Professional Documents
Culture Documents
WARNING
Read and follow the safety precautions and instructions in this manual and on the ma-
chine decals. Failure to do can cause serious injury, death or property damage. Keep this
manual with the machine for reading and future reference.
Sany Group
http://www.sanygroup.com
Tel: 0086-21-57008518
E-mail: crd@sany.com.cn
© 2016 by Sany Group. All right reserved.This is the original instruction. No part of this
publication may be reproduced, used, distributed or disclosed except during normal
operation of the machine as described herein. All information included within this
publication was accurate at the time of publication. Product improvements, revisions,
etc., may result in differences between your machine and what is presented here. Sany
Group assumes no liability. For more information, please contact Sany Group.
SY500H-10 Crawler Hydraulic Excavator
EXEMPTION CLAUSES
Specific Declaration
The crawler hydraulic excavator is a multi-purpose construction machine that is primarily used for
digging or loading earth and stones. It can also be used for grading, slope-trimming, lifting, break-
ing, demolishing and trenching applications. The excavator is widely used in road and railway
construction, bridge building, city construction, as well as airport, sea port and water conserva-
tion construction. It can also perform the function of bull dozer, loader and crane. Application oth-
er than the specified range are excluded from the scope. Sany assumes no responsibility for any
consequence caused by unauthorized applications.
Sany assumes no responsibility for consequences caused by the following factors:
●● Misuse of the excavator due to failure to observe the information provided hereunder in this
manual;
●● Machine failure or damage resulted from natural disasters (such as earthquake, typhoon,
etc.), wars and other force majeure.
Sany cannot anticipate all potential hazards that may occur on work site. Therefore, excavator
operator and owner shall attach great importance to the issue of safety.
Local government may impose higher standards for use of a hydraulic excavator. If local regula-
tions have conflicts to the safety rules described herein, whichever the stricter applies.
Obligations of Sany
●● Offer quality excavators along with correct information.
●● Abide by after-sales service commitment and keep a record for all maintenance work and re-
pair work.
●● Make sure that the excavator operator and service person are qualified for this job and know
their responsibilities.
●● Should any fault threatening safety occurs, shut down the excavator immediately.
SY500H-10 Crawler Hydraulic Excavator
●● Sany service personnel have the right to carry out safety inspection to the excavator when re-
quired.
●● Besides the checks specified by Sany, local laws and regulations on excavator shall also be
observed.
●● All workers around the hydraulic excavator must know and obey all warning signals, and be
alert to safety of oneself and others.
●● Be alert to any hazardous situation and immediately inform operator and signalman of the
hazards such as high voltage cables, irrelevant people and worse ground condition.
Obligations of manager
●● The operator must have been trained and fully understand the provision of the Safety, Opera-
tion and Maintenance Manual. The operator must be healthy and licensed. Otherwise he/she
is not allowed to operate the hydraulic excavator.
●● Make sure that the operator has good sense, cooperation awareness and psychological qual-
ity, or he/she is not allowed to operate or service the hydraulic excavator.
●● Make sure that the signal person has good visibility and hearing ability, knows standard com-
mand signals and can give signals clearly and correctly. The signal person shall also have
enough experience to recognize hazardous factors and timely tell the operator to avoid the
hazards.
●● Make sure that the assistant person can positively identify the model and working condition of
hydraulic excavator and choose a suitable hydraulic excavator.
●● Each operating personnel of a project shall bear certain safety responsibilities and is required
to timely report unsafe factors to the supervisor.
SY500H-10 Crawler Hydraulic Excavator Table of Contents
Table of Contents
1 Introduction
1.1 Overview................................................................................................................... 1-3
1.2 Your Documentation Package.................................................................................. 1-4
1.2.1 CD system requirements................................................................................ 1-4
1.2.2 Recommendations on using the documentation............................................. 1-5
1.2.3 Documentation storage................................................................................... 1-5
1.2.4 Manual organization....................................................................................... 1-5
1.2.4.1 Introduction............................................................................................ 1-6
1.2.4.2 Safety..................................................................................................... 1-6
1.2.4.3 System functions.................................................................................... 1-6
1.2.4.4 Operation............................................................................................... 1-6
1.2.4.5 Maintenance.......................................................................................... 1-6
1.2.4.6 Troubleshooting..................................................................................... 1-7
1.2.4.7 Specifications......................................................................................... 1-7
1.2.4.8 Optional Equipment............................................................................... 1-7
1.3 Your Sany Machine................................................................................................... 1-8
1.3.1 Machine applications...................................................................................... 1-8
1.3.2 Machine directions.......................................................................................... 1-8
1.3.3 Breaking in a new machine............................................................................. 1-9
1.3.4 Machine information....................................................................................... 1-9
1.3.4.1 Product identification plate..................................................................... 1-9
1.3.4.2 Engine identification plates.................................................................. 1-10
1.3.4.3 Right and left drive motor identification plates......................................1-11
1.3.4.4 Swing motor identification plate............................................................1-11
1.3.4.5 Hydraulic pump identification plate.......................................................1-11
1.3.4.6 Chassis serial number......................................................................... 1-12
1.3.5 Table for serial number and distributor information....................................... 1-13
1.4 Noise and Vibration Statements............................................................................. 1-14
1.5 Correction Request Form - Technical Publications................................................. 1-15
1.6 Contact Information................................................................................................ 1-16
2 Safety
2.1 Safety Information.................................................................................................... 2-5
2.2 Safety Messages...................................................................................................... 2-7
2.2.1 Hazard alert message..................................................................................... 2-7
2.2.2 Safety decals.................................................................................................. 2-9
3 System Functions
3.1 Machine general drawing......................................................................................... 3-5
3.2 Monitoring System.................................................................................................... 3-6
3.2.1 Monitor functions............................................................................................ 3-6
3.2.2 Monitor operation.......................................................................................... 3-10
3.2.2.1 Default page......................................................................................... 3-10
3.2.2.2 Main Menu........................................................................................... 3-12
3.2.2.3 Main Menu Password entry to system information.............................. 3-12
3.2.2.4 System Lockout................................................................................... 3-13
3.2.2.5 Engine & Throttle Signals.................................................................... 3-13
3.2.2.6 Pilot Pressure Signals.......................................................................... 3-14
3.2.2.7 Main & Cooling Pump Signals............................................................. 3-14
3.2.2.8 Input & Output Switch Signals............................................................. 3-15
3.2.2.9 Failure information............................................................................... 3-15
3.2.2.10 GPS Information................................................................................ 3-16
3.2.2.11 Language Selection........................................................................... 3-16
3.2.2.12 System Time Calibration ................................................................... 3-17
3.2.2.13 Maintenance Information................................................................... 3-17
3.2.2.14 Maintenance Confirmation................................................................. 3-18
3.2.2.15 System Setting................................................................................... 3-18
3.12 Controller.............................................................................................................. 3-50
3.13 Fusible Link.......................................................................................................... 3-51
3.14 Air Conditioning System....................................................................................... 3-52
3.14.1 Control panel.............................................................................................. 3-52
3.14.2 Operation method....................................................................................... 3-58
3.14.3 Air conditioner operation precautions......................................................... 3-61
3.15 Radio.................................................................................................................... 3-63
3.15.1 Control panel.............................................................................................. 3-63
3.15.2 Operation.................................................................................................... 3-66
3.16 Cab door catch..................................................................................................... 3-70
3.17 Lockable Caps and Covers.................................................................................. 3-70
3.17.1 Lockable caps............................................................................................. 3-71
3.17.2 Lockable covers.......................................................................................... 3-72
3.18 Toolbox................................................................................................................. 3-72
4 Operation
4.1 Before Starting the Engine....................................................................................... 4-5
4.1.1 Walk-around inspection.................................................................................. 4-5
4.1.2 Inspection before starting............................................................................... 4-7
4.1.2.1 Water and sediment in fuel tank - drain................................................. 4-7
4.1.2.2 Water and sediment in water separator - check/drain........................... 4-8
4.1.2.3 Hydraulic oil level - check/refill ............................................................. 4-9
4.1.2.4 Coolant level - check/refill.................................................................... 4-10
4.1.2.5 Oil level in oil pan - check/add..............................................................4-11
4.1.2.6 Electric wires - check........................................................................... 4-12
4.1.2.7 Fuel level - Check and add.................................................................. 4-12
4.1.2.8 Work lamp switches - check................................................................ 4-14
4.1.2.9 Horn - check......................................................................................... 4-14
4.1.3 Adjustment before operation......................................................................... 4-15
4.1.3.1 Operator seat adjustment.................................................................... 4-15
4.1.3.2 Rear view mirrors................................................................................. 4-17
4.1.3.3 Seat belt............................................................................................... 4-19
4.1.4 Operation before engine startup................................................................... 4-20
4.2 Engine Starting....................................................................................................... 4-22
4.2.1 Engine Preheating ....................................................................................... 4-25
4.2.2 Warm-up operation....................................................................................... 4-26
4.3 Engine Shutdown................................................................................................... 4-27
5 Maintenance
5.1 Maintenance Information.......................................................................................... 5-3
5.2 Oil, fuel and coolant.................................................................................................. 5-8
5.2.1 Oil................................................................................................................... 5-8
5.2.2 Fuel................................................................................................................. 5-9
5.2.3 Coolant .........................................................................................................5-11
5.2.4 Grease.......................................................................................................... 5-12
5.2.5 Oil and fuel storage....................................................................................... 5-12
5.2.6 Filter element................................................................................................ 5-12
5.2.7 Electrical system .......................................................................................... 5-13
5.3 Wear Parts.............................................................................................................. 5-14
5.4 Recommended Fuel, Coolant and Lubricant.......................................................... 5-15
5.4.1 Table of recommended fuel, oil and coolant................................................. 5-16
5.4.2 Table of capacities ....................................................................................... 5-18
5.5 Tightening Torque Table.......................................................................................... 5-19
5.5.1 Table of bolt tightening torques..................................................................... 5-19
5.5.2 Table of hydraulic hose tightening torques.................................................... 5-20
