PS00012346 SY115 125 135 155H Operation & Maintenance Manual - en A.1

Quality Changes the World
Crawler Hydraulic
Excavator
SY115C9
SY125C9
SY135C9
SY155C9
SY155H
Operation and Maintenance Manual

SY115/125/135/155/155 Crawler Hydraulic Excavator
SY115/125/135/155/155
Crawler Hydraulic Excavator
Operation and Maintenance Manual
WARNING
Please read and follow the safety precautions and instructions in this manual and on the
machine nameplate. Otherwise, severe injuries, deaths or property loss may occur. Please
keep this manual together with the machine for future reference
Operation & Maintenance Manual-Oct. 2019 1

2 Operation & Maintenance Manual-Oct. 2019

Sany Group
Sany Heavy Machinery Limited.
SANY Industrial Park, Economic and Technological Development Zone, Kunshan,
Jiangsu, China
Postcode: 215300
http://www.sany.com.cn
After-sale Service Hotline: 4008 28 2318
Consultation and Complaint Telephone: 4008 28 2333
Since our technologies and products are constantly updated, materials and technical
specifications are subject to change without prior notice. Copyright © 2013 Sany Group,
no part of this manual may be reproduced, transmitted, sold or altered without the
written permission of Sany Group.


Important statements
The wheeled hydraulic excavator is a multipurpose earthwork construction machinery mainly in-
tended for earth excavation and loading, land leveling, slope finishing, hoisting, crushing, demoli-
tion, ditching, and widely applied in highway and railway construction, bridge construction, urban
construction, and construction of airports, ports and water conservancy. The excavator has the
features of bulldozers, loaders and cranes, and can replace them during operation. The machine
is not intended for other purposes than those designated. We do not accept any responsibility for
any consequence of use for purposes other than those designated.
We do not accept any responsibility for the following:
• Consequences of failure to correctly use the machine according to the instructions in the
manual.
• Consequences of unauthorized retrofitting or modification of the machine.
• Equipment damage or accidents caused by failure to use genuine accessories or use of un-
tested or unauthorized accessories or tools.
• Machine faults or damage because of nature disasters (earthquakes, typhoons, etc.), wars and
other force majeure.
We cannot foresee all risks that may occur at the working site; therefore, the machine operators
and customers shall pay high attention to safety issues.
The regions where the machine is used and their local governments may have more strict operat-
ing provisions which shall be observed if they conflict with these rules for safe operation.
Responsibilities of our manufacturer
• Ensure that the machine quality is acceptable and accompanying documents are accurate.
• Fulfill the after-sales service commitment, and document all the maintenance and repair work
performed by after-sales service personnel.
•Provide trainings to the equipment operators and maintenance staff as required.
Responsibilities of customers or other authorized personnel concerned
• Personnel concerned shall be welled trained and fully acquainted with the Parts Catalogue and
the Operation and Maintenance Manual before operating and maintaining the machine.
• Make sure that personnel operating and maintaining the machine are competent and aware of
their respective responsibilities.
• Regularly inspect the safety awareness of personnel concerned in working.
• Immediately stop the machine in the event of any fault influencing safety.
• Our service personnel have the right to carry out the relevant safety check on the machine when
necessary.
• Besides checks specified by Sany, carry out the relevant inspection according to the related reg-
ulations by the country or region where the machine is used.
• Make sure that the machine is timely maintained and repaired.

•Make a use planning carefully and consciously.

Responsibilities of all the operation personnel
• In the event of any abnormalities that may cause abnormal operation of the machine or pose a
potential risk, timely report to the supervisor, and rectify in time if possible.
• All staff working around the machine must obey all the warning signals and caution for safety of
themselves and others.
• All the operation personnel shall be acquainted with the content and procedures of work
activities.
• Observe whether there are dangerous situations such as high voltage wires, irrelevant person-
nel, poor ground condition, and timely warn the operators and signalmen of them .
Responsibilities of management
Make sure that only operators that are well trained, fully understand the content of this manual, en-
joy good health and possess the operation certificate can operate the machine.
• Make sure that only operators with good judgment, cooperation consciousness and psychologi-
cal quality can operate or maintain the machine.
• Make sure that signalmen have good visual and audible judgment, know well standard com-
manding signals and send clear and accurate signals, and possess rich experience in hazard
identification and instruct operators to avoid in time.
• Make sure that assistants can correctly determine the machine model and working condition,
and choose an appropriate machine.
• Assign the corresponding safety responsibility to each operation personnel and ask them to
timely report unsafe factors to the supervisor.

SY115/125/135/155/155 Crawler Hydraulic Excavator Table of Contents
Table of Contents
1 Foreword..............................................................................................................................1-1
1.1 General ...................................................................................................................................1-3
1.2 Safety information .................................................................................................................1-4
1.3 Page description....................................................................................................................1-6
1.4 Introduction ............................................................................................................................1-6
1.4.1 General ..........................................................................................................................1-6
1.4.2 Directions of the machine............................................................................................1-7
1.4.3 Running-in of new machines ......................................................................................1-7
1.5 Product information...............................................................................................................1-8
1.5.1 General ..........................................................................................................................1-8
1.5.2 Machine data plate .......................................................................................................1-8
1.5.3 Engine data plate..........................................................................................................1-8
2 Safety.....................................................................................................................................2-1
2.1 Safety decals .........................................................................................................................2-5
2.1.1 General ..........................................................................................................................2-5
2.1.2 Location .........................................................................................................................2-5
2.1.3 Description.....................................................................................................................2-7
2.2 Safety information .............................................................................................................. 2-17
2.2.1 Safety rules................................................................................................................. 2-17
2.2.2 Handling of abnormalities......................................................................................... 2-17
2.2.3 Personal protective equipment............................................................................... 2-18
2.2.4 Fire extinguisher and first aid kit.............................................................................. 2-19
2.2.5 Safety equipment....................................................................................................... 2-19
2.2.6 Keeping the machine clean ..................................................................................... 2-20
2.2.7 Keeping the cab clean .............................................................................................. 2-20
2.2.8 Locking of safety lock control lever ......................................................................... 2-21
2.2.9 Armrest and ladder.................................................................................................... 2-22
2.2.10 Precautions for working at heights........................................................................ 2-23
2.2.11 Keeping clear of the accessory ............................................................................. 2-23
2.2.12 Don’t get stuck in the articulation section ............................................................ 2-23
2.2.13 Preventing scald...................................................................................................... 2-23
2.2.13.1 Hot coolant........................................................................................................ 2-23
2.2.13.2 Hot oil................................................................................................................. 2-24
2.2.14 Fire and explosion prevention ............................................................................... 2-25
2.2.14.1 Fire caused by fuel or engine oil .................................................................... 2-25
2.2.14.2 Fire caused by inflammable materials .......................................................... 2-26
Operation & Maintenance Manual-Oct. 2019 I

Table of Contents SY115/125/135/155/155 Crawler Hydraulic Excavator
2.2.14.3 Fire caused by electrical wire......................................................................... 2-26

2.2.14.4 Fire caused by hydraulic circuit...................................................................... 2-26
2.2.14.5 Fire caused by lighting equipment................................................................. 2-26
2.2.14.6 Fire caused by heat shield.............................................................................. 2-26
2.2.15 Actions in case of a fire........................................................................................... 2-27
2.2.16 Windshield cleaning solution ................................................................................. 2-27
2.2.17 Preventing flying components ............................................................................... 2-27
2.2.18 Prevent falling, flying and invading objects ........................................................ 2-28
2.2.19 Accessory installation ............................................................................................. 2-28
2.2.20 Accessory combination .......................................................................................... 2-29
2.2.21 Cab windows glasses ............................................................................................. 2-29
2.2.22 Unauthorized modification ..................................................................................... 2-29
2.2.23 Site survey in advance ........................................................................................... 2-30
2.2.24 Operation on loose ground .................................................................................... 2-31
2.2.25 Don’t approach high voltage cable ....................................................................... 2-32
2.2.26 Ensuring favorable view ......................................................................................... 2-33
2.2.27 Ventilation of working environment....................................................................... 2-33
2.2.28 Prevention of asbestos dust .................................................................................. 2-34
2.2.29 Cab emergency exit ................................................................................................ 2-35
2.3 Safe machine operation .................................................................................................... 2-35
2.3.1 Start ............................................................................................................................. 2-35
2.3.1.1 Boarding the machine safely ............................................................................ 2-35
2.3.1.2 Adjusting the seat............................................................................................... 2-36
2.3.1.3 Fastening safety belt.......................................................................................... 2-36
2.3.1.4 Check before starting the engine..................................................................... 2-36
2.3.1.5 Starting the machine safely .............................................................................. 2-37
2.3.1.6 Engine start in cold weather ............................................................................. 2-38
2.3.1.7 Required auxiliary equipment for start ............................................................ 2-38
2.3.1.8 After starting the engine .................................................................................... 2-39
2.3.2 Operation .................................................................................................................... 2-39
2.3.2.1 Inspection before operation .............................................................................. 2-39
2.3.2.2 Precautions before operation ........................................................................... 2-40
2.3.2.3 Verifying the travel direction ............................................................................. 2-41
2.3.2.4 Safety rules for changing the machine direction ........................................... 2-42
2.3.2.5 Travel safety rules.............................................................................................. 2-44
2.3.2.6 Driving the machine safely ............................................................................... 2-45
2.3.2.7 Operation on slope............................................................................................ 2-47
2.3.2.8 Operation in snowy weather ............................................................................. 2-47
2.3.2.9 Forbidden operation........................................................................................... 2-48
II Operation & Maintenance Manual-Oct. 2019

2.3.3 Parking ........................................................................................................................ 2-50

2.3.3.1 Choosing parking lot .......................................................................................... 2-50
2.3.3.2 Machine shutdown ............................................................................................. 2-51
2.3.4 Transportation............................................................................................................ 2-51
2.3.4.1 Transportation..................................................................................................... 2-51
2.3.4.2 Loading and unloading ...................................................................................... 2-52
2.3.5 Battery......................................................................................................................... 2-53
2.3.6 Towing ......................................................................................................................... 2-55
2.3.7 Lifting objects with the machine .............................................................................. 2-56
2.4 Safe maintenance instruction........................................................................................... 2-57
2.4.1 Pre-maintenance precautions ................................................................................. 2-57
2.4.2 Self-preparation ......................................................................................................... 2-57
2.4.3 Preparation of working area..................................................................................... 2-58
2.4.4 Steps of engine shutdown before maintenance .................................................. 2-59
2.4.5 Warning decal ............................................................................................................ 2-60
2.4.6 Use proper tools ........................................................................................................ 2-60
2.4.7 Maintenance with engine running ........................................................................... 2-61
2.4.8 Work under the machine .......................................................................................... 2-62
2.4.9 Track maintenance.................................................................................................... 2-62
2.4.10 Track tension adjustment ....................................................................................... 2-63
2.4.11 Recoil spring............................................................................................................. 2-64
2.4.12 Be careful of hot cooling system ........................................................................... 2-64
2.4.13 Safe operation of high pressure hose .................................................................. 2-64
2.4.14 Be careful of high pressure liquid.......................................................................... 2-65
2.4.15 Welding operation ................................................................................................... 2-66
2.4.16 Safe maintenance of HVAC group........................................................................ 2-66
2.4.17 High voltage precautions........................................................................................ 2-67
2.4.18 Accumulator ............................................................................................................. 2-67
2.4.19 Preventing the danger of fire and explosion........................................................ 2-68
2.4.20 Regular replacement of safety related parts ....................................................... 2-68
2.4.21 Maintenance operation ......................................................................................... 2-68
2.4.22 Proper waste treatment .......................................................................................... 2-69
3 Technical Specifications.............................................................................................3-1
3.1 Machine Dimensions ............................................................................................................3-3
3.2 Working Ranges....................................................................................................................3-4
3.3 Technical parameters ...........................................................................................................3-5
4 Operation.............................................................................................................................4-1
4.1 Machine general drawing.....................................................................................................4-5
Operation & Maintenance Manual-Oct. 2019 III

4.2 Description of controls and instruments.............................................................................4-6

4.2.1 Display ...........................................................................................................................4-6
4.2.2 Operation method of each page of the display ..................................................... 4-10
4.2.3 Switch.......................................................................................................................... 4-24
4.2.3.1 General ................................................................................................................ 4-24
4.2.3.2 Ignition switch ..................................................................................................... 4-24
4.2.3.3 Throttle control knob .......................................................................................... 4-26
4.2.3.4 Working lamp switch.......................................................................................... 4-26
4.2.3.5 Ceiling lamp switch ............................................................................................ 4-27
4.2.3.6 Wiper switch........................................................................................................ 4-28
4.2.3.7 Washer switch .................................................................................................... 4-28
4.2.3.8 Horn switch ......................................................................................................... 4-29
4.2.3.9 Indoor lamp switch ............................................................................................. 4-29
4.2.3.10 Cigar lighter and auxiliary power supply....................................................... 4-30
4.2.3.11 Preheating indicator lamp ............................................................................... 4-30
4.2.3.12 Charging indicator............................................................................................ 4-30
4.2.4 Control Levers and Pedals....................................................................................... 4-31
4.2.4.1 General ................................................................................................................ 4-31
4.2.4.2 Safety lock control lever .................................................................................... 4-32
4.2.4.3 Travel control levers........................................................................................... 4-33
4.2.4.4 Control levers...................................................................................................... 4-34
4.2.5 Ceiling window ........................................................................................................... 4-36
4.2.6 Windshield .................................................................................................................. 4-37
4.2.7 Doors and windows of cab ....................................................................................... 4-44
4.2.8 Cup Holder ................................................................................................................. 4-45
4.2.9 Ashtray ........................................................................................................................ 4-45
4.2.10 Information pack...................................................................................................... 4-46
4.2.11 Drink box................................................................................................................... 4-46
4.2.12 Emergency exit........................................................................................................ 4-47
4.2.13 Fire Extinguisher ..................................................................................................... 4-47
4.2.14 Controller .................................................................................................................. 4-48
4.2.15 Fuse link ................................................................................................................... 4-48
4.2.16 HVAC group ............................................................................................................. 4-49
4.2.16.1 Control panel .................................................................................................... 4-49
4.2.16.2 Control switch and LCD .................................................................................. 4-49
4.2.16.3 Operation of HVAC .......................................................................................... 4-55
4.2.16.4 Use HVAC carefully ......................................................................................... 4-58
4.2.17 Radio......................................................................................................................... 4-60
4.2.17.1 Control panel .................................................................................................... 4-60
IV Operation & Maintenance Manual-Oct. 2019

4.2.17.2 Control key and LCD ....................................................................................... 4-60

4.2.17.3 Operation .......................................................................................................... 4-62
4.2.18 Door lock................................................................................................................... 4-67
4.2.19 Lock cap ................................................................................................................... 4-68
4.2.19.1 General.............................................................................................................. 4-68
4.2.19.2 Open and close the lock cap .......................................................................... 4-68
4.2.19.3 Open and close the lock cover....................................................................... 4-69
4.2.20 Toolbox...................................................................................................................... 4-71
4.2.21 Lubricating grease pump rack (if assembled) ..................................................... 4-71
4.3 Operation and control of machine.................................................................................... 4-71
4.3.1 Before engine start .................................................................................................... 4-71
4.3.1.1 Routing inspection ............................................................................................. 4-71
4.3.1.2 Inspection before start....................................................................................... 4-73
4.3.1.3 Adjustment before operation ............................................................................ 4-80
4.3.1.4 Operation before engine start........................................................................... 4-85
4.3.2 Engine start ................................................................................................................ 4-87
4.3.3 Engine Preheating..................................................................................................... 4-90
4.3.4 Warm-up operation.................................................................................................... 4-90
4.3.5 Stop the engine.......................................................................................................... 4-91
4.3.6 Machine Operation.................................................................................................... 4-92
4.3.6.1 General ................................................................................................................ 4-92
4.3.6.2 Preparation of moving machine ....................................................................... 4-93
4.3.6.3 Move machine .................................................................................................... 4-94
4.3.6.4 Stop machine...................................................................................................... 4-95
4.3.7 Machine steering ....................................................................................................... 4-95
4.3.7.1 General ................................................................................................................ 4-95
4.3.7.2 Turn the machine when it stops ..................................................................... 4-96
4.3.7.3 In-situ steering .................................................................................................... 4-98
4.3.8 Working mode selection ........................................................................................... 4-98
4.3.9 Control and operation of work equipment.............................................................. 4-99
4.3.10 Prohibited operation.............................................................................................. 4-101
4.3.11 Allowed water depth.............................................................................................. 4-104
4.3.12 Operation on the slope ......................................................................................... 4-105
4.3.12.1 General............................................................................................................ 4-105
4.3.12.2 Downhill traveling .......................................................................................... 4-107
4.3.12.3 Stop engine on the slope .............................................................................. 4-108
4.3.12.4 Cab door when the machine is on the slope .............................................. 4-108
4.3.13 Drive the machine out of the mud ....................................................................... 4-108
4.3.13.1 General............................................................................................................ 4-108
Operation & Maintenance Manual-Oct. 2019 V

4.3.13.2 Track on one side gets stuck in the mud .................................................... 4-108
4.3.13.3 Tracks on both sides get stuck in the mud ................................................. 4-109
4.3.14 Recommended purpose....................................................................................... 4-109
4.3.14.1 General............................................................................................................ 4-109
4.3.14.2 Backhoe operation......................................................................................... 4-109
4.3.14.3 Ditching operation...........................................................................................4-110
4.3.14.4 Loading operation ...........................................................................................4-111
4.3.15 Parking.....................................................................................................................4-111
4.3.16 Machine inspection after daily work.....................................................................4-113
4.3.17 Locking.....................................................................................................................4-114
4.3.18 Operation in cold season ......................................................................................4-115
4.3.18.1 Description of operation in cold season.......................................................4-115
4.3.18.2 After daily work................................................................................................4-115
4.3.18.3 After cold season ............................................................................................4-117
4.3.19 Long-Term Storage ................................................................................................4-117
4.3.19.1 Before storage.................................................................................................4-117
4.3.19.2 During storage.................................................................................................4-118
4.3.19.3 After storage ....................................................................................................4-118
4.3.19.4 Start the engine after long-term storage.....................................................4-118
4.4 Transportation....................................................................................................................4-119
4.4.1 General ......................................................................................................................4-119
4.4.2 Transport methods ...................................................................................................4-119
4.4.3 Machine loading and unloading machine with trailer ......................................... 4-120
4.4.3.1 General .............................................................................................................. 4-120
4.4.3.2 Loading .............................................................................................................. 4-121
4.4.3.3 Securing the machine...................................................................................... 4-123
4.4.3.4 Unloading .......................................................................................................... 4-126
4.5 Lifting.................................................................................................................................. 4-128
5 Maintenance.......................................................................................................................5-1
5.1 Maintenance Guideline ........................................................................................................5-5
5.2 Treatment of Oil, Fuel and Coolant.....................................................................................5-7
5.2.1 Oil....................................................................................................................................5-7
5.2.2 Fuel.................................................................................................................................5-8
5.2.3 Coolant in the cooling system.....................................................................................5-9
5.2.4 Grease ...........................................................................................................................5-9
5.2.5 Storage of engine oil and fuel .................................................................................. 5-10
5.2.6 Filter element ............................................................................................................. 5-10
5.3 Electrical System Maintenance........................................................................................ 5-10
5.4 Wear Parts .......................................................................................................................... 5-10
VI Operation & Maintenance Manual-Oct. 2019

5.5 Recommended Fuel, Coolant and Lubricating Oil ........................................................ 5-12

5.6 Tightening Torque .............................................................................................................. 5-15
5.7 Safety Critical Parts ........................................................................................................... 5-17
5.8 Maintenance Schedule...................................................................................................... 5-18
5.9 Maintenance Procedures.................................................................................................. 5-20
5.9.1 Initial 50-hour maintenance (after the first 50 hours only) ................................... 5-20
5.9.2 Maintenance as demanded...................................................................................... 5-20
5.9.2.1 Checking and tightening track shoe bolts....................................................... 5-20
5.9.2.2 Checking and adjusting track tension ............................................................. 5-21
5.9.2.3 Replacement of bucket...................................................................................... 5-25
5.9.2.4 Replacing bucket teeth (horizontal pin type).................................................. 5-27
5.9.2.5 Adjusting bucket clearance............................................................................... 5-29
5.9.2.6 Checking window washer fluid level and filling washer fluid........................ 5-31
5.9.2.7 Checking and maintaining air conditioning..................................................... 5-32
5.9.2.8 Ceiling window gas spring - inspect ............................................................... 5-34
5.9.3 Checks before startup............................................................................................... 5-36
5.9.4 Maintenance after every 100 h ................................................................................ 5-38
5.9.4.1 Lubricating work equipment.............................................................................. 5-38
5.9.5.1 Checking, cleaning and replacing air filter element ...................................... 5-41
5.9.5.2 Checking and adjusting belt tension of HVAC compressor ......................... 5-45
5.9.6.1 Geberal ................................................................................................................ 5-46
5.9.6.2 Lubricating swing bearing ................................................................................ 5-46
5.9.6.3 Replacing the oil in engine oil pan, and replace the oil filter
element............................................................................................................... 5-47
5.9.6.4 Checking the level of grease in swing pinion and add grease..................... 5-48
5.9.6.5 Replacing fuel primary filter element............................................................... 5-49
5.9.6.6 Secondary fuel filter element - replace ........................................................... 5-51
5.9.6.7 Radiator and oil cooler fins - inspect/clean..................................................... 5-54
5.9.6.8 Cleaning the ventilation/circulation filter of HVAC ......................................... 5-56
5.9.6.9 Checking the oil level in swing gearbox and refilling..................................... 5-59
5.9.6.10 Checking the oil level of travel gearbox and refilling .................................. 5-60
5.9.7 Maintenance after every 1000 h.............................................................................. 5-61
5.9.7.1 General ................................................................................................................ 5-61
5.9.7.2 Hydraulic oil suction filter element - replace................................................... 5-61
5.9.7.3 Swing drive oil - change .................................................................................... 5-63
5.9.7.4 Checking the cab door lock and the front window lock for
fastening............................................................................................................. 5-65
Operation & Maintenance Manual-Oct. 2019 VII

5.9.7.5 Checking the lubricating oil of cab door hinge and front window slide
guide and refill ................................................................................................... 5-66
5.9.7.6 Checking the rocker nut of wiper for looseness............................................. 5-67
5.9.7.7 Checking all fastening parts of the engine exhaust pipe clamp .................. 5-67
5.9.7.8 Checking the fan belt tension and replace the fan belt................................. 5-67
5.9.7.9 Checking the nitrogen pressure in accumulator (for hammer) .................... 5-67
5.9.7.10 Replacing the hydraulic tank breather filter - cleaning/
replacement....................................................................................................... 5-68
5.9.8.1 General ................................................................................................................ 5-68
5.9.8.2 Replacing the oil in final drive case ................................................................. 5-69
5.9.8.3 Hydraulic oil suction filter element - cleaning or replacement ..................... 5-70
5.9.8.4 Checking the nitrogen pressure in accumulator ............................................ 5-71
5.9.8.5 Replacing the engine coolant and cleaning the inside of cooling
system ................................................................................................................ 5-75
5.9.8.6 Checking alternator............................................................................................ 5-77
5.9.8.7 Checking and adjusting engine valve clearance ........................................... 5-77
5.9.9.1 General ................................................................................................................ 5-77
5.9.9.2 Checking water pump........................................................................................ 5-78
5.9.9.3 Checking starter motor ...................................................................................... 5-78
5.9.9.4 Replacing accumulator...................................................................................... 5-79
5.9.9.5 Checking the high pressure pipe clamp for looseness, and the rubber for
hardening ........................................................................................................... 5-80
5.9.9.6 Checking the operation of compressor ........................................................... 5-80
5.9.9.7 Replacing the oil in hydraulic tank ................................................................... 5-81
5.9.10 Maintenance after every 8000 h............................................................................ 5-82
5.9.10.1 Maintenance after every 8000 h .................................................................... 5-82
5.9.10.2 Replacing high pressure pipe clamp............................................................. 5-82
5.9.11 Maintenance after every 10000 h.......................................................................... 5-82
6 Troubleshooting ..............................................................................................................6-1
6.1 Special Instructions...............................................................................................................6-3
6.2 Preparations before Troubleshooting.................................................................................6-4
6.2.1 Checks before troubleshooting...................................................................................6-4
6.2.2 Troubleshooting precautions ......................................................................................6-5
6.2.3 Precautions in Circuit Troubleshooting .....................................................................6-7
6.2.4 Hydraulic components handling precautions ...........................................................6-7
6.2.5 Towing ...........................................................................................................................6-9
VIII Operation & Maintenance Manual-Oct. 2019

6.3 Engine Faults.......................................................................................................................6-11

6.3.1 Faults Diagnosis Table for Engine ...........................................................................6-11
6.3.2 High Water Temperature .......................................................................................... 6-16
6.3.3 Engine Oil Pressure Abnormality (Low Engine Oil Pressure)............................. 6-17
6.3.4 Fuel Run-Out.............................................................................................................. 6-18
6.3.5 Engine Kick-Back ...................................................................................................... 6-21
6.4 Electrical System Failure .................................................................................................. 6-22
6.4.1 Faults Diagnosis Table of Electrical System ......................................................... 6-22
6.4.2 Display Monitor .......................................................................................................... 6-24
6.4.3 Battery......................................................................................................................... 6-27
6.4.3.1 general................................................................................................................. 6-27
6.4.3.2 Removal and Refitting of Battery .................................................................... 6-28
6.4.3.3 Battery Charge .................................................................................................. 6-28
6.4.3.4 Start Engine with Auxiliary Wire....................................................................... 6-29
6.5 Failures of the Hydraulic System .................................................................................... 6-32
6.6 Other Common Failures ................................................................................................... 6-36
7 Accessories and Options ...........................................................................................7-1

7.1 General ...................................................................................................................................7-3
7.2 Hydraulic control components and lines supporting accessories ..................................7-5
7.2.1 Position of components ...............................................................................................7-5
7.2.2 Hydraulic lines...............................................................................................................7-6
7.2.3 Removal and installation of accessories...................................................................7-9
7.2.4 Replacement of hydraulic fluid and hydraulic tank filter....................................... 7-13
7.2.5 Long-term storage ..................................................................................................... 7-14
7.3 Combinations of work equipment .................................................................................... 7-15
7.4 Recommended accessory operation .............................................................................. 7-15
7.4.1 General ....................................................................................................................... 7-15
7.4.2 Hydraulic breaker ...................................................................................................... 7-16
7.4.3 Operation of hydraulic breaker ................................................................................ 7-16
7.4.4 Forbidden operation.................................................................................................. 7-18
7.4.5 Greasing of hydraulic breaker ................................................................................. 7-21
7.5 Quick coupler and control system.................................................................................... 7-22
7.5.1 Operation method of quick coupler......................................................................... 7-22
7.5.2 Precautions for safety operation of quick coupler................................................. 7-23
7.6 Refueling system................................................................................................................ 7-25
7.6.1 Introduction to refueling system .............................................................................. 7-25
7.6.2 Composition of refueling system ............................................................................. 7-25
7.7 Centralized lubrication system ......................................................................................... 7-26
7.7.1 Lubrication scheme and system makeup .............................................................. 7-26
Operation & Maintenance Manual-Oct. 2019 IX

7.7.2 System working principle.......................................................................................... 7-28

7.7.3 Lubrication time setting of electric grease pump .................................................. 7-29
7.7.4 System technical specification ................................................................................ 7-31
7.7.5 Refilling method of electric grease pump............................................................... 7-31
X Operation & Maintenance Manual-Oct. 2019

SY115/125/135/155/155 Crawler Hydraulic Foreword
Excavator
Foreword
1 Foreword..............................................................................................................................1-1
1.1 General ...................................................................................................................................1-3
1.2 Safety information .................................................................................................................1-4
1.3 Page description....................................................................................................................1-6
1.4 Introduction ............................................................................................................................1-6
1.4.1 General .........................................................................................................................1-6
1.4.2 Directions of the machine ..........................................................................................1-7
1.4.3 Running-in of new machines .....................................................................................1-7
1.5 Product information...............................................................................................................1-8
1.5.1 General .........................................................................................................................1-8
1.5.2 Machine data plate......................................................................................................1-8
1.5.3 Engine data plate ........................................................................................................1-8
Operation & Maintenance Manual-Oct. 2019 1-1

Foreword SY115/125/135/155/155 Crawler Hydraulic Excavator
WARNING
Read and understand all safety precautions and instructions in this manual before reading any
other manuals provided with this machine and before operation or maintaining it.Failure to do
this could result in death or serious injury.
1-2 Operation & Maintenance Manual-Oct. 2019

Excavator
1.Foreword
1.1 General
This manual is a guide for correct use of the machine and mainly provides technical and safety in-
formation required in operation. Please be sure to read each part of it carefully.
Only qualified and experienced operators with an official license (according to local laws) can oper-
ate the machine.
Make sure that the relevant laws and regulations of the state, a province, an autonomous region or
a municipality are always observed in operation of the machine, and the operation safety informa-
tion and instructions contained herein are only provided as suggestions and cautions.
We cannot foresee all situations in operation and maintenance that may pose risks. Therefore, the
safety information in this manual and on the machine do not contain all the possible safety meas-
ures. When methods or actions other than those specifically recommended or allowed in this man-
ual are used or taken, you are obliged to take necessary measures to ensure safety.
Unauthorized retrofitting or abuse of the machine may influence the performance or even cause
greater safety hazard, for instance, settings more than the specified fuel quantity may overload the
machine. Please drive and use the machine carefully, as faulty operation and misuse may also
cause damage, and we do not accept any responsibility for the loss thus caused.
The machine referred to in this manual is used for various operations under normal conditions;
please do not use it in an inflammable and explosive place or an area with asbestic dust.
Please use Sany excavators for highland work for applications in areas at an altitude over 2000 m.
This machine is subject to the electromagnetism and capacitance test according to EN 13309-
2000. Therefore, all the unapproved electronic auxiliary devices such as communication apparatus
shall be tested before installation and use to ensure that they will not produce electromagnetic in-
terference to the machine.
All data, charts and specifications in this manual are the latest product information available at the
time of publication. We reserve the right to alter the above information without notice. Please con-
tact us or our authorized dealer for the latest product information or the problems related to the in-
formation covered in this manual.
Scope of application of machine of normal series: altitude below 2000 m, atmospheric tempera-
ture: -20°C ~ 40°C.

CAUTION
Before operation and maintenance, the operators and maintenance personnel must do the
following:
• Be sure to read through and understand this manual.
• Read and fully understand the safety notices in the manual and safety labels on the machine.
• Shall in no circumstances use the machine for applications or operations forbidden in the
manual.
• If fuel amount, particulate size or latitude exceeds the upper limit specified for the model and
application, it may result in injuries and is not covered by the warranty.
• Always keep the manual in the cab for reference at anytime.
• Immediately contact our authorized dealer for reissue or replacement if this manual is lost or
stained and thus unreadable.
• This manual shall be deemed as a permanent part of the machine, so please be sure to hand it
over to a new user together with the machine if you resell it.
• Hydraulic excavators that provided by Sany Heavy Machinery Co., Ltd. to the country of pur-
chase meet all applicable regulations and standards. Purchasing from another country or a per-
son of another country may deprive you of some safety devices and specifications necessary
for use in your country. If you have any questions about hydraulic excavator’s compliance with
national standards and regulations for use, contact your Sany Heavy Machinery Co., Ltd. au-
thorized distributor before using it.
1.2 Safety information

For safe use of the machine, this manual contains and explains the safety precautions and labels
attached to the machine, to provide a description of potential hazards involved and methods to
avoid them.
Before operation and maintenance, users and after-sales service personnel must get familiar with
the warning signs and symbols on the machine, strictly observe the safety rules and recommenda-
tions in this manual, and actively take safety precautions and countermeasures to minimize the
risks of personal injuries, machine damage due to improper repair or the risks due to unsafe
factors.
1.Safety warning
A safety warning comprises an attention symbol and signal words, used as a reminder of potential
hazards that may cause personal injuries or damage. Safety warnings can be classified by signal
words according to the severity of hazardous situations.
Three types of signal words are used in this manual: DANGER, WARNING and CAUTION, each
representing the following:
DANGER
Existing dangers that, if not evaded, will cause deaths or severe injuries.

Excavator
WARNING
Potential dangers that, if not evaded, may cause deaths or severe injuries.
CAUTION
Potential dangers that, if not evaded, may cause light or moderate injuries. “CAU-
TION” statements may also be used in some occasions as a reminder of unsafe operations that
may cause personal injuries, damage to the machine and environment.
Examples of safety warnings
WARNING
• Before standing up from the driver seat, make sure to set the control lever to the LOCK
position.
• Severe injuries or deaths can occur if the control lever is not locked and touched by accident.
2.Safety decals
A safety decals is attached to the machine to remind the operators or maintenance personnel of
potential hazards during operation or maintenance.
The "literal safety decals" and "graphic safety decals " are used on the machine to represent safety
measures.
a. Examples of literal safety decals
Fig.1-1

b. Examples of graphic safety decals Safety

icons are graphic representations of the se-
verity of hazards, equivalent to the literal
statement. Graphics are used in these safety
icons to keep operators or maintenance per-
sonnel informed of the type and severity of
hazards.
In the figure on the right, the safety icon above

represents the type of hazard and the icon be-
low indicates the method to avoid it.
Fig.1-2
1.3 Page description

1. For the purpose of this manual, the page is
numbed by chapter.
Example:
Page 20 in Chapter 3
Chapter 3
1.4 Introduction
1.4.1 General
Sany hydraulic excavator is designed for:
Excavation
Leveling
Ditching
Loading
Demolition

Excavator
Please refer to the relevant part of this manual in detail.
Numbers in illustrations are corresponding to those in 【】in the text. (Example: 1→【1】).
The international system of units (SI) is used in this manual.
1.4.2 Directions of the machine
1. Directions of the machine
In this manual, the front, back, left and right

are directions of travel when seen from the
cab with the cab facing forward and the driv-
ing wheel behind the machine.
【A】Front
【B】Rear
【C】Left
【D】Right
【E】Driver seat
【F】Driving wheel
Fig.1-3
1.4.3 Running-in of new machines
Our machines are fully commissioned and tested before delivery. However, keeping machines at
full load before running-in process will seriously affect the performance and shorten the useful life.
Be sure to carry out running-in within the initial 100 h (according to the indication of working hours
on the display).
Be sure that you are fully aware of the content of this manual and note the following during the run-
ning-in process:
After start-up, keeping the machine idling for 3 ~ 5 min. During this time, do not operate the control
lever or fuel control knob, and then slowly set the engine to 1500 rpm until the coolant temperature
reaches about 60°C.
Avoid high-speed operation at heavy load.
Avoid abrupt engine start, and do not accelerate or shut down the engine or change the machine
direction abruptly after engine start.

1.5 Product information

1.5.1 General
To maintain, order or replace components, please inform our authorized dealer of the following:
1.5.2 Machine data plate
The machine data plate is at lower right of the cab (as shown below).
Environmental Protection Information Label

Conforming to China III emission standard specified Production date
in GB 20891-2014.
Environmental protection information
disclosure number: CN F J G 3 00
Model: Product name: Brand: SANY
General Hydraulic excavator
information Name of machine manufacturer: Sany Heavy Machinery Co., Ltd. Type of machine: Engineering
Engine model: machinery
Type of fuel injection
Name of engine manufacturer:
system
Critical parts for
environmental protection
Fig.1-4
1.5.3 Engine data plate
The engine data plate is located as shown below. The location of the engine data plate may vary
with the engine type.
ISUZU Engine

Excavator
Type approval according to the Emission Standard

for the Diesel Engines of Non-road Mobile
Machinery (China III)
Family name
Engine model
Engine power
Manufacturer Isuzu Motors Limited
Production date
Power range
Type approval
number
Engine number
Fig.1-5


SY115/125/135/155/155 Crawler Hydraulic Safety
Excavator
Safety
2 Safety.....................................................................................................................................2-1
2.1 Safety decals .........................................................................................................................2-5
2.1.1 General .........................................................................................................................2-5
2.1.2 Location ........................................................................................................................2-5
2.1.3 Description ...................................................................................................................2-7
2.2 Safety information .............................................................................................................. 2-17
2.2.1 Safety rules ............................................................................................................... 2-17
2.2.2 Handling of abnormalities ....................................................................................... 2-17
2.2.3 Personal protective equipment ............................................................................. 2-18
2.2.4 Fire extinguisher and first aid kit ............................................................................ 2-19
2.2.5 Safety equipment ..................................................................................................... 2-19
2.2.6 Keeping the machine clean ................................................................................... 2-20
2.2.7 Keeping the cab clean ............................................................................................. 2-20
2.2.8 Locking of safety lock control lever........................................................................ 2-21
2.2.9 Armrest and ladder .................................................................................................. 2-22
2.2.10 Precautions for working at heights ...................................................................... 2-23
2.2.11 Keeping clear of the accessory ............................................................................ 2-23
2.2.12 Don’t get stuck in the articulation section ........................................................... 2-23
2.2.13 Preventing scald..................................................................................................... 2-23
2.2.13.1 Hot coolant....................................................................................................... 2-23
2.2.13.2 Hot oil ............................................................................................................... 2-24
2.2.14 Fire and explosion prevention.............................................................................. 2-25
2.2.14.1 Fire caused by fuel or engine oil................................................................... 2-25
2.2.14.2 Fire caused by inflammable materials......................................................... 2-26
2.2.14.3 Fire caused by electrical wire........................................................................ 2-26
2.2.14.4 Fire caused by hydraulic circuit .................................................................... 2-26
2.2.14.5 Fire caused by lighting equipment ............................................................... 2-26
2.2.14.6 Fire caused by heat shield ............................................................................ 2-26
2.2.15 Actions in case of a fire ......................................................................................... 2-27
Safety SY115/125/135/155/155 Crawler Hydraulic Excavator
2.2.16 Windshield cleaning solution................................................................................ 2-27

2.2.17 Preventing flying components.............................................................................. 2-27
2.2.18 Prevent falling, flying and invading objects ....................................................... 2-28
2.2.19 Accessory installation............................................................................................ 2-28
2.2.20 Accessory combination ......................................................................................... 2-29
2.2.21 Cab windows glasses............................................................................................ 2-29
2.2.22 Unauthorized modification.................................................................................... 2-29
2.2.23 Site survey in advance .......................................................................................... 2-30
2.2.24 Operation on loose ground ................................................................................... 2-31
2.2.25 Don’t approach high voltage cable ...................................................................... 2-32
2.2.26 Ensuring favorable view........................................................................................ 2-33
2.2.27 Ventilation of working environment ..................................................................... 2-33
2.2.28 Prevention of asbestos dust ................................................................................. 2-34
2.2.29 Cab emergency exit............................................................................................... 2-35
2.3 Safe machine operation .................................................................................................... 2-35
2.3.1 Start............................................................................................................................ 2-35
2.3.1.1 Boarding the machine safely........................................................................... 2-35
2.3.1.2 Adjusting the seat ............................................................................................. 2-36
2.3.1.3 Fastening safety belt ........................................................................................ 2-36
2.3.1.4 Check before starting the engine.................................................................... 2-36
2.3.1.5 Starting the machine safely ............................................................................. 2-37
2.3.1.6 Engine start in cold weather ............................................................................ 2-38
2.3.1.7 Required auxiliary equipment for start........................................................... 2-38
2.3.1.8 After starting the engine................................................................................... 2-39
2.3.2 Operation................................................................................................................... 2-39
2.3.2.1 Inspection before operation............................................................................. 2-39
2.3.2.2 Precautions before operation.......................................................................... 2-40
2.3.2.3 Verifying the travel direction ............................................................................ 2-41
2.3.2.4 Safety rules for changing the machine direction .......................................... 2-42
2.3.2.5 Travel safety rules............................................................................................. 2-44
2.3.2.6 Driving the machine safely ............................................................................. 2-45
2.3.2.7 Operation on slope .......................................................................................... 2-47
2.3.2.8 Operation in snowy weather............................................................................ 2-47
2.3.2.9 Forbidden operation ......................................................................................... 2-48
2.3.3 Parking....................................................................................................................... 2-50
2.3.3.1 Choosing parking lot......................................................................................... 2-50
2.3.3.2 Machine shutdown............................................................................................ 2-51
2.3.4 Transportation........................................................................................................... 2-51
2.3.4.1 Transportation ................................................................................................... 2-51
2.3.4.2 Loading and unloading..................................................................................... 2-52
2.3.5 Battery........................................................................................................................ 2-53
Excavator
2.3.6 Towing........................................................................................................................ 2-55

2.3.7 Lifting objects with the machine ............................................................................. 2-56
2.4 Safe maintenance instruction........................................................................................... 2-57
2.4.1 Pre-maintenance precautions ................................................................................ 2-57
2.4.2 Self-preparation........................................................................................................ 2-57
2.4.3 Preparation of working area ................................................................................... 2-58
2.4.4 Steps of engine shutdown before maintenance ................................................ 2-59
2.4.5 Warning decal........................................................................................................... 2-60
2.4.6 Use proper tools ....................................................................................................... 2-60
2.4.7 Maintenance with engine running.......................................................................... 2-61
2.4.8 Work under the machine ......................................................................................... 2-62
2.4.9 Track maintenance .................................................................................................. 2-62
2.4.10 Track tension adjustment...................................................................................... 2-63
2.4.11 Recoil spring ........................................................................................................... 2-64
2.4.12 Be careful of hot cooling system.......................................................................... 2-64
2.4.13 Safe operation of high pressure hose ................................................................. 2-64
2.4.14 Be careful of high pressure liquid ........................................................................ 2-65
2.4.15 Welding operation.................................................................................................. 2-66
2.4.16 Safe maintenance of HVAC group ...................................................................... 2-66
2.4.17 High voltage precautions ...................................................................................... 2-67
2.4.18 Accumulator............................................................................................................ 2-67
2.4.19 Preventing the danger of fire and explosion ...................................................... 2-68
2.4.20 Regular replacement of safety related parts...................................................... 2-68
2.4.21 Maintenance operation ....................................................................................... 2-68
2.4.22 Proper waste treatment......................................................................................... 2-69

WARNING

Excavator
2.Safety
2.1 Safety decals

2.1.1 General
This machine uses the following warning and safety decals.
• Make sure to know clearly the location and content of the decals.
• Please keep the decals in the right positions and clean to ensure their readability. Do not clean
the decals with organic solvent or gasoline, which may peel off the decal paint.
• Treat other decals in the same way as warning and safety decals.
• When the decals are damaged, lost or unreadable, please replace them. As for detail of decal
part number, please see this manual or the actual decals.
2.1.2 Location
1. 2.1.1Location
Emergency exit
WARNING
Fig.2-1

Safety SY 9/ C
Fig.2-2

Excavator
2.1.3 Description
[1] Seat belt warning decal
Fig.2-3
[2] High voltage warning decal
• This decal indicates if the machine is too

close to the power transmission line, there
will be the danger of electric shock.
• Keep the safety distance from the power
transmission line.
Fig.2-4
[3] Cab seat adjustment instruction decal
Fig.2-5

[4] "Read manual" warning decalt
• Please read this manual before operation,

maintenance, disassembly, assembly and
transportation of the machine.
A820601990971
Fig.2-6
[5] Power-off warning decal
• Before leaving the machine, lower the work

equipment to the ground, secure the lockout
lever in the LOCKED position and remove
the ignition key
.
A820699001020
Fig.2-7
[6] Emergency exit decal
Emergency exit
Fig.2-8

Excavator
[7] Front window lockout warning decal
• This decal indicates the danger of the front

window falling down.
• After raising the front window, please lock it

with the lock pin.
Fig. 2-
A820699001019
Fig.2-9
[8] Unlocking instruction decal
Fig.2-10
[9] Operation instruction decal
• To avoid casualty during operation, please

verify the running status of the machine and
the displayed running mode, pay attention
to the surrounding environment and operate
the machine slowly.
A820601990961
Fig.2-11

[10] “No tilting during working” warning decal
Fig.2-12
[11] "No climbing" warning decal
WARNING
Fig. 2
Fig.2-13

Excavator
[12] Noise level decal
115C9/125C9/135C9/155C9/
Fig.2-14
[13] Center of gravity decal
Fig. 2-14
Fig.2-15
[14] Track tension adjustment warning decal Fig. 2-15
• Don’t loosen the track more than 1 turn, or

there will be the danger of injury caused by
the flying regulating valve under high
pressure.
Fig. 2-16
Fig.2-16

[15] Shipping tie-down decal
Fig.2-17
[16] Swing bearing greasing warning decal Fig. 2-17
Fig. 2-18
Fig.2-18
[17] Lift point decal
Fig. 2-19
Fig.2-19

Excavator
[18] "No entry" warning decal
• The decal indicates there is the danger of

being collided by the machine, please don’t
enter the turning circle of the machine.
being collided by the machine, please don’t
enter the turning circle of the machine.
Fig.2-20
Fig. 2-20
[19] Work equipment caution decal

being collided by the work equipment.
• Keep away from the machine when it is
operating.
Fig. 2-21
Fig.2-21
[20] Fall warning decal
• There may be the danger of falling.

• Don’t stay close to the edge of the machine. Fig. 2-22
Fig.2-22

[21] "Injury by fan” warning decal

Fig. 2-24
• Please keep away from the rotary object to

avoid injury.
Fig.2-23
[22] Belt safety warning decal
• This decal indicates the danger of the rotary

belt.
• Please stop the belt before maintenance.
Fig.2-24

Excavator
[23] "Stand clear of the area" warning decal
• Stand clear of the area as there may be the

danger of falling.
Fig.2-25 Fig. 2-25
[24] Anti-spray warning decal
• Please release the tank pressure in accord-

ance with the operation instruction before
opening the tank cover like fuel tank cover,
and open the cover slowly to avoid
Fig. 2-26
spraying.
Fig.2-26
[25] Hot surface warning decal
• Please don’t touch the hot surface to avoid

Fig. 2-27
scald.
Fig.2-27

[26] No-sitting warning decal
Fig.2-28
[27] Hydraulic oil warning decal

Fig. 2-28
Fig. 2-29
Fig.2-29
[28] Diesel fuel tank warning decal
Fig. 2-30
Fig.2-30

Excavator
2.2 Safety information

2.2.1 Safety rules
• Only trained workers can be assigned to

operate and maintain the machine..
• Please abide by all safety rules, precautions

and instructions when operating and main-
taining the machine.
• Alcohol and medicine will severely reduce/

weaken workers’ ability to operate or main-
tain the machine in a safe manner, endan-
gering himself/herself and other people on
the site.
• When working with another operator or a

commander, please keep all informed of all
adopted hand signals.
2.2.2 Handling of abnormalities
When any abnormalities (noise, vibration,

odor, incorrect instrument display, smoke, oil
leakage and etc. or any abnormal display in
the warning device or monitor) are discovered
in the process of operation and maintenance,
please report to the supervisor and take nec-
essary measures. Don’t operate the machine
before removing all faults.

