SY500H-10 Crawler Hydraulic Excavator: Operation and Maintenance Manual

SY500H-10
Crawler Hydraulic Excavator

Operation and Maintenance Manual
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
Sany Heavy Machinery Limited
Sany industrial park, economic and technology development zone,
Kunshan, jiangsu 215300, P.R.China
http://www.sanygroup.com
Tel: 0086-21-57008518
Service hotline: 0086-4006 098 318
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;
●● Unauthorized restructuring or modification to the excavator;
●● Use of non-genuine parts, or untested or unapproved parts or tools.
●● 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.
●● Provide training for excavator operators and service persons as required.

Obligations of owners or authorized persons
●● Only trained personnel who fully understand the Parts Book and the Safety, Operation and
Maintenance Manual are allowed to operate and service the hydraulic excavator.
●● Make sure that the excavator operator and service person are qualified for this job and know
their responsibilities.
●● Regularly inspect the safety awareness of related persons at work.
●● 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.
●● Ensure timely maintenance and repair of the hydraulic excavator.
●● Make a detailed plan for proper use of the hydraulic excavator.

Obligations of all operating personnel
●● Any abnormalities that could bring improper operation of the hydraulic excavator or potential
hazards should be reported to your supervisor. The abnormalities should be corrected timely
if possible.
●● All workers around the hydraulic excavator must know and obey all warning signals, and be
alert to safety of oneself and others.
●● All operators must know the operating items and procedures.
●● 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
Operation & Maintenance Manual - May 2016 I

Table of Contents SY500H-10 Crawler Hydraulic Excavator
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
2.3.14.1 Fire caused by fuel or oils................................................................. 2-29
2.3.14.2 Fire caused by flammable materials.................................................. 2-30
2.3.14.3 Fire caused by electric lines............................................................... 2-30
2.3.14.4 Fire caused by hydraulic lines ........................................................... 2-30
2.3.14.5 Fire caused by illumination equipment............................................... 2-31
2.3.14.6 Fire caused by heat shield................................................................. 2-31
2.3.15 In the event of fire....................................................................................... 2-31
2.3.16 Windshield cleaning detergent.................................................................... 2-31
2.3.17 Preventing ejection of part ......................................................................... 2-32
2.3.18 Falling object protection.............................................................................. 2-33
2.3.19 Attachment installation................................................................................ 2-33
2.3.20 Attachment combination ............................................................................ 2-34
2.3.21 Cab window glasses................................................................................... 2-34
2.3.22 Unauthorized modification.......................................................................... 2-34
2.3.23 Work site investigation................................................................................ 2-35
2.3.24 Operation on soft ground............................................................................ 2-36
2.3.25 Overhead power cables.............................................................................. 2-37
II Operation & Maintenance Manual - May 2016

2.3.26 Ensuring a good view................................................................................. 2-38

2.3.27 Ventilating enclosed area............................................................................ 2-39
2.3.28 Asbestos hazard......................................................................................... 2-39
2.3.29 Alternate exit............................................................................................... 2-39
2.4 Operation Safety..................................................................................................... 2-40
2.4.1 Safe starting ................................................................................................. 2-40
2.4.1.1 Safe mounting...................................................................................... 2-40
2.4.1.2 Seat adjustment................................................................................... 2-40
2.4.1.3 Seat belt............................................................................................... 2-41
2.4.1.4 Before starting the engine.................................................................... 2-41
2.4.1.5 Safe starting......................................................................................... 2-42
2.4.1.6 Starting engine in cold season............................................................. 2-43
2.4.1.7 Engine starting aid............................................................................... 2-43
2.4.1.8 After starting the engine....................................................................... 2-44
2.4.2 Operation...................................................................................................... 2-45
2.4.2.1 Inspection before operation................................................................. 2-45
2.4.2.2 Precautions before operation............................................................... 2-46
2.4.2.3 Travel directions................................................................................... 2-47
2.4.2.4 Steering safety rules............................................................................ 2-48
2.4.2.5 Traveling safety rules........................................................................... 2-50
2.4.2.6 Safe traveling ...................................................................................... 2-51
2.4.2.7 Operation on an incline........................................................................ 2-53
2.4.2.8 Operation in snowy weather................................................................ 2-53
2.4.2.9 Restricted operations........................................................................... 2-54
2.4.3 Parking the machine..................................................................................... 2-56
2.4.3.1 Selecting a parking place..................................................................... 2-56
2.4.3.2 Machine shutdown............................................................................... 2-57
2.4.4 Transportation............................................................................................... 2-58
2.4.4.1 Transporting the machine.................................................................... 2-58
2.4.4.2 Loading and unloading the machine.................................................... 2-58
2.4.5 Battery.......................................................................................................... 2-60
2.4.6 Towing safety................................................................................................ 2-62
2.4.7 Lifting objects ............................................................................................... 2-63
2.5 Maintenance Safety................................................................................................ 2-64
2.5.1 Precautions before maintenance.................................................................. 2-64
2.5.2 Self-preparation............................................................................................ 2-65
2.5.3 Work area preparation.................................................................................. 2-66
2.5.4 Engine shutdown procedure ........................................................................ 2-67
Operation & Maintenance Manual - May 2016 III

2.5.5 Lock out and tag out ................................................................................... 2-68

2.5.6 Suitable tools................................................................................................ 2-68
2.5.7 Maintenance with engine running................................................................. 2-69
2.5.8 Working under the machine.......................................................................... 2-70
2.5.9 Track maintenance....................................................................................... 2-71
2.5.10 Track tension adjustment precautions........................................................ 2-72
2.5.11 Do not remove the recoil spring.................................................................. 2-72
2.5.12 Hot cooling system..................................................................................... 2-73
2.5.13 High-pressure hoses................................................................................... 2-73
2.5.14 Pressurized fluid......................................................................................... 2-74
2.5.15 Welding operation....................................................................................... 2-75
2.5.16 Air-conditioning system .............................................................................. 2-75
2.5.17 High voltage precautions............................................................................ 2-76
2.5.18 Accumulator................................................................................................ 2-76
2.5.19 Regular replacement of safety-related parts............................................... 2-77
2.5.20 Maintenance operation .............................................................................. 2-77
2.5.21 Proper disposal of wastes........................................................................... 2-78
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
IV Operation & Maintenance Manual - May 2016

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
3.2.2.23 Engine Failure Information................................................................. 3-23
3.2.2.24 Engine other information.................................................................... 3-23
3.2.2.25 Daily maintenance information........................................................... 3-24
3.2.2.26 System lockout information................................................................ 3-24
3.3 Switches................................................................................................................. 3-25
3.3.1 Start switch................................................................................................... 3-26
3.3.2 Fuel control dial............................................................................................ 3-27
3.3.3 Work lamp switch.......................................................................................... 3-27
3.3.4 Head lamp switch......................................................................................... 3-29
3.3.5 Windshield wiper switch................................................................................ 3-30
3.3.6 Washer switch............................................................................................... 3-31
3.3.7 Horn switch................................................................................................... 3-31
3.3.8 Cab lamp switch........................................................................................... 3-31
3.3.9 Cigarette lighter............................................................................................ 3-32
3.3.10 Preheat switch (If equipped)....................................................................... 3-32
3.3.11 Preheat indicator......................................................................................... 3-33
3.3.12 Charging indicator....................................................................................... 3-33
3.4 Control Levers and Pedals..................................................................................... 3-34
3.4.1 Hydraulic lockout control............................................................................... 3-35
3.4.2 Travel control levers...................................................................................... 3-36
3.4.3 Joysticks....................................................................................................... 3-37
3.5 Cab Windows and Cab Door ................................................................................. 3-39
3.5.1 Ceiling window.............................................................................................. 3-39
3.5.2 Front window................................................................................................ 3-40
3.5.3 Cab door window.......................................................................................... 3-47
3.6 Cup Holder............................................................................................................. 3-48
3.7 Ash Tray.................................................................................................................. 3-48
3.8 Manual Pocket........................................................................................................ 3-48
3.9 Drink Box................................................................................................................ 3-49
3.10 Alternate exit......................................................................................................... 3-49
3.11 Fire Extinguisher................................................................................................... 3-50
Operation & Maintenance Manual - May 2016 V

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
VI Operation & Maintenance Manual - May 2016

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
4.5.1 Direction change when the machine is stopped .......................................... 4-32
4.5.2 Pivot turning.................................................................................................. 4-34
4.6 Selecting a Working Mode...................................................................................... 4-34
4.7 Work Equipment Control......................................................................................... 4-35
4.8 Restricted Operations............................................................................................. 4-37
4.8.1 Operation with swinging force....................................................................... 4-37
4.8.2 Operation with traveling force....................................................................... 4-37
4.8.3 Operation when hydraulic cylinder reaches its stroke end .......................... 4-38
4.8.4 Operation with bucket landing force............................................................. 4-38
4.8.5 Hard rocky ground ....................................................................................... 4-38
4.8.6 Operation with machine weight..................................................................... 4-39
4.8.7 Sudden shift of control levers/ pedals .......................................................... 4-39
4.9 Permissible depth of water..................................................................................... 4-40
4.10 Traveling on a Slope............................................................................................. 4-41
4.10.1 Traveling downhill ...................................................................................... 4-42
4.10.2 When engine stalls on a slope.................................................................... 4-42
4.10.3 Cab door on a slope................................................................................... 4-42
4.11 Escaping from Mud............................................................................................... 4-43
4.11.1 When one track is trapped.......................................................................... 4-43
4.11.2 When both tracks are trapped..................................................................... 4-43
4.12 Recommended Application................................................................................... 4-44
4.12.1 Backhoe operation...................................................................................... 4-44
4.12.2 Trenching work........................................................................................... 4-45
4.12.3 Loading operation....................................................................................... 4-45
4.13 Parking................................................................................................................. 4-46
4.14 Inspection after Each Workday............................................................................. 4-48
4.15 Locking................................................................................................................. 4-49
4.16 Operation in Cold Weather................................................................................... 4-50
4.16.1 Fuel and lubricant....................................................................................... 4-50
4.16.2 Coolant....................................................................................................... 4-50
4.16.3 Battery........................................................................................................ 4-51
4.16.4 After each workday..................................................................................... 4-51
4.16.5 After cold season........................................................................................ 4-52
Operation & Maintenance Manual - May 2016 VII

4.17 Long-Term Storage............................................................................................... 4-53

4.17.1 Before storage............................................................................................ 4-53
4.17.2 During storage............................................................................................ 4-54
4.17.3 After storage............................................................................................... 4-55
4.17.4 Engine startup after long-term storage....................................................... 4-55
4.18 Transportation Information.................................................................................... 4-56
4.18.1 Transport methods...................................................................................... 4-56
4.18.2 Loading and unloading............................................................................... 4-57
4.18.2.1 Loading.............................................................................................. 4-58
4.18.2.2 Securing the machine........................................................................ 4-61
4.18.2.3 Unloading........................................................................................... 4-63
4.18.2.4 Lifting the machine............................................................................. 4-65
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
VIII Operation & Maintenance Manual - May 2016

5.8.2.3 Bucket - replace................................................................................... 5-29

5.8.2.4 Bucket tips (lateral pin) - replace......................................................... 5-32
5.8.2.5 Bucket clearance - adjust..................................................................... 5-34
5.8.2.6 Window washer fluid level - check/refill............................................... 5-36
5.8.2.7 Air conditioner - inspect/service........................................................... 5-37
5.8.2.8 Ceiling window gas spring - inspect..................................................... 5-39
5.8.3 Inspection Prior to Startup............................................................................ 5-41
5.8.4 Every 100 service hours............................................................................... 5-42
5.8.4.1 Lubrication........................................................................................... 5-42
5.8.5.1 Air filter element - inspect/clean/replace.............................................. 5-45
5.8.5.2 Compressor belt tension - inspect/adjust............................................. 5-49
5.8.5.3 Swing bearing - lubricate..................................................................... 5-50
5.8.5.4 Pipe clamps of hydraulic system - check............................................. 5-51
5.8.6.1 Swing pinion gear grease level - inspect/fill......................................... 5-52
5.8.6.2 Engine pan oil and filter element - change/replace.............................. 5-54
5.8.6.3 Primary fuel filter element - replace..................................................... 5-56
5.8.6.4 Secondary fuel filter element - replace................................................ 5-59
5.8.6.5 Tertiary fuel filter element – replace..................................................... 5-61
5.8.6.6 Radiator and oil cooler fins - inspect/clean.......................................... 5-64
5.8.6.7 Air conditioner fresh air/recirculation filter - clean................................ 5-66
5.8.6.8 Swing drive oil level - check/refill......................................................... 5-68
5.8.6.9 Final drive oil level - check/refill........................................................... 5-69
5.8.6.10 Engine coolant pump (fan shaft) - lubricate....................................... 5-70
5.8.7 Every 1000 service hours............................................................................. 5-71
5.8.7.1 Hydraulic oil return filter element /oil drain filter element/pilot filter
element- replace............................................................................................... 5-71
5.8.7.2 Swing drive oil - change....................................................................... 5-73
5.8.7.3 Engine exhaust pipe clamps - check................................................... 5-74
5.8.7.4 Fan belt tension - check/replace.......................................................... 5-74
5.8.7.5 Nitrogen pressure in accumulator (breaker) - check............................ 5-74
5.8.7.6 Breather valve - check/replace............................................................ 5-75
5.8.7.7 Filling lubricating grease of Rotary Reduction Gear............................ 5-76
5.8.8.1 Final drive oil - change......................................................................... 5-77
5.8.8.2 Hydraulic oil suction filter element – clean/replace.............................. 5-78
Operation & Maintenance Manual - May 2016 IX

5.8.8.3 Nitrogen pressure in accumulator (control oil circuit) - check.............. 5-79

5.8.8.4 Cooling system interior - clean............................................................. 5-83
5.8.8.5 Alternator - inspect............................................................................... 5-85
5.8.8.6 Engine valve clearance - check/adjust................................................. 5-85
5.8.9.1 Water pump - inspect........................................................................... 5-86
5.8.9.2 Start motor - check............................................................................... 5-86
5.8.9.3 Oil in hydraulic tank - change............................................................... 5-87
5.8.9.4 Accumulator - replace.......................................................................... 5-89
5.8.9.5 High-pressure tube clamps and rubber - check................................... 5-90
5.8.9.6 Compressor working condition - inspect.............................................. 5-90
5.8.10 Every 8000 service hours........................................................................... 5-91
5.8.10.1 High-pressure tube clamps - replace................................................. 5-91
5.8.11 Every 10000 service hours.......................................................................... 5-91
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
X Operation & Maintenance Manual - May 2016

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
7 Specifications
7.1 Machine Dimensions................................................................................................ 7-3
7.2 Working Ranges....................................................................................................... 7-4
7.3 Technical Specifications............................................................................................ 7-5
8 Optional Equipment
8.1.1 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
Operation & Maintenance Manual - May 2016 XI

8.4 Quick Coupler......................................................................................................... 8-24

8.4.1 Quick coupler control.................................................................................... 8-24
8.4.2 Precautions for quick coupler safe operation ............................................... 8-26
8.5 Fueling System....................................................................................................... 8-28
8.5.1 Introduction................................................................................................... 8-28
8.5.2 Fueling system makeup................................................................................ 8-28
9 EC DECLARATION
9.1 DECLARATION OF CONFORMITY......................................................................... 9-2
XII Operation & Maintenance Manual - May 2016

SY500H-10 Crawler Hydraulic Excavator Introduction
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
Operation & Maintenance Manual - May 2016 1-1

Introduction SY500H-10 Crawler Hydraulic Excavator
1.4 Noise and Vibration Statements............................................................................. 1-14

1.5 Correction Request Form - Technical Publications................................................. 1-15
1.6 Contact Information................................................................................................ 1-16
1-2 Operation & Maintenance Manual - May 2016

1 INTRODUCTION
1.1 Overview
●● Sany-built machines offer high-quality per-
formance and star-grade after-sales ser-
vice.
●● Sany-built machines are widely used

throughout the industry for various types of
applications.
●● Sany is a leading manufacturer of con-

struction equipment worldwide.
This operator manual provides safety, opera-

tion, maintenance, troubleshooting and techni-
cal specifications. In order to properly use your
equipment, it is important to read this manual
carefully before beginning any operations.
Items addressed in this manual are designed

to help you:
●● Understand the structure and performance

of your crawler hydraulic excavator.
CZ335-1102004
●● Reduce improper operation and point out
possible hazardous situations. Fig. 1-1
●● Increase equipment efficiency during op-

eration.
●● Prolong the service life of equipment.
●● Reduce maintenance costs.
Always keep this manual nearby and have all

personnel involved with any job-related proce-
dures read it periodically.
If you sell the machine, be sure to give this

manual to the new owner.
Continuing improvements in the design of this

model can lead to changes in details which
may not be covered in this manual. Always
consult your Sany distributor for the latest
available information on your machine or if you
have questions regarding information in this
manual.
1.2 Your Documentation Package

The documentation for this machine includes
the following items:
●● Safety, Operation & Maintenance Manual

(SOMM) — This manual is in the operator
cab seat pocket.
●● Parts Book — This publication consists of

parts lists and matching drawings for or-
dering spare parts as-needed. If it was not
already shipped with your machine, the
parts book for your machine is available
directly from Sany.
●● CD — Along with this machine you will re-

ceive a CD that contains video instructions
on safety, operation and maintenance of
this machine.
1.2.1 CD system requirements
In order to use the Sany CD, be sure of the

following:
Hardware:
●● Intel® Pentium II® running at 500 MHz or

above
●● At least 128 MB RAM
●● CD-ROM drive
●● Minimum screen resolution of 800 x 600

pixels, high-color depth
Software:
●● Windows 2000, XP, Vista or Windows 7

operating systems
●● Internet Explorer 6.0 or later version (pop-

up blocker disabled)
●● Acrobat Reader 7.0 or later version

1.2.2 Recommendations on using the

documentation
●● This documentation applies only to this

machine and should not be used with any
other machines.
●● To ensure that the documentation is always

complete and up to date:
●● Keep all pages inside its binder (if shipped

loose leaf).
●● Insert Sany replacement pages immedi-

ately into the appropriate book; destroy old
versions of those pages.
●● Replace outdated CDs with new ones; de-

stroy the old ones to prevent any confusion
in the future.
1.2.3 Documentation storage
Always keep the operator manual and load

charts with the machine in the operator cab.
The parts book is best left either shelved in

the workshop area or office. It should always
be available to the maintenance and service
personnel as required.
1.2.4 Manual organization
The operator manual is designed for use and

maintenance of this machine. Each section of
this manual provides information you should
be familiar with before operating this machine.
Keep this manual with the machine for your

reference at all times. Replace it immediately
if it is damaged or lost. Due to improvement
and updating of products, some information
may differ from your machine. If you have any
questions on the machine, contact your Sany
distributor before operating or repairing the
machine.