5.6 Safety-Related Parts.............................................................................................. 5-21
5.7 Maintenance Schedule........................................................................................... 5-22
5.8 Maintenance Procedures........................................................................................ 5-24
5.8.1 Initial 50 hours of operation.......................................................................... 5-24
5.8.2 When Required............................................................................................. 5-25
5.8.2.1 Track shoe bolts - inspect/tighten........................................................ 5-25
5.8.2.2 Track tension - inspect/adjust.............................................................. 5-26
6 Troubleshooting
6.1 Troubleshooting Preparation.................................................................................... 6-3
6.1.1 Checks before troubleshooting....................................................................... 6-3
6.1.2 Troubleshooting precautions........................................................................... 6-4
6.1.3 Electrical circuits troubleshooting precautions................................................ 6-7
6.1.4 Hydraulic components handling precautions.................................................. 6-8
6.2 Measures Taken When Failure Occurs................................................................... 6-10
6.2.1 Failure-like phenomena................................................................................ 6-10
6.2.2 Towing the machine.......................................................................................6-11
6.3 Engine Failures....................................................................................................... 6-13
6.3.1 Engine troubleshooting table........................................................................ 6-13
6.3.2 Coolant temperature high............................................................................. 6-16
6.3.3 Engine oil pressure low................................................................................. 6-18
6.3.4 When fuel runs out........................................................................................ 6-19
6.3.5 When engine rotates reversely..................................................................... 6-23
6.4 Failures of the Electrical System............................................................................ 6-24
6.4.1 Electrical system troubleshooting table........................................................ 6-24
6.4.2 Failure codes................................................................................................ 6-27
6.5 Battery.................................................................................................................... 6-29
6.5.1 Battery removal and installation.................................................................... 6-29
6.5.2 Battery charging............................................................................................ 6-30
6.5.3 Starting engine with jumper cable................................................................. 6-31
6.5.3.1 Connecting jumper cables................................................................... 6-32
7 Specifications
7.1 Machine Dimensions................................................................................................ 7-3
7.2 Working Ranges....................................................................................................... 7-4
7.3 Technical Specifications............................................................................................ 7-5
8 Optional Equipment
8.1 Safety Information.................................................................................................... 8-3
8.1.1 Optional equipment selection......................................................................... 8-3
8.1.2 Read equipment instruction............................................................................ 8-3
8.1.3 Optional equipment removal and installation precautions ............................. 8-3
8.1.4 Optional equipment operation precautions..................................................... 8-4
8.2 Hydraulic Control Elements and Oil Circuit ............................................................. 8-6
8.2.1 Component locations...................................................................................... 8-6
8.2.1.2 Stop valve.............................................................................................. 8-7
8.2.1.3 Selector valve........................................................................................ 8-7
8.2.1.1 Attachment control pedal....................................................................... 8-7
8.2.2 Hydraulic circuit.............................................................................................. 8-8
8.2.2.1 Hydraulic circuit switching...................................................................... 8-8
8.2.2.2 Switching between breaker and general attachment............................. 8-8
8.2.2.3 Connecting hydraulic oil circuit ............................................................. 8-9
8.2.2.4 Hydraulic oil path................................................................................. 8-10
8.2.3 Attachment removal and installation..............................................................8-11
8.2.3.1 Removal................................................................................................8-11
8.2.3.2 Installation ........................................................................................... 8-13
8.2.4 Hydraulic oil and filter - change/replace........................................................ 8-15
8.2.5 Long-term storage........................................................................................ 8-16
8.3 Recommended Operations..................................................................................... 8-17
8.3.1 Hydraulic breaker.......................................................................................... 8-17
8.3.2 Hydraulic breaker operation.......................................................................... 8-18
8.3.3 Restricted operations.................................................................................... 8-20
8.3.4 Hydraulic breaker greasing........................................................................... 8-23
9 EC DECLARATION
9.1 DECLARATION OF CONFORMITY......................................................................... 9-2
Introduction
1 Introduction
1.1 Overview................................................................................................................... 1-3
1.2 Your Documentation Package.................................................................................. 1-4
1.2.1 CD system requirements................................................................................ 1-4
1.2.2 Recommendations on using the documentation............................................. 1-5
1.2.3 Documentation storage................................................................................... 1-5
1.2.4 Manual organization....................................................................................... 1-5
1.2.4.1 Introduction............................................................................................ 1-6
1.2.4.2 Safety..................................................................................................... 1-6
1.2.4.3 System functions.................................................................................... 1-6
1.2.4.4 Operation............................................................................................... 1-6
1.2.4.5 Maintenance.......................................................................................... 1-6
1.2.4.6 Troubleshooting..................................................................................... 1-7
1.2.4.7 Specifications......................................................................................... 1-7
1.2.4.8 Optional Equipment............................................................................... 1-7
1.3 Your Sany Machine................................................................................................... 1-8
1.3.1 Machine applications...................................................................................... 1-8
1.3.2 Machine directions.......................................................................................... 1-8
1.3.3 Breaking in a new machine............................................................................. 1-9
1.3.4 Machine information....................................................................................... 1-9
1.3.4.1 Product identification plate..................................................................... 1-9
1.3.4.2 Engine identification plates.................................................................. 1-10
1.3.4.3 Right and left drive motor identification plates......................................1-11
1.3.4.4 Swing motor identification plate............................................................1-11
1.3.4.5 Hydraulic pump identification plate.......................................................1-11
1.3.4.6 Chassis serial number......................................................................... 1-12
1.3.5 Table for serial number and distributor information....................................... 1-13
1 INTRODUCTION
1.1 Overview
●● Sany-built machines offer high-quality per-
formance and star-grade after-sales ser-
vice.
Hardware:
●● CD-ROM drive
Software:
1.2.4.1 Introduction
1.2.4.2 Safety
1.2.4.4 Operation
1.2.4.5 Maintenance
1.2.4.6 Troubleshooting
1.2.4.7 Specifications
3 4
2
CZ335-1101001
Fig. 1-2
(1) Front In this manual, the front, back, left or right di-
(2) Back rection indicates, when the cab faces the front
and the final drive is behind of the machine,
(3) Left
the moving direction that you could see from
(4) Right the cab.
(5) Operator’s seat
(6) Sprocket
Your machine has been thoroughly adjusted and tested before shipment. However, initial opera-
tion of the machine under severe conditions can adversely affect the performance of the machine
or shorten the machine life. Therefore, Sany recommends that you allow a break-in period of 100
operating hours for a new machine.
●● Always let the system cool down at the end of the working day.
The serial numbers and model numbers on the components are the only numbers that your Sany
distributor will need when ordering replacement parts or requiring assistance for your equipment.
It is a good idea to record this information in this manual for future use. Below are the locations of
the data plates
CB2016050301
Fig. 1-3
CB2016050302
Fig. 1-4
Model:_______________________________
ID No.: ______________________________
CZ235-3100801
Fig. 1-5
1.3.4.4 Swing motor identification plate
Model:_______________________________
ID No.: ______________________________
CZ235-3100802
Fig. 1-6
On bottom of pump.
Model:_______________________________
ID No.: _______________________________
CZ235-3100803
Fig. 1-7
SYJ263038018060480
CZ235-3100804
Fig. 1-8
This location is for you to record information relating to your machine. It is advised that you
keep this manual with your machine at all times for reference.
Machine Serial No.
Engine Serial No.
Distributor Name:
Address:
Phone Numbers:
Reference standards: ISO 6395, ISO/DIS 6396, EN ISO 3744. Noise value is measured
according to the method described in EN 474-1. The operator’s seat meets the requirements of
EN ISO 7096:2000
Tel: 0086-21-57008518
E-mail: crd@sany.com.cn
Safety
2 Safety
2.1 Safety Information.................................................................................................... 2-5
2.2 Safety Messages...................................................................................................... 2-7
2.2.1 Hazard alert message..................................................................................... 2-7
2.2.2 Safety decals.................................................................................................. 2-9
2.2.2.1 Textual safety decals.............................................................................. 2-9
2.2.2.2 Graphical safety decals.......................................................................... 2-9
2.2.2.3 Safety decal locations.......................................................................... 2-10
2.2.2.4 Safety decal explanation...................................................................... 2-12
2.3 General Precautions............................................................................................... 2-18
2.3.1 Safety rules................................................................................................... 2-18
2.3.2 Abnormalities................................................................................................ 2-18
2.3.3 Personal protective equipment..................................................................... 2-19
2.3.4 Fire extinguisher and first aid kit................................................................... 2-20
2.3.5 Safety equipment.......................................................................................... 2-21
2.3.6 Cleaning your machine ................................................................................ 2-22
2.3.7 Keeping the cab clean.................................................................................. 2-22
2.3.8 Engaging the hydraulic lockout control......................................................... 2-23
2.3.9 Handholds and steps ................................................................................... 2-24
2.3.10 Overhead work........................................................................................... 2-25
2.3.11 No sitting on attachment ............................................................................ 2-25
2.3.12 Articulated parts.......................................................................................... 2-25
2.3.13 Preventing burns ........................................................................................ 2-26
2.3.13.1 Hot coolant......................................................................................... 2-26
2.3.13.2 Hot oil................................................................................................. 2-27
2.3.14 Preventing fire and explosion..................................................................... 2-28
2 SAFETY
2.1 Safety Information
The Safety, Operation and Maintenance
Manual is a guide for proper use this machine.
The book mainly contains technical and safety
information necessary for machine operation.
Users are obligated to read and understand
each part of this Manual.
WARNING
CAUTION
NOTICE
For example,
WARNING
A820601990968
Fig. 2-1
A820601990973
Fig. 2-2
16 14
17
12
3 A
B 5
1 4
9
18 10
7 15
B
13
11
12
CZ425-1102001
Fig. 2-3
NOTE: The decals illustrated above will be explained in the following pages.
A820601990971
Fig. 2-4
A820699001019
Fig. 2-5
A820601990961
Fig. 2-6
A820601990974
Fig. 2-7
A820699001020
Fig. 2-8
6. Alternate exit
A820601990969
Fig. 2-9
A820699001016
Fig. 2-10
A820601990963
Fig. 2-11
9. Hot surface
危险DANGER
●● Hot parts can cause burns. Do not touch
hot parts.
10123433
Fig. 2-12
A820699000948
Fig. 2-13
危险 DANGER
●● Rotating components can cause injury. Do
not approach rotating components.
A820600000002
Fig. 2-14
A820601990968
Fig. 2-15
STOP
A820699001017
Fig. 2-16
14. Possible to fall
A820601990926
Fig. 2-17
15. No step
A820601990973
Fig. 2-18
16. No sitting
注意 CAUTION
A820699001023
Fig. 2-19
注意 CAUTION
为放水方向;
This is the direction to release the water.
为拧紧方向。
This is the direction to close the drain.
适当拧紧,不得用力过大,否则将引起油水分离器
损坏。
Tighten with proper force to prevent damage
to the water separator.
A820601990962
Fig. 2-20
更换系统部件时,必须补充冷冻油.
Refrigerant must be refilled when
replacing air-conditioning system
components.