2.2.3 Personal protective equipment
equipment required by working conditions.

You may need:
• Hard hat
• Safety shoes
• Safety glasses, goggles or face shield
• Protective gloves
• Hearing protection CZ335-1102002
• Reflective clothing Fig.2-31
• Wet weather gear
• Respirator or filter mask
Wear necessary safety protection equipment

and the equipment required by the employer,
the public service management department,
and the government, as well as laws and reg-
ulations. Don't take chances to avoid un-
necessary danger.
WARNING
• Don’t wear accessories and loose
clothes. There will be the danger of
hooking the control lever or other pro-
truding components.
• If the hair is too long and exposed out
of the helmet, there will be the danger
of intertwining in the machine.
• Wear the helmet and safety shoes all
the time. If necessary, please wear
safety glasses, mask, gloves, earplug
and safety belt when operating or main-
tain the machine.
• Please check that all protective equip-
ment function normally before use.

Excavator
2.2.4 Fire extinguisher and first aid kit
To prevent injury or fire, please observe the

following precautions:
• Prepare first-aid kit and fire extinguisher

nearby.
• Please read the instruction attached on the

fire extinguisher carefully to ensure proper
use of the fire extinguisher.
• Please check and maintain the fire extin- CZ335-1102003
guisher regularly to ensure it’s available at

Fig.2-32
any time.
• Please check the first-aid kit regularly and

add medicine if necessary.
• Establish emergency plan to deal with fire

and accident.
2.2.5 Safety equipment
To protect you and the people around, your

machine can be equipped with the following
safety equipment. Please ensure each one is
fixed in the right position and in the working
condition.
• Falling object protective structures
• Protective guard
• Guard board CZ335-1102004
• Lamps Fig.2-33
• Safety decals
• Horn
• Travel warning
• Mirror
• Fire extinguisher
• First aid kit

Please ensure all equipment above is avail-

able. You are forbidden to take down or dis-
connect any safety equipment.
CAUTION
• Please ensure all equipment above is
available. You are forbidden to take
down or disconnect any safety
equipment.
• Understand how to use safety equip-
ment and use it correctly.
• Don’t take down the cab protective
guard without authorization (except ma-
chine maintenance).
2.2.6 Keeping the machine clean
• Clean the wiper, mirror and lamps. Clean

away grass, snow, ice or mud in operation
area, steps and handles in time. Remove
the mud on shoes before entering the
machine.
• Checking and maintaining the machine with

mud or greasy dirt will cause the danger of
slipping, falling or dirt entering eyes. Keep
CZ335-1102005
the machine clean all the time.
• If water enters the electrical system, don’t Fig.2-34

hurry to start the power or the engine, which
could cause machine failure, computer
mainboard damage or other malfunctions.
Don’t wash the electrical system (sensor,
connector etc.) by water or vapor.
2.2.7 Keeping the cab clean
• Please remove the mud and grease on

shoes before entering the cab, or there will
be severe accident caused by slip when
treading the pedal.

Excavator
• Store scattered objects in the toolbox, and

don’t put them in the cab casually.
• Don’t use mobile phone when operating or

driving the machine.
• Don’t bring dangerous objects such as in-

flammable and explosive materials into the
cab.
2.2.8 Locking of safety lock control lever
• Before standing up from the seat (for pur-

poses such as opening or closing the front
window and skylight, removing or installing
bottom window, or adjusting the seat),
please lower down the work equipment fully
to the ground, firmly turn the safety lock
control lever to the lock position and shut
down the engine. If the control lever or the
pedal isn’t locked, the machine may move
CC13031805
suddenly and lead to serious personal injury
or machine damage. Fig.2-35
• Before leaving the machine, make sure to

lower down the work equipment fully to the
ground, firmly turn the safety lock control
lever to the lock position and shut down the
engine. Lock all equipment with the key,
take off the key and put it in the specified
place.
CZ335-1102074
Fig.2-36

2.2.9 Armrest and ladder
CAUTION
• Face the machine all the time when en-
tering and leaving the machine.
• Don’t jump up to or down from the ma-
chine, don’t climb it when it travels, and
don’t jump up to it to try to stop it.
• Before entering and leaving the cab, be
sure to check that it is in the front
position.
To prevent personal injury due to slipping or

falling down from the machine, please comply
with the following:
• Check the armrest and ladder (including the

track shoe) before entering and leaving the
machine. If there is oil, grease or mud on
the armrest or ladder (including the track
shoe), please clean it away at once and
keep all these parts clean; if these parts are
damaged, please repair them and tighten
the loose bolts.
• Please use the arrow marked armrests and CZ335-1102008
ladder shown on the right when entering Fig.2-37

and leaving the machine.
• To ensure safety, please face the machine

and keep three body parts (two feet and
one hand or two hands and one foot) touch
the armrests and ladder (including the track
shoe) to support the body.
• Don’t grasp or hold the control lever or lock

lever.
• Don’t enter or leave the machine with tool in

the hand.
• Don’t climb the engine head or cap without

anti-skid mat.

Excavator
2.2.10 Precautions for working at heights
When working at heights, please use steplad-

der or other brackets to ensure safe
operation.
2.2.11 Keeping clear of the accessory
Don't allow anyone to sit on the work equip-

ment or other accessories because there will
be the danger of falling and severe injury.
2.2.12 Don’t get stuck in the articulation section
The interspace around the work equipment

will change with the movement of the link.
Getting stuck in it will lead to severe injury.
Don’t allow anyone to approach the rotating or
stretching part.
2.2.13 Preventing scald
2.2.13.1 Hot coolant
• To prevent scald caused by squirt of hot

coolant or vapor, please wait for full cooling
of the coolant before checking or draining
the hot coolant.
• Do not 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
CZ335-1102011
avoid serious scalds.
Fig.2-38

2.2.13.2 Hot oil
To prevent scald caused by squirt of hot oil,

please wait for full cooling of coolant before
checking or draining the oil. Even the oil is
cold, be sure to slowly loosen the cap or the
screw plug before removing it to release the
internal pressure.
CZ335-1102012
Fig.2-39
CZ335-1102013
Fig.2-40

Excavator
2.2.14 Fire and explosion prevention
2.2.14.1 Fire caused by fuel or engine

oil
• Fuel and engine oil shall be stored in the

specified place. Don't approach it without
permission.
• Forbid smoking or open fire near fuel and

engine oil.
• Check if the pipe clamp is lost or slack, the

hose is twisty or knotting, hose and pipeline
rub each other, oil cooler is damaged, the CZ335-1102014
flange bolt of the oil cooler is slack, to pre-

Fig.2-41
vent fuel/oil leakage; and tighten, repair or
replace any lost, slack or damaged clamp,
pipeline, hose, oil cooler and its flange bolt.
• Add or store fuel and engine oil in a well-

ventilated place.
• Shut down the engine before refilling.
• Don’t leave the machine when refilling it

with fuel and engine oil.
CZ335-1102015
• Don’t spill the fuel to the overheated surface
or electrical system component. Fig.2-42
• Wipe off spilled fuel or engine oil in time

after refilling with fuel or engine oil.
• Place the cleaning cloth with oil or other in-

flammable materials into the safety contain-
er to ensure the safety of the work site.
• Firmly tighten the fuel and engine oil tank

covers.
• If required, please rinse the components

with nonflammable oil. Do not rinse compo-
nents with diesel or gasoline as it is
inflammable.

• Before conducting grinding or welding oper-

ation on the chassis, make sure to move all
inflammable materials to a safe place.
• Don’t weld the pipeline containing inflam-

mable liquid or cut it through the cutting
torch.
2.2.14.2 Fire caused by inflammable materials
• Eliminate dry leaves, wood chips, paper scraps, dust and other inflammable objects stacking or
sticking around the engine, exhaust manifold, silencer and battery or inside the hood.
2.2.14.3 Fire caused by electrical wire
The short circuit of the electrical system will lead to fire.
• Keep the connector of the electrical wire clean and fix it firmly.
• After operation for 8~10 h, check if the cable or electrical wire is slack, twisty or knotting, hard or
broken; and check if the connector end cap is lost or damaged at the same time.
• When the cable or wire is slack, twisty or knotting, firmly tighten the slack connector or wire
clamp, straighten out the routing, and repair or replace damaged electrical wire.
2.2.14.4 Fire caused by hydraulic circuit
• Check if all clamps, caps and cushions of hoses and pipeline are fixed in the right places.
• If any is loose, it will vibrate and rub with other components, leading to hose damage, high pres-
sure oil squirt, which will cause fire hazard or severe injury.
2.2.14.5 Fire caused by lighting equipment
• Make sure to use explosion proof lighting equipment when checking fuel, engine oil, battery
acid, window cleaning solution or coolant. Otherwise, there will be the danger of explosion, lead-
ing to severe injury.
• When using the electric power of the machine as the lighting, please follow the regulations in this
manual.
2.2.14.6 Fire caused by heat shield
• Lost or damaged heat shield will cause fire.
• If any abnormalities are discovered, please repair or install a new heat shield before operation.

Excavator
2.2.15 Actions in case of a fire
If there is a fire, please leave the machine

quickly as per the following requirements.
• Turn the starter switch to OFF position to

shut down the engine.
• Leave the machine by the armrest and

ladder.
2.2.16 Windshield cleaning solution
Please use ethanol-based cleaning solution

instead of methanol-based cleaning solution
as the later one can hurt eyes.
2.2.17 Preventing flying components
The grease in the track tensioning regulating

device is under high pressure, therefore if the
following precautions aren't observed, acci-
dents of severe injury, blindness or death may
occur:
• Do not disassemble grease nozzle or valve

components. These parts may eject. Keep
your body and face away from the valve.
CZ335-1102016
• Pressure exists inside the travel drive
assembly. Fig.2-43
• Gear oil is hot, so make sure to wait for

cooling of gear oil before gradually loosen-
ing the air exhaust plug to release pressure.
Because parts may fly off, please keep the
body and face away from the air exhaust
plug to avoid injury.

2.2.18 Prevent falling, flying and invading objects
On the dangerous work site where falling, fly-

ing and invading objects would hit or enter the
cab, install necessary protection shield to pro-
tect the operator according to the operation
conditions.
• When conducting removal or breaking oper-

ation, install front protection shield and
paste transparent cellophane on the front
window. CZ335-1102017
• When operating in a mine or quarry with the Fig.2-44

risk of rock falling, install FOPS (Falling Ob-
ject Protective Structures) and front protec-
tion shield, and paste transparent
cellophane on the front window; and opera-
tor shall wear helmet and protective
glasses.
• When conducting the above operation,

please close the front window. In addition,
ensure that other workers keep proper
safety distance from the falling hazard
zone.
• The conditions described above are typical

working conditions, and there may be other
protective shields required to install based
on the site conditions. Please contact the
agents authorized by Sany Heavy Machi-
nery Co., Ltd. in advance.
2.2.19 Accessory installation
• Issues of safety or legal restraint are exist-

ing for installation of options or accessories.
Therefore, please contact the agents au-
thorized by Sany Heavy Machinery Co.,
Ltd.
• For any injury, accidents or product mal-

function caused by use of unapproved

Excavator
accessory or part, Sany Heavy Machinery

Co., Ltd takes no responsibility.
• When installing and using purchased ac-

cessory, please read the instruction manual
of related accessory and the general in-
struction of related accessory in this
manual.
2.2.20 Accessory combination
Different types or combinations of work equip-

ment may lead to the danger of colliding with
the cab or other parts of the machine. Before
using unfamiliar work equipment, please
check if there is the danger of collision and be
careful to operate.
2.2.21 Cab windows glasses
• f the cab window glass near the side of the

work equipment is damaged or broken,
there will be the danger of the work equip-
ment touching the operator’s body. In that
case, please stop operation at once and
change glass.
• If the skylight is damaged and fails, please

replace it with new glass.
2.2.22 Unauthorized modification
Machine retrofit, unauthorized by Sany Heavy

Machinery Co., Ltd, may lead to safety issues
and personal injury. Retrofit will have severe
influence on the strength and view of the ma-
chine. Before any retrofit, please contact the
agents authorized by Sany Heavy Machinery
Co., Ltd. For any accident, malfunction or
damage caused by unauthorized retrofit, Sany
Heavy Machinery Co., Ltd will take no
responsibility.

2.2.23 Site survey in advance
• During operation near such inflammable

materials as grass roof, dry leaves or dry
grass, there will be the danger of fire, so
please be careful during operation.
• Check the terrain and ground conditions of

the work site and determine the safest oper-
ation methods. Don’t operate the machine
in dangerous zones of landslide or rockfall.
CZ335-1102018
• During operation in dangerous areas such
as near-ditch area or road shoulder, please Fig.2-45
reinforce the ground based on the actual
need and keep the safety distance from the
machine to the near-ditch area or road
shoulder. Assign a signalman to command
when necessary to prevent casualty.
• If there are pipelines such as water pipe,

gas pipe, cable or high voltage electrical
wire buried under the ground, please con-
tact related public administration depart- CZ335-1102019
ments and mark the positions before

Fig.2-46
operation and pay attention not to breaking
or damaging any pipeline.
• Take necessary measures to prevent any-

one without access permission from enter-
ing the operation area. During operation on
the road, please assign a signalman to in-
stall a retaining plate to ensure smooth traf-
fic and pedestrian safety.
• During operation on the frozen ground,

please be cautious, because the increasing
environment temperature will make the
foundation soft, wet and slippery.
• When the machine travels or is operated in

shallow water or soft ground, please check

Excavator
the type and conditions of the bedrock as

well as the depth and flow rate of water.
2.2.24 Operation on loose ground
• Avoid the traveling and operation of the ma-

chine near the cliff, on the road shoulder
and deep ditch. In these areas with soft
ground, there is the danger of the machine
falling or rollover because of the weight of
the machine and vibration. Please notice
that the ground will be much softer after
heavy rain, blasting or earthquake.
• During operation on the dam or near the

digging ditch, there is the danger of ground
subsidence because of the weight of the
machine and vibration. Before operation,
please take measures to ensure ground
safety and prevent machine rollover or
falling.

2.2.25 Don’t approach high voltage cable
Don’t operate the machine or control it to trav-

el near the cable, as there may be the danger
of electric shock, which will lead to equipment
damage or casualty. Please operate the ma-
chine as per the following steps in the work
site near the cable:
• Before operation in the work site near the

cable, please inform the local electric power
CZ335-1102020
company and ask the company to take nec-
essary measures..
Fig.2-47
• There is high possibility of electric shock if
Cable Voltage Min. Safe Distance
the machine stays close to the cable, which
leads to severe burn and even death. 100V-200V more than 2 m ( 7 ft)
Please keep the safety distance from the 6,600V more than 2 m ( 7 ft)
machine to the cable (see the right table). 22,000V more than 3 m ( 10 ft)
Before operation, please consult with the lo-
66,000V more than 4 m ( 14 ft)
cal electric power company about meas-
154,000V more than 5 m ( 17 ft)
ures of safety operation.
187,000V more than 6 m ( 20 ft)
• If the machine stays close to the cable, a
275,000V more than 7 m ( 23 ft)
signalman shall be assigned to command.
500,000V more than 12 m ( 36 ft)
• Don’t allow anyone to approach the ma-
chine during operation near the high voltage Table 2–1
cable.
• When the machine stays close to the cable

or touches the cable, the operator shall not
leave the cab before verifying the cable is
cut off to avoid electric shock. In addition,
don’t allow anyone to approach the
machine.
• To prevent accidents, please wear rubber

shoes and gloves before operation. Cover a
layer of rubber pad on the seat and pay at-
tention to ensuring that exposed parts of
the body will not touch the lower part of the
machine.

Excavator
2.2.26 Ensuring favorable view
This machine is equipped with a rearview mir-

ror to improve the view; but even with it, also
there are places unseen from the seat. There-
fore, be cautious during operation.
Before operating the machine in a place with

bad view, make sure to verify the conditions of
the work site or the obstacles around the ma-
chine; otherwise machine damage or personal
injury may occur. Please strictly observe the
following precautions when operating the ma-
chine in a place with bad view:
• Before operation every day, please check

the rearview mirror. Clean it and adjust the
view range to ensure favorable view.
• During operation in dim places, turn on the

work light and the front lamp of the machine
and install auxiliary lighting in the working
region if necessary.
• Stop operation if favorable view can’t be

guaranteed, such as days of fog, snow, rain
or sand wind.
• Install signs on the road shoulder or soft

ground. When the view is bad, assign a sig-
nalman if necessary. Operator shall pay
great attention to the signs and follow sig-
nalman’s command.
• Ensure all workers understand all signals

and gestures before operation.
2.2.27 Ventilation of working environment
• Exhaust gases from the engine can be

deadly, therefore if it is necessary to start
the engine, or deal with fuel, cleaning oil or
paint in a closed zone, the door and window

shall be open to ensure sufficient ventilation

for preventing gas poisoning.
• Do not operate the machine in the environ-
ment of toxic gas or underground; if neces-
sary, please wear gas mask and ensure
ventilation.
2.2.28 Prevention of asbestos dust
Inhaling asbestos dust from the air would lead

to lung cancer. There is the danger of inhaling
asbestos when workers are engaged in re-
moval operation or handling industrial waste.
Please observe the following rules:
• During cleaning, reduce dust by spraying

water, and don’t clean by compressed air.
• If there is asbestos dust in the air, please

CZ335-1102022
operate the machine in the windward posi-
tion. Every worker shall wear dust mask. Fig.2-48
• Don’t allow anyone to approach the ma-

chine during operation.
• Please observe the local regulations, rules

and environment standards.
WARNING
• This machine uses no asbestos, but
counterfeit parts may contain asbestos.
Vastly inhaling asbestos may harm lung
or lead to death. Therefore, please use
genuine parts of Sany Heavy Machinery
Co., Ltd.

Excavator
2.2.29 Cab emergency exit
• If the cab door can’t be opened for some

reason, use the safety hammer to break the
window, creating an emergency exit.
• For escape, remove all glass fragments in

the window frame firstly and be careful not
to be hurt by glass. Also, be careful not to
slip because of glass fragments..
A820601990969
Fig.2-49
2.3 Safe machine operation

2.3.1 Start
2.3.1.1 Boarding the machine safely
When you come into and leave the machine:
• Face the machine and keep three body

parts (two feet and one hand or two hands
and one foot) touch the machine.
• Don’t jump up to and down from the ma-

chine, and don’t climb it when it runs.
• Don’t take any control levers as the

armrest.
• RMud, greasy dirt and water on all pedals, CA13031506
armrests and shoes shall be cleaned away Fig.2-50

at any time.
• Before entering and leaving the cab, it must

be in the front position.

2.3.1.2 Adjusting the seat
Uncomfortable seat position may easily make

the operator tired, leading to wrong operation.
Every time the machine operator changes,
the operator shall readjust the seat position.
When the operator backs against the back-
rest, he/she shall be able to step on the pedal
to the floor and correctly operate the joysticks.
Otherwise, move the seat forward and back-
ward to readjust it.
CZ335-1102026
Fig.2-51
2.3.1.3 Fastening safety belt
When rollover accident occurs, operator may

be hurt or thrown out of the cab, or likely to be
squashed by the machine, leading to severe
casualty accident. Before operation, please
check the safety belt, buckle and fixture care-
fully. The safety belt or its components, if
damaged or worn, shall be replaced before
operation. Please sit on the seat and fasten
the safety belt during the running process of
the machine to avoid accident. CZ335-1102027
It’s best to replace the safety belt once three Fig.2-52

years regardless of its service condition.
2.3.1.4 Check before starting the engine
Before starting the daily work, please check

the followings before starting the engine:
• Wipe off dust on the window glass surface

to ensure favorable view.
• Wipe off dust on the lens surfaces of the

front lamp and work light and check if the
work light works well.
• Check the engine coolant level, fuel and en- CZ335-1102028
gine oil level.

Fig.2-53

Excavator
• Check if the air cleaner is blocked.
• Check if the electrical wire is damaged.
• Adjust the seat to the position which is easy

for operation and check if the seat belt and
fixture are damaged or worn.
• Check if the instruments work well, check

the angle of the work light and check if all
control levers are in the neutral position.
• Check if the safety lock control lever is in
the lock position.
• Adjust the rearview mirror so as to clearly
see the rear of the machine from the cab
seat.
2.3.1.5 Starting the machine safely
For the correct start steps, see the instruction

about starting machine in the Section
Operation.
• Before starting the machine, ensure no peo-

ple stays on, below and around the ma-
chine and press the horn button to give the
start warning.
• Sit on the driver’s seat and adjust it until
you feel comfortable to operate all control
devices. CZ335-1102029
• Be familiar with all warning devices, instru- Fig.2-54

ments and operational control devices.
• Set all control devices to the neutral /park-
ing position.
• Don’t allow anyone to stay on the machine
except for the operator.
• Please strictly observe the instruction of the
Section Operation in this manual to start the
engine. Don’t follow the way that will cause
the motor short circuit to start the engine.

WARNING
• When it is necessary to start the engine
or operate the machine in a closed envi-
ronment, please ensure sufficient venti-
lation. Inhaling too much tail gas could
lead to death.
• If you cannot shut down the machine,
please do not start it.
2.3.1.6 Engine start in cold weather
• Warm up the engine fully. If the engine isn’t fully warmed up, operation of joysticks will be re-
sponded slowly by the machine, leading to accidents.
• Check if the battery acid is frozen or leaks before starting. If the battery acid is frozen, don’t
charge the battery or start the engine by different electric power. In that case, please melt the
battery acid firstly, otherwise the battery may be on fire.
2.3.1.7 Required auxiliary equipment for start
Please follow the instruction in the operation manual when starting the engine by connecting auxili-
ary cable. Incorrect operation will lead to battery explosion or the machine out of control, and
cause casualties. It is forbidden to start the engine by auxiliary cable without permission. Please
contact the agents authorized by Sany Heavy Machinery Co., Ltd. if necessary.
• 2 persons are needed to cooperate to start the engine by auxiliary cable (one sits on the driver's
seat and the other operates the battery).
• Please wear goggles and rubber gloves before starting the engine by auxiliary cable.
• When connecting the normal machine with the machine with malfunction by auxiliary cable, the
battery voltage of the former shall be the same as that of latter. Meanwhile, please pay attention
not to making two machines contact each other.
• Turn the ignition switches of the normal machine and the machine with malfunction to OFF posi-
tion when connecting auxiliary cable. Otherwise when the power is on, the machines may move
and pose a risk.
• Please make sure to connect the positive pole (+) at first, when connecting the auxiliary cable.
Please disconnect the grounding or the negative (-) cable (grounding side) when removing the
auxiliary cable.
• When removing the auxiliary cable, be careful not to make the auxiliary cable clamps contact
each other or the cable clamps contact the machine. As diethyl ether cold starting fluid is ex-
tremely inflammable and explosive, please read the instructions on the container before use.

Excavator
Don’t use diethyl ether when the engine is equipped with glow plug preheater or other types of
preheater.
2.3.1.8 After starting the engine
After the engine is started, idle it for 3～5 min, and observe the system parameters displayed in
the instruments to ensure the instruments function well and each reading is in normal operational
range.
2.3.2 Operation
2.3.2.1 Inspection before operation
• Move the machine to a wide zone without obstacle, slowly operate it and allow no one to ap-
proach during the check.
• Please fasten the seat belt.
• Check if the instruments and equipment are working properly and check if the bucket, arm,
boom, travel system, swing system and steering system function well.
• Check if the sound, vibration, heating, odor or instruments of the machine are normal, and check
if there is leakage of engine oil or fuel.
• Test the engine speed control device with the travel control lever placed in the neutral position;
operate the control lever of every device to check that each device functions well and know the
control mode of the work equipment.
• If any abnormalities are discovered, don’t continue to operate the machine but repair it at once.
CAUTION
• Observe and carefully listen to the machine to check for any abnormality. If any, stop the ma-
chine at once. Before further operation, please resolve the malfunction at once and report to
the superior.

2.3.2.2 Precautions before operation
To prevent severe personal injury or death,

please pay attention to the followings before
operation:
• The turning circle of a 12 m radius is the

working area (hazard zone) of the machine.
12
Please press the horn button to warn the m
workers in this area before operation.
• No one shall be on, near the machine or in

CZ215S-1102003
the turning circle.
Fig.2-55
• To ensure the view in the travel direction,
please turn the cab if necessary.
• Please assign a signalman in the place with

bad view.

Excavator
2.3.2.3 Verifying the travel direction
• Verify the position of the carrier relative to

the operator before driving the machine.
• Pushing the joystick forward/stepping on

the pedal should move the machine for-
ward, when the guide wheel is under the
front of the cab.
• Pushing the joystick forward/stepping on

the pedal should move the machine back-
CZ335-1102031
ward, when the travel motor is under the
front of the cab. Fig.2-56
• There is a travel direction sign inside the

lower structure. When the operator pushes
FRONT
the joystick forward/steps on the pedal, the Operator Seat
arrow on the sign points to the actual travel Idler
direction of the machine. LEFT RIGHT
In this manual, front, rear, left and right refer

Sprocket
to the direction seen from the cab when the
REAR
cab faces the front while the driving wheel is
CZ335-1102032
in the rear of the machine.
Fig.2-57
WARNING
• Wrong operation of travel control lever/
pedal may lead to severe accident.

2.3.2.4 Safety rules for changing the

machine direction
• Operate the machine only when you are

seated.
• Don’t allow anyone on the machine except

for the operator.
• Check if the travel warning device functions

well.
• The door and window of the cab shall be

CZ335-1102033
locked in the opening/closing position. At
the work site where there is the danger of Fig.2-58
falling or flying objects entering the cab,
please check if the door and window are
closed tightly.
• Check that there is no one or obstacle in

the working area and press the horn button
to give warning before reversing or swing.
• Be cautious to check if anyone enters the

working area of the machine. Pay greater
attention not to contacting other machine or
person when the machine makes a turn or
swings.
CZ335-1102034
Fig.2-59
• Adjust the machine before traveling to place

the driving wheel in back of the driver's
seat. When the driving wheel is in the front
of the cab, the machine will move in the op-
posite direction of the operation of the joy-
stick (i. e. forward and backward operation
for backward and forward travel, and right-
ward and leftward operation for left and
right turn). Please pay greater attention in CZ335-1102035
case of that.
Fig.2-60

Excavator
• Please assign a signalman to command

and keep the signalman in the view, when
your view is hindered during reversing;
• When a signalman is required under specif-

ic working conditions, please adopt hand
signals in accordance with local
regulations;
• Only when both the signalman and the op-

CZ335-1102045
erator know well the signals can the ma-
chine be moved; Fig.2-61
• Understand the meaning of all flags, signals

and marks in work and confirm who is in
charge of signaling;
• Keep the window, rearview mirror and work

light clean and in good condition;
• Dust, heavy rain, fog and etc. will reduce

visibility. Please slow down and use proper
lighting when the visibility reduces.
WARNING
• If someone is near the machine during
reversing or swing of the superstruc-
ture, he/she may be knocked down or
squashed

2.3.2.5 Travel safety rules
• To prevent engine stall because of overload

and work equipment damage during opera-
tion, don’t exceed the maximum allowable
load or performance parameters of the
machine.
• Please keep the safety distance from peo-

ple, buildings and other machines to pre- 20~30cm
(8~12i n)
vent collision during traveling or operation.
CZ335-1102036
• Please contact relevant departments and
follow their guidance when traveling on the
road.
• When the machine travels on a flat ground,
make sure to retract the work equipment
and keep a 20 ～ 30 cm (8 ～ 12 in) height
above the ground.
• The machine shall travel at a low speed on
the rough ground and not make a turn sud-
denly, otherwise the machine may roll over. CZ335-1102037
If the work equipment hits the ground, the

Fig.2-62
machine will lose balance and be damaged.
• For traveling on the rough ground or steep

slope, if the machine has a function of auto-
matic idling, turn off the automatic idling
switch (cancel the function); if the switch is
turned on, the engine speed will reduce and
travel speed will slow down abruptly.
• Avoid traveling on the obstacle as far as

possible; if it’s necessary, lower down the
work equipment to approach the ground
and move the machine at a low speed.
• Before passing over a bridge or structure,

check if the structure strength is able to
support the machine weight firstly.
• During operation in areas with limited height

such as in tunnel, under bridge and under

Excavator
electrical wire, slowly operate the machine

and pay greater attention not to making the
work equipment contact any other objects.
2.3.2.6 Driving the machine safely
• Verify the guide wheel is under the front of

the cab and clearly know how to move the
joystick or step on the pedal before driving
the machine.
• Step on the forepart of the travel pedal or

push forward the travel control lever to
move the machine towards the guide 20~30cm
(8~12i n)
wheel.
CZ335-1102038
• When traveling on a slope, please keep the
work equipment 20～30 cm(8～12in) above Fig.2-63
the ground. In case of emergency, lower
down the work equipment to the ground
rapidly to help stop the machine.
WARNING
• Traveling on a slope may lead to slip or
rollover, causing severe accident.
• When running up a steep slope, extend the

work equipment forward for keeping bal-
ance and keep it 20 ～ 30cm (8 ～ 12in)
above the ground, and move the machine
at a low speed.
• When running down a slope, reduce the en-

gine speed, keep the travel control lever
near the neutral position and move the ma-
CZ335-1102040
chine at a low speed.
Fig.2-64

• For uphill traveling, adjust the cab to make

it face the uphill direction; for downhill trav-
eling, adjust the cab to make it face the
downhill direction.
• Please check the hardness of the ground in

front of the machine before traveling.
CZ335-1102039
Fig.2-65
• Straightly travel uphill and downhill, be-

cause it’s extremely dangerous to make a
turn on the slope or cross the slope.
• Don’t make a turn on the slope or cross the

slope. Make sure to move the machine
down to a flat ground, change the machine
position, and then drive the machine uphill.
• Travel at a low speed on ground with grass,

CZ335-1102041
fallen leaves or wet steel plate. There may
be the danger of slip even on a gentle Fig.2-66
slope.
• If the engine stops when the machine trav-

els on a slope, please move the joystick to
the neutral position immediately and restart
the engine.
CZ335-1102042
Fig.2-67

Excavator
2.3.2.7 Operation on slope
During operation of the superstructure or work

equipment of the machine on a slope, there
will be the danger of losing balance and roll-
over, which may lead to severe injury or
equipment damage. These operations shall
be done on a flat work platform and with care.
• When the bucket is fully loaded, don’t swing

the work equipment from the uphill side to
the downhill side. This operation is danger- CZ335-1102046
ous and may lead to machine rollover.

Fig.2-68
• When the machine must be used on a
slope, please build a work platform with soil
to keep the machine horizontal as far as
possible.
2.3.2.8 Operation in snowy weather
• During traveling or operation on a highly

slippery snow-covered and frozen ground,
please do not operate the control lever
abruptly; pay greater attention especially
during operation on a slope, because the
machine may slip even on a gentle slope.
• For frozen ground, it will be soft after the

temperature rises up, leading to machine
rollover.
• When the machine travels over deep snow,

there will be the danger of rollover and
being buried in snow. Pay attention not to
leaving the road shoulder and getting stuck
in snow.
• When cleaning the snow, it’s hard to see

the road shoulder and objects near the road
buried in snow. There will be the danger of
rollover and colliding with buried objects.
Therefore, be careful to operate the ma-
chine in that case.

2.3.2.9 Forbidden operation
• Don’t excavate the working surface under

the suspending part. Otherwise, there will
be the danger of rock falling, even leading
to collapse of the suspending part and se-
vere accident.
CZ335-1102047
Fig.2-69
• Don’t excavate the front area under the ma-

chine too deep. Otherwise, after the under-
neath part is hollowed out, the ground will
collapse and lead to accident.
CZ335-1102048
Fig.2-70
• Don’t conduct removal operation under the

machine, which makes the machine unsta-
ble and face the danger of rollover.
• Before operation over the buildings or other

structures, please check the structure
strength to prevent casualty due to collapse
of structure.
CZ335-1102050
Fig.2-71

Excavator
• When conducting removal operation, don’t

remove the part immediately above. Frag-
ment falling down and structure collapse will
lead to machine damage and casualties.
CZ335-1102051
Fig.2-72
• Don’t break the target by the impact force of

the work equipment; otherwise scattering
fragment material may hurt people and
damage the work equipment, and also the
impact reaction may lead to machine
rollover.
• Generally speaking, the work equipment on

the side of the machine is easier to turn
over than the one in the front or the back. CZ335-1102052
Fig.2-73
• Lifting, moving or swing of the bucket must

not pass above anyone or the truck cab. If
the materials in the bucket fall down or the
bucket hits something, personal injury or
machine damage may occur.
• Never lift or transport people with the ma-

chine, which may lead to casualty.
• The machine with breaker or other heavy
CZ335-1102053
work equipment has the danger of losing
balance and rollover. Fig.2-74
• Don’t suddenly lower down, swing or stop
the work equipment.
• Don’t suddenly extend or retract the boom
cylinder; otherwise, there will be the danger
of rollover because of the impact force.

2.3.3 Parking
2.3.3.1 Choosing parking lot
• Park the machine on a solid and flat

ground.
• Choose a safe region without risk of falling

rock and collapse etc to park the machine.
For low-lying area, park the machine at the
place without flood risk.
• Park the machine on a level ground as far

as possible. If it's necessary to park it on a CZ335-1102054
slope, following rules must be observed:
Fig.2-75
• Adjust the bucket to make it face the down-
hill side and insert the bucket tooth into the
ground.
• Place a cushion block under the track to
prevent machine movement.
• Don’t park the machine on a construction
120°
road. If it’s necessary, please comply with

local rules to reminder other people or ve-
hicles by flag in the daytime and signal lamp
at night. CZ335-1102055
Fig.2-76

Excavator
2.3.3.2 Machine shutdown
See the Section Operation of this Manual for

detailed machine shut down steps. General
shutdown procedure is as follow:
• Stop the machine.
• Adjust the body.
• Lower the work equipment to the ground or

place it at fixed position.
CZ335-1102074
• Slow down the engine and run it at a low
idle speed for 5 min. Fig.2-77
• Turn the ignition switch to [OFF] position to

stop the engine.
• Move the lockout lever to the LOCKED

position.
• Pull the safety control lever to the lock

position.
• Take out the ignition key.

CZ335-1102028
• Close the window, skylight and cab door.

Fig.2-78
• Lock all access doors and boxes.
• When you leave the machine, please keep three-point contact and face the machine, and don’t
jump down from the machine.
• When leaving the machine, be careful of the smooth track, steps and handles.
2.3.4 Transportation
2.3.4.1 Transportation
When transporting the machine, pay attention

to the followings:
• Know the overall length, width and height of

the transport vehicle and the machine and
avoid contacting the obstacles at a high
place and narrow channel.
• Before passing the bridge, please check if

the bridge is able to support the weight in

advance; when driving on road, please fol-

low traffic laws and traffic police’s
command.
2.3.4.2 Loading and unloading
During loading and unloading, wrong opera-

tion will lead to machine rollover and falling
down, therefore pay attention to the
followings:
• Load or unload the machine only on a solid

and flat surface. Keep it a safe distance
away from road sides or a cliff.
• Access board with sufficient strength must

be used. Ensure that the access board is
wide, long and thick enough to form a safe
loading and unloading slope (≤15°).
• Ensure the access board surface is clean CZ335-1102059
and without grease, oil, water and scattered

materials and clean dirt on the machine Fig.2-79
track. During loading and unloading in rainy
or snowy weather, please be careful of the
wet and slippery access board surface.
• Don’t load or unload the machine by the

work equipment; otherwise machine falling
down or rollover may occur.
• Cancel the function of automatic idling, run

the engine at a low speed and slowly drive
CZ335-1102060
the machine.
Fig.2-80
• Don’t operate any joysticks except for the
travel control lever on the access board.
• Don’t correct the direction on the access

board. If necessary, drive the machine away
from the access board, correct the direction,
and then drive the machine to the board
again.

Excavator
• At the connection between the access

board and trailer, the machine center of
gravity will change suddenly, making the
machine liable to lose balance. Therefore,
move the machine slowly when passing this
part.
• For loading and unloading on an embank-

ment or platform, ensure the embankment
or platform has sufficient width, strength
and gradient.
• The trailer where the superstructure is

swung will be instable, therefore, retract the
work equipment and slowly swing the
superstructure.
• After loading the machine, please lock the

cab door. Otherwise the cab door may open
suddenly during transport.
• Fix the machine by chain and cushion

block. Fix all work equipment, lower down
the bucket, boom and arm, and place them
in the transport position.
• Once the machine is loaded, lock the cab

door. Otherwise, it may swing open during
transportation.
2.3.5 Battery
Preventing the danger caused by battery Bat-

tery acid comprises sulfuric acid and is able to
generate flammable and explosive hydrogen.
Wrong operation will lead to injury or fire.
Therefore, it is important to observe the fol-
lowing rules:
• No smoking or open flame near the battery.
• Turn the ignition switch to OFF position be-

CZ335-1102061
fore checking or handling the battery.
Fig.2-81

• Please wear safety glasses and rubber

gloves when handling the battery.
• Battery acid is highly corrosive. If battery

acid splashes on clothes and skin, flush
with plenty of water at once. If it enters your
eyes, there will be the danger of blindness,
therefore make sure to flush with plenty of
water at once and seek for medical care.
To avoid battery explosion, please observe

the following precautions during operation:
• Don’t allow tool or other metal objects to

contact battery terminal; don’t allow tool or
other metal objects to be placed near the
battery.
• For disconnecting the battery, 1 min after

the engine is shut down, disconnect the CZ335-1102062
negative (-) terminal firstly, and then the
positive (+) terminal; For connecting, con- Fig.2-82
nect the positive (+) terminal firstly, and
then the negative (-) terminal. Ensure all
terminals connect well.
• During charging process, when battery tem-

perature exceeds 45℃, stop charging and
lower the temperature to the room tempera-
ture; then half the charging current before
continuing to charge the battery.
• When battery is charging, it will generate in-

flammable hydrogen. Therefore, before
charging, dismantle the battery from the
superstructure, place it in a well-ventilated
place and dismantle the battery cover.
• If acid sprays out of the battery exhaust

hole during charging, please stop charging
at once.
• Never smoke or keep off any fire source

during charging.

Excavator
• When the battery electrical eye becomes

green, it indicates completion of charging.
In that case, stop charging.
• After charging, screw up the battery cover
tightly.
• Install the battery to specified position
tightly.
2.3.6 Towing
For towing of a damaged machine, incorrect

operation method or choosing nonconforming
wire rope will lead to severe accident: A
• Don’t tow the machine on a slope.

B
• Wear protective gloves and helmet when

using wire rope. C
• Check that the wire rope is of adequate

strength that it can bear the weight of towed CZ335-1102063
machine.
Fig.2-83
• Don’t use wire rope having such problems
as broken strand [A], reduced diameter [B]
and twisting [C]. These wire rope may break
off during towing.
• Don’t stand between the towing machine

and the towed machine during towing.
• Slowly operate the machine and pay atten-

tion not to loading the wire rope suddenly.

2.3.7 Lifting objects with the machine
• Allow no one to enter the working area.
• Before operation, determine all possible

signals used in operation and assign a
signalman.
• To prevent rollover or falling down, operate

the machine on a flat ground.
• Don’t use damaged chain, wire rope, lifting

CZ335-1102064
eye and brace.
• Hang the lifting sling on the lifting point Fig.2-84

specified by the manufacturer. Never hang
lifting eye or rope on the bucket teeth. Oth-
erwise, the bucket teeth may fall off, leading
to falling down of lifted object.
• Don’t leave driver's seat during lifting.
• To prevent the load from hitting any person

or building, inspect carefully the machine
surroundings before swinging or operating CZ335-1102065
the work equipment.

Fig.2-85
• Don’t suddenly swing or operate the work
equipment. This will lead to the swing of the
lifted objects, and even machine rollover.
Use a tow rope to strengthen control if
necessary.
• Don’t tow the load in any directions by the

work equipment or by rotation. Once the lift-
ing hook breaks and load separates from it,
the work equipment will move suddenly and
CZ335-1102066
cause injury.
Fig.2-86

Excavator
2.4 Safe maintenance instruction

2.4.1 Pre-maintenance precautions
To prevent accidents:
• Understand the maintenance procedure be-

fore operation.
• Keep the work region clean and dry.
• Don’t spray water or vapor in the cab.
• Never do refueling, lubrication and other

maintenance work while the machine
moves.
• Keep your hands, feet and clothes off the

rotary parts.
2.4.2 Self-preparation
The machine can be maintained or repaired

by approved workers only. An observer could
be assigned if necessary.
• Wear protection suit and safety shoes re-

quired by the work.
• When you remove spring, flexible compo-

nents or add acid to the battery, please
wear face shield. Wear helmets and eye
CZ335-1102069
protection when you weld or cut something.
Fig.2-87
• During cleaning with compressed air, flying
granules may cause personal injury. There-
fore please wear goggles, dust mask,
gloves and other protective equipment.
• When you hit hard metallic parts such as

the pins, loading buckets teeth, cutting
edges or bearings with a hammer, there
might be parts and metallic fragments flying
off and resulting in injuries. Thus, always
wear eye protection and protective gloves

and make sure that there are no people

around.
• Don’t conduct grinding, flame cutting or

welding if breather or ventilation equipment
is not available. If it is necessary to perform
welding on the hydraulic excavator, refer to
relevant manual for correct procedures.
• If the machine creates too much noise, it

may lead to temporary or permanent hear-
ing problem. When maintaining the engine,
please wear ear muff or plug before working CZ335-1102071
in the noise for a long time. Fig.2-88
• Please wear rubber apron and rubber

gloves when contacting corrosive materials.
Please wear protective gloves when han-
dling wooden materials, wire ropes or metal
with sharp edge.
2.4.3 Preparation of working area
• Select a working area with enough space,

sufficient light, good ventilation, clean and
flat ground for maintenance.
• Clean the working ground, wipe off fuel, lu-

bricant and water, and cover the slippery
ground with sand or other adsorptive
materials.
• Don’t leave hammer or other tools in the

working area.
• If you fail to keep the working area clean

and tidy, there will be the danger of stumble,
slip and fall, leading to personal injury.

Excavator
2.4.4 Steps of engine shutdown before maintenance
Before maintaining the machine:
• Park the machine on solid and fl at ground.
• Lower the bucket to the ground.
• Place cushion blocks under the track to pre-

vent the machine from moving.
• Turn the accelerator control knob to "1" po-

sition to run the engine at a low idle speed
CZ335-1102054
and under no load for 5 min.
Fig.2-89
• Turn the ignition switch to [OFF] position to
stop the engine.
• Turn the switch to [ON] position and move

the control lever to the front, back, left and
right twice and three times respectively to
release pressure in the hydraulic system.
• Take off the key from the ignition switch.
• Turn the safety lock control lever to “LOCK”

CZ335-1102074
position.
Fig.2-90

2.4.5 Warning decal
• Before maintaining the machine, hang a

“Do Not Operate” sign or a similar warning
sign on the start switch or direction control
to warn others that the machine is under
maintenance. If necessary, an additional
warning decal can be attached around the
hydraulic excavator.
• If someone starts the engine, contacts and

CZ335-1102067
operates the control lever or pedal during
maintenance, it will lead to severe accident. Fig.2-91
CZ335-1102068
Fig.2-92
2.4.6 Use proper tools
Only proper tools can be selected for mainte-

nance and they shall be used correctly; using
damaged, bad, defective and temporary tools
or incorrectly using tools will lead to severe
accident.
CZ335-1102072
Fig.2-93

Excavator
2.4.7 Maintenance with engine running
Don’t maintain the machine when the engine

runs to prevent injury. If necessary, the main-
tenance during engine running requires at
least 2 workers and shall be conducted as the
followings:
• One worker must sit in the driver’s seat all

the time and be ready to shut down the en-
gine at any time. All workers must keep in
touch.
• Turn the safety lock control lever to "LOCK"

position to prevent the work equipment from
moving unexpectedly.
CZ335-1102028
Fig.2-94
• Operation near the fan, fan belt or other ro-

tary components will cause the danger of
being rolled by the components. Please pay
greater attention to it.
• Tools or other objects shall not fall into fan

or fan belt, otherwise, parts will be broken
or fly off.
• Don’t touch any control levers. If necessary, CZ335-1102077

please signal others and warn them to
move to a safe place. Fig.2-95

2.4.8 Work under the machine
• Don’t maintain the machine before well sup-

porting it.
• Lower down the work equipment to the

ground before maintenance.
• If the machine or the work equipment must

be lifted for maintenance, support it firmly
with cushion block or bracket of sufficient
strength , rather than slag brick, cord tyre or CZ335-1102078
shelf; don’t support the machine by a single

Fig.2-96
jack.
• If the track shoe leaves the ground while

the machine is only supported by the work
equipment, it’s very dangerous to operate
under the machine. If the hydraulic pipeline
is damaged or the control lever is contacted
by accident, the work equipment or ma-
chine may fall down suddenly, causing
casualty. Therefore never work under the
hydraulic excavator if it is not firmly sup-
ported by the cushion blocks or brackets.
2.4.9 Track maintenance
• Due to dry friction, the track pin and track

bushing are very hot. To prevent scald,
please wear safety protective gloves.
• Keep proper track tension. During operation

on mud and snow ground, mud and snow
will stick to the track parts, making the track
too tight. In that case, please adjust track
tension according to the operation manual
of the product.
• Check if the track shoe is loose or broken,

and if the track pin and the track bushing
are worn or damaged, and check the track
roller and the carrier roller.

Excavator
CAUTION
• Don’t knock the track tension springs, as
they may bear huge pressure and break
suddenly, leading to injury. Don’t remove
springs under compression condition. Ten-
sion spring should not be compressed.
• Follow the track maintenance guidance
provided by the manufacturer.
2.4.10 Track tension adjustment
• Grease is pressed into the track tension ad-

justment system under a high pressure
condition.
• To loosen track tension, slowly loosen the
grease drain plug and don’t unscrew it for
more than one turn.
WARNING
• Failure to follow the specified mainte- CZ335-1102080
nance process during adjustment will
cause flying off of the grease drain Fig.2-97
plug, leading to severe injury or
damage.
• Keep your face, hands, feet or other
parts of the body off the drain hole of
the grease drain plug.