1.2.4.1 Introduction
This chapter provides an overview of what is

covered in the rest of this manual, including
machine label information and Sany contact
information.
1.2.4.2 Safety
This chapter covers basic safety information

relating to this equipment. Make sure you fully
understand all the precautions described in
this manual and the safety labels on the ma-
chine before operating or maintaining this ma-
chine. Failure to do so may result in serious
injury or death.
1.2.4.3 System functions
This chapter provides an overview of all the

controls, alerts and operating systems on the
machine. It is important to study and become
familiar with all systems before proceeding
with any operations.
1.2.4.4 Operation
This chapter provides some basic operating

procedures for this machine. Study and be-
come familiar with all operating procedures
before performing any job functions with the
machine.
1.2.4.5 Maintenance
This chapter provides all general maintenance

and repair procedures. (Detailed rebuild/re-
placement/repair information are covered in
a separate shop manual.) Study and become
familiar with all repair and maintenance proce-
dures before performing any repair or mainte-
nance operations.

1.2.4.6 Troubleshooting
This chapter includes common malfunctions

and fault diagnostics procedures for this crawl-
er hydraulic excavator operating system. Basic
mechanical, hydraulic and electrical system
troubleshooting is included.
1.2.4.7 Specifications
This chapter provides general required ma-

chine information for this crawler hydraulic
excavator. Some information may vary due to
design changes.
1.2.4.8 Optional Equipment
This section provides information regarding

optional equipment for the excavator as autho-
rized by Sany. If you will be using any optional
equipment, it is important to read the instruc-
tion manual for the optional equipment and the
general information related to optional equip-
ment in this manual.

1.3 Your Sany Machine
1.3.1 Machine applications
Sany Hydraulic Excavators are designed for the following operations:

●● Excavating
●● Leveling
●● Digging
●● Loading
●● Demolishing
1.3.2 Machine directions
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

1.3.3 Breaking in a new machine
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.
During the break-in period:

●● Let the machine preheat prior to any operation.
●● Avoid operating with severe loads or at high speeds.
●● Avoid sudden starts, fast movements or stops.
●● Always let the system cool down at the end of the working day.
1.3.4 Machine information
The serial numbers and model numbers on the components are the only numbers that your Sany
distributor will need when ordering replacement parts or requiring assistance for your equipment.
It is a good idea to record this information in this manual for future use. Below are the locations of
the data plates
1.3.4.1 Product identification plate
On the lower right side of the operator station.
CB2016050301
Fig. 1-3

1.3.4.2 Engine identification plates

SY500
TYPE APPROVAL CONFORMED TO NATIONAL STAGE Ⅲ

EMISSION STANDARD FOR OFF-ROAD DIESEL ENGINES
Engine family：G30097L1568HXA
Engine model ：6WG1-XDHAG-03-C3
Engine power ：300.0 kw/1800 r/min
Manufacturer ：ISUZU AUTO
Date of production：
Pwoer range ：130 ≤ kW ＜ 560
Approval No. ：CN FC G3 0097 06 0003
Engine S/N ：
CB2016050302
Fig. 1-4

1.3.4.3 Right and left drive motor identifi-

cation plates
On each drive motor.
Model:_______________________________
ID No.: ______________________________
CZ235-3100801
Fig. 1-5
1.3.4.4 Swing motor identification plate
On top of swing motor.
Model:_______________________________
ID No.: ______________________________
CZ235-3100802
Fig. 1-6
1.3.4.5 Hydraulic pump identification plate
On bottom of pump.
Model:_______________________________
ID No.: _______________________________
CZ235-3100803
Fig. 1-7

1.3.4.6 Chassis serial number
An additional serial number is stamped on the

front part of the travel carriage frame.
SYJ263038018060480
CZ235-3100804
Fig. 1-8

1.3.5 Table for serial number and distributor information
This location is for you to record information relating to your machine. It is advised that you
keep this manual with your machine at all times for reference.
Machine Serial No.
Engine Serial No.
Distributor Name:
Address:
Phone Numbers:

1.4 Noise and Vibration Statements
Test Item Measured Values

Measured A-weighted emission sound pressure level, LPA at the
74
operator’s position, in decibels.
Measured A-weighted sound power level, LWA in decibels 103.5
Noise uncertainty in decibels 1.5
Operator seat vibration when the engine is idling in m/s2 0.1707
Cabin floor vibration when the engine is idling in m/s2 0.1898
Operator seat vibration during digging in m/s2 0.6662
Operator seat vibration during digging in m/s2 0.6662
Cabin floor vibration during digging in m/s2 0.7158
Operator seat vibration when the machine is moving 1.814
Cabin floor vibration when the machine is moving in m/s2 1.944
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

1.5 Correction Request Form - Technical Publications

If you find a problem with this manual, please make a copy of this page, fill out the information
and send it to us attention Technical Publications. See Contact Information” on next page.
Date of this request

Your Name
Company Name
Your Department
Street Address
City, State & ZIP
Phone
E-mail
Machine Model & Serial No.
Description of Problem (Wrong information, unclear or erroneous procedure, etc.)
Corrective Action by You (if any)

1.6 Contact Information

Thank you for purchasing a Sany machine. In
the event that you need to contact us for any
reason, you can reach us as follows:
Sany Heavy Machinery Limited
Sany industrial park, economic and technology

development zone,Kunshan, jiangsu 215300,
P.R.China
Tel: 0086-21-57008518
Service hotline: 0086-4006 098 318
E-mail: crd@sany.com.cn

SY500H-10 Crawler Hydraulic Excavator Safety
Safety
2 Safety
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

Safety SY500H-10 Crawler Hydraulic Excavator
2.3.14.1 Fire caused by fuel or oils................................................................. 2-29

2.3.14.2 Fire caused by flammable materials.................................................. 2-30
2.3.14.3 Fire caused by electric lines............................................................... 2-30
2.3.14.4 Fire caused by hydraulic lines ........................................................... 2-30
2.3.14.5 Fire caused by illumination equipment............................................... 2-31
2.3.14.6 Fire caused by heat shield................................................................. 2-31
2.3.15 In the event of fire....................................................................................... 2-31
2.3.16 Windshield cleaning detergent.................................................................... 2-31
2.3.17 Preventing ejection of part ......................................................................... 2-32
2.3.18 Falling object protection.............................................................................. 2-33
2.3.19 Attachment installation................................................................................ 2-33
2.3.20 Attachment combination ............................................................................ 2-34
2.3.21 Cab window glasses................................................................................... 2-34
2.3.22 Unauthorized modification.......................................................................... 2-34
2.3.23 Work site investigation................................................................................ 2-35
2.3.24 Operation on soft ground............................................................................ 2-36
2.3.25 Overhead power cables.............................................................................. 2-37
2.3.26 Ensuring a good view................................................................................. 2-38
2.3.27 Ventilating enclosed area............................................................................ 2-39
2.3.28 Asbestos hazard......................................................................................... 2-39
2.3.29 Alternate exit............................................................................................... 2-39
2.4 Operation Safety..................................................................................................... 2-40
2.4.1 Safe starting ................................................................................................. 2-40
2.4.1.1 Safe mounting...................................................................................... 2-40
2.4.1.2 Seat adjustment................................................................................... 2-40
2.4.1.3 Seat belt............................................................................................... 2-41
2.4.1.4 Before starting the engine.................................................................... 2-41
2.4.1.5 Safe starting......................................................................................... 2-42
2.4.1.6 Starting engine in cold season............................................................. 2-43
2.4.1.7 Engine starting aid............................................................................... 2-43
2.4.1.8 After starting the engine....................................................................... 2-44
2.4.2 Operation...................................................................................................... 2-45
2.4.2.1 Inspection before operation................................................................. 2-45
2.4.2.2 Precautions before operation............................................................... 2-46
2.4.2.3 Travel directions................................................................................... 2-47
2.4.2.4 Steering safety rules............................................................................ 2-48
2.4.2.5 Traveling safety rules........................................................................... 2-50
2.4.2.6 Safe traveling ...................................................................................... 2-51
2.4.2.7 Operation on an incline........................................................................ 2-53
2.4.2.8 Operation in snowy weather................................................................ 2-53

2.4.2.9 Restricted operations........................................................................... 2-54
2.4.3 Parking the machine..................................................................................... 2-56
2.4.3.1 Selecting a parking place..................................................................... 2-56
2.4.3.2 Machine shutdown............................................................................... 2-57
2.4.4 Transportation............................................................................................... 2-58
2.4.4.1 Transporting the machine.................................................................... 2-58
2.4.4.2 Loading and unloading the machine.................................................... 2-58
2.4.5 Battery.......................................................................................................... 2-60
2.4.6 Towing safety................................................................................................ 2-62
2.4.7 Lifting objects ............................................................................................... 2-63
2.5 Maintenance Safety................................................................................................ 2-64
2.5.1 Precautions before maintenance.................................................................. 2-64
2.5.2 Self-preparation............................................................................................ 2-65
2.5.3 Work area preparation.................................................................................. 2-66
2.5.4 Engine shutdown procedure ........................................................................ 2-67
2.5.5 Lock out and tag out ................................................................................... 2-68
2.5.6 Suitable tools................................................................................................ 2-68
2.5.7 Maintenance with engine running................................................................. 2-69
2.5.8 Working under the machine.......................................................................... 2-70
2.5.9 Track maintenance....................................................................................... 2-71
2.5.10 Track tension adjustment precautions........................................................ 2-72
2.5.11 Do not remove the recoil spring.................................................................. 2-72
2.5.12 Hot cooling system..................................................................................... 2-73
2.5.13 High-pressure hoses................................................................................... 2-73
2.5.14 Pressurized fluid......................................................................................... 2-74
2.5.15 Welding operation....................................................................................... 2-75
2.5.16 Air-conditioning system .............................................................................. 2-75
2.5.17 High voltage precautions............................................................................ 2-76
2.5.18 Accumulator................................................................................................ 2-76
2.5.19 Regular replacement of safety-related parts............................................... 2-77
2.5.20 Maintenance operation .............................................................................. 2-77
2.5.21 Proper disposal of wastes........................................................................... 2-78


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.
This Manual helps you use the machine safely

and efficiently. Precautions throughout this
Manual must be abided by during operation.
Accidents could be prevented by observing
the basic safety rules for machine operation.
Proper use and maintenance of this machine
is your responsibility. Failure to do so can
cause personal injury or machine damage.
Only eligible, experienced operators with an

official license (according to local laws) are al-
lowed to operate the machine.
Always operate your machine according to

national, provincial, prefectural, municipal laws
and regulations. The operation safety informa-
tion and instructions provided in this manual
are just suggestive and attentive.
Sany cannot anticipate every possible circum-

stance that might involve a potential hazard
during operation and maintenance. The Safety
messages in this manual and on the product
are, therefore, not all inclusive. If a procedure,
work method or operating technique that is not
specifically recommended in this manual is
used, you must be sure that it is safe for you
and for others. You should also ensure that the
product will not be damaged or unsafe by the
operation, lubrication, maintenance or repair
procedures that you choose.
All materials, figures and specifications pro-

vided in this Manual are the latest available in-
formation at the time of publication. Sany has

the right to modify these information without

prior notice. For the latest information about
the machine and questions about this Manual
please contact Sany or your distributor.
A standard model is applicable from -20°C to

40°C under 2000 meters above the sea level.
Before operation and maintenance, operator

and maintenance personnel must observe the
following items:
●● Read and understand the whole Manual.
●● Read and understand the safety notices

provided in this manual and the safety de-
cals on the machine.
●● Never use the machine in applications or

operations restricted by this Manual.
●● If refueling quantity, particle content, or

latitude is beyond the specification of this
model, personal injury or machine damage
could result. Such casualties are not cov-
ered by the warranty.
●● Keep this Manual in the cab for reference

at any time.
●● If the Manual is missing or blurred, contact

your Sany distributor to get a new one.
●● This manual should be regarded as a per-

manent component of your machine. If you
sell the machine to a third party, be sure to
give this manual to the new owner.
●● The machine provided by Sany to its buyer

is in line with all specifications and stan-
dards of buyer's country. If the machine is
purchased from another country or some-
one of a third country, it might be lacking of
some safety devices or technical require-
ments necessary for using the machine in
your country. If you have question whether
the machine is in line with the standards
and specifications of your country, please
contact local Sany distributor before using
the machine.
2.2 Safety Messages

To help you use the machine safety, this Man-
ual introduces safety precautions and decals
attached to the machine. These messages
deal with potential hazards and how to prevent
them.
User and after-sale persons must understand

the alert signs and symbols on the machine
before operation and maintenance, strictly fol-
low the safety rules and suggestions provided
in this Manual, and actively take preventive
measures to minimize the risks of personal
injury, machine damage caused by inappropri-
ate repair, and unsafe factors.
2.2.1 Hazard alert message
Hazard alert message consists of alert sym-

bol and words. It is used to indicator possible
hazards that could lead to personal injury or
machine damage. Hazard alert messages are
classified into several levels according to se-
verity of a hazardous situation.
This Manual uses the following hazard alert

messages to define a hazardous situation.
DANGER
It indicates an imminently hazardous situation

which, if not avoided, will result in death or se-
rious injury.
WARNING
It indicates a potentially hazardous situation

which, if not avoided, could result in death or
serious injury.

CAUTION
It indicates a potentially hazardous situation

which, if not avoided, may result in minor or
moderate injury. It can also be used to alert
unsafe operation that can cause property loss.
NOTICE
It indicates a situation which can cause dam-

age to the machine, personal property and/or
the environment, or cause the equipment to
operate improperly.
This is the safety alert symbol. It is used to

alert you to potential personal injury hazards.
Obey all safety messages that follow this sym-
bol to avoid possible injury or death.
For example,
WARNING
●● The hydraulic lockout control must be

placed in the locked position before
you leave the operator cab.
●● An unlocked hydraulic lockout control
lever can cause serious injury or death
if maneuvered unexpectedly.

2.2.2 Safety decals
Safety decals are attached to the machine and

used to alert operator or maintenance workers
on potential hazards on the spot during opera-
tion or maintenance.
Textual and graphical decals are used on the

machine to tell you how to prevent a hazard-
ous situation.
2.2.2.1 Textual safety decals
Textual safety decals use brief text to indicate 警告 WARNING

hazardous situation and safety measures.
卸压时只允许拧松一圈。如果
将阀拧得太松，阀内的高压脂
Fig. 2-1 is an example of textual safety decals. 会使阀喷出。
To release pressure, loosen
only one turn. If the valve is
loosened too much, grease
under high pressure may
squirt out.
A820601990968
Fig. 2-1
2.2.2.2 Graphical safety decals
Graphical safety decals use images or sym-

bols to indicate a hazardous situation and how
to avoid it.
Fig. 2-2 is an example of graphical safety de-

cals.
The upper triangle indicates the type of haz-

ardous situation while the lower circle shows
the way to avoid it.
A820601990973
Fig. 2-2

2.2.2.3 Safety decal locations
The following safety decals are used on the

machine.
●● Be sure to recognize the correct locations

of and information on the decals.
●● To ensure that the decals can be read

and understood easily, they have to be at-
tached to correct locations and always kept
clean. The use of organic solution or gaso-
line to clean the decals is not allowed as
they can cause the paint on decal to peel
off.
●● There are also other decals besides those

for warning and safety. They must be treat-
ed in the same way as those for warning
and safety.
●● If any decal is broken, missing or blurred,

replace it with a new one. For part number
of a decal see this Manual or the decal on
machine.

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.