A820699001284
2.3.2 Abnormalities
WARNING
●● Hard hat
●● Safety shoes
●● Protective gloves
Fig. 2-21
●● Reflective protective clothing
●● Dust mask
WARNING
●● Front guard
●● Lamps
●● Safety signs
●● Horn
●● Guards
●● Travel alarm
●● Mirrors
●● Fire extinguisher
●● Windshield wipers
NOTICE
Fig. 2-23
Fig. 2-24
CZ335-1102074
Fig. 2-25
WARNING
WARNING
Fig. 2-27
CZ335-1102012
Fig. 2-28
CZ335-1102013
Fig. 2-29
DANGER
WARNING
WARNING
WARNING
Fig. 2-36
●● Before operation in the vicinity of power
cables, inform local power company of the
coming operation and ask them to take Cable Voltage Safe Distance
necessary measures. 100V-200V Over 2 m ( 7 ft)
CZ335-1102026
Fig. 2-41
Fig. 2-42
WARNING
Fig. 2-44
●● Place all controls to the neutral/parking po-
sition.
2.4.2 Operation
NOTICE
WARNING
Fig. 2-47
Fig. 2-48
CZ335-1102034
Fig. 2-49
1
CZ335-1102035
Fig. 2-50
WARNING
Fig. 2-51
●● Understand all vocal, graphic and flag
signals used in work and decide who is to
give signals.
WARNING
CZ335-1102039
Fig. 2-55
CZ335-1102040
Fig. 2-56
CZ335-1102041
Fig. 2-57
CZ335-1102047
Fig. 2-60
CZ335-1102048
Fig. 2-61
CZ335-1102050
Fig. 2-62
CZ335-1102051
Fig. 2-63
Fig. 2-64
●● Lifting, moving or swinging the bucket shall
never pass over anybody or a truck's cab.
The falling of substances from the bucket
or collision of buckets could result in per-
sonal injury or machine damage.
Fig. 2-67
Fig. 2-68
5. Turn start switch to the OFF position to
stop the engine.
NOTE:
2.4.4 Transportation
2.4.5 Battery
WARNING
WARNING
A
●● When towing a damaged machine, im-
proper operation or use of unaccept-
B
able wire cable could lead to serious
accident:
C
WARNING
area. Fig. 2-76
To prevent accidents:
2.5.2 Self-preparation
Fig. 2-79
●● When compressed air is used for cleaning,
flying particles can cause injury. So wear
goggles, dust mask, gloves and other pro-
tective articles.
Fig. 2-81
6. Turn the start switch to the ON position.
Operate the control levers 2 or 3 times in
all directions to relieve internal pressure of
the hydraulic system.
CZ335-1102074
Fig. 2-82
Fig. 2-83
CZ335-1102068
Fig. 2-84
CZ335-1102072
Fig. 2-85
Fig. 2-87
WARNING
WARNING
WARNING
CZ335-1102080
Fig. 2-89
CZ335-1102081
Fig. 2-90
WARNING
CZ215L-1102001
Fig. 2-91
WARNING
WARNING
CZ335-1102084
Fig. 2-94
2.5.18 Accumulator
CZ335-1102087
Fig. 2-97
System Functions
3 System Functions
3.1 Machine general drawing......................................................................................... 3-5
3.2 Monitoring System.................................................................................................... 3-6
3.2.1 Monitor functions............................................................................................ 3-6
3.2.2 Monitor operation.......................................................................................... 3-10
3.2.2.1 Default page......................................................................................... 3-10
3.2.2.2 Main Menu........................................................................................... 3-12
3.2.2.3 Main Menu Password entry to system information.............................. 3-12
3.2.2.4 System Lockout................................................................................... 3-13
3.2.2.5 Engine & Throttle Signals.................................................................... 3-13
3.2.2.6 Pilot Pressure Signals.......................................................................... 3-14
3.2.2.7 Main & Cooling Pump Signals............................................................. 3-14
3.2.2.8 Input & Output Switch Signals............................................................. 3-15
3.2.2.9 Failure information............................................................................... 3-15
3.2.2.10 GPS Information................................................................................ 3-16
3.2.2.11 Language Selection........................................................................... 3-16
3.2.2.12 System Time Calibration ................................................................... 3-17
3.2.2.13 Maintenance Information................................................................... 3-17
3.2.2.14 Maintenance Confirmation................................................................. 3-18
3.2.2.15 System Setting................................................................................... 3-18
3.2.2.16 Machine Configuration Setting........................................................... 3-19
3.2.2.17 Operation Time Calibration................................................................ 3-19
3.2.2.18 Machine Configuration Setup............................................................. 3-20
3.2.2.19 Alarm Content Setting........................................................................ 3-21
3.2.2.20 Screen Backlight Adjust..................................................................... 3-21
3.2.2.21 Running Correct Setting..................................................................... 3-22
3.2.2.22 Engine Information............................................................................. 3-22
3.15 Radio.................................................................................................................... 3-63
3.15.1 Control panel.............................................................................................. 3-63
3.15.2 Operation.................................................................................................... 3-66
3.16 Cab door catch..................................................................................................... 3-70
3.17 Lockable Caps and Covers.................................................................................. 3-70
3.17.1 Lockable caps............................................................................................. 3-71
3.17.2 Lockable covers.......................................................................................... 3-72
3.18 Toolbox................................................................................................................. 3-72
3 SYSTEM FUNCTIONS
3.1 Machine general drawing
4 5 6
1
7
8
9
10
CZ425-1103001
Fig. 3-1
NOTICE
A
●● Stop operation when alert indicator is
on. Check and repair related compo-
nents.
●● Not all conditions of the machine are
displayed on the monitor.
●● Do not totally depend on monitor infor- B
mation when you perform maintenance
and inspection to the machine.
B: LCD screen
C: Operation keys
Screen display
3
C XP13031503
Fig. 3-5
Operation keys
Function keys
Common icons and corresponding keys are given in the following table:
F4 Enter an option/setup. ——
Table 3-1
Operation
n/min
idle.
4. Failure Information
Operation
●● F1 Selection function
●● F2 -
●● F3 Confirmation
●● F4 Access System Setting page
●● F5 Return to the default page
CB2016042501
Fig. 3-7
Operation
cursor.
●● F2 Move the cursor to the left or to the
right.
●● F3 Confirmation CB2016042502
Operation
right.
●● F3 Confirmation
●● F4 -
●● F5 Return to the default page
CB2016042503
Fig. 3-9
Operation
CB2016042504
Fig. 3-10
Operation
CB2016042505
Fig. 3-11
Operation
CB2016042506
Fig. 3-12
Operation
CB2016042507
Fig. 3-13
Operation
CB2016042508
Fig. 3-14
Operation
●● F1 -
●● F2 -
●● F3 -
●● F4 -
●● F5 Return to Main Menu page
CB2016042509
Fig. 3-15
Operation
●● F1 -
●● F2 Chinse
●● F3 English
●● F4 -
●● F5 Return to Main Menu page
CB2016042510
Fig. 3-16
Operation
Operation
●● F1 -
●● F2 -
●● F3 Enter maintenance code confirmation
CB2016042512
●● F4 Pause and open of maintenance items
cycle play
Fig. 3-18
●● F5 Return to Main Menu page
Operation
cursor
●● F2Move the cursor to the left or to the
right
●● F3 Confirme maintenance
●● F4 -
●● F5 Return to Main Menu page
CB2016042513
Fig. 3-20
Operation
●● F1 Selection
●● F2 -
●● F3 Confirme maintenance
●● F4 -
●● F5 Return to Main Menu page
CB2016042514
●● F1 -
●● F2 -
●● F3 -
●● F4 -
●● F5 Return to Main Menu page
CB2016042515
Fig. 3-21
Fig. 3-22
Operation
page
●● F4 Change model of the hydraulic system CB2016042603
Operation
CB2016042517
Fig. 3-24
3.2.2.20 Screen Backlight Adjust
Operation
CB2016042518
Fig. 3-25
Operation
CB2016042519
Fig. 3-26
Operation
page
●● F5 Return to System Setting page
CB2016042520
Fig. 3-27
Operation
CB2016042521
Fig. 3-28
Operation
CB2016042522
Fig. 3-29
Operation
●● F1 -
●● F2 -
●● F3 -
●● F4 -
●● F5 Return to Engine Information page
CB2016042523
Fig. 3-30
Operation
●● F1 -
●● F2 -
●● F3 -
●● F4 -
●● F5 Enter system unlock page
CB2016042524
Fig. 3-31
3.3 Switches
11
2
12
3
4
5
10 6
9
24V
CC13040207-3
Fig. 3-32
OFF position
START
turn the ignition key from ON position to OFF
position.
ON position
CC13031503
When the ignition key is turned to ON position,
the electrical system is energized. Fig. 3-33
START position
HEAT position
MIN
●● MIN position: Low idle speed
CC13031401
Fig. 3-34
CC13040203
Fig. 3-35
CZ335-1103040
Fig. 3-36
CZ335-1103041
Fig. 3-37
CC13040204
Fig. 3-38
CZ335-1103047
Fig. 3-39
NOTICE
CC13040205
Fig. 3-40
Operating range
CZ335-1103044
Fig. 3-41
NOTICE
Fig. 3-42
CC13040209
Fig. 3-43
3.3.8 Cab lamp switch
CC13041501-2
Fig. 3-44
2
4
CC13040210-2
Fig. 3-48
WARNING
regard. Fig. 3-50
WARNING
3.4.3 Joysticks
WARNING
2
Left Joystick Control 4
1 Forward Arm out
2 Backward Arm in
3 Left Swing to left
4 Right Swing to right
Table 3-2 CC13031505
Fig. 3-52
●● Moving a joystick diagonally can perform
two functions at the same time.
3 4
CZ335-1103056
Fig. 3-53
Fig. 3-54
NOTE:
WARNING
Open
CC13031403
Fig. 3-56
Close
Fig. 3-57
2. If the locks are not engaged properly, open
the ceiling window and try again.
WARNING
Fig. 3-58
CZ335-1103062
Fig. 3-59
1 1
CZ335-1103063
Fig. 3-60
2
1
CZ335-1103064
Fig. 3-61
CZ335-1103065
Fig. 3-62
CZ335-1103067
Fig. 3-63
CZ335-1103066
Fig. 3-64
Fig. 3-65
CAUTION
CC13031403
Fig. 3-66
CZ335-1103069
Fig. 3-67
CZ335-1103070
Fig. 3-68
CZ135B-1103009
Fig. 3-69
CZ335-1103072
Fig. 3-70
Fig. 3-71
CZ335-1103077
Fig. 3-72
CZ335-1103078
Fig. 3-73
Opening
CZ335-1103079
Fig. 3-74
Closing
0-13004
Fig. 3-75
3.7 Ash Tray
●● This tray is located above the cigarette
lighter.