2.4.11 Recoil spring
Buffer spring assembly is used for reducing

the impact force of the guide wheel. It com-
prises a high pressure spring, which, if incor-
rectly removed, will cause flying off of the
spring, leading to severe casualty. If the buffer
spring assembly must be removed, please
contact the agents authorized by Sany Heavy
Machinery Co., Ltd. to conduct this operation.
CZ335-1102081
Fig.2-98
2.4.12 Be careful of hot cooling system
As temperature of engine increases, pressure

in cooling system builds up. Stop the engine
to allow the system to cool down before re-
moval of radiator cap. You should not remove
it until the coolant cools down.
WARNING
• Contacting hot high pressure coolant
will cause severe injury.
CZ215L-1102001
Fig.2-99
2.4.13 Safe operation of high pressure hose
If leakage is found in the high-pressure hose,

it may cause an operational failure and even
lead to a fire. If bolts on the hose come loose,
stop working and tighten the bolts to specified
torque. If any damage is discovered in the
hose, please stop operation at once and con-
tact the agents authorized by Sany Heavy Ma-
chinery Co., Ltd.
RReplace the hose at once when the follow-

ing problems are discovered:

Excavator
• Hydraulic tube connectors are damaged or

leak.
• The covering is worn or broken, or steel

wire of the reinforcement layer is exposed.
• Some parts of the covering swell.
• There are impurities inside the covering.
• Removable parts are twisty or squashed.
2.4.14 Be careful of high pressure liquid
Pressure always exists in the hydraulic sys-

tem. When you check or replace the hose, al-
ways check if pressure in the hydraulic oil line
has been relieved. If there is remaining pres-
sure in the hydraulic oil line, serious accidents
will occur. Therefore, it is important to observe
following rules:
• Release system pressure before maintain-

ing the hydraulic system;
1) Screw off the butterfly nut of the breather
valve, and press the exhaust button to re-
lease the internal pressure in the hydraulic
tank.
2) Release pressure in pilot lines group. In
15 seconds after shutdown, turn the key
switch to ON position, set the safety lock
control lever to unlock position, and move
the travel control lever and the left and right
joysticks to all directions to release pres-
CZ335-1102082
sure in the accumulator.
Fig.2-100
• Keep the hydraulic system off any open
flame, and eliminate splashing hydraulic oil,
if any, at once.
• Diesel or hydraulic fluid under pressure is

able to penetrate skin or eyes, leading to
severe injury, blindness or death. It is diffi-
cult to check if the pressurized hydraulic oil
leaks with naked eyes. You need to find

leakage with a piece of cardboard or wood

chip instead of touching leaked oil directly.
Wear a face mask or protective goggles to
protect your eyes. If oil penetrates your
skin, rinse it with water and seek medical at-
tention as soon as possible.
• When the engine is running, high pressure

will arise inside the fuel pipeline. Before
checking or maintaining the fuel pipeline
system, wait at least 30 seconds after the
engine is shut down, to allow the internal
pressure of the system to reduce.
2.4.15 Welding operation
There is a risk of fire or electric shock during

welding, therefore, welding must be carried
out by qualified welders with appropriate
equipment. Unqualified personnel are not al-
lowed for welding.
2.4.16 Safe maintenance of HVAC group
WARNING
R134a refrigerant is a non-toxic gas at room
temperature, but it turns into a highly toxic
gas when it exposes to fire.
• Keep the HVAC group away from fire

source during maintenance.
• Please use the refrigerant correctly accord-

ing to the instruction on the refrigerant con- CZ335-1102083
tainer when maintaining the HVAC group.
Fig.2-101
Use R134a as the refrigerant. Don’t use
other refrigerants. Otherwise, the HVAC
group will be damaged.
• If the refrigerant enters eyes, it may cause

blindness; if it splashes on skin, it will cause
cold injury.

Excavator
• It is strictly forbidden to discharge the refrig-

erant directly into the atmosphere, instead,
a refrigerant circulation system should be
used.
2.4.17 High voltage precautions
• When the engine is running or was just shut

down, high pressure will arise in the injector
terminal and inside the engine controller,
causing the danger of electric shock. There-
fore, please don't contact the injector or the
inside of the engine controller.
• If it’s necessary to contact the injector termi-
nal or the inside of the engine controller,
please contact the agents authorized by CZ335-1102084
Sany Heavy Machinery Co., Ltd.
Fig.2-102
2.4.18 Accumulator
The accumulator is filled with high-pressure

nitrogen, thus improper operation to the accu-
mulator may cause an explosion, which may
lead to serious accidents. Therefore please
comply with the following precautions:
• Do not disassemble the accumulator.
• Keep the accumulator off fire source or do

not expose it to fire.
CZ335-1102085
• Do not punch, weld or flame-cut on

Fig.2-103
accumulator.
• Do not strike or roll the accumulator, or let it

bear any impact.
• Deflation is required for handling of the ac-

cumulator. Please contact the agents au-
thorized by Sany Heavy Machinery Co., Ltd
to conduct this operation.

2.4.19 Preventing the danger of fire and explosion
WARNING
• Don’t smoke when handling fuel or maintaining the fuel system, as fuel vapor in the
empty fuel tank is highly liable to explode. Don't conduct cutting and welding operation
on the fuel pipe, fuel tank or other fuel containers. Otherwise fire and explosion may oc-
cur, leading to casualties.
• Please shut down the engine and turn off the electrical equipment when refueling the tank. Be
extremely cautious when refueling the hot engine. Avoid any spark around the grounding fuel
nozzle.
• Please handle all solvents and dry chemicals according to the steps marked on the containers in
a well-ventilated place.
• Clean away dust and residues on the machine, and don’t place greasy cleaning cloth or other in-
flammable materials on it.
• Please clean parts with non-inflammable solvent rather than gasoline, diesel or other inflamma-
ble liquid.
• Store inflammable liquid and materials in proper containers according to safety regulations.
• Check if fire extinguisher, fire extinguishing system and fire detectors (if equipped) are ready for
use.
2.4.20 Regular replacement of safety related parts
• To ensure long-term safe operation of the machine, parts related to safety such as hose, seat
belt must be replaced regularly.
• Exceeding the specified replacement interval may cause aging problem of part materials. Over-
use will lead to abrasion and damage, causing machine malfunction and personal injury. At the
same time, it’s hard to identify how long these parts can work well only through visual inspection
or touch. Therefore regular replacement is necessary.
• Safety related parts, if defective, shall be replaced or repaired even before the specified replace-
ment interval.
2.4.21 Maintenance operation
• Check all components and parts and replace worn, broken and damaged ones during repair. Ex-
cessively worn and damaged components and parts will be inoperative during the operation of
the machine, causing casualties. Replace damaged or illegible signal marks.

Excavator
• Screw down all fasteners and connectors to specified torque.
• Install all guards, covers and shields after maintenance. Damaged guard boards shall be re-
placed or repaired. The system shall be refilled with the hydraulic fluid approved or suggested
by Sany Heavy Machinery Co., Ltd only.
• Start the engine and check leakage condition (check the hydraulic system); then operate all con-
trol devices to confirm all functions of the machine are in well condition. Conduct road test if nec-
essary. After test, shut down the engine and do self-check (check if there are lost cotter pins,
washers and nuts etc). Make sure to check all hydraulic fluid levels again before operating the
machine.
2.4.22 Proper waste treatment
Improper disposal for waste may lead to envi-

ronmental and ecological perils. Consult your
local environmental collection center or Sany
Heavy Machinery Co., Ltd. authorized distrib-
utor about collection or disposal methods.
• Potential harmful waste from the equipment

of Sany Heavy Machinery Co., Ltd includes
hydraulic fluid, fuel, coolant, refrigerant, fil-
ter, battery and etc. CZ335-1102086
• Please store the drained liquid with a leak- Fig.2-104

proof container instead of a food or drink
container, as the latter may cause mistaken
drinking.
• Don’t pour waste liquid onto the ground, in-

to the sewer or any other water sources
directly.
• Leakage of refrigerant will damage the

earth atmosphere. Please recycle or regen-
CZ335-1102087
erate the refrigerant according to relevant
laws and regulations. Fig.2-105


SY115/125/135/155/155 Crawler Hydraulic Technical Specifications
Excavator
Technical Specifications
3 Technical Specifications.............................................................................................3-1
3.1 Machine Dimensions ............................................................................................................3-3
3.2 Working Ranges....................................................................................................................3-4
3.3 Technical parameters ...........................................................................................................3-5

Technical Specifications SY115/125/135/155/155 Crawler Hydraulic Excavator
WARNING

Excavator
3.Technical Specifications
3.1 Machine Dimensions
D I
E C
L
H
G F J
B K
CJ13032601-1
Fig.3-1
Unit: mm
Item SY115C9 SY125C9 SY135C9 SY155C9 SY155H
A Overall length (for 7280 7280 7700 7870 7870
transportation)
B Overall width 2490 2490 2490 2490 2490
C Overall height (for 2890 2890 2815 2880 2880
transportation)
D Width of upper 2550 2550 2550 2570 2570
structure
E Overall height (top of 2740 2740 2740 2740 2740
the cab)
F Standard track shoe 500 500 500 500 500
width
G Track gauge 1990 1990 1990 1990 1990
H Min. ground clearance 425 425 425 425 425
(excluding the flange
height of the track
shoe)
I Tail swing radius 2205 2205 2240 2210 2210
J Ground contact length 2680 2680 2930 2930 3010
of track
K Track length 3360 3360 3665 3665 3730
L Ground clearance of 903 903 903 903 903
upper structure
(excluding the flange
height of the track
shoe)

3.2 Working Ranges
g
b
c d
CJ13032602-1
Fig.3-2
Unit: mm
Name SY115C9 SY125C9 SY135C9 SY155C9 SY155H
a Max. digging height 7695 7695 8,685 8610 8610
b Max. dumping height 5440 5440 6180 6115 6115
c Max. digging depth 5190 5190 5510 5500 5500
d Max. vertical digging 4720 4720 4890 5085 5085
depth
e Max. digging reach 7735 7735 8290 8330 8330
f Min. swing radius 2880 2880 2500 2490 2490
g Max. height at min. swing 5905 5905 6500 6495 6495
radius

Excavator
3.3 Technical parameters

Travel-
ing
Overall Bucket Swing Engine
speed
weight/ capacity/ speed/ Engine model power
(high/
kg m³ rpm kW/rpm
low) km/
h
SY115C9 12400 0.5 5.5/3.5 13.06 4JJ1-XDJAG-01-C3 73/2000
SY115C9 12450 0.6 5.5/3.5 10.5 4JJ1-XDJAG-01-C3 73/2000
72.7 /
13500 0.6 5.5/3.5 12 4BG1-TABGC-03-C2
SY135C9* 2200
13500 0.6 5.5/3.5 12 4JJ1-XDJAG-01-C3 73/2000
SY155C9 14100 0.6 5.5/3.5 12 4JJ1-XDJAG-01-C3 73/2000
SY155H 14200 0.65 5.5/3.5 12 4JJ1XKSC-0 84/2200
*Note: The SY135C9I2K machine uses 4BG1-TABGC-03-C2 ISUZU engine;
The SY135C9I3K machine uses AJ-4JJ1XYSS-02S ISUZU engine.


SY115/125/135/155/155 Crawler Hydraulic Operation
Excavator
Operation
4 Operation.............................................................................................................................4-1
4.1 Machine general drawing.....................................................................................................4-5
4.2 Description of controls and instruments.............................................................................4-6
4.2.1 Display ..........................................................................................................................4-6
4.2.2 Operation method of each page of the display .................................................... 4-10
4.2.3 Switch ........................................................................................................................ 4-24
4.2.3.1 General............................................................................................................... 4-24
4.2.3.2 Ignition switch.................................................................................................... 4-24
4.2.3.3 Throttle control knob......................................................................................... 4-26
4.2.3.4 Working lamp switch ........................................................................................ 4-26
4.2.3.5 Ceiling lamp switch........................................................................................... 4-27
4.2.3.6 Wiper switch ...................................................................................................... 4-28
4.2.3.7 Washer switch ................................................................................................... 4-28
4.2.3.8 Horn switch ........................................................................................................ 4-29
4.2.3.9 Indoor lamp switch............................................................................................ 4-29
4.2.3.10 Cigar lighter and auxiliary power supply ..................................................... 4-30
4.2.3.11 Preheating indicator lamp.............................................................................. 4-30
4.2.3.12 Charging indicator .......................................................................................... 4-30
4.2.4 Control Levers and Pedals ..................................................................................... 4-31
4.2.4.1 General............................................................................................................... 4-31
4.2.4.2 Safety lock control lever................................................................................... 4-32
4.2.4.3 Travel control levers ......................................................................................... 4-33
4.2.4.4 Control levers .................................................................................................... 4-34
4.2.5 Ceiling window.......................................................................................................... 4-36
4.2.6 Windshield................................................................................................................. 4-37
4.2.7 Doors and windows of cab...................................................................................... 4-44
4.2.8 Cup Holder ................................................................................................................ 4-45
4.2.9 Ashtray....................................................................................................................... 4-45
4.2.10 Information pack..................................................................................................... 4-46
Operation SY115/125/135/155/155 Crawler Hydraulic Excavator
4.2.11 Drink box ................................................................................................................. 4-46

4.2.12 Emergency exit....................................................................................................... 4-47
4.2.13 Fire Extinguisher .................................................................................................... 4-47
4.2.14 Controller................................................................................................................. 4-48
4.2.15 Fuse link .................................................................................................................. 4-48
4.2.16 HVAC group ............................................................................................................ 4-49
4.2.16.1 Control panel ................................................................................................... 4-49
4.2.16.2 Control switch and LCD ................................................................................. 4-49
4.2.16.3 Operation of HVAC ......................................................................................... 4-55
4.2.16.4 Use HVAC carefully........................................................................................ 4-58
4.2.17 Radio........................................................................................................................ 4-60
4.2.17.1 Control panel ................................................................................................... 4-60
4.2.17.2 Control key and LCD...................................................................................... 4-60
4.2.17.3 Operation ......................................................................................................... 4-62
4.2.18 Door lock ................................................................................................................. 4-67
4.2.19 Lock cap .................................................................................................................. 4-68
4.2.19.1 General ............................................................................................................ 4-68
4.2.19.2 Open and close the lock cap......................................................................... 4-68
4.2.19.3 Open and close the lock cover ..................................................................... 4-69
4.2.20 Toolbox .................................................................................................................... 4-71
4.2.21 Lubricating grease pump rack (if assembled).................................................... 4-71
4.3 Operation and control of machine.................................................................................... 4-71
4.3.1 Before engine start................................................................................................... 4-71
4.3.1.1 Routing inspection ............................................................................................ 4-71
4.3.1.2 Inspection before start...................................................................................... 4-73
4.3.1.3 Adjustment before operation........................................................................... 4-80
4.3.1.4 Operation before engine start ......................................................................... 4-85
4.3.2 Engine start ............................................................................................................... 4-87
4.3.3 Engine Preheating ................................................................................................... 4-90
4.3.4 Warm-up operation .................................................................................................. 4-90
4.3.5 Stop the engine ........................................................................................................ 4-91
4.3.6 Machine Operation................................................................................................... 4-92
4.3.6.1 General............................................................................................................... 4-92
4.3.6.2 Preparation of moving machine...................................................................... 4-93
4.3.6.3 Move machine ................................................................................................... 4-94
4.3.6.4 Stop machine..................................................................................................... 4-95
4.3.7 Machine steering...................................................................................................... 4-95
4.3.7.1 General............................................................................................................... 4-95
4.3.7.2 Turn the machine when it stops .................................................................... 4-96
4.3.7.3 In-situ steering................................................................................................... 4-98
4.3.8 Working mode selection.......................................................................................... 4-98
Excavator
4.3.9 Control and operation of work equipment............................................................. 4-99

4.3.10 Prohibited operation ............................................................................................ 4-101
4.3.11 Allowed water depth ............................................................................................ 4-104
4.3.12 Operation on the slope........................................................................................ 4-105
4.3.12.1 General .......................................................................................................... 4-105
4.3.12.2 Downhill traveling ........................................................................................ 4-107
4.3.12.3 Stop engine on the slope............................................................................. 4-108
4.3.12.4 Cab door when the machine is on the slope............................................. 4-108
4.3.13 Drive the machine out of the mud...................................................................... 4-108
4.3.13.1 General .......................................................................................................... 4-108
4.3.13.2 Track on one side gets stuck in the mud ................................................... 4-108
4.3.13.3 Tracks on both sides get stuck in the mud................................................ 4-109
4.3.14 Recommended purpose ..................................................................................... 4-109
4.3.14.1 General .......................................................................................................... 4-109
4.3.14.2 Backhoe operation ....................................................................................... 4-109
4.3.14.3 Ditching operation..........................................................................................4-110
4.3.14.4 Loading operation..........................................................................................4-111
4.3.15 Parking ...................................................................................................................4-111
4.3.16 Machine inspection after daily work ...................................................................4-113
4.3.17 Locking ...................................................................................................................4-114
4.3.18 Operation in cold season .....................................................................................4-115
4.3.18.1 Description of operation in cold season .....................................................4-115
4.3.18.2 After daily work...............................................................................................4-115
4.3.18.3 After cold season ...........................................................................................4-117
4.3.19 Long-Term Storage...............................................................................................4-117
4.3.19.1 Before storage................................................................................................4-117
4.3.19.2 During storage................................................................................................4-118
4.3.19.3 After storage...................................................................................................4-118
4.3.19.4 Start the engine after long-term storage ...................................................4-118
4.4 Transportation....................................................................................................................4-119
4.4.1 General .....................................................................................................................4-119
4.4.2 Transport methods..................................................................................................4-119
4.4.3 Machine loading and unloading machine with trailer ........................................ 4-120
4.4.3.1 General............................................................................................................. 4-120
4.4.3.2 Loading............................................................................................................. 4-121
4.4.3.3 Securing the machine .................................................................................... 4-123
4.4.3.4 Unloading......................................................................................................... 4-126
4.5 Lifting.................................................................................................................................. 4-128

WARNING

Excavator
4.Operation
4.1 Machine general drawing
4 5 6
9
10
CC13051001-1
Fig.4-1
1) Bucket 6) Boom cylinder

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

4.2 Description of controls and instruments

4.2.1 Display
CAUTION
• When the alarm indicator lamp comes on,
stop the operation immediately and check A
and repair relevant parts.
• The display can’t display the whole work-
ing status of the machine.
• Do not rely on the display completely in
B
case of maintenance and inspection of the
machine.
The display panel has the functions of moni-

toring display, working mode selection and
switching of electrical components.
F1 F2 F3 F4 F5
C Esc Enter
Display appearance
This display mainly consists of 3 parts:

XP13031506
A. Alarm and signal indicator area
Fig.4-2
B. Main image display area
C. Key area
Alarm and signal indicator area
Fault alarm indicator lamp
The fault alarm indicator will turn on to remind

the user of troubleshooting when the excava-
tor is faulty.
XP13031505
Fig.4-3

Excavator
Main image display area

1
When the excavator ignition switch is turned 2 17
to "ON", the display will be powered and 3 16
started by the battery to enter the initial inter-
face. The fullscreen display of the working
4
state is shown in the right figure. Where:
1. Current date
15
2. Current time 14
5
6 13
3. GPS signal
12
4. Fuel level gauge
5. Coolant thermometer
7 8 9 10 11
6. Maintenance indicator
Fig.4-4
7. Working mode switching icon
8. Automatic idling icon
9. High/low traveling speed switching icon
10.Icon of entering the “DTC query”
11.Icon of entering the “Information Query”
12.Charging indicator
13.Glow plug indicator
14.DTC
15.Fault indicator
16.Machine working time
17.Working mode and gear

• Coolant thermometer:
The range indicates the temperature of

49~109°C.
A: indication when the water temperature is

below 49°C; A
B: indication when the water temperature is

49° C-99° C; the indication in the middle indi-
cates the water temperature of 79°C;
C: indication when the water temperature is

B
above 99°C. When the water temperature ex-
ceeds 103° C, an alarm will be given and the
speed will be limited. When the temperature
returns below 110℃, the alarm indicator lamp
will go out automatically.
Fig.4-5
• Fuel level gauge: The range has 13 divi-

sions (yellow) indicating the fuel level of
0~100%.
A: Insufficient fuel;
B: Fuel level of 30%;

A
C: Fuel level of 100%.
Fig.4-6

Excavator
Key area
The key area includes function keys and op-

erational keys.
1 F1 F2 F3 F4 F5
Function key
Esc Enter
2
Function buttons are F1, F2, F3, F4, and F5
(as shown) with purposes corresponding to
the function icons displayed on the main inter-
face display area above them.
XP13031502
• When different function icons are displayed,

Fig.4-7
each key will have a different purpose.
• When no corresponding function icon is dis-
played in the main image display area, this
function button will be invalid.
The corresponding relationship between common function display icons and keys is shown in the
table below.
Function key Display icon Function Display range

F1 Working mode switching S，H，L，B
F2 Idle/non-idle state switching Idle/non-idle
F3 High/low traveling speed High/low speed

switching
F4 Enter the selected/set item The same as the operational key Enter
Select information query ——
F5 Return to the previous The same as the operational key Esc
interface
NOTE: When no icon is displayed above a function key, this key is disabled.

Operational key
Operational key Function

Enter the selected/set item
Return to the previous interface
Select the upper item (select the lowermost item after selection of the
uppermost item)
Progressive increase of the value at the cursor position
Select the lower item (select the uppermost item after selection of the
lowermost item)
Progressive decrease of the value at the cursor position
Select the left item (select the rightmost item after selection of the leftmost
item)
Move the cursor leftwards
Select the right item (select the leftmost item after selection of the rightmost
item)
Move the cursor rightwards
4.2.2 Operation method of each page of

the display
Home page
The home page is the operation interface

when the excavator works normally.
Operation methods
1. Temporary working mode selection

Use F1 to select the working mode. Every
time this key is pressed down, the working
mode will be switched circularly:
S→H→L→B→S.
Note: The default working mode will be recov-
ered after each power-off.
2. Automatic idle speed selection

Use F2 to cancel and start automatic idle
Fig.4-8
speed function.
When the symbol is displayed above, press
down this key to cancel the automatic idle
speed function; when the symbol is displayed
above the key, press down this key to start the
automatic idle speed function.

Excavator
The default mode of the automatic idle speed

is the “Start” mode when the machine is pow-
ered on each time.
• By default, the automatic idle speed switch
is turned on. When all travel levers are put
in the neutral position for 3 s, the engine will
enter the idle state automatically (the con-
troller will automatically adjust the speed to
the idle speed) to save fuel and reduce
noise.
• If the controller detects an action or position
change in the idle state, the engine will au-
tomatically return to the speed correspond-
ing to the position.
3. High/low traveling speed selection

Use F3 to realize switching between “High
Traveling Speed” and “Low Traveling Speed”.
When the symbol is displayed above the
key F3, press down this key to select high
traveling speed; when the symbol is dis-
played above the key , press down this key to
select low traveling speed.
Note: The default traveling speed is the low
speed when the machine is powered on each
time.
4. Fault information query

When the alarm indicator light lights up on the
display, a DTC will appear at the bottom of the
display. At this time, the red symbol will ap-
pear above F4 .
Press down this key to enter the fault informa-
tion query page.
5. System information query

Press F5 to enter the system information
query interface.
Note: Enter the password before entering the
system information page. Please contact the
local SANY agent to obtain the password.

6. Information query - password entry
Press on the “Main Page” to enter the “Infor-

mation Query - Password Entry” page. Enter
the password before entering the “Information
List” page.
Key operation
• Press F1 or and to achieve progres-

sive increase or decrease of the number in
the password digit indicated by the cursor.
• Press F2 or and to move the cursor
leftwards or rightwards.
• Press F3 to enter the “Clock Calibration”
page.
Fig.4-9
• Press F4 to enter the “System Unlocking”
page.
• Press F5 or ESC to return to the “Home
Page”.
• Press Enter to confirm the correctness of the
password. If it is correct, switch to the “Infor-
mation List”.
7. Time calibration
Press F3 on the “Information Query - Pass-

word Entry” page to enter the “Clock Calibra-
tion” page.
This page is used to display the clock setting

information
Key operation
• Press and to achieve progressive

increase or decrease of the number at the
cursor position.
• Press and to move the cursor left-
wards or rightwards.
• Press F1 to confirm the calibration result. Fig.4-10
• Press F5 to return to “Information Query”.

Excavator
8. Information List
Input the correct password on the “Information

Query - Password Entry” page and press Enter
to enter the “Information List” page
This page is used to display the system func-

tion list. Different pages can be entered
through selection of different entries in the list.
When an entry is selected, a description of
the entry function will be displayed at the bot-
tom of the screen.
Key operation
• Press F1 or and to select different
entries in the system function list, move the
Fig.4-11
cursor from top to bottom, and return to the
topmost position when the cursor reaches
the bottom.
• Press F2 or Enter to enter the page corre-
sponding to the entry selected by the
cursor.
• Press F4 to switch to “System Setting”.
Page”.
9. Engine and throttle signal
Select "Operation Information Query" on the

"Information List" page, and then press F2 or
Enter to enter the “Engine and Throttle Signal”
page.
This page is used to display the engine opera-

tion parameters.
Key operation
• Press F1 to switch to “Main Pump Signal”.

• Press F5 or ESC to return to “Information
List”.
Fig.4-12

10. Main pump signal
Press F1 on the “Engine and Throttle Signal”

page to enter the “Main Pump Signal” page.
This page is used to display the main pump

signal.
Key operation
• Press F1 to switch to the “Input Switch Sig-

nal Query” page.
• Press F1 or to ESC : return to “Information
List”.
(The figure above applies to SY125C)
Fig.4-13

Excavator
11. Input switching signal query
Press F1 on the “Main Pump Signal” page to

enter the “Input Switch Signal Query” page.
This page is used to display the input switch-
ing signals.
Key operation
• Press F1 to switch to the “Output Switch
Signal Query” page.
List”.
Fig.4-14
12. Output switching signal query
Press F1 on the “Input Switch Signal Query”

page to enter the “Output Switch Signal
Query” page.
This page is used to display the output switch-

ing signals.
Key operation
• Press F1to switch to the [Engine and Throt-
tle Signal] page.
List”.
Fig.4-15

13. Machine configuration
Select "Machine Configuration Query" on the

"Information List" page, and then press F2 or
Enter to enter this page. The information about
critical parts and components is shown on this

page. Key operation
Key operation
List”.
Fig.4-16
14. DTC query
Select "Fault Information Query" on the "Infor-

mation List" page, and then press F2 or Enter t
to enter this page.
This page is used to display the DTC and

information.
Key operation
• Press F1 to switch to the DTC on the next
page.
List”.
Note: When the DTC alarm appears on the

home page, press F4 to enter the "DTC Fig.4-17
Query” page.

Excavator
15. Maintenance information query
Maintenance information query Select "Main-

tenance Information Query" on the "Informa-
tion List" page, and then press F2 or Enter to
enter this page
This page is used to display the maintenance

information of different hours. The mainte-
nance information page is divided into 6 sub-
pages: Maintenance after every 50 h, 250 h,
500 h, 1,000 h, 2,000 h and 4,000 h.
Key operation
• After the completion of maintenance, press
F1 or Enter for confirmation.
• Press F4to pause or start the display of Fig.4-18
“Maintenance Interval” and “Maintenance
Content”.
List”.
Note: When the maintenance indicator
(symbol ) appears on the home page,
press to enter the “Maintenance Infor-
mation Query” page.
• Note
SY115C9, SY125C9I3H, SY135C9, SY155C9,

and SY155H of China III needs no speed
calibration.
Fig.4-19

16. System Language Selection
Select “System Language Selection” on the

“Information List” page, and then press F2 or
Enter to enter this page.
This page is used to select the system

language.
Key operation
• Press F1or and r and to move the
cursor upward or downward to select differ-
ent entries in the list.
• Press F2 to confirm the language selection
result.
List”. Fig.4-20
17. GPS monitoring information
Select “GPS Monitoring Information” on the

“Information List” page, and then press F2 or
Enter to enter this page.
This page is used to display the GPS monitor-

ing information.
Key operation
List”.
Fig.4-21

Excavator
18. Basic settings
Press F2 on the “Information List” page to en-

ter this page. Key operation.
Press F1 to switch between the “Information

List” page and the “Basic Settings” page.
Press F2 to select setting items.
Press F3 to enter the “System Setting - Pass-

word” page.
Press F4 or Enter r to enter the selected setting

items.
Press F5 to return to the “Information List”

page
Fig.4-22

19. Default mode selection (for SY155H)
01: Press F5 on the home page, and enter the

first level password (31868) to enter the “Infor-
mation List” page (Fig. 1).
02: Press F2 to turn the page rightward to en-

ter the “Basic Settings” page (Fig. 2).
03: Press F1 to select “Default Mode Setting”

to enter the default mode setting page .
04: Press F1 to switch to the desired mode,

and press F4 or Enter to save the selected
mode. Press F5 to return to the “Information
List” page.
Note: After the default mode (for example, H

mode) is set and saved, this default mode (for
example, H mode) will be recovered after
each power-off and then power-on. The set
default mode is not affected by the temporary
switching mode. Fig.4-23
Fig.4-24

Excavator
20. System setting password
Press F4 on the “Information List” page to en-

ter the “System Setting - Password” page.
Key operation
• Press F1 or and and to achieve pro-
gressive increase or decrease of the num-
ber in the password digit indicated by the
cursor
• Press F2 or and to move the cursor
leftwards or rightwards.
• Press F3 or Enter to confirm the correctness
of the password. If the password is correct,
switch to the “Machine Configuration Cali-
Fig.4-25
bration” page.
List”.
Note: The system setting password is only

authorized to the relevant debugging or serv-
ice personnel.
21. System Setting
This page is used for gear calibration, configu-

ration calibration, time setting, etc.
Key operation
• Press F1 to select setting items
• Press F4 to enter the selected setting items
• Press F5 to return to the “Information List”
page
Fig.4-26

22. Machine configuration calibration
This page is used to set the machine number.
Key operation
• Press the up arrow key to increase by an in-
crement of 1, and press the down arrow key
to decrease by an increment of 1.
• Press the left or right arrow key to select the
digit position where you want to set the
number.
• Press F5 or Enter to save the calibration re-
sult, and press F2 to confirm the calibration
result.
• Press Esc to return to “System Setting”
page. Fig.4-27
23. Working time calibration
This page is used to set the machine number.
Key operation
• Press F1 or the up arrow key to increase by
an increment of 1.
• Press F2 or the left or right arrow key to
switch between hour and minute.
• Press F4 to save the calibration working
time.
• Press F5 to return to “System Setting”
page.
• Note: Press and hold the up or down arrow
to make a quick switching of the numbers.
Fig.4-28

Excavator
24. Coolant temperature
Enter the password on the “System Setting”

page to enter the “Coolant Temperature”
page. This page is used to display the coolant
temperature.
Key operation
List”.
Fig.4-29
25. Service call

• Press on the “Home Page” to enter the
“Service Call” page. This page is used to
send a call to the service center.
Key operation
• Press F2 to start or end the modification of
mobile phone number.
• Press or to achieve progressive in-
crease or decrease of the number. Press
and hold the key to achieve progressive in-
crease or decrease by 10.
• Press or to select the digit position
of phone number.
• Press Enter to send a service call.
Fig.4-30
Page”.
Note:
• If the call is unsuccessful, the page will al-
ways display "Calling..., please wait!” ；
• If the call is successful, the page will display
“Service department has received your fault
information and will contact you as soon as
possible!”.

4.2.3 Switch
4.2.3.1 General
Fig.4-31
[1] Ignition switch [6] Ceiling lamp switch

[2] Throttle control knob [7] Horn switch
[3] Working lamp switch [8] Indoor lamp switch
[4] Wiper switch [9] Cigar lighter
[5] Washer switch
4.2.3.2 Ignition switch
The ignition switch is used to turn on or turn

off the engine. The ignition switch has four po-
sitions: HEAT, OFF, ON and START.

Excavator
OFF position
The key can be inserted or removed. Both the

switches of the electric system (except the
outdoor lamp) and the engine are turned off.
ON position
The current will flow through the charge and

the lamp circuit. When the engine is running,
the ignition switch key will remain in this
position.
Fig.4-32
START position
This is the engine start position. The key will

remain in this position upon start. Immediately
release the key after the engine start. It will
automatically return to the [ON] position.
HEAT position
This is the engine warm-up position. Insert the

key, then anticlockwise turn it to the [HEAT]
position and keep it at the position to warm up
the engine. After released, the key will auto-
matically return to the [OFF] position to stop
the warm-up.
Note: For the machine equipped with glow

plug switch, the engine warm-up method may
be different. The [HEAT] position of ignition
switch for some models is invalid. For details,
see the Section “Glow plug switch” on Page
4-28.

4.2.3.3 Throttle control knob
The throttle knob can be used adjust the en-

gine speed and output power. Rotate it clock-
wise to increase the engine speed, and rotate
it counterclockwise to reduce the engine
speed.
Leftmost position [MIN]: Low idle speed
Rightmost position [MAX]: Full speed
Fig.4-33
4.2.3.4 Working lamp switch
The working lamp switch is used to turn on

and turn off the boom working lamp and the
platform working lamp.
Fig.4-34
Working lamp position
a. Boom working lamp―1
Fig.4-35

Excavator
b. Right platform working lamp―1
Fig.4-36
4.2.3.5 Ceiling lamp switch
The ceiling lamp switch is used to turn on and

turn off the external ceiling lamp of cab.
Fig.4-37
Ceiling lamp position
Fig.4-38

4.2.3.6 Wiper switch
CAUTION
• When using the wiper, please press down
the washer switch to spray a certain
amount of detergent to prevent friction and
damage of the wiper.
When the wiper shall be opened when it is

raining or the front windshield is dirty, press
down the wiper switch, and the wiper will
work.
Fig.4-39
Fig.4-40
4.2.3.7 Washer switch
CAUTION
• Before pressing down the switch, it is nec-
essary to confirm that the front windshield
of the cab is closed.
Press down the washer switch to spray the

detergent. Press down and hold this switch,
and the detergent will be sprayed continu-
ously; After release, the switch will bounce
back automatically and the detergent will not
be sprayed anymore. Fig.4-41

Excavator
4.2.3.8 Horn switch
The horn switch is installed on the top of the

right control lever, which is used to sound the
horn.
Press down and hold the switch, and the horn

will sound continuously.
Fig.4-42
4.2.3.9 Indoor lamp switch
The indoor lamp is installed inside the cab,

and the indoor lamp switch can be pressed
down to “Turn On” or “Turn Off” the indoor
lamp of cab.
Position [a]: The lamp is turned on
Position [b]: The lamp is turned off
Note: Even though the ignition switch is at

OFF position, the indoor lamp can be turned
on.
Fig.4-43

4.2.3.10 Cigar lighter and auxiliary

power supply
Use a cigar lighter when lighting a cigarette.
When a cigar lighter is pushed in, it will return

to its original position a few seconds later, and
it can be used after removal.
If the cigar lighter is removed, its socket can

be used as the power supply not higher than
240 W (24 V×10 A).
Note: This cigar lighter is 24 V, and it can’t be

used as the power supply of 12 V equipment.
Fig.4-44
4.2.3.11 Preheating indicator lamp
During engine warm-up in case the coolant

temperature is too low, the glow plug indicator
[1] comes on. After warm-up, the indicator
goes out, after which the engine may be
started.
Fig.4-45
4.2.3.12 Charging indicator
The charging indicator [2] comes on when the

ignition switch is at ON position; the indicator
goes out when the engine is running and the

Excavator
alternator works normally; if the indicator

stays on, check if the alternator is faulty.
4.2.4 Control Levers and Pedals
4.2.4.1 General
2
4
CC13040210-1
Fig.4-46
1) Hydraulic lockout control 3) Travel control

2) Left joystick 4) Right joystick

4.2.4.2 Safety lock control lever
WARNING
• When leaving the cab, the safety lock con-
trol lever shall be firmly located at the lock-
ing position. If the safety lock control lever
is not in the locking position, accidental
touching of the control lever can cause
serious casualties.
• If the safety lock control lever is not firmly
located at the locking position, movement
of the control lever can cause serious acci-
dents. The inspection of the control lever is
as shown in the Figure.
• When pulling or pushing the safety lock
control lever, do not touch the left control
lever.
A safety lock control lever is a device that

locks the work equipment, and swing, travel-
ing and accessory (if equipped) control levers.
• LOCKED position : Push the safety lock

control lever downwards and apply the lock-
ing. The machine will not move even if the
control lever is operated.
• FREE position : The machine will move
according to operation of the control lever. CC13031504
The lever is a hydraulic locking lever. Fig.4-47

Therefore, when it is locked, the control lev-
er or the control pedal will move, but the
machine will not move.

Excavator
When all the control levers are at the neutral

position and the safety lock control lever is
pushed to “UNLOCK” position, if any part of
the machine moves, it indicates that the ma-
chine is faulty. In this case, immediately pull
the safety lock control lever back to the LOCK
position and stop the engine. And then con-
tact SANY Heavy Machinery or its authorized
agent.
CC13030402
Fig.4-48
4.2.4.3 Travel control levers
WARNING
• Do not put your feet on the pedal while op-
erating. If the pedal is stepped down acci-
dentally, the machine will suddenly move
and cause a serious accident.
• Please be cautious when using a pedal for
traveling or steering. Do not put your feet
on the pedal when you do not use the
pedal.
The travel lever and traveling control pedal

a
(as shown in the right Figure) are used to con-
trol machine traveling and change traveling di- N
a
rection of the machine.
a.Forward: N b
Push the travel lever forwards (or step down

b
front part of pedal) a
a
(The pedal tilts forward) b
b
b. Reverse:
Pull the travel lever backwards (or step down

rear part of pedal)
CZ335-1103054
N -Stop the machine (return the travel lever

Fig.4-49
and pedal to the neutral position)

NOTE: Confirm the sprocket position before

operating the travel lever or pedal. Ensure
that the sprocket is at the back of the ma-
chine. If the sprocket is in front of the machine
and the travel lever is pushed forwards, the
machine will move backwards.
4.2.4.4 Control levers
WARNING
• Do not extend any part of your body out of
the window. If you knock into the boom
control lever accidentally or for other rea-
sons, you may be hit by the boom. If the
window is lost or damaged, it shall be re-
paired or replaced immediately.
• Before operation, be familiar with the posi-
tion and function of each control lever to
prevent injury caused by accidental move-
ment of the machine.

Excavator
The following is an example of the SAE mode.

For details, see the “Work Equipment Control
and Operation” on page 4-90. 3
1
Left control lever 2
4
Action of the left control lever
1 Front Arm dumping
2 Back Arm digging
3 Left Left swing
4 Right Right swing CC13031505
Fig.4-50
• The diagonal movement of the joystick can
realize two functions simultaneously and al-
low compound action.
3 4
CZ335-1103056
Fig.4-51

Right control lever
Action of the right control lever 8

5
5 Front Boom lowering
6 Back Boom lifting 6
7
7 Left Bucket digging
8 Right Bucket dumping
• The diagonal movement of the joystick can

realize two functions simultaneously and al-
CC13031506
low compound action.
Fig.4-52
NOTE:
• When the travel lever and control lever are

in the neutral position, even if the fuel con-
trol knob is turned to the speed higher than 5
the medium speed, if one of the travel lev-

7 8
ers is operated, the engine speed will rise
to the speed set by the fuel control knob. 6
• If the control levers and joysticks are all at
neutral position, the engine speed drops by
approximately 100 rpm, and after approxi-
CZ335-1103058
mately 3 seconds, it drops automatically to
Fig.4-53
the set speed (approximately 1400 rpm).
• When the travel lever and the control lever
are released, it will automatically return to
the neutral position and the machine func-
tion will be disabled.
4.2.5 Ceiling window
WARNING
• When leaving the driver’s seat, the safety
lock control lever shall be firmly located at
the locking position. If the safety lock con-
trol lever is in the unlocking position, acci-
dental touching of the travel lever or pedal
can cause serious accident.

Excavator
ON
1. Turn the safety lock control lever to the

“LOCK” position.
CC13031403
Fig.4-54
2. Push the lock [B] on both sides of the roof

handle [A] upwards, and then hold the handle
B B
[A] and push the roof upwards.
OFF
1. Hold the handle [A] to pull the roof down-

wards, and the lock [B] will be automatically
CZ335-1103060
applied. If the lock can't be properly engaged,
Fig.4-55
open the roof and try to lock it.
4.2.6 Windshield
• The front windshield can be retracted

(pulled) to the top of the cab.
• Before opening or closing the front wind-
shield, stop the machine on the level
ground, completely drop the work equip-
ment to the ground, stop the engine, and
then operate it.
• When opening the front windshield, hold
the handle and pull it upwards with both
hands, and do not loosen hands until the
automatic latch bolt is locked.
• When the front windshield is closed, the
window will move quickly under its own

deadweight. When it is closed, hold the

handle with both hands.
WARNING
• Turn the safety lock control lever to the
locking position when the front windshield,
bottom window or door are opened or
closed.
• If the safety lock control lever is in the un-
locking position, accidental touching of the
travel lever or control pedal can cause seri-
ous accident.
ON
1. Stop the machine on the level ground, com-

pletely drop the work equipment to the
ground, and then stop the engine.

CC13031403
Fig.4-56
3. Check the wiper blade and place it in the

right support.
CZ335-1103062
Fig.4-57

Excavator
4. Hold the left and right handle [A] on the top

of the front windshield and pull two handles
[B] to release the lock on the top of the front
windshield. The top of the front windshield will
be released.
A A
CZ335-1103063
Fig.4-58
B
A
CZ335-1103064
Fig.4-59

5. Hold the bottom handle [C] with left hand

and hold the top handle [D] with right hand in
the cab, and pull it upwards. In addition, push
the latch bolt [E] towards the back of the cab
D
to firmly lock the front windshield.
CZ335-1103065
Fig.4-60
CZ335-1103067
Fig.4-61
CZ335-1103066
Fig.4-62

Excavator
6. Check whether the handle [B] in firmly lo-

cated in the “LOCK” position.
• Check whether the arrow on the lock shell F

[F] is aligned with the arrow on the handle
[B], if yes, the lock will be engaged.
• If the arrow on the lock shell [F] is not
aligned with the arrow on the handle [B], B
the lock will not be engaged. Please repeat

operations in the step 5 to engage the lock. CZ335-1103068
Fig.4-63
OFF
CAUTION
• When closing the front windshield, slowly
lower it down and be careful not to get
stuck.
1. Stop the machine on the level ground, com-

pletely drop the work equipment to the
ground, and then stop the engine.
2. Secure the hydraulic lockout control to the

LOCKED position.
CC13031403
Fig.4-64

3. Hold the left and right handle [A] and pull

the handle [B] downwards to release the lock.
CZ335-1103069
Fig.4-65
4.Hold the handle [C] at the bottom of the front

windshield with left hand, hold the handle [D]
on the top of the front windshield with right
hand, push it forwards, and then slowly lower C
it down.
D
CZ335-1103070
Fig.4-66
CZ135B-1103009
Fig.4-67

Excavator
5. When the bottom of the front windshield

reaches the top of the bottom window, push
the top of the front windshield forwards to G
push it to the left and right latch bolt [G] and

engage the lock.
CZ335-1103072
Fig.4-68
6. Check whether the handle [B] in firmly lo-

cated in the “LOCK” position.
• Check whether the arrow on the lock shell F

[F] is aligned with the arrow on the handle
[B], if yes, the lock will be engaged.
• If the arrow on the lock shell [F] is not
B
aligned with the arrow on the handle [B],
the lock will not be engaged. Please repeat
operations in the step 5 to engage the lock. CZ335-1103068
Fig.4-69
Remove the lower windshield
1. Open the front windshield, and then hold

the left and right handles and pull them up-
wards, and remove the lower windshield.
CZ335-1103077
Fig.4-70

• If the bottom of the front windshield has ac-

cumulated sand or dust, it will be difficult to
remove the front windshield. In addition,
when the front windshield is retracted, the
sticky sand and dust will be brought into the
cab. To prevent this condition, clean the [A]
area before removal. A
CZ335-1103078
Fig.4-71
4.2.7 Doors and windows of cab
ON
1. Press down the latch when opening the

window of the cab door.
2. Slide the front windshield backwards and

(or) slide the rear window forwards.
OFF
1. Slide the front windshield forwards and (or)

CZ335-1103079
slide the rear window backwards.
Fig.4-72
2. Close the doors and windows and ensure
that the latch is completely locked.

Excavator
4.2.8 Cup Holder
There is a cup holder in the cab to facilitate

the driver to place cup (kettle).
Fig.4-73
Fig. 4-70
4.2.9 Ashtray
• This ashtray is on the left of the cup holder.

• When cigarette is put in the ashtray, it shall
be put out. Close the ashtray when it is
placed in.
Fig.4-74
Fig. 4-71

4.2.10 Information pack
• The information pack is located on the back

of the driver’s seat back. The right Figure is
the effect when the seat back is completely
lowered down.
• The “Operation and Maintenance Manual”
is placed in this pack, which can be read
when necessary.
CZ335-1103090
Fig.4-75
4.2.11 Drink box
• The drink box is located on the left side of

the back of the driver’s seat. It can keep the
beverage warm and cool in the winter and
summer.
• It can blow hot or cool air to the drink box
according to the setting of HVAC.
0-13005
Fig.4-76

Excavator
4.2.12 Emergency exit
If the door and window of the cab can't be

opened in case of emergency, the rear win-
dow can be used as an emergency exit.
• If the door and window of the cab can't be

opened in case of emergency, the rear win-
dow can be used as an emergency exit.
CZ215-1103029
Fig.4-77
• For the pull ring rear window, pull the pull Fig.4-78
ring, remove the rubber core from the win-
dow frame rubber, and then push the glass
corner to remove the glass from the
window.
Note: The rear window can be used as an es-

cape exit only in case of emergency. Do not
use it at any time.
4.2.13 Fire Extinguisher
CAUTION
• Be sure to prepare a fire extinguisher and
read the label, and be familiar with the op-
eration method in case of emergency.
-74
• Regularly check the fire extinguisher and
ensure that it is in the warranty period.
• If the fire extinguisher has expired, it shall
be replaced timely.
The fire extinguisher shall be kept in the rear CZ215-1103044

Pull ring
part of the cab.
Fig.4-79
Fig. 4-75
4.2.14 Controller
Be careful not to get water, mud or other liquid

onto the controller. This will cause a fault.
If the controller has any fault, please do not

disassemble it without permission, and con-
tact the authorized agent of SANY Heavy Ma-
chinery for repair
CB13041001-1
Fig.4-80
4.2.15 Fuse link
When the ignition switch is turned to the [ON]

position, if the starting motor can't be started,
the fuse link may have an open circuit. Open
the fuse box cover at the back of the seat, and
check and replace it.
NOTE:
• The fuse link (as shown in the Figure) refers

to the fuse installed on the circuit to prevent
CC13032901
burning electric parts and wires.
• The fuse link has specifications including 5 Fig.4-81
A, 10 A, 15 A and 20 A, which is distin-
guished with different colors. Replace the
old fuse link with the one with the same
capacity.
• Always turn off the ignition switch before re-
placing the fuse link.

Excavator
4.2.16 HVAC group
4.2.16.1 Control panel
1 2 3 4 5
6 7 8
CZ205-1203020G
Fig.4-82
1) OFF switch 5) AUTO switch

2) Fan control switch 6) Air circulation mode switch
3) TEMP switch 7) LCD panel
4) MODE switch 8) HVAC switch
4.2.16.2 Control switch and LCD
1. OFF switch
This switch can be used to turn off fan and

HVAC.
Press down the OFF switch [1], and indication

of the setting temperature and air volume of
the LCD will disappear, the upper lamp of the
automatic mode switch [5] and the HVAC
OFF
switch [8] will be off, and running will be
stopped. CZ335-1103094
Fig.4-83

2. Fan control switch
This switch is used to regulate the volume of

air flow, which can be set to any of six levels.
The amount of air flow is displayed on the

LCD panel.
• Press to increase the air flow.

• Press to decrease the air flow.
• The air flow changes automatically in the
CZ335-1103095
automatic control mode.
Fig.4-84
LCD panel and air flow volume
Table 3–5
3.Temperature setting switch
This switch is used to set the cab tempera-

ture. Temperature setting range: 18~32° C
(64.4~89.6°F)
• Press to increase temperature.

• Press to decrease temperature.
• The temperature is generally set at 25° C
(77°F).
CZ335-1103096
LCD display and function
Fig.4-85

Excavator
LCD displa y Set Temperature

18.0 (°C) Maximum cooling
Adjust temperature inside opera-
18.5~31.5 (°C)
tor cab to selected temperature
32.0 (°C) Maximum heating
Table 3–6
4. Air vent mode setting switch
This switch can be used to select the air vent.
• Press down the switch [4], and the LCD dis-

play mode will be changed, and the air will
be supplied from the air vent under the dis-
played mode. MODE
• The air vent mode will be automatically
switched under the automatic operation
mode. CZ335-1103225
Fig.4-86
Air outlet mode
Air Outlet
LCD Displa y Air Outlet Mode Remark
A B C D
Front ○ Disabled in auto mode
Front-Rear ○ ○
Front-Rear-Bottom ○ ○ ○
Bottom ○
Defrost-Bottom ○ ○ Disabled in auto mode
Defrost ○ Disabled in auto mode
Table 3-7
NOTE: Air comes out of the outlet identified

with ○.