2.2.2.4 Safety decal explanation
1. Read the Manual.
●● Read this Manual before operating, ser-

vicing, disassembling, reassembling and
transporting the machine.
A820601990971
Fig. 2-4
2. Lock the front window.
●● The front window may fall.
●● Always secure the front window with the

latch after it is lifted open.
A820699001019
Fig. 2-5
3. Excavator control pattern
●● To prevent bodily injury or death, confirm

the running condition and the working
mode displayed when you operate the ma-
chine. Pay attention to your surrounding
and operate the machine slowly.
A820601990961
Fig. 2-6

4. High voltage hazard
●● There is electrocution hazard if your ma-

chine is too close to power cable.
●● Keep a safe distance from power transmis-

sion lines.
A820601990974
Fig. 2-7
5. Remove the ignition key.
●● Before leaving the machine, the operator

must lower the work equipment to ground,
place the hydraulic lockout control in the
locked position and remove the ignition key
from engine start switch.
A820699001020
Fig. 2-8
6. Alternate exit
A820601990969
Fig. 2-9

7. Do not enter the working range.
●● It is possible to be hurt by the machine if

one stays in the working range.
●● Keep a safe distance from the machine

when it is working.
A820699001016
Fig. 2-10
8. Watch out the work equipment.
●● There is the possibility of being hit by the

work equipment.
●● Keep a safe distance from the machine

when it is working.
A820601990963
Fig. 2-11
9. Hot surface
危险DANGER
●● Hot parts can cause burns. Do not touch
hot parts.
10123433
Fig. 2-12

10. Squirting hazard
●● Read the instruction before removing the

cap of pressure vessels such as oil tank.
To prevent squirting, turn the cap slowly to
release internal pressure before removing
it.
A820699000948
Fig. 2-13
11. Fan cutting hazard
危险 DANGER
●● Rotating components can cause injury. Do
not approach rotating components.
A820600000002
Fig. 2-14
12. Track tension adjustment
●● Never loosen the regulator valve more 警告 WARNING

than one turn, otherwise the high pressure
卸压时只允许拧松一圈。如果
can eject the valve and cause injury. 将阀拧得太松，阀内的高压脂
会使阀喷出。
To release pressure, loosen
only one turn. If the valve is
loosened too much, grease
under high pressure may
squirt out.
A820601990968
Fig. 2-15

13. Rotating belt hazard
●● Rotating belt is hazardous.
●● Stop the belt prior to maintenance.
STOP
A820699001017
Fig. 2-16
14. Possible to fall
●● There is the possibility of falling down.
●● Do not stand near the edges of the ma-

chine.
A820601990926
Fig. 2-17
15. No step
●● It is possible to fall. No step here.
A820601990973
Fig. 2-18

16. No sitting
注意 CAUTION
A820699001023
Fig. 2-19
17. Water separator draining instruction
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
18. Refrigerant change instruction
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 General Precautions

2.3.1 Safety rules
●● Only trained personnel are allowed to op-

erate and maintain the machine.
●● All safety rules, precautions and instruc-

tions must be followed when you perform
operation or maintenance on the machine.
●● If you are being affected by alcohol or drug,

your ability of safe operation or repair of
the machine would be severely impaired.
This could bring you and others on the site
under hazardous situation.
●● When you work with another operator or

a traffic signalman on the site, be sure to
make all persons on the site understand all
hand signals.
2.3.2 Abnormalities
In case of any abnormalities found during

operation and maintenance, such as noise,
vibration, odor, incorrect gauge reading, smok-
ing, or oil leaking, contact your Sany distributor
and take necessary measures. Never operate
the machine before the faults are corrected.

2.3.3 Personal protective equipment
WARNING
●● Never wear slack clothing and jewelry,

which may get caught by control levers
or other machine parts.
●● Long hair can be caught in moving
parts. Tie your hair if necessary to
avoid such hazard.
●● Always have your hard hat and safety
shoes on. Wear safety goggles, face
masks, gloves, hearing protection and
safety belt if necessary.
●● Make sure all PPEs are in good condi-
tion before use.
Wear proper work clothes and personal pro-

tective equipment (PPE) suitable for the envi-
ronment of the job site. You may need:
●● Hard hat
●● Safety shoes
●● Safety glasses, goggles or face shield
●● Protective gloves
●● Hearing protection CZ335-1102002
Fig. 2-21
●● Reflective protective clothing
●● Dust mask
Wear all necessary PPEs as well as other

equipment required by your employer, local
government, and local laws and regulations.
Never take a risk.

2.3.4 Fire extinguisher and first aid kit
To prevent injury or fire, observe the following

precautions:
●● First aid kit and fire extinguisher should be

available nearby.
●● Read and understand the instruction at-

tached to fire extinguisher. Use fire extin-
guisher properly.
●● Regular inspection and maintenance shall CZ335-1102003

be done to ensure proper functioning of fire
Fig. 2-22
extinguisher at any time.
●● Check the first aid kit regularly and replen-

ish it when necessary.
●● Make emergency scheme to deal with fire

and accidents.

2.3.5 Safety equipment
WARNING
●● Make sure all covers and caps are in

proper place. Repair or replace any of
them immediately once found damaged.
●● Know how to use these facilities and
use them correctly.
●● Never remove the guard rail of the op-
erator cab (unless necessary) .
To protect you and others around you, your

machine may be equipped with the following
safety equipment. Make sure that they are se-
cured in place and in good condition.
●● Falling object protective structure (FOPS)
●● Front guard
●● Lamps
●● Safety signs
●● Horn
●● Guards
●● Travel alarm
●● Mirrors
●● Fire extinguisher
●● First aid kit
●● Windshield wipers
Make sure the above equipment are opera-

tional. Never remove or disconnect any safety
equipment.

2.3.6 Cleaning your machine
NOTICE
●● If water has penetrated into the electri-

cal system, never rush to power on your
machine and start the engine, which can
cause machine failure or PC board dam-
age. Never flush the electrical system
(including sensors, connectors, etc.) with
water or steam.
●● Clean the windshields, mirrors and lights.

Make sure that the operating area, steps
and handholds are free from oil, grass,
snow, ice or mud, which can cause you
to slip and fall. Remove the mud on your
soles before getting on the machine.
●● If the machine is checked or serviced with

presence of mud or oil dirt, it may cause
you to slip or fall, or dirt may get into your
eyes. Keep the machine clean all the time. CZ335-1102005
Fig. 2-23
2.3.7 Keeping the cab clean
●● Clean the mud and oil on your soles when

getting into the cab. Mud or oil under your
shoes can cause your foot to slip on the
pedal during operation, and serious acci-
dent could result.
●● Remove all loose personal items or other

objects from the operator's area. Secure
these items in the tool box or remove them
from the machine.
●● Never use cellular phone when operating

or driving the machine.
●● Never bring Hazardous articles, such as

flammable or explosive products, into the
cab.

2.3.8 Engaging the hydraulic lockout

control
●● Before you rise from the operator seat

(e.g. to open or close the front window or
to adjust the seat), lower work equipment
to ground, place hydraulic lockout control
securely to the locked position, and then
stop the engine. If hydraulic lockout control
is unlocked, accidental touching of control
levers can cause sudden machine move-
ment and serious injury, or machine dam-
age could result.
CC13031805
Fig. 2-24
●● Before leaving your machine, always lower

work equipment to ground, place hydraulic
lockout control to the locked position, and
then shut down the engine. Lock all lock-
able components and remove ignition key.
CZ335-1102074
Fig. 2-25

2.3.9 Handholds and steps
WARNING
●● Always face the machine when you

mount or dismount the machine.
●● Never jump onto/off the machine. Never
mount a moving machine. Never jump
onto the machine and try to stop it.
●● When you enter and exit the operator
cab, make sure the cab is on the central
line of undercarriage.
To avoid personal injury caused by slippery

handholds or steps, observe the following in-
structions:
●● Before mounting and dismounting, check

the handholds and steps (including tracks)
for oil, grease or mud. Always keep them
clean. Make necessary repairs and tighten
loose bolts if any.
●● When mounting and dismounting the CZ335-1102008

machine, use the handholds and steps Fig. 2-26
marked by the arrows.
●● Face the machine and maintain a 3-point

contact with the handholds and steps (in-
cluding tracks) . A 3-point contact can be
both feet and one hand, or both hands and
one foot.
●● Never use any control lever as a handhold

when mounting or dismounting the ma-
chine.
●● Never carry tools when mounting or dis-

mounting the machine.
●● Never work on an engine hood or cover

with no non-slip mat on it.

2.3.10 Overhead work
When working on a overhead place, use a lad-

der or other support to ensure your safety.
2.3.11 No sitting on attachment
To avoid falling hazard, no one is allowed to sit

on work equipment or other machine attach-
ments.
2.3.12 Articulated parts
The space around work equipment changes

with movement of linkages. Serious personal
injury could result if one is stuck in between.
Never stay close to rotating or retracting/ex-
tending components.

2.3.13 Preventing burns
WARNING
●● The coolant and oil are still hot when

the engine has just been shut down. To
prevent burns, never proceed until they
are cool enough.
2.3.13.1 Hot coolant
●● To prevent burns caused by hot coolant or

steam when checking or discharging the
coolant, wait until the engine coolant is
cool enough before proceeding.
●● Never open the cap of radiator before the

engine cools down. Loosen the cap of the
radiator slowly before removing it. Internal
pressure of radiator must be relieved to
avoid serious burns.
CZ335-1102011
Fig. 2-27

2.3.13.2 Hot oil
●● To prevent scalds caused by hot oil when

checking or discharging the oil, always
wait for the engine oil to cool down before
you proceed. When the engine has cooled
down, loosen the cover or screw plug slow-
ly to relieve internal pressure.
CZ335-1102012
Fig. 2-28
CZ335-1102013
Fig. 2-29

2.3.14 Preventing fire and explosion
DANGER
●● Never smoke when handling the fuel or

maintaining the fuel system. The gases
in empty fuel tank can cause explosion
easily.
●● All flammable materials should be
moved to a safe place before carrying
out grinding or welding operation on
the chassis.
●● Never carry out flame-cutting or weld-
ing operation on fuel pipe, fuel tank or CZ335-1102015
fuel vessels, which can lead to fire, ex- Fig. 2-30

plosion, injury or death.
●● Then engine must be shut down and elec-

trical equipment must be switched off when
refueling the tank. Be extremely care-
ful when adding fuel to a hot engine. No
sparks shall occur around the grounding
nozzle.
●● Handle all solvents and dry chemicals in a

place with good ventilation according to the
steps indicated on vessel.
●● Clean the machine of all dust and residu-

als. Never place greasy rag or other flam-
mable materials on machine.
●● When cleaning the parts and components,

use nonflammable solvents instead of gas-
oline, diesel oil or other flammable fluids.
●● Store flammable liquids and materials in

suitable vessels as required by safety laws
and regulations.
●● Check fire extinguishers, fire-fighting sys-

tem and fire detectors (if equipment) and
make sure they are ready for use.

2.3.14.1 Fire caused by fuel or oils
●● Engine oil and fuel must be stored in des-

ignated place, where unauthorized persons
cannot enter.
●● Check for missing or loose pipe clamps,

twisted hoses, hoses rubbing against pipe-
line, damaged oil cooler, and loose bolts in
flange of oil cooler, so as avoid oil leakage.
Tighten, repair or replace any missing,
loose or damaged pipe clamps, pipelines,
hoses, oil coolers or other flange bolts.
●● Refuel or store oils in a place with good

ventilation.
CZ335-1102014
●● Shut down the engine before refueling. Fig. 2-31
●● Never leave the machine when refilling the

fuel or engine oil.
●● Never let fuel overflow onto overheated

surface or electrical components.
●● Remove overflowed fuel or engine oil after

refilling.
●● Store oily rags and any flammable materi-

als in protective containers in order to keep
the job site safe.
●● Screw on the caps of fuel tank and oil tank

tightly.
●● When oil is used to clean the parts, use

non-flammable oil. Never use diesel oil or
gasoline as they can easily catch on fire.

2.3.14.2 Fire caused by flammable materi-

als
●● Remove at any time dry leaves, wood

chips, paper pieces, dirt and other flamma-
ble materials built up or stuck on engine,
exhaust manifold, battery or interior of en-
gine hood to prevent fire.
2.3.14.3 Fire caused by electric lines
Short circuit of electrical system can cause

fire.
●● Keep electric terminals clean and fastened.
●● Check power cables and electric lines for

looseness, entanglement, hardening or
break each day after operating for 8-10
hours. Check the presence or damage of
wiring terminal cover.
●● In case of slack or entangled power cables

or electric wires, tighten the connections
or wire clips, and repair or replace broken
wires.
2.3.14.4 Fire caused by hydraulic lines
●● Check the clamps, guards and gaskets of

all hoses and pipes to see whether they
are tightened in position.
●● In case of loosening, their vibration in op-

eration may lead to friction against other
components, resulting damage of hose,
ejection of high-pressure oil, disastrous fire
or serious injury.

2.3.14.5 Fire caused by illumination equip-

ment
●● Anti-blast illumination equipment shall be

used to avoid explosion when fuel, oil,
electrolyte, window cleaning detergent or
cooling fluid is being checked.
●● Instructions in this manual must be fol-

lowed when power outlet on the machine
is used for illumination.
2.3.14.6 Fire caused by heat shield
●● Damage or missing of heat shield may

lead to fire.
●● In case of any abnormality, heat shield

must be repaired or replaced before opera-
tion of machine.
2.3.15 In the event of fire
When a fire breaks out, leave the machine im-

mediately by the following steps.
●● Turn the start switch to the OFF position to

shut down the engine.
●● Leave the machine with the help of hand-

holds and steps.
2.3.16 Windshield cleaning detergent
Use alcohol based detergent. Never use meth-

anol based detergent as it irritates eyes.

2.3.17 Preventing ejection of part
●● Never disassemble grease nozzle or valve

components. These parts may eject. Never
stay in front of the valve.
●● Travel reducer is under pressure.
●● Gear oil is hot liquid. Wait for it to cool

down before loosening the plug to release
pressure. To avoid injury, never face the CZ335-1102016
plug during operation. Fig. 2-32
WARNING
●● The grease in track tensioning device is

under high pressure. Improper handling
may result in serious injury, blindness
or death.

2.3.18 Falling object protection
When the machine is operated in places

where the cab is likely to be hit or invaded by
falling objects, scattered materials or foreign
bodies, protective structure shall be used to
protect the operator.
●● In demolishing or breaking operation, a

front guard is necessary. In addition, a
transparent glass film shall be applied to
the windshield.
CZ335-1102017
●● In a coal mine or a quarry where falling ob-
Fig. 2-33
jects are present, install falling object pro-
tective structure (FOPS) and front guard,
and apply a transparent glass film to the
windshield. The operator shall wear a hard
hat and goggles.
●● Keep the windshield shut in such condi-

tions and make sure other people are kept
a safe distance away from the operating
area.
●● Other guards may be necessary according

to different working conditions. In this case,
contact Sany distributor in advance.
2.3.19 Attachment installation
●● Installation of optional parts or attachments

may involve safety issues or be limited by
the law. In this case, contact your Sany
distributor in advance.
●● Sany assumes no responsibility for the in-

jury, accidents and product failure caused
by the use of unauthorized attachments
and parts.
●● Before installing and using machine attach-

ments, read related instructions regarding
the attachment and general precautions on
attachment in this manual.

2.3.20 Attachment combination
Different or combined work equipment may

collide with the cab or interfere with other
machine components. Before operating work
equipment you are not familiar with, check the
clearance between it and the machine and op-
erate it carefully.
2.3.21 Cab window glasses
●● Broken cab windows at the side of the

work equipment may expose the operator
in direct contact with the work equipment.
In this case, stop operation immediately
and replace the glasses.
●● Broken or damaged window provides no

protection to the operator. When the roof
window is damaged, replace it immediately
with a new one.
2.3.22 Unauthorized modification
Improper modification can affect machine

strength and operator's view. Contact your
Sany distributor before making any modifica-
tion. Sany assumes no responsibility for the
accidents, failure or damage caused by unau-
thorized modification.
WARNING
●● Any modification unauthorized by Sany

may lead to safety problems, personal
injury or death.

2.3.23 Work site investigation
●● Machine operation near flammable materi-

als (e.g. dry tree leaves) poses a fire haz-
ard. Be careful during operation.
●● Check the terrain and ground condition and

use the safest operating method. Never
operate in areas with the risk of landslide
or falling stones.
●● Solidify the ground when operating beside

a ditch or on road shoulders. Keep your CZ335-1102018
machine a safe distance away from the Fig. 2-34

ditch or road shoulder. Designate a signal
man, when necessary, to avoid accidental
injury.
●● When underground water mains, gas lines,

cables or high-voltage electric cables are
available on the job site, inform related
utilities providers and mark the area. Be
careful not to cut or damage any lines.
●● Prevent any unauthorized personnel from

entering the job site. Designate a signal
man and fence the job site when operating CZ335-1102019
your machine on a highway. Fig. 2-35
●● Be especially alert when operating on fro-

zen ground. Increase of ambient tempera-
ture may result in soft and slippery ground.
●● When traveling or operating in shallow wa-

ter or soft ground, check the type and con-
dition of rock bed as well as the depth and
water flow before operation.

2.3.24 Operation on soft ground
●● Avoid traveling or operating your machine

near cliffs, road shoulders or trenches. The
soft ground plus machine weight and vibra-
tion can cause your machine to sink or tip
over. The ground may become even softer
after heavy rain, explosion or earthquake.
●● When operating on a dam or near an exca-

vated ditch, vibration and machine weight
may trigger a landslide. Before operation,
take protective measures to prevent your
machine from tipping over or falling.