0-13007
Fig. 3-76
3.8 Manual Pocket
●● The pocket is on the back of the operator
seat.
CZ335-1103090
Fig. 3-77
0-13005
Fig. 3-78
3.10 Alternate exit
CZ215-1103029
Fig. 3-79
CC13050801
NOTICE
3.12 Controller
Be careful not to get the controller contami-
nated by water, mud or juice, which can cause
controller failure.
CB13041001-1
Fig. 3-80
NOTE:
wires. Fig. 3-82
1 2 3 4 5
6 7 8
CZ205-1203020G
Fig. 3-83
1. OFF switch
CZ335-1103094
Fig. 3-84
3. TEMP switch
4. MODE switch
Fig. 3-87
Air outlet mode
Air Outlet
LCD Display 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
Table 3-6
0-13010-1
Fig. 3-88
24V
3 2
0-13011-1
Fig. 3-89
Bottom air outlet (4)
NOTE:
4
●● The grill of the front, rear and defrosting
outlet is adjustable; whereas, the bottom
air outlet is not adjustable.
CZ335-1103100
Fig. 3-90
5. AUTO switch
cally. Fig. 3-91
Table 3-7
7. LCD display
CZ335-1103103
Fig. 3-93
8. A/C switch
Automatic control
Fig. 3-96
Manual control
1
3. Press the switch to set the internal
TEMP
Bi-level mode
Defrosting operation
CZ335-1103103
Fig. 3-99
CZ335-1103109
Fig. 3-100
●● When you operate the machine in rainy
season or need to eliminate mist or mois-
ture from the windows, just press the
switch A/C to turn on the air conditioner.
Ventilation
Temperature control
3.15 Radio
3.15.1 Control panel
6 5 4 3 2 1
FM
H M ADJ - +
7 8 9 10
CZ335-1103111
Fig. 3-101
●● Press to turn on the radio. The frequency is shown on the LCD display (7). Press this
switch again to turn off the radio.
●● Press the button to select a sound effect from VOL (volume), BAS (bass), TRE (treble)
SEL
●● The LCD returns to frequency display when no operation is done within 5 seconds.
●● When the radio is on, the LCD displays system time once the TIME
button is pressed. The LCD
returns to frequency display after 5 seconds.
●● Automatic scanning:
3.15.2 Operation
FM
H M ADJ - +
3. When desired frequency is shown on the
display (7), depress one of the preset 7 8
buttons for at least 1.5 seconds. The voice
will disappear. But the voice will come CZ335-1103112
Manual tuning
Automatic tuning
2. When radio time is displayed on the LCD, 1 2 3 4 5 6 AS/PS AM/FM TIME SEL
FM
H M ADJ - +
H : Hour adjustment
9
(Hour goes up by 1 with each press)
M : Minute adjustment CZ335-1103113
Example:
10:05→10:00
10:59→11:00
10:26→10:26
Antenna
CZ335-1103114
Radio operation precautions
Fig. 3-104
●● Keep radio volume at a proper level so that
you can hear the outside sound during op-
eration.
CAUTION
CZ335-1103082
Fig. 3-105
3.17 Lockable Caps and Covers
CZ335-1103083
Fig. 3-106
NOTICE
Unlocking
Fig. 3-107
Locking
CZ215-1103002
Fig. 3-108
Unlocking
3.18 Toolbox
Store tools in this box.
CZ205-1203022G
Fig. 3-110
Operation
4 Operation
4.1 Before Starting the Engine....................................................................................... 4-5
4.1.1 Walk-around inspection.................................................................................. 4-5
4.1.2 Inspection before starting............................................................................... 4-7
4.1.2.1 Water and sediment in fuel tank - drain................................................. 4-7
4.1.2.2 Water and sediment in water separator - check/drain........................... 4-8
4.1.2.3 Hydraulic oil level - check/refill ............................................................. 4-9
4.1.2.4 Coolant level - check/refill.................................................................... 4-10
4.1.2.5 Oil level in oil pan - check/add..............................................................4-11
4.1.2.6 Electric wires - check........................................................................... 4-12
4.1.2.7 Fuel level - Check and add.................................................................. 4-12
4.1.2.8 Work lamp switches - check................................................................ 4-14
4.1.2.9 Horn - check......................................................................................... 4-14
4.1.3 Adjustment before operation......................................................................... 4-15
4.1.3.1 Operator seat adjustment.................................................................... 4-15
4.1.3.2 Rear view mirrors................................................................................. 4-17
4.1.3.3 Seat belt............................................................................................... 4-19
4.1.4 Operation before engine startup................................................................... 4-20
4.2 Engine Starting....................................................................................................... 4-22
4.2.1 Engine Preheating ....................................................................................... 4-25
4.2.2 Warm-up operation....................................................................................... 4-26
4.3 Engine Shutdown................................................................................................... 4-27
4.4 Machine Operation................................................................................................. 4-28
4.4.1 Before moving the machine.......................................................................... 4-29
4.4.2 Move the machine........................................................................................ 4-30
4.4.3 Stopping the machine................................................................................... 4-31
4.5 Machine Turning..................................................................................................... 4-32
4 OPERATION
4.1 Before Starting the Engine
4.1.1 Walk-around inspection
WARNING
3. O p e n t h e d r a i n v a l v e t o d i s c h a r g e
sediment, water and fuel from tank.
CB20160512002
NOTE:
CC13040702
Fig. 4-3
CAUTION
Fig. 4-5
4. If oil level is below the L mark, add oil
through the filler opening (1) on top of the
hydraulic tank.
CZ335-1103127
Fig. 4-6
CAUTION
0-13013
1. The coolant level must remain between
Fig. 4-7
the upper and lower limits marked on
the reserve tank (2) when the engine is
running. If coolant level is below the lower
limit, add coolant to the radiator as well as
to the reserve tank.
2
2. Open the rear door on the left side of
FULL
machine and check the level of coolant in LOW
the reserve tank (2). If coolant level is low,
add coolant to FULL position through the
filler opening of the reserve tank (2).
WARNING
2
●● Engine oil and components are still hot
and may cause burns after the engine
has been just shut down. Wait for them
to cool down before working on them.
2. Take out oil dipstick (2) and wipe the oil off
the dipstick with cloth.
0-13015
3. Insert the dipstick (2) to bottom and then
pull it out. Fig. 4-9
NOTE:
CZ335S-1103057
Fig. 4-11
NOTICE
WARNING
CZ335-1103134
Fig. 4-13
NOTE:
CC13040209
Fig. 4-16
CZ335-1103140
Fig. 4-18
6
Turning the plate (7) beneath armrest (6)
can adjust the angle of armrest to desired
position.
CC13031516
Fig. 4-19
CAUTION
B A
Fig. 4-20
●● Install rear mirror (A) to the position as
shown in the right illustration.
Fig. 4-21
4.0~5.4 N·m (0.41~0.55 kgf·m)
CZ335-1103144
Fig. 4-22
Fig. 4-23
M: 120 mm
(0.41~0.55 kgf·m)
WARNING
Fig. 4-25
2. Release
WARNING
CC13031403
Fig. 4-26
ON
OFF
STA
T
HEA
RT
CC13031804
Fig. 4-27
WARNING
Fig. 4-28
●● After starting he engine, you shall wait for
the hydraulic oil pressure to be in the op-
erational range before operation. Do not
operate the machine if the hydraulic oil
pressure is abnormal. Stop the machine
and check it immediately.
CC13031403
Fig. 4-29
MIN
CC13031401
Fig. 4-30
NOTE:
ON
OFF
When ambient temperature is below 10°C,
STA
T
HEA
CC13031804
Fig. 4-31
ON
OFF
STA
T
HEA
RT
CC13031801
Fig. 4-32
STA
T
HEA
RT
kept at START position for more than 10 sec-
onds. In this case, wait at least for 1 minute
before restarting the engine.
CC13031802
Fig. 4-33
X
MA
up, engine preheating begins.
N
T OFF O
HEA
MIN
WARNING
●● In case of emergency, abnormal running of engine, or other faults, turn the start switch
key to OFF position and shut off the engine.
●● Do not operate any control lever or pedal suddenly when hydraulic oil remains at low
temperature. Make sure to warm up the machine till temperature of hydraulic oil rises
to a suitable point.
●● Insufficient warm-up of the machine may cause slow response or abrupt movement
during operation, resulting in serious accidents. Warm-up is especially necessary in
cold areas.
●● Do not accelerate the machine suddenly before warm-up process is finished. Do not
continuously run the engine at low or high speed for more than 20 minutes, which may
cause leaks in the oil supply pipe of the turbocharger. If the engine has to be run at idle
speed, add load to it or run it at a moderate speed.
Do not start machine operation immediately after engine start. Check the following items:
1. Adjust the fuel control dial to run the engine at a low speed (about 1,100 rpm) for about five
minutes.
2. Adjust the fuel control dial to run the engine at a moderate speed (about 1,400 rpm), and then
slowly operate the bucket for five minutes.
3. Adjust the fuel control dial to run the engine at a high speed, and operate the boom, arm and
bucket for 5-10 minutes.
4. Cycle each action of excavator for several times before ending the preheat operation.
5. Check all gauges for normal display after preheating the machine.
Continue to warm up the machine if coolant temperature (see monitor display) and hydraulic
oil temperature (50~80°C) fail to reach normal values.
CAUTION
ON
2. Turn the start switch to the OFF position OFF
to shut off the engine. Remove the ignition
STA
T
HEA
key.
RT
NOTE: If the engine is overheated, do not
stop it. Run it at low idling speed so that it can
be cooled down gradually. Do not turn off the
engine until it is cool enough. CC13031803
Fig. 4-35
WARNING
CC13031518
Fig. 4-36
MIN
CC13031507
Fig. 4-37
CC13031404
Fig. 4-38
40~50cm
CC13050601
Fig. 4-39
Forward moving
CC13031508
Fig. 4-40
Backward moving
NOTE:
Fig. 4-41
●● To ensure straight travel, operate the travel
control levers or pedals at the same with
equal force.
CAUTION
CZ335-1103169
Fig. 4-42
Left turn
CC13031510
Fig. 4-43
or,
CC13031511
Fig. 4-44
Right turn
CC13031512
Fig. 4-45
or,
CC13031513
Fig. 4-46
Left turn
CC13031514
Fig. 4-47
Right turn
CC13031515
Fig. 4-48
CAUTION
●● Arm control
CZ335-1103175
Fig. 4-49
●● Swing control
CZ335-1103176
Fig. 4-50
●● Boom control
CZ335-1103177
Fig. 4-51
●● Bucket control
CAUTION
CZ335-1103181
Fig. 4-53
4.8.2 Operation with traveling force
CZ335-1103182
Fig. 4-54
CZ335-1103183
Fig. 4-55
CZ335-1103184
Fig. 4-56
4.8.5 Hard rocky ground
CZ335-1103185
Fig. 4-57
CZ335-1103189
Fig. 4-59
WARNING
Fig. 4-63
CZ335-1102040
Fig. 4-64
CZ335-1103196
Fig. 4-66
CZ335-1103197
Fig. 4-67
CZ335-1103198
Fig. 4-68
CZ335-1102049
Fig. 4-70
4.12.3 Loading operation
CZ335-1103200
Fig. 4-71
4.13 Parking
WARNING
sures.
