.4.1.4 Before starting the engine ................................................................... 2-38
2.4.1.5 Engine starting rules ........................................................................... 2-39
2.4.1.6 Safe starting ........................................................................................ 2-39
2.4.1.7 Starting engine in cold season ............................................................ 2-40
2.4.1.8 Engine starting aid .............................................................................. 2-40
2.4.1.9 After starting the engine ...................................................................... 2-41
2.4.2 Operation ..................................................................................................... 2-42
2.4.2.1 Inspection before operation ................................................................ 2-42
2.4.2.2 Prior-operation precautions ................................................................. 2-42
2.4.2.4 Travel directions .................................................................................. 2-43
2.4.2.3 Rules for steering safety ..................................................................... 2-43
2.4.2.5 Rules for traveling safety .................................................................... 2-45
2.4.2.6 Safe traveling ..................................................................................... 2-46
2.4.2.7 Operation on an incline ....................................................................... 2-47
2.4.2.8 Operation in snowy weather ............................................................... 2-48
2.4.2.9 Restricted operations .......................................................................... 2-48
2.4.3 Parking the machine .................................................................................... 2-51
2.4.3.1 Select a parking place ......................................................................... 2-51
2.4.3.2 Machine shutdown .............................................................................. 2-51
2.4.4 Transportation .............................................................................................. 2-52
2.4.4.1 Loading and unloading the machine ................................................... 2-52
2.4.4.2 Transporting the machine ................................................................... 2-53
2.4.5 Battery.......................................................................................................... 2-54
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Safety, Operation and Maintenance Manual - Aug 2012IV
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2.4.6 Lifting objects with the machine ................................................................... 2-56
2.5 Precautions for Maintenance ................................................................................. 2-57
2.5.1 Prior-maintenance precautions .................................................................... 2-57
2.5.2 Select a working area .................................................................................. 2-57
2.5.3 Preparing the machine ................................................................................ 2-58
2.5.4 Preparing yourself ........................................................................................ 2-59
2.5.5 Lock-out and tag-out .................................................................................. 2-60
2.5.6 Using proper tools ........................................................................................ 2-60
2.5.7 Maintenance with engine running ................................................................ 2-61
2.5.8 Working under the machine ......................................................................... 2-61
2.5.9 Track maintenance....................................................................................... 2-62
2.5.10 Track tension adjustment precautions ....................................................... 2-63
2.5.11 Recoil spring .............................................................................................. 2-63
2.5.12 Welding operation ...................................................................................... 2-64
2.5.13 High-pressure hoses .................................................................................. 2-64
2.5.14 Pressurized fl uid ........................................................................................ 2-65
2.5.15 Hot cooling system..................................................................................... 2-66
2.5.16 Air-conditioning system ............................................................................. 2-66
2.5.17 High voltage precautions ........................................................................... 2-67
2.5.18 Accumulator ............................................................................................... 2-67
2.5.19 Avoiding fi re and explosion ........................................................................ 2-68
2.5.20 Regular replacement of safety-related parts .............................................. 2-69
2.5.21 Maintenance operation ............................................................................. 2-70
2.5.22 Proper disposal of wastes .......................................................................... 2-71
3 System Functions
3.1 Machine Overview ................................................................................................... 3-5
3.2 Machine Controls ..................................................................................................... 3-6
3.3 Monitor ..................................................................................................................... 3-7
3.3.1 Monitor introduction ....................................................................................... 3-7
3.3.2 System information and operation ............................................................... 3-10
3.3.2.1 Main Page ........................................................................................... 3-10
3.3.2.2 System Information ............................................................................. 3-12
3.3.2.3 Time Setup .......................................................................................... 3-13
3.3.2.4 Main Menu .......................................................................................... 3-14
3.3.2.5 Engine & Throttle Signals .................................................................. 3-15
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SY115C9/135C/155H Crawler Hydraulic Excavator
3.3.2.6 Main Pump Signals ............................................................................ 3-15
3.3.2.7 Input Switch Signals ........................................................................... 3-16
3.3.2.8 Output Switch Signals ........................................................................ 3-16
3.3.2.9 Machine Confi guration ....................................................................... 3-17
3.3.2.10 Failure codes ................................................................................... 3-17
3.3.2.11 Maintenance Information ................................................................... 3-18
3.3.2.12 Engine Speed Calibration ................................................................. 3-23
3.3.2.13 Language Selection .......................................................................... 3-25
3.3.2.14 GPS Monitoring Information .............................................................. 3-26
3.3.2.15 System Setup .................................................................................... 3-27
3.3.2.16 Machine confi guration setup ............................................................. 3-28
3.3.2.17 Coolant Temperature ........................................................................ 3-29
3.3.2.18 Service Call ....................................................................................... 3-30
3.4 Switches ................................................................................................................ 3-31
3.4.2.1 Start switch ......................................................................................... 3-32
3.4.2.2 Fuel control dial ................................................................................... 3-33
3.4.2.3 Work lamp switch ................................................................................ 3-33
3.4.2.4 Wiper switch ........................................................................................ 3-35
3.4.2.5 Washer switch ..................................................................................... 3-36
3.4.2.6 Head lamp switch ................................................................................ 3-36
3.4.2.7 Horn switch ......................................................................................... 3-37
3.4.2.8 Cab lamp ............................................................................................ 3-37
3.4.2.9 Cigar lighter ......................................................................................... 3-37
3.4.2.10 Preheat switch (only for SY135C8M) ................................................ 3-38
3.4.2.11 Alternator indicator ............................................................................ 3-38
3.5 Control levers and pedals ...................................................................................... 3-39
3.5.1 Hydraulic lockout control .............................................................................. 3-40
3.5.2 Travel controls.............................................................................................. 3-41
3.5.3 Joystick controls........................................................................................... 3-42
3.6 Roof Hatch ............................................................................................................. 3-44
3.6.1 Opening the roof hatch ............................................................................... 3-44
3.6.2 Closing the roof hatch ................................................................................. 3-44
3.7 Windshield ............................................................................................................. 3-45
3.7.1 Opening the window ................................................................................... 3-45
3.7.2 Closing the window ..................................................................................... 3-48
3.7.3 Removing the lower window ...................................................................... 3-50
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3.8 Alternate Exit.......................................................................................................... 3-51
3.9 Door Catch............................................................................................................. 3-52
3.10 Cover/cap with a Latch ........................................................................................ 3-52
3.10.1 Opening/closing the cover with lock........................................................... 3-53
3.10.2 Opening/closing the cap with lock.............................................................. 3-54
3.11 Cup Holder ........................................................................................................... 3-55
3.12 Storage Box ......................................................................................................... 3-56
3.13 Literature Bag ...................................................................................................... 3-56
3.14 Ashtray ................................................................................................................. 3-57
3.15 Air Conditioning System....................................................................................... 3-58
3.15.1 Control panel.............................................................................................. 3-58
3.15.2 Operation method ...................................................................................... 3-64
3.15.3 A/C operation precautions.......................................................................... 3-72
3.16 Radio ................................................................................................................... 3-74
3.16.1 Control panel.............................................................................................. 3-74
3.16.2 Radio operation.......................................................................................... 3-76
3.17 Auxiliary Power Supply ........................................................................................ 3-80
3.18 Fuses ................................................................................................................... 3-80
3.19 Fusible Link.......................................................................................................... 3-81
3.20 Controller ............................................................................................................. 3-82
3.21 Toolbox ................................................................................................................ 3-82
3.22 Grease pump frame ............................................................................................. 3-82
3.23 Fire extinguisher .................................................................................................. 3-83
4 Operation
4.1 Before Starting the Engine....................................................................................... 4-5
4.1.1 Routine checks ............................................................................................. 4-5
4.1.2 Checks before starting ................................................................................... 4-7
4.1.2.1 Fuel tank - check/drain .......................................................................... 4-7
4.1.2.2 Water separator - check/drain .............................................................. 4-7
4.1.2.3 Drain valve - regulate ............................................................................ 4-8
4.1.2.4 Hydraulic oil - check/refi ll ...................................................................... 4-9
4.1.2.5 Coolant - check/refi ll ........................................................................... 4-10
4.1.2.6 Oil in engine oil pan - check/refi ll .........................................................4-11
4.1.2.7 Electric wires - check .......................................................................... 4-12
4.1.2.8 Fuel tank - check/refuel ....................................................................... 4-13
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SY115C9/135C/155H Crawler Hydraulic Excavator
4.1.2.9 Work lamp switch - check ................................................................... 4-14
4.1.2.10 Horn - check ...................................................................................... 4-15
4.1.3 Adjustment before operation ........................................................................ 4-15
4.1.3.1 Operator seat ...................................................................................... 4-15
4.1.3.2 Rear view mirrors ................................................................................ 4-17
4.1.3.3 Seat belt .............................................................................................. 4-19
4.1.4 Before Starting the Engine ........................................................................... 4-20
4.2 Engine Starting ...................................................................................................... 4-22
4.2.1 Engine Preheating ...................................................................................... 4-25
4.2.2 Warm-up operation ...................................................................................... 4-26
4.2.3 Selecting a working mode ........................................................................... 4-26
4.3 Engine Shutdown................................................................................................... 4-27
4.4 Machine Operation ................................................................................................ 4-28
4.4.1 Before moving the machine ......................................................................... 4-28
4.4.2 Moving the machine forward ........................................................................ 4-29
4.4.3 Moving the machine backward .................................................................... 4-30
4.4.4 Parking the machine .................................................................................... 4-31
4.5 Steering Operation................................................................................................. 4-32
4.5.4.1 Steering with travel controls ............................................................... 4-32
4.5.4.2 Steering with machine stopped ........................................................... 4-32
4.5.4.3 Steering during traveling ..................................................................... 4-33
4.5.4.4 Pivot turn ............................................................................................. 4-33
4.5.1 Swing operation ........................................................................................... 4-34
4.6 Work Equipment Control and Operation ................................................................ 4-35
4.7 Working mode ........................................................................................................ 4-37
4.8 Restricted Operations ............................................................................................ 4-38
4.8.1 Operation with swinging force ...................................................................... 4-38
4.8.2 Operation with traveling force ...................................................................... 4-38
4.8.3 Operation when hydraulic cylinder reaches its stroke end ......................... 4-39
4.8.4 Operation with bucket landing force............................................................. 4-39
4.8.5 Operation with machine weight .................................................................... 4-40
4.8.6 Hard rocky ground ...................................................................................... 4-40
4.8.7 Sudden shift of travel speed during fast traveling ....................................... 4-41
4.9 General Operation ................................................................................................ 4-41
4.9.1 Traveling operation ...................................................................................... 4-41
4.9.2 High-speed travel ......................................................................................... 4-41
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4.9.3 Permissible depth of water........................................................................... 4-42
4.10 Traveling on Slope ............................................................................................... 4-42
4.10.1 Traveling downhill ..................................................................................... 4-44
4.10.2 Engine stalls on an incline ......................................................................... 4-44
4.10.3 Cab door on an incline ............................................................................... 4-44
4.11 Removing Machine from Mud .............................................................................. 4-44
4.11.1 One track trapped ...................................................................................... 4-44
4.11.2 Both tracks trapped .................................................................................... 4-45
4.12 Recommended Applications ................................................................................ 4-45
4.12.1 Backhoe operation ..................................................................................... 4-45
4.12.2 Trench work ............................................................................................... 4-46
4.12.3 Loading operation ...................................................................................... 4-46
4.13 Parking Operation ................................................................................................ 4-47
4.14 Checks after Each Workday ................................................................................ 4-49
4.15 Locking the Machine ............................................................................................ 4-50
4.16 Operation in Cold Weather .................................................................................. 4-50
4.16.1 Operation instruction .................................................................................. 4-50
4.16.1.1 Fuel and lubricant ............................................................................. 4-50
4.16.1.2 Battery ............................................................................................... 4-51
4.16.2 After each workday .................................................................................... 4-52
4.16.3 After cold season ....................................................................................... 4-53
4.17 Long-Term Storage .............................................................................................. 4-54
4.17.1 Before storage ........................................................................................... 4-54
4.17.2 During storage ........................................................................................... 4-55
4.17.3 After storage............................................................................................... 4-56
4.17.4 Starting the engine after long-term storage ............................................... 4-56