2.3.25 Overhead power cables
WARNING
●● Never drive or operate your machine

near power cables, which may bring
electrocution hazard and cause ma-
chine damage, personal injury or death.
The following steps are to be followed while

working at where power cables could be near-
by. CZ335-1102020
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)
●● If your machine is too close to power 6,600V Over 2 m ( 7 ft)

cable, electrocution is most likely to occur 22,000V Over 3 m ( 10 ft)
and cause burns or death. A safe distance 66,000V Over 4 m ( 14 ft)
must be kept between machine and power 154,000V Over 5 m ( 17 ft)
cable (See Table 2-1). Before operation,
187,000V Over 6 m ( 20 ft)
communicate with local power company
regarding safety measures. 275,000V Over 7 m ( 23 ft)
500,000V Over 12 m ( 36 ft)
●● A signalman is to be designated to give
Table 2-1
signals if your machine is too close to pow-
er cables.
●● Nobody is allowed to approach the ma-

chine when it is operated near high-voltage
cables.
●● If your machine is too close to the cable

or touches the cable, to prevent electrocu-
tion, operator shall not leave the cab until
machine power is surely cut off. In addi-
tion, Nobody is allowed to approach the
machine.
●● To prevent accidents, wear rubber shoes

and rubber gloves during operation. Cover
the operator’s seat with rubber sheet and
pay attention to exposed part of body that
should not touch the lower part of machine.

2.3.26 Ensuring a good view
This machine has rearview mirrors to improve

the view of operator. However, you cannot see
every places from the operator seat. So be
careful when you operate the machine.
When you operate the machine in a place

where renders you a poor view and you are
not sure of the working conditions and barriers
around the machine, damage or personal in-
jury could result. The following items must be
observed when you operate the machine in a
place that provides you a poor view.
CZ335-1103144
●● Check the rear view mirrors each day be- Fig. 2-37

fore working. Clean the mirrors and adjust
them to ensure a good view.
●● Turn on the work lamps and head lamps

when you work in a dim place. Auxiliary il-
lumination equipment may be required in
the working area when it is necessary.
●● Stop operation if you do not have a clear

view in days with fog, snow, rain or sand
storm.
●● Road shoulder or soft ground should be

marked. In case of poor view, designate
a signalman when necessary. The opera-
tor shall pay special attention to the marks
and follow the instruction of signalman.
●● Make sure all workers understand all sig-

nals and gestures before operation.

2.3.27 Ventilating enclosed area
Engine exhaust gas can be fatal. If you have

to start the engine in an enclosed space or
handle fuel, cleaning oil or paint in such a
place, open the doors and windows to ensure
sufficient ventilation in order to prevent gas
poisoning.
Never use this machine in an environment with

poisonous gas or under ground. If you have to
use the machine in such an environment, wear
a gas mask and ensure good ventilation. CZ335-1102022
2.3.28 Asbestos hazard Fig. 2-38
Inhalation of asbestos dust can cause lung

cancer. It is possible to inhale asbestos dust WARNING
when performing tear-down operation or han-
dling industrial wastes in the field. The follow- ●● No asbestos is used on this machine.
ing rules must be followed. But aftermarket parts could contain as-
bestos. Therefore, use only the parts
●● Use water, instead of compressed air, to and components supplied by Sany.
remove the dust.
●● If the air contains asbestos dust, operate

the machine following the wind. All persons
shall wear acceptable filter mask.
●● Nobody is allowed to approach the ma-

chine during operation.
●● The regulations, rules and environment cri-

terion at job site shall be observed.
2.3.29 Alternate exit
●● If you are unable to open the cab door in

case of emergency, use the safety hammer
to break the rear window to escape.
●● Remove the pieces of glass from the win-

dow frame before escaping. Be careful not
to be cut by broken glass. Pay attention to
the broken glass on the ground, which may A820601990969
cause you to slip and fall. Fig. 2-39

2.4 Operation Safety
2.4.1 Safe starting
2.4.1.1 Safe mounting
When you mount or dismount the machine:
●● Always face the machine and maintain a

three-point contact (one hand and two feet
or two hands and one foot).
●● Never jump on/off the machine. Never

mount a moving machine.
●● Never use any control lever as handhold.

CA13031506
●● Remove the mud, oil dirt and water from
the pedals, handholds and your soles at all Fig. 2-40
times.
●● The cab must be aligned with the under-

carriage centerline before you enter or exit
the cab.
2.4.1.2 Seat adjustment
Uncomfortable seat position can easily lead to

operator fatigue and mistakes. The seat posi-
tion should be adjusted upon change of opera-
tor. Leaning against the back of seat, operator
shall be able to push the pedal to its limit with
his foot, and operate the control lever properly.
Otherwise, the seat should be readjusted by
moving it forward or backward.
CZ335-1102026
Fig. 2-41

2.4.1.3 Seat belt
The operator may get seriously injured or

killed when the machine tips over. Before
operating the machine, carefully check your
seat belt, the buckles and the anchor point.
Replace the seat belt if damage or excessive
wear is observed. When the machine is being
operated, keep your seat belt buckled up.
The seat belt must be replaced every three

years regardless of its condition.
CZ335-1102027
Fig. 2-42
2.4.1.4 Before starting the engine
Before starting your daily work, the following

items must be observed before starting the
engine.
●● Clean the windows to ensure a good vis-

ibility.
●● Clean the head lamps and work lamps,

and check if they are in good condition.
●● Check coolant level, fuel level and engine

CZ335-1102028
oil level.
Fig. 2-43
●● Check the air cleaner for plugging.
●● Check electric wires for damage.
●● Adjust the seat to a position easy for op-

eration; check seat belt and buckles for
damage and wear.
●● Check the instrument panel. Check if the

control levers are all in neutral position.
●● Check if the hydraulic lockout control is in

the locked position.
●● Adjust the rear view mirrors so as to see

clearly from the operator seat what is hap-
pening behind the machine.

2.4.1.5 Safe starting
WARNING
●● Ample ventilation must be provided if

you have to start the engine or operate
the machine in an enclosed environ-
ment. Excessive inhalation of exhaust
gas can be fatal.
●● If you do not know how to stop the ma-
chine, never start it.
For correct starting steps of the machine see

“Engine Starting” on page 4-22.
●● Before starting the machine, make sure

there is nobody on, under and around the
machine. Hoot the horn as starting alert.
●● Sit in the operator seat and adjust the seat

so that you can access all controls easily.
●● Know all alarming devices, gauges and

maneuvering controls. CZ335-1102029
Fig. 2-44
●● Place all controls to the neutral/parking po-
sition.
●● Nobody else is allowed to stay on the ma-

chine except the operator.
●● The starting instruction specified in the

Operation section must be followed strictly
when you start the engine. Never try to
start the engine in a way that may short-
circuit the start motor.

2.4.1.6 Starting engine in cold season
●● Sufficient preheating of the engine is nec-

essary. If the machine is not preheated suf-
ficiently before operation, slow response
might occur to your machine and accident
could happen.
●● Before starting check the battery electro-

lyte to see if it is frozen or leaks. If the elec-
trolyte is frozen, do not charge the battery
or use an alternate power source to start
the engine. The electrolyte must be melted
first, or a frozen battery can cause fire.
2.4.1.7 Engine starting aid
Follow procedures in the Operation section

when using jumper cables to start the engine.
Improper handling may cause battery explo-
sion or loss of machine control, resulting in
personal injury and death. Never use jumper
cables to start the engine unless necessary.
Contact your Sany distributor before such an
attempt.
●● Using jumper cables to start the engine

needs two persons working together with
one seated in the operator seat and the
other handling the battery.
●● Wear goggles and rubber gloves before

starting the engine with jumper cables.
●● When connecting a normal machine with a

faulty machine with jumper cables, battery
voltage of the two machines shall be the
same. Be careful not to allow the two ma-
chines to contact with each other.
●● Turn both start switches to the OFF posi-

tion when connecting the two machines.
Otherwise, the machine may move and
cause danger when it is powered on.

●● Start with the positive terminal when con-

necting the jumper cable. Start with the
ground or negative terminal when discon-
necting the jump cable.
●● When disconnecting the jumper cable, take

care not to allow the clips of jumper cable
to contact with each other or with the ma-
chine.
Ether is a liquid used for cold start, which is

extremely flammable and explosive. Read
the instructions on the ether container be-
fore application.
Never use ether if the engine is equipped

with spark-plug preheater or other forms of
preheater.
2.4.1.8 After starting the engine
Run the engine at low idle for 3 to 5 minutes

after engine startup, and check the running
parameters and make sure they are normal
and all readings are within normal working
range.

2.4.2 Operation
2.4.2.1 Inspection before operation
NOTICE
●● Observe and listen carefully for abnor-

mal noise inside the machine. If fault or
abnormality exists, immediately stop
the machine. Solve the problem in no
time and report it to upper level before
further operation is performed.
●● When conducting inspection, move the

machine to a spacious area without barri-
ers and operate slowly. Any other person is
not allowed to approach the machine.
●● Be sure to buckle the seat belt.
●● Check the gauges and machine operation

for abnormality; check the bucket, arm,
boom, travel system, swivel system and
steering system for abnormal operation.
●● Check for abnormal noise, vibration, heat-

ing, odor or gauge reading; check oil or
fuel for leakage.
●● When the travel control lever is in neutral

position, test the engine's speed control
device; operate each control lever and
confirm they work properly. Understand the
control mode of work equipment.
●● In case of any abnormality, stop operation

and take corrective measures immediately.

2.4.2.2 Precautions before operation
To prevent serious injury or death, observe the

following precautions before operating your
machine.
●● It is dangerous to stay in the working range

(12 m radius from swivel center ) during 12
m
machine operation. Sound the horn to warn
people within the working range before op-
erating your machine.
CZ215S-1102003
●● Nobody is allowed to stay on or near the
machine, or within the working range. Fig. 2-45
●● To improve the view in travel direction, the

cab can be turned when necessary.
●● Designate a signalman at where the view

is poor.

2.4.2.3 Travel directions
WARNING
●● Improper operation of travel control

lever/pedal can cause serious injury or
death.
●● Confirm the relative positions between the

undercarriage and operator before operat-
ing the machine.
●● If the motor is under the cab, pushing the

control lever/pedal forward will move the
machine backward.
●● If the guide roller is under the cab, push

the control lever/pedal to move machine CZ335-1102031
forward.
Fig. 2-46
●● A sign for travel direction can be found on

internal side of undercarriage. When oper-
ator pushes control lever/pedal, the actual Front
travel direction is the direction indicated by
arrow.
Operator seat
Idler
NOTE: In this manual, the forward, backward, Left Right

left or right direct is the direction seen from the
cab when the cab is straight forward and the
driving wheels are in the rear. Sprocket
Back
CZ335-1102032
Fig. 2-47

2.4.2.4 Steering safety rules
●● You shall only operate the machine in the

operator seat.
●● Nobody is allowed to take a ride on the

machine except the operator.
●● Check travel alarm device to see if it func-

tions normally.
●● Always lock the cab door and windows

in open or shut positions. At where there
may be hazard of falling objects, check the
doors and windows of the machine to see
if they are properly shut.
●● Make sure there is nobody in the working

range and hoot to give alert before revers-
ing or swinging.
●● Keep alert at any time that nobody should

enter the working range. Be especially
careful to avoid crashing other machine or
person while turning or swinging the ma-
chine.
CZ335-1102030
Fig. 2-48
CZ335-1102034
Fig. 2-49

●● It is necessary to reposition your machine

before traveling so as to have the sprocket
(1) behind the operator seat. If the sprocket
is in front of the cab, machine will move in
direction opposite to the operating direction
of control lever(s). Be very careful when
operating the machine under such circum-
stances.
1
CZ335-1102035
Fig. 2-50
WARNING
●● During reverse or swivel operation,

people around the machine may get hit
by the counterweight or work equip-
ment, resulting in serious injury or even
death.
●● If your view is limited during reverse travel,

designate a signalman and keep him within
your eyesight.
●● When a signalman is required for a specific

job, hand signals specified in local regula-
tions must be used.
●● Only when both signalman and operator

understand the signals can the machine be
moved. CZ335-1102045
Fig. 2-51
●● Understand all vocal, graphic and flag
signals used in work and decide who is to
give signals.
●● Keep the windows, rear view mirrors and

work lamps clean and intact.
●● Dust, heavy rain or fog will reduce visibility.

Drive slowly and use proper lights in case
of low visibility.

2.4.2.5 Traveling safety rules
●● To prevent machine from stalling due to

overload or damage of work equipment,
never operate the machine over allowable
maximum load or performance parameters.
●● Keep your machine a safe distance from

people, building or other machines in order
to avoid collision during traveling or opera-
tion.
●● Communicate with related authorities and

follow their instruction before driving your
machine on highway.
20~30cm
(8~12i n)
●● It is to curl the work equipment and keep it
20-30 cm (8-12in) off ground when driving CZ335-1102036
your machine on a level ground.
Fig. 2-52
●● Driving your machine on rough ground

requires a low speed and no sharp turn,
or the machine may tip over. If the work
equipment clash ground, the machine may
lose balance or be damaged.
●● When traveling on rough ground or up a

steep slope, the auto-deceleration switch (if
equipped) shall be turned off. If auto decel-
eration switch is on, engine speed will drop
and travel speed will reduces.
●● Avoid traveling on any barrier if possible.

If you have to drive on a barrier, lower the
work equipment close to ground and drive
CZ335-1102037
at low speed.
Fig. 2-53
●● When you are to drive the machine on a
bridge or building, check first strength of
the structure to see if it is strong enough to
bear weight of the machine.
●● When you operate the machine in a tunnel,

under a bridge or power cables or at where
the height is limited, be especially careful
not to ruin any other object.

2.4.2.6 Safe traveling
WARNING
●● Driving the machine on a slope may

cause it to slip or tumble down, result-
ing in serious injury or death.
●● Check the travel direction of the machine

before driving it. Make sure you know how
to operate the control levers and pedals.
●● Press the upper part of the control pedal or

push the control lever forward to move the
machine in the direction of the idlers.
●● Work equipment should be kept 20-30 cm 20~30cm

(8~12i n)
(8-12 in) off the ground when moving on a
slope. In case of an emergency, the work CZ335-1102038
equipment could be lowered to ground im- Fig. 2-54
mediately to help stop the machine.
●● When driving the machine up a slope, face

the cab to the uphill direction; when driving
down a slope, face the cab to the downhill
direction.
●● Before traveling, always check the hard-

ness of ground before your machine.
CZ335-1102039
Fig. 2-55

●● When driving the machine up a slope, ex-

tend the work equipment to keep balance.
Keep the work equipment 20-30 cm (8-
12in) off the ground and drive the machine
slowly.
●● When driving down a slope, lower the en-

gine speed, keep the travel control levers
close to “neutral” position and drive slowly.
CZ335-1102040
Fig. 2-56
●● Drive straight up and down a steep slope.

It is very dangerous to turn on or drive
across a slope.
CZ335-1102041
Fig. 2-57
●● To adjust the position of the machine on a

slope, drive it onto a flat surface, reposi-
tion it and driving the machine to the slope
again.
●● Drive at low speed on meadow, fallen

leaves or wet steel plate because even a
small grade could cause the machine to
slip.
CZ335-1102042
●● If your engine stalls out when traveling on
a slope, place the control levers to “neutral” Fig. 2-58
position immediately and restart the en-
gine.

2.4.2.7 Operation on an incline
If you swing upper structure or operate work

equipment on an incline, you machine could
loose balance and tip over, causing serious
injury or damage. Therefore, such operations
must be performed carefully on a flat platform.
●● When the bucket is fully loaded, never turn

work equipment from uphill to downhill.
Such operation is dangerous and your ma-
chine could tip over.
CZ335-1102046
●● If you have to operate your machine on an
incline, always build an earth platform so Fig. 2-59
that your machine can work on a level sur-
face.
2.4.2.8 Operation in snowy weather
●● Snow-covered or frozen surfaces are slip-

pery. Never manipulate the control lever
suddenly when driving or operating the
machine. Extra attention should be paid to
operation on a slope because even small
inclination could cause the machine to slip.
●● The machine may tip over on frozen sur-

face which may become soft upon increase
of ambient temperature.
●● Avoid deep snow, which may cause your

machine to tip over or to be buried in
snow. Be noted that you shall never be
away from road shoulder and avoid being
trapped in snow.
●● When cleaning the snow, it is hard to see

the snow-covered road shoulder and ob-
jects near the road. There is danger for
your machine to tip over or hit the covered
objects. Therefore, please operate with ex-
treme caution.