CZ335-1102055
Fig. 4-72
CZ335-1103169
Fig. 4-73
MIN
CC13031401
Fig. 4-74
CZ335-1103207
Fig. 4-75
CC13031403
Fig. 4-76
Fig. 4-77
4.15 Locking
Make sure the following parts are locked prop-
erly when the machine is not used. The igni-
tion key is used to lock and unlock all the lock-
able components on the machine. 3
(1) Cab door
(2) Filler cap of fuel tank 4
6
CZ335-1103209
Fig. 4-79
4.16.2 Coolant
WARNING
4.16.3 Battery
CAUTION
WARNING
CZ335-1103228
Fig. 4-83
4.18.2.1 Loading
WARNING
CC13031401
Fig. 4-85
Fig. 4-86
WARNING
Fig. 4-87
6. Align your machine with the ramps before
driving up the ramp. The centerline of ma-
chine shall match the centerline of trailer.
CZ335-1102060
Fig. 4-89
Fig. 4-90
CC13031403
Fig. 4-91
CZ335-1103237
Fig. 4-92
Rear view mirror
Removal
2. Loosen bolt (4) and remove the bar (3) and Fig. 4-93
the clamp (5).
Installation
1
1. Install the bar (3) and the clamp (5) to the 2
handhold, and tighten bolt (4).
Fig. 4-94
4.18.2.3 Unloading
CC13031404
WARNING
Fig. 4-96
NOTE:
CZ335-1103242
●● Keep an angle of 90 - 110° between the
Fig. 4-98
arm and the boom when unloading the ma-
chine.
CZ335-1103243
Fig. 4-99
CZ335-1103244
Fig. 4-100
WARNING
●● Only eligible, experienced operator with official license (as per local laws) is allowed to
operate a crane.
●● Do not lift the machine when someone is riding on it.
●● Nobody shall be allowed to enter the area below or around the lifted machine.
●● Make sure that the wire ropes used for lifting are strong enough to bear the weight of
machine. Never use damaged or aged wire cable or sling.
●● Do not lift the machine when its upper structure is sideways. Swing the work equip-
ment to the side of sprocket before lifting. The longitudinal centerline of undercarriage
must be parallel to that of upper structure.
●● Before lifting, place the hydraulic lockout control in the locked position to prevent un-
expected movement of the machine.
●● Keep the machine horizontal during lifting.
●● Do not lift the machine at a fast speed, which may otherwise overload the wire cables
or slings and result in rupture.
●● Besides the attitude described below, no other attitudes shall be employed to lift the
machine or no hoisting equipment other than those specified below is used. Otherwise
the machine is possible to loose balance.
Lifting instructions
Refer to the following table to choose and use proper wire ropes.
Wire ropes
Wire Ropes
(Z or S laid wire cable, ungalvanized)
Diameter Allowable Load
mm kN t
10 9.8 1.0
11.5 13.7 1.4
12.5 15.7 1.6
14 21.6 2.2
16 27.5 2.8
18 35.5 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
Table 4-1
Allowable load is 1/6 or 1/7 of the breaking strength of the wire rope.
Standard machine
WARNING
CZ335-1103245
Fig. 4-101
CC13031403
Fig. 4-102
Maintenance
5 Maintenance
5.1 Maintenance Information.......................................................................................... 5-3
5.2 Oil, fuel and coolant.................................................................................................. 5-8
5.2.1 Oil................................................................................................................... 5-8
5.2.2 Fuel................................................................................................................. 5-9
5.2.3 Coolant .........................................................................................................5-11
5.2.4 Grease.......................................................................................................... 5-12
5.2.5 Oil and fuel storage....................................................................................... 5-12
5.2.6 Filter element................................................................................................ 5-12
5.2.7 Electrical system .......................................................................................... 5-13
5.3 Wear Parts.............................................................................................................. 5-14
5.4 Recommended Fuel, Coolant and Lubricant.......................................................... 5-15
5.4.1 Table of recommended fuel, oil and coolant................................................. 5-16
5.4.2 Table of capacities ....................................................................................... 5-18
5.5 Tightening Torque Table.......................................................................................... 5-19
5.5.1 Table of bolt tightening torques..................................................................... 5-19
5.5.2 Table of hydraulic hose tightening torques.................................................... 5-20
5.6 Safety-Related Parts.............................................................................................. 5-21
5.7 Maintenance Schedule........................................................................................... 5-22
5.8 Maintenance Procedures........................................................................................ 5-24
5 MAINTENANCE
Fuel strainer
Welding instruction
5.2.2 Fuel
●● Pay special attention to prevention of impurities when storing or refilling the fuel.
NOTE:
●● To ensure favorable consumption and exhaust of the fuel, the engine installed to your ma-
chine uses high-pressure oil injection unit with mechanical control. The unit contains high-
precision components that require high-quality lubrication. Therefore, the use of low-viscosity
fuel with low lubricating capability will considerably reduce the service life of the unit.
●● Sulfur content in fuel generates sulfur oxide in combustion, which reacts with water and pro-
duces dilute sulphuric acid that will impair the engine. To prevent such fault, always use a fuel
whose sulfur content is lower than 0.2%.
5.2.3 Coolant
●● Sany recommends TEEC-L35 antifreeze. This antifreeze has a concentration of 50% and
needs no dilution. TEEC-L35 antifreeze has excellent performance in anticorrosion, anti-
freezing and cooling, and can last for one year or 2000 hours.
Sany does not recommend you using coolants other than TEEC-L35 antifreeze. The use of
other coolants is possible to cause serious problems, such as corrosion of the light metal
parts of the engine and cooling system.
●● If you buy antifreeze from the market, make sure that the antifreeze's concentration is within
the range 30-68% in order to ensure its performance against corrosion.
●● The ratio of mixing antifreeze with water is determined by the minimum ambient temperature,
as shown in the following table.
NOTE:
●● Use distilled water or tap water (softened water) to dilute anti-freezing coolant.
●● Natural water, such as river water and well water (hard water), contains large amount of min-
erals (calcium, magnesium, etc.), which can easily scale in the engine and radiator. The scale
is hardly removed once formed in the engine and radiator. Overheat can occur due to unfa-
vorable heat exchange.
5.2.4 Grease
●● It is necessary to add grease to any component that appears inflexible or noisy after operation
for a long period.
●● Always use the recommended greases. Select the grease according to change interval and
ambient temperature recommended in this manual.
●● Wipe off the used grease that has been squeezed out when greasing. Make sure to wipe off
the used grease that has been contaminated by sand or debris, which can otherwise lead to
wear of rotating components.
●● Store the oils and fuel indoors in order to keep them free from water, dust and other foreign
substances.
●● To store the barrel of oil or fuel for a long period, it is necessary to place the barrel with its
opening facing the side in order to prevent intake of moisture. If you have to place the barrels
outdoors, cover them properly with waterproof canvas or take other protective measures.
●● To prevent deterioration of oil or fuel during long-term storage, use the oil or fuel that has
been stored earlier than others.
●● Filter element is extremely important for safety. It can prevent failures by keeping important
devices free from impurities coming from oil path or air path.
When operating in severe conditions, the filter elements shall be replaced more frequently
according to the sulfur content in lubricant and fuel.
●● In replacement of filter element, check the element for attached metal particles. Contact your
Sany distributor if metal particles are found.
●● Humid electrical devices or damaged wire can cause short circuit and machine failure. Do not
flush the interior of your cab with water. When flushing your machine, be careful with water,
which shall not penetrate into the electrical components.
●● Electrical system maintenance correlates to checking the tension, damage or wear of fan belt.
●● Do not install any other electrical components except those specified by Sany.
●● External electromagnetic interference can cause failure of system controller. Contact your
Sany distributor before installing radio receiver or other wireless devices.
●● Operating on beach requires cleaning the electrical system thoroughly in order to prevent cor-
rosion.
●● When installing an electrical device, connect it to dedicated power source. Do not connect
other power sources to the fuse, start switch or battery relay.
Table 5-2
●● Unless specified otherwise, your machine contains the following oils and coolants when deliv-
ered from the factory.
Item Type
Engine Oil Pan Caltex CI-4 15W-30
Swing Drive
Gear oil 85W/140
Final Drive
Hydraulic System Caltex HDZ46/HDZ46- Ⅱ
Radiator TEEC-L35 antifreeze
Table 5-3
●● To keep your machine at the maximum state for a long period of time, it is necessary follow
the oil instructions described in this manual. Failure to do so can cause overwear and service
life reduction of the engine, power train, cooling system and other components.
●● The additives available in market could benefit your machine, but they could impair your ma-
chine as well. We do not recommend any lubricant additives.
●● The specific capacity refers to the overall oil volume in tanks and lines. Supplementary vol-
ume refers to the amount of oil used to make up the system in inspection and maintenance.
●● The use of multigrade oils is strongly recommended when starting the engine at temperatures
below 0°C (32°F), even if the daytime temperatures rises above 0°C (32°F).
●● Use the recommended oils according the ambient temperatures given in the following table.
Ambient temperature
Oil type
System
Recom-
-22 -4 14 32 50 68 86 104 122°F mended oil
-30 -20 -10 0 10 20 30 40 50°C
5W-30
5W-40
Engine oil pan
Engine oil
10W-30
15W-40NOTE
40
HDZ32
HYD SYS
(ISO VG32)
HYD oil
HDZ46/
HDZ46- Ⅱ
(ISO VG46)
-30
Fuel tank
Diesel oil
-10
0
Radiator
Coolant
TEEC-L35
antifreeze
Table 5-4
NOTE: The HTHS (high-temperature high-shear viscosity at 150°C) required by ASTM D4741
must be equal to or more than 3.5 mPa-S. Sany recommends use of Caltex15W-40 engine oil.
Recommended oils:
1. Engine oil
Select the oil of proper viscosity according to the temperature range given in the oil change
schedule.