Air vent of HVAC
[A]: Rear air vent: It is generally located at the

back of the cab..
Fig. 4-84
Fig.4-87
[B]: Face air ventt
[C]:Defroster port
Fig.4-88

Excavator
[D]: Foot air vent: It is located below the cab.
NOTE:
• The appearance and quantity of air vent of

HVAC may vary slightly depending on ma-
chine model.
D
• The direction of the face air vent, defroster
port and rear air vent can be adjusted, but
the foot air vent can’t be adjusted.
CZ335-1103100
Fig.4-89
5. Automatic mode setting switch
This switch is used to automatically set the air

volume, air vent and inside and outside air
switching according to the set temperature.
• Press down the automatic mode setting

switch [5], and the indicator lamp on the top AUTO
of the switch will be on.
• Generally, press down this switch and set to
the proper temperature with the tempera- CZ335-1103101
ture setting switch [3], and the HVAC will

Fig.4-90
run automatically.
• When switching from automatic mode to
manual mode, just reset the air volume, air
vent and inside and outside air switching
mode with the switches. In this case, the in-
dicator lamp on the top of the switch will be
off.
When the automatic mode is selected, if the

temperature is set to 18 ℃ (64.4℉) or 32℃
(89.6℉) and the air flow always keeps at
HIGH, this is not a fault.

6.Internal/external circulation mode setting

switch
This switch is used to switch internal circula-

tion and external circulation.
• Press down one of the switches [6], and the

indicator lamp on the top of the switch will
be on.
• The external circulation mode and the inter-
nal circulation mode will be automatically
switched during operation under the auto- CZ335-1103102
matic mode.
Fig.4-91
The external circulation is closed, only the internal circulation

mode is activated
Internal circulation
It is suitable for internal fast cooling and heating or when the
external air is dirty
A mode the external air is introduced into the inside
External circulation
It is suitable for clean air introduction and defogging
7. LCD display
The LCD [7] is used to display the setting tem-

perature [a], air volume [b] and air vent status c
[c] during running.
• Press down the OFF switch [1], and indica-

tion of the setting temperature, air volume a
and air vent status will disappear, and run-
ning will be stopped. b
CZ335-1103103
Fig.4-92
8. HVAC switch

Excavator
This switch is used to control start and stop of

actions (refrigeration, dehumidification and
heating) of HVAC.
• When the fan is working ([b] is displayed on

the LCD), press down the HVAC switch [8], A/C
and the HVAC will be turned on and the in-
dicator lamp on the top of the switch will be
on; press it down again, the HVAC will be
CZ335-1103104
turned off, and the indicator lamp will be off.
• When the fan is turned off (no air supply Fig.4-93
status is displayed on the LCD), the HVAC
can’t be turned on.
4.2.16.3 Operation of HVAC
Operation of HVACl
The HVAC can be controlled automatically or

manually. Select the control mode as re- c
quired. Automatic operation
1. Turn on the automatic mode setting switch

AUTO
a
• In this case, the temperature [a] and air vol-

b
ume [b] will be displayed on the LCD, and
the lamp on the top of the automatic switch
CZ335-1103103
AUTO
and the A/C switch A/C
will be on.
Fig.4-94
2. Adjust the temperature switch and set the TEMP
comfortable temperature.
• Set the temperature accordingly, and the

HVAC will automatically switch the air vol-
ume, the air vent and the inside and outside
air to provide the set temperature.
NOTE:

When the air vent mode [c] displays [d] or [e]

status and the engine coolant temperature is
d e
lower, the air volume will be automatically re-
stricted to prevent blowing air cool air.
Stop AUTO operation
• Press down the OFF

switch， and automatic
operation will be stopped.
CZ335-1103107
Fig.4-95
Manual operation
c
1. Press down the fan speed setting switch
to adjust air volume. In this case, check the
temperature [a] and air volume [b] displayed
on the LCD. a
2.Turn on the A/C switch A/C

.
b
3. Press down the temperature adjustment
switch sto set the cab temperature.
TEMP
CZ335-1103103
4.Press the air vent mode setting switch to MODE

Fig.4-96
set the required mode. In this case, the dis-
play of the [c] on the LCD will be changed ac-
cording to selections.
5. Press down the inside/outside air change-

over switch or and select the cab inside
air circulation or outside air guidance mode.
Stop manual operation
Press down the switch，and manual opera-

OFF
tion will be stopped.
Bi-Level mode

Excavator
To blow cool air to face and hot air to foot,

make setting with the following methods:
1. Press down the fan speed setting switch t

o adjust air volume. In this case, check the
temperature [a] and air volume [b] displayed
on the LCD.
2.Press down the air vent mode setting switch

， and display the air vent mode on the
MODE
LCD as the status as shown in the right CZ335-1103226
Figure.
Fig.4-97
3Turn on the A/C switch A/C
.
4.Adjust the fan speed setting switch switch,

temperature setting switch and inside/out-
TEMP
side air mode setting switch or to the re-

quired position.
Defrosting
1.Press down the fan switch to adjust air vol-

ume. In this case, check the temperature [a] c
and air volume [b] displayed on the LCD.
CZ335-1103103
Fig.4-98

2.Press down the air vent mode setting switch

， and display the air vent mode on the
MODE
LCD as the [f] or [g] as shown in the right f g

Figure.

over switch or ，and set it to the outside
air guidance mode.

over switch ，and set the temperature on the
TEMP
CZ335-1103109
LCD to the hottest (32℃).

Fig.4-99
• During operation in the rainy season or de-
fogging or dehumidification of the window,
turn on the HVAC switch A/C
for
dehumidification.
4.2.16.4 Use HVAC carefully
• When operating HVAC, be sure to start it

when the engine is running at low speed.
Do not turn on the HVAC when the engine
is running at high speed. Otherwise, it will
cause HVAC fault.
• If the water enters the control panel or the
daylight sensor, it will cause an accident
fault. Be careful not to get water on these
parts. In addition, do not make open fire
close to these parts.
• For normal operation of automatic function
Fig.4-100
of the HVAC, be sure to keep the daylight
sensor clean, and do not place anything
around the daylight sensor, otherwise it will
affect the function of the sensor.
Ventilation
• When the HVAC is running for a long time,

the “Inside and Outside Air Mode” shall be
changed to the “Outside Air Guidance”
mode every 1 h for ventilation.
• In case of smoking when the HVAC is
turned on, the smoke will hurt your eyes,

Excavator
therefore, the “Inside and Outside Air Mode”

shall be changed to the “Outside Air Guid-
ance” mode to ensure that smoke can be
removed in continuous cooling.
Temperature control
• When the cooler works, set the temperature

to a value (5 or 6℃ (9 or 10.8 ℉) lower than
outdoor temperature) slightly lower than
that when entering the cab. The tempera-
ture difference is considered to be the most
suitable for health
Inspection and maintenance of machine

with HVAC
• The inspection and maintenance of ma-

chine with HVAC shall be carried out ac-
cording to charts. For details, see the
“Inspection and Maintenance of HVAC” on
page 5-27.
• When the HVAC is not used for a long time,
it is necessary to operate the engine at a
low speed to prevent the loss of the oil film
on each part, and perform refrigeration, de-
humidification and heating for a few
minutes.
• If the cab temperature is lower than the out-
door temperature, the HVAC will not work.
In this case, the circulation of fresh air will
heat up the cab, and the HVAC will work
when the HVAC switch is turned on again.
• If any device or sensor on the HVAC has
any fault, please contact the authorized
agent of SANY Heavy Machinery for in-
spection and repair.

4.2.17 Radio
4.2.17.1 Control panel
6 5 4 3 2 1
PRESET STATION SANY
AS/PS AM/FM TIME SEL
TUNING TIME ADJ VOL

ST
AM
FM
7 8 9 10
CZ335-1103111
Fig.4-101
[1] Power switch key [6] Preset station key (1~6)

[2] Audio conversion key [7] LCD
[3] Time display key [8] Tuning key
[4] FM/AM conversion key [9] Time adjustment key
[5] AS/PS key [10] Volume adjustment key
4.2.17.2 Control key and LCD
[1] Power switch key
• Press down the power switch to power on the radio. The frequency will be displayed on the
display [7]. Press down this switch again to power it off.
[2] Audio conversion key
• After pressing down the audio conversion key ，the audio status will be displayed as fol-
lows: VOL→BAS →TRE →BAL.
• The host will return to the frequency display interface if there is no operation within 5 s.
• there is no operation within 5 s. The audio status will be displayed on the display [7].
[3] Time display key

Excavator
• Press down the time display key when the frequency is displayed, and the current time will
be displayed on the display for 5 s. The display will automatically recover to the frequency dis-
play 5 s later. If pressing down and holding the key [3] for more than 5 s, the national area: ASA:
EU (Asia: Europe) will be displayed.
[4] FM / AM conversion key
• Press down the FM/AM conversion k to select the required band. After this key is pressed
down each time, the band will be switched between FM→AM→FM.
[5] AS/PS (automatic search and preset station) key
• The function of the AS/PS key is to: Automatically search and save the station and browse and
play the preset station.
Automatically search and save the station:
• In the radio status, press down the AS/PS key tand wait for more than 2 s, and it will begin to
automatically search the current band station, save 6 stations with the strongest signal in 1-6
memories in order, and finally lock the station and begin playing.
[6] Preset station key
• If the preset station keys (1~6) are used to determine which stations are preset, you can select
the required station with the key.
[7] LCD
• The receiving band, frequency, preset number and time will be displayed on the display.
[8] Tuning key (TUNING)
• Press down the tuning key and to change frequency.

• key ：Move frequency downwards.
• key ：Move frequency upwards
[9] Time adjustment key (TIME ADJ)
• Press , and to adjust time.

• : Hour adjustment
• : Minute adjustment.
• : Set to zero.
[10] Volume adjustment key (VOL)
• Press down the key in the keys to increase the volume in turn to 40.
• Press to raise radio volume up to 40.
• Press to lower radio volume up to 0.

• It will return to the frequency display interface if there is no operation within 5 s.
4.2.17.3 Operation
Presetting radio station
1. Press to turn on the radio. Radio fre-

quency is displayed on the LCD [7].
6 2 1
2. Press or to locate the desired fre-
quency. There are two tuning ways: manual PRESET STATION SANY
AS/PS AM/FM TIME SEL
and automatic. ST TUNING TIME ADJ VOL

AM
FM
3. When desired frequency is shown on the

display [7], depress one of the preset buttons 7 8
for at least 1.5 seconds. The voice will disap-
CZ335-1103112
pear. But the voice will come back when the
presetting operation (storing to the memory) is
Fig.4-102
completed. The preset button number and the
frequency will be displayed, indicating the
completion of presetting operation. After pre-
setting the stations, press one of the preset
buttons (6) for at least 1.5 seconds in order to
tune in the preset station.
NOTE: The button can be used to preset

the stations automatically.
Searching radio station
1. Press to turn on the radio. Radio fre-

quency is displayed the LCD [7].
2. Press or to locate the desired fre-

quency. There are two tuning ways: manual
and automatic.
• Manual tuning
– Press the tuning buttons [8] till the fre-
quency appears on the display [7].
– When the frequency reaches the top or
bottom frequency, it will automatically
continue in the order of top→bottom or
bottom→top.

Excavator
• Automatic tuning
– Press down and hold the tuning key [8]
to automatically search the station up or
down. When a station is received, the
tuning will stop automatically. In order to
search for the next station, just press
down and hold the tuning key [8].
– If this key is pressed down during the
automatic tuning, the automatic tuning
will be canceled. The setting will recover
it to the frequency used before this key
is pressed down.
Sound effect adjustment
• VOL adjustment (VOL): Press down the

key to increase the volume in turn to 40;
press down the key to reduce the volume
in turn to 0;
• BAS adjustment (BAS): Firstly press down
the key to switch the audio to the BAS

mode, and then press down the or key
within 5 s to change the BAS loudness with-
in the range of +7~-7.
• TRE adjustment (TRE): Firstly press down
the key to switch the audio to the TRE

within 5 s to change the TRE loudness with-
in the range of +7~-7.
• BAL adjustment (BAL): Firstly press down
the key to switch the audio to the BAL

within 5 s to change balance of the left and
right sound tracks within the range of L9-
R9. BAL.0 represents balance between left
and right sound tracks.
NOTE:

For all modes, if there is no operation within 5

s, the LED will be automatically recovered to
the original setting.

Excavator
Time setting
1. Press the TIME button [3] to display the

time. After 5 seconds, the display will return to
3
the frequency display and the time cannot be
corrected. In that case, press the TIME button PRESET STATION SANY
[3] again. 1 2 3 4 5 6 AS/PS AM/FM TIME SEL
TUNING TIME ADJ VOL

ST
AM
H M ADJ - +
2. Press the time adjustment key [9] to set FM
hours or minutes.
9
key : Adjust hours.

CZ335-1103113
(Press this key once to increase 1 hour)
Fig.4-103
key : Adjust minutes.
(Press this key once to increase 1 minute)
Press and hold or key to increase hours

or minutes continuously.
Key Preset time as follows:
• When “00-05” minutes are shown, press the

key to set the time as 00 minute and 00 sec-
ond. (The hours do not change)
• When “55-59” minutes are shown, press the
key to set the time as 00 minute and 00 sec-
ond. (One hour is added)
• When “06-54” minutes are shown, the time
cannot be preset.
(The time remains unchanged)
Example:
10:05→10:00
10:59→11:00
10:26→10:26

Antenna
Before moving the machine to the inside of

the building, the antenna shall be retracted to
prevent any interference. Retract the antenna
as follows:
1
1. Loosen the mounting bolts of the antenna
[1], and place the antenna in the position [A]. A
2. After retracting the antenna, tighten the bolt

[1].
Use the radio carefully CZ335-1103114
• In order to ensure safety, the volume shall Fig.4-104

be kept at the level where the external noise
can be heard during operation.
• If water flows into the loudspeaker box or
radio, it will cause an accident, so be careful
not to get the water on the device.
• Do not use benzene, diluent or other sol-
vent to wipe off the control panel or key.
Wipe it off with a piece of soft cloth. If the
device is too dirty, wipe it off with a piece of
cloth dipped with alcohol.
• When the battery is disconnected or re-
placed, the setting of the preset key and the
clock will be cleared, so all settings shall be
reset.

Excavator
4.2.18 Door lock
CAUTION
• Stop the machine on the level ground be-
fore releasing the door lock.
• Do not release the door lock on the slope.
The door may be closed suddenly and
damaged.
• Do not extend your body or hand out of the
door before you release the door lock. Do
not put your hand on the door frame. The
door may be suddenly closed and
damaged.
1. Push the cab door to the latch bolt [1] direc-

tion to lock it.
2. When closing the door, press down the

handle [2] on the left side of the driver’s seat
to release the latch bolt [1].
1
When the door is opened, lock the door firmly
to the latch bolt [1].
2
CZ335-1103082
Fig.4-105

4.2.19 Lock cap
4.2.19.1 General
Open/close lock on the cap and cover with the

starting switch key.
• For details of the lock cap and cover, see

the “Locking” on page 4-104.
• Insert the key to the shoulder [A].
CZ335-1103083
Fig.4-106
Turning the key when it is not inserted at the bottom may cause breakage.
4.2.19.2 Open and close the lock cap

Excavator
Unlocking
1. Slide off cover [1] to expose the key slot.

1
2. Insert the ignition key into the slot. 2
3. Turn the key clockwise to mark A on the

cap to unlock the cap [2].
B
Position [A]: Unlock

A
Position [B]: Lock
CZ215-1103001
Fig.4-107
Locking
1. Screw on the cover [2] tightly and insert the

ignition key into the key slot.
1
2. Turn the key to LOCK position [B], and then
remove the key.
3. Slide cover [1] onto the key slot.

B
CZ215-1103002
Fig.4-108
4.2.19.3 Open and close the lock cover
Open the cover (locked cover)
1. Insert the ignition key into the key slot.

A
2. Turn the key counterclockwise to unlock the
cover and open it by the handle.
Position [A]: Unlock
Position [B]: Lock
Lock the cover B
CZ335-1103085
1. Close the cover, and insert the key into the
key slot. Fig.4-109

2. Rotate the key clockwise and remove it.

Excavator
4.2.20 Toolbox
It is used to store tools.
CZ205-1203022G
Fig.4-110
4.2.21 Lubricating grease pump rack (if

assembled)
The lubricating grease pump rack is installed

in the right front tool box of the machine. Hook
the lubricating grease pump on this rack when
it is not used.
4.3 Operation and control of machine

4.3.1 Before engine start
4.3.1.1 Routing inspection
Before starting the engine, check the machine and the part below it. Check whether bolts or nuts
are loose, whether there is oil, fuel or coolant leakage, and check conditions of the work equipment
and hydraulic system. In addition, check whether the wires near the high temperature area are
loose, and there are clearance and dust accumulation.
CAUTION
• Remove the combustible materials around the battery, engine, muffler, turbocharger or other
high temperature parts, otherwise, it may cause fire.
• The leakage of fuel or oil will cause the machine burning.
The following inspection and cleaning shall be performed before starting the engine every day:

1. Check whether the work equipment, cylinder, hose, etc. have cracks and excessive wear or
looseness, and check whether the bucket and arm connections are damaged. If any problem is
discovered, it shall be repaired or replaced.
2. Remove the dirt and debris around the engine, battery and radiator.
Check whether there are dirts around the engine and radiator. In addition, check whether there are
combustible materials (dry leaves, twigs, etc.) around the battery, engine muffler, turbocharger, or
other high temperature parts. If dirts or combustibles are discovered, remove them.
For a method to remove dirt from the radiator, see the “Cleaning and Inspection of the Radiator
and Cooler Fins” on page 5-48.
3. Check for leakage of coolant and oil around the engine.
Check whether the engine has oil leakage and the cooling system has coolant leakage. If any
problem is discovered, repair it.
4.Check whether the hydraulic device, hydraulic tank, hose and adapter have oil leakage.
Check for oil leakage. If any problem is discovered, repair the leaky oil part.
5.Check whether the lower body (track, sprocket, guide wheel, guard board) is damaged and worn,
and whether bolts are loose or roller has oil leakage. If any problem is discovered, repair it.
6. Check whether the handrail and step are defective, and whether bolts are loose.
If any problem is discovered, repair it. Tighten loose bolts.
7. Check whether the instrument and monitor are defective.
Check whether the instrument and monitor inside the cab are defective. If any problem is discov-
ered, replace the parts. Remove dirts from the surface.
8. Clean and check the rearview mirror.
Check whether the rearview mirror is damaged. If damaged, repair it. Clean the surface of the mir-
ror and adjust the angle, so as to ensure that the rear area can be seen while sitting on the driver’s
seat.
9. Check seat belt and fixing clamp.
Check whether the seat belt and fixing clamp are damaged or worn. If damaged, replace the part
with a new one.
10. Check whether the bucket with hook (if equipped) is damaged.
Check whether the hook, guide plate, and hook seat are damaged. If any fault is discovered,
please contact the authorized agent of SANY Heavy Machinery for repair.

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4.3.1.2 Inspection before start
Always check the items in this section before starting the engine every day.
Drain water and sediment from the fuel tank.
1. Remove the fuel tank lower cover.
2. Place a container under the drain valve [1]

to hold discharged fuel.
3. Turn the drain valve [2] to "Open" [O] posi-

tion to make all sediments and water accumu-
lated at the bottom flow out with the fuel.
4. When clean fuel flows out, turn the drain

valve [2] to "Close" [S] position.
Fig.4-111
5. Refit the lower cover.
Check and drain out water and sediment in

water separator
1. Open the access door on the right side of

the machine. 1
2. Observe it through the transparent shell [1]

to judge the water level and the amount of
sediment. If there is water or sediment accu- 2
3
mulation at the bottom, place a container
CC13040701
under the drain hose [3] to hold discharged
water. Fig.4-112
3. Release the drain valve [2] for drainage.
4. Tighten the drain valve [2] immediately

when the fuel begins to flow from the drain
hose [3].
NOTE:
4
• If transparent shell [2] is too dirty or when it
is difficult to see inside, clean the transpar- CC13040702
ent shell during replacement of the filter
element. Fig.4-113

• If drain valve [3] is removed during clean-

ing, apply the O-ring [4] with lubricating
grease and tighten it to contact with the
bottom.
Check oil level of the hydraulic tank
WARNING
• When the engine is stopped, the parts and
oil are still very hot, which may cause
scalding. Start operation after they are
cooled down.
• When the filler cap is removed, slowly ro-
tate it to release the internal pressure and
then remove it. CC13041001-1
Fig.4-114
1. Adjust the work equipment to the position
as shown in the right Figure, and then stop
the engine.
F
2. Move the work equipment travel lever and
travel lever in all directions during the whole
G
trip within 15 s after the engine is stopped to
release the internal pressure. P

the machine to check the oil lever gauge [G].
CZ335-1103126
When the engine is cold: (oil temperature:
Fig.4-115
10~30°C or 50~86°F) L+12.5~L+32.5
• When the engine is warm: (oil temperature:
55~80°C or 131~176°F)
• When the engine is warm: higher than the
middle oil level H
4. If the oil level is lower than the L line, fill oil

through the filler [F] on the top of the tank.
• Caltex anti-wear hydraulic oil HDZ46 is rec-
ommended. （B420106000036） L
• Capacity of hydraulic tank: 150 L

CZ335-1103127-1
Note:
Fig.4-116

Excavator
Stop oil filling when it reaches the H line. This

will damage the hydraulic device and cause
oil spraying. If oil level is higher than the H
line, stop the engine. After oil is cooled down,
place an oil container below the drain plug [P]
at the bottom of the hydraulic tank, and then
drain the excessive oil from the drain plug.
Check the coolant level Fig.4-117
WARNING
• After the engine is stopped, the coolant will
be very hot and the radiator will have a
high pressure status. If the radiator cap [1]
is removed and the coolant level is
checked at this time, there will be a scald-
ing hazard. Therefore, remove the cap [1]
after it is cooled down. After that, slowly ro-
tate the cap to release the internal
pressure.
1. When the engine is working, the cooling

water level shall be located between the
upper and lower limit marks of the cooling
water tank. If the coolant level is lower than
the lower limit, the radiator and the expansion
tank shall be filled with coolant.
2. Open the door on the left rear side of the

machine to check whether the coolant in the
auxiliary water tank [2] is between FULL and
LOW marks. If the coolant level is low, the
coolant shall be filled to FULL liquid level
through the filler of the auxiliary water tank [2].
3. Tighten the cap after filling the coolant.
4. If the auxiliary water tank [2] is empty, there

may be a leakage of coolant. After inspection,
repair it immediately. If there is no problem,
check the coolant level in the radiator. If the

SY115C9/125C9/135C9/ C9/
coolant level is low, fill the coolant to the auxili-

ary water tank [2].
5. If the auxiliary water tank [2] is very dirty

and the liquid level can't be seen, refer to the
“Replacement of Engine Coolant and Clean-
ing of Cooling System” on page 5-66.
Check oil level of engine oil pan Fig.4-118
WARNING
scalding. Relevant operation can be car-
ried out after they are cooled down.
1. Open the engine hood.
2. Remove the oil dipstick [G] and wipe off oil

on it with a piece of cloth.
3. Insert the oil dipstick [G] completely and

Fig.4-119
then remove it.
4. The oil level shall be located between the H

and L marks on the oil dipstick [G]. If the oil
level is lower than the L mark, fill oil through
the filler [F].
5. If the oil level is higher than the H line, open

the drain valve [P] at the bottom of the engine
oil pan, drain the excessive oil, and then
check the oil level.
If the oil level is proper, tighten the filler cap

firmly and close the engine hood.
• Before checking oil level after engine opera-

tion, wait at least 15 minutes after the en-
gine stop.
• Keep the machine level before the
inspection.
P
Check wires
CZ335S-1103057
Fig.4-120

Excavator
CAUTION
• If the fuse has been burnt frequently or if
there is a short circuit in the wire, please
contact the authorized agent of SANY
Heavy Machinery to find the cause and re-
pair it.
• Keep the upper surface of the battery
clean, and check the air vent on the battery
cap. If the battery cap is blocked by dirt or
dust, flush it to clean the air vent.
Check whether the fuse is damaged, whether

the specified capacity fuse is used, whether
the wire has trace of open circuit or short cir-
cuit, or whether the cable cladding is
damaged.
Check whether the terminal is loose. If loose,

tighten them.
In addition, pay special attention to wires

when checking batteries, motors, starting mo-
tors and alternators. Be sure to check whether
there is a flammable accumulation around the
battery. If flammable material is discovered,
remove it immediately
Check the fuel level
WARNING
• When filling fuel, do not spill or overflow
the fuel. This will cause a fire.
• Fuel is flammable. Do not make open fire
close to fuel.
• If the fuel is spilled, clean it thoroughly. If
the fuel flows to the ground or sand, re-
move it.

1. Turn the ignition switch to the [ON] position,

and check the fuel level indicated on the dis-
play. After inspection, turn the switch back to
[OFF] position.
E F
CZ215-1303002
Fig.4-121
2. If discovering that the fuel level is low, re-

lease the filler cap [F] on the fuel tank, and fill
F
the fuel through the filler until the float of the
float level meter [G] reaches the highest point.
• Capacity of fuel tank: 240L

• When the fuel tank is filled up, the top [a]
position of the float level meter [G] is about
50 mm.
• When the fuel amount is less than 10%, the CZ335-1103134
display will send an alarm.

Fig.4-122
3. Fill the fuel, press down float level meter [G]

in a straight line through the filler cap [F], be F
careful not to clamp it to the boss of the filler
cap [F], and then tighten the filler cap [F]. a
CZ335-1103135
Fig.4-123

Excavator
NOTE:
• If the air vent on the cap is blocked, the

pressure in the tank will drop and the fuel
will not flow. Clean the air vent frequently.
• When the lock cap is tightened, the stroke
is larger. Ensure that the lock cap is rotated
properly, and then turn the key to lock the
lock cap. If the key is removed when rota-
tion is not completed, the latch bolt will CZ335-1103136
touch on the inner wall of the filler to dam-

Fig.4-124
age the lock cylinder.
• It is necessary to ensure the cleanness of
the sealing ring in the lock cap. If the seal-
ing ring is stained with impurities including
iron chips and stones, it will be easily dam-
aged during tightening, causing improper
sealing of the lock cap.
4.
Check the working lamp switch
Check whether the working lamp can be nor-

mally turned on.
Check for any dirt or damage.
If any lamp does not work, the bulb may be

burned or broken circuit may be present. Con-
tact your Sany dealer for repair.
CC13040203
1. Turn the ignition switch to the [ON] position.
Fig.4-125
2. Turn on the working lamp switch to check
whether the working lamp is turned on.

Check the horn
2. Check whether the horn makes a sound im-

mediately after the horn switch is pressed on,
and confirm whether the sound is normal. If
the horn doesn’t make a sound or its sound is
abnormal, please contact the authorized
agent of SANY Heavy Machinery for repair CC13040209
Fig.4-126
4.3.1.3 Adjustment before operation
Driver’s seat
D
Before starting operation or after changing the
driver, adjust the seat position to ensure that
the driver can operate the travel lever, pedal
and switch freely and easily when sitting in
the seat.
[A] Depth adjustment of seat E
• Pull up the pull rod [1] to move the seat to

A
the required position, and then release it.
C
• Adjustment distance: 200 mm (10 mm per
grade)
[B] Overall dept adjustment of seat
• Pull up the pull rod [2] to adjust it to the re- 1
quired position, and then release it. In this

3 2 4
case, the driver’s seat, left and right armrest
boxes and the pilot lock rod will slide B CZ335-1103139
together. Fig.4-127
[C] Adjustment of suspension (if
equipped)
• Turn the shifter lever [3] to the left, and the

suspension will become harder to suit the
heavier driver. Turn the shifter lever [3] to

Excavator
the right, and the suspension will become

softer to suit the lighter driver.
NOTE:
In order to achieve the best adjustment, adjust

the reading (kg) of dial [4] to the position cor-
responding to the driver’s weight.
[D] Adjustment of rear seatback
• Pull up the handle [5], place the seatback

back to the best position for easy operation,
and then release the handle.
CZ335-1103140
Fig.4-128
When adjusting the inclination of the seatback, be careful not to interfere with the rear HVAC panel,
and be careful not to make the handrail contact with the operation lever.
[E] Adjustment of handrail angle
• Rotate the adjustment dial [7] at the bottom 6

of the armrest [6] to adjust the angle of the
armrest to the required position.
• Lift the armrest to the vertical position to en-

7
sure that the driver can leave the seat.
• Armrest adjustment angle range: 40°
CC13031516
Fig.4-129

Rearview mirror
CAUTION
B A
• Be sure to adjust the rearview mirror be-
fore start. If no correct adjustment is made,
the sight line can’t be guaranteed, and per-
sonal injury may be caused.
The installation position of the rearview mirror

is as shown in the Figure.
CZ335-1103142
Rearview mirror [A]
Fig.4-130
Adjust installation of the rearview mirror [A] to
ensure the personnel at the left rear side of
the machine can be seen.
• Install the rearview mirror [A] in the position

as shown in the right Figure.
• Rotate the fixing rod [1] around the lever [4]

to a proper position, and fix the fixing rod
[1].
• If the mirror can’t move smoothly when ad-

justing the angle, release the fixing bolt [2]
and the fastening lever bolt [3] of mirror. Fig.4-131
Tightening torque of bolt [2]: 4.0~5.4 N·m

(0.41~0.55kgf·m)
Tightening torque of bolt [2]: 4.0~5.4 N·m

(0.41~0.55kgf·m)

Excavator
• When adjusting the angle of the rearview

mirror, the sight line entering the mirror on
the side of the machine shall prevail, as
shown in the right Figure.
Fig.4-132

Rearview mirror [B]
Adjust installation of the rearview mirror [B] to

ensure the personnel at the right rear side of
the machine can be seen.
• Install the rearview mirror [B] in the position

as shown in the right Figure.
M：120mm
• If the mirror can’t move smoothly when ad-

justing the angle, release the fixing bolt [5]
and the fastening lever bolt [6] of mirror.
Fig.4-133
Tightening torque of
bolt [5]x: 4.0~5.4
N·m
（0.41~0.55kgf·m）
Fig. 4-132
• When adjusting the angle of the rearview

mirror, the sight line entering the mirror on
the side of the machine shall prevail, as
Fig.4-134 Fig. 4-133
Seat belt
WARNING
• Before using the seat belt, check
whether the seat belt and its mounting
seat are defective, and replace them if
worn or damaged.
• Even if the seat belt looks normal, it
shall be replaced every 3 years. The
production date of the seat belt is
marked on its back.
• Wear seat belt during operation.
• The seat belt can’t be twisted when it is
fastened.

Excavator
Note: The seat belt is attached with a winding

device, so it is unnecessary to adjust the
length.
1. Fasten the seat belt 4 3 2 1
• Hold the seat belt clamp [2] and pull the

seat belt out from the winding device [1].
SS
PRE
Ensure that the seat belt is not twisted, and
then insert the latch bolt [3] into the latch
[4]. Pull the seat belt gently to ensure that it CZ335-1103147
is fastened. Fig.4-135
2. Release the seat belt
• Press down the red part on the latch [4],

and the latch bolt [3] will automatically pop
up from the lock [4].
• The seat belt will be automatically involved

in the winding device [1]. Hold the seat belt
clamp [2] to slowly wind the seat belt into
the winding device [1].
4.3.1.4 Operation before engine start
WARNING
• Before engine start, check whether the
safety lock control lever is firmly lo-
cated at the locking position.
• If the safety lock control lever is not
firmly locked and it knocks with the
travel lever or pedal during engine start,
the machine will move accidentally and
cause serious accidents.
• When standing from the driver’s seat,
be sure to set the safety lock control
lever to the locking position regardless
of whether the engine is running.

1. Check whether the safety lock control lever

is located at the “LOCK” position.
2. Check whether the travel lever and pedal

are in the “Neutral” position. If there is no con-
tact with the travel lever or pedal, they shall
be located in the “Neutral” position.
CC13031403
Fig.4-136
3. Turn the key to the [ON] position.
4. Monitor the status of the machine through

the main page of the display. For details of the ON
OFF
display, see the “Display Screen” section.
STA
T
HEA
RT
• If there is any fault, the alarm lamp will be
on.
• In this case, if the fault code is displayed,

the corresponding item of the fault code CC13031804
shall be checked immediately.

Fig.4-137
• If there is no fault code, there are two possi-
bilities: The engine coolant temperature is
too high;
The engine oil pressure is too high or too low.

Excavator
4.3.2 Engine start
WARNING
• Start the engine only when sitting in the
driver’ s seat.
• Do not start the engine by short circuit-
ing the engine. This can cause serious
personal injury or fire.
• Ensure that there are no personnel or
obstacles in the surrounding area, and
then make the horn sound and start the
engine.
• Do not use start-assisted liquid, be-
cause it will cause explosions.
• The exhaust gas is poisonous. When
starting the engine in enclosed space,
special attention shall be paid to ensure
good ventilation.
• Before starting the engine, check whether

the fuel control knob is located at a low idle
speed [MIN] position. If the fuel control knob START X
MA
is located at the full speed [MAX] position, ON
the engine start will suddenly accelerate

O FF
AT
and damage the engine parts.

HE
NIM
• The ignition switch key can’t be kept at the
[START] position for more than 10 s
consecutively. CC13031502
• If the engine is not started, wait for at least
Fig.4-138
1 minute before restart.
• After the engine is started, it can be oper-
ated after the engine oil pressure value is
within the normal range. When the engine
oil pressure is abnormal, do not operate the
travel lever or pedal, and stop the machine
immediately for inspection.

1. Check whether the safety lock control lever

is located at the “LOCK” position. If the safety
lock control lever is in the “Unlocking” posi-
tion, the engine can’t be started.
CC13031403
Fig.4-139
2. Set the fuel control knob to a low idle speed

[MIN] position.
MA
X
MIN
CC13031401
Fig.4-140
3. Turn the ignition switch key to the [ON]

position.
NOTE: ON
OFF
STA
T
HEA
When the ambient temperature is lower than

RT
10 ℃ or when required, the engine shall be

preheated before start. For details, see the
section “Glow plug indicator” on Page 4-28.
CC13031804
Fig.4-141

Excavator
4. Turn the ignition switch to the [START] posi-

tion to start the engine.
ON
OFF
STA
T
HEA
RT
CC13031801
Fig.4-142
5. After the engine starts, release the ignition

switch key, and the key will automatically re-
turn to the [ON] position.
ON
OFF
Note:
STA
T
HEA
RT
• If the ambient temperature is low, the en-
gine can’t be started after the ignition switch
key remains in the [ON] position for 10 s. If
this condition occurs, wait for at least 1 mi-
CC13031802
nute before restart.
Fig.4-143
6. Even the engine is started, wait for the en-
gine oil pressure alarm release. When the en-
gine oil pressure is abnormal, do not touch
the travel lever or pedal.
Note:
• If the engine oil pressure is still abnormal

after 4~5 s, the engine shall be stopped im-
mediately to check the oil level and oil leak-
age, and take necessary measures.

4.3.3 Engine Preheating
1. ISUZU Engine:
• Turn the accelerator rotary switch to [MIN]

position, and turn the ignition switch to [ON]
position. Then the engine will be warmed
up automatically, and the glow plug indica-
tor will come on. After warm-up, the glow
plug indicator will go out automatically, after
which the engine may be started.
• After warm-up, turn the ignition switch to
[START] position to start the engine.
• If the engine is not started, wait for at least
1 minute before next warm-up and start
attempt.
4.3.4 Warm-up operation
WARNING
• Turn the ignition switch to the OFF position to stop the engine when there is an emer-
gency or the engine works abnormally or it has other faults.
• When the hydraulic oil temperature is low, do not operate the travel lever or pedal sud-
denly. Be sure to carry out warm-up operation until the hydraulic oil temperature reaches
the proper temperature.
• If no complete warm-up operation is carried out, the machine will have no reaction or
sudden and quick action during operation, resulting in serious accidents. The complete
warm-up shall be carried out especially in the cold region.
• Before warm-up operation is completed, do not make the engine suddenly accelerate.
Do not run the engine at low speed or high speed for more than 20 minutes. This will
cause oil leakage of oil supply pipe of the turbocharger, which may lead to a fire hazard.
If the engine shall be operated at idle speed, the load shall be always applied to run the
engine at medium speed.
After starting the engine, do not start the operation immediately, first carry out the following opera-
tions and inspection:
1. Adjust the throttle knob to keep the engine running at low speed (1,100 rpm) for about 5
minutes.
2. Adjust the throttle knob to make the engine run at medium speed (about 1,400 rpm), and then
slowly operate the bucket back and forth for 5 minutes.

Excavator
3. Adjust the throttle knob to make the engine run at high speed, and then operate the boom, arm
and bucket for 5~10 minutes.
4. Complete the operation of the actions of the excavator for several times, and its warm-up will be
completed.
5. Check whether displays of the instrument are normal after the warm-up operation. If coolant
temperature (see the display) and hydraulic oil temperature (50~80℃) fail to reach the normal val-
ue, continue to carryout warm-up operation.
6. Check whether the color, noise, or vibration of the exhaust is abnormal. If abnormal, repair it.
4.3.5 Stop the engine
CAUTION
• If the engine is not stopped under the
idle status, its service life will be short-
ened. In case of emergency, do not
emergently stop the engine at high
speed. Otherwise, the cylinder head will
have fatigue crack and the supercharg-
er bearing will be burnt.
1. Operate the engine at a low idle speed for

about 5 minutes to gradually cool it down.
ON
2. Turn the ignition switch to the [OFF] posi- OFF
STA
T
HEA
tion, stop the engine, and remove the key

RT
from the ignition switch.
Note:
If the engine is too hot, do not suddenly stop CC13031803
it, but run it at low idle speed to cool it down

Fig.4-144
and then stop it.

4.3.6 Machine Operation
4.3.6.1 General
WARNING
• Before moving the machine, check
whether the area around the machine is
safety and sound the horn.
• No one is allowed to enter the area
around the machine.
• Remove any obstacles on the traveling
path.
• There is a blind spot at the back of the
machine, so pay special attention to it
during reverse traveling.
NOTE:
Before operating the travel lever or traveling

pedal, it is necessary to confirm that the guide
wheel [A] is in front of the machine and the C
sprocket [B] is at the end of the machine [C]. If
the sprocket is located in front of the machine,
the driving direction of the machine will be op-
posite to the operation direction of the travel
lever or the traveling pedal. (The front and A B
rear traveling directions are opposite, and the CC13031518
left and right steering directions are also

Fig.4-145
opposite)

Excavator
4.3.6.2 Preparation of moving machine
1. Turn the fuel control knob to the MAX posi-

tion to the required throttle position to in-
crease the engine speed. MA
X
MIN
CC13031507
Fig.4-146
2. Turn the safety lock control lever to the “Un-

locking” position, and retract the work equip-
ment and lift it up to 40~50 cm from the
ground. As shown on the right Figure.
NOTE:
If the sight line on the right side is poor, lift the

boom to ensure a better sight line.
CC13031404
Fig.4-147
40~50cm
CC13050601
Fig.4-148

4.3.6.3 Move machine
Forward
Push the left and right travel levers forwards

or step down the front part of the left and right
pedals at the same time to move the machine
forwards.
CC13031508
Fig.4-149
Reverse
Pull the left and right travel levers backwards

or step down the rear part of the left and right
pedals at the same time to move the machine
backwards.
NOTE:
• If the sprocket is located in front of the ma-

chine, when operating the travel lever or the
pedal, the driving direction of the machine CC13031509
will be opposite to the operation direction of

Fig.4-150
the travel lever or the traveling pedal.
• Operate the travel pedal or pedal in the

same direction and in the same range to en-
sure that the machine runs in a straight line.
• If the traveling speed of the machine is ab-

normal at low temperature, carry out com-
plete warm-up operation. In addition, if the
undercarriage traveling body is blocked by
mud and the traveling speed of the machine
is abnormal, remove the dirt.

Excavator
4.3.6.4 Stop machine
CAUTION
• Avoid stopping the machine suddenly.
• When stopping the machine, reserve
enough space to leave the machine.
• Release the left and right travel levers or

pedals at the same time to stop the
machine. N
• The travel lever or pedal will automatically

return to the neutral [N] position after N
release.
CZ335-1103169
Fig.4-151
4.3.7 Machine steering
4.3.7.1 General
• Check the sprocket position before operat-

ing the travel lever or traveling pedal. If the
sprocket is located in front part, the opera-
tion direction of the travel lever or pedal will
be opposite to the movement direction of
the machine.
• Try to avoid sudden change of direction. In

particular, stop the machine before steering
in case of reverse rotation (in-situ steering).

4.3.7.2 Turn the machine when it stops
Left turn
• Push the right travel lever forwards, and the

right track will travel forwards, and the ma-
chine will turn to left;
CC13031510
Fig.4-152
or,
• Pull the left travel lever backwards, and the

left track will travel backwards, and the ma-
chine will turn to left..
CC13031511
Fig.4-153
Right turn
• Push the left travel lever forwards, and the

left track will travel forwards, and the ma-
chine will turn to right;
CC13031512
Fig.4-154

Excavator
or,
• Pull the right travel lever backwards, and

the right track will travel backwards, and the
machine will turn to right.
CC13031513
Fig.4-155

4.3.7.3 In-situ steering
In-situ left turn
• Push the right travel lever forwards, and pull

back the left travel lever.
CC13031514
Fig.4-156
In-situ right turn
• Push the left travel lever forwards, and pull

back the right travel lever.
CC13031515
Fig.4-157
4.3.8 Working mode selection
Appropriate working mode shall be selected by the machine display.
Please refer to the relevant instructions in the section “Display” for details.

Excavator
4.3.9 Control and operation of work equipment
CAUTION
• When the engine speed has been re-
duced by the automatic idle speed func-
tion, if the travel lever is operated, the
engine speed will suddenly rise, there-
fore, the travel lever shall be operated
carefully.
• Work equipment is controlled with the left

and right joysticks.
• The joysticks will return to the neutral posi-

tion once released, and the work equipment
will hold at the same time.
• Arm control
Operate the travel lever of the left work equip-

ment forwards or backwards to control action
of the arm.
CZ335-1103175
Fig.4-158
• Slewing control
Operate the travel lever of the left work equip-

ment leftward or rightwards to control slewing
of the upper body.
CZ335-1103176
Fig.4-159

• Boom control
Operate the travel lever of the right work

equipment forwards or backwards to control
action of the boom.
CZ335-1103177
Fig.4-160
• Bucket control
Operate the travel lever of the right work

equipment leftwards or rightwards to control
action of the bucket.
When the work equipment travel lever returns

back to the neutral position, even the fuel con-
trol knob is set to the full speed position within
5 s after the operation stops, the automatic
idle speed mechanism will act and reduce the CZ335-1103178
engine speed to idle speed. Fig.4-161

NOTE:
• The control oil circuit of the machine is

equipped with an accumulator. If the ignition
switch key is turned to the [ON] position and
the safety lock control lever is turned to the
“UNLOCK” position within 15 s after engine
stop, even though the engine is stopped,
the travel lever can be operated to lower
down the work equipment to the ground..
• This step can also be used to release the

residual pressure in oil circuit of the hy-
draulic cylinder or to remove boom after the
machine loaded onto the trailer.

Excavator
4.3.10 Prohibited operation
CAUTION
• When the machine is traveling, if it is nec-
essary to operate travel lever of the work
equipment, stop the machine and then op-
erate the travel lever.
• If any travel lever shall be operated at the
automatic idle speed, the engine speed will
suddenly rise.
The operation with slewing force is prohibited

Do not compress the ground or break objects
with slewing force. This will be dangerous,
and will dramatically shorten the service life of
the machine.
CZ335-1103181
Fig.4-162

The operation with traveling force is prohibited

Do not insert the bucket into the ground and
use the traveling force for digging. This will
damage the machine or the work equipment.
CZ335-1103182
Fig.4-163
The operation when the hydraulic cylinder

reaches the end of the stroke is prohibited
If the cylinder piston rod is operated to the

end of its stroke, the use of the work equip-
ment and the impact of some external force
will damage the hydraulic cylinder and cause
personal injury. Avoid operation when the hy-
draulic cylinder is fully retracted or fully
extended.
CZ335-1103183
Fig.4-164

Excavator
The operation with the bucket drop force is

prohibited
1. Do not use the drop force of the bucket for

digging, crushing or piling. This will dramati-
cally shorten the service life of the machine.
2. To avoid damage to the hydraulic cylinder,

do not hit the ground with a bucket or tamp it
with a shovel when the bucket oil cylinder is
fully extended (the bucket is fully retracted).
It is forbidden to dig hard rock ground
Do not try to dig the hard rock ground directly,

and it is recommended to break it in other
ways before digging. This will not only reduce
the damage to the machine, but also be
economical. CZ335-1103184
Fig.4-165
The operation with the deadweight of the ma-

chine is prohibited
Do not dig with the force arising from dead-

weight of the machine.
CZ335-1103185
Fig.4-166

It is not allowed to suddenly switch the travel

lever or pedal during traveling at high speed
1. Do not operate the travel lever or pedal sud-

A 3
denly to make the machine move quickly.
2
1
2. Do not suddenly switch the travel lever or B
pedal to the reverse [B] from forward [A] (or
from reverse [B] to forward [A]).
3. Do not to suddenly release the travel lever

CZ335-1103186
or pedal during traveling at high speed to stop
the machine. Fig.4-167
4.3.11 Allowed water depth
When the machine is driven out from the

water, if the slope angle is larger than 15°, the
rear part of the upper slewing platform will fall
into the water, the engine fan will touch the
water, and the fan will be damaged.
Be careful when driving the machine out from

the water.
CZ335-1103189
Fig.4-168
• Do not drive the machine into water where

water level could reach the center of carrier
roller [1].
• Apply lubricating grease to the parts that

have been immersed in water for a long
time until the old lubricating grease is com-
pletely extruded from the bearing (espe-
cially around the bucket pin). 1
CZ335-1103190
• The machine can be operated in water only
when the work foundation of the machine Fig.4-169
has sufficient strength to avoid water depth

Excavator
higher than center of the sprocket in case of

sinking of the machine.
• If the slewing support, the slewing gear and

the center swivel joint are immersed in
water, remove the drain plug to remove the
muddy water, sweep the slewing area and
install the plug. Lubricate the internal slew-
ing mesh gear and slewing bearing.
4.3.12 Operation on the slope
4.3.12.1 General
Be sure to operate or drive the machine in the

following correct ways, the machine can be
stopped safely even when the machine is slip-
ping or becoming unstable.
CZ335-1102046
Fig.4-170

WARNING
• When working on a slope, turning or op-
eration of the work equipment will make
the machine unbalanced and tilting, so
this operation shall be avoided.
• It is very dangerous to slew the loaded
bucket downhill. If this operation is re-
quired, a platform shall be built on the
slope with soil to make the machine re-
main horizontal during operation.
• Do not drive the machine on a steep
slope or downhill, it may turn over.
• Do not turn the machine on a slope or
drive it across a slope. Be sure to carry
out these operations on a flat ground. It
may be a little bit further, but it will be
safe.
• When driving the machine uphill, if the
track shoe slips or only the force of the
track is available, the machine can't be
driven uphill. Do not use the pull of the
arm to help drive the machine uphill.
• When the slope angle is larger than 30°,
the engine lubrication will be
insufficient.