4.18 Transportation Information ................................................................................... 4-57
4.18.1 Transport methods ..................................................................................... 4-57
4.18.2 Loading/unloading machine to/from a trailer .............................................. 4-57
4.18.2.1 Loading the machine ......................................................................... 4-59
4.18.2.2 Securing the machine ....................................................................... 4-61
4.18.2.3 Rear view mirrors .............................................................................. 4-62
4.18.2.4 Unloading the machine ..................................................................... 4-63
4.18.3 Lifting the machine or its components ....................................................... 4-65
4.18.3.1 Lifting precautions ............................................................................. 4-65
4.18.3.2 Choosing a wire rope ........................................................................ 4-66
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4.18.3.3 Lifting the machine ............................................................................ 4-67
5 Maintenance
5.1 Maintenance Information ......................................................................................... 5-5
5.2 General Service ....................................................................................................... 5-9
5.2.1 Oil, fuel and coolant ....................................................................................... 5-9
5.2.1.1 Oil .......................................................................................................... 5-9
5.2.1.2 Fuel ..................................................................................................... 5-10
5.2.1.3 Coolant ................................................................................................5-11
5.2.2 Grease ......................................................................................................... 5-12
5.2.3 Oil and fuel storage ...................................................................................... 5-13
5.2.4 Filter element ............................................................................................... 5-13
5.2.5 Electrical system ......................................................................................... 5-14
5.2.6 Hydraulic system.......................................................................................... 5-14
5.3 Replacement Parts ................................................................................................ 5-16
5.4 Recommended Fluids ............................................................................................ 5-17
5.4.1 Fluid capacities ............................................................................................ 5-19
5.4.2 Recommended oils: .................................................................................... 5-20
5.5 Tightening Torque Specifi cation ............................................................................. 5-22
5.6 Safety-Related Parts.............................................................................................. 5-24
5.7 Maintenance Schedule .......................................................................................... 5-25
5.7.1 List of maintenance schedule ...................................................................... 5-25
5.7.2 Hydraulic Breaker Service Interval............................................................... 5-27
5.8 Maintenance Procedures ....................................................................................... 5-28
5.8.1 Maintenance after initial 50 service hours.................................................... 5-28
5.8.1.1 Engine oil and fi lter - change/replace .................................................. 5-28
5.8.1.2 Fuel fi lter - replace ............................................................................. 5-28
5.8.2 When Required ............................................................................................ 5-29
5.8.2.1 Air cleaner - clean/replace .................................................................. 5-29
5.8.2.2 Cooling system - clean ....................................................................... 5-37
5.8.2.3 Track shoe bolts - inspect/tighten ....................................................... 5-41
5.8.2.4 Track tension - inspect/adjust ............................................................. 5-42
5.8.2.5 Bucket tips (lateral pin) - replace ........................................................ 5-45
5.8.2.6 Bucket Replacement ........................................................................... 5-47
5.8.2.7 Bucket clearance - adjust .................................................................... 5-49
5.8.2.8 Window washer fl uid - check/refi ll ...................................................... 5-51
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5.8.2.9 Air conditioner - inspect/service .......................................................... 5-52
5.8.2.10 Gas spring - inspect .......................................................................... 5-54
5.8.2.11 Air in hydraulic system - purge .......................................................... 5-55
5.8.2.12 Hydraulic circuit internal pressure - release ...................................... 5-58
5.8.3 Checks before starting ................................................................................. 5-59
5.8.4 Every 100 service hours .............................................................................. 5-60
5.8.4.1 Lubrication .......................................................................................... 5-60
5.8.5 Every 250 service hours .............................................................................. 5-63
5.8.5.1 Compressor belt tension - inspect/adjust ............................................ 5-63
5.8.5.2 Oil in engine oil pan and oil fi lter - change/replace ............................. 5-65
5.8.5.3 Primary fuel fi lter - replace .................................................................. 5-67
5.8.5.4 Secondary fuel fi lter - replace ............................................................. 5-71
5.8.6 Every 500 service hours .............................................................................. 5-74
5.8.6.1 Swing bearing - lubricate .................................................................... 5-74
5.8.6.2 Swing pinion gear grease - check/refi ll ............................................... 5-75
5.8.6.3 Coolant tank and radiator fi ns - inspect/clean ..................................... 5-76
5.8.6.4 Air conditioner fi lters - clean ................................................................ 5-77
5.8.6.5 Swing drive oil - check/refi ll ................................................................. 5-80
5.8.6.6 Final drive oil - check/fi ll ...................................................................... 5-81
5.8.7 Every 1000 service hours ............................................................................ 5-82
5.8.7.1 Hydraulic oil fi lter - replace .................................................................. 5-82
5.8.7.2 Swing drive oil - change ...................................................................... 5-84
5.8.7.3 Engine exhaust pipe clamps - check .................................................. 5-85
5.8.7.4 Fan belt tension - check/replace ......................................................... 5-85
5.8.7.5 Nitrogen pressure in accumulator (breaker) - check ........................... 5-85
5.8.8 Every 2000 service hours ............................................................................ 5-86
5.8.8.1 Final drive oil - change ........................................................................ 5-86
5.8.8.2 Hydraulic tank fi lter screen - clean ...................................................... 5-88
5.8.8.3 Nitrogen pressure in accumulator (control oil circuit) - check ............. 5-89
5.8.8.4 Hydraulic circuit internal pressure - release ........................................ 5-92
5.8.8.5 Oil in hydraulic tank - change .............................................................. 5-93
5.8.8.6 Alternator - inspect .............................................................................. 5-95
5.8.8.7 Engine valve clearance - check/adjust ................................................ 5-95
5.8.9 Every 4000 service hours ............................................................................ 5-95
5.8.9.1 Coolant pump - inspect ....................................................................... 5-95
5.8.9.2 Start motor - check .............................................................................. 5-95
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5.8.9.3 Accumulator (control oil circuit) - replace ............................................ 5-96
5.8.9.4 High-pressure tube clamps and rubber - check .................................. 5-97
5.8.9.5 Compressor working condition - inspect ............................................. 5-97
5.8.10 Every 8000 service hours .......................................................................... 5-98
5.8.10.1 High-pressure tube clamps - replace ................................................ 5-98
5.8.11 Every 10000 service hours ......................................................................... 5-98
6 Troubleshooting
6.1 Troubleshooting Preparation.................................................................................... 6-3
6.1.1 Checks before troubleshooting ...................................................................... 6-3
6.1.2 Troubleshooting procedure ............................................................................ 6-4
6.1.3 Troubleshooting precautions .......................................................................... 6-6
6.1.4 Electrical circuits troubleshooting precautions ............................................... 6-9
6.1.5 Hydraulic components handling precautions ............................................... 6-10
6.2 Pseudo Failures ..................................................................................................... 6-12
6.3 Towing the Machine ............................................................................................... 6-13
6.4 Towing Hook for Light Loads ................................................................................. 6-15
6.5 Severe Operating Conditions................................................................................. 6-15
6.6 Engine Failures ...................................................................................................... 6-16
6.6.1 Engine troubleshooting table ....................................................................... 6-16
6.6.2 Coolant temperature high ............................................................................ 6-19
6.6.3 Engine oil pressure low ................................................................................ 6-20
6.6.4 When fuel exhausts ..................................................................................... 6-22
6.6.5 When engine rotates reversely ................................................................... 6-24
6.7 Failures of the Electrical System ........................................................................... 6-25
6.7.1 Electrical system troubleshooting table........................................................ 6-25
6.7.2 Failure codes ............................................................................................... 6-28
6.8 Battery .................................................................................................................. 6-30
6.8.1 Battery removal and installation ................................................................... 6-30
6.8.2 Battery charging ........................................................................................... 6-31
6.8.3 Jump-starting the engine ............................................................................. 6-32
6.8.3.1 Connecting the jumper cables ............................................................ 6-33
6.8.3.2 Starting the engine .............................................................................. 6-34
6.8.3.3 Disconnecting the jumper cables ........................................................ 6-34
6.9 Failures of the Hydraulic System ........................................................................... 6-35
6.10 Other Common Failures ...................................................................................... 6-39
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Safety, Operation and Maintenance Manual - Aug 2012XII
SY115C9/135C/155H Crawler Hydraulic Excavator
7 Specifi cations
7.1 Machine Dimensions ............................................................................................... 7-3
7.2 Working Ranges ..................................................................................................... 7-4
8 Optional Equipment
8.1 General Safety ........................................................................................................ 8-3
8.1.1 Selection precautions..................................................................................... 8-3
8.1.2 Reading the instruction books........................................................................ 8-3
8.1.3 Removal and installation precautions ........................................................... 8-3
8.1.4 Operation precautions.................................................................................... 8-4
8.2 Hydraulic Control Elements and Oil Circuit ............................................................. 8-6
8.2.1 Location of the components ........................................................................... 8-6
8.2.1.1 Stop valve ............................................................................................. 8-6
8.2.1.2 Selector valve ....................................................................................... 8-7
8.2.1.3 Control pedal ......................................................................................... 8-7
8.2.2 Hydraulic circuit.............................................................................................. 8-8
8.2.2.1 Hydraulic circuit switching ..................................................................... 8-8
8.2.2.2 Shifting to breaker / general optional equipment .................................. 8-8
8.2.2.3 Connecting hydraulic oil circuit ............................................................. 8-9
8.2.2.4 Hydraulic oil passage .......................................................................... 8-10
8.2.3 Optional equipment removal and installation ................................................8-11
8.2.3.1 Removal ...............................................................................................8-11
8.2.3.2 Optional equipment installation .......................................................... 8-13
8.2.4 Hydraulic oil and hydraulic tank fi lter - change/replace ............................... 8-15
8.2.5 Long-term storage........................................................................................ 8-16
8.2.6 Hydraulic specifi cations ............................................................................... 8-16
8.3 Optional equipment Guide ..................................................................................... 8-17
8.3.1 Work equipment combination ...................................................................... 8-17
8.3.2 Bucket tips selection .................................................................................... 8-19
8.3.2.1 Rockwork bucket tips .......................................................................... 8-19
8.3.2.2 Earthwork bucket tips .......................................................................... 8-19
8.4 Recommended Operations .................................................................................... 8-20
8.4.1 Hydraulic breaker ......................................................................................... 8-20
8.4.2 Hydraulic breaker operation ......................................................................... 8-21
8.5 Restricted Operations ............................................................................................ 8-22
8.6 Hydraulic Breaker Lubrication................................................................................ 8-25
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8.7 Quick Coupler and Control System ....................................................................... 8-26
8.7.1 Quick coupler installation ............................................................................. 8-26
8.7.2 Operating precautions ................................................................................. 8-28
8.8 Refueling System.................................................................................................. 8-29
8.8.1 Introduction .................................................................................................. 8-29
8.8.2 Components................................................................................................. 8-30
8.9 Central Lubrication System.................................................................................... 8-31
8.9.1 Scheme and components ............................................................................ 8-31
8.9.2 System working principle ............................................................................. 8-33
8.9.3 Setting the lubrication time of electric grease pump .................................... 8-34
8.9.4 Technical description .................................................................................... 8-35
8.9.5 Adding grease with electric pump ................................................................ 8-36
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SY115C9/135C/155H Crawler Hydraulic Excavator
Page 18
Introduction
SY115C9/135C/155H Crawler Hydraulic Excavator Introduction
Safety, Operation and Maintenance Manual - Aug 2012 1-1
1 Introduction
1.1 Overview .................................................................................................................. 1-3
1.2 Your Documentation Package ................................................................................. 1-4
1.2.1 Recommendations on using the documentation ............................................ 1-5
1.2.2 Documentation storage .................................................................................. 1-5
1.2.3 Manual organization....................................................................................... 1-5
1.2.3.1 Introduction ........................................................................................... 1-6
1.2.3.2 Safety .................................................................................................... 1-6
1.2.3.3 System functions ................................................................................... 1-6
1.2.3.4 Operation .............................................................................................. 1-6
1.2.3.5 Maintenance ......................................................................................... 1-6
1.2.3.6 Troubleshooting .................................................................................... 1-7
1.2.3.7 Specifi cations ........................................................................................ 1-7
1.2.3.8 Optional Equipment .............................................................................. 1-7
1.2.4 Page numbers................................................................................................ 1-7
1.3 Your Sany Machine .................................................................................................. 1-8
1.3.1 Machine applications ..................................................................................... 1-8
1.3.2 Machine directions ......................................................................................... 1-8
1.3.3 Breaking in a new machine ............................................................................ 1-9
1.3.4 Machine information....................................................................................... 1-9
1.3.4.1 Product identifi cation plate .................................................................... 1-9
1.3.4.2 Engine identifi cation plate ................................................................... 1-10
1.3.4.3 Right and left drive motors ...................................................................1-11
1.3.4.4 Swing motor .........................................................................................1-11
1.3.4.5 Hydraulic pump ....................................................................................1-11
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Introduction SY115C9/135C/155H Crawler Hydraulic Excavator
1-2 Safety, Operation and Maintenance Manual - Aug 2012
1.3.4.6 Chassis serial number ........................................................................ 1-12
1.3.4.7 Machine monitor ................................................................................. 1-12
1.4 Table for serial number and distributor information ................................................ 1-13
1.5 Correction Request Form - Technical Publications ................................................ 1-14
1.6 Contact Information ............................................................................................... 1-15
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Introduction
Safety, Operation and Maintenance Manual - Aug 2012 1-3
SY115C9/135C/155H Crawler Hydraulic Excavator
1 INTRODUCTION
1.1 Overview
♦Sany-built machines offer high-quality per-
formance and star-grade, after-sales service.