Machine oil grade: Above API CI-4
Recommended engine oil brand and type: Caltex CI-4 15W-40
2. Engine fuel
Light diesel oil (GB252.81)
NOTICE
●● When low sulfur content fuel is used, its cloud point shall at least be lower than the
expected fuel temperature by 10°C. Cloud point is the temperature under which waxy
crystal begins to form in diesel fuel.
●● Commercially universal diesel fuel brand contains sulfur less than 0.2%.
●● Keep the fuel clean during refilling. The fuel shall be free from water and impurities.
3. Hydraulic oil
The hydraulic system uses Caltex HDZ46 hydraulic oil (code B420106000036) or HDZ46-
Ⅱ (code 60272633) .
NOTICE
When ambient temperature is lower than 0°C, temperature of hydraulic oil must be in-
creased to ensure safety of the hydraulic system.
●● Start the engine. Increase engine speed to 1000-1200 rpm after seven to ten minutes.
Do not perform any operation. Run the engine unloaded for 30 to 40 minutes, or more
so as to heat up the hydraulic oil. The temperature of hydraulic oil should be more than
20°C.
●● Normal operation can be performed after the above heat-up operation. The heat-up
time depends on ambient temperature. In normal construction operation the joysticks
and pedal valves shall be operated slowly. Pay close attention to the system's operat-
ing condition. Hydraulic components could be damaged when temperature of hydraulic
oil is lower than 20°C during operation.
●● Choose suitable hydraulic oil according to working condition of the machine. We have
pre-filled the machine with suitable brand of hydraulic oil before delivery. It is user's re-
sponsibility to change the oil after delivery of the machine. You may consult our after-
sale service persons to obtain the correct specifications and brands.
Table 5-5
NOTICE
●● Nuts, bolts or other parts not tightened to specific torque values may lead to loose or
damaged parts, resulting in machine failure and operating troubles.
●● Special attention shall be paid when tightening parts.
Unless specified otherwise, the metric nuts and bolts shall be tightened to the values given in the
following table.
In replacement of the bolts or nuts, use Sany genuine parts of equivalent size.
Torque (N·m)
No. Bolt Size
Grade 10.9 Grade 12.9
1 M6 13.2±1.4 16.2±1.6
2 M8 31±3 38.7±4
3 M10 66±7 78±7
4 M12 113±10 137±10
5 M14 177±19 210±20
6 M16 279±30 339±30
7 M18 382±39 450±40
8 M20 549±59 664±59
9 M22 697±70 864±85
10 M24 927±103 1100±100
11 M27 1320±140 1683±150
12 M30 1785±170 2200±200
13 M33 2295±200 2900±280
14 M42 4700±450 5985±590
15 M48 7140±650 9100±900
Table 5-6
Hoses
Nut Torque(N·m) Connectors Torque(N·m)
M14 24.5±5 M14 34.3±5
M18 51±8 M16 54±5
M22 74±14 M18 70±10
M26 105±20 M20 93±10
M30 135±20 M22 125±10
M36 166±26 M24 142±20
M42 240±30 M26 180±20
(Tube) Connectors
Metric Torque(N·m) British Torque(N·m)
M14 24.5±5 G1/8″ 16.7±2
M16 45±7 G1/4″ 36.7±2.5
M18 51±8 G3/8″ 73.5±5
M20 58±8 G1/2″ 107.8±7.8
M22 74±14 G3/4″ 161.7±14.7
M24 74±14 G1″ 220±25
M26 105±20
Plug
Metric Torque(N·m) British Torque(N·m)
M20 49±5 G3/8 68.6±20
M24 68.6±10
Fitting
British Torque(N·m)
G3/4(A) 161.7±14.7
Table 5-7
●● Safety-related parts may easily wear or deteriorate due to material change as time passes
and it is hard to judge their conditions through regular maintenance. These parts shall be re-
placed as scheduled regardless of their conditions, which can effectively guarantee the func-
tions of these parts.
●● If these parts show signs of abnormality before its scheduled replacement, they must be re-
paired or replaced immediately.
●● If the hose clamps show any deterioration, such as deforming or cracking, replace the clamps
at the same time as the hoses.
●● O-rings, gaskets and other such parts shall also be replaced when replacing hoses.
If your machine is equipped with hydraulic breaker, the maintenance schedule for some parts
may vary. For more information and proper maintenance see "Hydraulic oil and filter - change/
replace" on page 8-15.
Tightening
Tightening sequence
4 2
CZ335-1104015
Fig. 5-2
Inspection
Adjustment
WARNING
Fig. 5-4
3. Check the track tension again. Readjust
the tension if it is still beyond the standard
range.
CZ335-1104019
Fig. 5-5
WARNING
1
CZ335-1104020
CZ335-1104022
Fig. 5-8
WARNING
Fig. 5-9
respectively.
WARNING
Fig. 5-11
Fig. 5-12
●● Inject sufficient amount of grease till the
grease is squeezed out of the end face.
WARNING
CZ335-1104023
Fig. 5-13
CC13031403
Fig. 5-14
Fig. 5-16
WARNING
Operating
Mixture Ratio Temperature
Regions
Cold regions
1:1 - 20°C (- 4°F)
in winter
WARNING
CZ215-1104007
Fig. 5-21
When the air conditioner will not be used for a long period of time, the air conditioner shall be op-
erated for 3-4 minutes each month in order to lubricate the compressor components.
Twice a year
Refilling
(spring and autumn)
Refrigerant (gas)
Tube connections and internal leakage of
Daily
parts and components
Fan motor and fan Function (check for abnormal noise) When necessary
Air conditioner air flow switch Air flow control switch and switching function Daily
Control unit Function (make sure the function is normal) When necessary
WARNING
CZ335-1104036
Fig. 5-22
WARNING
CZ335-1103207
Fig. 5-23
Fig. 5-24
For more information about the following items, see "Inspection before starting" on page 4-7.
●● Check the water separator for water and sediment. Drain the water.
●● Check the oil level in the engine oil pan. Add oil.
●● Air vent pipe under the engine. (This item shall be checked all the time when the machine is
operating in muddy places)
5.8.4.1 Lubrication
NOTICE
1. Adjust the machine to a to-be-greased position, lower the work equipment to the ground and
shutdown the engine. Lock out and tag out the machine as required before proceeding. See
“Lock out and tag out” on page 2-68.
2. Use a grease gun to inject grease at the greasing points shown in the following illustration.
3. Finally, 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. 5-25
CZ425-1104015
Fig. 5-26
CZ425-1104016
Fig. 5-27
CZ425-1104017
Fig. 5-28
CZ425-1104018
Fig. 5-29
CZ425-1104019
Fig. 5-30
CZ425-1104020
Fig. 5-31
CAUTION
●● Dust may enter the engine when the filter element is checked or replaced with the
engine running. To protect the engine, shut it down before conducting this job.
●● The sealing rubber of the end cap must be held tightly against the filter.
●● Never take out the inner filter element to clean it. Dust may enter the engine and cause
engine failure.
●● Inner filter element must be replaced together with outer filter element.
●● When compressed air is used for such cleaning, wear goggles, dust mask or other
protective articles.
●● Never pull out the outer filter element with great force. When you stand on some place
high or unstable, take care not to fall due to reaction of pulling force.
●● Clean: Every 250 service hours or when the air cleaner clogging alarm appears.
●● Replace
Every 12 months or when it has been cleaned for six times, whichever occurs first.
Always prepare your machine as required and lock out/tag out your machine before proceeding.
See “Engine shutdown procedure prior to maintenance” on page 2-67 and “Lock out and
tag out” on page 2-68.
CB20160512004
Fig. 5-32
Fig. 5-33
inside (5).
NOTE:
Fig. 5-35
Fig. 5-36
5. Install the outer filter element (3).
1
NOTE:
CZ215-1304006
●● Never use the inner filter element after
cleaning it. Replace the inner filter element Fig. 5-37
when the outer one is replaced.
Inspection
Adjustment
Fig. 5-39
NOTE:
●● Check for damaged pulleys and worn V-
groove and V-belt. In addition, make sure
that the V-belt must not rub against the
bottom of the V-groove.
●● Consult your Sany distributor to replace
the belt timely in case of the following con-
ditions.
●● The fan belt has been stretched and
little margin is left for adjustment.
●● Cuts or cracks are found in the belt.
●● The belt skids or squeaks.
●● A newly installed V-belt shall be readjusted
after one hour of operation.
WARNING
NOTE:
●● Check the hydraulic system for missing, deformed pipe clamps and loose bolts. Replace
missing or deformed pipe clamps if any. Tighten loosened bolts to specified torques.
●● Check if the hoops of the return oil hose and the T-clamp of the main pump suction hose are
loose. Replace these hoops and clamps or tighten them to specified torques if necessary.
●● Prepare a dipstick.
CZ335-1104068
Fig. 5-41
Fig. 5-42
CZ335-1104070
Fig. 5-43
CAUTION
CZ335S-1103057
1. Remove the bottom cover plate of the
Fig. 5-44
machine. Place a container under the drain
valve (1). Let the oil pass through a piece
of clean cloth.
Container
CZ335-1104057
Fig. 5-45
NOTICE
WARNING
●● Do not replace the filter immediately after the engine is shut off, as all parts are still
hot. Wait for the parts to cool down before you proceed.
●● High pressure is generated in the fuel system when the engine is running.
●● Wait at least 30 seconds after engine shutdown and replace the filter when internal
pressure drops to a safe level.
●● Be away from fire sources.
NOTE:
●● Sany genuine fuel filter element is a special filter of effective filtration. The filter element must
be replaced with a genuine one.
●● The use of other parts may allow dirt or debris to pass through and cause the spray system
failure. Therefore, avoid using any substitutes.
●● Prevent dirt from entering the fuel system during inspection and service. In case of any parts
contaminated by dust, flush them clean with machine oil.
Always prepare your machine as required and lock out/tag out your machine before proceeding.
See “Engine shutdown procedure” on page 2-67 and “Lock out and tag out” on page 2-68.
8. Check the drain valve (1) to see if it has been tightened enough.
For air-bleeding method see "Secondary fuel filter element - replace" on next page.
10. After replacing the filter element, start the engine and run it at low idle for 10 minutes.
Check the filter-sealing surfaces and the bowl for fuel leakage. Check the tightening degree of
the filter element when fuel leaks.
If the fuel still leaks, repeat the steps 1-7. Remove the filter element and replace it with a new
filter element if any damage or foreign object is found on the sealing surface. Repeat the
steps 8-15 in order to install a new filter cartridge.
WARNING
●● Do not replace the filter immediately after the engine is shut off, as all parts are still
hot. Wait for the parts to cool down before you proceed.
●● High pressure is generated in the fuel system when the engine is running.
●● Wait at least 30 seconds after engine shutdown and replace the filter when internal
pressure drops to a safe level.