Excavator
1. When driving down the steep slope, use the

travel lever and fuel control knob to keep the
low traveling speed. When driving down the
steep slope with an angle larger than 15°, ad-
just the work equipment to the position as
shown in the right Figure and reduce the en-
gine speed.
CZ335-1103192
Fig.4-171
CZ335-1102039
Fig.4-172
2. When driving up the steep slope, extend

the work equipment to the front part to ensure
balance. Keep the work equipment about
20~30 cm higher than the ground and ensure
traveling at low speed.
CZ335-1102040
Fig.4-173
4.3.12.2 Downhill traveling
• Turn the travel lever to the neutral position

to ensure that the brake can work
automatically.

4.3.12.3 Stop engine on the slope
• If the engine is stopped during the uphill

traveling, turn the travel lever to the neutral
position, lower down the bucket to the
ground, stop the machine, and then restart
the engine.
4.3.12.4 Cab door when the machine is on the slope
• If the engine is stopped when the machine

is on the slope, do not use travel lever of
the left work equipment for slewing. The
upper slewing platform will be rotated under
its own deadweight.
• When the machine is on the slope, do not

open or close the cab door, which will
change the machine stress suddenly. Be
sure to keep the cab door open or closed.
4.3.13 Drive the machine out of the mud
4.3.13.1 General
Be careful to avoid getting stuck in the mud. If

the machine is stuck in the mud, drive the ma-
chine out with the following methods.
4.3.13.2 Track on one side gets stuck in the mud
Ensure that the bottom of the bucket is in con-

tact with the ground when the machine is
jacked up with the boom or the arm. The angle
between the boom and arm shall be 90°
~110°. It also applies when using reverse
mounted bucket.
When only track on one side gets stuck in the

mud, jack up the track with a bucket, and then
pave a board or log on it and drive out the
machine. CZ335-1103195
Fig.4-174

Excavator
4.3.13.3 Tracks on both sides get stuck in the mud
When tracks on both sides get stuck in the

mud and slip and the machine can't move,
pave the board with the above method, and
dig the bucket into the ground ahead. After
that, retract the arm and turn the travel lever
to the “Forward” position with the normal dig-
ging operation methods, and drive out the
machine.
CZ335-1103196
Fig.4-175
4.3.14 Recommended purpose
4.3.14.1 General
In addition to the following purposes, the oper-

ation range can be increased with the
accessories.
4.3.14.2 Backhoe operation
The backhoe is suitable for digging of area be-

low the machine.
When the status of the machine is as shown

in the right Figure (namely, both angle be- 90°
tween the bucket cylinder and H-link and an- 90°
gle between the arm cylinder and arm is 90°),
the maximum digging strength can be ob-
tained from the cylinder thrust.
When effectively using this angle during dig- CZ335-1103197
ging, the work efficiency can be fully played. Fig.4-176

The arm digging range includes the area be-

tween 45° away from the machine and 30° 45° 30°
close to the machine.
Depending on the digging depth, the above

range may be slightly different, but it shall be
kept in the above range as much as possible,
and do not operate the cylinder to the end of
its stroke.
CZ335-1103198
Fig.4-177
4.3.14.3 Ditching operation
CZ335-1103199
Fig.4-178
• The ditching operation can be carried out effectively by installing a bucket that matches with the
digging operation and adjusting the track to be parallel with the line of the trench to be dug.
• When digging a wide trench, both sides shall be dug, and then the central part shall be cleared.
• When digging in the longitudinal direction, the travel motor shall be placed in the rear part to en-
sure that the stability and lifting capacity of the machine is the maximum.

Excavator
• During digging operation, adjust the track to

be vertical to the shoulder or cliff and locate
the sprocket at the back of the cab, so as to
ensure that the machine can be easily
evacuated when abnormality occurs
CZ335-1102049
Fig.4-179
4.3.14.4 Loading operation
When the slewing angle is smaller, park the

dump truck in a place visible to the driver to
improve work efficiency.
It is more convenient to start loading from the

rear part of the dump truck than from the side,
and the loading capacity is higher.
CZ335-1103200
Fig.4-180
4.3.15 Parking
WARNING
• If accidentally touching the travel lever,
the machine will suddenly move, which
may cause serious accidents.
• Before leaving the cab, be sure to turn
the safety lock control lever to the

When parking the machine, choose a flat, sol-

id ground and avoid dangerous places. If the
machine shall be parked on the slope, place a
cushion block under the track shoe (as shown
in the Figure). The bucket can be inserted into
120°
the ground as an auxiliary safety measure.
CZ335-1102055
Fig.4-181
1. Turn the left and right travel levers to the

neutral [N] position to stop the machine.
N
CZ335-1103169
Fig.4-182
2. Turn the fuel control knob to a low idle

speed [MIN] position to reduce the engine
speed. MA
X
MIN
CC13031401
Fig.4-183

Excavator
3. Lower down the bucket horizontally until its

bottom reaches the ground.
CZ335-1103207
Fig.4-184

CC13031403
Fig.4-185
5. Check the engine coolant temperature (as

shown in the Figure) and the engine oil pres-
sure through the display.
• If the coolant thermometer is in the red

range, cool down the coolant until the nee-
dle reaches the yellow range, and then stop
the engine. C H
• If the alarm prompt is displayed on the dis-

CC13050802-1
play and abnormal engine oil pressure is
determined, stop the engine immediately. Fig.4-186
6. Stop the engine.
4.3.16 Machine inspection after daily work
1. Check the machine and the work equip-

ment, outside and lower body for leakage of

oil or coolant. If any problem is discovered, re-

pair it.
2. Fill up the fuel tank.
3. Check whether there are paper or other im-

purities in the engine room. Remove paper or
other impurities to avoid fire hazard.
4. Remove dirt from the lower body.
5. If the ambient temperature is lower than -

35 ℃ , be sure to drain coolant in the radiator
and engine (the freezing point of antifreeze
used for SANY Heavy Machinery is -35℃).
4.3.17 Locking
Be sure to lock the following positions
1) Cab door
2) Fuel tank filler 3
3) Engine hood 4
4) Tool box cover 5

7
5) Left door of the machine
1
6) Right door of the machine

CZ335-1103208
7) HVAC “Fresh Air” inlet

Fig.4-187
Note:
Lock and unlock these positions with the igni-

tion switch key.
6
CZ335-1103209
Fig.4-188

Excavator
4.3.18 Operation in cold season
4.3.18.1 Description of operation in cold season
The engine will not be able to start and the coolant may be frozen in a low temperature environ-
ment, so it shall be operated according to the following content.
Fuel and lubricating oil
• All the parts shall be applied with low viscosity fuel and lubricating oil.
• For details of viscosity provisions, see the “Recommended Fuel, Coolant and Lubricating Oil” on
page 5-9.
Coolant of cooling system
WARNING
• The antifreeze is poisonous. Be careful not to get it on your eyes or skin. If your eyes or skin
are stained with it, rinse with plenty of water and see the doctor immediately.
• When replacing coolant or processing coolant containing antifreeze during radiator repair,
please contact the authorized agent of SANY Heavy Machinery or professional company for
processing. The antifreeze is toxic, and do not drain it into the sewer or spill it on the ground.
• The antifreeze is flammable. Do not get close to open fire. Do not smoke when dealing with
antifreeze.
Note:
Please use SANY pure TEEC-L35 antifreeze as coolant. In principle, we do not recommend using
any other coolant other than the pure full-effect antifreeze of SANY Heavy Machinery.
For details on the mixing ratio of the antifreeze during coolant replacement, see the “Coolant of
Cooling System” on page 5-6.
Battery
• When the ambient temperature drops, the battery capacity will also be reduced. Keep the bat-
tery capacity as close to 100% as possible. Do not keep the storage at a low temperature for a
long time to avoid difficult start of the machine.
• Because the battery capacity will drop at low temperature, it is necessary to cover the battery, or
remove it from the machine, store it in a warmer site, and then reinstall the battery when using
the machine.
4.3.18.2 After daily work
In order to prevent movement failure of the

machine on the next day due to frozen mud

and water on the lower body, the following

precautions shall be observed:
• Remove all mud and water from the body.

In particular, the hydraulic cylinder piston
rod shall be cleaned to prevent mud, dirt or
water on the piston rod from entering the
seal and damaging it.
• The machine shall parked on a hard, dry

ground. If possible, park the machine on the
board and prevent the track from freezing
on the ground to ensure that the machine
can be moved on the next day.
• Turn on the drain valve to drain water accu-
mulated in the fuel system to prevent
freezing.
• Fill up the fuel tank. This can minimize

moisture condensation in the tank when the
temperature drops.
• After operation in the water or in the mud,

remove the water on the lower body accord-
ing to the following instructions to extend
the service life of the lower body.
1. When the engine runs at idle speed, rotate

the upper structure by 90° to locate the work
equipment in the side of the track.
2. As shown in the Figure, lift the machine and

lift the track slightly off the ground and idly run
the track. Repeat this operation on both left
and right tracks.
CAUTION CZ335-1103210
• It is dangerous when the track is run- Fig.4-189

ning idly, and the personnel shall keep
a certain distance from the track.

Excavator
4.3.18.3 After cold season
When the seasons change and it becomes

warmer, operate according to the following
content:
• Replace fuel and lubricant with specified

viscosity oil.
For details, see the “Recommended Fuel,

Coolant and Lubricating Oil” on page 5-9.
4.3.19 Long-Term Storage
4.3.19.1 Before storage
When the machine is stored (for more than 1

month), it shall be changed to the position as
shown in the right Figure to protect the cylin-
der piston rod and prevent it from rusting.
When the machine is stored for a long time

(for more than 1 month), operate according to
the following content:
• Clean and flush all the parts, and then store

the machine indoors. If the machine has to
CZ335-1103211
be stored outdoors, choose a flat ground
and cover the machine with canvas. Fig.4-190
• Fill up the fuel tank to prevent moisture

accumulation.
• Before storage, lubricate and replace oil.
• Apply lubricating grease to the exposed part

of the piston rod of the hydraulic cylinder.
• Disconnect the negative terminal of the bat-

tery and cover it, or remove the battery from
the machine and store it separately.
• For machines equipped with accessories,

the accessory control pedal shall be turned
to a locking position.

• To prevent rust, fill the coolant recom-

mended by SANY Heavy Machinery.
4.3.19.2 During storage
CAUTION
• When the machine is indoors and it needs to anti-rust operation, open doors and win-
dows to improve ventilation and prevent gas poisoning.
• During storage, the machine shall be operated once a month and shall be driven in a short dis-
tance, and the parts shall be coated with a new oil film. In addition, the battery shall be charged.
• Wipe off all lubricating grease on the piston rod of the hydraulic cylinder prior to the work equip-
ment operation.
• If the machine is equipped with HVAC, operate the HVAC for 3-5 minutes every month to lubri-
cate all parts of the HVAC compressor. The engine shall be operate at a low idle speed when
the HVAC is operated. In addition, the refrigerant shall be checked twice a year.
4.3.19.3 After storage
If the machine is stored for a long time, but it is not subject to anti-rust operation every month,
please contact the authorized agent of SANY Heavy Machinery before reuse. When reusing the
machine after long-term storage, please observe the following content before use:
• Wipe off lubricating grease of the piston rod of the hydraulic cylinder.
• Fill all lubricating parts with oil and lubricating grease.
• When the machine is stored for a long time, the moisture in the air will be mixed with oil. Check
the oil before and after starting the engine. If there is water in the oil, drain the water completely
and timely.
4.3.19.4 Start the engine after long-term storage
When the engine is started after long-term storage, it shall be fully warmed up.
For details, see the “Warm-up Operation” on page 4-82.

Excavator
4.4 Transportation
4.4.1 General
• When transporting machines, comply with

all relevant laws and regulations, and pay
attention to safety.
4.4.2 Transport methods
• Select a transportation method that

matches the weight and size provided in the
“Technical Specification” section.
• The weight and size provided in the “Tech-

nical Specification” may vary depending on
the type of track shoe, bucket or other
accessories.
• For details of transportation of machines

equipped with the cab protection cover,
please contact the authorized agent of
SANY Heavy Machinery.

4.4.3 Machine loading and unloading machine with trailer
4.4.3.1 General
Be sure to observe the following items of the

access board and trailer platform:
• Use access board with sufficient width,

length, thickness and strength and with a
maximum slope of 15° for loading and
unloading.
• When using the accumulated soil, it is nec-

essary to fully compact the accumulated
soil to prevent the slope from collapsing. CZ335-1103227
• To prevent the machine from slipping on the Fig.4-191

access board, clean the track and access
board of the machine before loading and
unloading.
• If there is water, snow, lubricating grease,

oil or ice on the surface of access board,
the machine may slip.
CZ335-1103228
Fig.4-192

Excavator
4.4.3.2 Loading
1. It can only be loaded and unloaded on a

solid and flat ground. Keep a safe distance
from the roadside.
2. Apply a brake to the trailer and place a

cushion block [1] under the tyre to prevent the
trailer from moving. 2
• Place the left and right access boards [2] to

1
make them parallel to each other and equal 4
3
to the left and right spacing of the trailer
CZ335-1103229
center [3]. The maximum installation Angle
[4] will be 15°. If the access board is bent Fig.4-193
significantly under the weight of the ma-
chine, place a cushion block under the ac-
cess board to prevent the access board MA
from bending. X
MIN
3. Switch the traveling speed to the low speed
status by pressing down the function key of
the display, and disable the automatic idle
speed.
4. Turn the fuel control knob to the [MIN] posi- CC13031401
tion, and set the engine speed to low idle

Fig.4-194
speed.
WARNING
• When driving the machine up or down
the trailer, the automatic idle function
shall be canceled. If the automatic idle
speed function is enabled, the speed of
the engine will change dramatically.
the trailer, the traveling speed shall be
kept in the “Low Speed” mode. Do not
switch the traveling speed randomly.

5. If the machine is equipped with the work

equipment, place the work equipment in the
front part, and drive the machine forwards to
the access board. If there is no work equip-
ment, drive the machine backwards to the ac-
cess board. 90°-11 0°
Support the bucket onto the trailer immedi-

ately after the machine is driven on the access
board. Especially in case of backward travel-
ing, be sure to follow the instructions and sig-
CZ335-1103231
nals of the commander.
Fig.4-195
WARNING
• Do not adjust direction on the access
board, otherwise, the machine will turn
over.
• Do not operate any control lever other
than the travel lever on the access
board.
• If needed, drive the machine to the
ground away from the access board or
back to the trailer before direction
CZ335-1103232
adjustment.
Fig.4-196
6. Ensure that the machine is in a straight line
with the access board and the centerline of
the machine corresponds to that of the trailer
before the machine is driven on the access
board.
Slowly drive the machine in the direction of

the access board.
Lower down the work equipment as much as

possible provided no impact is made.

Excavator
7. Drive the machine slowly forwards until all

the tracks are located on the trailer and firmly
contact with the flat plate.
8. When the machine is passing the rear

wheel of the trailer, the machine will lean for-
ward. Be slow and careful, and do not make
the work equipment touch the trailer body.
9. Slightly lift the bucket, retract the arm and

keep it in the lower part, and then slowly rotate
the upper structure by 180° CZ335-1103233
10.Fully extend the bucket cylinder and arm Fig.4-197

cylinder, and then slowly lower down the
boom.
11.Place a wooden cushion block on one end

of the bucket cylinder to prevent it from touch-
ing the baseplate and damaging the cylinder.
CZ335-1102060
Fig.4-198
4.4.3.3 Securing the machine
• In order to prevent the damage of the buck-

et cylinder during transportation, the wood
shall be placed under the top end of the
bucket H-link to prevent the bucket cylinder
from touching the floor directly.
• Check whether the engine hood latch is

locked. If the engine hood is not locked, it
will be opened during transportation.
Fix the machine on the trailer with following CZ335-1104086

method:
Fig.4-199
1. Fully extend the bucket and arm cylinder,
and then slowly lower down the boom.


3. Stop the engine, and then remove the key

from the ignition switch.
4. Close all the doors, windows and covers.

Lock the cover, cap and door with locks.
CC13031403
Fig.4-200
5. Place the cushion block on both ends of the

track to prevent the machine from moving dur-
ing transportation, and fix the machine with
iron chains or wire ropes with proper strength.
In particular, fix the machine in a proper posi-

tion to ensure that it will not slip to the side.
CZ335-1103237
Fig.4-201

Excavator
Rearview mirror
The rearview mirror is located in the position

as shown in the right Figure. B A
If the rearview mirror is damaged or it shall be

reinstalled after removal for transportation,
the following method shall be adopted.
Removal
1. Release the mounting bolt [2], and then re-

CZ335-1103142
move the rearview mirror [1] from the support
[3]. Fig.4-202
2. Release the bolt [4], and remove the sup-

port [3] and clamp [5] from the handrail.
4
Installation 1
5
1. Install the support [3] and clamp [5] onto the 2
handrail, and then tighten the bolt [4].
3
2. Install the rearview mirror [1] onto the sup-
port [3], and then tighten the mounting bolt [2].
CB13041002-2
Note:
Fig.4-203
Make adjustment after installing the rearview
mirror. For details, see the “Rearview Mirror”
on page 4-74.

4.4.3.4 Unloading
1. The machine can only be loaded and un-

loaded on a solid and flat ground. Keep a safe
distance from the roadside.
2. Brake the trailer and place blocks [1] behind

tires to prevent the trailer from moving.
2
• Place the left and right access boards [2] to
make them parallel to each other and equal
1
4
to the left and right spacing of the trailer 3
center [3]. The maximum installation Angle
CZ335-1103229
[4] will be 15°. If the access board is bent
significantly under the weight of the ma- Fig.4-204
chine, place a cushion block under the ac-
cess board.
3. Remove iron chains and wire ropes for fas-

tening the machine.
4. Start the engine, and fully warm it up.
5. Place the hydraulic lockout control to FREE

position. Turn the safety lock control lever to
the “UNLOCK” position.
CC13031404
6. Switch the traveling speed to the low speed

Fig.4-205
status by pressing down the function key of
the display, and disable the automatic idle
speed.
MA
X
WARNING
MIN

the trailer, the automatic idle function
shall be canceled. If the automatic idle
speed function is enabled, the speed of
the engine will change dramatically. CC13031401
Fig.4-206
the trailer, the traveling speed shall be
kept in the “Low Speed” mode. Do not
switch the traveling speed randomly.

Excavator
7. Turn the fuel control knob to the [MIN] posi-

tion, and set the engine speed to low idle
speed.
8. Lift the work equipment, retract the arm

back to the lower part of the boom, and slowly
start the machine.
9. When driving the machine to the top of the

rear wheel of the trailer, stop it.
CZ335-1103242
Fig.4-207
NOTE:
• When unloading machine, the angle be-

tween the arm and the boom shall be
90~110°
90°-110°
• The machine will be damaged if it is un-
loaded when the bucket is retracted.
• Do not insert the bucket into the ground and

the machine is driven onto the access
CZ335-1103243
board. This will damage the hydraulic
cylinder. Fig.4-208
10.When driving the machine onto the access

board, adjust the angle between the arm and
the boom to 90~110 °, lower down the bucket
to the ground, and slowly move the machine.
11.When driving the machine away from the

access board, slowly operate the boom and
the bucket, and drive down carefully until the
machine is completely away from the access
board.
CZ335-1103244
Fig.4-209

4.5 Lifting
WARNING
• Only the qualified and experienced operator holding official licensee (according to local
law) can operate the crane.
• Do not lift a machine when someone stands on the machine.
• Do not allow anyone to enter the lower or surrounding area of the lifted machine.
• Ensure that the wire rope used for lifting is strong enough to bear the weight of the ma-
chine. Do not use damaged or aged cables or lifting tools.
• Do not lift the machine when the upper body turns to the side of the machine.
• Before lifting, rotate the work equipment to one end of the sprocket and make the under-
carriage parallel to the longitudinal centerline of the upper structure.
• The safety lock control lever shall be turned to the locking position before lifting to pre-
vent the machine from accidentally moving.
• Keep the machine level during lifting.
• Do not lift the machine quickly. Otherwise, the lifting cable or lifting tool will be over-
loaded, which may lead to fracture.
• Do not lift the machine with any other position except that provided in the following
steps, or use any of the lifting equipment except that provided in the following steps.
Otherwise, the machine will lose its balance.
Wire rope selection
• The lifting procedure is applicable to the standard technical specification machine. For details of
machine weight, see the “Technical Specification” section of this manual.
• Select the suitable wire rope according to the weight of the excavator. Refer to the following
table.
Wire Rope
(Ungalvanized standard “Z” twisted rope)
Diameter Allowable Load
mm kN t
10 8.8 0.9
12 12.7 1.3
14 17.3 1.7
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1

Excavator
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
The allowed load value will be estimated by 1/6 or 1/7 of the fracture strength of the cable used.
WARNING
The lifting method will be different according

to the actual accessories and options on the
machine. For proper lifting method, please
contact the authorized agent of SANY Heavy
Machinery.
Lift the machine on the flat ground through the

following methods Standard specification
machine
1. Start the engine, and then swing the upper

structure to locate the work equipment on the
side of the sprocket [1].
2. Fully extend the bucket cylinder and arm

cylinder, and then lower down the work equip-
ment to the ground with the boom cylinder, as
1
CZ335-1103245
Fig.4-210

4. Stop the engine, check whether there are

obstacles around the cab, and then leave the
machine. Close doors and windows of cab.
CC13031403
Fig.4-211

5. Make the wire rope cross through the part

between the first and second front supporting A
wheels and between the first and second rear

supporting wheels. The wire rope of the ma-
chine equipped with a roller guard shall cross
through the wire rope under the track.
6. Adjust the lifting angle of wire rope [A] to

30~40°, and then slowly lift the machine.
7. After the machine is lifted off the ground,

confirm that the hook condition and lifting con- CZ335-1103246
dition are normal, and then slowly lift the

Fig.4-212
machine.
WARNING
• If the cable is too close to the hook, it
will slip off the hook and cause a seri-
ous accident. The middle part of the
hook has the maximum strength.
• Do not lift heavy objects when the sus-
pension angle between the cable and
the hook is large. If the heavy object is
lifted with two or more cables, the
strength of each cable will be increased
along with the increase of the suspen-
sion angle.
• If lifting with a single wire rope, the load
may rotate during lifting, and the wire
rope may be released or slip from the
winding position and cause a danger-
ous accident.

SY115/125/135/155/155 Crawler Hydraulic Maintenance
Excavator
Maintenance
5 Maintenance.......................................................................................................................5-1
5.1 Maintenance Guideline ........................................................................................................5-5
5.2 Treatment of Oil, Fuel and Coolant.....................................................................................5-7
5.2.1 Oil ..................................................................................................................................5-7
5.2.2 Fuel ...............................................................................................................................5-8
5.2.3 Coolant in the cooling system ...................................................................................5-9
5.2.4 Grease ..........................................................................................................................5-9
5.2.5 Storage of engine oil and fuel................................................................................. 5-10
5.2.6 Filter element ............................................................................................................ 5-10
5.3 Electrical System Maintenance........................................................................................ 5-10
5.4 Wear Parts .......................................................................................................................... 5-10
5.5 Recommended Fuel, Coolant and Lubricating Oil ........................................................ 5-12
5.6 Tightening Torque .............................................................................................................. 5-15
5.7 Safety Critical Parts ........................................................................................................... 5-17
5.8 Maintenance Schedule...................................................................................................... 5-18
5.9 Maintenance Procedures.................................................................................................. 5-20
5.9.1 Initial 50-hour maintenance (after the first 50 hours only).................................. 5-20
5.9.2 Maintenance as demanded .................................................................................... 5-20
5.9.2.1 Checking and tightening track shoe bolts ..................................................... 5-20
5.9.2.2 Checking and adjusting track tension ............................................................ 5-21
5.9.2.3 Replacement of bucket .................................................................................... 5-25
5.9.2.4 Replacing bucket teeth (horizontal pin type) ................................................ 5-27
5.9.2.5 Adjusting bucket clearance ............................................................................. 5-29
5.9.2.6 Checking window washer fluid level and filling washer fluid ...................... 5-31
5.9.2.7 Checking and maintaining air conditioning ................................................... 5-32
5.9.2.8 Ceiling window gas spring - inspect .............................................................. 5-34
5.9.3 Checks before startup ............................................................................................. 5-36
5.9.4 Maintenance after every 100 h............................................................................... 5-38
5.9.4.1 Lubricating work equipment ............................................................................ 5-38

Maintenance SY115/125/135/155/155 Crawler Hydraulic Excavator

5.9.5.1 Checking, cleaning and replacing air filter element ..................................... 5-41
5.9.5.2 Checking and adjusting belt tension of HVAC compressor ........................ 5-45
5.9.6.1 Geberal............................................................................................................... 5-46
5.9.6.2 Lubricating swing bearing ............................................................................... 5-46
5.9.6.3 Replacing the oil in engine oil pan, and replace the oil filter
element....................................................................................................... 5-47
5.9.6.4 Checking the level of grease in swing pinion and add grease ................... 5-48
5.9.6.5 Replacing fuel primary filter element.............................................................. 5-49
5.9.6.6 Secondary fuel filter element - replace .......................................................... 5-51
5.9.6.7 Radiator and oil cooler fins - inspect/clean ................................................... 5-54
5.9.6.8 Cleaning the ventilation/circulation filter of HVAC........................................ 5-56
5.9.6.9 Checking the oil level in swing gearbox and refilling ................................... 5-59
5.9.6.10 Checking the oil level of travel gearbox and refilling ................................ 5-60
5.9.7 Maintenance after every 1000 h ............................................................................ 5-61
5.9.7.1 General............................................................................................................... 5-61
5.9.7.2 Hydraulic oil suction filter element - replace ................................................. 5-61
5.9.7.3 Swing drive oil - change................................................................................... 5-63
5.9.7.4 Checking the cab door lock and the front window lock for
fastening..................................................................................................... 5-65
5.9.7.5 Checking the lubricating oil of cab door hinge and front window slide
guide and refill ........................................................................................... 5-66
5.9.7.6 Checking the rocker nut of wiper for looseness ........................................... 5-67
5.9.7.7 Checking all fastening parts of the engine exhaust pipe clamp ................. 5-67
5.9.7.8 Checking the fan belt tension and replace the fan belt ............................... 5-67
5.9.7.9 Checking the nitrogen pressure in accumulator (for hammer)................... 5-67
5.9.7.10 Replacing the hydraulic tank breather filter - cleaning/
replacement............................................................................................... 5-68
5.9.8.1 General............................................................................................................... 5-68
5.9.8.2 Replacing the oil in final drive case ................................................................ 5-69
5.9.8.3 Hydraulic oil suction filter element - cleaning or replacement .................... 5-70
5.9.8.4 Checking the nitrogen pressure in accumulator........................................... 5-71
5.9.8.5 Replacing the engine coolant and cleaning the inside of cooling
system ........................................................................................................ 5-75
5.9.8.6 Checking alternator .......................................................................................... 5-77
5.9.8.7 Checking and adjusting engine valve clearance.......................................... 5-77
5.9.9.1 General............................................................................................................... 5-77
5.9.9.2 Checking water pump ...................................................................................... 5-78
Excavator
5.9.9.3 Checking starter motor..................................................................................... 5-78

5.9.9.4 Replacing accumulator .................................................................................... 5-79
5.9.9.5 Checking the high pressure pipe clamp for looseness, and the rubber
for hardening ............................................................................................. 5-80
5.9.9.6 Checking the operation of compressor.......................................................... 5-80
5.9.9.7 Replacing the oil in hydraulic tank.................................................................. 5-81
5.9.10 Maintenance after every 8000 h .......................................................................... 5-82
5.9.10.1 Maintenance after every 8000 h................................................................... 5-82
5.9.10.2 Replacing high pressure pipe clamp............................................................ 5-82
5.9.11 Maintenance after every 10000 h ........................................................................ 5-82

WARNING

Excavator
5.Maintenance
5.1 Maintenance Guideline
Do not perform any inspection and maintenance not described in this manual.
Hour meter reading
• Check the hour meter reading daily to determine whether maintenance must be performed.
Sany Heavy Machinery Co., Ltd. original wear parts.
Sany Heavy Machinery Co., Ltd. original wear parts
• Use Sany Heavy Machinery Co., Ltd. original parts specified in the parts manual for
replacement.
Sany Heavy Machinery Co., Ltd. original lubricating oil
• Use Sany Heavy Machinery Co., Ltd. original engine oil and grease. Select the appropriate en-
gine oil and grease according to the ambient temperature.
Windshield washer fluid
• Use automobile washer fluid and take care to prevent dirt from getting into such washer fluid.
Clean engine and lubricating oil
• Use clean engine oil and grease. Keep the oil and grease containers clean and prevent foreign
matters from getting into such oil and grease.
Check drained oil and used filter element
• After changing the oil or the filter element, check the used oil and filter element for metal chips
and foreign matters. If you find a lot of metal chips and foreign matters, report this to your super-
visor and take appropriate measures.
Fuel strainer
• If a fuel filter screen is provided at the fuel filler, do not remove the filter screen upon fueling.
Warning sign plate
• Before maintaining the machine, hang a “Do Not Operate” sign or a similar warning sign on the
start switch or direction control to warn others that the machine is under maintenance. If neces-
sary, an additional warning decal can be attached around the hydraulic excavator
Welding instructions

• Turn off the engine starting switch for about one minute and then disconnect the negative (-) ter-
minal of the battery.
• Connect the grounding cable at more than 1 m away from the welding position. If the grounding
cable is connected to instruments, connectors, or other accessories, such meters will malfunc-
tion. If there is a seal or bearing between the welding position and the grounding point, the
grounding point shall be changed to keep away from such parts.
• Do not select the grounding point in the area around the work equipment pins or hydraulic
cylinders.
• Do not use voltages greater than 200 V continuously.
Prevent items from falling into the machine
• When opening the inspection hatch or the fuel tank filler for inspection, take care to prevent nuts,
bolts, or tools from falling into the machine. If they falls into the machine, they will damage the
machine and cause malfunctions and accidents. Therefore, such items shall be taken out imme-
diately after they falls into the machine.
• The items necessary for inspection can be put into your pockets only.
Dusty sites
When working in dusty sites, you shall follow these steps:
• When checking the machine or replacing the oil, stop the machine in a dust-free place to prevent
dust from entering the oil.
• Clean the filter element in a timely manner when the blocking alarm on the air filter gives an
alarm.
• Clean the radiator fins and other parts of the heat exchanger devices frequently and be careful
not to block such fins.
• Clean and replace the fuel filter frequently.
• Clean the electrical components, especially motors and alternators, to prevent dust
accumulation.
Avoid mixing lubricating oil
Do not mix different brands or grades of oil. If you need to add different brands or grades of oil,
drain the old oil and then replace it with new oil.
Lock inspection cover
When opening the inspection cover for maintenance, use the locking lever to firmly lock the cover
on the designated position. If the inspection or maintenance is performed without locking such cov-
er, the cover may suddenly close due to wind and cause personal injuries.
Hydraulic system bleeding

Excavator
When the hydraulic equipment is repaired or replaced, or the hydraulic lines are disassembled and
installed, the air in the oil lines must be discharged.
Installation of hydraulic hoses
• When removing parts at the positions sealed with O-rings or gaskets, clean the mounting sur-
face and replace them with new ones. Be careful not to forget to install O-rings and gaskets.
• Do not twist or bend the hoses during installation. This will damage the hoses and significantly
shorten their service lives.
Inspection after inspection and maintenance
If the inspection is not performed after inspection and maintenance, an unexpected malfunction
may occur, resulting in serious injuries or damages. Be sure to follow the steps below:
• Check when operating the engine

• For details on checking when operating the engine, see “Maintenance during Running of the En-
gine” on the page 2-53, and be careful to ensure your safety.
• Check whether the inspected and maintained items are working properly.
• Check for oil leakage when the engine speed rises and the load is applied on the oil.
• Check after operation (with the engine turned off)
• Check whether you have forgotten any inspection or maintenance position.
• Check whether you have finished all inspection and maintenance items correctly.
• Check whether there is any tool or part that has fallen into the machine. It is very dangerous if
the part falls into the machine and snaps into the linkage mechanism.
• Check whether water or oil leakage occurs and whether all bolts are tightened.
Closing engine hood properly
When closing the engine hood after inspection and maintenance, hold the handle and lift the hood
slightly to check whether the lock tongue is firmly locked. If the engine hood is not locked, it may
open, thus causing dangers.
5.2 Treatment of Oil, Fuel and Coolant

5.2.1 Oil
• The oil in the engine and hydraulic equipment will continuously deteriorate in use due to ex-
tremely harsh working conditions (high temperature and pressure).
• Be sure to use the oil recommended in this manual and matching the highest and lowest ambi-
ent temperatures.
• The oil shall be changed within the specified oil change interval even if it is not dirty.
• As the blood in the human body, lubricating oil shall be treated with care to prevent foreign mat-
ters (water, metal particles or dust) from entering..

• Most of the machine’s failures are caused by the ingress of foreign matters. During storing or fill-
ing oil, special care shall be taken to prevent any foreign matter from getting into the oil.
• The oil shall be filled according to the specified amount of oil, otherwise it will cause abnormality.
• Do not mix different grades or brands of oil.
• If the oil in the work equipment is not clean, there is water in the oil, or the air gets into the oil
lines, contact your Sany Heavy Machinery Co., Ltd. authorized dealer.
• In order to check the condition of the machine, it is recommended that oil analysis shall be per-
formed regularly. If you need this service, please contact your Sany Heavy Machinery Co., Ltd.
authorized dealer.
• When replacing the oil filter element, fill the oil meeting the specification in the new filter element
before installation.
• Please use the oil recommended by our company. Do not use unrecommended hydraulic oil be-
cause it may block the filter element once you use it.
• When changing the hydraulic oil, drain the residual oil in the lines and the cylinder as far as pos-
sible. It is allowed to mix a small amount of two types of oil.
5.2.2 Fuel
• Be sure to fill the fuel tank after the completion of daily work in order to prevent the condensation
of moisture in the air and the formation of water in the tank.
• The fuel injection pump is a precision part and it will not work properly if the fuel being used con-
tains any water or dirt.
• Drain the sediment and water from the fuel tank before starting the engine or 10 minutes after
refueling.
• Flush the fuel tank and the fuel system in case of any impurities found in the fuel tank.
• If the engine has run out of fuel, or if the filter element has been replaced, the air in the lines
must be vented.
• Be sure to use the fuel specified in the “Operation and Maintenance Manual”. The fuel will solidi-
fy when it is used below the specified temperature (especially at temperatures below -15°C (5°
F)). When the fuel is used above the specified temperature, its viscosity will decrease and the
output power will drop.
• When storing the fuel or refueling, care shall be taken to prevent foreign matters from getting into
the fuel.
Note:
• Use diesel as the fuel.

• To ensure good fuel consumption and exhaust characteristics, the engine mounted on the ma-
chine uses a mechanically controlled high-pressure fuel injection device. This device requires
high-precision parts and lubrication, so its durability will be significantly reduced if you use low-
viscosity fuel with low lubricating capacity.

Excavator
• Sulfur in the fuel will produce sulfur oxides during burning and react with water to become dilute
sulfuric acid, causing the engine damage. To prevent such failures, be sure to use the fuel con-
taining less than 0.2% of sulfur.
5.2.3 Coolant in the cooling system
• Coolant has important anti-corrosion and anti-freeze features. Even in areas not requiring anti-
freeze measures, it is essential to use antifreeze coolant.
Sany Heavy Machinery Co., Ltd. recommends the use of TEEC-L35 antifreeze with a concentra-
tion of 50% and without dilution. With excellent anti-corrosion, anti-freeze and cooling character-
istics, TEEC-L35 antifreeze can be used continuously for 1 year or 2000 hours.
• Sany Heavy Machinery Co., Ltd. does not recommend using any coolant other than TEEC-L35
antifreeze. If you use other coolant, it may cause serious problems such as corrosion of the en-
gine and cooling system parts made of light metals including aluminum.
If you use commercially available antifreeze as the coolant, be sure to keep its concentration fall
between 30% and 68% to ensure its corrosion resistance characteristic.
The mixing ratio of antifreeze and water is determined by the lowest ambient temperature, as
shown in the mixing table below.
Mixing ratio of water and antifreeze
°C -10 -15 -20 -25 -30 -35 -40

Min. temperature
°F 14 5 -4 -13 -22 -31 -40
Mixing ratio (%) 30 36 41 46 50 54 58
Table 5-1
NOTE:
• Use distilled or tap water (soft water) when diluting the anti-freeze coolant.
• Natural water, such as river and well water (hard water), contains a lot of minerals (calcium and
magnesium), which are easy to form fouling inside the engine and the radiator. The fouling
formed inside the engine or the radiator will be difficult to be removed. Poor heat exchange may
also cause overheating.
5.2.4 Grease
• Grease is used to prevent twisting at the connections and noise.

• Fill grease if any part becomes inflexible or produces noise after used for a long time.
• Be sure to use the recommended grease, and select grease in accordance with the replacement
cycle and ambient temperature recommended in this manual.
• When filling grease, wipe away the old grease that has been squeezed out. Be sure to wipe
away the old grease that has been stained with sand and dirt, otherwise it will cause wear of the
rotating parts.

5.2.5 Storage of engine oil and fuel
• Place them indoors to prevent water, dust, or other debris from getting into them.
• When storing the oil drums for a long time, place the drums side so that the fillers of the drums
are on the side (to prevent inhalation of moisture). If the oil drums have to be placed outdoors,
cover them with tarpaulins or take other protective measures.
• In order to prevent the oil or fuel from deteriorating during long-term storage, it must be used in
the order of first-in and first-out (namely the lubricating oil or fuel stored for longer time is used
first).
5.2.6 Filter element
• The filter element is an extremely important safety component that prevents foreign matters in
the oil and air lines from getting into important devices and causing malfunctions. Replace all fil-
ter elements regularly. When used under harsh conditions, the filter element shall be replaced
within a short period based on the sulfur content in all lubricating oil and fuel.
• Check whether metal particles are adsorbed on the old filter element when replacing it. If you
found metal particles, please contact your Sany Heavy Machinery Co., Ltd. authorized dealer.
• Do not unpack the spare filter elements before use.
• Use Sany Heavy Machinery Co., Ltd. original filter elements.
5.3 Electrical System Maintenance
• Wet electrical equipment or damaged wire claddings will cause electrical short circuits and ma-
chine malfunctions. Do not flush the cab with water. When rinsing the machine, take care to pre-
vent water from getting into the electrical components.
• Electrical system maintenance includes checking the fan belt tension and checking the fan belt
for damage and wear.
• Do not install any electrical component other than those specified by Sany Heavy Machinery
Co., Ltd.
• External electromagnetic interference may cause malfunction of the controller in the control sys-
tem. Contact your Sany Heavy Machinery Co., Ltd. authorized dealer when you install radio re-
ceivers or other wireless devices.
• When working on a beach, carefully clean the electrical system to prevent corrosion.
• When installing the electrical equipment, connect it to a dedicated power connector. Do not con-
nect the optional power supply to the fuse, starter switch or battery relay.
5.4 Wear Parts
• Wear parts (such as filter elements, and bucket teeth) shall be replaced during regular mainte-
nance or before reaching their wear limits.
• In order to use the machine economically, wear parts shall be replaced correctly.

Excavator
• High-quality Sany Heavy Machinery Co., Ltd. original parts shall be used for replacement.
• When ordering such parts, check the part numbers in the part manual.
Table of Wear Parts
Item Part No. Part name Quantity Replacement Interval

Fuel coarse filter 60307173 Filter element 1 Every 500 h
Fuel fine filter 6050941 Filter 1 Every 500 h
Engine oil filter B222100000494
Filter 1 Every 500 h
element /②
Return filter
Return filter
60101256 element 1 Every 500 h
element
assembly
Oil suction filter
Oil suction filter
60101257 element 1 Every 1000 h
element
assembly
Pilot filter 1
Pilot filter A222100000119 Every 1000 h
element （1）
B222100000500 Replace every 1000
Air cleaner Air cleaner
60222811 (only 1 hours and clean every
primary element primary element
for SY155H) 250 hours
Air cleaner B222100000501 Air cleaner Replace every 3

secondary 60222812 (only secondary 1 replacements of primary
element for SY155H) element element
Breather valve
60049793 Filter element 1 Every 1000 h
filter element
60154445 Bucket teeth 5
Tooth pin
60154443 5
assembly
Bucket （SY115/ A229900007131 Left side teeth 1 Replace as needed
135/155 )
A229900007130 Right side teeth 1
A210111000301 Bolt 8
A229900007130 Nut 8
Note:Parts in brackets shall be replaced at the same time.
1. For machines equipped with an Isuzu 4BG1-TABGC-03-C2;
2. For machines equipped with an Mitsubishi 4D34-TLC1A;
3. For machines equipped with an Isuzu AJ-4JJ1XYSS-02S.

5.5 Recommended Fuel, Coolant and Lubricating Oil
• Unless otherwise specified, the machine is filled with the oil and coolant listed in the table below
when it is shipped from the factory.
Item Model
Engine oil pan Diesel engine oil Caltex CI-4 15W-40
Superstructure box
Gear oil 85W/140
Travel gearbox
Hydraulic System Caltex anti-wear hydraulic oil HDZ46-Ⅱ
Radiator TEEC-L35 Antifreeze
Table 5-3
• In order to keep the best condition of the machine for a long time, it is essential to follow the oil
operation and maintenance instructions in this manual. Failure to do so may result in excessive
wear of the engine, drive system, cooling system, and other parts, thus shortening their service
lives.
• Commercially available lubricating oil additives may cause damage to the machine. Sany Heavy
Machinery Co., Ltd. does not recommend any lubricating oil additive.
• The specified capacity means the total amount of oil in the tank and lines. The adding capacity
means the amount of oil that needs to be added to the system during inspection and
maintenance.
• When starting the engine at temperatures below 0°C (32°F), be sure to use the recommended
multi-grade oil even if the ambient temperature is high in the daytime.
• Use the recommended oil according to the ambient temperature in the table below.

Excavator
Ambient Temperature
Recommended
Liquids -22 -4 14 32 50 68 86 104 122 °F liquids
-30 -20 -10 0 10 20 30 40 50°C
5W-30
5W-40
10W-30
Engine oil
15W-40
(Note 1)
40
HDZ32
(ISO VG32)
Hydraulic
oil
HDZ46
(ISO VG46)
-30# diesel fuel
Diesel fuel -10# light diesel
0# light diesel
TEEC-L35
Coolant
Antifreeze
Note:The HTHS (high temperature high shear viscosity at 150°C) specified by ASTM D4741 must
be no less than 3.5 mPa-S, and the engine oil 15W-40 recommended by Sany Heavy Machinery
Co., Ltd. is the most suitable.
1. Recommended oil:
• Engine oil; Select and use the oil of suitable viscosity grade according to the specified air tem-
perature range during oil change. Engine oil grade: above API CI-4.
• Name and brand of recommended engine oil: Caltex CI-4 15W-40 engine oil.
2. Engine fuel
Ordinary fuel GB252-2011

CAUTION
• Use low sulfur fuel with a cloud point of at least 10°C below the minimum desired fuel tempera-
ture. Cloud point means the temperature at which the waxy crystals in the diesel begin to form.
• Commercially available brands of diesel used shall have the sulfur content of less than 0.035%.
• Keep the fuel clean and free of moisture or foreign matters when refueling.
• The recommended oil and oil filter replacement cycle is 250h in case the machine is used under
dusty conditions.
• As the fuel quality differs from place to place and the replacement cycle of fuel filter is a theoret-
ical reference value, please have the fuel filter replaced according to actual conditions by the
service department of each dealer.
3. Hydraulic oil
The hydraulic system uses Caltex anti-wear hydraulic oil HDZ46-II (code: 60272633).
CAUTION
When operating at low ambient temperatures below 0°C, the following temperature-raising
operations must be performed to ensure the safety of the hydraulic system:
• Start the engine and let it idle for 7 to 10 minutes and then increase the speed to 1000 to 1200
r/min. Do not perform any operation on the excavator, and allow it to run for 30 to 40 minutes or
more under no load in order to increase the hydraulic oil temperature to 20℃ or more.
• After the above temperature-raising operations are completed, normal construction works can
be performed, and the temperature-raising time shall be appropriately adjusted according to
the ambient temperature. When normal construction works start, the handle and the foot valve
shall be slowly operated, and close attention shall be paid to the operation conditions of the sys-
tem. Working at the hydraulic oil temperature below 20 ° C may damage the hydraulic
components.
• Select the appropriate hydraulic oil according to the working area where the machine is located.
Before the machine leaves the factory, our company is responsible for filling the appropriate
brand of hydraulic oil. After the machine leaves the factory, the user is responsible for changing
the oil. The user may consult our company’s after-sales service personnel to obtain the correct
hydraulic oil specifications and brands.
Capacity table
Specified Engine oil Superstruc Final Hydraulic Cooling Fuel tank

capacity pan ture box gearbox system system
L 15 3 2×2.6 150 10 240
US gal 4 0.8 2×0.7 40 2.6 63.4

Excavator
5.6 Tightening Torque
CAUTION
• If the nuts, bolts, or other parts are not tightened to the specified torques, the tightened parts
may become loose or damaged, causing the machine faults or problems during operation.
• Be careful when tightening the parts.
bolts shall be tightened to the torques shown

in the table below.
If the bolts or nuts need to be replaced, they

shall be replaced with the same sizes of Sany
b
Heavy Machinery Co., Ltd. original parts.
Table of Tightening Torques

a
CZ335-1104001
Fig.5-1
Diameter Width Tightening torque

of across
Target value Service limit
thread, a flats, b
（mm）（mm） N·m kgf·m lbft N·m kgf·m lbft
6 10 13.2 1.35 9.8 11.8～14.7 1.2～1.5 8.7～10.8

8 13 31 3.2 23.1 27～34 2.8～3.5 20.3～25.3
10 17 66 6.7 48.5 59～74 6.0～7.5 43.4～54.2
12 19 113 11.5 83.2 98～123 10.0～12.5 72.3～90.4
14 22 177 18 130.2 157～196 16.0～20.0 115.7～144.7
16 24 279 28.5 206.1 245～309 25.0～31.5 180.8～227.8
18 27 382 39 282.1 343～425 35.0～43.5 253.2～314.6
20 30 549 56 405 490～608 50.0～62.0 361.7～448.4
22 32 745 76 549.7 662～829 67.5～84.5 488.2～611.2
24 36 927 94.5 683.5 824～1030 84.0～105.0 607.6～759.5
27 41 1320 135 976.5 1180～1470 120.0～150.0 868.0～1085.0
30 46 1720 175 1265.8 1520～1910 155.0～195.0 1121.1～1410.4
33 50 2210 225 1627.4 1960～2450 200.0～250.0 1446.6～1808.3
36 55 2750 280 2025.2 2450～3040 250.0～310.0 1808.3～2242.2
39 60 3280 335 2423.1 2890～3630 295.0～370.0 2133.7～2676.2

• Use the following table for hydraulic hoses
b a
CZ335-1104002
Fig.5-2
Tightening Torques
Nominal Thread Square Size
Target Value s Permissible Range
Number (a) (b) (mm)
N·m kgf· m lbf t N·m kgf· m lbft
9/16-18UNF 19 44 4.5 32.5 35~63 3.5~6.5 25.3~47
11/16-16UN 22 74 7.5 54.2 54~93 5.5~9.5 39.8~68.7
13/16-16UN 27 103 10.5 75.9 84~132 8.5~13.5 61.5~97.6
1-14UNS 32 157 16.0 115.7 128~186 13.0~19.0 94~137.4
13/16-12UN 36 216 22.0 159.1 177~245 18.0~25.0 130.2~180.8
*1 -7/16 - 12UN
41 215 22.0 159.1 176~234 18.0~24.0 130.2~180.8
- 2B
Note: The torque marked with ☆ refers to the tightening torque for the hose at the top of the swivel
joint.