2.4.2.9 Restricted operations
●● Never dig under an overhang, which may

lead to falling stones, collapse of overhang,
and accidents.
CZ335-1102047
Fig. 2-60
●● Never dig too much under the machine,

which may cause the ground to collapse
due to cave-in, hence the accidents.
CZ335-1102048
Fig. 2-61
●● Never tear down under your machine,

which may destabilize your machine and
cause it to tip over.
●● When operating on building or other

structures, strength of structure must be
checked to avoid collapse of building, thus
resulting injury or death.
CZ335-1102050
Fig. 2-62

●● Never tear down any structure over your

machine. The falling of broken objects or
collapse of building could damage your
machine and cause personal injury or
death.
CZ335-1102051
Fig. 2-63
●● Never break anything with the impact force

of work equipment as broken pieces could
lead to personal injury, the work equipment
could be damaged, and the counter-action
of impact force could roll over your ma-
chine.
●● Generally speaking, it is easier to tip over

with the work equipment at one side than it
is positioned in the front or rear.
CZ335-1102052
Fig. 2-64
●● 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.
●● Never use the work equipment to lift or car-

ry any person, which can cause personal
injury or death.
●● The use of crusher or other heavy work

equipment could cause your machine to
lose balance and tip over. When operating
on a flat surface or slope: CZ335-1102053
●● Never lower, swing or stop the work equip- Fig. 2-65

ment suddenly.
●● Never extend or retract the boom cylinder

suddenly as which may cause your ma-
chine to tip over due to impact.

2.4.3 Parking the machine
2.4.3.1 Selecting a parking place
●● Park your machine on a solid and flat sur-

face.
●● Park the machine in an ares free of such

hazards as falling stones or landslide. If the
terrain is low, park it in a relatively higher
place.
●● If you have to park the machine on a slope,

observe the following instructions:
CZ335-1102054
●● Position the bucket in the downhill di-
Fig. 2-66
rection and cut the bucket tips into the
earth.
●● Chock the tracks to prevent unexpected

movement.
●● Never park your machine on a road under-

120°
going construction. If you have to park your
machine in such a place, flags are to be
used on daytime and signal lamps at night
to warn other people or vehicles according
to local regulations.
CZ335-1102055
Fig. 2-67

2.4.3.2 Machine shutdown
Follow the procedures below to shut down the

machine. For details on shutting down the en-
gine see “Engine Shutdown” on page 4-27.
1. Stop the machine.
2. Position the machine properly.
3. Lower work equipment to ground or hold it

in a position.
4. Reduce engine speed to idle and keep it

running for 5 minutes. CZ335-1102074
Fig. 2-68
5. Turn start switch to the OFF position to
stop the engine.
6. Place hydraulic lockout control to the

locked position.
7. Remove the ignition key.
8. Shut the windows and the cab door.
9. Lock all access doors, boxes and cham-

bers.
NOTE:
●● Always face the machine and maintain a CZ335-1102028
three-point contact with it when dismount- Fig. 2-69

ing. Never jump off the machine.
●● Be careful with slippery track, step and

handholds when dismounting the machine.

2.4.4 Transportation
2.4.4.1 Transporting the machine
Observe the following items when transporting

the machine:
●● Note the dimension of the trailer and the

machine, especially the height. Watch out
for barriers overhead and in narrow pas-
sages.
●● Check the structure and strength of a

bridge before crossing it. Obey local traf-
fic regulations and traffic police directions
when transporting the machine on high-
ways.
2.4.4.2 Loading and unloading the machine
Improper loading and unloading of the ma-

chine may cause it to fall or tip over. Follow
the procedures below:
●● Load or unload the machine only on a solid

and flat surface. Keep it a safe distance
away from road sides or a cliff.
●● Use an access ramp with enough strength.

Make sure that the width, length and thick-
ness of the access ramp is capable of pro-
Space
viding a safe loading/unloading operation Maximum 15º
Blocks
(at an angle ≤15°).
●● Make sure the access ramp is free from CZ335-1102058

grease, oil, water and debris. Clean the
Fig. 2-70
track if necessary. Be extremely careful
when loading or unloading the machine in
rainy or snowy weather.
●● Never load or unload the machine using

the force of work equipment, which may
cause the machine to fall or tip over.

●● Disable auto deceleration function. Run the

engine at low idle and drive the machine
slowly.
●● Never operate any control levers other

than the travel control lever when the ma-
chine is driving up the ramp.
●● Never reposition the machine on the ac-

cess ramp. If necessary, drive it off the
CZ335-1102059
ramp, reposition, and get on the ramp
again. Fig. 2-71
●● Gravity center of the machine may alter

when it passes the jointing area between
the ramp and the trailer. The machine may
tilt at this moment. Travel slowly when the
machine is on the joint area.
●● When loading or unloading the machine on

a platform, make sure the platform has ad-
equate width, strength and a proper grade.
●● The trailer may become less stable with

CZ335-1102060
the machine on it. Retract the work equip-
ment and swing the upper structure slowly. Fig. 2-72
●● Once the machine is loaded, lock the cab

door. Otherwise, it may swing open during
transportation.
●● Secure the machine with chains and

chocks. Secure all work equipment, lower
the bucket, the arm and the boom, and
place them in position for transport.

2.4.5 Battery
WARNING
●● Electrolyte contains sulfuric acid, which

gives off flammable and explosive gas-
es. Improper handling may cause per-
sonal injury or fire.
Observe the instructions below when handling

battery:
●● Never smoke or use fire near a battery.
●● Turn the engine ignition key to the OFF po-

sition before working on the battery.
●● Wear safety glasses and rubber gloves

when handling battery.
CZ335-1102061
●● Electrolyte is a strong acid. If electrolyte Fig. 2-73
contacts your clothig or skin, flush immedi-
ately with plenty of water. Electrolyte may
cause blindness if it contacts your eyes.
Flush immediately with plenty of clean wa-
ter under such circumstances and seek
medical treatment.

To avoid battery-induced explosion, observe

the following precautions:
●● Never allow tools and other metal parts to

contact with battery terminals. Keep tools
or metal parts away from batteries.
●● Stop the engine and wait for one minute

before you proceed. Always disconnect the
grounding terminal (negative(-) ) first. To
connect battery cables, always begin with CZ335-1102062
the positive (+) terminal, and then connect Fig. 2-74

the negative (-) terminal. Ensure all termi-
nals are securely connected.
●● Battery temperature rises when it is be-

ing charged. When battery temperature
exceeds 45°C, stop charging and wait till
it is at ambient temperature. Reduce the
charging current by half and continue the
charging process.
●● A battery being charged may give off flam-

mable gases. Before charging a battery,
remove it from the undercarriage, put it in
well-ventilated area and remove the cap.
●● If acid squirts out of battery vent during

charging, stop charging immediately.
●● Never smoke and keep flames or sparks

out when charging.
●● When the battery has been fully charged, a

green indicator will be on. Stop the charg-
ing process at this time.
●● Restore the battery cover after charging.
●● Put the battery back to its original position.

2.4.6 Towing safety
WARNING
A
●● When towing a damaged machine, im-
proper operation or use of unaccept-
B
able wire cable could lead to serious
accident:
C
●● Never tow the machine on a slope.

CZ335-1102063
●● Wear protective gloves and a had hat
Fig. 2-75
when using wire ropes.
●● Check the strength of wire cable and make

sure it could bear the weight of machine.
●● Never use ropes with broken wires (A), re-

duced diameter (B) and twisting (C). Such
ropes may break when towing.
●● Never stand between the towing machine

and the towed machine during towing op-
eration.
●● Operate the machine slowly. Never add

load to the wire cable suddenly.

2.4.7 Lifting objects
WARNING
●● Overload is dangerous and can cause

serious injury and death.
●● Make sure the load is within the loading
range and working radius of the ma-
chine.
●● Nobody is allowed to enter the working CZ335-1102064
area. Fig. 2-76
●● Confirm all signals to be used and assign a

signalman before operation.
●● Lift a load on a flat surface to prevent the

machine from tilting or tipping over.
●● Never use chains, wire ropes, shackles

and slings that are damaged.
●● Anchor wire ropes or slings onto the desig-

nated lifting lug. Never attach the shackle
or sling onto the bucket tips. Loosened CZ335-1102065
bucket tips could cause the load to fall.

Fig. 2-77
●● Never leave the operator seat when lifting
is in progress.
●● To prevent the load from hitting any person

or building, inspect carefully the machine
surroundings before swinging or operating
the work equipment.
●● Never swing or operate the work equip-

ment suddenly. This may cause the load
to drift and the machine to tip over. Use a
drag rope if necessary. CZ335-1102066
●● Never use the work equipment or the Fig. 2-78

swing force to drag the load in any direc-
tion. The work equipment will jerk if the
shackle breaks and the load comes free,
resulting in serious personal injury.

2.5 Maintenance Safety

2.5.1 Precautions before maintenance
To prevent accidents:
●● Understand maintenance procedure before

operation.
●● Keep a clean and dry working area.
●● Never spray water or steam in the cab.
●● Never add lubricant and carry out other

maintenance work when your machine is
moving.
●● Keep your hands, feet and clothing away

from rotating parts.

2.5.2 Self-preparation
Only authorized personnel are allowed to

maintain or repair the machine. An observer
may be designated when necessary.
●● Wear protective clothing and shoes as re-

quired for the job.
●● Wear a face shield when you remove

spring or elastic parts, or adding acid to
battery. Wear safety hat and goggles when
you perform welding or cutting operation. CZ335-1102069
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.
●● When a hammer is used to strike a metal-

lic part such as pin, bucket tip, side cutter
or bearing, flying part or pieces can cause
injury. So wear goggles and gloves and
make sure there is nobody else around.
●● Never perform grinding, flame cutting or

welding operation without an aspirator and CZ335-1102071
ventilation equipment. If welding operation Fig. 2-80

has to be done on the machine, read relat-
ed instructions, and proper work procedure
must be known.
●● If noise of the machine is too loud, tempo-

rary or permanent hearing problem could
result. When you service the engine and
work in such noise for a long time, be sure
to wear earplugs or ear mufflers.
●● Wear rubber apron and rubber gloves

when handling corrosive materials. Wear
heavy gloves when handling wooden ma-
terials, wire ropes or sharp-edged metals.

2.5.3 Work area preparation
●● For maintenance work, select a clean flat

area with plenty of space, ample sunlight
and good ventilation.
●● Clean the working area by removing fuel,

lubricant and water, and covering slippery
ground with sand or other absorptive mate-
rials.
●● Never leave your hammer or other tools at

the working area.
●● If a clean, tidy working area cannot be

guaranteed, there would be danger of tip-
ping, thus resulting in personal injury.

2.5.4 Engine shutdown procedure
Before maintaining the machine:

1. Park the machine on solid and flat ground.
2. Lower the bucket to the ground.
3. Place blocks under the tracks to prevent

movement of the machine.
4. Turn the fuel control dial to first gear. Run

the engine at low speed for 5 minutes.
5. Turn the start switch to the OFF position

and stop the engine. CZ335-1102073
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.
7. Remove the key from the switch.
8. Place the hydraulic lockout control to the

locked position.
CZ335-1102074
Fig. 2-82

2.5.5 Lock out and tag out
●● Before maintenance, attach a DO NOT

OPERATE tag or similar sign to the ma-
chine start switch or control levers to warn
others that this machine is under mainte-
nance. Attach other warning tags around
the machine if necessary.
●● When maintenance is underway, starting

the engine or moving the control levers or
pedals could lead to serious accident.
CZ335-1102067
Fig. 2-83
CZ335-1102068
Fig. 2-84
2.5.6 Suitable tools
Use proper tools and use them correctly. Us-

ing damaged, inferior, defective, temporary
tools or using the tools incorrectly could lead
to serious accidents.
CZ335-1102072
Fig. 2-85

2.5.7 Maintenance with engine running
To prevent injury, no maintenance shall be car-

ried out when the engine is running. However,
if maintenance has to be done on a running
engine, at least two worker are needed to car-
ry out the maintenance.
●● One of the workers shall stay in the opera-

tor seat ready to shut down the engine at
any time. All the workers involved shall
keep in touch.
CZ335-1102028
●● Place the hydraulic lockout control to the
Fig. 2-86
locked position to prevent movement of
work equipment.
●● Pay special attention to rotating parts like

fan and fan belt.
●● Never leave or insert any tool or other ob-

jects in the fan or the fan belt, which may
cause the parts to break or fly.
●● Never touch any control lever. If one of the

control levers must be used, give signal
to other workers and warn them to move
quickly to a safe area. CZ335-1102077
Fig. 2-87

2.5.8 Working under the machine
WARNING
●● If the track shoes are lifted and the ma-

chine is solely supported by the work
equipment, it is very dangerous to work
under the machine. In case of failure
of hydraulic pipe or accidental touch
of control lever, the work equipment or
machine may fall suddenly, causing in-
jury or death. Never work under the ma-
chine if it is not firmly supported with
blocks or supports.
●● Never carry out maintenance before the

machine is well supported.
●● Lower the work equipment to the ground

before maintaining the machine.
●● If the machine or work equipment has to

be lifted for maintenance, blocks or sup-
ports that are strong enough to support
the machine or work equipment should be
used. Never use slag bricks, empty tires CZ335-1102078
or stands to support the machine. These Fig. 2-88

things may collapse under continuing load.
Never use single jack to support the ma-
chine.

2.5.9 Track maintenance
WARNING
●● Never strike the recoil springs of the

track. Recoil springs are under im-
mense pressure and spring rupture
may cause bodily injury. Never remove
any spring when it is compressed.
●● Dry rubbing of pin against bushing may

produces extreme heat. Wear protective
gloves to avoid burns.
●● Maintain proper track tension. When work-

ing on mud- or snow-covered ground, mud
or snow may attach to track components
and causes over tension. For track tension
inspection and adjustment see “Track ten-
sion - inspect/adjust” on page 5-27.
●● Check for loosened or broken track shoes.

Check the pins and bushings for wear or
damages. Check the track rollers and car-
rier roller.

2.5.10 Track tension adjustment precautions
WARNING
●● Failure to observe specified main-

tenance procedures may cause the
grease discharge plug to eject and
cause serious injury and damage.
●● Keep your face, hand, foot or any other
body part away from the grease dis-
charge plug.
●● Grease is injected into track tension adjust-

ment system under high pressure.
●● When loosening the grease discharge plug

(1) to reduce track tension, the plug shall
be unscrewed slowly for no more than one
turn.
1
CZ335-1102080
Fig. 2-89
2.5.11 Do not remove the recoil spring
Recoil spring is used to reduce impact on ten-

sion rollers. It includes a high pressure spring,
which may fly out and cause serious injury or
death if removed by mistake. If it has to be re-
moved, contact your Sany distributor.
CZ335-1102081
Fig. 2-90

2.5.12 Hot cooling system
WARNING
●● Touching hot high-pressure coolant

may cause serious injury.
When engine temperature rises, pressure of

the cooling system increases. Before remov-
ing the radiator cover, stop the engine and
let the system cool down. The radiator cover
could only be removed after the coolant in it
has cooled down.
CZ215L-1102001
Fig. 2-91
2.5.13 High-pressure hoses
If oil leaks from high-pressure hose, fault or

even fire may occur. If any bolt on hose is
loose, stop operation and tighten it to specified
torque. In case of hose damage, stop opera-
tion immediately and contact Sany HM autho-
rized dealer.
Replace the hose immediately in case of the

following problems:
●● Damage or leak of hydraulic hose fitting
●● Damage or break of outer cover, or ex-

posed steel wires of reinforcement layer
●● Ballooning outer cover in some places
●● Distortion or crushing of movable parts
●● Impurities in outer cover

2.5.14 Pressurized fluid
WARNING
●● Diesel oil or pressurized hydraulic oil

can penetrate skin or eyes, causing se-
rious injury, blindness or death.
●● Never touch leaking liquid with bare
hand. Wear face shield or safety gog-
gles to protect your eyes.
●● If any liquid penetrates your skin, flush
with clean water immediately and get
medical attention as soon as possible.
The hydraulic system is always under pres-

sure. Make sure pressure in hydraulic circuits
has been relieved before checking or replac-
ing the lines. Residual pressure in the circuit
may cause serious accidents.
●● Release system pressure before maintain-

ing the hydraulic system: 1) Remove the
butterfly nut of the vent valve and press the
venting key to release the internal pres-
sure of the hydraulic tank; 2) Turn the start
switch to ON position within 15 seconds
after engine shutdown and place the hy-
draulic lockout control to unlocked position.
Move the control levers to all directions to
release the pressure in the accumulator.
Open fire is not allowed around the hydrau-
lic system. Remove splashed hydraulic oil
as quickly as possible.
●● The fuel lines are under high pressure

when the engine is running. When check-
ing or servicing the fuel system, shut down CZ335-1102082
the engine and wait for 30 seconds till in- Fig. 2-92
ternal pressure drops before operation.
●● It is hard to find the leaking of hydraulic oil

with naked eyes. A cardboard or wooden
board is necessary for checking for leaks.

2.5.15 Welding operation
Welding operation can cause fire or electrocu-

tion. It must be performed by qualified welder
with suitable equipment. Never allow unquali-
fied person to perform welding operation.
2.5.16 Air-conditioning system
WARNING
●● Refrigerant R134 a is a harmless gas

under room temperature. It will change
into highly toxic gas when burning.
●● Refrigerant getting into eyes may cause
blindness. It may cause frostbite if
splashed on your skin.
●● Keep fire source away when servicing air-

conditioning system.
●● In maintenance of air-conditioning system,

observe the instruction on the refrigerant
cylinder and use it correctly. The type of
refrigerant is R134a. Use of other refriger-
ants may damage the air-conditioning sys-
tem.
●● Obey local material disposal regulations. CZ335-1102083

Never discharge refrigerant directly into the Fig. 2-93
air.