♦Sany-built machines are widely used
throughout the industry for various types of
applications.
♦Sany is a leading manufacturer of con-
struction equipment worldwide.
This operator’s manual provides safety, operation, maintenance, troubleshooting and technical specifi cations. In order to properly use your
equipment, it is important to read this manual
carefully before beginning any operations.
Items addressed in this manual are designed
to help you:
●Understand the structure and performance
of your crawler hydraulic excavator.
●Reduce improper operation and point out
possible hazardous situations.
●Increase equipment efficiency during operation.
●Prolong the service life of equipment.
●Reduce maintenance costs.
Always keep this manual nearby and have all
personnel involved with any job-related procedures read it periodically.
If you sell the machine, be sure to give this
manual to the new owner.
Continuing improvements in the design of this
machine can lead to changes in detail which
may not be covered in this manual. Always
consult your Sany distributor for the latest
available information or if you have questions
regarding information in this manual.
Fig. 1-1
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1.2 Your Documentation Package
The documentation for this machine includes
the following items:
●Safety, Operation & Maintenance Manual
(SOMM) — This manual is in the operator
cab seat pocket.
●Parts Book — This publication consists of
parts lists and matching drawings for ordering spare parts as-needed. If it was not
already shipped with your machine, the
parts book for your machine is available
directly from Sany.
●CD — A VCR on safety, operation and
maintenance of your excavator is delivered
with the machine.
CD system requirements
In order to use the Sany CD, be sure of the
following:
Hardware:
●Intel® Pentium II® running at 500 MHz or
above
●At least 128 MB RAM
●CD-ROM drive
●Minimum screen resolution of 800 x 600
pixels, high-color depth
Software:
●Windows 2000, XP, Vista and Windows 7
operating systems
●Internet Explorer 6.0 or later (pop-up blocker disabled)
●Acrobat Reader 7.0 or later version
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SY115C9/135C/155H Crawler Hydraulic Excavator
1.2.1 Recommendations on using the
documentation
●This documentation applies only to this
machine and should not be used with any
other machines.
●To ensure that the documentation is always
complete and up to date:
●Keep all pages inside its binder (if shipped
loose leaf).
●Use the CD to print and replace any missing pages or those made unreadable due
to damage, grease, dirt, etc.
●Insert Sany replacement pages immediately into the appropriate book; destroy old
versions of those pages.
●Replace outdated CD’s with new ones;
destroy the old ones to prevent any confusion in the future.
1.2.2 Documentation storage
Always keep the operator manual and load
charts with the machine in the operator cab.
The parts book is best left either shelved in
the workshop area or offi ce. It should always
be available to the maintenance and service
personnel as required.
These can be printed out from the CD.
1.2.3 Manual organization
The operator’s manual is designed for use
and maintenance of this machine. Each section of this manual provides information you
should be familiar with before operating this
machine. Keep this manual with the machine
for your reference at all times. Replace it immediately if it is damaged or lost. Due to improvement and updating of products, some
information may differ from your machine. If
you have any questions on the machine, con-
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Introduction
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SY115C9/135C/155H Crawler Hydraulic Excavator
tact your Sany distributor before operating or
repairing the machine.
1.2.3.1 Introduction
This section provides an overview of what is
covered in the rest of this manual, including
machine label information and Sany contact
information.
1.2.3.2 Safety
This section covers basic safety information
relating to this equipment. Make sure you fully
understand all the precautions described in
this manual and the safety labels on the machine before operating or maintaining this machine. Failure to do so may result in serious
injury or death.
1.2.3.3 System functions
This section provides an overview of all the
controls, alerts and operating systems on the
machine. It is important to study and become
familiar with all systems before proceeding
with any operations.
1.2.3.4 Operation
This section provides some basic operating
procedures for this machine. Study and become familiar with all operating procedures
before performing any job functions with the
machine.
1.2.3.5 Maintenance
This section provides all general maintenance
and repair procedures. (Detailed rebuild / replacement / repair information are covered in
a separate shop manual.) Study and become
familiar with all repair and maintenance proce-
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Introduction
Safety, Operation and Maintenance Manual - Aug 2012 1-7
SY115C9/135C/155H Crawler Hydraulic Excavator
dures before performing any repair or maintenance operations.
1.2.3.6 Troubleshooting
This section includes common malfunctions
and fault diagnostics procedures for this crawler hydraulic excavator operating system. Basic
mechanical, hydraulic and electrical system
troubleshooting is included.
1.2.3.7 Specifi cations
This section provides general required machine information for this crawler hydraulic
excavator. Some information may vary due to
design changes.
1.2.3.8 Optional Equipment
This section provides information regarding
optional equipment for the excavator as authorized by Sany. If you will be using any optional
equipment, it is important to read the instruction manual for the optional equipment and the
general information related to optional equipment in this manual.
1.2.4 Page numbers
The pages in this manual are numbered as the
following:
3-
20
Page 20 of Chapter 3
Chapter 3
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SY115C9/135C/155H Crawler Hydraulic Excavator
1.3.2 Machine directions
1.3 Your Sany Machine
1.3.1 Machine applications
Sany Hydraulic Excavators are designed for the following operations:
●Excavating
●Leveling
●Digging
●Loading
●Demolishing
In this manual, the front, back, left or right direction indicates, when the cab faces the front
and the final drive is behind of the machine,
the moving direction that you could see from
the cab.
(A) Front
(B) Back
(C) Left
(D) Right
(E) Operator Seat
(F) Sprocket
Fig. 1-2
A
D
F
B
C
E
CZ335-1101001
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SY115C9/135C/155H Crawler Hydraulic Excavator
1.3.3 Breaking in a new machine
Your machine has been thoroughly adjusted and tested before shipment. However, initial operation of the machine under severe conditions can adversely affect the performance of the machine
or shorten the machine life. Therefore, Sany recommends that you allow a break-in period of 100
operating hours for a new machine.
During the break-in period:
●Let the machine warm up before any operation.
●Avoid operating with severe loads or at high speeds.
●Avoid sudden starts or fast movements or stops.
●Always let the system cool down at the end of the working day.
1.3.4 Machine information
The serial numbers and model numbers on the components are the only numbers that your Sany
distributor will need when ordering replacement parts or requiring assistance for your equipment.
It is a good idea to record this information in this manual for future use. Below are the locations of
the data plates.
1.3.4.1 Product identifi cation plate
On the right side of the operator station on the bottom.
CZ335-1101002
Fig. 1-3
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1.3.4.2 Engine identifi cation plate
On cover of engine cylinder head.
SY115C9/SY135C8/SY135C9/SY155H
SY135C8(M)
CZ155-1101001
ENGINE FAMILY: G20097L0433GTA
ENGINE MODEL: 4BG1-TABGC-03-C2
ENGINE POWER: 72.7 kW/ 2200 r/min
MANUFACTURER: ISUZU
DATE OF MANUFACTURE:
POWER RANGE: 37 ≤ kW ＜ 75
APPROVAL NO.: CN FC G2 0097 21 0003
ENGINE CODE:
CONFORMED TO NATIONAL STAGE II NON-ROAD DIESL
ENGINE EMISSION CONTROL STANDARD
CZ155-1101002
MITSUBISHI FUSO
TRUCK & BUS CORPORATION
ENGINE FAMILY
ENGINE MODEL 4D34-TLU2B
APPROVAL NUMBER
ENGINE POWER 70kW-2050 r/min
THIS ENGINE CONFORMS TO CHINA NATIONAL STANDARD
GB20891-2007 STAGE II 37kW≤POWER＜75kW
DATE OF MANUFACTURE： MONTH, YEAR
Fig. 1-4
Fig. 1-5
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SY115C9/135C/155H Crawler Hydraulic Excavator
1.3.4.3 Right and left drive motors
On each drive motor:
Model: _____________________________
ID No.: _____________________________
1.3.4.4 Swing motor
1.3.4.5 Hydraulic pump
On top of swing motor:
Model: ______________________________
ID No.: ______________________________
On bottom of pump:
Model: ______________________________
ID No.: ______________________________
CZ235-3100801
CZ235-3100802
CZ235-3100803
Fig. 1-6
Fig. 1-7
Fig. 1-8
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An additional serial number is stamped on the
front part of the travel carriage frame.
SYJ263038018060480
CZ235-3100804
1.3.4.6 Chassis serial number
Fig. 1-9
Fig. 1-10
1.3.4.7 Machine monitor
Location of machine monitor is shown in the
right illustration.
CZ335-1101004
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SY115C9/135C/155H Crawler Hydraulic Excavator
1.4 Table for serial number and distributor information
This location is for you to record information relating to your machine. It is advised that you keep
this manual with your machine at all times for reference.
Machine Serial No.
Engine Serial No.
Distributor Name:
Address:
Phone Numbers:
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1.5 Correction Request Form - Technical Publications
If you fi nd a problem with this manual, please make a copy of this page, fi ll out: the information
and send it to us attention Technical Publications. See Contact Information” on next page.
Date of this request
Your Name
Company Name
Your Department
Street Address
City, State & ZIP
Phone
E-mail
Machine Model & Serial No.
Description of Problem (Wrong information, unclear or erroneous procedure, etc.)