Excavator
5.7 Safety Critical Parts

When operating or driving the machine, the user must regularly maintain the machine in order to
always ensure safety. In addition, in order to further improve safety, the user shall periodically re-
place the parts listed in the table. These parts are closely related to safety and fire protection.
As the safety critical parts will become easily worn or deteriorated or their materials will also
change over time, it is difficult to completely judge the conditions of such parts through regular
maintenance. Therefore, they shall be replaced regardless of their conditions once the specified
time expires. This can effectively guarantee the functions of these parts.
The safety critical parts, if have any abnormality before the end of their replacement cycles, must
be repaired or replaced immediately.
If the hoses clips are deteriorated (such as deformation or cracks), they shall be replaced together
with the hoses.
O-rings, gaskets, and other similar parts must be replaced while you replace the hoses.
Contact your Sany Heavy Machinery Co., Ltd. authorized dealer to replace the safety critical parts.
List of Safety Critical Parts
Replacement
No. Regular Replacement of Safety Critical Parts Quantity
Cycle
1 Fuel hoses (fuel tank - water separator) 1
2 Fuel hoses (oil-water separator - fuel primary filter) 1
3 Fuel return hoses (engine - fuel tank) 1
4 Fuel hoses (fuel primary filter - engine) 1
5 Pump outlet hoses (pump - control valve) 2
6 Work equipment hoses (boom cylinder inlet) 4
Work equipment hoses (bucket cylinder line - boom
7 2
root) Every 2 years or
Work equipment hoses (bucket cylinder inlet) 4,000 h,
8 2
whichever comes
9 Work equipment hoses (arm cylinder line - boom root) 2 first.
10 Work equipment hoses (arm cylinder inlet) 2
11 Swing line hose (swing motor inlet) 2
12 Main oil suction hose 1
13 Travel control hose (control valve - swivel joint) 4
14 Travel control hose (swivel joint - travel motor) 4
15 Pump pressure hose 1
16 Accumulator (for oil line control) 1

17 High pressure line clamp 1 Every 8000

18 Anti-fuel injection cover 1 hours
19 Seat belt 1 Every 3 years
Table 5-8
5.8 Maintenance Schedule

The standard calendar time or operation time is used as inspection and maintenance time, which-
ever occurs first.
If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts may
vary. See “Replacing Hydraulic Oil and Hydraulic Oil Tank Filter” on the page 7-13 for details.
Maintenance schedule list
Initial 50-hour maintenance (after the first 50 hours only) .............................................5-17
Maintenance as demanded ...........................................................................................5-17
Checking and tightening track shoe bolts ......................................................................5-17
Checking and adjusting track tension ............................................................................ 5-18
Replacing bucket ............................................................................................................ 5-21
Replacing bucket teeth (horizontal pin type) ..................................................................5-23
Adjusting bucket clearance ............................................................................................5-25
Checking window washer fluid level and filling washer fluid ...........................................5-26
Checking and maintaining A/C ...................................................................................... 5-27
Checking air spring ............................................................................................................5-29
Inspection before engine start ...........................................................................................5-31
Maintenance after every 100 h ...........................................................................................5-32
Lubricating work equipment ...............................................................................................5-32
Maintenance after every 250 h ............................................................................................5-35
Checking, cleaning and replacing air filter element ...........................................................5-35
Checking and adjusting belt tension of HVAC compressor ................................................5-38
Lubricating swing bearing....................................................................................................5-39

Excavator
Replacing the oil in engine oil pan, and replace the oil filter element ..................................5-40
Checking the level of grease in swing pinion and add grease.............................................. 5-42
Replacing fuel coarse filter element ....................................................................................5-43
Replacing fuel fine filter element ...........................................................................................5-45
Cleaning and inspecting radiator and cooler fins .................................................................5-48
Cleaning the ventilation/circulation filter of HVAC ................................................................5-50
Checking the oil level in swing gearbox and refilling .............................................................5-52
Checking the oil level of travel gearbox and refilling ..............................................................5-53
Replacing the hydraulic oil return filter element ......................................................................5-54
Changing oil in the swing gearbox ......................................................................................... .5-56
Checking the cab door lock and the front window lock for fastening .......................................5-57
Checking the lubricating oil of cab door hinge and front window slide guide and refill ........... 5-58
Checking the rocker nut of wiper for looseness .................................................................. .5-58
Checking all fastening parts of the engine exhaust pipe clamp..............................................5-59
Checking the fan belt tension and replace the fan belt .............................................................5-59
Checking the nitrogen pressure in accumulator (for hammer) ...............................................5-59
Replacing the hydraulic tank breather filter - cleaning/replacement .......................................5-60
Maintenance after every 2000 h ...................................................................................... ...5-61
Changing oil in final drive case ..................................................................................... ...... .5-61
Hydraulic oil suction filter element - cleaning or replacement ............................................. .5-62
Checking nitrogen pressure in accumulator .................................................................. .....5-63
Replacing the engine coolant and cleaning the inside of cooling system ............................. 5-66
Checking alternator ............................................................................................................... 5-67
Checking and adjusting engine valve clearance ................................................................. ..5-67
Maintenance after every 4000 h .................................................................................. .......... 5-68
Checking starter motor .................................................................................................. .......5-68

Replacing accumulator .................................................................................................. .........5-69
Checking the high pressure pipe clamp for looseness, and the rubber for hardening ...........5-70
Checking the operation of compressor .......................................................................... ........5-70
Changing oil in hydraulic tank ..................................................................................................5-71
Maintenance after every 8000 h ................................................................................ ........... .5-72
Replacing high pressure pipe clamp ....................................................................................5-72
Maintenance after every 10000 h............................................................................................5-72
5.9 Maintenance Procedures

5.9.1 Initial 50-hour maintenance (after
the first 50 hours only)
• Replace the engine oil and the oil filter ele-

ment. For details on the replacement or
maintenance method, see the “Mainte-
nance after Every 500 Hours” section.
• Replace the fuel filter element. For details
on the replacement or maintenance meth-
od, see the “Maintenance after Every 500
Hours” section.
5.9.2 Maintenance as demanded
5.9.2.1 Checking and tightening track

shoe bolts
If the machine is used with the loose track

shoe bolts [1], you must tighten the loose bolts
immediately because they will break.

Excavator
Tightening
Three-grouser track shoe
1. 1. Tighten them to 340~380N·m

(34.7~38.8kgf·m), and then check if the nuts
and track shoes are in close contact with the
chain link faces.
2. 2. After inspection, tighten them 120° ±10°

again.
CZ335-1104014
Tightening sequence
Fig.5-3
Tighten the bolts in the order shown on the
right figure. After tightening, check whether
the mating surfaces between the nuts and the
track shoes and the links are in close contact.
1 3
4 2
CZ335-1104015
Fig.5-4
5.9.2.2 Checking and adjusting track

tension
The wear of the pins and their bushings on

the lower body part varies with the work condi-
tions and soil types. Therefore, the track ten-
sion shall always be checked to maintain the
standard tension.
Stop the machine on a flat, solid ground to

check and adjust the track shoes.

Inspection
1. Start the engine and operate it at an idle

speed and then move the machine forward a 2
distance. This distance is equivalent to the a
length of the tracks on the ground. Then stop

the machine slowly.
2. Select a straight stick and place it over the

track shoes above the idler [1] and the carrier 1
roller [2] (see the right figure). CZ335-1104016
Fig.5-5
3. Measure the maximum distance “a” (sag)
between the upper surface of the track and
the bottom surface of the stick.
The standard value of “a” should be: 10 to 30

mm (0.4 to 1.2 in).
Adjustment
If the track tension is not standard, adjust it as

follows.
WARNING
• If the specified maintenance procedures
are not followed during the adjustment of
the track tension, the grease drain plug
may fly off, causing serious injuries or even CZ335-1102081
deaths.
Fig.5-6
• When adjusting the track tension, keep
your face, hands, feet, or other parts of
your body away from the front of the
grease drain plug.
Increase track tension

Excavator
WARNING
• Never loosen the grease drain plug when
you increase the track tension. Otherwise,
this may cause serious injuries or deaths.
CZ335-1102080
Fig.5-7
Prepare a grease gun when increasing the

tension.
1
1. Use the grease gun to fill grease through 2
the grease fitting [2]. (The grease fitting [2] is
combined with the grease drain plug [1].)
2. To check if the track tension is proper,

slowly move the machine 7 to 8 m (23 ft- 26ft
3in) forward and then stop it slowly.
CZ335-1104020
3. Check the track tension again. Readjust it if
Fig.5-8
the tension is inappropriate.
4. Continue to fill grease until the size [S] is

zero. If the tension is still loose, this shows the
pins and their bushings are worn excessively.
You must reverse or replace them. Contact
your Sany Heavy Machinery Co., Ltd. author-
ized dealer for repairs.
S
CZ335-1104019
Fig.5-9

Loose track tension
WARNING
• Do not loosen the grease drain plug more
than one turn because it may fly off under
high pressure conditions.
• Do not loosen any part other than the
grease drain plug.
Prepare a long socket wrench when loosening

the tension. CZ335-1102080
Fig.5-10
1. Use the long socket wrench to slowly rotate

the grease drain plug [1] counterclockwise to 1
release grease. The grease will be discharged 2
from the grease fitting [2].

You can only loosen the plug [1] one turn at
most.
2. If the grease cannot be drained smoothly,

you may move the machine a short distance
CZ335-1104020
forward and backward.
Fig.5-11
3. After obtaining a proper track sag, tighten
the plug [1] clockwise.
To check if the tension is appropriate, run the
engine at an idle speed, slowly move the ma-
chine forward (the distance is equivalent to
the length of the track shoe on the ground)
and then stop it.
4. Check the track tension again. Readjust it if

the tension is inappropriate.
NOTE:
• Gravel or soil between the chain wheels

and the track chains shall be removed be-
fore loosening of the tracks.
• If the track tension cannot be loosened as
described above, contact your Sany Heavy

Excavator
Machinery Co., Ltd. authorized dealer for

repairs.
5.9.2.3 Replacement of bucket
WARNING
• When you knock on the pins with a ham-
mer, metal fragments may fly off and cause
serious injuries. You must wear goggles,
safety helmets, protective gloves, and oth-
er protective equipment when performing
such operation.
• The pins, if knocked forcedly, may fly off
and injure people surrounding them. Be-
fore starting such operation, make sure
that there are no other persons in the sur-
rounding area.
• Do not stand behind the bucket when dis-
assembling the pins. Be careful not to
place your feet under the bucket when
working at one side.
• When removing or installing the pins, be
careful not to get your fingers caught.
• When aligning the pin holes, do not insert
your fingers into the holes.
1. Stop the machine on a solid, level ground.

Gently lower the bucket to a position just in
contact with the ground.
If you lower the bucket to the ground with ex-

cessive force, the resistance will increase at
the pins, which will not be easily removed.
CZ335-1103207
Fig.5-12

2.Remove the double nuts on the arm pin [A]

and the link pin [B], remove the bolts, pull out
the arm pin [A] and the link pin [B], and finally
remove the bucket. Arm
Link pin
NOTE:
A
• After removing the pins, make sure not to

get mud or sand on the pins.
• Take care not to damage the dust seals in-
B
stalled on both ends of the bushings.
CZ335-1103201
Fig.5-13
3. Align the arm with the hole [1] of the re-

placed bucket and the link with the hole [2].
1
Then insert the greased pins [A] and [B] into
the holes [1] and [2] respectively. 2
WARNING
• When performing connection works, ap-
point a commander and follow his com-
mands and instructions.
CZ335-1103202
Fig.5-14
NOTE:
When installing the bucket, for the arm pin po-

sition [A], put the bucket O-ring [3] into the po-
sition shown in the right figure. After inserting
the pins, install them into standard slots.
4. Install the retaining plate bolts and nuts for

all pins and then fill grease to such pins.
NOTE:
3 3
CB13031501
• Lubricate them thoroughly with grease until
grease is squeezed out of the end faces. Fig.5-15
• The dust seals, if damaged, shall be re-
placed while you replace the bucket. If the
damaged seals are used, sand or dust may
enter the pins, causing their abnormal wear.

Excavator
5.9.2.4 Replacing bucket teeth (hori-

zontal pin type)
Replace the bucket teeth before the bucket

teeth base is worn.
CAUTION
• Before replacing the bucket teeth, keep the
work equipment in a stable state, turn off
the engine and lock all travel levers se-
curely. Otherwise, this may cause danger
due to misoperation.
• If you knock out the lock pin with excessive
force, there is a danger that the pin will fly
off. Check and make sure that there is no
person in the surrounding area.
• You must wear safety glasses, gloves and
other protective equipment because frag-
ments may fly off during replacement.
1. Place a block at the bottom of the bucket

(as shown on the right figure) to remove the
bucket teeth pins and keep the bottom of the
bucket level.
CZ335-1104023
Fig.5-16

2. Check and make sure that the work equip-

ment is in a stable state and then place the
safety lock lever on the “lock” position.
CC13031403
Fig.5-17
3. Place a metal rod on the top of the pin [1],

knock the rod with a hammer to knock the pin
[1] out and remove the bucket teeth [2]. 2
NOTE:
1
• Use a metal rod slightly smaller in diameter

than the pin.
• If you cannot safely remove the bucket
teeth with this method, contact your Sany
Heavy Machinery Co., Ltd. authorized deal-
CZ335-1104025
er for replacement
Fig.5-18
4. Remove the tooth bushings and check the

lock pin for any damage. Replace it if neces-
sary. Worn lock pins and bucket teeth must be
replaced with new ones. 2
5. Clean the mounting surface, put the clip

spring into the mounting hole of the tooth base
and then put the new bucket teeth [2] into the
tooth base, push the pin [1] into the part by
hand, and then use a hammer to knock in the 1
pin to lock the bucket teeth onto the tooth CZ335-1104026
base.
Fig.5-19

Excavator
5.9.2.5 Adjusting bucket clearance
CAUTION
• When adjusting the clearance, keep the
work equipment in a stable state, turn off
the engine and lock all travel levers se-
curely. Otherwise, this may cause danger
due to misoperation.
The bucket clearance must be readjusted

after the machine has been operated for a pe-
riod of time. When the clearance is exces-
sively large or small, it is necessary to install
or remove the shims. After the machine is
used for a period of time, the connection
clearance of the bucket must be properly ad-
justed. When the connection clearance is too
large or too small, you need to install or re-
move the adjusting shims.

1. Stop the machine on a level ground. Lower

the bucket to the ground. The location where
the work equipment is placed is shown in the
right figure.
2. Run the engine at an idle speed. Secure

the bucket on the ground and slowly rotate
the superstructure counterclockwise until the
left inner end face of the bucket is in close
CZ335-1103207
contact with the left end face of the arm.
Fig.5-20
3. Turn off the engine and pull the safety lock
lever to the “lock” position.
4. Move the O-ring [1] and accurately measure

a 4 3
the clearance “a” with a feeler gauge.
5. Remove 4 plate mounting bolts [2] and

loosen the plate [3]. The shim is of open type,
and during adjustment, not all bolts should be
necessarily removed. 1 2
CB13031502-1
6. Remove the shims according to the gap “a”
Fig.5-21
measured above.
EXAMPLE:
If the gap is 3mm (0.118in), remove two 1.0
mm (0.039in) shims and one 0.5mm (0.020in)
shim, or remove one 2.0mm (0.078in) shim
and one 0.5mm (0.020in) shim. In this way,
the gap is reduced to 0.5mm (0.020in). For
shim [4], 2.0mm (0.078in), 1.0mm (0.039in)
and 0.5mm (0.020in) types may be available.
When the gap “a” is smaller for one shim, do
not make any adjustment.
7. Tighten 4 bolts [2].

Excavator
5.9.2.6 Checking window washer fluid

level and filling washer fluid
During each routine maintenance of the ma-

chine, check and fill the washer fluid and
check the working condition of the washer by
turning on its switch.
When the washer fluid is insufficient, the

ejected washer fluid will contain bubbles.
When this occurs, check the fluid level in the
reservoir (located in the access door on the
left side of the machine). Fill the washer fluid if
CZ335-1104030
needed.
Fig.5-22
1. Open the access door on the left side of the
machine and then you can see the reservoir.
2. Open the cover of the reservoir, fill the

washer fluid, and then close the cover tightly.
3. Turn on the washer switch to check if the

spray is normal.
Note:When filling the washer fluid, be careful

to prevent dust from getting into the fluid.
Mixing ratio of pure washer fluid to water
Select the mixing ratio according to the ambi-

ent temperature. Before filling, dilute the
washer fluid with water at the ratio shown in
the table below.
Operating Mixture
Temperature
Regions Ratio
General 1:2 - 10°C (14°F)
Cold regions in
1:1 - 20°C (- 4°F)
winter
Extremely cold Pure wash-

- 30°C (- 22°F)
regions in winter er solvent
Note:There are two kinds of washer fluid used

at -10°C (14 °F) (common) and -30°C (-22°F)

(in cold areas), depending on the operation

areas and seasons.
5.9.2.7 Checking and maintaining air conditioning
Check the refrigerant (gas) level
WARNING
• Do not touch the refrigerant because it will
cause blindness or frostbite after getting in-
to your eyes or dipping on your hands. Do
not loosen any part of the refrigerant line.
• Keep any open fire away from the position
where the refrigerant gas leaks.
The refrigeration performance of the air condi-

tioner will be poor if the refrigerant (R134a) is
not sufficient. When the air conditioner is op-
erated with insufficient refrigerant, the com-
pressor may be damaged.
When the engine idles at a high speed and

the air conditioner is in a state of maximum re-
frigeration, observe the inspection window [2]
on the condenser reservoir [1] and check the
situation of the refrigerant flowing into the re-
frigerant lines.
Fig.5-23

Excavator
• The refrigerant flows and there is no bub-

ble: it is appropriate.
• The refrigerant flows and there are bubbles
2
(continuous passage of bubbles): it is OK
insufficient.
• The lines are colorless and transparent: Insufficient
there is no refrigerant.
1 None
NOTE: In the case of insufficient refrigerant,
contact your Sany Heavy Machinery Co., Ltd.
authorized dealer to fill the refrigerant. CZ215-1104007
Fig.5-24
Inspection under unused circumstance
When the machine is not used for a long time, it is necessary to operate the air conditioning equip-
ment for 3 to 5 minutes once every month and lubricate various parts of the compressor.
Table of Inspection and Maintenance Items of Air Conditioning Equipment
Inspection and Main- Content Maintenance Period

tenance Item
Refrigerant (gas) Filling amount Twice a year, in spring
and autumn
respectively
Leakage at the line connections and inside Daily
the parts
Condenser Clogging of radiator fin Every 500 h
Compressor Function Every 4000 h
Loosing and bending Every 250 h
V-type belt Deterioration, wear, scratch and crack Every 250 h
Noise, odor, or abnormal heating When necessary
Fan motor and fan Function (check for abnormal noise) When necessary
Air conditioning Air volume switch control and switching Daily
volume switch function
Control mechanism Function (check whether the function is When necessary
normal)
Connecting bolt Loosing at the connections, and loosing or Half a year
falling off of nuts or bolts

Inspection and Main- Content Maintenance Period

tenance Item
Connecting line Installation situation, whether the connection When necessary
positions are loose and whether there is any
leakage or damage
Receiver-drier The temperature difference indicates that the One year
temperature dryer is clogged
difference
5.9.2.8 Ceiling window gas spring -

inspect
WARNING
• The air springs are filled with high-pressure
nitrogen. Improper operation may cause
explosion, resulting in damage to the ma-
chine and personal casualties.
• Keep away from fire.
• Do not punch or weld them.
• Do not knock them to avoid any impact.
The air springs are located on the top of the

cab (at the left and right).
In the following cases, contact your Sany

Heavy Machinery Co., Ltd. authorized dealer
for inspection, repair and replacement.
• When the top window of the cab cannot be

easily opened.
• When the top window of the cab cannot be
kept open.
CZ335-1104036
• When oil or gas leakage of the air springs is
found. Fig.5-25
The method for release of internal pres-

sure of hydraulic oil lines

Excavator
WARNING
• When checking or replacing the fittings or
the hoses, release the pressure in the hy-
draulic oil lines because they are always
under pressure. If the pressure is not re-
leased, high pressure oil will be ejected
and cause serious personal injuries.
• After the engine is turned off, the parts and
oil are still at high temperatures, which
may cause burns. Be sure to wait for cool-
ing down and then start the operation.
• When the filler cap is removed, the oil will
be ejected. Therefore, you shall slowly turn
the cap to release the internal pressure be-
fore removing the cap.
1. Stop the machine on a level and solid

ground.
CZ335-1103207
Fig.5-26
2. Within 15 seconds after stopping, turn the

1
ignition switch to the [ON] position, pull up the
safety lock lever to the “UNLOCK” position,
and fully operate the travel lever and the oper- Press
ating handle in all directions to release the
pressure of the pilot oil lines.
3.Unscrew the butterfly nut [1] of the breather

valve on the hydraulic oil tank, and then press
the exhaust button to release the internal
pressure of the hydraulic oil tank. CZ215-1304004
Fig.5-27

5.9.3 Checks before startup
For details on the following items, see

“Checks before startup” in the operation
manual.
• Drain water and sediments from the fuel

tank.
• Check the oil-water separator for water and
sediments and drain water.
• Check the level of oil in the hydraulic oil
tank and fill oil.
• Check the coolant level and fill the coolant.
• Check the level of oil in the engine oil pan
and fill oil.
• CCheck the wires.
• Check the fuel level and refuel.
• Check the work light switch.
• Check the function of the horn.
• Check and keep the exhaust pipe under the
engine smooth (under soil working condi-
tions, check it at any time during working).
Check oil level of the hydraulic tank
WARNING
scalding. Start operation after they are
cooled down.
• When the filler cap is removed, slowly ro-
tate it to release the internal pressure and
then remove it.

Excavator
1. Adjust the work equipment to the position

as shown in the right Figure, and then stop
the engine.
2. Move the work equipment travel lever and

travel lever in all directions during the whole
trip within 15 s after the engine is stopped to
release the internal pressure.

the machine to check the oil lever gauge [G].
When the engine is cold: (oil temperature: CC13041001-1
10~30°C or 50~86°F) L+12.5~L+32.5.
When the engine is warm: (oil temperature:

55~80°C or 131~176°F).
F
When the engine is warm: higher than the
middle oil level.
4. If the oil level is lower than the L line, fill oil G
through the filler [F] on the top of the tank.

• Caltex anti-wear hydraulic oil HDZ46 is rec- P
ommended. （B420106000036）.
• Capacity of hydraulic tank: 150 L.
CZ335-1103126
Note:Stop oil filling when it reaches the H line.

This will damage the hydraulic device and
cause oil spraying. If oil level is higher than
the H line, stop the engine. After oil is cooled H
down, place an oil container below the drain

plug [P] at the bottom of the hydraulic tank,
and then drain the excessive oil from the drain
plug.
L
CC13052101

5.9.4 Maintenance after every 100 h
5.9.4.1 Lubricating work equipment
CAUTION
• If there is abnormal noise at the lubrication positions, perform other lubrication in addition to the
lubrication during maintenance period.
• After excavating in water, lubricate the pins that are immersed in water.
1. Set the work equipment to the lubrication positions shown in the figure below, and then lower the
work equipment to the ground and shut off the engine.
2. Use a grease gun to fill grease through the lubrication positions shown in the figure below.
3. After filling the grease, wipe off the old grease that has been squeezed out.
2,3,4 1
6 5
7 8 9 10,11 12
CZ335-1104046
Fig.5-28
[1] Boom cylinder root pins (2 positions)
1
1
CZ335-1104047
Fig.5-29

Excavator
[2] Boom foot pins (2 positions)
[3] Boom cylinder piston rod end (2 positions)
[4] Arm cylinder root pin (1 position)
4 3
3
2
2
CZ335-1104048
Fig.5-30
[5] Boom-arm connecting pin (2 position)
CZ335-1104049
Fig.5-31
[6] Arm cylinder piston rod end (1 position)

6
[7] Bucket cylinder root pin (1 position)
7
CZ335-1104051
Fig.5-32

[8] Arm-rocker connecting pin (1 position) Fig.5-33
[9] Link connecting pins (2 positions)
CZ135B-1104016
[10] Bucket cylinder piston rod end (1

position)
10
[11] Bucket-link connecting pin (1 position)
11
10
12 CZ335-1104053
Fig.5-34

Excavator
5.9.5.1 Checking, cleaning and replac-

ing air filter element
CAUTION
• If you carry out checking, cleaning or re-
placement while the engine is running,
dust may get into the engine and cause
damage to it. Be sure to shut off the engine
before performing these operations.
• Be sure to keep close matching between
the sealing rubber of the end cover and the
filter.
• Never take out the inner filter element for
cleaning. This will get dust in and cause
the engine failures.
• The inner and outer filter elements must be
replaced at the same time.
• Wear goggles, dust masks or other protec-
tive devices when cleaning with com-
pressed air.
• Do not forcibly pull out the outer filter ele-
ment. When working at a high place or a
place where footholds are unstable, be
careful not to drop the outer filter element
under the reaction force when pulling it
out.

Cleaning and replacement of outer filter

element
• Cleaning: when hearing the air filter block-

ing alarm or every 250 h.
• Replacement: cleaning for 6 times or every
1 year (whichever comes first).
1. Open the door at the radiator side (left rear)

of the machine, remove the clip (or clamp) [1],
and then remove the cover [2].
Fig.5-35
Fig.5-36
1. 2. Hold the outer filter element [3], gently

shake it up and down and left and right, and
turn the filter element left and right to pull it
out. 4
3.Check if the inner filter element [4] is shifted 3

or tilted. If it is tilted, put it correctly by hand. 5
4.Use a clean cloth to cover the inner filter ele-

ment [4] to prevent dust from getting into.
5. Clean the dust on the cover and inside the CZ335-1104006

air filter housing [5].
Fig.5-37

Excavator
1. 6.Purge with compressed air of 0.2 MPa or

less along the wrinkles at the inner and outer
sides of the outer filter element.
Note:
• Do not knock the filter element with any ob-

ject when cleaning it.
• The filter paper, filter element, and seal ring,
if damaged, cannot be used.
CZ335-1104008
• If you have used the filter element or O-ring
for one year, do not use them again after Fig.5-38
cleaning them because their reuse will
cause malfunctions.
7.When the filter element is illuminated with a

lamp after cleaning, the element must be re-
placed if small holes or thin portions are found
on it.
CZ335-1104107
Fig.5-39

Replacement of inner filter element
1. Remove the outer filter element [3] and then

remove the inner filter element [4].
4
2. Cover the air connector side with a clean
cloth to prevent dust from falling in it.
3
3. Clean the inside of the filter body and then

remove the covered cloth.
4. Install a new inner filter element [4] on the

CZ215-1304005
connector.
Fig.5-40
5. Install the outer filter element [3] and
straightly push it into by hand. Hold the outer
filter element gently and shake it up and down
and left and right in order to easily insert the
filter element.
6. Install the cover [2] correctly with the arrow

mark facing up and then buckle the clip (or
clamp) [1]. Check the gap between the air fil-
ter housing and the cover. Reinstall it if the
gap is too big.
Note:
• The inner filter element must not be used

again after being cleaned. Replace the in-
ner filter element while replacing the outer
filter element. Fig.5-41
• If the inner filter element is not properly in-
stalled, but the outer filter element and the
cover have been installed, this will put the
outer filter element at risk of damage.
• Do not use counterfeit parts because they
may allow dust to enter due to insufficient
precision and cause damage to the engine.

Excavator
5.9.5.2 Checking and adjusting belt ten-

sion of HVAC compressor
Inspection
With the finger force of approximately 58.8 N

(6 kgf), press the belt in the middle between
the drive pulley and the compressor pulley
and check that the deflection [A] should be 5-
8 mm (0.20 in-0.31 in).
Adjustment
1. Loosen the bolts [1] and [2].
2. Move the compressor [3] and the bracket A

[4] together to adjust the belt tension.
3. Position the compressor [3]. And then tight-

en the bolts [1] and [2].
4. Check the belt tension again after

adjustment. CZ335-1104054
Fig.5-42
Note:
2
• Check whether each pulley is damaged,

3
and check whether the V groove and V belt
are worn. In particular, ensure that the V
belt does not contact the bottom of the V 1
groove.
• If any of the following occurs, please con-
tact the dealer authorized by SANY in your
region to replace your belt.
• The fan belt is already extended, with little WX235-1306003
margin for adjustment. Fig.5-43

• Any cutting or crack is found on the belt.
• Abnormal slipping occurs or a squeaking
sound is heard.
• After installing a new V-type belt, readjust it
after being used for 1 h.

5.9.6.1 Geberal
Maintenance task scheduled for every 100

and 250 hours should be carried out
simultaneously.
5.9.6.2 Lubricating swing bearing
CAUTION
• It is dangerous to fill grease on the gear
ring of the swing bearing. It is strictly pro-
hibited to fill grease while it is rotating.
1. Lower the work equipment to the ground,

shut off the engine and then pull the safety
lock lever to the “lock” position.
2. Fill grease to both grease fittings while the

machine is in a stable state.
3. Start the engine, pull the safety lock lever to

the “unlock” position, lift the bucket 20 to 30
mm above the ground, turn the machine 90°, CZ335-1104065
and fill grease by following the steps 1 and 2. Fig.5-44
4. Repeat the operation for 2 times according

to the step 3 to finish grease filling.
Note:
• Grease is used to prevent twisting at the

connections and noise.
• Fill grease if any part becomes inflexible or
produces noise after used for a long time.
• When filling grease, wipe away the old
grease that has been squeezed out.
• Special care shall be taken to wipe away
the old grease at all positions, and sand or
dust getting into the grease may cause
wear of the rotating parts.

Excavator
5.9.6.3 Replacing the oil in engine oil

pan, and replace the oil filter element
CAUTION
• When the engine has just stopped, the hot
parts and oil may cause burns. Be sure to
wait for cooling down and then start the
operation.
• Oil pan capacity: see Capacity Table on the

page 5-11.
• Prepare a filter element wrench.
1. Remove the cover of the oil pan drain valve,

and install the drain pipe onto the drain valve. Fig.5-45
2. Tighten the drain pipe to the drain valve,

and open the drain valve to drain the oil.
3. After draining the oil, remove the drain pipe

and install the drain valve cover.

the machine, then turn the filter element [1] to
the left with filter element wrench to remove it.
5. Clean the filter element base [2], fill the new

filter element with clean oil, apply oil (or a thin
layer of grease) on the sealing surface and
thread of the filter element, and then install
the filter element on the filter element seat.
Fig.5-46
Note: Check whether there is old seal on the
filter element base [2], for fear of leakage.

6.When installing, contact the sealing surface

with the sealing surface of filter element base
[2], and then tighten 3/4-1 turn.
7After replacing the filter element, open the

engine hood and add oil through filler to the
level between H and L on the dipstick. L H
8.Turn off the engine after a short time of idle

running. Check the oil level again to ensure it CZ335-1103131
is between L and H.
Fig.5-48
For details, see "Check the oil level in oil pan"
on the page 4-67.
9.Install the bottom cover.
CAUTION
• Please purchase original oil from the Sany
authorized dealer so that the oil qualify can
realize replacement cycle of 500 hours.
5.9.6.4 Checking the level of grease in

swing pinion and add grease
• Prepare a dipstick.
1. Remove the bolts [1] (2) on the upper part

of swing frame, then remove the lower cover
[2]. 2
CZ335-1104068
Fig.5-49

Excavator
Insert the dipstick [3] into the grease through

the inspection and adjustment holes, and
check whether the grease level [S] of the part A 3
where the pinion passes is at least 14 mm
(0.6 in). Add grease if it is less than such
value.
S
3. Check whether the grease is opalescent. If
so, it has been contaminated. Please contact
your Sany Heavy Machinery authorized deal-
er for replacement.
CZ335-1104069
Total grease: 10 L (2.6 US gal)

Fig.5-50
4. Install the cover [2] with bolts [1].
CZ335-1104070
Fig.5-51
5.9.6.5 Replacing fuel primary filter

element
CAUTION
• After the engine is shut down, all parts are
hot. Do not replace the filter until these
parts are cooled.
will be generated in the fuel piping system.
• Replace the filter at least 30 seconds after
the engine is shut down when the internal
pressure has been reduced.

Note:
• The original Sany fuel filter element is a

special filter with efficient filtration capacity.
Therefore, when replacing the filter ele-
ment, it is necessary to use original part.
• Use of other parts may cause dust or dirt
contamination, resulting in faulted injection
system. Therefore, alternative parts are not
recommended.
• It is even more important to protect the fuel CB13040702
system against dirt during inspection or Fig.5-52

maintenance. If there is dust on the part, it
should be rinsed with oil.
• Prepare a container to hold fuel discharged
• Prepare a filter wrench

the machine.
2. Put an appropriate container under the fuel

pre-filter to catch the fuel discharged.
3.Loosen the filter drain valve [5] to remove all

the water and sediment in transparent hous-
ing [4], as well as the fuel in filter element.
1
4.Remove the transparent housing [4] by turn-
ing it leftward with the filter wrench (the hous- 2
ing may be reused).
3
5.Remove the old filter element, clean the fil-
ter seat, and replace with a new filter element 4
[2]. 5
CB13040701
6.Replace the washer [3] and attach the trans-
parent housing [4] to the filter seat [1]. Fig.5-53
7.When installing, apply oil on the sealing sur-

face, contact the sealing surface with the seal-
ing surface of filter base closely, then tighten
1/4-1/2 turn.
NOTE:

Excavator
If the transparent housing is tightened exces-

sively, this will cause damage to O-ring, result-
ing in leakage. If it is not tightened sufficiently,
this will cause leakage from the gap of O-ring.
To prevent such problems, it must be tight-
ened to the specified angle.
8. Check whether the drain valve [5] is firmly

tightened.
9.Discharge air after the filter element [2] is re-

placed. For discharging method, see "Re-
place fuel fine filter element".
10. After replacing the filter element, start the

engine and let it run for 10 minutes at low idle
speed.
Check the sealing surface of filter base and

the position where the transparent cover is in-
stalled for any leakage. If so, check whether
the filter element is properly tightened.
If oil still leaks, repeat steps 1-7 and remove

the filter element. If the sealing surface shows
any damage or foreign matter, replace with a
new one.
5.9.6.6 Secondary fuel filter element -

replace
CAUTION
• After the engine is shut down, all parts are
hot. Do not replace the filter until these
parts are cooled.
will be generated in the fuel piping system.
• Replace the filter at least 30 seconds after
the engine is shut down when the internal
pressure has been reduced.
• The original Sany fuel filter element is a

special filter with efficient filtration capacity.

Therefore, when replacing the filter ele-

ment, it is necessary to use original part.
• Use of other parts may cause dust or dirt
contamination, resulting in faulted injection
system. Therefore, alternative parts are not
recommended.
• It is even more important to protect the fuel
system against dirt during inspection or
maintenance. If there is dust on the part, it
should be rinsed with diesel.
1. Prepare a container to hold fuel discharged.

Prepare a filter element wrench.
1. Open the engine hood.
2. Put the fuel container under the filter

element.
3. Remove the filter cartridge [1] by turning it

counterclockwise with the filter wrench.
4. Clean the filter base, apply a thin layer of oil

Fig.5-54
to the sealing surface of the new filter car-
tridge, and then install the filter cartridge to
the filter base.
Note:
• Do not fill the new filter cartridge with fuel. A B
• Remove the cover B and install the filter
cartridge.
CZ335-1104067
Fig.5-55

Excavator
5. Replace the internal seal [2] with a new

one.
6. During installation, tighten the filter car-

tridge until the sealing surface comes into
contact with that of the filter base, and then
tighten the filter cartridge by 3/4 turn again.
If the filter cartridge is overtightened, the seal

may be damaged, causing fuel leakage. If the 2
filter cartridge is not tightened enough, fuel
may leak from the seal. Therefore, be sure to CZ335-1104090
tighten the filter cartridge to an appropriate

Fig.5-56
angle.
7. Bleed air after replacing the filter element.
Exhaust process:
1. Loosen the fuel filter drain plug.
2. Operate the priming pump on the fuel sup-

ply pump to bleed air from the fuel filter, and
tighten the priming pump.
3. Operate the priming pump to bleed the re-

maining air.
4. Tighten the fuel filter drain plug.
5. Loosen the vent plug on the fuel supply

pump, and operate the priming pump until no
air bubbles appear.
6. Tighten the vent plug on the fuel supply

pump.
7. After tightening the vent plug, operate the

priming pump until you feel slight resistance.
Fig.5-57
8. Tighten the priming pump in its original po-
sition and start the engine. If the engine fails
to be started at this time, repeat step 7).

5.9.6.7 Radiator and oil cooler fins - in-

spect/clean
CAUTION
• If the compressed air, high pressure water,
vapor is directed towards the body or is
used to remove dust or dirt, there is a risk
of personal injury. Be sure to wear goggles,
dust covers or other protective equipment.
CAUTION
• When the compressed air is used for
cleaning, a certain distance shall be main-
tained to avoid damaging the radiator fins.
• In dusty workplaces, inspect the radiator
fins daily irrespective of maintenance
period.

Excavator
1. Unlatch the hood, open it and support it with

the stay bar.
2. Loosen the screws [3] and [7] and pull up

the screens [2] and [8].
3. Clean the dust screens.
4. Check radiator [4], A/C condenser fins [5]

and hydraulic oil radiator fins [6]. If there is
dirt, dust and leaves, remove with com-
Fig.5-58
pressed air or high pressure water in the op-
posite direction of air flow.
7
8
6
CZ135B-1104024
Fig.5-59
For high pressure water, the hydraulic giant

shall have lower spraying pressure and set to
mist at a distance of about 30 cm from the ra-
diator fins. Otherwise, they may be deformed,
causing premature clogging and cracking.
CAUTION
• Do not use hard objects to remove dirt dur-
ing cleaning to avoid damaging the radiator
fins.
Fig.5-60

1. 5.After cleaning, check the radiator fins for

deformation, holes and cracks. If yes, make
an immediate adjustment and replacement.
Check the rubber hose for cracks or aging, if
any, replace with a new one; check and tight- 9
en the hose clamp.
6.Remove the cover plate [9] under the radia-

tor and clear the soil, dirt and leaves that have
been swept to the outside.
7.Refit the cleaned screens [2] and [8] in origi- CZ135B-1104026
nal places and fix them with screws [3] and

Fig.5-61
[7].
8. Install the cover plate [9], lock the engine

hood and access door at the left of the
machine.
5.9.6.8 Cleaning the ventilation/circula-

tion filter of HVAC
WARNING
• When compressed air is used, the flying
dust may cause personal injury. Therefore,
be sure to wear goggles, dust covers or
other protective equipment.
The filter shall be cleaned once every 500

hours, or more frequently in dusty workplace.
If the filter is blocked, the air volume will be
decreased and the air conditioning unit will
make an abnormal noise.

Excavator
Clean the internal air filter of HVAC

1
1. Remove the screw [1] from the sight glass
on the bottom of the left rear of the cab, and
then loosen the clamp nut [2] and remove the
internal air filter [3].
2. Clean the filter with compressed air. If the

filter is oily or dirty, flush it with neutral me-
dium. After rinsing with water, make it dry thor-
CZ335-1104075
oughly prior to use. Replace the filter with a
Fig.5-62
new one each year. If the blocked filter cannot
be cleaned with air or water, replace with a
new one.
CZ335-1104076
Fig.5-63

1. Clean the external air filter
1) Open the cover [4] on the left rear of the

cab with the key to the ignition switch , then
open the cover [4] by hand, remove the fix- 4
ing nut [5], and take out the external air filter
[6].
2) Clean the filter with compressed air. If the

filter is oily or dirty, flush it with neutral me-
CZ335-1104077
dium. After rinsing with water, make it dry
Fig.5-64
thoroughly prior to use. Replace the filter
with a new one each year. If the blocked fil-
ter cannot be cleaned with air or water, re-
place with a new one.
3) After cleaning, put the filter [6] in place,

4 5
tighten the nut [5], and close the cover. Lock
the cover with the key to the ignition switch, 6
then remove the key.
CZ335-1104078
Fig.5-65
NOTE：
The external air filter must be installed in the
S
correct direction. When installing, insert the
L
long [L] end of the filter [6] into the filter box. If
the short [S] end is installed first, the cover [4]
will not be closed.
6
4
CZ335-1104079
Fig.5-66

Excavator
5.9.6.9 Checking the oil level in swing

gearbox and refilling
WARNING
• When the engine has just shut off, the hot
parts and oil may cause burns. Do not op-
erate until they are cooled.
1. Pull out the dipstick [G] and wipe the oil with
a cloth.
2. Insert the dipstick [G] completely into the fil-

ter pipe.
Fig.5-67

3. Pull out the oil dipstick [G] and check

whether the oil level is between [H] and [L]
scales on the dipstick.
4. If the oil level is not at [L] on the dipstick [G],

remove the cap of filler [F] and refill.
H
5. If the oil level exceeds [H] on the dipstick
[G], loosen the drain valve [P] and drain the
excess oil.
L
• If the oil level is too high, hydraulic oil may CZ335-1204006
leak. Please contact your Sany Heavy Ma-

Fig.5-68
chinery authorized dealer for inspection.
• Before draining oil, place a container under
the drain valve.
6. After checking the oil level or refilling, insert

the dipstick [G] into the hole and install the
cap of filler [F].
Fig.5-69
5.9.6.10 Checking the oil level of travel

gearbox and refilling
WARNING
• When the engine has just shut off, the hot
oil may cause burns. No not operate until it
is cooled.
• If there is residual pressure in the box, the
oil or plug will burst out. Slowly loosen the
plug to release pressure.
• When loosening the plug, do not stand in
front of it.

Excavator
1. During checking, place the machine on flat

ground with the oil drain plug [D] downwards.
F
Then turn off the engine and set the safety L
lock level in "LOCK" position. D
2. Remove the dust in hexagon socket head Oil level
plug with a suitable screwdriver to avoid

damage.
3. Remove the oil level plug [L] with wrench,

CZ235-1104017
then check the quantity of oil and contamina-
Fig.5-70
tion. When the oil surface reaches the oil level
plug port, there is appropriate quantity of oil. If
insufficient, add specified quantity of oil
through oil level plug.
4. If the oil level is low, add specified gear oil

through the fill port.
5. Before installing, clean the oil level plug [L]

with diesel.
6. Check the travel gearbox on the other side

in the same way.
5.9.7.1 General
Maintenance task scheduled for every 100,

250 and 500 hours should be carried out
simultaneously.
5.9.7.2 Hydraulic oil suction filter ele-

ment - replace
CAUTION
• When the engine is shut off, the hot parts
and oil may cause burns. Do not operate
until they are cooled.

If the machine is equipped with hydraulic

hammer, the hydraulic oil will deteriorate fast-
er than the normal bucket operation. For
maintenance, see “Replace the hydraulic oil
and replace the hydraulic tank filter” on the
page 7- 13.
1. Place the machine on solid and flat ground,

with the work equipment placed as shown in
the figure. Lower the work equipment to the
ground and shut off the engine. CZ335-1104086
2. Unscrew the butterfly nut [1] of the breather Fig.5-71
valve on the hydraulic tank, press the exhaust

1
button to release the pressure in tank.
Press
CZ215-1304004
Fig.5-72
3.Loosen 4 bolts and remove the lower cover

[2]. During disassembly, the cover will burst
out due to the action of spring [3]. Press and 2
hold the cover when removing the bolts. 3
4.Remove the spring [3], valve [4] and coarse 4
filter [5], and then take off the filter element 5
[6]. 6
• Check the bottom of the filter tank and re-

move the dirt if any. Be careful not to let any
dirt fall into the hydraulic tank. CZ335-1104088
5.Clean the removed parts with cleaning oil. Fig.5-73
6.Install new filter element.
7. Install the valve [4], coarse filter [5] and

spring [3].

Excavator
8.Install the cover [2] in place, press and hold

the cover, then tighten the bolts to install the
cover.
9. To exhaust air, start the exhaust and let it

run for 10 minutes at low idle speed.
10. To exhaust air, start the exhaust and let it

run for 10 minutes at low idle speed.
9. In order to bleed internal air, start and run

the engine at low idle for 10 minutes.
10.Stop the engine.
5.9.7.3 Swing drive oil - change
CAUTION
• When the engine has just been stopped,
the parts and oil are still hot and can cause
serious burns. Wait for them to cool down
before you proceed.

• Swing drive casing capacity: 4.0 L (1.06 US

gal)
1. Place a container under the drain valve (P)

to collect the gear oil drained. P
2. Loosen the drain valve (P) to drain the gear

oil. Tighten the drain valve upon completion of
the draining.
NOTE:
• If the gear oil flows out in a thin thread pat- CB13051401-1
tern, stop draining.

Fig.5-74
• When ambient temperature is low, you can
swing the work equipment to slightly in-
crease the oil temperature before draining
the oil. However, the work equipment shall
not be swung during draining, which may F
G
otherwise damage the swing unit.
3. Remove the filler cap (F) and add oil as re-

quired through the filler opening.
4. Check the oil level. For more information,

CB13050901-1
see "Swing drive oil level - check/fill" on
page 5-65. Fig.5-75
5. Apply sealant onto the thread of the filler

opening and tighten the filler cap.
Tightening torque: 2.7N·m
NOTE:
Improper tightening of the filler cap may cause

the gear oil in the swing drive to leak.

Excavator
5.9.7.4 Checking the cab door lock and

the front window lock for fastening
1. Check the cab door lock body
Cab door lock
C13082201
Fig.5-76
2. Door lock latch
Lock catch
C13082202
Fig.5-77
3. Cab windshield lock latches (each at the left

and right)
If it is found that the above parts are loose,

tighten in time to ensure the normal opening
and closing of cab doors and windows
Windshield lock catch
C13082203
Fig.5-78

5.9.7.5 Checking the lubricating oil of

cab door hinge and front window slide
guide and refill
Add grease through door hinge grease fitting

till it overflows.
Grease fitting
C13082204
Fig.5-79
Apply grease to the left and right slide guide

grooves of the front window.
Slide rail
C13082205
Fig.5-80

Excavator
5.9.7.6 Checking the rocker nut of

wiper for looseness
Check the wiper nut during each routine main-

tenance of the machine. Tighten the loose nut
if any to ensure the normal operation of the
Cap
wiper.
Pull up the protective cover at the bottom end

of the wiper arm to check for any loose nut; if
any, tighten it with torque wrench (35 to 40
N·m) or conventional wrench.
Nut
C13082206
Fig.5-81
5.9.7.7 Checking all fastening parts of

the engine exhaust pipe clamp
Contact your Sany Heavy Machinery author-

ized dealer to check the pipe clamp between
air cleaner-turbocharger-aftercooler-engine
for looseness.
5.9.7.8 Checking the fan belt tension

and replace the fan belt
Check the fan belt tension. If the belt is

cracked or damaged, replace with a new one.
If you have any question, please contact your
Sany Heavy Machinery authorized dealer.
5.9.7.9 Checking the nitrogen pressure

in accumulator (for hammer)
Check the accumulator and the special tool

for nitrogen filling.
Please contact your Sany Heavy Machinery

authorized dealer for inspection and nitrogen
filling.