2.5.17 High voltage precautions
When the engine is running or has just been

shut down, high voltage can occur in fuel in-
jector terminal and engine controller. Since
there is danger of electrocution, never touch
fuel injector or interior of engine controller.
Please contact Sany distributor if you have to

access fuel injector terminal or interior of en-
gine controller.
CZ335-1102084
Fig. 2-94
2.5.18 Accumulator
Accumulator contains highly pressurized ni-

trogen. Improper operation of accumulator
can cause explosion and serious accidents.
Therefore, the following precautions must be
observed:
●● Never disassemble the accumulator.
●● Never let the accumulator be near a fire

source or exposed in flame.
CZ335-1102085
●● Never punch, weld or flame-cut on accu-
Fig. 2-95
mulator.
●● Never strike or roll the accumulator, or let it

bear any impact.
●● The gas must be released when disposing

of the accumulator. Contact Sany distribu-
tor for this disposal.

2.5.19 Regular replacement of safety-

related parts
●● Safety-related parts such as hoses and

seat belt must be replaced regularly for
the consideration of operating the machine
safely in a long term.
●● Materials of some parts may deteriorate

naturally when exceeding specific time
limit. Repeated use may lead to deteriora-
tion, wear and damage, hence the acci-
dents and serious injury. Through merely
visual inspection or feel it is hard to find out
how long the parts could serve. Therefore,
regular replacement is necessary.
●● Repair or replace any safety parts once

found defective regardless of its service
time.
2.5.20 Maintenance operation
●● Check all parts and replace the worn, bro-

ken and damaged parts during repairing
operation. Over-worn and over-damaged
parts may fail in operation and cause injury
and death. Replace damaged or illegible
signs and marks.
●● Tighten all fasteners and connectors to

specified torque.
●● Install all guards, covers and hoods after

repair and service. Replace or repair dam-
aged guards. Only the type of hydraulic oil
approved or recommended by Sany should
be used to make up the hydraulic system.
●● Start the engine and check for any leaks

(check the hydraulic system), and operate
all control devices to be sure of their prop-
er functioning. Make road test if necessary.
Shut down the engine and check the work
you have done (see if there are missing
pins, gaskets and nuts). Check again all
hydraulic oil levels before operation.

2.5.21 Proper disposal of wastes
Improper disposal of wastes harms the envi-

ronment and ecology. Consult local environ-
mental protection department or Sany dis-
tributors for methods of recycling and waste
disposal.
●● Potential harmful substances used in Sany

products include hydraulic oil, fuel, cooling
liquid, refrigerant, filter and batteries etc..
●● Use leak-proof vessels to hold discharged

CZ335-1102086
fluids. Never use food or beverage contain-
ers. Fig. 2-96
●● Never dump waste fluids directly to the

ground, sewage or water source.
●● Leaking of refrigerant from air conditioner

can spoil the atmosphere of the globe.
Related laws and regulations must be fol-
lowed to recover or regenerate the refriger-
ant.
CZ335-1102087
Fig. 2-97

SY500H-10 Crawler Hydraulic Excavator System Functions
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

System Functions SY500H-10 Crawler Hydraulic Excavator
3.2.2.23 Engine Failure Information................................................................. 3-23

3.2.2.24 Engine other information.................................................................... 3-23
3.2.2.25 Daily maintenance information........................................................... 3-24
3.2.2.26 System lockout information................................................................ 3-24
3.3 Switches................................................................................................................. 3-25
3.3.1 Start switch................................................................................................... 3-26
3.3.2 Fuel control dial............................................................................................ 3-27
3.3.3 Work lamp switch.......................................................................................... 3-27
3.3.4 Head lamp switch......................................................................................... 3-29
3.3.5 Windshield wiper switch................................................................................ 3-30
3.3.6 Washer switch............................................................................................... 3-31
3.3.7 Horn switch................................................................................................... 3-31
3.3.8 Cab lamp switch........................................................................................... 3-31
3.3.9 Cigarette lighter............................................................................................ 3-32
3.3.10 Preheat switch (If equipped)....................................................................... 3-32
3.3.11 Preheat indicator......................................................................................... 3-33
3.3.12 Charging indicator....................................................................................... 3-33
3.4 Control Levers and Pedals..................................................................................... 3-34
3.4.1 Hydraulic lockout control............................................................................... 3-35
3.4.2 Travel control levers...................................................................................... 3-36
3.4.3 Joysticks....................................................................................................... 3-37
3.5 Cab Windows and Cab Door ................................................................................. 3-39
3.5.1 Ceiling window.............................................................................................. 3-39
3.5.2 Front window................................................................................................ 3-40
3.5.3 Cab door window.......................................................................................... 3-47
3.6 Cup Holder............................................................................................................. 3-48
3.7 Ash Tray.................................................................................................................. 3-48
3.8 Manual Pocket........................................................................................................ 3-48
3.9 Drink Box................................................................................................................ 3-49
3.10 Alternate exit......................................................................................................... 3-49
3.11 Fire Extinguisher................................................................................................... 3-50
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


3 SYSTEM FUNCTIONS
3.1 Machine general drawing
4 5 6
1
7
8
9
10
CZ425-1103001
Fig. 3-1
(1) Bucket (6) Boom cylinder

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

3.2 Monitoring System
3.2.1 Monitor functions
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.
The monitor control panel performs functions

of monitoring, selecting a working mode and
switching on/off an electrical device.
C
Monitor appearance 15091601
The monitor consists of three parts: Fig. 3-2
A: Display area of SANY LOG
B: LCD screen
C: Operation keys

Screen display
3
When the excavator start switch is turned to 1

4
the on position, the monitor is energized by the
2 5
battery and initializes. A fully displayed screen
is as shown in the right figure, where in,
1. System time
6
2. Working mode (Divided by engine speed
level)
3. GPS information 7
8
4. Engine speed level (According to the 9 12
throttle knob psition) 10
11
5. Operation time
6. Fuel level gauge
7. Lock indicator (Lock countdown reminder) 13 14 15 16 17 15091602
8. Maintenance indicator and time
9. Fuel instaneous flow Fig. 3-3
10. Operate time of this time

11. Coolant temperature gauge
12. Malfunction alert and signal indicators
13. Video page
14. Auto deceleration
15. High/low travel speed
16. Icon for entering Failure Information
17. Icon for entering System Information
●● Coolant temperature gauge

A
There are 13 segments (yellow) indicating
a range from zero to 120°C.
A: When the engine is just started.
B: When the temperature is 0-110°C. B
C: when the temperature exceeds 110°C.

The last segment turns red and the alert
indicator is on at the same time.
When the temperature is back to normal C

level (under 110°C), the alert indicator will XP13031504
be off automatically. Fig. 3-4

●● Fuel level gauge
There are 13 segments (yellow) indicating

a range from zero to 100%.
A: When fuel level is under 8%, the seg-

ments disappear and the alert indicator is A
on at the same time.
B: When fuel level is above 8%, the alert

indicator is off.
C: When the fuel tank is full.

B
C XP13031503
Fig. 3-5
Operation keys
The operation keys include five function keys.
Function keys
The function keys include F1, F2, F3, F4 and

F5, as show by the figure. Function of each
key is defined by the icon above it.
●● A different icon defines different function of

a key.
●● When no icon is shown, the corresponding

key is undefined.

Common icons and corresponding keys are given in the following table:
Key Icon Function Monitor display
F1 Enter the video Page. ——
F2 Auto idle/non-idle shift Idle/non-idle
F3 High/low travel speed shift High/low
F4 Enter an option/setup. ——
View system information. ——

F5
Back to previous page. ——
Table 3-1

3.2.2 Monitor operation
3.2.2.1 Default page
The Default page is the normal operation dis-

play of the monitor.
Operation
1. Enter the Video Page
If the machine is equipped with a camera,

press F1 enter the Video Page.
2. Auto-idle and Non auto-idle mode
Press F2 to switch between auto-idle and

Non auto-idle mode. 15091603
When the icon above F2 shows , press

AUTO
n/min
the key to disable auto idle. When the icon

shows , press the key to enable auto
n/min
idle.
NOTE: Auto-idle mode is the default mode Fig. 3-6

after the machine is powered on.
●● Auto idle is on as default. When all controls

are in neutral position, engine speed will
drop by 100 rpm after 0.2 second and then
enter auto idle after another 3 seconds (as
the controller automatically changes en-
gine speed to idling) in order to save fuel
and reduce noise.
●● In auto idle, if the controller detects any

maneuver or gear position change, engine
speed will rise to corresponding level.

3. High and low travel speed
Press F3 to switch between high and low

travel speed.
When the icon above F3 shows , press

the key to select high travel speed. When
the icon shows , press the key to select
low travel speed.
NOTE: Default travel speed is Low after the

machine is powered on.
4. Failure Information
When the alert indicator is on, failure code

appears on bottom of monitor screen.
Above the key F4 you will see a red .
Press this key to view failure Information.
5. Main menu (5)
Press F5 view system information.
NOTE: Password is required to access system

information. You may contact local Sany dis-
tributor to get the password.

3.2.2.2 Main Menu
Press F5 on the default page of monitor to

enter Main Menu. This page contains a list of
system functions. You can select an item and
enter corresponding page.
Operation
●● F1 Selection function
●● F2 -
●● F3 Confirmation
●● F4 Access System Setting page
●● F5 Return to the default page
CB2016042501
Fig. 3-7
3.2.2.3 Main Menu Password entry to

system information
Choose “Running Iinformation” on the “Main

Menu”, Press F3 to call the password entry to
system information (After power-on, you only
should enter the correct passwords to access
at the first time).
Operation
●● Increase or decrease the number at the

F1
cursor.
●● F2 Move the cursor to the left or to the
right.
●● F3 Confirmation CB2016042502
●● F4 Access System Lockout page

Fig. 3-8

3.2.2.4 System Lockout
Operation
●● F1 Increase or decrease the number at the

cursor.
right.
●● F4 -
CB2016042503
Fig. 3-9
3.2.2.5 Engine & Throttle Signals
Select Running Information on the Main Menu

page to access Engine & Throttle Signals at
first.
Operation
●● F1 Enter Input & Output Switch Signals

query.
●● F2 Enter Pilot Pressure Signals.
CB2016042504
Fig. 3-10

3.2.2.6 Pilot Pressure Signals
Press F2 on the Engine & Throttle Signals

page or press F1 on the Main & Cooling Pump
Signals page to access Pilot Pressure Signals.
This page displays real-time pilot pressure

signals collected by the controller.
Operation
●● F1 Enter Engine & Throttle Signals.

●● F2 Enter Main & Cooling Pump Signals.
CB2016042505
Fig. 3-11
3.2.2.7 Main & Cooling Pump Signals
Press F2 on the Engine & Throttle Signals

page or press F1 on the Input & Output Switch
Signals page to access Main & Cooling Pump
Signals.
Operation
●● F1 Enter Pilot Pressure Signals.

●● F2 Enter Input & Output Switch Signals.
CB2016042506
Fig. 3-12

3.2.2.8 Input & Output Switch Signals
Press F2 on the Main & Cooling Pump Signals

page or press F1 on the Engine & Throttle
Signals page to access Input & Output Switch
Signals.
Operation
●● F1 Enter Main & Cooling Pump Signals.

●● F2 Enter Engine & Throttle Signals.
CB2016042507
Fig. 3-13
3.2.2.9 Failure information
Select Failure Information on the Main Menu to

enter and check failure code and information.
Operation
●● F1 Return to the previous page.

●● F2 -
●● F3 -
●● F4 -
●● F5 Return to Main Menu page
CB2016042508
Fig. 3-14

3.2.2.10 GPS Information
Select GPS Information on the Main Menu to

check GPS information.
Operation
●● F1 -
●● F2 -
●● F3 -
●● F4 -
CB2016042509
Fig. 3-15
3.2.2.11 Language Selection
Select Language Selection on the Main

Menu to enter Language Setting page, the
currently available languages are Chinse
and English.
Operation
●● F1 -
●● F2 Chinse
●● F3 English
●● F4 -
CB2016042510
Fig. 3-16

3.2.2.12 System Time Calibration
Select System Clock on the Main Menu to

enter System Time Calibration page.
Operation

cursor.
right
●● F4 -
NOTE: System clock can only be set up once CB2016042511

after the system is powered on. When the
machine is powered on and the F1 key is Fig. 3-17
pressed, you will only see the prompt of setup
result.
3.2.2.13 Maintenance Information
Select Maintenance Information on the

Main Menu to enter Maintenance Info.
page. Maintenance Information includes
maintenance items of every 50 & 250 & 500 &
1000 & 2000 service hours.
NOTE: Just enter operation when maintenance

is reminded.
Operation
●● F1 -
●● F2 -
●● F3 Enter maintenance code confirmation
CB2016042512
●● F4 Pause and open of maintenance items
cycle play
Fig. 3-18

3.2.2.14 Maintenance Confirmation
Press F3 on the Main Menu to access

Maintain Password page and input password
to confirm maintenance.
Operation
●● Increase or decrease the number at the

F1
cursor
●● F2Move the cursor to the left or to the
right
●● F3 Confirme maintenance
●● F4 -
CB2016042513
Fig. 3-20
3.2.2.15 System Setting
Press F4 on the Main Menu to access System

Setting page, Password is required to access
Operation Time Calibration. For method of
entering the password see Password Entry to
System Information.
Operation
●● F1 Selection
●● F2 -
●● F3 Confirme maintenance
●● F4 -
CB2016042514

3.2.2.16 Machine Configuration Setting
Select Machine Configuration on the

System Setting page to check the machine
configuration information.
●● F1 -
●● F2 -
●● F3 -
●● F4 -
CB2016042515
Fig. 3-21
3.2.2.17 Operation Time Calibration
Press Operating Hours on the System Setting

page to calibrate operating time. Password is
required to access Operation Time Calibration.
For method of entering the password see
Password Entry to System Information.

cursor
right
●● F4 -
●● F5 Return to System Setting page
CB2016042516
Fig. 3-22

3.2.2.18 Machine Configuration Setup
Select Machine Demarcration on the

System Setting page to calibrate machine
configuration information. Password is
required to access Machine Configuration
Setting. For method of entering the password
see Password Entry to System Information.
Operation
●● F1 Change Machine S/N

●● F2 Change engine model
●● Confirm and Return to System Setting
F3
page
●● F4 Change model of the hydraulic system CB2016042603
●● F5 Change controller model

Fig. 3-23

3.2.2.19 Alarm Content Setting
Select Alarm Contet on the System Setting

page to acess Alarm Content Setting page.
Operation
●● F1 Select setting item

●● F2 -
●● F3 Confirm setting item
●● F4 -
CB2016042517
Fig. 3-24
3.2.2.20 Screen Backlight Adjust
Select Screen Backlight on the System Setting

page to acess Alarm Content Adjust page.
Operation
●● F1 Enhance the backlight

●● F2 Dim the backlight
●● F4 -
CB2016042518
Fig. 3-25

3.2.2.21 Running Correct Setting
System set the second level password to

enter.
Operation
●● F1 Select setting item

●● F2 Increase the number at the cursor
●● F3 Decrease the number at the cursor
CB2016042519
Fig. 3-26
3.2.2.22 Engine Information
Display history fail and work times of engine.
Operation
●● F1 Display history fail and work times

●● F2 Enter the history fails query page
●● F3 Confirm sending request
●● Enter the engine other information
F4
page
CB2016042520
Fig. 3-27

3.2.2.23 Engine Failure Information
Display engine history fails.
Operation
●● F1 Enter the next page

●● F2 -
●● F3 -
●● F4 -
●● F5 Return to Engine Information page
CB2016042521
Fig. 3-28
3.2.2.24 Engine other information
Display engine related information.
Operation
●● F1 Enter basic engine information-4 page

●● F2 Enter basic engine information-2 page
●● F3 -
●● F4 -
CB2016042522
Fig. 3-29

3.2.2.25 Daily maintenance information
It pop up automatically when stars at first time

every day.
Operation
●● F1 -
●● F2 -
●● F3 -
●● F4 -
CB2016042523
Fig. 3-30
3.2.2.26 System lockout information
The excavator enters level system lockout

when receive lockout singals. Lockout singals
include two kinds system status of level 1 and
level 2.
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
(1) Start switch (6) Head lamp switch

(2) Fuel control dial (7) Horn switch
(3) Work lamp switch (8) Cab lamp switch
(4) Wiper switch (9) Cigarette lighter
(5) Washer switch (10) Indicator lights
*NOTE: Preheat switch is available on machines equipped with MITSUBISHI engines.

3.3.1 Start switch
The start switch is used to start or stop the en-

gine. There are four positions around the start
switch: HEAT, OFF, ON and START.
OFF position
This is the position for the insertion and re-

moval of the ignition key. When the key slot OFF ON
points to OFF position, all devices in the elec- E AT
H
trical system are power off. To stop the engine,
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
This is engine start position. To start the en-

gine, turn the ignition key to this position. Re-
lease the key once the engine is started, and it
returns to ON position automatically.
HEAT position
This is engine preheating position. Insert the

ignition key, turn and keep it at the HEAT posi-
tion to preheat the engine. It returns to OFF
position automatically once released, and pre-
heating process ends.
NOTE: For machines designed with a preheat

switch the engine may be heated in a different
way. The HEAT position on some models is
undefined. For more information see "Preheat
switch (If equipped)" on page 3-32.