●● Be away from fire sources.
NOTE:
●● Sany genuine fuel filter element is a special filter of effective filtration. The filter element must
be replaced with a genuine one.
●● The use of other parts may allow dirt or debris to pass through and cause the spray system
failure. Therefore, avoid using any substitutes.
●● Prevent dirt from entering the fuel system during inspection and service. In case of any parts
contaminated by dust, flush them clean with machine oil.
Always prepare your machine as required and lock out/tag out your machine before proceeding.
See “Engine shutdown procedure” on page 2-67 and “Lock out and tag out” on page 2-68.
NOTE:
WARNING
●● Do not replace the filter immediately after the engine is shut off, as all parts are still
hot. Wait for the parts to cool down before you proceed.
●● High pressure is generated in the fuel system when the engine is running.
●● Wait at least 30 seconds after engine shutdown and replace the filter when internal
pressure drops to a safe level.
●● Be away from fire sources.
NOTE:
●● Sany genuine fuel filter element is a special filter of effective filtration. The filter element must
be replaced with a genuine one.
●● The use of other parts may allow dirt or debris to pass through and cause the spray system
failure. Therefore, avoid using any substitutes.
●● Prevent dirt from entering the fuel system during inspection and service. In case of any parts
contaminated by dust, flush them clean with machine oil.
Always prepare your machine as required and lock out/tag out your machine before proceeding.
See “Engine shutdown procedure” on page 2-67 and “Lock out and tag out” on page 2-68.
NOTE:
CZ335-1104191
Fig. 5-52
WARNING
CAUTION
CZ425-1104026
Fig. 5-54
Fig. 5-55
Note: However, a safe distance to the ma-
chine shall be kept when cleaning the heat
exchangers (of radiator, oil cooler, intercooler
and air conditioner condenser) with powerful
steam (from high-pressure flushing machine).
With steam cleaning (high-pressure machine
flushing) at a near distance, the heat exchang-
er could be deformed and premature plugging
and cracking could be resulted.
CZ425-1104029
Fig. 5-56
WARNING
CZ335-1104076
Fig. 5-58
4 5
CZ335-1104078
Fig. 5-60
6
4
CZ335-1104079
Fig. 5-61
WARNING
Fig. 5-62
2. Insert the dipstick (2) back into the tube.
L
CZ335-1204006
Fig. 5-63
WARNING
CB20160512011
Fig. 5-66
WARNING
Fig. 5-67
Fig. 5-69
9. For SY500H beginning with a number
SY0502BG00098, replacement of filter
element 【6】 on the side of hydraulic tank
is also required. Replacement procedure is
similar to the aboe step 3 through step 8.
CZ365-140625001
Fig. 5-70
Fig. 5-71
WARNING
NOTE:
(If equipped)
WARNING
1. Lower the work equipment to the groundand then shut down the engine. Place thehydraulic
lockout control to the locked position.
NOTE:
●● Wipe off the used grease that has been squeezed out when greasing.
WARNING
WARNING
CZ215-1304004
Fig. 5-77
WARNING
leased. Fig. 5-79
CAUTION
CC13031404
Fig. 5-81
Fig. 5-82
Fig. 5-83
ON
OFF
STA
T
HEA
RT
CC13031804
Fig. 5-84
WARNING
CB2015051301
Fig. 5-86
Check the engine every 1000 service hours if the engine is started frequently.
Special tools are necessary for inspection and maintenance. Consult your Sany distributor to do
this job.
CZ335-1104104
Fig. 5-88
WARNING
NOTE:
WARNING
CB2016051303
Fig. 5-91
CB2016051304
Fig. 5-92
Check, through visual inspection and feel, for any loose bolts on the five mounting clamps of
high-pressure pipe between the supply pump and the spray nozzle. Contact your Sany distributor
to replace the parts in trouble.
1. Whether the compressor and the magnetic clutch are switched on/off when switching on/off
the air conditioner.
In case of any problem, Contact your Sany distributor for disassembly, repair or replacement
of the parts.
The 100, 250, 500, 1000, 2000 and 4000 hour services shall be carried out in the meantime.
Contact your Sany distributor to replace the high-pressure tube clamps of the engine.
Contact your Sany’s authorized dealer if service hours of the machine reaches 10, 000 hours or
overall maintenance.
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Troubleshooting
6 Troubleshooting
6.1 Troubleshooting Preparation.................................................................................... 6-3
6.1.1 Checks before troubleshooting....................................................................... 6-3
6.1.2 Troubleshooting precautions........................................................................... 6-4
6.1.3 Electrical circuits troubleshooting precautions................................................ 6-7
6.1.4 Hydraulic components handling precautions.................................................. 6-8
6.2 Measures Taken When Failure Occurs................................................................... 6-10
6.2.1 Failure-like phenomena................................................................................ 6-10
6.2.2 Towing the machine.......................................................................................6-11
6.3 Engine Failures....................................................................................................... 6-13
6.3.1 Engine troubleshooting table........................................................................ 6-13
6.3.2 Coolant temperature high............................................................................. 6-16
6.3.3 Engine oil pressure low................................................................................. 6-18
6.3.4 When fuel runs out........................................................................................ 6-19
6.3.5 When engine rotates reversely..................................................................... 6-23
6.4 Failures of the Electrical System............................................................................ 6-24
6.4.1 Electrical system troubleshooting table........................................................ 6-24
6.4.2 Failure codes................................................................................................ 6-27
6.5 Battery.................................................................................................................... 6-29
6.5.1 Battery removal and installation.................................................................... 6-29
6.5.2 Battery charging............................................................................................ 6-30
6.5.3 Starting engine with jumper cable................................................................. 6-31
6.5.3.1 Connecting jumper cables................................................................... 6-32
6.5.3.2 Starting engine..................................................................................... 6-33
6.5.3.3 Disconnecting jumper cables.............................................................. 6-33
6.6 Failures of the Hydraulic System............................................................................ 6-34
6.7 Other Common Failures......................................................................................... 6-38
6 TROUBLESHOOTING
—
1. Check for looseness and corrosion of battery termi-
— Tighten or replace
nal and wiring
—
Electrical 2. Check for looseness and corrosion of alternator
Tighten or replace
equipment terminal and wiring
3. Check for looseness and corrosion of start motor
Tighten or replace
terminal and wiring
Table 6-1
CAUTION
4. Confirming failure
5. Troubleshooting
Fig. 6-2
5. Flushing operations
ZX215-1000026
Fig. 6-3
6. Cleaning operations
Fig. 6-4
CZ335-1103213
Fig. 6-5
CZ335-1103214
Fig. 6-6
WARNING
CZ335-1103217
Fig. 6-9
Check the engine according to the following table if any failure occurs to it. Contact your Sany
distributor to repair the engine.
WARNING
NOTICE
Fig. 6-10
NOTICE
WARNING
One method:
CB2016051306
Fig. 6-13
CB2016051307
Fig. 6-14
CB2016051308
Fig. 6-15
CB2016051309
Fig. 6-16
WARNING
Another method:
CB2016051310
Fig. 6-18
CB2016051311
Fig. 6-19
WARNING
CB2016051312
●● The electromagnetic pump is prohibited
working, when the engine is in Fig. 6-20
operation. And keep the valve open.
WARNING
Trouble-shoot the electrical system according to the following tables. Contact your Sany distribu-
tor solve the problem.
The failure code displayed on the monitor can be used to make failure analysis. For more infor-
mation on failure codes see "Failure information" on page 3-16.
Failure
Symptom Alarm condition
Code
Oil pressure lower than 200 and engine speed higher
3 Engine oil pressure low
than 800 for 15s
4 Fuel level low Fuel level lower than 10% for 10s
Coolant temperature higher than 105°C or coolant tem-
5 Coolant temperature high
perature over-high pressure switch off
6 Air cleaner plugged Air cleaner plugging pressure switch off
Engine speed lower than 800 rpm but higher than 400
7 Engine speed low
rpm for 3s
8 Engine speed high Engine speed higher than 2500 rpm
10 Hydraulic oil temperature high Hydraulic oil temperature higher than 90°C for 10s
Motor feedback voltage lower than 0.25V or higher
12 Motor working range irregular
than 4.75V for 3s
Front pump pressure collecting volt lower than 0.25V or
20 Front pump pressure sensor abnormal
higher than 4.75V for 3s
Rear pump pressure collecting volt lower than 0.25V or
21 Rear pump pressure sensor abnormal
higher than 4.75V for 3s
Bucket-dig pilot pressure sensor abnor- Bucket-dig pilot pressure collecting volt lower than
22
mal 0.25V or higher than 4.75V for 3s
Bucket-dump pilot pressure sensor ab- Bucket-dig pilot pressure collecting volt lower than
23
normal 0.25V or higher than 4.75V for 3s
Arm-in pilot pressure collecting volt lower than 0.25 and
24 Arm-in pilot pressure sensor abnormal
higher than 4.75 for 3s
Arm-out pilot pressure collecting volt lower than 0.25
25 Arm-out pilot pressure sensor abnormal
and higher than 4.75 for 3s
Boom-up pilot pressure sensor abnor- Boom-up pilot pressure collecting volt lower than 0.25
26
mal and higher than 4.75 for 3s
Boom-down pilot pressure sensor ab- Boom-down pilot pressure collecting volt lower than
27
normal 0.25 and higher than 4.75 for 3s
Left travel pilot pressure sensor abnor- Left travel pilot pressure collecting volt lower than 0.25
28
mal and higher than 4.75 for 3s
Right travel pilot pressure sensor abnor- Right travel pilot pressure collecting volt lower than 0.25
29
mal and higher than 4.75 for 3s
Swing pilot pressure collecting volt lower than 0.25 and
30 Swing pilot pressure sensor abnormal
higher than 4.75 for 3s
Failure
Symptom Alarm condition
Code
Front pump proportional valve overcur- Front pump proportional valve current higher than
31
rent 1300mA for 3s
Rear pump proportional valve overcur- Rear pump proportional valve current higher than
32
rent 1300mA for 3s
Front pump proportional valve current lower than
Front pump proportional valve undercur-
33 200mA for 3s and controller PWM output higher than
rent
10V
Rear pump proportional valve current lower than
Rear pump proportional valve undercur-
34 200mA for 3s and controller PWM output higher than
rent
10V
Front pump proportional valve feedback current lower
35 Front pump proportional valve than 150mA or higher than 1350mA for 3s and control-
ler PWM duty output higher than 10V
Rear pump proportional valve feedback current lower
36 Rear pump proportional valve than 150mA or higher than 1350mA for 3s and control-
ler PWM duty output higher than 10V
Hydraulic oil temperature sensor abnor- Hydraulic oil temperature collecting volt lower than
37
mal 0.25V or higher than 4.75V for 3s
Coolant temperature collecting resistance lower than
38 Coolant sensor abnormal 10Ω or higher than 120 Ω for 3s after 30 minutes since
engine starting
Fuel level collecting resistance lower than 10Ω or high-
39 Fuel level sensor abnormal
er than 120 Ω for 3s
Speed collecting frequency lower than 100 for 3s un-
40 Speed sensor abnormal
der load
Fuel control dial collecting volt lower than 0.25V or
41 Fuel control dial abnormal
higher than 4.75V for 3s
CAN communication monitoring component overtime or
42 CAN bus abnormal
reset characters changed for 3s
Table 6-4
6.5 Battery
WARNING
CZ335-1103220
●● Regulate the charging current to 1/10 of
the rated capacity of battery. In case of Fig. 6-22
quick charging, regulate the charging cur-
rent to a level below the rated capacity of
battery. Larger charging current may cause
leakage or evaporation of electrolyte,
hence fire and explosion.