Corrective Action by You (if any)
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SY115C9/135C/155H Crawler Hydraulic Excavator
1.6 Contact Information
Thank you for purchasing a Sany machine. In the event that you should need to contact us for
any reason, you can reach us as follows:
Sany Heavy Machinery Limited
318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P. R. of China
201413
Tel: (86) 21 5700 8518
Service hotline: (86) 4006 098 318
E-mail: [email protected]
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BLANK
P
AGE
Page 34
Safety
SY115C9/135C/155H Crawler Hydraulic Excavator Safety
Safety, Operation and Maintenance Manual - Sep 2012 2-1
2 Safety
2.1 Safety Information.................................................................................................... 2-5
2.2 Safety Messages ..................................................................................................... 2-7
2.2.1 Hazard alert wording ...................................................................................... 2-8
2.2.2 Other alert wording ........................................................................................ 2-9
2.2.3 Safety decals ................................................................................................. 2-9
2.2.3.1 Textual safety decals ........................................................................... 2-10
2.2.3.2 Graphical safety decals ....................................................................... 2-10
2.2.3.3 Safety decal locations ..........................................................................2-11
2.3 General Precautions .............................................................................................. 2-19
2.3.1 Safety rules .................................................................................................. 2-19
2.3.2 Abnormalities ............................................................................................... 2-19
2.3.3 Personal protective equipment .................................................................... 2-19
2.3.4 Fire extinguisher and fi rst aid kit .................................................................. 2-21
2.3.5 Safety equipment ......................................................................................... 2-21
2.3.6 Cleaning your machine ............................................................................... 2-22
2.3.7 Keeping the cab clean ................................................................................. 2-23
2.3.8 Engaging the hydraulic lockout control ........................................................ 2-23
2.3.9 Handholds and steps .................................................................................. 2-24
2.3.10 Overhead work........................................................................................... 2-25
2.3.11 No sitting on attachment ........................................................................... 2-25
2.3.12 Articulated parts ......................................................................................... 2-25
2.3.13 Preventing burns ....................................................................................... 2-25
2.3.13.1 Hot coolant ........................................................................................ 2-25
2.3.13.2 Hot oil ................................................................................................ 2-26
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Safety SY115C9/135C/155H Crawler Hydraulic Excavator
2-2 Safety, Operation and Maintenance Manual - Sep 2012
2.3.14 Preventing fi re and explosion .................................................................... 2-26
2.3.14.1 Fire caused by fuel or oils ................................................................. 2-26
2.3.14.2 Fire caused by fl ammable materials ................................................. 2-27
2.3.14.3 Fire caused by electric lines .............................................................. 2-27
2.3.14.4 Fire caused by hydraulic lines .......................................................... 2-28
2.3.14.5 Fire caused by illumination equipment .............................................. 2-28
2.3.14.6 Fire caused by heat shield ................................................................ 2-28
2.3.15 In the event of fi re ...................................................................................... 2-28
2.3.16 Windshield cleaning detergent ................................................................... 2-29
2.3.17 Preventing ejection of part ........................................................................ 2-29
2.3.18 Falling object protection ............................................................................. 2-30
2.3.19 Attachment installation ............................................................................... 2-30
2.3.20 Attachment combination ............................................................................ 2-31
2.3.21 Cab windows glasses ................................................................................ 2-31
2.3.22 Unauthorized modifi cation ......................................................................... 2-31
2.3.23 Job site investigation.................................................................................. 2-31
2.3.24 Operation on soft ground ........................................................................... 2-32
2.3.25 Overhead power cables ............................................................................. 2-33
2.3.26 Ensuring a good visibility ........................................................................... 2-34
2.3.27 Ventilating enclosed area ........................................................................... 2-35
2.3.28 Asbestos hazard ........................................................................................ 2-35
2.3.29 Alternate exit .............................................................................................. 2-36
2.4 Safe Operation Precautions................................................................................... 2-37
2.4.1 Safe starting ................................................................................................ 2-37
2.4.1.1 Safe mounting ..................................................................................... 2-37
2.4.1.2 Seat adjustment .................................................................................. 2-38
2.4.1.3 Seat belt .............................................................................................. 2-38
2.4.1.4 Before starting the engine ................................................................... 2-38
2.4.1.5 Engine starting rules ........................................................................... 2-39
2.4.1.6 Safe starting ........................................................................................ 2-39
2.4.1.7 Starting engine in cold season ............................................................ 2-40
2.4.1.8 Engine starting aid .............................................................................. 2-40
2.4.1.9 After starting the engine ...................................................................... 2-41
2.4.2 Operation ..................................................................................................... 2-42
2.4.2.1 Inspection before operation ................................................................ 2-42
2.4.2.2 Prior-operation precautions ................................................................. 2-42
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2.4.2.4 Travel directions .................................................................................. 2-43
2.4.2.3 Rules for steering safety ..................................................................... 2-43
2.4.2.5 Rules for traveling safety .................................................................... 2-45
2.4.2.6 Safe traveling ..................................................................................... 2-46
2.4.2.7 Operation on an incline ....................................................................... 2-47
2.4.2.8 Operation in snowy weather ............................................................... 2-48
2.4.2.9 Restricted operations .......................................................................... 2-48
2.4.3 Parking the machine .................................................................................... 2-51
2.4.3.1 Select a parking place ......................................................................... 2-51
2.4.3.2 Machine shutdown .............................................................................. 2-51
2.4.4 Transportation .............................................................................................. 2-52
2.4.4.1 Loading and unloading the machine ................................................... 2-52
2.4.4.2 Transporting the machine ................................................................... 2-53
2.4.5 Battery.......................................................................................................... 2-54
2.4.6 Lifting objects with the machine ................................................................... 2-56
2.5 Precautions for Maintenance ................................................................................. 2-57
2.5.1 Prior-maintenance precautions .................................................................... 2-57
2.5.2 Select a working area .................................................................................. 2-57
2.5.3 Preparing the machine ................................................................................ 2-58
2.5.4 Preparing yourself ........................................................................................ 2-59
2.5.5 Lock-out and tag-out .................................................................................. 2-60
2.5.6 Using proper tools ........................................................................................ 2-60
2.5.7 Maintenance with engine running ................................................................ 2-61
2.5.8 Working under the machine ......................................................................... 2-61
2.5.9 Track maintenance....................................................................................... 2-62
2.5.10 Track tension adjustment precautions ....................................................... 2-63
2.5.11 Recoil spring .............................................................................................. 2-63
2.5.12 Welding operation ...................................................................................... 2-64
2.5.13 High-pressure hoses .................................................................................. 2-64
2.5.14 Pressurized fl uid ........................................................................................ 2-65
2.5.15 Hot cooling system..................................................................................... 2-66
2.5.16 Air-conditioning system ............................................................................. 2-66
2.5.17 High voltage precautions ........................................................................... 2-67
2.5.18 Accumulator ............................................................................................... 2-67
2.5.19 Avoiding fi re and explosion ........................................................................ 2-68
2.5.20 Regular replacement of safety-related parts .............................................. 2-69
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2.5.21 Maintenance operation ............................................................................. 2-70
2.5.22 Proper disposal of wastes .......................................................................... 2-71
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2 SAFETY
2.1 Safety Information
This Operation and Maintenance Manual is a
guide for you to operate your machine properly. It contains technical and safety information necessary for operation of your machine.
Read and understand each section of the
manual.
Only eligible, experienced operators with an
offi cial license (according to local laws) are al-
lowed to operate the machine.
Always operate your machine according to
national, provincial, prefectural and municipal
laws and regulations. The operation safety
information and description in this manual are
just suggestive and attentive.
Sany cannot anticipate every possible circumstance that might involve a potential hazard
during operation and maintenance. The Safety
messages in this manual and on the product
are, therefore, not all inclusive. If a procedure,
work method or operating technique that is not
specifically recommended in this manual is
used, you must be sure that it is safe for you
and for others. You should also ensure that
the product will not be damaged or be made
unsafe by the operation, lubrication, maintenance or repair procedures that you choose.
Modifying or abusing the machine according
to your own will might impair the machine's
performance, or result in more serious potential hazard. For instance, the specific volume
of fuel exceeds set limit or the machine is
overloaded. Drive and operate the machine
carefully. Improper operation or application
may cause personal injury or machine damage. Sany assumes no responsibility for such
losses.
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Machines covered by this manual are used
for various operations under normal conditions. Never use the machine in fl ammable or
explosive environment, or in areas containing
asbestos dust.
Select a Sany excavator that is suitable for
high-plateau operation when operating in
areas 2,000 m above the sea level.
This machine has gone through electromagnetic capacity test according to EN 13309200C. All unapproved electronic attachments
(such as communication devices) are therefore to be tested before installation and application. Make sure that the electromagnetic
attachments will not cause interference.
The information, specifications, and illustrations in this publication are on the basis of
information that was available at the time that
the publication was written. Sany reserves the
right to change these information at any time
without prior notice. Consult your Sany distributor to obtain the latest information or if you
have any question on the information provided
in this manual.
Before starting operation and maintenance,
operator and service personnel shall observe
the following items:
●Read and understand the whole manual.
●Read and understand the safety notices
contained in this manual and the safety decals on the machine.
●Never apply or operate your machine under any circumstances that are prohibited
by the manual.
●If the amount of fuel added, content of particulates ,or latitude is beyond the specification of this type of machine, damage
could result and the warranty of your machine would become invalid.
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The manual must be kept in the operator cab
for reference at any time.
If the book delivery with machine is missing or
cannot be read, contact your Sany distributor
to obtain a new one.
This manual should be regarded as a permanent component of your machine. If the machine is sold to a third party, give this manual
to new owner.
The machine provided by Sany to its buyer is
in line with all specifi cations and standards of
buyer's country. If the machine is purchased
from another country or someone of a third
country, it might be lacking of some safety
devices or technical requirements necessary
for using the machine in your country. In case
you question whether the machine is in accordance with the standards and specifi cations of
your country, you may contact local Sany distributor before operating the machine.
2.2 Safety Messages
Safety precautions given in this manual and
on machine decals, both textual and graphical,
provide information of hazardous situations
and methods to avoid such situations.
Before performing operation and maintenance
on the machine, the operator and after-sale
service personnel must understand all warning signs or symbols on the machine decals,
strictly follow the safety rules and precautions
specified in this manual, and take positive
actions so as to reduce the possibility of personal injury or death, the damage of machine
caused by improper service, and the risk of
unsafe factors, to the minimum.
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2.2.1 Hazard alert wording
Hazard alert words are used in this manual
and on some machine decals to inform the
operator of imminent or potential hazards that
lead to death, personal injury or property damage.
Different alert words are used to indicate the
degree of hazard.
It indicates an imminently
hazardous situation which,
if not avoided, will result in
death or serious injury.
It indicates a potentially
hazardous situation which,
if not avoided, could result
in death or serious injury.
It indicates a potentially
hazardous situation which,
if not avoided, may result
in minor or moderate injury. It can also be used to
alert unsafe operation as
which may cause property
loss.
DANGER
CAUTION
WARNING
It indicates a situation
which can cause damage
to the machine, personal
property and/or the environment, or cause the
equipment to operate improperly.
This is the safety alert symbol. It is used
to alert you to potential personal injury
hazards. Obey all safety messages that
follow this symbol to avoid possible injury
or death.
NOTICE
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●The hydraulic lockout control must be
placed in the LOCK position before you
leave the operator cab.
●An unlocked hydraulic lockout control
lever can cause serious injury or death
if maneuvered unexpectedly.
An example alert wording and alert text
2.2.2 Other alert wording
In addition to the safety-related alert words
above, the following words are used in this
manual to provide additional information to
which extra attention must be paid.
Note:
It is followed by information on how to avoid
reduction of machine service life.
Remark:
It is followed by very useful information.
2.2.3 Safety decals
Safety decals on the machine are used to
alert operator or maintenance personnel that
potential hazards might be involved when the
machine is being operated or serviced.
We use textual and graphical (or combined)
decals to indicate a hazardous situation and
how to avoid such situation.
WARNING
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A820601990973
Possible to fall
Never step.
Code
2.2.3.2 Graphical safety decals
Graphical safety decals use images or symbols to indicate a hazardous situation and how
to avoid it.
Fig. 2-2 is an example of graphical safety decals.
The upper triangle indicates the type of hazardous situation while the lower circle shows
the way to avoid it.
Fig. 2-2
2.2.3.1 Textual safety decals
Textual safety decals use brief text to indicate
hazardous situation and safety measures.
Fig. 2-1 is an example of textual safety decals.
A820601990968
TO RELEASE PRESSURE,
LOOSEN ONLY ONE TURN.
CAUTION
Code
Fig. 2-1
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2.2.3.3 Safety decal locations
Sany cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this manual and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifi cally recommended by
Sany is used, you must be sure that it is safe
for you and for others.
Application or operation not specified in this
manual shall not be performed at any time.
The following safety decals are used on the
machine.
●Be sure to recognize the correct locations
and information on the decals.
●To ensure that the decals can be read
and understood easily, they have to be attached to the right locations and always
kept clean. The use of organic solution or
gasoline to clean the decals is not allowed.
●There are also other decals besides those
for warning and safety. These messages
should be treated in the same way.
●A new decal should be used for replacement if the old one is broken or missing,
or cannot be read. See the manual or the
message for part number of the decal. You
may order a new one from your Sany distributor.
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Fig. 2-3
A
1
4
12
10
15
13
12
9
6
B
A
18
7
11
2
8
5
17
16
14
3
B
CZ335-1102001
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(1) Read the manual
A820601990971
●Warning!
●Read the Manual before operation, maintenance, disassembly, reassembly and
transportation of your machine.
A820699001019
(2) Lock the front window
(3) Excavator control pattern
●Always lock the front window if it is open.
●If the front window is unlocked in the open
position, it may fall and personal injury
could result.
A820601990961
●To prevent bodily injury or death, be aware
of the running condition and mode of your
machine. Pay attention to your surrounding
and operate your machine slowly.
Fig. 2-4
Fig. 2-5
Fig. 2-6
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(5) Alternate exit
A820601990969
A820601990974
A820699001020
(4) High voltage
●Electrocution hazard.
●Keep a safe distance from power transmission lines.
(5) Remove key after power-off
Before leaving your machine, lower the work
equipment to ground, engage the hydraulic
lockout control and remove the ignition key.
Fig. 2-7
Fig. 2-8
Fig. 2-9
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(7) Away from swinging range
(8) Watch out work equipment
●This decal shows the possibility of being hit
by the machine. Be away from the swinging range.
●Keep a safe distance from the machine
when it is working.
●It is possible to be hurt by the work equipment.
●Keep a safe distance from the machine
when it is working.
(9) Hot surface
●Hot parts can cause burns. Never touch
any hot part.
A820699001016
A820601990963
Fig. 2-10
Fig. 2-11
10123433
WARNING
Fig. 2-12
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(12) Track tension adjustment warning
(10) Squirting hazard
(11) Fan cutting hazard
A820601990968
WARNING
To release pressure,
loosen only one turn.