3.3.2 Fuel control dial
The fuel control dial is used to adjust engine

speed and output power. Turn the dial clock-
wise to increase engine speed and counter- MA
clockwise to decrease engine speed. X
MIN
●● MIN position: Low idle speed
●● MAX position: Full speed
CC13031401
Fig. 3-34
3.3.3 Work lamp switch
The work lamp switch is used to turn on/off the

boom lamps and chassis lamp.
CC13040203
Fig. 3-35

Work lamp locations
Two work lamps on the boom
CZ335-1103040
Fig. 3-36
One work lamp on the right platform.
CZ335-1103041
Fig. 3-37

3.3.4 Head lamp switch
The head lamp switch is used to turn on/off

the lamps on top of the cab.
CC13040204
Fig. 3-38
Head lamp locations
CZ335-1103047
Fig. 3-39

3.3.5 Windshield wiper switch
NOTICE
●● When you are going to use the wiper,

press the washer switch to eject some
detergent in order to prevent damaging
the wiper due to friction.
When it is raining or when the front window is

dirty, you can press the switch to activate the
windshield wiper.
CC13040205
Fig. 3-40
Operating range
CZ335-1103044
Fig. 3-41

3.3.6 Washer switch
NOTICE
●● Make sure the front window of cab is

closed before you press this switch.
Press this switch to spray cleaning detergent

onto the windshield. Depress the switch to
continue spraying detergent.
It returns to its original position automatically

once released, and spray of detergent stops. CC13040206
Fig. 3-42
3.3.7 Horn switch
The horn switch is located on top of the right

joystick. Press the button to sound the horn.
With the button depressed, the horn keeps

hooting.
CC13040209
Fig. 3-43
3.3.8 Cab lamp switch
The cab lamp is installed inside the cab. Move

the toggle-switch up and down to turn on and
off the cab lamp.
a
Position (a) - ON
Position (b) - OFF

b
NOTE: The cab lamp can be turned on when

the start switch is in the OFF position.
CC13041501-2
Fig. 3-44

3.3.9 Cigarette lighter
A cigarette lighter is installed in the cab for op-

erators who smoke.
To light a cigarette, push the lighter inward

first. Take it out of the socket when it springs
back after a few seconds and light a cigarette.
24V
When the lighter removed, its socket can
serve as a 240W (24V×10A) power source.
NOTE: The cigarette lighter is 24V. Do not use CC13041502

it to power 12V devices.
Fig. 3-45
3.3.10 Preheat switch (If equipped)
Preheat switch is designed on machines

equipped with MITSUBISHI engines.
This switch is used in combination with the en-

gine start switch.
●● Press the preheat switch and turn the start

switch to the HEAT position to start pre-
heating process.
●● Preheating continues when the start key is CC13040208
hold at the HEAT position. Fig. 3-46
●● Release the start key, and it will return to

the OFF position and engine preheating
stops.
●● Turn off the preheat switch.
NOTE: Time needed for preheating may vary

according to ambient temperature. Do not heat
the engine for more than 30 seconds.
Fore more information, see "Engine Preheat-

ing" on page 4-25.

3.3.11 Preheat indicator
Preheating indicator (1) lights up when ambi-

ent temperature is low and engine preheating
is in progress. It goes out when preheating
process is over.
3.3.12 Charging indicator
The battery charging indicator (2) lights up 2 1

when the ignition key is turned to ON position.
CC13040211-2
It goes out when the engine is started and the
alternator is working. Check the alternator if Fig. 3-47
the indicator is on all the time.

3.4 Control Levers and Pedals
2
4
CC13040210-2
Fig. 3-48
(1) Hydraulic lockout control (3) Left joystick

(2) Travel control (4) Right joystick

3.4.1 Hydraulic lockout control
WARNING
●● When leaving the operator cab, always

place the hydraulic lockout control to
●● If the hydraulic lockout control lever is
not placed in the locked position, inad-
vertent touching of any of the control
levers may cause serious injury or even
death.
●● When moving the hydraulic lockout
control lever, be careful not to touch the
joysticks.
The hydraulic lockout control is used to lock

the work equipment controls, swing and travel
systems and the attachment (if equipped).
●● Locked position ( ): Push the lever down-

ward to apply the lock. With the lockout
control in the locked position, the machine
will not move when the joysticks are oper-
ated.
●● Unlocked position ( ): When the lockout CC13031504

control is at unlocked position, the machine Fig. 3-49
will move as you operate the joysticks.
The lockout control is hydraulic. When it is en-

gaged, the machine will not move even if you
maneuver the control levers or pedals.
When all control levers are neutralized and

the lockout control is place in the unlocked
position, any movement of any part of your
machine is indicative of an error on the ma-
chine. In this case, place the lockout control to
the locked position immediately, and stop the
engine. Contact your Sany distributor in this CC13030402
regard. Fig. 3-50

3.4.2 Travel control levers
WARNING
●● Accidental touching of the travel con-

trol pedals during machine operation
may cause the machine to move sud-
denly, resulting in serious accidents.
●● Keep your feet off the pedal unless you
are moving the machine.
The travel control levers and pedals are used

a
to control the movement of the undercarriage
and the travel direction of the machine. N
a
a. Forward travel:
b
Push the control lever forward. N
(The pedal tilts forward)

b a
b. Backward travel: a
b
Pull the control lever backward.
b
(The pedal tilts backward)
N - (Neutral Position): The machine stops.

CZ335-1103054
NOTE: Confirm the position of sprockets be-
fore maneuvering the control levers or pedals. Fig. 3-51
Make sure the sprockets are in the rear of
machine. If the sprockets are in the front, the
machine will move backward when you push
the control levers.

3.4.3 Joysticks
WARNING
●● Never expose any part of your body

outside the window. If a joystick is
moved unexpectedly, you could be in-
jured by the boom. If the window glass
is missing or broken, install a new one
or replace it immediately.
●● To prevent injury caused by unexpected
movement of the machine, you aught
to know the positions and functions of
both joysticks before operation.
Hereunder is an example of SAE mode. For

more information see "Work Equipment Con-
trol" on page 4-35. 3
1
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

Right Joystick Control

5 Forward Boom down 8
5
6 Backward Boom up
7 Left Bucket in 6
7
8 Right Bucket out
Table 3-3
●● Moving a joystick diagonally can perform

two functions at the same time.
CC13031506
Fig. 3-54
NOTE:
●● When the travel controls and the joysticks

are neutralized, engine speed drops to a
moderate level even if the fuel control dial
is set at a higher speed. Engine speed 5
rises to previous level set by the fuel con-
trol dial when any of the control levers is 7 8
moved.
6
●● If all the control levers are placed in neutral
position, the engine speed will decrease by
about 100 rpm. After about 4 seconds, the
engine will fall to the speed (about 1,400 CZ335-1103058
rpm) set by auto-deceleration. Fig. 3-55
●● Releasing the control lever or joystick, it re-

turns to the neutral position automatically.
Machine function stops.

3.5 Cab Windows and Cab Door
3.5.1 Ceiling window
WARNING
●● Place the hydraulic lockout control to

the locked position before standing
up from the operator seat. When the
hydraulic lockout control is unlocked,
serious accidents may result if the joy-
sticks are operated by mistake.
Open
1. Secure the hydraulic lockout control to the

locked position.
CC13031403
Fig. 3-56
2. Push upward the locks (2) at both sides of

grip (1). Hold the grip (1) and push upward
the ceiling window. 2 2
Close
1. Hold grip (1) and pull downward the ceiling

window. The locks (2) will be engaged
automatically. CZ335-1103060
Fig. 3-57
2. If the locks are not engaged properly, open
the ceiling window and try again.

3.5.2 Front window

●● The front window can be stored (pulled up)
in roof of the cab.
●● Before you open or close the front window,

park your machine on a level ground, lower
the work equipment to ground, and shut
down the engine.
●● To open the front window, hold the hand-

holds tightly with both hands and pull the
window upward. Do not let it go before the
latch is in position.
●● When you are closing the window, it may

fall quickly under weight. So hold the hand-
holds tightly with both hands when you
close the window.
WARNING
●● Move the hydraulic lockout control to

the locked position when opening or
closing the front window.
●● Serious accidents may result if the joy-
sticks are operated by mistake when
the hydraulic lockout control is un-
locked.
●● Do not raise or lower the front window
when the machine is on a slope.
Raising the front window
1. Park your machine on a level ground,

lower the work equipment to the ground,
and stop the engine.

locked position.
CC13031403
Fig. 3-58

4. Check that the wiper blade is stored in the

right bracket.
CZ335-1103062
Fig. 3-59
3. Hold the left and right hand grips (1) and

pull the two levers (2) to release the locks
on top of the front window.
1 1
CZ335-1103063
Fig. 3-60
2
1
CZ335-1103064
Fig. 3-61

5. Hold the lower hand hold (3) with your left

hand and the upper hand hold (4) with your
right hand, and push the window upward.
Continue to push the window toward
4
the latch (5) in the rear of the cab till it is
locked securely.
CZ335-1103065
Fig. 3-62
CZ335-1103067
Fig. 3-63
CZ335-1103066
Fig. 3-64

6. Check the lever (2), which shall be secured

in the locked position.
●● Check the arrow on the catch (6), which 6

shall be aligned with the arrow on lever (2).
The lock is engaged.
●● If the arrow on the catch (6) is not aligned 2

with the arrow on lever (2), the lock is not
engaged. Repeat step 5 to engage the
lock. CZ335-1103068
Fig. 3-65

Lowering the front window
CAUTION
●● Close the front window slowly and do

not get your hand caught by the win-
dow.
●● When closing the front window, hold
the hand grips and allow the windshield
to drop under its own weight.
1. Park your machine on a level ground,

lower the work equipment to the ground,
and stop the engine.

locked position.
CC13031403
Fig. 3-66
3. Hold the left and right hand grips (1) and

pull the lever (2) downward to release the
lock.
CZ335-1103069
Fig. 3-67

4. Hold the lower hand hold (3) with your left

hand and upper hand hold (4) with your
right hand, push the window forward and
lower the window slowly.
3
CZ335-1103070
Fig. 3-68
CZ135B-1103009
Fig. 3-69
5. When the bottom of the windshield meets

the top of bottom window, push the top of
7
the front window to engage both the left
and right latches (7) of the locks.
CZ335-1103072
Fig. 3-70

6. Check the lever (2), which shall be secured

in the locked position.
●● Check the arrow on the catch (6), which 6

shall be aligned with the arrow on lever (2).
The lock is engaged.
●● If the arrow on the catch (6) is not aligned 2

with the arrow on lever (2), the lock is not
engaged. Repeat step 5 to engage the
lock. CZ335-1103068
Fig. 3-71
Removing bottom front window
1. Raise the front window.
2. Hold hand grips and pull to remove the

bottom glass of the front window.
CZ335-1103077
Fig. 3-72
●● Removal of the bottom glass may be diffi-

cult if sand or dust if built up at the bottom.
The sand or dust may be brought into the
cab along with the glass when storing the
glass. To avoid this, the area (A) shall be
cleaned before removing the bottom glass.
CZ335-1103078
Fig. 3-73

3.5.3 Cab door window
Opening
1. Disengage the latch.
2. Pull the front half backward or push the

rear half forward.
CZ335-1103079
Fig. 3-74
Closing
1. Push the front half forward or pull the rear

half backward.
2. Make sure the latch is properly engaged.

3.6 Cup Holder
A cup holder is designed and installed below

the machine monitor.
0-13004
Fig. 3-75
3.7 Ash Tray
●● This tray is located above the cigarette
lighter.
●● Make sure that the cigarette has been

extinguished before closing the ash tray
cover.
0-13007
Fig. 3-76
3.8 Manual Pocket
●● The pocket is on the back of the operator
seat.
●● The operation manual of the machine can

be stored in this pocket for reference when
necessary.
CZ335-1103090
Fig. 3-77

3.9 Drink Box

●● The box is located to the rear right of op-
erator seat. It is used to keep your drink
warm in winter and cool in summer.
●● Cool or warm air is blown into the box as

per the setting of air conditioner.
0-13005
Fig. 3-78
3.10 Alternate exit
If you are unable to open the cab door in case

of emergency, you can use the rear window as
an alternate exit.
●● For cabs equipped with a safety hammer,

you can use the hammer to break the rear
window. The safety hammer is stored in
the cab on the left side of the rear window.
CZ215-1103029
Fig. 3-79
●● For rear windows designed with a pull ring,

you can pull the ring to tear off the rubber
seal and push the window with force so as
to let it fall outside.
NOTE: The rear window is only used as alter-

Pull ring
nate exit in case of emergency.
CC13050801

3.11 Fire Extinguisher
NOTICE
●● Read the instruction label on the extin-

guisher and understand how to use it in
case of emergency.
●● Inspect the fire extinguisher periodical-
ly and make sure it is in good condition.
●● Replace the fire extinguisher if it has
expired.
A fire extinguisher is installed at the rear of the CZ215-1103044
operator cab. Fig. 3-81
3.12 Controller
Be careful not to get the controller contami-
nated by water, mud or juice, which can cause
controller failure.
Do not disassemble the controller in case of

any failure. Contact your Sany distributor to fix
it.
CB13041001-1
Fig. 3-80

3.13 Fusible Link

If the start motor fails to start when the start
switch is turned to the ON position, there may
be a broken circuit in the fusible links. Open
the fuse box behind the operator seat and
check the fusible links.
NOTE:
●● Fusible link (as shown) is the fuse installed

on electric circuit. It is used to prevent
burning of electrical components and CC13032901
wires. Fig. 3-82
●● There are 5A, 10A, 15A and 20A fusible

links that are identified with different colors.
Always replace a fusible link with one of
the same specification.
●● Always turn of the start switch before re-

placing a fusible link.

3.14 Air Conditioning System

3.14.1 Control panel
1 2 3 4 5
FULL AUTO AIRCONDITIONER
6 7 8
CZ205-1203020G
Fig. 3-83
(1) OFF switch (5) AUTO switch

(2) Fan control switch (6) Air circulation mode switch
(3) TEMP switch (7) LCD panel
(4) MODE switch (8) A/C switch
1. OFF switch
This switch is used to stop the fan and the air-

conditioner.
When the OFF switch is pressed, the tempera-

ture and air flow displayed on the LCD panel
disappear, and the indicators above the AUTO
switch and the A/C switch go out, and the op-
OFF
eration stops.
CZ335-1103094
Fig. 3-84

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

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

LCD panel.
●● Press to increase the air flow.

●● Press to decrease the air flow.
●● The air flow changes automatically in the
automatic control mode. CZ335-1103095
LCD panel and air flow volume Fig. 3-85
LCD display Air flow volume

Low flow
Moderate flow -1
Moderate flow - 2
Moderate flow - 3
Moderate flow - 4
High flow
Table 3-4
3. TEMP switch
This switch is used to set the temperature in-

side the operator cab.
The temperature can be set between 18°C

(64.4°F) and 32°C (89.6°F).
●● Press to increase temperature.

●● Press to decrease temperature.
●● The temperature is generally set at 25°C CZ335-1103096
(77°F).
Fig. 3-86
LCD display and function
LCD display Set Temperature

18.0 (°C) Maximum cooling
Adjust temperature inside opera-
18.5~31.5 (°C)
tor cab to selected temperature
32.0 (°C) Maximum heating
Table 3-5

4. MODE switch
This switch is used to select air outlet mode.
●● When this switch is pressed, the LCD pan-

el will display the selected air outlet mode
and air will blow out from the selected
outlet(s). MODE
●● Air outlet is regulated automatically in au-
tomatic control mode.
CZ335-1103225
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
Defrost ○ Disabled in auto mode
Table 3-6
NOTE: Air comes out of the outlet identified with ○.

Air outlet locations
Rear air outlets (1)
They are located generally behind the opera-

tor seat. 1 1
0-13010-1
Fig. 3-88
Front air outlet (2)
Defrosting air outlet (3)

F1 F2 F3 F4 F5
Esc
Enter
24V
3 2
0-13011-1
Fig. 3-89
Bottom air outlet (4)
NOTE:
●● The number and design of the air outlet(s)

may vary depending on machine models.
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
This switch is used to set air flow, outlets and

fresh air or circulation automatically according
to the preset temperature.
●● Press the AUTO switch and the indicator

above it will light up. AUTO
●● Press the AUTO switch and press the
TEMP switch to set a suitable temperature,
and the air conditioner will run automati- CZ335-1103101
cally. Fig. 3-91
●● When manual control mode, instead of

auto mode, is selected, air flow, air outlet
mode and circulation mode will have to be
set manually with the switches. The indica-
tor above the AUTO switch goes out.
NOTE: Under automatic control mode, the air

flow may remain at HIGH if the temperature is
set at 18 °C (64.4°F) or 32 °C (89.6°F). This is
not a fault.
6. Air circulation mode switch
This switch is used to switch between fresh air

intake and air recirculation mode.
●● After the switch is pressed, the indicator

above the switch lights up to indicate that
fresh air is being taken in.
●● Fresh air intake and recirculation modes CZ335-1103102
toggle automatically in automatic control. Fig. 3-92
Fresh air inlet is closed and air

recirculates inside the cab.
Air recirculation
Quick heating/Quick cooling
When external air is not clean
Take fresh air into the cab.
Fresh air intake Take in clean air
Defrosting
Table 3-7

7. LCD display
LCD display shows preset temperature (1), air

flow (2) and air outlet mode (3) during opera-
tion. 3
●● When the OFF switch is pressed, the LCD

display goes off and the A/C operation 1
stops.
2
CZ335-1103103
Fig. 3-93
8. A/C switch
This switch is used to activate and deactivate

air conditioner operation (heating, defrosting
and cooling).
●● When the fan is working (LCD displays

(b)), press the A/C switch to activate the air A/C
conditioner. The indicator above it will light
up. Press this switch again to deactivate
the air conditioner. The indicator goes out.
CZ335-1103104
●● The air conditioner is disabled when the Fig. 3-94

fan is switched off (air flow symbol on the
LCD disappears).