5.9.7.10 Replacing the hydraulic tank

breather filter - cleaning/replacement
CAUTION
• Before replacing the breather valve filter el-
ement, shut off the engine.
• The hot parts and oil may cause burns. Do
not operate until they are cooled.
1. Before disassembly, clean the top of the hy-

draulic tank, especially the contaminants
around the breather valve (as shown in the
figure). The site shall be kept away from fire
and dust.
2. Unscrew the butterfly nut [1] of breather

valve, then pressure the exhaust valve to re-
lease the internal pressure. CZ335-1104080
3. Remove the fixing nut [2] and filter element Fig.5-82

cover [3], then remove the filter element [4].
4. If the filter element cover [3] is clogged by

1
dirt inside, please clean it with a soft brush,
3
and replace with a new one if it is damaged. 2
4
5. Install the filter element cover [3] and tight-
en the fixing nut [2].
NOTE:
• Tighten the fixing nut [2] to the specified tor- CC13031501
que (10 to 14 N·m). It is forbidden to tighten Fig.5-83

with brute force for sealing.
5.9.8.1 General

500 and 1,000 hours should be carried out
simultaneously..

Excavator
5.9.8.2 Replacing the oil in final drive

case
WARNING
• When the engine is shut off, the hot oil and
parts may cause burns. Do not operate un-
til they are cooled.
• If there is pressure in the case, oil or plug
will burst out and cause injury. Be sure to
loosen the plug slowly to release pressure
and do not stand in front of it.
Make-up capacity:
See "Capacity Table" on the page 5-11.
1. Place the machine on flat ground with the

oil drain plug [D] downwards,. Then turn off F
the engine and set the safety lock level in L

D
"LOCK" position.
Oil level
2. Remove the dust in hexagon socket head
plug with a suitable screwdriver to avoid
damage.
3. Put an oil container under the oil drain plug CZ235-1104017
[D], slowly loosen the oil level plug [L] and oil Fig.5-84
drain plug [D] to drain oil.
4. After the gear oil is completely discharged,

clean the oil drain plug [D] with diesel and in-
stall it.
5. Unscrew the filler plug [F] and add the

specified quantity of gear oil through filler until
the oil flows out of the plug hole [L].
6. Before installing, clean the plug with diesel.

Check the O-ring of the plug. In case of dam-
age, replace it with a new one.

5.9.8.3 Hydraulic oil suction filter ele-

ment - cleaning or replacement
CAUTION
1. Unscrew the butterfly nut [1] of the breather

1
valve on the hydraulic tank, press the exhaust
button to release the pressure in tank.
Press
CZ215-1304004
Fig.5-85
2. Loosen 4 bolts and remove the cover [2].

Then the cover will burst out under the action 2
of spring [3]. Press and hold the cover when

3
removing bolts.
3. Hold and lift the top of the rod [4], then re- 4
move the spring [3] and filter element [5].

5
4. Remove all dirt on filter element [5], then
6
rinse with cleaning oil. If the filter element is
damaged, replace it with a new one.
CZ335-1104093
5. During installation, fix the filter element [5]
on the convex part [6] of the tank and assem- Fig.5-86
ble it.
6. When assembling, fix the spring [3] with the

convex part at the bottom of the cover [2],
then tighten with bolt.

Excavator
5.9.8.4 Checking the nitrogen pressure

in accumulator
WARNING
• As the accumulator is filled with HP nitro-
gen, improper operation will cause explo-
sion, resulting in mechanical damage and
personal injury.
• Keep away from fire. Do not collide or roll
the accumulator to avoid any shock.
• The gas in the accumulator must be re-
leased completely during handling. Please
contact your Sany Heavy Machinery au-
thorized dealer for doing this.
Note:
If the accumulator is filled with nitrogen at low

pressure continuously, it is difficult to release
the residual pressure in hydraulic circuit in
case of mechanical failure.
Functions of accumulator
The accumulator stores the pressure in con-

CB13041502-2
trol oil circuit. The control oil circuit works
properly to complete the following actions Fig.5-87
even if the engine is turned off:
• The work equipment can be lowered under

the effect of self-weight by joystick.
• The pressure in hydraulic circuit can be
released.

Check the functions of accumulator
WARNING
• First check whether there is any person or
obstruction in the surrounding area.
Check the nitrogen filling pressure according

to the following steps: 1.5m
1. Place the machine on a solid and flat

ground.
CZ335-1104095
2. Keep the work equipment 1.5 m (4 ft 11 in) Fig.5-88

from the ground, i.e. the maximum working ra-
dius, with arm fully extended, bucket com-
pletely turned over.
Complete steps 3 to 5 within 15 seconds.
As the pressure in accumulator gradually
drops when the engine is shut off, the check
must be done immediately after the engine is
shut off.
3. Keep the work equipment at the maximum

working radius, then turn the ignition switch to
[OFF] and turn off the engine.
5. Set the safety lock control lever to “unlock"

position, and lower the work equipment to
ground by joystick.
CC13031404
Fig.5-89

Excavator
6. If the work equipment is lowered to the

ground under the effect of self-weight, the ac-
cumulator is normal.
If the work equipment cannot be lowered or

suspended, the pressure in hydraulic circuit
accumulator may have dropped. Please con-
tact your Sany Heavy Machinery authorized
dealer for inspection.
7. If the work equipment cannot be lowered or

suspended, the pressure in hydraulic circuit CZ335-1104099
accumulator may have dropped. Please con-

Fig.5-90
tact your Sany Heavy Machinery authorized
dealer for inspection.
Method for releasing pressure in control

oil circuit
1. Lower the work equipment to the ground.

“LOCK” position. Complete steps 4 to 6 within
15 seconds. The pressure in accumulator
gradually drops when the engine is shut off.
Therefore, the pressure must be released as CC13031403
soon as the engine is turned off.

Fig.5-91
3. Stop the engine.
4. Turn the starting switch to [ON] position.

ON
OFF
STA
T
HEA
RT
CC13031804
Fig.5-92

5.Set the safety lock control lever on the “un-

lock” position, then operate the work equip-
ment joystick forward, backward, left and right
to release the pressure in control oil circuit.
6.Set the safety lock control lever on the “lock”

position and turn the ignition switch to OFF
position.
CC13031404
Fig.5-93

Excavator
5.9.8.5 Replacing the engine coolant

and cleaning the inside of cooling
system
WARNING
• When the engine is just turned off, the
highpressure hot coolant in radiator may
cause burns if the radiator cover is re-
moved for discharging. After it is cooled,
slowly turn the cover to release pressure.
• When starting the engine for cleaning, set
the lock lever to the lock position to prevent
the machine from moving.
• The coolant is flammable and shall be kept
away from open flames.
• Be careful not to splash the coolant on
your body. If splashed into eyes, flush with
plenty of water and see a doctor
immediately.
• Antifreeze is toxic. Never allow it to contact
your eyes and/or your skin. Wash with
plenty of water and seek medical treatment
immediately if antifreeze contacts your
eyes or skin. It is strictly forbidden to dis-
charge the coolant to sewers or the surface
of the earth. When replacing the coolant,
please contact your Sany Heavy Machi-
nery authorized dealer.
Clean the inside of radiator fins and re-

place coolant 1
1. Place the machine on flat ground, then turn

the ignition switch to [OFF] position to shut
down the engine.
2. When the cooling water is so cooled that

the radiator cover can be touched by hand,
slowly turn the radiator cap [1] until it contacts
with the stopper to release pressure, then re-
0-13018
move it.
Fig.5-94

3Remove the bottom cover plate under the ra-

diator, then place a container under the drain
valve [2] to hold coolant. 2
Open drain valve [2] at the bottom of the radi-

ator to drain coolant.
4. After draining the coolant, close drain valve

[2] and add running water and radiator clean-
ing agent. When the radiator is filled, start the
engine and let it run at low speed until the
temperature rises to at least 90℃ (194 ℉), CZ335-1104012
then keep running for about 10 minutes.

Fig.5-95
5.Shut off the engine and open the drain valve
[2] to drain water. Then flush the cooling sys-
tem with clean water until the discharged
water is clean to help remove rust and
deposits.
6.Close the drain valve [2], slowly add speci-

fied quantity of coolant until it overflows from
filling port.
7. Let the engine run for about 5 minutes at

low speed followed by 5 minutes at high
speed to drain the air in coolant. (At this time,
the radiator cap shall be opened).
8. Check coolant level once again. Add more

if necessary.
9.Drain the coolant in auxiliary tank [3], clean

its interior, and then add coolant until the level
is between FULL and LOW.
If the auxiliary tank is too dirty to clean, re-

place with a new one.
10. Turn off the engine, add water to the filling

port after about 3 minutes, and then tighten
the radiator cap.
Fig.5-96
11.Install the bottom cover plate.
Cleaning the hydraulic oil radiator fin

internally

Excavator
1. Remove the hydraulic oil radiator fin before

cleaning and rinse on clean rinsing table.
2. Use the same brand of hydraulic oil, avia-

tion kerosene, gasoline, and diesel for clean-
ing, then blow with air pump.
3. Do not use cotton, linen and chemical fiber

after cleaning to prevent the system from
being polluted by the falling fiber.
NOTE:
• The radiator shall be internally clean during

the whole rinsing process.
• The recommended cleaning medium are
the same brand of hydraulic oil, aviation
kerosene, gasoline, and diesel
successively.
5.9.8.6 Checking alternator
Please contact your Sany Heavy Machinery

authorized dealer to inspect alternator.
If the engine is started frequently, check the

alternator every 1,000 hours.
5.9.8.7 Checking and adjusting engine

valve clearance
Special tools are required for inspection and

maintenance. For this, please contact the au-
thorized dealer of Sany.
5.9.9.1 General

250, 500, 1,000 and 2,000 hours should be
carried out simultaneously.

5.9.9.2 Checking water pump
Check whether there is water or oil leakage

around the water pump. If you have any prob-
lem found, contact your Sany Heavy Machi-
nery authorized dealer for disassembly,
repairing, or replacement.
CZ335-1104104
Fig.5-97
5.9.9.3 Checking starter motor
Contact your Sany Heavy Machinery author-

ized dealer to check the starter motor.
If the engine is started frequently, check the

starter motor every 1,000 hours.

Excavator
5.9.9.4 Replacing accumulator
Replace the accumulator every 2 years or

4,000 hours, whichever comes first.
CAUTION
• As the accumulator is filled with HP nitro-
gen, improper operation will cause explo-
sion, resulting in mechanical damage and
personal injury.
• Keep away from fire. Do not collide or roll
the accumulator to avoid any shock.
• The gas in the accumulator must be re-
leased completely during handling. Please
contact your Sany Heavy Machinery au-
thorized dealer for doing this.
If the operation continues when the accumula-

tor is degraded, the pressure in hydraulic cir-
cuit will not be released in case of mechanical
failure. Please contact your Sany Heavy Ma-
chinery authorized dealer to replace
accumulator.
CB13041502-2
Fig.5-98

5.9.9.5 Checking the high pressure pipe clamp for looseness, and the rubber for
hardening
CZ335-1104106
Fig.5-99
Check whether there is loose bolt on the high pressure pipe clamps (5) between supply pump and
fuel spray nozzle through observation and touching. If you have any problem, please contact your
Sany Heavy Machinery authorized dealer to replace parts
5.9.9.6 Checking the operation of compressor
Check the following two items:
1. Whether the compressor and magnetic clutch are opened/closed when the HVAC switch is
turned on/off.
2. Whether the clutch or compressor makes abnormal noise.
If you have any problem, contact your Sany Heavy Machinery authorized dealer for disassembly,
repairing, or replacement.

Excavator
5.9.9.7 Replacing the oil in hydraulic

tank
WARNING
• When removing the oil suction cap, pres-
sure the exhaust button of breather valve
to release the internal pressure.
If the machine is equipped with hydraulic

hammer, the hydraulic oil will deteriorate fast-
er than the bucket operation. For mainte-
nance, see “Replace the hydraulic oil and
replace the hydraulic tank filter” on the page
7-13.
Refilling quantity: See "Capacity Table" on the

page 5-11. Prepare a handle (for 36 mm sock-
et wrench).
1. Remove the bolts on the bottom cover CZ335-1104102
plate, and then remove the bottom cover

plate. F
2. Rotate the upper mechanism so that the

drain plug at the bottom of the hydraulic tank
is located in the middle of the tracks on both
sides.
3. Retract the arm and bucket cylinder, then

lower the swing arm so that the bucket teeth
P
are in contact with the ground. CZ335-1104103-1
Fig.5-100
4. Place the safety lock control lever on “lock”
position and shut off the engine.
5. Remove the suction port cap [F] on the

upper part of the hydraulic tank.
6. Place an oil container below the drain plug

and use handle to remove the drain plug [P].

Check the O-ring on drain plug [P]. Replace

the damaged O-ring if any. After draining all
oil, tighten the drain plug [P].
Note: Be careful not to splash the oil on your-

self when removing the drain plug [P].
7. Add a specified quantity of hydraulic oil

through oil suction port [F]. Check whether the
level is between H and L of the dipstick.
• For details on applicable hydraulic oil, see

"Recommended fuel, coolant and lubricat-
ing oil" on the page 5-9.
• For details on check for oil level, see
“Check the oil level in hydraulic tank” on the
page 4- 65.
5.9.10.1 Maintenance after every 8000 h
Maintenance task scheduled for every 100, 250, 500, 1,000, 2,000 and 4,000 hours should be car-
ried out simultaneously.
5.9.10.2 Replacing high pressure pipe clamp
Please contact your Sany Heavy Machinery authorized dealer to replace the engine high pressure
pipe clamp.
If the machine runs up to 10,000 hours cumulatively, please contact your Sany Heavy Machinery
authorized dealer for maintaining the whole machine.

SY115/125/135/155/155 Crawler Hydraulic Troubleshooting
Excavator
Troubleshooting
6 Troubleshooting ..............................................................................................................6-1
6.1 Special Instructions...............................................................................................................6-3
6.2 Preparations before Troubleshooting.................................................................................6-4
6.2.1 Checks before troubleshooting .................................................................................6-4
6.2.2 Troubleshooting precautions .....................................................................................6-5
6.2.3 Precautions in Circuit Troubleshooting ....................................................................6-7
6.2.4 Hydraulic components handling precautions ..........................................................6-7
6.2.5 Towing ..........................................................................................................................6-9
6.3 Engine Faults.......................................................................................................................6-11
6.3.1 Faults Diagnosis Table for Engine ..........................................................................6-11
6.3.2 High Water Temperature ......................................................................................... 6-16
6.3.3 Engine Oil Pressure Abnormality (Low Engine Oil Pressure) ........................... 6-17
6.3.4 Fuel Run-Out ............................................................................................................ 6-18
6.3.5 Engine Kick-Back ..................................................................................................... 6-21
6.4 Electrical System Failure .................................................................................................. 6-22
6.4.1 Faults Diagnosis Table of Electrical System ....................................................... 6-22
6.4.2 Display Monitor......................................................................................................... 6-24
6.4.3 Battery........................................................................................................................ 6-27
6.4.3.1 general................................................................................................................ 6-27
6.4.3.2 Removal and Refitting of Battery ................................................................... 6-28
6.4.3.3 Battery Charge ................................................................................................. 6-28
6.4.3.4 Start Engine with Auxiliary Wire...................................................................... 6-29
6.5 Failures of the Hydraulic System .................................................................................... 6-32
6.6 Other Common Failures ................................................................................................... 6-36

Troubleshooting SY115/125/135/155/155 Crawler Hydraulic Excavator
WARNING

Excavator
6.Troubleshooting
6.1 Special Instructions
Situations described below, if occurred during operation, are normal and in line with industry stand-
ard, and thus please feel relieved to use.
1. You misunderstand an unavailable function as a fault due to unfamiliarity with the features of the
machine (For example, the product is not applicable to a altitude higher than 4km)
2. Stalling or black smoke occurs but the engine is proved by the field test in the normal operating
range, i.e. the FSNs at instantaneous load and steady load are not greater than 4.5RP and 1.5RP
respectively at an ambient temperature below 30℃.
3. Excessive consumption of engine oil and fuel occurs but turn out in the normal range specified
by the manufacturer in the field test.
4. Poor operation stability, grade ability, offset travel and slow movement occurs due to your un-
skilled operation and unfamiliarity with working condition, but all the parameters are proved by the
field test in the normal range specified by the manufacturer.(e.g., the tail of the counterweight is
up, grade ability is greater than 35°, etc.)
5. Unusual noise comes up in process of oil return of the hydraulic system (such as unusual noise
in oil return and from pipelines), but it is checked that the hydraulic system is normal and the return
oil filter is free of without impurities as iron chips, cooper chips and aluminum chips such that no af-
fect will be exerted to the normal operation of the device.
6. Common phenomena in the industry, such as discoloration or blackening of piston rod, reverse
or automatic movement of cylinder, and start difficulty of engine in chilly winter days.

6.2 Preparations before Troubleshooting

6.2.1 Checks before troubleshooting
检查项目判断标准措施
7. Confirm fuel level and type
8.Check the fuel for foreign matters
— Refuel
9. Check the hydraulic oil level
— Clean and drain
10.Check the hydraulic oil filter screen
— Refuel
Lubri 11. Check oil level of upper structure
— Clean and drain
cating 12. Check the engine oil level (oil pan
— Refuel
oil, oil level)
— Refuel
cool 13.Check the coolant level
— Add coolant
ant 14. Check blockage of air cleaner
— Clean or replace
15. Check the hydraulic oil filter
— Replacement
element
— Refuel
10. Check oil level of the final drive
case
1. Check the looseness and corrosion
Elec of battery terminals and wires
— Tighten or replace
tric 2.Check the looseness and corrosion
equip of alternator terminals and wires
ment 3. Check the looseness and corrosion
of starter motor terminals and wires

Excavator
检查项目判断标准措施
Hy
1. Check for abnormal noises and
draul — Repair it
odors
ic — Repair it
2. Check for oil leakage
devi — Exhaust
3. Bleed the air
ces
1.Check the battery voltage (with
engine shut down)
2. Check the battery electrolyte level
3. Check for discolored, burnt or
peeled wires Exhaust
20-30V
4. Check for falling clamps or hanging Refill or replace it
—
电 wires Replacement
—
气 5. Check whether the wire is wet Repair it
—
、 (check connectors or terminals Remove the
—
电 carefully) connector and blow it
—
气 6. Check whether the fuse is fused or dry
After running for a few
设 corroded Replacement
minutes:
备 7. Check the alternator voltage (with Replacement
27.5~ 29.5V
the engine running under the
—
condition over half throttle) Replacement
8. Check the alternator voltage (with

the engine running under the
condition over half throttle)
Table 6-1
6.2.2 Troubleshooting precautions
CAUTION
• Park the machine on the horizontal ground, and confirm the function of safety pin, cushion block
and parking brake.
• During the collaborative operation, the signal shall be strictly unified and no irrelevant personnel
can be allowed to be close to it.
• If the radiator cap is removed when the engine is hot, hot water will be sprayed and cause burn-
ing, so maintenance shall be carried out after the engine is cooled down.
• Do not touch any hot parts or hold any rotary parts.
• Always dismantle the negative terminal [-]] first.
• When removing the internal oil pressure, water pressure or air pressure plug or cap, release
the internal pressure first.
• When installing the measuring equipment, ensure that the connection is correct.

• The purpose of fault diagnosis is to accurately determine the root cause of the faults and expedi-
tiously fix them and prevent their recurrence.
• During the fault diagnosis, to know the structure and function is of great importance.
• In order to conduct effective fault diagnosis, turning to operators to get a general knowledge of
the possible fault causes is also one of the shortcut for fault diagnosis.
1. Do not disassemble parts immediately during fault diagnosis. If parts are disassembled immedi-
ately, it may cause:
• The parts that are disassembled are irrelevant to the fault, or the parts have been disassembled
unnecessarily.
• The fault cause cannot be found out.
This will waste labor, parts, or oil and grease, while losing the user or operator’s trust in the prod-
uct. Therefore, during fault diagnosis, it is necessary to check in advance and make fault diagnosis
according to the specified procedures.
2.Issues to be asked from users or operators:
• Are there any other unreported problems?

• Was there any abnormality before the fault appeared?
• Did the fault come up suddenly or following some signs?
• Under which circumstance the fault occurs?
• Was the machine repaired before the fault occurred?
• When was the machine repaired?
• Did this fault once appear?
3.Check other inspection items.
• Check the engine oil level.

• Check whether the oil leaks from the pipes or the hydraulic devices.
• Check the lever travel.
• Check the spool travel of the control valve.
• Other daily maintenance items can be inspected from the appearance, so only those deemed
necessary can be checked.
4.Confirm the fault
• Confirm the fault, and determine whether it is a true fault, whether there are problems in use and
operation, etc.
• When the machine is operated and the fault phenomenon reoccurs, no inspection or measure-
ment which will make the problem more serious shall be carried out.
5.Troubleshooting

Excavator
• Conduct the inspections and tests according to item 2~4 to narrow the scope of fault causes,
then identify the faulty point according to the fault diagnosis flow chart.
• The basic process of fault diagnosis is as follows:
1)Start with the easy problem.
2)Start with the possible problem.
3)Check other relevant content.
5.Method of eliminating root cause of fault
• Even if the troubleshooting is done but the root cause is not eliminated, the same fault will occur
again.
Therefore, it is necessary to find out the cause of the fault and eliminate the root cause.
6.2.3 Precautions in Circuit Troubleshooting
1.Always turn off the power before disconnecting or connecting the connector.
2. Check if all related connectors are correctly inserted plugged before fault diagnosis.
• Disconnect or connect the related connectors for several times for checking.
3. Always connect all the disconnected connectors before transferring to next step of operation.
• When the power is turned on with connectors disconnected, undesired abnormal indication will
occur.
4. When circuit fault diagnosis (measurement of voltage, resistance, connectivity or current) is

undergoing, related wires and connectors should be moved for several times and the meters read-
ings checked to be unchanged.
• If the readings change, contact failure may exist in the circuit.
6.2.4 Hydraulic components handling

precautions
The most common fault cause is the sludge

(foreign matter) in the hydraulic circuit due to
the pressure increase and accuracy improve-
ment of hydraulic components. Special care
must be taken when adding hydraulic oil or
disassembling or assembling hydraulic
components.

1. Working environment
Avoid adding hydraulic oil, replacing the filter

or repairing the machine in the rain or strong
wind or a dusty place.
2. On-site disassembling and maintenance

operations
On-site disassembly and maintenance of hy-

draulic components may cause ingress of
ZX215-1000023
dust. It is also difficult to check the perform-
ance after repair, so you’d better replace with Fig.6-1
an assembly unit. Disassembly and mainte-
nance of hydraulic components shall be car-
ried out in a specially prepared dust-proof
workshop, and the performance shall be
checked by special test equipment.
3. Adding hydraulic oil
When filing the hydraulic oil, do not let oil

sludge or dust mix in. Always keep the filter el-
ements and their surrounding areas clean with
the use of sanitary pumps and oil containers.
The use of oil cleaning device is a more effec-
tive way to filter the oil sludge accumulated
during storage.
ZX215-1000025
4. Change the hydraulic oil under high
temperature Fig.6-2
Hydraulic oil or other oil is easy to move when
kept warm. Besides, sediments may be easily
expelled from the oil circuit together with oil.
Therefore, it is best to replace the oil while
hot. During replacement, drain the used hy-
draulic oil as much as possible. (Drain from
hydraulic tank; and drain from the filter and
the drain plug in the oil circuit.) The impurities
and sediments in the used oil, if any, will be
mixed with the new oil and thereby shorten
the useful life of hydraulic oil.

Excavator
5. Flushing
When disassembling and reassembling the

device or changing the oil, remove the impur-
Flushing oil
ities, sediments and old oil in hydraulic lines.
Normally, twice flush is needed: use flushing
oil for primary flushing, and designated hy-
draulic oil for secondary flushing.
ZX215-1000026
Fig.6-3
6. Cleaning
The sediments and impurities in the hydraulic

lines need to be cleaned after repairing the
hydraulic components (pump, control valve,
etc.) or during the operation of the machine.
Oil cleaning device can clear up fine particles
(about 3 μ), and can effectively clean the oil
lines without dismantling the built-in filter of
the hydraulic components.
ZX215-1000027
Fig.6-4
6.2.5 Towing
CZ335-1102063
Fig.6-5

WARNING
• Always check whether the rope for trac-
tion have enough strength to tow the
machine, otherwise accidents may
happen.
• In the process of towing, do not use
rope with breakage[A], decreased diam-
eter [B] or twist [C], in case the rope
would be broken.
• Always wear protective gloves to han-
dle the rope.
• Don’t tow the machine on a slope.
• In the process of towing, do not stand
between the towing machine and the
towed machine.
• Operate the machine slowly, and do not
apply load suddenly to the rope.

Excavator
Make sure to tow the machine under the maxi-

mum capacity.
• If the excavator is trapped in the mud and

cannot be driven out by it own power, or the
if excavator is used for towing other heavy
object, it is allowed to use the rope as the
right picture shows.
• Put wooden blocks or other protective ma-

terials under the contact site of the rope
CZ335-1103216
and the machine to prevent abrasion for
both. Fig.6-6
• Keep the rope horizontal and in the same

direction with the track frame.
• Tow machine be to the desired repairing

place with a speed less than 1 km/h. Pre-
vent long-distance towing.
• Never tow the machine except in

emergency.
CZ335-1103217
Fig.6-7
6.3 Engine Faults

6.3.1 Faults Diagnosis Table for Engine
When a fault occurs, please conduct inspections according to the table below, and contact Sany
authorized dealer to carry out repairs.

Fault content Fault Analysis Measures

● Power run-out of battery ● Please charge or change the
Starter failure or battery
difficult rotation of ● Disconnection, looseness and ● Please clean the corroded place
starter corrosion of battery cables
● Fuse short-circuit ● Please replace the fuse
● Failure of the ignition switch or ● Please replace the ignition switch
starting relay or starting relay
● Failure of the starter motor ● Please repair or replace the starter
motor
● High viscosity of engine oil ● Please replace the engine oil with
proper viscosity
● Fuel run-out ● Please refuel and eliminate air
● Low starting pressure of fuel injector ● Please adjust or replace the fuel
injector
● Failure of the outlet valve of fuel ● Please replace the outlet valve
injection pump
Engine
● Failure of injection pump control rack ● Please repair or replace the control
start
rack
failure
● Rod abrasion or adhesion of fuel ● Please replace the rod assembly
injection pump
● Wrong starting operation ● Please operate following the
correct starting steps
The starter starts
● Air mixed into the fuel system ● Please discharge the air in the fuel
properly
system
● Fuel filter occlusion ● Please replace the element or
cartridge of the fuel filter
● Clogging of air filter ● Please clean or replace the
element of the air cleaner
● Clutch slip ● Please repair or replace the clutch
● Looseness of clamps for fixing air ● Please fasten the clamp
suction rubber hose to the
turbocharger
● Cracking of air suction rubber hose of ● Please replace the air suction
the turbocharger rubber hose
● The idle speed is too low ● Power run-out of battery
Engine stop after starting cartridge of the fuel filter
● Clogging of air filter ● Please clean or replace the
element of the air cleaner
● Failure of low idle speed control ● Please repair or replace the low
system idle speed control system
● Leakage or clogging of fuel system ● Please overhaul the fuel system
● Air in fuel system ● Please discharge the air in the fuel
system
● Water in fuel system ● Please replace the fuel
● Blocking of fuel filter element ● Please replace the element or
cartridge of the fuel filter
Unstable low idle speed
● Fuel injection pump fault ● Please repair or replace the related
parts of the fuel injection pump
● Improper adjustment of valve ● Please adjust the valve clearance
clearance
● Leakage at cylinder gasket, wear of ● Please replace the related parts
cylinder liner, sticking or cracking of
piston ring, improper alignment of
valve and valve seat

Excavator

● Water in the fuel cartridge of the fuel filter
● Air cleaner occlusion ● Please replace the fuel
● Failure of fuel transfer pump ● Please clean or replace the element
● Low starting pressure and poor injection of the air cleaner
effect of the fuel injector ● Please repair or replace the fuel
● Fuel injection pump fault transfer pump
● Exhaust gas leaking from the exhaust ● Please adjust or replace the fuel
system injector
Underpower ● Air leaking from the intake system ● Please repair or replace the related
● Turbocharger assembly damaged parts of the fuel injection pump
● Exhaust pipe blocked ● Please repair or replace the related
● Improper adjustment of valve clearance parts
● Weakening or breakage of valve spring ● Please replace the turbocharger
● Leakage at cylinder gasket, wear of assembly
cylinder liner, piston ring sticking or ● Please clean the exhaust pipe
cracking, improper alignment of valve and ● Please adjust the valve clearance
valve seat ● Please replace the valve spring
● Please replace the related parts
● Insufficient coolant ● Please add coolant
● Slippage of fan belt due to looseness or ● Please replace fan belt
cracking
● Cooler damaged or cooler core blocked ● Please replace cooler cover or
clean the cooler core
● Water pump damaged ● Please repair or replace the water
pump
Engine overheating ● Coolant leakage due to damage of ● Please repair or replace the seal
cylinder head or/and cylinder block seal cover
cover
● Thermostat damage ● Please replace the thermostat
● Cooling system blocked by foreign ● Please remove the foreign matters
matters in the cooling system
● Improper adjustment of fuel injection ● Please adjust the fuel injection
timing timing
● Water in the fuel ● Please replace the fuel
● Fuel injection timing delay ● Please adjust the fuel injection
timing
● Leakage at cylinder gasket, wear of ● Please replace the related parts
cylinder liner, sticking or cracking of
piston ring,
improper alignment of valve and valve
White smoke
seat
● Turbocharger assembly failure ● Please repair or replace
● Failure of oil seal, and wear of valve ● Please replace the valve oil seal,
stem and valve guide valve and valve guide
● Wear, breakage or improper setting of ● Please replace the piston or
piston ring reposition it properly
● Cylinder liner scratched or worn ● Please replace the cylinder liner
● Clogging of air filter ● Please clean or replace the element
of the air cleaner
● Low starting pressure of fuel injector, and ● Please adjust or replace the fuel
poor injection effect injector
● Improper adjustment of fuel injection ● Please adjust the fuel injection
Black smoke timing timing
● Fuel dripping due to damaged outlet ● Please replace the outlet valve
valve of fuel injection pump
● Excessive injection of the fuel injection ● Adjust the amount of fuel injection
pump

Fai l u r e Cau s es Rem ed y
● Insufficiency of coolant ● Refill coolant.

● Fan belt skids due to looseness or crack- ● Replace fan belt.
ing.
● Radiator cap damaged or radiator cor e ● Replace radiator cap or clean radia-
plugged tor core.
Engine overheat- ● Coolant pump damaged ● Repair/replace coolant pump.
ed ● Coolant leaks due to broken cylinder head ● Replace seal cap.
or cylinder block seal cap
● Thermostat damaged ● Replace thermostat.
● Cooling system blocked by foreign object ● Remove foreign objec t from the
● Improper adjustment of fuel injection tim- cooling system.
ing ● Readjust fuel injection timing.
● Fuel contaminated by water ● Change the fuel.
● Sluggish fuel injection timing ● Readjust fuel injection timing.
● Broken cylinder gasket, worn cylinder liner, ● Replace relevant parts.
stuck or ruptured piston ring, or defective
contact between air valve and its seat
White exhaust
● Failure of turbocharger ● Repair/replace.
gas
● Defective valve oil seal or worn valve stem ● Repla ce val ve oil seal , valve and
and valve guide tube valve guide tube.
● Wear, rupture or incorrect setup of piston ● Replace the piston or reset it cor-
ring rectly.
● Scratch or wear of cylinder liner ● Replace cylinder liner.
● Air cleaner plugged ● Clean/replace air cleaner element.
● Fuel injector activating pressure low or bad ● Readjust/replace fuel injector.
injection effect
● Improper adjustment of fuel injection tim- ● Readjust fuel injection timing.
Black exhaust gas
ing
● Fuel drips after injection due to damage of ● Replace fuel delivery valve.
fuel injection pump delivery valve
● Excessive injection of the injection pump ● Readjust fuel injection amount.

Excavator

● Fuel leakage ● Please repair or replace the related
● Air cleaner occlusion parts of the fuel system
● Improper adjustment of low idle speed ● Please clean or replace the element
● Low starting pressure of fuel injector, and of the air cleaner
poor injection effect ● Please adjust the low idle speed
● Improper adjustment of fuel injection ● Please adjust or replace the fuel
timing injector
● Fuel dripping due to damaged outlet ● Please adjust the fuel injection
valve of fuel injection timing
High fuel consumption
● Air leaking from the intake-side of the ● Please replace the outlet valve
turbocharger ● Please repair the intake-side of the
● Turbocharger assembly damaged turbocharger
● Improper adjustment of valve clearance ● Please replace the turbocharger
● Weakening or breakage of valve spring assembly
● Leakage at cylinder gasket, wear of ● Please adjust the valve clearance
cylinder liner, piston ring sticking or ● Please replace the valve spring
cracking, improper alignment of valve and ● Please replace the related parts
valve seat
● Unsuitable engine oil ● Please replace with suitable
engine oil
● Engine oil excess ● Please adjust the amount of
engine oil
● Engine oil leaking from oil seal and/or ● Please replace the oil seal and/or
gasket gasket
High oil consumption ● No preheating operation ● Please follow the correct steps in
operation
● Failure of oil seal, and wear of valve ● Please replace the related parts
stem and valve guide
● Wear, breakage or improper setting of ● Please replace the piston or
piston ring reposition it properly
● Cylinder liner scratched or worn ● Please replace the cylinder liner
● Low engine oil level ● Please refill engine oil
● Improper viscosity of engine oil ● Please use lubricant of proper
viscosity
● Engine oil leaking from oil seal and/or ● Please replace the oil seal and/or
gasket gasket
● Fuel filter element occlusion ● Please replace the element or
Low engine oil pressure cylinder of the fuel filter
● Relief valve sticking and/or by-pass ● Please replace the spring of safety
valve spring weakening valve and/or by-pass valve
● Strainer of oil pump blocked ● Please clean the strainer of the oil
pump
● Relevant parts of oil pump abrasion ● Please replace the related parts of
the oil pump
● Fitting looseness or damage of the ● Please screw down exhaust pipe
exhaust pipe fittings or replace the exhaust pipe
● Fuel injector looseness ● Please tighten up the fuel injector
Noise of air
and replace the gasket
leakage
● Looseness of exhaust manifold fitting ● Please tighten up the exhaust
Unusual manifold fitting
noise of ● Cylinder gasket broken ● Please replace the cylinder liner
engine ● Fan belt looseness ● Please adjust the tension of the
belt
Continuous ● Cooling fan looseness ● Please tighten the cooling fan
noise ● Wear or damage of water pump ● Please replace the bearing of the
bearing water pump
● Improper adjustment of valve clearance ● Please adjust the valve clearance

6.3.2 High Water Temperature
WARNING
• Do not open the cover of the cooler
when the water temperature is exces-
sively high, and if you do so, the boiling
water or steam may splash and cause
scald. When the temperature of the
coolant goes down, please pad a thick
cloth on the cover and open it slowly.
CAUTION
• Do not stop the engine immediately.
Otherwise the rising temperature will
burn the engine parts.
• Please add water slowly in multiple
times in case the sudden injection of
cool water cracks the engine.
When the reading of the water thermometer

exceeds 100℃ and the indication light is on, it
means the water temperature of the cooler ex-
ceeds the limit. Please stop the device, and
keep the engine running at a speed a little
higher than idle speed to cool down. When
the pointer of the water thermometer goes to
the center and the High Temperature Light is
off, stop the engine, then do as follows.
1. Check whether there is coolant leakage of

the cooler rubber hose.
Fig.6-8
2. Check whether the V-belt is broken and the
tension of the belt normal.
3. Check the amount of coolant. Please refill

coolant when it is insufficient.
• Screw up the cover of the cooler [1], and re-
fill the coolant to the cover mouth. After re-
filling, tighten up the cooler cover.

Excavator
• Open the cover of the coolant reservoir [ 2 ],

refill the coolant to the place where marks
“FULL”. After refilling, tighten up the cover
of the coolant reservoir.
4. Check whether there is object in front of the

cooler.
5. Coolant leakage or constant water tempera-

ture out-of-gauge indicates cooling system
failure.
6.3.3 Engine Oil Pressure Abnormality (Low Engine Oil Pressure)
• When the engine is just started, oil pressure

gauge indicates high pressure. After ad-
equate preheating operation, please check
the oil pressure once more
• When the indicator warns abnormal oil

pressure. Please stop the machine, and
shut down the engine immediately and do
as follows.
CAUTION
• Please shut down the engine immediately
for continuing operation may bring damage
to the engine.

1. Check whether the engine oil leaks

1
2. Check the amount of the engine oil, and re-
fill if insufficient
• Take out the engine oil dipstick [1], and

clean the engine oil with cloth.
• Dip the dipstick completely into the engine

oil, then take out slowly.
• If the engine oil trace on the dipstick is be-

CZ215-1105004
tween H and L, the oil amount is normal.
Fig.6-9
• Refill the engine with oil timely if it is insuffi-
cient. Replace the engine oil if it is obviously
unclean.
• Put the dipstick back to the slot after

examination.
3. When the engine oil is of normal amount L H

but the warning light still indicates abnormal
pressure, please contact Sany authorized
CZ335-1103131
dealer to repair.
Fig.6-10
6.3.4 Fuel Run-Out
When fuel runs out, remember to add fuel be-

fore starting the engine, and discharge air
from fuel system.

Excavator
WARNING
• Neither use lighter nor smoke during
bleeding. Otherwise it may lead to fire and
cause serious accident.
• Splashed engine oil or fuel may catch fire
in case of heat source or cause slipping
accident, so please clean up the splashed
engine oil and fuel at the exhaust pipe or
other places.
• Since the operation area is cramped, be
careful not to get hurt by the surrounding
parts.
Exhaust process:
1. Loosen the fuel filter drain plug.
2. Operate the priming pump on the fuel sup-

ply pump to bleed air from the fuel filter , and
tighten the priming pump.
3. Operate the priming pump to bleed the re-

maining air.
4. Tighten the fuel filter drain plug.
5. Loosen the vent plug on the fuel supply

pump, and operate the priming pump until no
air bubbles appear.
6. Tighten the vent plug on the fuel supply

pump.
7. After tightening the vent plug, operate the

priming pump until you feel slight resistance.
Fig.6-11
8. Tighten the priming pump in its original po-
sition and start the engine. If the engine fails
to be started at this time, repeat step 7).
1. Press the priming pump to deliver fuel con-

tinuously until there is no more bubbles com-
ing out of the vent plug.

2. Tighten the vent plug after making sure no

bubbles coming out [2].
CZ215-1105007
Fig.6-12
3. Press the priming pump again continuously

until the pressure becomes high. When the
fuel is under such a low temperature that the 2
pressure of manual pump won’t go up, please
press the manual pumps for multiple times.
CZ215-1105009
Fig.6-13
4. After the air is completely discharged, clean

up the splashed fuel, then start the engine.
With the fuel temperature is low, the pressure

of hand pump may not grow. It is important to
operate the hand pump many a time continu-
ously .
5. Please confirm if there is fuel leakage.
WARNING
CZ215-1105008
• Please confirm if there is fuel leakage
around the filter, since the fuel leakage can Fig.6-14
cause a fire.

Excavator
6.3.5 Engine Kick-Back
WARNING
• When the engine kicks back, please
shut down the engine immediately, oth-
erwise the engine will burn in a few mi-
nutes or serious accident may occur,
and the exhaust gas from the air cleaner
may also cause a fire.
When the engine kicks back, following situa-

tion will come up.
• Harsh impacting noise at the beginning of

running
• Black smoke from the air cleaner
• Low engine oil pressure warning on the

display
Please check and clean the air cleaner and

rubber hose after stop, and if any abnormality
is found, replace the affected part with a new
one.

6.4 Electrical System Failure

6.4.1 Faults Diagnosis Table of Electrical System
When a fault occurs, please conduct inspections according to the table below, and contact Sany
authorized dealer to carry out repairs.

● Low battery ● Charge or replace the
battery
● Internal fault of ignition switch ● Replacement
● Pilot switch fault ● Repair or replace the
part
● Starter motor fault ● Repair or replace the
part
The engine cannot be ● Wire harness open circuit ● Inspect and repair
started
● Fuse F1 fault ● Replacement
● Short circuit of wire (grounding fault) ● Inspect and repair
● Internal fault of alternator ● Repair or replace the
part
● Starter relay fault ● Replacement
● ● Failure of shutdown device ● Repair or replace the
part
● Open circuit of wire harness ● Inspect and repair
Irregular fluctuation of ● Internal fault of sensor ● Replacement
engine speed ● Short circuit of wire (grounding fault) ● Inspect and repair
● Internal fault of controller ● Replacement
The complete vehicle ● Battery relay fault ● Replacement
can't be powered off
● Boom lifting signal fault ● Inspect and repair
● Boom lowering signal fault ● Inspect and repair
● Arm digging signal fault ● Inspect and repair
● Arm unloading signal fault ● Inspect and repair
It runs idly automatically ● Bucket digging signal fault ● Inspect and repair
and doesn’t work ● Bucket dumping signal fault ● Inspect and repair
● Swing signal fault ● Inspect and repair
● Traveling signal fault ● Inspect and repair
● Accessory signal fault ● Inspect and repair
● Controller fault ● Replacement
● Failure of glow plug fuse ● Replacement
The preheating function ● Failure of glow plug relay ● Replacement
is disabled ● Short circuit of wire (grounding fault) ● Inspect and repair
● ● Failure of glow plug controller ● Replacement
● Safety lock switch fault ● Repair or replace the
part
No equipment works ● Short circuit of wire (grounding fault) ● Inspect and repair
● Internal coil failure of pilot lockout ● Replacement
solenoid valve

Excavator

● Sensor fault ● Replacement
● Short circuit of wire harness (grounding ● Inspect and repair
Slow and powerless rising fault)
movement of the boom
● Harness open circuit ● Inspect and repair
Slow and powerless fault)
movement of the arm
fault)
Slow and powerless
movement of the bucket
● ● Bucket converging solenoid valve ● Replacement
fault
Slow and powerless fault)
traveling movement
● Fuse fault ● Replacement
● Wire disconnection fault ● Inspect and repair
The display is blank
● Display screen fault ● Replacement
● Resistance fault ● Replacement
The display has no ● Wire disconnection fault ● Inspect and repair
display ● Short circuit of wire (grounding fault) ● Inspect and repair
● Fault of display or controller ● Replacement
● Fault of high/low speed traveling ● Replacement
The high/low traveling solenoid valve
speed function is disabled ● Wire disconnection fault ● Inspect and repair
● Coolant temperature sensor fault ● Replacement
Incorrect temperature ● Wire disconnection fault ● Inspect and repair
display of engine coolant ● Short circuit of wire (grounding fault) ● Inspect and repair
● Short circuit of wire and 24 V ● Inspect and repair
● Oil level sensor fault ● Replacement
The display of fuel level is ● Wire disconnection fault ● Inspect and repair
inaccurate ● Short circuit of wire (grounding fault) ● Inspect and repair
● Short circuit of wire and 24 V ● Inspect and repair


● Internal fault of wiper motor ● Repair or replace
the part
The wiper doesn’t work
● Wire disconnection fault ● Inspect and repair
● 5 V power supply fault ● Repair or replace
the part
The display of arm digging ● Signal wire open circuit ● Inspect and repair
pilot pressure is inaccurate
● Signal wire short circuit ● Inspect and repair
the part
The display of arm unloading ● Signal wire open circuit ● Inspect and repair
the part
The display of boom lifting ● Signal wire open circuit ● Inspect and repair
the part
The display of boom drop ● Signal wire open circuit ● Inspect and repair
the part
The display of bucket digging ● Signal wire open circuit ● Inspect and repair
The display of bucket the part
unloading pilot pressure is ● Signal wire open circuit ● Inspect and repair
inaccurate ● Signal wire short circuit ● Inspect and repair
the part
The display of swing pilot ● Signal wire open circuit ● Inspect and repair
pressure is inaccurate
the part
Incorrect display of travel ● Signal wire open circuit ● Inspect and repair
pilot pressure
6.4.2 Display Monitor
The failure code displayed on the monitor can be used to make failure analysis.

Excavator
SANY DTC Faul t des crip tion Faul t co nditio ns or SPN-FMI cod e
E001 Low power voltage Power voltage <18V, delay = 10s.
Power voltage <8V, delay = 10s
E002 High power voltage 1. Power voltage >32V, delay = 10s
2. Power voltage >18V, delay = 10s
E003 CAN bus abnormality CAN communication monitoring component incurs
communication timeout or reset bit changes, and
the time delay is 3s.
E004 Throttle knob abnormality The voltage of accelerator rotary switch is smaller
than 0.25V or greater than 4.75V, and the time
delay is 3s.
H001 Bucket digging pilot pressure The acquired voltage of pressure sensor is smaller
abnormality than 0.25V or greater than 4.75V, and the time
delay is 1s.
H002 Bucket unloading pilot pressure The acquired voltage of pressure sensor is smaller
delay is 1s.
H003 Arm digging pilot pressure The acquired voltage of pressure sensor is smaller
delay is 1s.
H004 Arm unloading pilot pressure The acquired voltage of pressure sensor is smaller
delay is 1s.
H005 Boom lifting pilot pressure The acquired voltage of pressure sensor is smaller
delay is 1s.
H006 Boom lifting pilot pressure The acquired voltage of pressure sensor is smaller
delay is 1s.
H007 Left travel pilot pressure The acquired voltage of pressure sensor is smaller
delay is 1s.
H008 Right travel pilot pressure The acquired voltage of pressure sensor is smaller
delay is 1s.
H009 Swing pilot pressure abnormality The acquired voltage of pressure sensor is smaller
than 0.25V or greater than 4.75V, and the time
delay is 1s.
H010 Hydraulic oil temperature too Hydraulic temperature above 90℃
high
H011 Front pump pressure abnormal The acquired voltage of front pump pressure
sensor is smaller than 0.25V or greater than
4.75V, and the time delay is 3s.
H012 Rear pump pressure abnormal The acquired voltage of rear pump pressure
sensor is smaller than 0.25V or greater than
4.75V, and the time delay is 3s.
H014 Low hydraulic oil level Low hydraulic oil level switch is actuated.
P001 Cam sensor abnormality (no 636 2
pulse)
P002 Crankshaft and cam sensor 636 7
abnormality (phase abnormality)
P003 Too high common rail pressure 157 15
P004 EEPROM error 10013 2
P005 Overlimited charge air pressure 102 0
P006 Preheating relay abnormality 676 5
P007 Open pressure limit valve 633 7
P008 QR code abnormality 10032 2

P041 Abnormality of throttle opening

sensor 1 or 2 (too high voltage) 91 3
P042 Abnormality of throttle opening
sensor 1 or 2 (too low voltage) 91 4
P043 Contrast abnormality of throttle 91 2
opening sensor 1-2
P044 Fuel nozzle#1 drive breakage 651 5
P048 Overspeed rotation 190 0
P049 abnormality of start and trip relay 677 5
P050 Abnormality of preheating 675 5
indicator lamp
P051 Abnormality of fault indicator 987 5
lamp
P052 High battery voltage 158 3
P053 A/D conversion abnormality 10008 2
P054 CPU abnormality 1077 2
P055 ROM abnormality 628 2
P056 5 V power supply 1 voltage 1079 2
abnormality
abnormality
abnormality
abnormality
P060 RAM abnormality 10033 2
P061 INJ-IC abnormality 10050 2
P062 Fuel nozzle Com1 drive 10003 2
abnormality
P063 Fuel nozzle Com2 drive 10004 2
abnormality
P064 CAN Bus abnormality 639 19
P065 ISO-CAN Bus abnormality 10040 19
P066 CAN TimeOut abnormality 639 2
P068 Cooling water overheating Water temperature >103°C or water temperature
switch is actuated, delay = 2s
P070 Low fuel level 2. Fuel level ≤10%, delay = 10s
P072 Air filter blocked Air filter on-off action blocked
P073 EGR position abnormal
P074 Blocking of the preliminary fuel 1381 17
filter (stage I)
P075 CPU monitoring IC abnormality 10007 2
P076 SWIC-1 abnormality 10046 2
P077 SWIC-1 communication 10048 2
abnormality
P078 INJ-IC communication 10051 2
abnormality
P079 INJ-IC CheckSum abnormality 10052 2
P080 Wheel Loader CAN TimeOut 10034 2
abnormality
P088 Too high engine speed For speed > 2500, timing 15S in power-on state
and timing 2S in other states
P090 Engine overspeed For speed > 2800, after being forcibly reduced to
the speeds of 1st gear, if it can not be recovered
within 3s, alarm code will be displayed.