A820699000948
A820600000002
WARNING
●Read the instruction before removing the
cap of any pressure vessel. To prevent
squirting, turn the cap slowly to release internal pressure before removing it.
●A rotating part may cause injury. Keep a
safe distance from any rotating part.
●The regulator valve under high pressure
may eject and cause bodily injury. Never
loosen it over one turn.
Fig. 2-13
Fig. 2-14
Fig. 2-15
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(13) Moving belt
(14) Possible to fall
●A rotating belt is dangerous.
●Stop the belt before maintenance.
●It is possible to fall.
●Stay away from the edge.
(15) Engine hood
●It is possible to fall.
●Never step here!
A820699001017
STOP
A820601990926
Fig. 2-17
Fig. 2-18
A820601990973
Fig. 2-16
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(16) Not seating
A820699001023
CAUTION
(18) Refi ll refrigerant
(17) Water separator draining precautions
A820699001284
Refill the refrigerant after
replacing system component.
Direction to drain.
Direction to close. Tighten it
properly. Never tighten it with
extra force. Over-tightening could
damage the water separator.
NOTICE
A820601990962
Fig. 2-19
Fig. 2-20
Fig. 2-21
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2.3 General Precautions
2.3.1 Safety rules
●Only trained personnel are allowed to operate and service the machine.
●All safety rules, precautions and instructions must be followed when operating and
servicing the machine.
●Taking alcohol or drug could seriously impair one's ability in operating or repairing
the machine, and it is hazardous for you
and other persons.
●When working with another operator or job
site traffic signalman, be sure to make all
people understand all hand signals to be
used.
2.3.2 Abnormalities
In case of any abnormalities found during
operation and maintenance, such as noise, vibration, odor, incorrect gauge display, smoke,
or oil leakage, contact your Sany distributor
and take necessary measures. Never operate
the machine before the faults are corrected.
2.3.3 Personal protective equipment
Wear proper work clothes and personal protective equipment (PPE) suitable for the environment of the job site. You may need:
●Hard hat
●Safety shoes
●Safety glasses, goggles or face shield
●Protective gloves
●Hearing protection
●Refl ective protective clothing
●Rain gear
CZ335-1102002
Fig. 2-22
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Observe the following items before performing any operations. Failure to do so
could cause machine damage, personal
injury or death.
●Never wear slack clothing and jewelry,
which may get caught by control levers
or other machine parts.
●Long hair can be caught in moving
parts. Tie your hair if necessary to
avoid such hazard.
●Always have your hard hat and safety
shoes on. Wear safety goggles, face
masks, gloves, hearing protection and
safety belt if necessary.
●Make sure all PPEs are in good condition before use.
●Never listen to radio or music with ear
plugs on during operation.
●Dust mask
Wear all necessary PPEs as well as other
equipment required by your employer, local
government, and local laws and regulations.
Never take a risk.
WARNING
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2.3.4 Fire extinguisher and fi rst aid kit
To prevent injury or fi re, observe the following
precautions:
●First aid kit and fi re extinguisher should be
available nearby.
●Read and understand the instruction attached to fire extinguisher. Use fire extinguisher properly.
●Regular inspection and maintenance shall
be done to ensure proper functioning of fi re
extinguisher at any time.
●Check the fi rst aid kit regularly and replen-
ish it when necessary.
●Make emergency scheme to deal with fi re
and accidents.
CZ335-1102003
Fig. 2-23
2.3.5 Safety equipment
To protect you and others around you, your
machine may be equipped with the following
safety equipment. Make sure that they are secured in place and in good condition.
●Falling object protective structure (FOPS)
●Front guard
●Lamps
●Safety signs
●Horn
●Guards
●Travel alarm
●Mirrors
●Fire extinguisher
●First aid kit
●Windshield wipers
Make sure the above equipment are operational. Never remove or disconnect any safety
equipment.
CZ335-1102004
Fig. 2-24
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Observe the following items before performing any operations. Failure to do so
could cause machine damage, personal
injury or death.
●Make sure all covers and caps are in
proper place. Repair or replace any of
them immediately once found damaged.
●Know how to use these facilities and
use them correctly.
●Never remove the guard rail of the operator cab (unless necessary) .
WARNING
2.3.6 Cleaning your machine
●Clean the windshields, mirrors and lights.
Make sure that the operating area, steps
and handholds are free from oil, grass,
snow, ice or mud, which can cause you
to slip and fall. Remove the mud on your
soles before getting on the machine.
●If the machine is checked or serviced with
presence of mud or oil dirt, it may cause
you to slip or fall, or dirt may get into your
eyes. Keep the machine clean all the time.
●If water has penetrated into the electrical system, never rush to power on your
machine and start the engine, which can
cause machine failure or PC board damage. Never flush the electrical system
(including sensors, connectors, etc.) with
water or steam.
CZ335-1102005
Fig. 2-25
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2.3.7 Keeping the cab clean
●Clean the mud and oil on your soles when
getting into the cab. Mud or oil under your
shoes can cause your foot to slip on the
pedal during operation, and serious accident could result.
●Remove all loose personal items or other
objects from the operator's area. Secure
these items in the tool box or remove them
from the machine.
●Never use cellular phone when operating
or driving the machine.
●Never bring Hazardous articles, such as
flammable or explosive products, into the
cab.
2.3.8 Engaging the hydraulic lockout
control
●Before you rise from the operator seat (e.g.
to open or close the front window or to
adjust the seat), lower work equipment to
ground, place hydraulic lockout control (1)
securely to the LOCK position, and then
stop the engine. If hydraulic lockout control
is FREE, accidental touching of control
levers can cause sudden machine movement and serious injury, or machine damage could result.
●Before leaving your machine, always lower
work equipment to ground, place hydraulic
lockout control (1) to the LOCK position,
and then shut down the engine. Lock all
lockable components and remove ignition
key.
CZ335-1102007
Fig. 2-26
Fig. 2-27
1
CZ335-1102006
FREE
LOCK
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2.3.9 Handholds and steps
To avoid personal injury caused by slippery
handholds or steps, observe the following instructions:
●Before mounting and dismounting, check
the handholds and steps (including tracks)
for oil, grease or mud. Always keep them
clean. Make necessary repairs and tighten
loose bolts if any.
●When mounting and dismounting the
machine, use the handholds and steps
marked by the arrows.
●Face the machine and maintain a 3-point
contact with the handholds and steps (including tracks) . A 3-point contact can be
both feet and one hand, or both hands and
one foot.
●Never use any control lever as a handhold
when mounting or dismounting the machine.
●Never carry tools when mounting or dismounting the machine.
●Never work on an engine hood or cover
with no non-slip mat on it.
●Always face the machine when you mount
or dismount the machine.
●Never jump onto/off the machine. Never
mount a moving machine. Never jump onto
the machine and try to stop it.
●When you enter and exit the operator cab,
make sure the cab is on the central line of
undercarriage.
CZ335-1102008
CZ335-1102009
CZ335-1102010
Fig. 2-28
Fig. 2-29
Fig. 2-30
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2.3.10 Overhead work
When working on a overhead place, use a ladder or other support to ensure your safety.
2.3.11 No sitting on attachment
To avoid falling hazard, no one is allowed to sit
on work equipment or other machine attachments.
2.3.12 Articulated parts
The space around work equipment changes
with movement of linkages. Serious personal
injury could result if one is stuck in between.
Never stay close to rotating or retracting/extending components.
2.3.13 Preventing burns
2.3.13.1 Hot coolant
●To prevent burns caused by hot coolant or
steam when checking or discharging the
coolant, wait until the engine coolant is
cool enough before proceeding.
●Never open the cap of radiator before the
engine cools down. Loosen the cap of the
radiator slowly before removing it. Internal
pressure of radiator must be relieved to
avoid serious burns.
CZ335-1102011
Fig. 2-31
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2.3.13.2 Hot oil
To prevent scalds caused by hot oil when
checking or discharging the oil, always wait
for the engine oil to cool down before you proceed.
When the engine has cooled down, loosen the
cover or screw plug slowly to relieve internal
pressure.
CZ335-1102012
CZ335-1102013
Fig. 2-32
Fig. 2-33
CZ335-1102014
Fig. 2-34
2.3.14 Preventing fi re and explosion
2.3.14.1 Fire caused by fuel or oils
●Engine oil and fuel must be stored in designated place, where unauthorized persons
cannot enter.
●Never smoke or use fire near fuel or engine oil.
●Check for missing or loose pipe clamps,
twisted hoses, hoses rubbing against pipeline, damaged oil cooler, and loose bolts in
fl ange of oil cooler, so as to avoid oil leakage. Tighten, repair or replace any missing,
loose or damaged pipe clamps, pipelines,
hoses, oil coolers or other fl ange bolts.
●Refuel or store oils in a place with good
ventilation.
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●Shut down the engine before refueling.
●Never leave the machine when refi lling the
fuel or engine oil.
●Never let fuel overflow onto overheated
surface or electrical components.
●Remove overfl owed fuel or engine oil after
refi lling.
●Store oily rags and any fl ammable materi-
als in protective containers in order to keep
the job site safe.
●Screw on the caps of fuel tank and oil tank
tightly.
●When oil is used to clean the parts, use
non-fl ammable oil. Never use diesel oil or
gasoline as they can easily catch on fi re.
●All flammable materials should be moved
to a safe place before carrying out grinding
or welding operation on the chassis.
●Never weld or fl ame cut the lines contain-
ing fl ammable fl uid.
2.3.14.2 Fire caused by fl ammable materi-
als
●Remove at any time dry leaves, wood
chips, paper pieces, dirt and other fl amma-
ble materials built up or stuck on engine,
exhaust manifold, battery or interior of engine hood to prevent fi re.
2.3.14.3 Fire caused by electric lines
Short circuit of electrical system can cause
fi re.
●Keep electric terminals clean and fastened.
●Check power cables and electric lines for
looseness, entanglement, hardening or
break each day after operating for 8-10
hours. Check the presence or damage of
wiring terminal cover.
CZ335-1102015
Fig. 2-35
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●In case of slack or entangled power cables
or electric wires, tighten the connections
or wire clips, and repair or replace broken
wires.
2.3.14.4 Fire caused by hydraulic lines
●Check the clamps, guards and gaskets of
all hoses and pipes to see whether they
are tightened in position.
●In case of loosening, their vibration in operation may lead to friction against other
components, resulting damage of hose,
ejection of high-pressure oil, disastrous fi re
or serious injury.
2.3.14.5 Fire caused by illumination equipment
●Anti-blast illumination equipment shall be
used to avoid explosion when fuel, oil,
electrolyte, window cleaning detergent or
cooling fl uid is being checked.
●Instructions in this manual must be followed when power outlet on the machine
is used for illumination.
2.3.14.6 Fire caused by heat shield
●Damage or missing of heat shield may
lead to fi re.
●In case of any abnormality, heat shield
must be repaired or replaced before operation of machine.
2.3.15 In the event of fi re
When a fi re breaks out, leave the machine im-
mediately by the following steps.
●Turn start switch to the OFF position to
shut down the engine.
●Leave the machine with the help of hand-
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holds and steps.
2.3.16 Windshield cleaning detergent
Use alcohol based detergent. Never use methanol based detergent as it irritates eyes.
2.3.17 Preventing ejection of part
The grease in track tensioning device is under
high pressure. Improper handling may result in
serious injury, blindness or death. Observe the
following instructions.
●Never disassemble grease nozzle or valve
components. These parts may eject. Never
stay in front of the valve.
●Travel reducer is under pressure.
●Gear oil is hot liquid. Wait for it to cool
down before loosening the plug to release
pressure. To avoid injury, never face the
plug during operation.
CZ335-1102016
Fig. 2-36
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2.3.18 Falling object protection
●When the machine is operated in places
where the cab is likely to be hit or invaded
by falling objects, scattered materials or
foreign bodies, protective structure shall be
used to protect the operator.
●In demolishing or breaking operation, a
front guard is necessary. In addition, a
transparent glass film shall be applied to
the windshield.
●In a coal mine or a quarry where falling objects are present, install falling object protective structure (FOPS) and front guard,
and apply a transparent glass film to the
windshield. The operator shall wear a hard
hat and goggles.
●Keep the windshield shut in such conditions and make sure other people are kept
a safe distance away from the operating
area.
●Other guards may be necessary according
to different working conditions. In this case,
contact Sany distributor in advance.
2.3.19 Attachment installation
●Installation of optional parts or attachments
may involve safety issues or be limited by
the law. In this case, contact your Sany
distributor in advance.
●Sany assumes no responsibility for the injury, accidents and product failure caused
by the use of unauthorized attachments
and parts.