WARNING
NOTE:
CZ335-1103222
4. Connect the clip on the other end of jumper Fig. 6-24
cable (B) to the swivel frame (E) of the
faulty machine.
CAUTION
3 4
2. Disconnect the clip of the jumper cable (B) 2
from the negative terminal (-) of battery (D)
of the normal machine.
D C
3. Disconnect the clip of jumper cable (A) 1
from the positive terminal (+) of battery (D) B E
of the normal machine.
CZ335-1103223
4. Disconnect the clip of jumper cable (A) Fig. 6-25
from the positive terminal (+) of battery (C)
of the faulty machine.
●● Trouble-shoot the hydraulic system according to the following tables. Contact your Sany dis-
tributor solve the problem.
●● Set the working mode to S and the fuel control dial to position 10 before troubleshooting
Table 6-5
frosted level.
low pressure
gauge read- ●● Refill refrigerant to the specified
●● Refrigerant insufficient
ings lower level.
the standard
value.
Low pressure
●● Low pressure hose blocked; expansion ●● Repair the system. Replace reser-
gauge could
valve blocked by ice or contaminants. voir in case of ice blockage.
read negative.
Evaporator
●● Thermostat failure ●● Replace thermostat.
frozen
Expansion valve inlet
●● Expansion valve blocked. ●● Clean/replace expansion valve.
felt cool and frosted.
Expansion valve outlet
is not felt cool. Low ●● Expansion valve thermo-tube or bulb ●● Replace expansion valve.
pressure could be leaks.
negative.
Both high/ ●● Air trapped in circulation system. ●● Empty the system and vacuate to
High pressure gauge reads
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Specifications
7 Specifications
7.1 Machine Dimensions................................................................................................ 7-3
7.2 Working Ranges....................................................................................................... 7-4
7.3 Technical Specifications............................................................................................ 7-5
7 SPECIFICATIONS
7.1 Machine Dimensions
A
D I
E C
L
H
G F J
B K
CJ13032601-3
Fig. 7-1
g
b
c d
CJ13032602
Fig. 7-2
Item Unit SY500H
a Max. cutting height mm 10950
b Max. unloading height mm 7450
c Max. digging depth mm 7490
d Max. vertical digging depth mm 5910
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Optional Equipment
8 Optional Equipment
8.1 Safety Information.................................................................................................... 8-3
8.1.1 Optional equipment selection......................................................................... 8-3
8.1.2 Read equipment instruction............................................................................ 8-3
8.1.3 Optional equipment removal and installation precautions ............................. 8-3
8.1.4 Optional equipment operation precautions..................................................... 8-4
8.2 Hydraulic Control Elements and Oil Circuit ............................................................. 8-6
8.2.1 Component locations...................................................................................... 8-6
8.2.1.2 Stop valve.............................................................................................. 8-7
8.2.1.3 Selector valve........................................................................................ 8-7
8.2.1.1 Attachment control pedal....................................................................... 8-7
8.2.2 Hydraulic circuit.............................................................................................. 8-8
8.2.2.1 Hydraulic circuit switching...................................................................... 8-8
8.2.2.2 Switching between breaker and general attachment............................. 8-8
8.2.2.3 Connecting hydraulic oil circuit ............................................................. 8-9
8.2.2.4 Hydraulic oil path................................................................................. 8-10
8.2.3 Attachment removal and installation..............................................................8-11
8.2.3.1 Removal................................................................................................8-11
8.2.3.2 Installation ........................................................................................... 8-13
8.2.4 Hydraulic oil and filter - change/replace........................................................ 8-15
8.2.5 Long-term storage........................................................................................ 8-16
8.3 Recommended Operations..................................................................................... 8-17
8.3.1 Hydraulic breaker.......................................................................................... 8-17
8.3.2 Hydraulic breaker operation.......................................................................... 8-18
8.3.3 Restricted operations.................................................................................... 8-20
8.3.4 Hydraulic breaker greasing........................................................................... 8-23
8.4 Quick Coupler......................................................................................................... 8-24
8 OPTIONAL EQUIPMENT
8.1 Safety Information
Observe the following precautions when se-
lecting, installing and operating attachments or
optional equipment of the machine.
CZ335-1105001-1
Fig. 8-1
CZ335-1105003
Fig. 8-3
●● When a breaker is installed on the machine, the return circuit must be connected directly to
the return filter. Therefore, do not use the return circuit except for mode B. For a machine that
has no breaker lines, if customer adds breaker lines personally to the machine, the return line
must have a filter. The breaker lines installation and the filtering system must be agreed by
your Sany distributor. Failure to do so can cause problems and the customer has to bear the
losses thereof.
●● Standard pressure of the safety valve in the service valve was set at the factory before deliv-
ery. When mode B is selected, this pressure is set at 20.6 MPa {210 kgf/cm²}. When hydrau-
lic shear mode is chosen, this pressure is set at 20.6/31.4 MPa (210/320 kgf/cm²). Further
adjustment may be needed depending on the type of attachment. In this case, please contact
Sany distributor for adjustment.
●● Select a working mode on the monitor according to attachment type as per the following stan-
dards.
●● The set pressures of the safety valve in the service valve and for the switch of hydraulic line
are determined by the working mode selected.
A
●● FREE position (A) allows flow of hy-
draulic oil. (The arrow is parallel to the
arm).
B
●● LOCK position (B) stops flow of hydrau-
lic oil. (The arrow is perpendicular to CZ335-1105002
the arm). Fig. 8-5
CZ335-1105005
Fig. 8-6
CZ335-1105006
Fig. 8-7
The operating directions of the pedal and hydraulic path are shown below.
CZ335-1105007
Fig. 8-8
Stepping on the front half of the pedal, oil flows to the line on the left side of work equipment;
stepping on the rear half of the pedal, oil flows to the line on the right side of work equipment. (Only
the front half of the pedal can be used when hydraulic breaker is applied.)
8.2.3.1 Removal
CC13031403
Fig. 8-10
CZ335-1105011
Fig. 8-11
Fig. 8-12
CZ335-1105013
Fig. 8-13
8.2.3.2 Installation
CZ335-1105014
Fig. 8-14
Fig. 8-15
CC13031403
Fig. 8-16
CZ335-1105012
9. Check the oil level in hydraulic tank after Fig. 8-18
installation of the attachment.
●● Hydraulic breaker application causes faster contamination of the hydraulic system and de-
terioration of hydraulic oil. As a result, the hydraulic oil and filter shall be replaced in shorter
intervals, as compared with machines installed with buckets. Otherwise, damage could occur
in the hydraulic breaker, hydraulic pump and other hydraulic components. Recommended re-
placement intervals are listed below. For information on how to change hydraulic oil and filter
see "Oil in hydraulic tank - change" on page 5-88 and "Hydraulic oil suction filter element –
clean/replace" on page 5-79.
Change interval (unit: hour)
NOTE:
●● The figures in the above table are determined at 100 percent operation with hydraulic breaker.
As the operating hours of hydraulic breaker reduce, the change intervals could be prolonged
correspondingly as shown in the following chart.
●● The filter cartridge must be replaced after the breaker has been operated for 100 hours.
100
Microglass Cartridge
Paper Cartridge
Change interval for
Hydraulic Breaker Operation Percentage%
80
hydraulic oil of 1,500
hour service life
60
Change interval for
hydraulic oil of 2,500
hour service life
40
Change interval for
hydraulic oil of 4,000
Table 8-3
Major applications:
●● Crushing rocks
●● Demolition
●● Road construction
90°
90°
CZ335-1105017
Fig. 8-20
CZ335-1105018
Fig. 8-21
CZ335-1105019
Fig. 8-22
CZ335-1105020
Fig. 8-23
CZ335-1105021
Fig. 8-24
CZ335-1105022
Fig. 8-25
CZ335-1105023
Fig. 8-26
CZ335-1105024
Fig. 8-27
CZ335-1105025
Fig. 8-28
CZ335-1105026
Fig. 8-29
6. Pecking operation.
CZ335-1105027
Fig. 8-30
CZ335-1105028
Fig. 8-31
CZ335-1105029
Fig. 8-32
NOTE:
CZ335-1105030
Fig. 8-33
CZ335-1105031
Fig. 8-34
Safety pin
Jaw
CZ335-1105032
Fig. 8-35
CZ335-1105033
Fig. 8-36
2 3
CZ335-1105034
Fig. 8-37
2
3
CZ335-1105035
Fig. 8-38
CZ335-1105036
Fig. 8-39
Fig. 8-40
CZ335-1105038
Fig. 8-41
CZ335-1105039
Fig. 8-42
8.5.1 Introduction
CZ335S-1105001
Fig. 8-44
Technical specifications:
Fig. 8-45
EC Declaration
9 EC DECLARATION
9.1 DECLARATION OF CONFORMITY......................................................................... 9-2
9 EC DECLARATION
MANUFACTURER
SANY HEAVY MACHINERY LIMITED
SANY INDUSTRIAL PARK, ECONOMIC AND TECHNOLOGICAL
DEVELOPMENT ZONE, KUNSHAN, JIANGSU 215300, P.R. CHINA
AUTHORIZED REPRESENTATIVE
SANY Germany GmbH
Sany Allee 1 DE-50181 Bedburg
AUTHORIZED TO HOLD TECHNICAL FILE ON BEHALF OF MANUFACTURER ABOVE
DESCRIPTION OF MACHINERY
PRODUCT NAME:Crawler Hydraulic Excavator
MODEL TYPE : SY500H
APPLICABLE STANDARDS
EN 474-1:2006+A4:2013/AC:2014 EN 474-5:2006+A3:2013
SIGNATURE :