Excavator
Table 6-4
6.4.3 Battery
6.4.3.1 general
WARNING
• It is dangerous to charge the battery
when the battery is mounted in the ma-
chine. Always disassemble the battery
from the machine before charging.
• When checking or handling the battery,
always turn the ignition key to OFF to
shut down the engine.
• When handling the battery, always wear
goggles and rubber gloves.
• When disassembling the battery, dis-
connect earthing cable (negative termi-
nal[-]) first. When mounting, first mount
the positive terminal [+]. Be careful not
get the tool touching the positive termi-
nal and chassis; otherwise, fire hazard
may ensue.
• Loose contact of terminal may generate
sparks, causing explosion.
• When disassembling or assembling ter-
minals, test which is the positive termi-
nal [+], and which is the negative
terminal[-].

6.4.3.2 Removal and Refitting of Battery
• Before disassembling battery, always disas-

semble earthing cable (normally connected 2
1
to negative terminal [-]) first.
• If the tool touches between the positive ter-

minal and chassis, fire disaster may occur.
• Use clamp to fix the battery when changing 1

2
battery.
• Order of connecting battery wire: first con-

CZ335-1103219
nect the battery positive wire, then connect
the battery negative wire. Fig.6-15
• Order of disconnecting battery wire: first
disconnect the battery negative wire, then
disconnect the battery positive wire.
6.4.3.3 Battery Charge
When charging the battery, any improper op-

eration may lead to explosion. Always operate
according to the battery and charger specifi-
cations, and do as follows:
• Adjust the charger voltage to match the bat-

tery. If the wrong voltage is selected, the
charger may go overheating, and cause
explosion.
• Connect the charger positive terminal [+] to

CZ335-1103220
the battery positive terminal [+], and con-
nect the charger negative terminal [-] to the Fig.6-16
battery negative terminal [-]. Always fix the
clamp.
• Adjust the charging current to the 1/10 of

the rated battery capacity; in case of fast
charging, tune down the charging current
under rated battery capacity. Overcurrent
may lead to electrolyte leakage or vaporiza-
tion, which will cause battery on fire or
exploding.

Excavator
• If the battery electrolyte freezes, do not

charge the battery or use different power
supply to start the engine. Otherwise it will
ignite the battery electrolyte and result in
battery explosion.
6.4.3.4 Start Engine with Auxiliary Wire
Connect and disconnect auxiliary wire
WARNING
• When connecting the wires, do no let
the positive terminal [+] contact the
negative terminal [-].
• Avoid the contact between normal ma-
chine and failed machine, so as to pre-
vent sparks being generated around the
battery igniting the hydrogen released CZ335-1103221
from the battery.
Fig.6-17
• Be careful not to make mistakes in con-
necting auxiliary wires. At the end of
connection (i. e. connection with upper
frame), sparks will come up, so you
need to connect the wire as far away
from the battery as possible. (But al-
ways avoid work equipment since it is
not good conductor)
• When removing the auxiliary wire, be
extremely careful not to let the wire
clamps touch each other or contact the
chassis.
Note:
• The starting system adopts 24V voltage, is

normally supplied by two 12V battery in
series.
• The specification of auxiliary wire and
clamp should conform to the battery
specification.
• The battery should have the same capacity
with the engine which it will start.

• Check whether the wires and clamps are

broken or corroded.
• Make sure the wires and clamps fixed well.
• Check whether the safety lock control lever
of the two machine both at the “LOCK”
position.
• Check whether all levers stay at the middle.
Auxiliary wire connection
Keep the ignition switches of normal machine

A
and failed machine at [OFF] position. Connect
the auxiliary wire according to the number or- 3 4
2
der marked on the picture.
1. Connect the clamp of auxiliary wire [A] to

D C
the positive terminal [+] of the failed machine
1
battery [C]. B E
2. Connect the other clamp of auxiliary wire CZ335-1103223

[A] to the positive terminal [+] of the normal
machine battery [D]. Fig.6-18
3. Connect the other clamp of auxiliary wire

[B] to the negative terminal [-] of the normal
machine battery [D].
4. Connect the other clamp of auxiliary wire

[B] to the failed machine swing frame [E].
1. Start the engine
CAUTION A
• No matter when the machine is operat-

2
3 4
ing normally or has failed already, al-
ways check the machine, and keep the
safety lock control lever at the “LOCK” D C
position, and check whether all levers 1
B E
stay at the neutral position.
CZ335-1103223
1. Make sure that the clamps and battery ter-

Fig.6-19
minals connected firmly.
2. Start the engine of a normal machine and

run it at high idle speed.

Excavator
3. Turn the ignition switch of the failed ma-

chine to the “START” position and start the
engine. If the engine fails to start in first time,
try again 2 minutes later.
Auxiliary wire disconnection
After the engine starting, disconnect the auxili-

ary wires in the reverse order of connecting
them.
1. Disassemble a clamp of auxiliary wire [B]

from swing frame of the failed machine [E].
2. Disassemble the clamps of auxiliary wire

[B]from the battery [D]negative terminal [-] of
the normal machine.

[A] from the battery [D] positive terminal [+] of
the normal machine.

[A] from the battery [C] positive terminal [+] of
the failed machine.

6.5 Failures of the Hydraulic System
• Trouble-shoot the hydraulic system according to the following tables. Contact your Sany dealer
to solve the problem.
• Set the working mode to S and the fuel control dial to position 10 before troubleshooting

● The main relief valve is improperly adjusted or ● Replacement
The work equipment fails
moves slowly, or it ● Pilot relief valve failure ● Replacement
has low traveling ● Regulator fault ● Repair or replace
and rotation speed ● Piston pump fault ● Inspect and
repair
● Fault of pilot pump relief valve ● Replacement
Work equipment, ● Hydraulic pump fault ● Inspect and
travel or swing repair
failure ● Coupler fault ● Inspect and
repair
● The hydraulic oil level drops ● Feeding with
hydraulic oil
● The hydraulic oil is poor ● Replace suitable
hydraulic oil
The hydraulic pump ● Blocking of ventilator of the top cap of the ● Clean up or
has unusual noise hydraulic tank replace
● Blocking of filter screen of the hydraulic tank ● Clean up or
replace
● Piston pump fault ● Inspect and
repair
Automatic idle
● Pilot valve failure ● Replacement
speed failure
● Controller fault ● Repair or replace
● Right pilot valve (boom oil line) failure ● Inspect and
repair
● Pressure sensor fault ● Replacement
● Boom control valve (spool) failure ● Repair or replace
Slow boom
movement ● Boom control valve (holding valve) failure ● Repair or replace
● Boom control valve (safety valve and refilling ● Repair or replace
valve) failure or seal failure
● Boom cylinder fault ● Inspect and
repair
● Left pilot valve (arm oil line) failure ● Inspect and
repair
● Arm control valve (spool) failure ● Repair or replace
Slow arm
movement ● Arm control valve (regeneration valve) failure ● Repair or replace
● Arm control valve (safety valve and refilling ● Repair or replace
valve) failure or seal failure
● Arm cylinder fault ● Inspect and
repair

Excavator

● Right pilot valve (bucket oil line) failure ● Inspect and repair
● Bucket control valve (spool) failure ● Repair or replace
Slow bucket
● Bucket control valve (holding valve) failure ● Repair or replace
movement
● Arm control valve (safety valve and ● Repair or replace
refilling valve) failure or seal failure
● Bucket cylinder fault ● Inspect and repair
● Pilot valve failure ● Inspect and repair
The single cylinder of
the work equipment
● Work equipment control valve (spool) ● Repair or replace
has no movement
failure
● Work equipment cylinder failure ● Repair or replace
The cylinder drift of ● Maintaining valve (boom, arm) failure ● Repair or replace
the work equipment is ● Work equipment control valve (safety ● Repair or replace
too large valve and refilling valve) seal failure
● Work equipment valve spool failure ● Repair or replace
● Arm regeneration valve failure ● Repair or replace
The work equipment
● Failure of the control valve (safety valve ● Repair or replace
moves slowly
and refilling valve)
Other work equipment ● Failure of seal of the control valve ● Replacement
moves when a single
oil line has an
overflow
Swinging or traveling ● Straight travel valve fault ● Repair or replace
speed decreasing the part
obviously
● Travel pilot valve failure ● Repair or replace
● Failure of pilot relief valve ● Replacement
● Regulator fault ● Repair or replace
The machine has off-
● Seizure of proportional solenoid valve ● Repair or replace
tracking during
● Seizure of traveling valve spool ● Repair or replace
traveling
● Hydraulic swivel stuck ● Repair or replace
● Travel motor failure ● Repair or replace
● Fault of traveling pilot pressure sensor ● Replacement
● Travel pilot valve failure ● Repair or replace
● Failure of pilot relief valve ● Replacement
Machine traveling
● Failure of traveling control valve (spool) ● Repair or replace
slowly
● Failure of traveling control valve (refilling ● Repair or replace
valve)
● Travel motor fault ● Inspect and repair


● Traveling pilot valve failure ● Repair or replace
● Failure of traveling pilot pressure ● Replacement
sensor
● Failure of traveling control valve ● Repair or replace
The machine is hard to turn
(spool)
or powerless
● Failure of traveling control valve ● Repair or replace
(refilling valve)
● Failure of travel motor (safety valve) ● Repair or replace
● Failure of travel motor (check valve) ● Repair or replace
● Failure of high/low speed changeover ● Replacement
The traveling speed cannot
solenoid valve
be shifted
● Travel base valve failure ● Repair or replace
● Travel motor safety valve failure ● Repair or replace
It cannot travel (only on one
● Travel motor balance valve failure ● Repair or replace
side)
● Fault of pilot pressure sensor ● Replacement
● Failure of swing motor (parking brake) ● Inspect and repair
● The swing valve (safety valve) is ● Adjust, replace
Swing failure to
improperly adjusted or fails
left and right
Swing ● swing motor fault ● Inspect and repair
failure ● Upper structure fault ● Inspect and repair
of ● Pilot valve failure ● Repair or replace
machine ● Failure of the swing control valve ● Repair or replace
Swing failure in
(spool)
single direction
● Failure of seal of the swing motor ● Replacement
(refilling valve)
● Failure of swing motor (parking brake) ● Inspect and repair
Poor acceleration
performance or
● swing motor fault ● Inspect and repair
slow swing
● Blocking of the brake control pipe ● Unclog or replace
the lines
Slow
● Pilot valve failure ● Repair or replace
swing
● Failure of swing motor (pressure ● Repair or replace
Poor acceleration
compensation valve)
performance in
● Failure of seal of the swing motor ● Replacement
single direction,
(refilling valve)
or slow swing
● Unilateral leakage of shuttle valve of ● Repair or replace
the swing pilot pressure sensor
The Overswing in two
overrun directions
● swing motor fault ● Inspect and repair
is too ● Pilot valve failure ● Repair or replace
large
when Overswing in ● Failure of the swing control valve ● Repair or replace
swing single direction (spool)
stops ● Failure of seal of the swing motor ● Replacement
(refilling valve)

Excavator

● swing pilot valve failure ● Repair or
replace
The impact is too large when ● Failure of swing damping valve ● Repair or
swing stops replace
● Failure of swing relief valve ● Repair or
replace
● Backpressure valve failure ● Repair or
replace
● Failure of the swing valve (safety valve) ● Repair or
The unusual noise is too loud replace
when swing stops ● Failure of swing motor (refilling valve) ● Repair or
replace
● swing mechanical device fault ● Inspect and
repair
● Fault of the swing brake control pipe ● Inspect and
When applying repair
swing parking
brake ● Swing motor (parking brake) ● Repair or
Excessive replace
swing ● Failure of the swing control valve (spool) ● Repair or
hydraulic replace
drifting When applying
● Fault of the swing motor (relief valve) ● Repair or
swing parking
replace
brake failure
● Fault of the swing motor (refilling valve) ● Repair or
replace
Table 6-5

6.6 Other Common Failures

● Looseness and unusual noise of ● Check and tighten up again
fasteners ● Adjust the clearance to 1mm
Noisy structural member
● Increasing end clearance between
bucket and arm due to abrasion
● Deformation and weakness of bucket ● Replace the bucket tooth pin
Bucket tooth dropping in tooth pin spring after long-term use
operation ● Mismatching of bucket tooth pin with
tooth base
● Loose track ● Tighten the track
Track twist under the
● Sprocket running fast in front on the ● Guide wheel running slow in front
excavator
bumpy road on the bumpy wheel
● Poor contact of electrics or connector ● Repair or replace
● Blowing rate switch, relay or temperature
Running failure of fan
control switch damage
● Fuse breakage or low battery voltage
● Obstacle at intake side ● Clean up
● Poor heat transfer due to blockage of ● Clean up
Small air volume with fan
evaporator or condenser fin ● Replace
running normally
● One of the fan impeller stuck or
damaged
● Clutch engagement failure because of ● Repair
broken line and poor contact in electric ● Adjust compressor belt tension
circuit ● Replace clutch coil
Failed or difficult running
● Undertensioning of compressor belt ● Adjust the filling amount of
of compressor
● Coil breakage and failure of compressor refrigerant
clutch coil
● Too much or too little refrigerant
● Coolant (freezing ● Coolant leakage ● Eliminate leaking point
medium) shortage ● Coolant underfilling ● Add coolant as appropriate
Readings of high and low ● When environment temperature is 30～50℃
pressure gauge in normal ● High pressure reading: 1.47~1.67MPa（15~17kgf/cm2）
working condition ● Reading of low pressure gauge: 0.13～0.20MPa（1.4～2.11kgf/cm2)
Low Frost ● Excessive opening width of expansion ● Replace the expansion valve
pressure attached on valve ● Properly mount the sensing bulb
above the surface of ● Poor contact of expansion valve sensing ● Drain some coolant to the
specified low pressure bulb specified amount
value pipe ● Excessive coolant inside the system
Both high and ● Coolant shortage ● Refill coolant to the specified
low pressure amount.
below normal
value
Low Negative ● Low pressure hose blocked, expansion ● Repair the system, replace the
pressure pressure valve blocked by ice or dirt liquid reservoir if blocked by ice
below sometimes
specified indicated on
value the low
pressure
gauge
Evaporator ● Thermostat out of operation ● Replace thermostat
freeze

Excavator

Frosting at inlet side of ● Expansion valve blocked ● Clean or replace the
expansion valve expansion valve
Expansion valve inlet ● Air leakage of expansion valve ● Replace the expansion valve
side not felt cold, but sensing pipe or sensing bulb
low pressure being
negative sometimes
Both high ● Air mixed into circulation system ● Drain away coolant,
and low vacuumize again, and then
High pressure add coolant
pressure above ● Coolant overfilling ● Drain coolant as appropriate
above normal
the value
specified Poor ● Condenser blocked by dust ● Clean and unblock the
value performance condenser
of ● Condenser fan damaged ● Check and replace condenser
condenser fan
Both high ● Insufficient refrigerant ● Repair, and refill with
and low refrigerant as specified
pressure ● Low pressure pipeline blocked ● Clean and replace failed part
below the and damaged
specified
value, with ● Internal failure of compressor ● Replace compressor
High
low
pressure
pressure
below
being
the
negative
specified
sometimes,
value
and
compressor
and high
pressure
pipe
overheating
Poor cooling effect due ● Closing failure of heater valve ● Replace heater solenoid valve
to warm air influence due to damage


SY115/125/135/155/155 Crawler Hydraulic Accessories and Options
Excavator
Accessories and Options
7 Accessories and Options ...........................................................................................7-1

7.1 General ...................................................................................................................................7-3
7.2 Hydraulic control components and lines supporting accessories ..................................7-5
7.2.1 Position of components..............................................................................................7-5
7.2.2 Hydraulic lines .............................................................................................................7-6
7.2.3 Removal and installation of accessories .................................................................7-9
7.2.4 Replacement of hydraulic fluid and hydraulic tank filter ..................................... 7-13
7.2.5 Long-term storage.................................................................................................... 7-14
7.3 Combinations of work equipment .................................................................................... 7-15
7.4 Recommended accessory operation .............................................................................. 7-15
7.4.1 General ...................................................................................................................... 7-15
7.4.2 Hydraulic breaker ..................................................................................................... 7-16
7.4.3 Operation of hydraulic breaker............................................................................... 7-16
7.4.4 Forbidden operation................................................................................................. 7-18
7.4.5 Greasing of hydraulic breaker ................................................................................ 7-21
7.5 Quick coupler and control system.................................................................................... 7-22
7.5.1 Operation method of quick coupler........................................................................ 7-22
7.5.2 Precautions for safety operation of quick coupler ............................................... 7-23
7.6 Refueling system................................................................................................................ 7-25
7.6.1 Introduction to refueling system ............................................................................. 7-25
7.6.2 Composition of refueling system............................................................................ 7-25
7.7 Centralized lubrication system ......................................................................................... 7-26
7.7.1 Lubrication scheme and system makeup ............................................................. 7-26
7.7.2 System working principle ........................................................................................ 7-28
7.7.3 Lubrication time setting of electric grease pump ................................................. 7-29
7.7.4 System technical specification ............................................................................... 7-31
7.7.5 Refilling method of electric grease pump ............................................................. 7-31

Accessories and Options SY115/125/135/155/155 Crawler Hydraulic Excavator
WARNING

Excavator
7.Accessories and Options

7.1 General
Pay attention to safety while installing accessories or options on board. Please comply with the fol-
lowing precautions for selection, installation and use of accessories or options:
Precautions for selection
• Before installing accessories or options on board, please consult the agents authorized by Sany
Heavy Machinery Co., Ltd. Depending on the type of accessory or option, front guard, overhead
guard or other safety structures may be required to be installed on board additionally.
• Only accessories or options approved by Sany Heavy Machinery Co., Ltd. shall be installed.
Sany Heavy Machinery Co., Ltd. will take no responsibility for the accident, damage or malfunc-
tion caused by unapproved accessories or options.
Please read the Operation Manual carefully
• Before installing and using any accessories or options, be sure to read carefully and understand
the contents of the corresponding Operation Manual.
• If the Operation Manual was lost or damaged, you should ask the manufacturer of accessories
or the agents authorized by Sany Heavy Machinery Co., Ltd. for a new one.
Precautions for removal and installation
Ensure safety while removing and installing accessories or options. Please comply with the follow-
ing precautions:
• Remove and install the accessories or options in a flat and solid place.
• When the cooperative work between two or more persons is required, one should be the
commander and others follow his/her commands.
• Use the lift to carry the object over 25 kg. (The lift must be operated by qualified and experienced
staff with official license.) It is forbidden to stay under the lifted object.
• During removal and installation process, please don’t use the machine while any object is being
lifted. Please use a holder to avoid the object falling if necessary.
• Before removing some heavy parts, consider the effect of the removal on the balance of the ma-
chine. To prevent rollover, the machine may be supported before removal of some heavy parts,
if necessary.
• Ensure the accessories or options to be installed or removed ones are stable and would not turn
over.
• As for more details about removal or installation, please consult the agents authorized by Sany
Heavy Machinery Co., Ltd.
Precautions for use
Please keep in mind the following precautions while installing large or heavy accessories or
options.

• Before operation, please move the machine to a safe place for trial operation and make sure that
you have clearly known the movement, center of gravity and working range of the machine.
• Do not swing the machine if it is inclined; otherwise, the machine would be in the risk of turning
over.
• In the process of operation, make sure to keep a safe distance from the machine to the sur-
rounding obstacles. Please pay attention to the followings while installing heavy accessories or
options
• The turning circle of heavy accessories or options may be large. Incorrectly calculating their
turning circle could cause a risk of hitting other objects. Please reserve a large space for rota-
tional motion.
• When the lifting process stops, the heavier the accessories or options are, the longer distance
they will move downwards under their dead weight. Therefore do not stop them at the lifting posi-
tion, but lower them down to the ground.
• Never swing, lower or stop the accessories or options abruptly to prevent the machine from turn-
ing over.
• Never extend or retract the boom cylinder abruptly to avoid machine rollover due to impact.

Excavator
7.2 Hydraulic control components and lines supporting accessories

7.2.1 Position of components
CZ335-1105001-2
Fig.7-1
[1]Ball valve [3] Control pedal

[3] Selector valve
1. Ball valve[1]
Ball valve is used for controlling the flow of hy-

draulic fluid.
Position[A]: FREE, hydraulic lines ON.

A
Position[B]: LOCK, hydraulic lines OFF.
When removing or installing accessories, ad-

just this valve to LOCK position. B
CZ335-1105002
Fig.7-2

Selector valve [2]
Selector valve is used for switching the flow

direction of hydraulic fluid.
This valve should be set based on the se-

lected working mode, which must match the
installed accessories.
For more details about working mode switch-

ing, see “Hydraulic lines” in Page 7-6.
CZ335-1105003
Fig.7-3
Control pedal [3]
Control pedal is used for controlling accesso- A

ries. When the forepart and rear-part of the
control pedal is depressed, the performance N
of the accessories is as follows:
B
• Hydraulic breaker
Forepart of the pedal [A]: ON
Rear-part of the pedal [B]: OFF
NOTE： CZ335-1105004
As for other accessories, please consult the

Fig.7-4
manufacturers before installation to determine
the operation of the pedal and accessories
before use.
7.2.2 Hydraulic lines
When the machine is equipped with a hydraulic breaker, the return lines must lead to the return fil-
ter directly. Therefore, do not use return lines except for in mode B. When the hydraulic breaker
pipeline is not pre-installed on the machine, if the user installs this pipeline by itself, the return pipe-
line must be provided with a filter. The pipeline of the hydraulic breaker and the filter must be veri-
fied by the agents authorized by Sany Heavy Machinery Co., Ltd, otherwise any subsequent
consequences shall be borne by the user.
The standard set pressure of the relief valve in the service valves has already been set when the
machine was delivered from the factory. For Mode B, it is set as 15~17MPa (153~174 kgf/cm2,
2178~2469 PSI); for hydraulic shear mode, it shall be set as 27.4 MPa (280 kgf/cm2, 3980 PSI).
Depending on the type of accessories, it may need to be adjusted. In case of that, please contact
the agents authorized by Sany Heavy Machinery Co., Ltd for adjustment.

Excavator
Switching of hydraulic lines
• Depending on the type of accessories, set the working mode in the display screen in accordance
with the following standard.
• The set pressure of the relief valve in the service valves and the switch of the hydraulic lines is
specified as per the selected working mode.
Set pressure of relief

Accessories Working mode Hydraulic lines
valve in service valves
The hydraulic line
When delivered from
automatically forms at
Accessories of No. 1 the factory: 15～
the point where the
hydraulic line, e.g. Mode B 17MPa（153～174
return line doesn’t
hydraulic breaker kgf/cm2，2178～
lead to the control
2469 PSI）
valve.
The hydraulic line
When delivered from
Accessories of double automatically forms at
the factory: 27.4
acting hydraulic line, Mode S the point where the
MPa（280 kgf/cm2,
e.g. hydraulic shear return line leads to the
3980 PSI）
control valve.
Switch between hydraulic breaker and general accessories
• When optional accessories are installed and Mode B is set as the working mode.
1. The hydraulic line of the hydraulic breaker (No. 1 hydraulic line) forms.
2. Overflow valve is set to low pressure.

When delivered from the factory: 15~17MPa (153~174 kgf/cm2, 2178~2469 PSI).
• When optional accessories are installed and Mode S is set as the working mode.
1. The hydraulic line of the hydraulic shear (double acting hydraulic line) forms.
2. Overflow valve is set to high pressure.

When delivered from the factory: 27.4 MPa (280 kgf/cm2, 3980 PSI).

Connection of hydraulic lines
When connecting accessories, please con-

nect the hydraulic lines as per the following
steps.
1. Check whether the ball valve is in LOCK po- A

sition [B].
[A] FREE: Hydraulic lines ON (the direction of

arrow is parallel to the length direction of the B
arm) CZ335-1105002
[B] LOCK: Hydraulic lines OFF (the direction Fig.7-5

of arrow is vertical to the length direction of
the arm)
2. Remove the screw plugs [1] at the end of

the ball valve pipeline (one on the left and one
on the right).
Note: Do not lose or damage the removed

parts.
1
CZ335-1105005
Fig.7-6
3. After removing the screw plug [1], ask the

manufacturer of the accessory to connect the
hydraulic line of the accessory [2].
As for the dimensions of the connector and 2

the added accumulator, different manufac-
turers require different measures. Therefore
please contact the agents authorized by Sany
CZ335-1105006
Fig.7-7
Flow path of hydraulic fluid

Excavator
The operation direction of the pedal and the flow path of hydraulic fluid are as shown below.
CZ335-1105007
Fig.7-8
When the forepart of the pedal is depressed, the hydraulic fluid will flow to the left pipeline of the
work equipment; when the rear part of the pedal is depressed, the hydraulic fluid will flow to the
right pipeline of the work equipment. (When a hydraulic breaker is installed, only the forepart of the
pedal works.).
7.2.3 Removal and installation of

accessories
Removal of accessories
1. Lower down the work equipment to the

ground and shut down the engine.
2. Turn the ignition switch to [ON] position,

then set the safety lock control lever to "UN-
LOCK" position.
3. After finishing step 2, fully operate two joy-

sticks frontward, rearward, leftward and right- CC13031404
ward in 15 seconds and step on the
Fig.7-9

accessory control pedal 2-3 times to release

the internal pressure in the hydraulic lines.
4. Turn the safety lock control lever to “LOCK”

position.
CC13031403
Fig.7-10
5. The internal pressure in the hydraulic lines

will be released through the breather valve [F]
F
at the top of the hydraulic tank.
To release all pressure, rotate and open the

butterfly nut of the breather valve [F] and
press the release button to release pressure.
CZ335-1105011
Fig.7-11
6. Check that the hydraulic fluid temperature

has declined, and turn the rotor of the ball
valve (installed at the outlet and inlet pipelines
at the side of the arm) to "LOCK" position [B].

arrow is parallel to the length direction of the A
arm).
[B] LOCK: Hydraulic lines OFF (the direction

B
CZ335-1105012
the arm).
Fig.7-12

Excavator
1. 7. Remove the hose at the side of acces-

sory. Install the screw plugs at two outlets.
The screw plugs are used to avoid intrusion of

foreign objects. Store the disconnected at-
tachment properly when the screw plugs are
in place.
8. Pull out the mounting pins (at 2 points), re-

move the accessories and install the bucket.
As for more detail about installation steps of

CZ335-1105013
the bucket, please see “Replacement of buck-
et” in Page 5-21. Fig.7-13
9. After installing the bucket, check the fluid

level in the hydraulic tank.
Installation of accessories
1.Remove the bucket.
2.Place the accessory horizontally, set pin [A],

and then use pin [B] to install the accessory to
the arm. A
3. Lower down the work equipment to the

ground and shut down the engine. B
CZ335-1105014
Fig.7-14
4. Turn the ignition switch to [ON] position,

then set the safety lock control lever to "UN-
LOCK" position
5. After finishing step 2, fully operate two joy-

sticks frontward, rearward, leftward and right-
ward in 15 seconds and step on the
accessory control pedal 2-3 times to release
the internal pressure in the hydraulic lines.
CC13031404
Fig.7-15

6.Turn the safety lock control lever to "LOCK"

position.
CC13031403
Fig.7-16
7. The internal pressure in the hydraulic lines

will be released through the breather valve [F]
F
at the top of the hydraulic tank.
To release all pressure, rotate and open the

butterfly nut of the breather valve [F] and
press the release button to release pressure.
CZ335-1105011
Fig.7-17
8. Check that the hydraulic fluid temperature

has declined, and remove the screw plugs
from the outlet and inlet respectively. Pay at-
tention to avoiding any dust or dirt affixed to
the connection of the hose.
If the O-ring is damaged, replace it with a new A
one.
9. Connect the hose at the side of the

B
accessory.
CZ335-1105012
During connection, check that the hydraulic
fluid flows in correct direction. Fig.7-18
10.Set the rotors of the ball valves installed at

the inlet and outlet pipelines at the side of the
arm to FREE position [A].

Excavator

arrow is parallel to the length direction of the
arm).
[B] LOCK: Hydraulic lines OFF (the direction

the arm).
11.After installing the accessory, check the flu-

id level of the hydraulic tank.
7.2.4 Replacement of hydraulic fluid and hydraulic tank filter
The operation of the hydraulic breaker will accelerate the pollution of the hydraulic system and the
degradation of hydraulic fluid. Therefore, compared with the machine equipped with the bucket,
the machine with hydraulic breaker requires frequenter replacement of hydraulic fluid and hydraul-
ic tank filter. Failure to observe this may cause damage to the hydraulic breaker, hydraulic pump
and other parts of the hydraulic system. Recommended replacement interval is as follows. (As for
the replacement method of the filter element and the hydraulic fluid, see the Section
“Maintenance”.).
Replacement interval (unit: hour)
Machine with hydraulic Machine with general

breaker bucket
Hydraulic oil 600 1,500 or 2,000 or 4,000
Filter element 100 1000
Table 8-2
NOTE:
• The data in the table above are based on the 100% operation time of the hydraulic breaker.
When the operation time of the hydraulic breaker declines, the replacement interval could be
prolonged as shown below.
• After continuous operation of the hydraulic breaker for 100 hours, the filter element must be
replaced.

When using micro-glass

filter element
Replacement interval When using paper filter
when the hydraulic oil element
Average operation rate of hydraulic breaker, %
with a service life of

1,500 h is used
Replacement interval
when the hydraulic oil
2,000 h is used
Replacement interval
when the hydraulic oil
4,000 h is used
Number of operation hours of excavator
Fig.7-19
7.2.5 Long-term storage
If the equipment will not be in use for a long time, please follow the steps below.
• Turn the ball valve to [LOCK ] position.

• Install the screw plug on the valve.
• Turn the lock pin to [LOCK] position. If no hydraulic breaker or general accessory is installed on
the machine, overheating or other issues may arise during operation of the pedal.

Excavator
7.3 Combinations of work equipment
CAUTION
• Different types or combinations of work equipment may lead to the danger of colliding with the
cab or body of the machine.
• Before using unfamiliar work equipment for the first time, please check for any risk of interfer-
ence and be careful to operate the equipment.
The accessory combinations that can be attached to long arm (standard) and short arm are listed
in the table below.
Note:
• In case the machine is equipped with a long arm, the arm will interfere with the machine body if
the bucket is retracted toward the machine body, so please operate the long arm carefully.
• During the excavation on a slope, the boom will interfere with the lower structure if the boom is
fully lowered, so please operate the boom carefully.
• For excavating or loading hard soil or soft rock-filled soil, a reinforced rock bucket with high
strength and high wear resistance is recommended.
*: Side edge plate is equipped.
Model Bucket Bucket Bucket width Bucket Standard arm Remarks

code capacity mm（ft in） weight length
m3 Kg（lb）（mm）
（cu.yd）
SY115C9 11654932 0.5（0.67） 860(2′10″) 405（893） 2360 Standard
bucket, rock
bucket
SY135C9 13946378 0.6（0.8） 950(3′1″) 483（1067） 2500
SY155C9 13946378 0.6（0.8） 950(3′1″) 483（1067） 2500
SY155H 14082101 0.65 1010(3′3″) 474（1045） 2500
（0.87）
Note: The bucket interfaces of the above models are in the same size and can be used
interchangeably.
7.4 Recommended accessory operation

7.4.1 General
TDuring operation of the hydraulic excavator

equipped with accessories, following specifi-
cations must be complied with.
Note:
The type of applicable accessories or the

model of special accessories depends on the
model of the hydraulic excavator. Therefore,
as for the selection of the related accessories,
please contact the agents authorized by Sany
7.4.2 Hydraulic breaker
Main purposes:
• Hydraulic breaker
• Removal operation
• Road project
This accessory is widely used for removing

buildings, crushing road or slag, tunnel opera-
tion, rock crushing and the crushing operation
in quarry.
CZ335-1105016
Fig.7-20
7.4.3 Operation of hydraulic breaker
1. When conducting crushing operation, tightly

press the drill rod vertically on the surface of
the target object.
90°
90°
CZ335-1105017
Fig.7-21

Excavator
2. When applying impact, press the drill rod on

the impact surface, leaving the forepart of the
lower structure about 5 cm (2 in) above the
ground, as shown on the right. Don’t leave the
machine more than that value above the
ground. Note: Don’t lift the excavator too high.
CZ335-1105018
Fig.7-22
3. During application of continuous impact to

the same surface, if the drill rod is unable to
pierce or crush the surface, change the im-
pact part and conduct crushing again on the
part near the edge.
CZ335-1105019
Fig.7-23
4. The piercing direction of the drill rod will

gradually be out of line with the direction of
the body of the hydraulic breaker. Adjust the R
bucket cylinder to align them.
CZ335-1105020
Fig.7-24

5. Consistently press the drill rod on the im-

pact surface properly to prevent the impact
without resistance.
CZ335-1105021
Fig.7-25
7.4.4 Forbidden operation
To ensure long service life and safe operation

of the machine, do not operate the machine
as the following.
• Do not operate all the cylinders to the end

of the stroke. Make sure to keep a distance
of about 5 cm (2 in).
1. Accumulate the rocks and stones by the hy-

draulic breaker.
CZ335-1105022
Fig.7-26

Excavator
2. Operate with swing force.
CZ335-1105023
Fig.7-27
3. Move the drill rod during application of

impact.
CZ335-1105024
Fig.7-28
4. Keep the drill rod horizontal or upward dur-

ing application of impact.
CZ335-1105025
Fig.7-29

5. Swing the drill rod when the rock has been

pierced.
CZ335-1105026
Fig.7-30
6. Pecking operation.
CZ335-1105027
Fig.7-31
7. Lift the machine away from the ground by

totally extending the bucket cylinder.
CZ335-1105028
Fig.7-32

Excavator
7.4.5 Greasing of hydraulic breaker
Add grease to the hydraulic breaker on the

right place (as shown).
CZ335-1105029
Fig.7-33
Note:
• Incorrect greasing operation may cause ex-

cessive grease. As a result, soil and sand
will enter the hydraulic lines, such that, dur-
ing operation of hydraulic breaker, the hy-
draulic parts will be damaged.
• Therefore, make sure to add grease to the
breaker kept in right position.
CZ335-1105030
Fig.7-34
CZ335-1105031
Fig.7-35

7.5 Quick coupler and control system

7.5.1 Operation method of quick
coupler
1. Take out the safety shaft of the quick cou-

pler, as shown on the right.
Safety pin
Jaw
CZ335-1105032
Fig.7-36
2. Press the quick coupler switch [1] (self-re-

set type) on the left joystick to close the mov- 1
ing and fixed jaws slowly.
CZ335-1105033
Fig.7-37
3. Make the fixed jaw of the quick coupler

catch the bucket shaft [2] slowly, as shown on
the right.
2 3
CZ335-1105034
Fig.7-38

Excavator
4. Extend the bucket cylinder and move the

moving jaw of the quick coupler towards the
bucket shaft [3] slowly.
2
3
CZ335-1105035
Fig.7-39
5. Allow the jaw of the quick coupler to get

stuck with the bucket shaft [3] totally.
6. Loosen the quick coupler switch to make

the quick coupler get stuck with the bucket
shaft, and conduct other operation.
7. After finishing installation, plug the safety

shaft again.
CZ335-1105036
Fig.7-40
7.5.2 Precautions for safety operation

of quick coupler
1. Due to installation of the quick coupler, the

turning radius will be longer when the bucket
and other connecting parts are operating. It is
possible that these parts would collide with
the cab or the boom of the excavator. There-
fore please operate with care.
Please retract the bucket (with the bucket cyl-

inder fully extended) in place fi rst and then
the arm of the excavator after the installation
of the quick coupl er. Never operate the buck-
CZ335-1105037
et when the arm has been retracted to the
Fig.7-41

right position (with the arm cylinder fully ex-

tended) to prevent collision with the boom.
2. Overload operation will damage the part

connected to the quick coupler and the exca-
vator, thus reducing the service life of the
machine.
CZ335-1105038
Fig.7-42
3. Do not exert pressure when the quick cou-

pler contacts the ground. Please check that
the quick coupler is connected to the bucket
or other part during operation.
CZ335-1105039
Fig.7-43
4. Moving a weight by the quick coupler is very

dangerous and may also reduce the service
life of the coupler.
Note:
If the installation of the quick coupler is neces-

sary, please consult the local agents author-
ized by Sany Heavy Machinery Co., Ltd. Be
sure to use the accessories designated by
Sany Heavy Machinery Co., Ltd. Otherwise,
CZ335-1105040
Sany Heavy Machinery Co., Ltd will take no
responsibility for any malfunction or accident Fig.7-44
caused by any unapproved accessories.

Excavator
7.6 Refueling system

7.6.1 Introduction to refueling system
SANY large excavator is equipped with refuel-

ing system as a standard configuration. The
system operates with the refueling pump as-
sembly. Being powered by the vehicle-
mounted battery, the refueling pump assem-
bly is free from the limits of the area and
power supply, thus having greatly enhanced
work efficiency, increased economic benefit
and reduced labor intensity.
The refueling volume of different types of ma-

chine is shown in the “Capacity table” in Page
5-11.
7.6.2 Composition of refueling system
• The refueling system of SANY large exca-

1 2
vator is mainly composed of: refueling
pump assembly (including related pipelines
and valves) and control switch.
• Open the battery box cover [1] to find the
3
control switch [2] and the refueling pump
[3].
CZ335S-1105001
Fig.7-45

• The main part of the refueling pump [3] is

as shown on the right.
Main performance parameters of refueling

pump
Pump flow 46L/min

Rated voltage 24V
Rated speed 2800 rpm
Connector thread
3/4’G
specification CZ335S-1105002
Weight 3.5kg Fig.7-46

Package dimension 215×120×160mm
7.7 Centralized lubrication system

7.7.1 Lubrication scheme and system makeup
1.The distribution diagram of the lubrication points in the excavator is shown as follows:
Fig.7-47

Excavator
2.System composition
1
• Electric grease pump
Open the left door; the electric grease pump

assembly [1] is installed at the rear of the cab
of the machine as shown on the right.
The electric grease pump consists of the

pump mounting base, electric pump, pump
unit, relief valve and filter.
CZ335-1105042
Fig.7-48
• Distributor Boom
The distributor mainly consists of: B

A
Primary distributor (1 piece)
MX-F3/3
Secondary sub-distributors (3 pieces)
MX-F5/10
MX-F3/5
CZ335-1105043
MX-F3/4
Fig.7-49
The primary distributor [A] installed at the root
of the boom and the secondary sub-distributor
[B] are as shown on the right.
The secondary sub-distributor [C] installed on

the arm is as shown.
Arm
C
CZ335-1105044
Fig.7-50

The sub-distributor [D] installed in the inside

of the link is as shown.
• Main pipeline
Linkage
The main pipeline of the system consists of
high pressure hose, straight fitting, elbow fit-
ting, straight core, bent core, wire protective
jacket, hose protective jacket, and bucket dis-
tributor protective plate.
D
CZ335-1105045
Fig.7-51
7.7.2 System working principle
Considering the lubrication points of SY series excavator of Sany Heavy Machinery Co., Ltd are
centralized and tightly spaced, a progressive centralized lubrication system structured as shown
below is adopted.
Working principle: pressure grease from the electric plunger pump is delivered through the pump
unit, the relief valve and the filter to the primary distributor, and then the grease from the main dis-
tributor is delivered through the grease transfer pipe branch to three secondary sub-distributors.
Afterwards, certain amount and proportion of grease is supplied to the following lubrication points
successively.

Excavator
Electric Grease Pump
Safety Valve
Pumping Unit
Filter
Secondary Distributor
Main Distributor
CZ335-1105046
Fig.7-52
7.7.3 Lubrication time setting of electric grease pump
The integrated electric controller in the electric grease pump is able to control the time or period of
the centralized lubrication system. At time programming control mode, after the power of the exca-
vator is on, the indicator light of the centralized lubrication system in the cab will flash intermittently,
and the yellow LED indicator light of the electric controller will be on for 25 seconds, which indi-
cates it is ready for operation.
When the start button on the motor casing or the dash board is pressed, the lubrication period will
begin. After the lubrication period, the motor of the lubrication pump will be shut down, and the halt
time begins. All follow-up lubrication operations will begin in accordance with the pre-set time

programs. If the electric motor is shut down in halt time or lubrication time period, the period will be
terminated and the time will be saved. When it starts again, the operation process will continue
based on the time saved during the last operation. In the interrupted lubrication period, the forced
start button can be pressed to start the lubrication pump at any time. Once the control device is
connected, a lubrication period will start. The panel of the grease pump electric controller is as
shown below
EA/PA Controller Type S-EP 4

Schmierzeit(min.)
Pausenzeit(h) Control Forced start button
4 2
2 6 1 3 LED
1 0.5
16 8 8 4
14 10 7 5
12 6
LED indicator
Lubrication time dial Lubrication interval dial
CZ335-1105047
Fig.7-53
• Parameter setting
The setting range of the interval time is from 0.5 h to 8 h; the setting range of the lubrication time is
from 1 min to 16 min, as shown below.

Excavator
If high speed time is necessary, remove the red rim with a slotted screwdriver, loosen four cross-
head screws, and then remove the transparent caps successively. If the caps are not closed tightly,
water may come into the control unit and cause damage.
2 4
1 3 2 6
0.5 1
8 4 16 8
7 5 14 10
6 12
Lubrication interval Lubrication time
(0.5~8 hr) (1~16 min)
CZ335-1105048
Fig.7-54
7.7.4 System technical specification
1. The default setting of the lubrication interval time is 0.5 h, and that of lubrication time is 10 min.
2. After 100 h operation, the lubrication time may be adjusted (increased or decreased) based on
the actual conditions, but the lubrication interval time can’t be changed.
3. Clean NLG12# lithium grease is recommended as the lubricating grease.
4. (24V/DC, 19kg) electric lubrication pump with the built-in electric controller is applied.
7.7.5 Refilling method of electric grease pump
The refilling methods of this electric grease pump of the centralized lubrication system include the
following 3 methods.
1. Standard method:
Refilling through the ball nozzle by manual or pneumatic gun as shown below.

Ball-type nozzle
CZ335-1105049
Fig.7-55
2.Refilling through the coupler is as shown below.
Remove the nozzle and

install the adapter.
Gasket
CZ335-1105050
Fig.7-56
Adapter Gasket
CZ335-1105051
Fig.7-57
3. Refilling through the grease gun is as shown below.

Excavator
Grease gun
Straight coupler
CZ335-1105052
Fig.7-58
Note:
If it is necessary to install the centralized lubrication system, please consult the agents authorized
by Sany Heavy Machinery Co., Ltd. Be sure to use the accessories designated by Sany Heavy Ma-
chinery Co., Ltd. Otherwise, Sany Heavy Machinery Co., Ltd will take no responsibility for any mal-
function or accident caused by any unapproved accessories.

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Quality Changes the World

Operation and Maintenance Manual

Operation and Maintenance Manual

Operation & Maintenance Manual-Oct. 2019 1

2 Operation & Maintenance Manual-Oct. 2019

Operation & Maintenance Manual-Oct. 2019 1

2 Operation & Maintenance Manual-Oct. 2019

We do not accept any responsibility for the following:

Responsibilities of our manufacturer

Operation & Maintenance Manual-Oct. 2019 1

•Make a use planning carefully and consciously.

2 Operation & Maintenance Manual-Oct. 2019

Operation & Maintenance Manual-Oct. 2019 I

2.2.14.3 Fire caused by electrical wire......................................................................... 2-26

II Operation & Maintenance Manual-Oct. 2019

2.3.3 Parking ........................................................................................................................ 2-50

Operation & Maintenance Manual-Oct. 2019 III

4.2 Description of controls and instruments.............................................................................4-6

IV Operation & Maintenance Manual-Oct. 2019

4.2.17.2 Control key and LCD ....................................................................................... 4-60

Operation & Maintenance Manual-Oct. 2019 V

VI Operation & Maintenance Manual-Oct. 2019

5.5 Recommended Fuel, Coolant and Lubricating Oil ........................................................ 5-12

Operation & Maintenance Manual-Oct. 2019 VII

VIII Operation & Maintenance Manual-Oct. 2019

6.3 Engine Faults.......................................................................................................................6-11

7 Accessories and Options ...........................................................................................7-1

Operation & Maintenance Manual-Oct. 2019 IX

7.7.2 System working principle.......................................................................................... 7-28

X Operation & Maintenance Manual-Oct. 2019

Operation & Maintenance Manual-Oct. 2019 1-1

1-2 Operation & Maintenance Manual-Oct. 2019

Operation & Maintenance Manual-Oct. 2019 1-3

1.2 Safety information

1-4 Operation & Maintenance Manual-Oct. 2019

Examples of safety warnings

a. Examples of literal safety decals

Operation & Maintenance Manual-Oct. 2019 1-5

b. Examples of graphic safety decals Safety

In the figure on the right, the safety icon above

1.3 Page description

Sany hydraulic excavator is designed for:

1-6 Operation & Maintenance Manual-Oct. 2019

Please refer to the relevant part of this manual in detail.

The international system of units (SI) is used in this manual.

1.4.2 Directions of the machine

1. Directions of the machine

In this manual, the front, back, left and right

1.4.3 Running-in of new machines

Avoid high-speed operation at heavy load.

Operation & Maintenance Manual-Oct. 2019 1-7

1.5 Product information

1.5.2 Machine data plate

Environmental Protection Information Label

1.5.3 Engine data plate

1-8 Operation & Maintenance Manual-Oct. 2019

Type approval according to the Emission Standard

Operation & Maintenance Manual-Oct. 2019 1-9

1-10 Operation & Maintenance Manual-Oct. 2019