●Before installing and using machine attachments, read related instructions regarding
the attachment and general precautions on
attachment in this manual.
CZ335-1102017
Fig. 2-37
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2.3.20 Attachment combination
Different or combined work equipment may
collide with the cab or interfere with other
machine components. Before operating work
equipment you are not familiar with, check the
clearance between it and the machine and operate it carefully.
2.3.21 Cab windows glasses
●Broken cab windows at the side of the
work equipment may expose the operator
in direct contact with the work equipment.
In this case, stop operation immediately
and replace the glasses.
●Broken or damaged window provides no
protection to the operator. When the roof
window is damaged, replace it immediately
with a new one.
2.3.22 Unauthorized modifi cation
Any modification unauthorized by Sany may
lead to safety problems, personal injury or
death. Improper modification can affect machine's strength and operator's view. Contact
your Sany distributor before making any modification. Sany assumes no responsibility for
the accidents, failure or damage caused by
unauthorized modifi cation.
2.3.23 Job site investigation
●Machine operation near fl ammable materi-
als (e.g. dry tree leaves) poses a fi re haz-
ard. Be careful during operation.
●Check the terrain and ground condition and
use the safest operating method. Never
operate in areas with the risk of landslide
or falling stones.
●Solidify the ground when operating beside
CZ335-1102018
Fig. 2-38
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a ditch or on road shoulders. Keep your
machine a safe distance away from the
ditch or road shoulder. Designate a signal
man, when necessary, to avoid accidental
injury.
●When underground water mains, gas lines,
cables or high-voltage electric cables are
available on the job site, inform related
utilities providers and mark the area. Be
careful not to cut or damage any lines.
●Prevent any unauthorized personnel from
entering the job site. Designate a signal
man and fence the job site when operating
your machine on a highway.
●Be especially alert when operating on frozen ground. Increase of ambient temperature may result in soft and slippery ground.
●When traveling or operating in shallow water or soft ground, check the type and condition of rock bed as well as the depth and
water fl ow before operation.
2.3.24 Operation on soft ground
●Avoid traveling or operating your machine
near cliffs, road shoulders or trenches. The
soft ground plus machine weight and vibration can cause your machine to sink or tip
over. The ground may become even softer
after heavy rain, explosion or earthquake.
●When operating on a dam or near an excavated ditch, vibration and machine weight
may trigger a landslide. Before operation,
take protective measures to prevent your
machine from tipping over or falling.
CZ335-1102019
Fig. 2-39
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2.3.25 Overhead power cables
Never drive or operate your machine near
power cables, which may bring electrocution
hazard and cause machine damage, personal
injury or death. The following steps are to be
followed while working at where power cables
could be nearby.
●Before operation in the vicinity of power
cables, inform local power company of the
coming operation and ask them to take
necessary measures.
●If your machine is too close to power
cable, electrocution is most likely to occur
and cause burns or death. A safe distance
must be kept between machine and power
cable (See Table 2-1). Before operation,
communicate with local power company
regarding safety measures.
●A signalman is to be designated to give
signals if your machine is too close to power cables.
●Nobody is allowed to approach the machine when it is operated near high-voltage
cables.
●If your machine is too close to the cable
or touches the cable, to prevent electrocution, operator shall not leave the cab until
machine power is surely cut off. In addition, Nobody is allowed to approach the
machine.
●To prevent accidents, wear rubber shoes
and rubber gloves during operation. Cover
the operator’s seat with rubber sheet and
pay attention to exposed part of body that
should not touch the lower part of machine.
Cable Voltage Safe Distance
100V-200V 2 m ( 7 ft) or above
6,600V 2 m ( 7 ft) or above
22,000V 3 m ( 10 ft) or above
66,000V 4 m ( 14 ft) or above
154,000V 5 m ( 17 ft) or above
187,000V 6 m ( 20 ft) or above
275,000V 7 m ( 23 ft) or above
500,000V 12 m ( 36 ft) or above
CZ335-1102020
Fig. 2-40
Table 2-1
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2.3.26 Ensuring a good visibility
The machine is equipped with rearview mirrors
to improve the visibility of the operator. However, some areas cannot be seen from the
operator seat. When operating your machine
in a position that gives you poor visibility, uncertainty of job site may cause machine damage and personal injury. Observe the following
instructions when operating or driving your
machine in a place without a clear view.
●Check rear view mirrors on each workday.
Remove debris and adjust the view to ensure good visibility.
●Working in a darkened area requires turning on work lamps and head lamps of the
machine. Set up auxiliary illumination on a
job site if necessary.
●Stop operation if you cannot have a clear
view in days with fog, snow, rain or sand
storm.
●Road shoulder or soft ground should be
marked. In case of bad vision, a signalman
should be available if necessary. Operator
shall especially pay attention to the marks
and follow the instruction of the signalman.
●Only one signalman is allowed to give signals.
●Make sure all workers understand all signals and gestures before operation.
CZ335-1103144
Fig. 2-41
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2.3.27 Ventilating enclosed area
Engine exhaust gas can be fatal. If the engine
must be started, or if fuel, cleaning oil or paint
must be handled in an enclosed area, to prevent gas poisoning, doors and windows shall
be opened to ensure suffi cient ventilation.
2.3.28 Asbestos hazard
Inhalation of asbestos dust can cause lung
cancer. It is possible to inhale asbestos dust
when performing tear-down operation or handling industrial wastes at job site. The following rules must be followed.
●Use water, instead of compressed air, to
remove the dust.
●If the air contains asbestos dust, operate
the machine following the wind. All persons
shall wear acceptable fi lter mask.
●Nobody is allowed to approach the machine during operation.
●The regulations, rules and environment criterion at job site shall be observed.
No asbestos is used in this machine. But after-
CZ335-1102022
Exposure to hazardous chemicals or dusts
pose a serious danger if released or mishandled. Performing demolition work or
handling hazardous materials often release
substances that could pose a hazard. Serious injury or death may result unless proper precautions are observed while working
with these materials. All workers involved
in demolition or handling of hazardous
materials should use approved personal
protective equipment and follow all environmental safety regulations.
Fig. 2-42
WARNING
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CZ215-1103030
Fig. 2-43
market parts could contain asbestos. Therefore, use only the parts and components supplied by Sany.
2.3.29 Alternate exit
●If you are unable to open the cab door in
case of emergency, use the safety hammer
to break the rear window to escape.
●Remove the pieces of glass from the window frame before escaping. Be careful not
to be cut by broken glass. Pay attention to
the broken glass on the ground, which may
cause you to slip and fall.
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2.4 Safe Operation Precautions
2.4.1 Safe starting
2.4.1.1 Safe mounting
When you mount or dismount the machine:
●Always face the machine and maintain a
three-point contact (one hand and two feet
or two hands and one foot).
●Never jump on/off the machine. Never
mount a moving machine.
●Never use any control lever as handhold.
●Remove the mud, oil dirt and water from
the pedals, handholds and your soles at all
times.
●The cab must be aligned with the undercarriage centerline before you enter or exit
the cab.
An unattended machine is dangerous.
CZ335-1102023
CZ335-1102024
CZ335-1102025
Fig. 2-44
Fig. 2-45
Fig. 2-46
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2.4.1.2 Seat adjustment
Uncomfortable seat position can easily lead to
operator fatigue and mistakes. The seat position should be adjusted upon change of operator. Leaning against the back of seat, operator
shall be able to push the pedal to its limit with
his foot, and operate the control lever properly.
Otherwise, the seat should be readjusted by
moving it forward or backward.
CZ335-1102026
CZ335-1102027
Fig. 2-47
Fig. 2-48
2.4.1.3 Seat belt
The operator may get seriously injured or
killed when the machine tips over. Before
operating the machine, check carefully your
seat belt, the buckles and the anchor point.
Replace the seat belt if damage or excessive
wear is observed. When the machine is being
operated, keep your seat belt buckled up.
The seat belt must be replaced every three
years regardless of its condition.
2.4.1.4 Before starting the engine
Before starting your daily work, the following
items must be observed before starting the
engine.
●Clean the windows to ensure a good visibility.
●Clean the head lamps and work lamps,
and check if they are in good condition.
●Check coolant level, fuel level and engine
oil level.
●Check for blocked air filter and damaged
electrical wires.
●Adjust the seat to a position easy for operation; check seat belt and buckles for
damage and wear.
CZ335-1102028
Locked
Fig. 2-49
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●Check the instrument panel. Check if the
control levers are all in neutral position.
●Check if the hydraulic lockout control is in
the LOCK position.
●Adjust the rear view mirrors so as to see
clearly from the operator seat what is happening behind the machine.
2.4.1.5 Engine starting rules
●Before starting the machine, make sure
nobody is on, under or around the machine. Sound the horn to warn people
around.
●Always start and operate the machine from
the operator seat.
●No one is allowed to stay on the machine
except the operator.
●Never start the engine by shorting the start
motor circuit, which is dangerous and may
cause machine damage.
2.4.1.6 Safe starting
●Ample ventilation must be provided if
you have to start the engine or operate
the machine in an enclosed environment.
●Excessive inhalation of exhaust gas can
be fatal.
●If you do not know how to stop the machine, never start it.
WARNING
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CZ335-1102029
To understand proper starting steps of the machine, see
“Engine Starting” on page 4-22
.
●Being seated in the operator's position, adjust the seat so you can easily access all
controls from a seated position.
●Familiarize all warning devices, gauges
and operation controls.
●Place all controls to neutral/shutdown position.
●Nobody is allowed to stay in the working
area.
●Start the engine as indicated in Operation
Section.
Fig. 2-50
2.4.1.7 Starting engine in cold season
●When ambient temperature is blow 10ºC,
pre-heat the engine before start it. For detailed information, see
“Engine Preheat-
ing” on page 4-25.
●When the machine is intended to work in
areas where temperature is always below
-15ºC, fuel heating system is recommended to improve engine startup performance.
●Suffi cient warm-up operation is necessary.
Incomplete warming up may result in slow
reaction and accidents.
●Before starting, check the battery electrolyte. In case of frozen electrolyte, never
charge the battery or use alternative power
source to start the engine; instead, melt the
electrolyte fi rst. Otherwise, fi re may break
out on the battery.
2.4.1.8 Engine starting aid
Follow procedures in the Operation section
when using jumper cables to start the engine.
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Improper handling may cause battery explosion or loss of machine control, resulting in
personal injury and death. Never use jumper
cables to start the engine unless necessary.
Contact your Sany distributor before such an
attempt.
●Using jumper cables to start the engine
needs two persons working together with
one seated in the operator seat and the
other handling the battery.
●Wear goggles and rubber gloves before
starting the engine with jumper cables.
●When connecting a normal machine with a
faulty machine with jumper cables, battery
voltage of the two machines shall be the
same. Be careful not to allow the two machines to contact with each other.
●Turn both start switches to OFF position
when connecting the two machines. Otherwise, the machine may move and cause
danger when it is powered on.
●Start with the positive terminal when connecting the jumper cable. Start with the
ground or negative terminal when disconnecting the jump cable.
●When disconnecting the jumper cable, take
care not to allow the clips of jumper cable
to contact with each other or with the machine.
Ether is a liquid used for cold start, which is
extremely fl ammable and explosive. Read the
instructions on the ether container before application.
Never use ether if the engine is equipped with
spark-plug preheater or other forms of preheater.
2.4.1.9 After starting the engine
Run the engine at low idle for 3 to 5 minutes
after engine startup, and check the running
parameters and make sure they are normal
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and all readings are within normal working
range.
2.4.2 Operation
2.4.2.1 Inspection before operation
●When conducting inspection, move the
machine to a spacious area without barriers and operate slowly. Any other person is
not allowed to approach the machine.
●Be sure to buckle the seat belt.
●Check the gauges and machine operation
for abnormality; check the bucket, arm,
boom, travel system, swivel system and
steering system for abnormal operation.
●Check for abnormal noise, vibration, heating, odor or gauge reading; check oil or
fuel for leakage.
●When the travel control level is in neutral
position, test the engine's speed control
device; operate each control lever and
confi rm they work properly. Understand the
control mode of work equipment.
●In case of any abnormality, stop operation
and take corrective measures immediately.
2.4.2.2 Prior-operation precautions
To prevent serious injury or death, follow the
items below before moving the machine.
●It is dangerous to stay in the working range
during machine operation. Sound the horn
to warn people within the working range
before operating your machine.
●Nobody is allowed to stay on and near the
machine, or within the working range.
●To improve the visibility in the travel direction, you may turn the cab if necessary.
●Assign a signalman at where visibility is
poor.
CZ335-1102030
Fig. 2-51
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2.4.2.4 Travel directions
Improper operation of travel control lever/
pedal can cause serious injury or death.
CZ335-1102031
CZ335-1102032
Front
Operator Seat
Idler
Right
Back
Sprocket
Left
●Confi rm the relative positions between the
undercarriage and operator before operating the machine.
●If the motor is under the cab, pushing the
control lever/pedal forward will move the
machine backward.
●If the guide roller is under the cab, push
the control lever/pedal to move machine
forward.
●A sign for travel direction can be found on
internal side of undercarriage. When operator pushes control lever/pedal, the actual
travel direction is the direction indicated by
arrow.
Note:
In this manual, the forward, backward, left or
right direct is the direction seen from the cab
when the cab is straight forward and the driving wheels are in the rear.
Fig. 2-52
Fig. 2-53
WARNING
2.4.2.3 Rules for steering safety
●Always drive and operate the machine in a
seated position.
●Nobody is allowed in the cab except the
operator.
●Check if the travel alarm works.
●Always secure the cab door or windows,
either open or closed. At job site where fl y-
ing objects may get into the cab, check if
the doors and windows are properly shut.
●Assign a signalman if a blind area exists
CZ335-1102033
Fig. 2-54
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CZ335-1102034
1
CZ335-1102035
at the rear of the machine. In turning or
swivel operation, be alert not to hit other
machines or personnel.
●Sound the horn to warn personnel in the
area before traveling.
●Check for the presence of personnel and/
or obstacles again in the machine surroundings before traveling.
●Before traveling, position the machine so
that the sprocket (1) is behind the operator
cab. If the sprockets are in front of the cab,
the machine will move in a direction opposite to the move direction of control levers.
Special attention must be paid to operations under such circumstances.
●If your vision is limited during reverse travel, assign a signalman and keep him within
the range of your vision.
●When a signalman is necessary on some
occasions, use hand signals specified in
local regulations.
●The machine can only be moved when
both signalman and operator understand
the signals.
●Understand all vocal, graphic and flag
signals used in work and decide who is to
give signals.
●Keep the windows, rear view mirrors and
work lights clean and intact.
●Dust, heavy rain and fog may reduce visibility. Drive slowly and use proper lights in
case of low visibility.
Fig. 2-55
Fig. 2-56
CZ335-1102045
During reverse or swivel operation, people
around the machine may get hit by the
counterweight or work equipment, resulting in serious injury or even death.
Fig. 2-57
WARNING
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2.4.2.5 Rules for traveling safety
●To prevent machine breakdown and avoid
damage of work equipment, never operate
the machine beyond its maximum load or
rated capacity.
●When driving or operating the machine,
keep the machine a safe distance away
from people, building or other machine so
as to avoid collision.
●When traveling on a highway, contact related departments in advance and follow
their instructions.
●When traveling on flat ground, the work
equipment should be retracted and kept
20-30cm(8-12in) off the ground.
●When traveling on rough ground, the machine shall move at a low speed and avoid
sudden change of direction, or the machine
may tumble down. If the work equipment
hits the ground, the machine will lose balance and get damaged.
●When traveling on rough ground or on a
steep slope, the auto-deceleration switch (if
equipped) shall be switched off. If the autoidle switch is on, engine speed and travel
speed may drop suddenly.
●Avoid traveling over a barrier if possible. If
you have to do that, lower the work equipment close to the ground and drive slowly.
Never let the machine travel on a barrier
that would make it tilt sharply.
●Check first the structural strength of a
bridge or a building before drive the machine on it.
●Operate slowly when you are working in a
tunnel, under a bridge or power cables or
under where working height is limited. Take
care not to damage anything with work
equipment.
20~30cm
(8~12in)
CZ335-1102036
CZ335-1102037
Fig. 2-58
Fig. 2-59
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2.4.2.6 Safe traveling
●Check the travel direction of the machine
before driving it. Make sure you know how
to operate the control levers and pedals.
●Press the upper part of the control pedal or
push the control lever forward to move the
machine in the direction of the idlers.
●Work equipment should be kept 20-30 cm
(8-12 in) off the ground when moving on a
slope. In case of an emergency, the work
equipment could be lowered to ground immediately to help stop the machine.
20~30cm
(8~12i n)
CZ335-1102038
CZ335-1102039
CZ335-1102040
Driving the machine on a slope may cause
it to slip or tumble down, resulting in serious injury or death.
●When driving the machine up a slope, face
the cab to the uphill direction; when driving
down a slope, face the cab to the downhill
direction.
●Before traveling, always check the hardness of ground before your machine.
●When driving the machine up a slope, extend the work equipment to keep balance.
Keep the work equipment 20-30 cm (812in) off the ground and drive the machine
slowly.
●When driving down a slope, lower the engine speed, keep the travel control levers
close to “neutral” position and drive
slowly.
Fig. 2-60
Fig. 2-61
Fig. 2-62
WARNING
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●Drive straight up and down a steep slope.
It is very dangerous to turn on or drive
across a slope.
●To adjust the position of the machine on a
slope, drive it onto a flat surface, reposition it and driving the machine to the slope
again.
●Drive at low speed on meadow, fallen
leaves or wet steel plate because even a
small grade could cause the machine to
slip.
●If your engine stalls out when traveling on
a slope, place the control levers to “neu-
tral” position immediately and restart the
engine.
CZ335-1102041
CZ335-1102042
Fig. 2-63
Fig. 2-64
2.4.2.7 Operation on an incline
If you swing upper structure or operate work
equipment on an incline, you machine could
loose balance and tip over, causing serious
injury or damage. Therefore, such operations
must be performed carefully on a fl at platform.
●When the bucket is fully loaded, never turn
work equipment from uphill to downhill.
Such operation is dangerous and your machine could tip over.
●If you have to operate your machine on an
incline, always build an earth platform so
that your machine can work on a level surface.
CZ335-1102046
Fig. 2-65
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2.4.2.8 Operation in snowy weather
●Snow-covered or frozen surfaces are slippery. Never manipulate the control lever
suddenly when driving or operating the
machine. Extra attention should be paid to
operation on a slope because even small
inclination could cause the machine to slip.
●The machine may tip over on frozen surface which may become soft upon increase
of ambient temperature.
●Avoid deep snow, which may cause your
machine to tip over or to be buried in
snow. Be noted that you shall never be
away from road shoulder and avoid being
trapped in snow.
●When cleaning the snow, it is hard to see
the snow-covered road shoulder and objects near the road. There is danger for
your machine to tip over or hit the covered
objects. Therefore, please operate with extreme caution.
2.4.2.9 Restricted operations
●Never dig under an overhang, which may
lead to falling stones, collapse of overhang,
and accidents.
CZ335-1102047
Fig. 2-66
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●Never dig too much under the machine,
which may cause the ground to collapse
due to cave-in, hence the accidents.
CZ335-1102048
Fig. 2-67
●In excavating operation, the track should
be adjusted vertical to road shoulder or
cliff, with sprockets behind the cab, so that
the machine can retreat easily in case of
an emergency.
CZ335-1102049
Fig. 2-68
●Never tear down under your machine,
which may cause your machine to destabilize and roll over.
●When operating on building or other
structures, strength of structure must be
checked to avoid collapse of building, thus
resulting injury or death.
CZ335-1102050
Fig. 2-69
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●Never tear down any structure over your
machine. The falling of broken objects or
collapse of building could damage your
machine and cause personal injury or
death.
CZ335-1102051
Fig. 2-70
●Never break anything with the impact force
of work equipment as broken pieces could
lead to personal injury, the work equipment
could be damaged, and the counter-action
of impact force could roll over your machine.
●Generally speaking, it is easier to tip over
with the work equipment at one side than it
is positioned in the front or rear.
CZ335-1102052
Fig. 2-71
●Lifting, moving or swinging the bucket shall
never pass over anybody or a truck's cab.
The falling of substances from the bucket
or collision of buckets could result in personal injury or machine damage.
●The use of crusher or other heavy working
unit could cause your machine to lose balance and tip over. When operating on a fl at
surface or slope:
Never lower, swing or stop the working unit
suddenly.
Never extend or retract the boom cylinder
suddenly as which may cause your machine to tip over due to impact.
CZ335-1102053
Fig. 2-72
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2.4.3 Parking the machine
2.4.3.1 Select a parking place
●Park your machine on a solid and fl at sur-
face.
●Park the machine in an ares free of such
hazards as falling stones or landslide. If the
terrain is low, park it in a relatively higher
place.
●If you have to park the machine on a slope,
observe the following instructions:
●Position the bucket in the downhill direction and cut the bucket tips into the
earth.
●Chock the tracks to prevent unexpected
movement.
●Never park your machine on a road undergoing construction. If you have to park your
machine in such a place, flags are to be
used on daytime and signal lamps at night
to warn other people or vehicles according
to local regulations.
2.4.3.2 Machine shutdown
Follow the procedures below to shut down the
machine.
1. Stop the machine.
2. Position the machine properly.
3. Lower work equipment to ground or hold it
in a position.
4. Reduce engine speed to idle and keep it
running for 5 minutes.
5. Turn start switch to OFF position to stop
the engine.
6. Place hydraulic lockout control to the
CZ335-1102054
120°
CZ335-1102055
Fig. 2-73
Fig. 2-74
CZ335-1102056
Fig. 2-75
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Locked
CZ335-1102057
LOCK position.
7. Remove ignition key.
8. Close the windows and the cab door.
9. Lock all access doors, boxes and chambers.
When leaving your machine, face the machine
and maintain a three-point contact with it. Never jump off the machine.
Be careful with slippery track, step and handholds when dismounting the machine.
Fig. 2-76
Fig. 2-77
Space
Blocks
Max. Angle
15°
CZ335-1102058
2.4.4 Transportation
2.4.4.1 Loading and unloading the machine
Improper loading and unloading of the machine may cause it to fall or tip over. Follow
the procedures below:
●Load or unload the machine only on a solid
and flat surface. Keep it a safe distance
away from road sides or a cliff.
●Keep on-lookers away.
●Use an access ramp with enough strength.
Make sure that the width, length and thickness of the access ramp is capable of providing a safe loading/unloading operation
(at an angle ≤ 15°).
●Make sure the access ramp is free from
grease, oil, water and debris. Clean the
track if necessary. Be extremely careful
when loading or unloading the machine in
rainy or snowy weather.
●Never load or unload the machine using
the force of work equipment, which may
cause the machine to fall or tip over.
●Run the engine at low speed and drive
slowly.
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●Place the work equipment straight forward.
●Never operate any control levers other
than the travel control lever when the machine is driving up the ramp.
●Never reposition the machine on the access ramp. If necessary, drive it off the
ramp, reposition, and get on the ramp
again.
●Gravity center of the machine may alter
when it passes the jointing area between
the ramp and the trailer. The machine may
tilt at this moment. Travel slowly when the
machine is on the joint area.
●When loading or unloading the machine on
a platform, make sure the platform has adequate width, strength and a proper grade.
●The trailer may become less stable with
the machine on it. Retract the work equipment and swing the upper structure slowly.
●Once the machine is loaded, lock the cab
door. Otherwise, it may swing open during
transportation.
●Secure the machine with chains and
chocks.
●Secure all work equipment, lower the bucket, the arm and the boom, and place them
in position for transport.
2.4.4.2 Transporting the machine
Observe the following items when transporting
the machine:
●Note the dimension of the trailer and the
machine, especially the height. Watch out
for barriers overhead and in narrow passages.
●Check the structure and strength of a
bridge before crossing it. Obey local traffic regulations and traffic police directions
when transporting the machine on highways.
CZ335-1102059
Fig. 2-78
CZ335-1102060
Fig. 2-79
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2.4.5 Battery
Electrolyte contains sulfuric acid, which gives
off fl ammable and explosive gases. Improper
handling may cause personal injury or fire.
Observe the instructions below when handling
battery:
●Never smoke or use fi re near a battery.
●Turn the engine ignition key to the OFF position before working on the battery.
●Wear safety glasses and rubber gloves
when handling battery.
CZ335-1102061
CZ335-1102062
●Electrolyte is a strong acid. If electrolyte
contacts your clothing or skin, fl ush imme-
diately with plenty of water. Electrolyte may
cause blindness if it contacts your eyes.
Flush immediately with plenty of clean water under such circumstances and seek
medical treatment.
To avoid battery-induced explosion, observe
the following precautions:
●Never allow tools and other metal parts to
contact with battery terminals. Keep tools
or metal parts away from batteries.
●Stop the engine and wait for one minute
before you proceed. Always disconnect the
grounding terminal (negative(-) ) first. To
connect battery cables, always begin with
the positive (+) terminal, and then connect
the negative (-) terminal. Ensure all terminals are securely connected.
●Battery temperature rises when it is being charged. When battery temperature
exceeds 45°C, stop charging and wait till
it is at ambient temperature. Reduce the
charging current by half and continue the
Fig. 2-80
Fig. 2-81
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charging process.
●A battery being charged may give off fl am-
mable gases. Before charging a battery,
remove it from the undercarriage, put it in
well-ventilated area and remove the cap.
●If acid squirts out of battery vent during
charging, stop charging immediately.
●Never smoke and keep flames or sparks
out when charging.
●When the battery has been fully charged, a
green indicator will be on. Stop the charging process at this time.
●Restore the battery cover after charging.
●Put the battery back to its original position.
When towing a damaged machine, improper
operation or use of unacceptable wire cable
could lead to serious accident:
●Never tow the machine on a slope.
●Wear protective gloves and a had hat
when using wire ropes.
●Check the strength of wire cable and make
sure it could bear the weight of machine.
●Never use ropes with broken wires (A), reduced diameter (B) and twisting (C). Such
ropes may break when towing.
●Never stand between the towing machine
and the towed machine during towing operation.
●Operate the machine slowly. Never add
load to the wire cable suddenly.
A
B
C
CZ335-1102063
Fig. 2-82
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2.4.6 Lifting objects with the machine
CZ335-1102064
CZ335-1102065
CZ335-1102066
●Overload is dangerous and can cause
serious injury and death.
●Make sure the load is within the loading
range and working radius of the machine.
●Nobody is allowed to enter the working
area.
●Confi rm all signals to be used and assign a
signalman before operation.
●Lift a load on a fl at surface to prevent the
machine from tilting or tipping over.
●Never use chains, wire ropes, shackles
and slings that are damaged.
●Anchor wire ropes or slings onto the designated lifting lug. Never attach the shackle
or sling onto the bucket tips. Loosened
bucket tips could cause the load to fall.
●Never leave the operator seat when lifting
is in progress.
●To prevent the load from hitting any person
or building, inspect carefully the machine
surroundings before swinging or operating
the work equipment.
●Never swing or operate the work equipment suddenly. This may cause the load
to drift and the machine to tip over. Use a
drag rope if necessary.
●Never use the work equipment or the
swing force to drag the load in any direction. The work equipment will jerk if the
shackle breaks and the load comes free,
resulting in serious personal injury.
Fig. 2-83
Fig. 2-84
Fig. 2-85
WARNING
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2.5 Precautions for Maintenance
2.5.1 Prior-maintenance precautions
To prevent accidents:
●Understand maintenance procedure before
operation.
●Keep a clean and dry working area.
●Never spray water or steam in the cab.
●Never add lubricant and carry out other
maintenance work when your machine is
moving.
●Keep your hands, feet and clothing away
from rotating parts.
2.5.2 Select a working area
●For maintenance work, select a clean flat
area with plenty of space, ample sunlight
and good ventilation.
●Clean the working area by removing fuel,
lubricant and water, and covering slippery
ground with sand or other absorptive materials.
●Never leave your hammer or other tools at
the working area.
●If a clean, tidy working area cannot be
guaranteed, there would be danger of tipping, thus resulting in personal injury.
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Locked
CZ335-1102075
2.5.3 Preparing the machine
Before maintaining the machine:
●Park the machine on solid and fl at ground.
●Lower the bucket to the ground.
●Place blocks under the tracks to prevent
movement of the machine.
●Turn the fuel control dial to fi rst gear. Run
the engine at low speed for 5 minutes.
●Turn the start switch to OFF position and
stop the engine.
●Turn the start switch to the ON position.
Operate the control levers 2 or 3 times in
all directions to relieve internal pressure of
the hydraulic system.
●Remove the key from the switch.
●Place the hydraulic lockout control to the
LOCK position.
CZ335-1102073
CZ335-1102074
Fig. 2-86
Fig. 2-87
Fig. 2-88
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CZ335-1102069
CZ335-1102070
CZ335-1102071
2.5.4 Preparing yourself
Only approved personnel can maintain or
repair the machine. An observer may be assigned if necessary.
●Wear protective clothing and shoes necessary for the job.
●Wear rubber apron and rubber gloves
when handling corrosive materials. Wear
heavy gloves when handling wooden materials, wire ropes or sharp-edged metals.
●Wear a face shield when removing spring
or elastic parts, or adding acid to battery.
Wear safety hat and goggles when you
weld or cut with a torch.
●Never carry out grinding, flame cutting or
welding without an aspirator and ventilation
equipment.
●Loud noise may impair your hearing permanent or temporary. When maintaining
the engine, wear ear covers or ear plugs if
you have to work in loud noise for a long
time.
●When using a hammer to strike hard metal
parts such as pin, bucket teeth, cutting
edge or shaft, the fl ying of parts and metal
pieces may cause bodily injury. Therefore,
wear goggles and gloves and ensure the
surrounding area is clear of any other people.
●When compressed air is used for cleaning,
fl ying particles may cause personal injury.
In this case, wear goggles, dust-preventive
mask, gloves and other protective gear.
Fig. 2-89
Fig. 2-90
Fig. 2-91
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Fig. 2-92
Fig. 2-93
Fig. 2-94
CZ335-1102072
CZ335-1102067
CZ335-1102068
2.5.5 Lock-out and tag-out
●When maintenance is underway, starting
the engine or moving the control levers or
pedals could lead to serious accident.
●Before maintenance, attach a Never OPERATE tag or similar sign to the machine's
start switch or control levers to warn others
that this machine is under maintenance.
●Attach other warning tags around the machine if necessary.
2.5.6 Using proper tools
Use proper tools and use them correctly. Using damaged, inferior, defective, temporary
tools or using the tools incorrectly could lead
to serious accidents.
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Locked
CZ335-1102076
2.5.7 Maintenance with engine running
To prevent injury, no maintenance shall be carried out when the engine is running. However,
if maintenance has to be done on a running
engine, at least two worker are needed to carry out the maintenance.
●One of the workers shall stay in the operator seat ready to shut down the engine at
any time. All the workers involved shall
keep in touch.
●Place the hydraulic lockout control to the
LOCK position to prevent movement of
work equipment.
●Pay special attention to rotating parts like
fan and fan belt.
●Never leave or insert any tool or other objects in the fan or the fan belt, which may
cause the parts to break or fl y.
●Never touch any control lever. If one of the
control levers must be used, give signal
to other workers and warn them to move
quickly to a safe area.
CZ335-1102077
Fig. 2-95
Fig. 2-96
Fig. 2-97
CZ335-1102078
2.5.8 Working under the machine
●Never carry out maintenance before the
machine is well supported.
●Lower the work equipment to the ground
before maintaining the machine.
●If the machine or work equipment has to
be lifted for maintenance, blocks or supports that are strong enough to support
the machine or work equipment should be
used. Never use slag bricks, empty tires
or stands to support the machine. These
things may collapse under continuing load.
Never use single jack to support the machine.
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2.5.9 Track maintenance
Never strike the recoil springs of the track.
Recoil springs are under immense pressure and spring rupture may cause bodily
injury. Never remove any spring when it is
compressed.
●Dry rubbing of pin against bushing may
produces extreme heat. Wear protective
gloves to avoid burns.
●Maintain proper track tension. When working on mud- or snow-covered ground, mud
or snow may attach to track components
and causes over tension. Adjust track tension properly.
●Check for loosened or broken track shoes.
Check the pins and bushings for wear or
damages. Check the track rollers and carrier rollers.
WARNING
●If the track shoes are lifted and the machine is solely supported by the work
equipment, it is very dangerous to work
under the machine. In case of failure of hydraulic pipe or accidental touch of control
lever, the work equipment or machine may
fall suddenly, causing injury or death. Never work under the machine if it is not fi rmly
supported with blocks or supports.
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Grease is injected into track tension adjustment system under high pressure. Failure to observe specifi ed maintenance pro-
cedures may cause the grease discharge
plug to eject and cause serious injury and
damage.
1
CZ335-1102080
Fig. 2-98
WARNING
2.5.10 Track tension adjustment precautions
CZ335-1102081
Fig. 2-99
●When loosening the grease discharge plug
(1) to reduce track tension, the plug shall
be unscrewed slowly for no more than one
turn.
●Keep your face, hand, foot or any other
body part away from the grease discharge
plug.
2.5.11 Recoil spring
The recoil springs are used to reduce the impact of tension rollers. It includes a high pressure spring, which may fl y out and cause seri-
ous injury or death if removed improperly.
If it has to be removed, contact your Sany distributor.
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2.5.12 Welding operation
Welding operation may lead to fi re or electro-
cution. Only qualified welders are allowed to
conduct welding operation using proper equipment.
2.5.13 High-pressure hoses
If oil leaks from high-pressure hose, fault or
even fire may occur. If any bolt on hose is
loose, stop operation and tighten it to specifi ed
torque. In case of hose damage, stop operation immediately and contact Sany HM authorized dealer.
Replace the hose immediately in case of the
following problems:
●Damage or leak of hydraulic hose fi tting
●Damage or break of outer cover, or exposed steel wires of reinforcement layer
●Ballooning outer cover in some places
●Distortion or crushing of movable parts
●Impurities in outer cover
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2.5.14 Pressurized fl uid
The hydraulic system is always under pressure. Make sure pressure in hydraulic circuits
has been relieved before checking or replacing the lines. Residual pressure in the circuit
may cause serious accidents.
●Release system pressure before maintaining the hydraulic system: 1) Remove the
butterfly nut of the vent valve and press
the venting button to release the internal
pressure of the hydraulic tank; 2) Turn the
start switch to ON position within 15 seconds after engine shutdown and place the
hydraulic lockout control to FREE position.
Move the control levers to all directions to
release the pressure in the accumulator.
Open fi re is not allowed around the hydrau-
lic system. Remove splashed hydraulic oil
as quickly as possible.
●Diesel oil or pressurized hydraulic oil can
penetrate skin or eyes, causing serious
injury, blindness or death. It is hard to fi nd
the leaking of hydraulic oil with naked eyes.
A cardboard or wooden board is necessary
for checking for leaks. Never touch leaking
liquid with bare hand. Wear face shield or
safety goggles to protect your eyes. If any
liquid penetrates your skin, fl ush with clean
water immediately and get medical attention as soon as possible.
●The fuel lines are under high pressure
when the engine is running. When checking or servicing the fuel system, shut down
the engine and wait for 30 seconds till internal pressure drops before operation.
CZ335-1102082
Fig. 2-100
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Fig. 2-101
Fig. 2-102
2.5.15 Hot cooling system
Touching hot high-pressure coolant may
cause serious injury.
When engine temperature rises, pressure of
the cooling system increases. Before removing the radiator cover, stop the engine and
let the system cool down. The radiator cover
could only be removed after the coolant in it
has cooled down.
2.5.16 Air-conditioning system
CZ335-1102083
●Refrigerant R134 a is a harmless gas
under room temperature. It will change
into highly toxic gas when burning.
●Refrigerant getting into eyes may cause
blindness. It may cause frostbite if
splashed on your skin.
●Keep fi re source away when servicing air-
conditioning system.
●In maintenance of air-conditioning system,
observe the instruction on the refrigerant
cylinder and use it correctly. The type of
refrigerant is R134a. Use of other refrigerants may damage the air-conditioning system.
●Obey local material disposal regulations.
Never discharge refrigerant directly into the
air.
CZ215L-1102001
WARNING
WARNING
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2.5.17 High voltage precautions
When the engine is running or has just been
shut down, high voltage can occur in fuel injector terminal and engine controller. Since
there is danger of electrocution, never touch
fuel injector or interior of engine controller.
Please contact Sany distributor if you have to
access fuel injector terminal or interior of engine controller.
2.5.18 Accumulator
Accumulator contains highly pressurized nitrogen. Improper operation of accumulator
can cause explosion and serious accidents.
Therefore, the following precautions must be
observed:
●Never disassemble the accumulator.
●Never let the accumulator be near a fire
source or exposed in fl ame.
●Never punch, weld or flame-cut on accumulator.
●Never strike or roll the accumulator, or let it
bear any impact.
●The gas must be released when disposing
of the accumulator. Contact Sany distributor for this disposal.
CZ335-1102085
CZ335-1102084
Fig. 2-103
Fig. 2-104
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