3.14.2 Operation method
Automatic control
1. Press the AUTO switch.
●● When the AUTO switch is pressed, the LCD

panel displays the temperature (1) and 3
air flow (2). The indicators above the AUTO
switch and the A/C switch will light up.
2. Use the TEMP

switch to set a desired tem- 1
perature.
2
●● Under automatic control mode, the air con-

ditioner adjusts air flow volume, air outlet CZ335-1103103
mode and air circulation mode automati-
Fig. 3-95
cally according to the preset temperature.
NOTE: When air outlet is in Front-Rear-Bot-

tom mode (4) or Bottom mode (5), and engine
4 5
coolant temperature is low, the air flow will be
restricted to prevent cool air from blowing out.
Stop AUTO operation
●● Press the OFF switch to stop automatic op-

eration.
CZ335-1103107
Fig. 3-96

Manual control
1. Press the switch to adjust air flow.

Check the temperature (1) and air flow (2)
displayed on the LCD display. 3
2. Press the A/C switch.
1
3. Press the switch to set the internal
TEMP
temperature of the operator cab. 2
4. Press the MODE switch to select an air outlet

mode. The selected mode is displayed at CZ335-1103103
(3) on the LCD panel. Fig. 3-97
5. Press the or switch to select the

recirculation or fresh air intake mode.
Stop manual operation
Press the OFF switch to stop the manual op-

eration.
Bi-level mode
In order to direct cooling air to your face and

warm air to your feet, observe the following
procedures:
1. Press the switch to adjust the air flow.

Check the temperature and air flow dis-
played on the LCD display.
2. Press the MODE switch and select the Front-

Rear-Bottom outlet mode.
CZ335-1103226
3. Press the A/C switch. Fig. 3-98
4. Press the switch, the switch and the

TEMP
or switch to set these features as

desired.

Defrosting operation
1. Press the switch to set air flow volume.

Check the temperature (1) and air flow (2)
displayed on the LCD panel. 3
CZ335-1103103
Fig. 3-99
2. Press the MODE switch and select the Defrost

mode (6) or Defrost-Bottom mode (7).
6 7
3. Press the switch and select fresh air
intake.
4. Press the switch and set the tempera-

TEMP
ture on the LCD panel to maximum (32°C).
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.

3.14.3 Air conditioner operation pre-

cautions
●● When running the air conditioning system,

always start with the engine running at a
low speed. Avoid starting the air condi-
tioner when the engine is running at a high
speed, or possible damage to the air con-
ditioner may result .
●● If water should get on control panel or sun-

light sensor, an unexpected failure may
result. Always keep these components
clear and free from water. In addition, keep
these components away from naked flame.
●● For the auto function of the air conditioner

to work properly, always keep the sunlight
sensor clean and free from debris, or it will
influence the function of sunlight sensor.
Ventilation
●● When the air conditioner has been oper-

ating for hours, the "fresh air/recircula-
tion mode" shall be switched to "fresh air
mode" every hour for ventilation.
●● If you smoke when air conditioner is run-

ning, the smoke may hurt your eyes. In
this case, the "fresh air/recirculation mode"
shall be switched to "fresh air mode" in
order to eliminate the smoke through con-
tinuous cooling.
Temperature control
●● When the compressor is working, set the

temperature (5 or 6°C (9 or 10.8°F) above
outdoor temperature) that just makes you
feel cool after entering the cab. This tem-
perature difference is considered as the
most healthy temperature. Therefore, the
temperature shall be adjusted properly.

Inspection and maintenance of air condi-

tioned machine
●● When you check and maintain a machine

equipped with an air conditioner, perform
this job according to the chart provided.
For more information see "Refrigerant
level - check" on page 5-38.
●● When the air conditioner has not been

used for a long time, it is necessary to of-
ten run the engine at low speed and con-
duct cooling, dehumidifying and heating
operations for several minutes in order to
prevent loss of oil film on each component.
●● The air conditioner will not work if the in-

ternal temperature of cab is low. You can
circulate fresh air into the cab so as to in-
crease the temperature. Switch on the air
conditioner again to make it work.
●● If a device or sensor used on the air con-

ditioner is detected abnormal, contact your
Sany distributor to check and repair it.

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

ST
AM
FM
H M ADJ - +
7 8 9 10
CZ335-1103111
Fig. 3-101
(1) Power switch (6) Preset buttons

(2) Sound effect selector (SEL) (7) LCD display
(3) TIME button (8) Tuning buttons
(4) FM/AM selector (9) Time adjustment buttons
(5) AS/PS button (10) Volume control
Power switch (1)
●● Press to turn on the radio. The frequency is shown on the LCD display (7). Press this
switch again to turn off the radio.
SEL (sound effect selector) (2)
●● Press the button to select a sound effect from VOL (volume), BAS (bass), TRE (treble)
SEL
and BAL (balance). Sound effect is displayed on the LCD panel.
●● The LCD returns to frequency display when no operation is done within 5 seconds.
TIME button (3)
●● 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.

●● Keep the button pressed for more than

TIME
5 seconds to display the region code. (ASA

and EU)
FM/AM selector (4)
Press the FM/AM

button to switch between FM
and AM.
AS/PS button (5)
The button is used for automatic scanning

AS/PS
of saved radio stations and automatic search-

ing of radio stations.
●● Automatic scanning:
Turn on the radio and press the button. AS/PS
The radio starts automatic scanning of the

previously saved radio stations. Each of
the preset stations is tuned in for 10 sec-
onds, with the number of the radio station
displayed on the LCD.
To tune in one of the save stations, press

the button.
AS/PS
●● Automatic searching of radio stations:
Turn on the radio and press the AS/PS
button for 2 seconds. The radio starts an

automatic searching of radio stations within
the present wave band. The first 6 radio
stations with good reception are saved in
the radio memory.
Preset stations (6)
●● Press any of the 6 preset station buttons to

tune in one of the preset station.
●● This function is available only when there

are saved radio stations in the radio mem-
ory.

LCD display (7)
Wave band, radio frequency, preset numbers

and time are displayed on the LCD display.
TUNING buttons (8)
Press and to decrease and increase ra-

dio frequency on the LCD display.
TIME ADJ (time adjustment) buttons
Radio time is reset using the time adjustment

buttons: H , M and ADJ .
H : Hour adjustment
M : Minute adjustment
ADJ : Set to zero.
VOL (volume control)
●● VOL buttons (10) are used to control radio

volume.
●● Press to raise radio volume up to 40.
●● Press to lower radio volume up to 0.
●● The LCD returns to frequency display

when no operation is done within 5 sec-
onds.

3.15.2 Operation
Presetting radio station
1. Press to turn on the radio. Radio fre-

quency is displayed on the LCD (7).
6 2 1
2. Press or to locate the desired
frequency. There are two tuning ways:
PRESET STATION SANY
1 2 3 4 5 6 AS/PS AM/FM TIME SEL
manual and automatic. ST TUNING TIME ADJ VOL

AM
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
back when the presetting operation (storing Fig. 3-102

to the memory) is completed. The preset
button number and the frequency will be
displayed, indicating the completion of
presetting operation. After presetting the
stations, press one of the preset buttons (6)
for at least 1.5 seconds in order to tune in
the preset station.
NOTE: The button can be used to preset

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

quency is displayed the LCD (7).
2. Press or to locate the desired fre-

quency. There are two tuning ways: manual
and automatic.
Manual tuning
Press the tuning buttons (8) till the frequency

appears on the display (7).
: Decrease radio frequency
: Increase radio frequency
When the frequency reaches its maximum or

minimum limit, it will cycle in the order of max-
min or min -max.

Automatic tuning
Depress one of the tuning buttons (8) will ac-

tivate automatic scanning of radio stations.
When any station is found, the tuning stops.
To scan next station, depress one of the tuning
buttons (8) again.
: Decrease radio frequency
: Increase radio frequency
If this button is pressed during automatic tun-

ing, automatic tuning will be cancelled. The
setting returns to the previous frequency be-
fore the button is pressed.
Sound effect adjustment
●● BAS: Press the button and select BAS.

SEL
Within 5 seconds, press or to adjust

BAS value between +7 and -7.
●● TRE: Press the button and select TRE.

SEL

TRE value between +7 and -7.
●● BAL: Press the button and select BAL.

SEL

BAL value between L9 and R9. BAL.0
means that the left and right sound track
are balanced.
NOTE: Sound effect mode returns to show

previous setting if no operation is done within
5 seconds.

Radio time adjustment
1. Press the button (3) to display radio

TIME
time on the LCD. The display will return to

3
radio frequency after 5 seconds.
PRESET STATION SANY
2. When radio time is displayed on the LCD, 1 2 3 4 5 6 AS/PS AM/FM TIME SEL
press H or M to select Hour or Minute. AM

ST TUNING TIME ADJ VOL
FM
H M ADJ - +
H : Hour adjustment
9
(Hour goes up by 1 with each press)
M : Minute adjustment CZ335-1103113
(Minute goes up by 1 with each press) Fig. 3-103

Keep H or M pressed, Hour or Minute will
keep going till the button is released.
ADJ is used for precision adjustment:
●● Press ADJ when Minute reading is between

00 and 05 to decrease Minute to zero.
(Hour reading does not change)
●● Press ADJ when Minute reading is between

55 and 59 to increase Minute to zero. (Hour
reading increases by 1)
●● When Minute reading is between 06 and

54, neither Hour nor Minute reading chang-
es when ADJ is pressed.
Example:
10:05→10:00
10:59→11:00
10:26→10:26

Antenna
To prevent interference, fold the antenna be-

fore you move the machine into an building.
Fold the antenna through the following steps:
1. Loosen the antenna-holding screw (1) to 1

fold it into the position (A).
A
2. Tighten the screw (1) after folding the

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.
●● Water penetration may cause dysfunction

of the loud speaker and the radio. Be care-
ful not to splash water on the radio.
●● Do not use benzol, diluent or other solvent

to clean the control panel and the buttons.
Soft dry cloth shall be used for cleaning. If
the device is too dirty, wipe it with alcohol-
soaked cloth.
●● Preset stations and radio time setup will be

cleared when the battery is disconnected.
Radio setting need to be done once again.

3.16 Cab door catch
CAUTION
●● Park the machine on a level ground be-

fore releasing the cab door catch.
●● Do not release the door catch when the
machine is on a slope. The door may
shut suddenly and cause injury.
●● Do not expose your body or hand out
of the cab or put your hand on the door
frame before releasing the door catch.
The door may shut suddenly and cause
injury.
Fasten the door to the door catch after open-

ing it.
1. Move the cab door toward catch (1) until it

engages with the catch.
2. When closing the door, press lever (2) to 1

the left of the operator seat to release the
catch (1).
2
CZ335-1103082
Fig. 3-105
3.17 Lockable Caps and Covers
The filler caps of the fuel tank, the cab door,

the engine hood and the access covers of the
machine are all lockable. Use the engine igni-
tion key to lock and unlock these places.
●● Always insert the key to its shoulder (A).
●● The key may break if it is turned before

fully inserted.
A
CZ335-1103083
Fig. 3-106

3.17.1 Lockable caps
NOTICE
●● Make sure the key slot is covered after

removing the key. Otherwise, invasion
of foreign objects may block or even
disable the lock.
●● Lock the filler cap after is has been fully
screwed on; otherwise, the lock may be
damaged.
●● Always keep the sealing in the filler cap
clean. Metal chips or sands on the seal-
ing may cause fuel leakage.
Unlocking
1. Slide off cover (1) to expose the key slot.

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

B
cap to unlock the cap (2).
A
Position (A): Unlock
Position (B): Lock

CZ215-1103001
Fig. 3-107
Locking
1. Screw on the cap (2) tightly and insert the 1

ignition key into the key slot.
2. Turn the key to locked position (B), and

then remove the key.
B
3. Slide cover (1) onto the key slot.
A
CZ215-1103002
Fig. 3-108

3.17.2 Lockable covers
Unlocking
1. Insert the ignition key into the key slot.

A
2. Turn the key counterclockwise to unlock
the cover and open it by the handle.
Position (A): Unlock
Position (B): Lock
Locking
B
1. Shut the cover properly and insert the key.
CZ335-1103085
2. Turn the key clockwise to position (B) and Fig. 3-109

remove the key.
3.18 Toolbox
Store tools in this box.
CZ205-1203022G
Fig. 3-110

SY500H-10 Crawler Hydraulic Excavator Operation
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

Operation SY500H-10 Crawler Hydraulic Excavator
4.5.1 Direction change when the machine is stopped .......................................... 4-32

4.5.2 Pivot turning.................................................................................................. 4-34
4.6 Selecting a Working Mode...................................................................................... 4-34
4.7 Work Equipment Control......................................................................................... 4-35
4.8 Restricted Operations............................................................................................. 4-37
4.8.1 Operation with swinging force....................................................................... 4-37
4.8.2 Operation with traveling force....................................................................... 4-37
4.8.3 Operation when hydraulic cylinder reaches its stroke end .......................... 4-38
4.8.4 Operation with bucket landing force............................................................. 4-38
4.8.5 Hard rocky ground ....................................................................................... 4-38
4.8.6 Operation with machine weight..................................................................... 4-39
4.8.7 Sudden shift of control levers/ pedals .......................................................... 4-39
4.9 Permissible depth of water..................................................................................... 4-40
4.10 Traveling on a Slope............................................................................................. 4-41
4.10.1 Traveling downhill ...................................................................................... 4-42
4.10.2 When engine stalls on a slope.................................................................... 4-42
4.10.3 Cab door on a slope................................................................................... 4-42
4.11 Escaping from Mud............................................................................................... 4-43
4.11.1 When one track is trapped.......................................................................... 4-43
4.11.2 When both tracks are trapped..................................................................... 4-43
4.12 Recommended Application................................................................................... 4-44
4.12.1 Backhoe operation...................................................................................... 4-44
4.12.2 Trenching work........................................................................................... 4-45
4.12.3 Loading operation....................................................................................... 4-45
4.13 Parking................................................................................................................. 4-46
4.14 Inspection after Each Workday............................................................................. 4-48
4.15 Locking................................................................................................................. 4-49
4.16 Operation in Cold Weather................................................................................... 4-50
4.16.1 Fuel and lubricant....................................................................................... 4-50
4.16.2 Coolant....................................................................................................... 4-50
4.16.3 Battery........................................................................................................ 4-51
4.16.4 After each workday..................................................................................... 4-51
4.16.5 After cold season........................................................................................ 4-52
4.17 Long-Term Storage............................................................................................... 4-53
4.17.1 Before storage............................................................................................ 4-53
4.17.2 During storage............................................................................................ 4-54
4.17.3 After storage............................................................................................... 4-55
4.17.4 Engine startup after long-term storage....................................................... 4-55

4.18 Transportation Information.................................................................................... 4-56

4.18.1 Transport methods...................................................................................... 4-56
4.18.2 Loading and unloading............................................................................... 4-57
4.18.2.1 Loading.............................................................................................. 4-58
4.18.2.2 Securing the machine........................................................................ 4-61
4.18.2.3 Unloading........................................................................................... 4-63
4.18.2.4 Lifting the machine............................................................................. 4-65


4 OPERATION
4.1 Before Starting the Engine
4.1.1 Walk-around inspection
WARNING
●● Remove flammable materials on the

battery, engine, muffler, turbocharger
and other components that heat up dur-
ing machine operation.
●● The leak of oil or fuel may cause the
machine to catch on fire.
Check and clean the following items each day

before starting the engine:
1. Check the work equipment, cylinders, arms

and hoses for cracks, excessive wear or
loosening. Check the O-ring between the
bucket and the arm for damage. Repair or
replace it in case of any problem.
2. Remove the dirt and debris around the

engine, battery and radiator.
Check the surrounding of engine and

radiator for buildup of dirt. Check the sur-
rounding of muffler, turbo charger or other
hot components for flammable materials
like dry leaves and thin branches. Remove
them if any dirt or flammable materials are
found.
For method of removing dirt from radia-

tor, see "Radiator and oil cooler fins -
inspect/clean" on page 5-65.
Check for any leaks of coolant or oil

around the engine.
Check the engine for leak of oil. Check the

cooling system for leak of coolant. Repair it

in case of any problem.
3. Check the hydraulic unit, hydraulic tank,

hoses and joints for any leaks of oil.
Check for oil leaks. Repair the leaks if any.
4. Check the undercarriage (track, sprockets,

tension rollers and guards) for damage,
wear, loose bolts or roller leakage.
Correct the problem if any.
5. Check the handholds and step for any

problem like loose bolts.
Repair it in case of any problem. Tighten

the loose bolts.
6. Check the gauges and monitor.
Check the gauges and monitor in operator

compartment. Change the parts or compo-
nents in case of any problem. Clean their
surfaces.
7. Clean and check rear mirrors
Clean and check the rear mirrors for any

damage. Repair it in case of any damage.
Clean the mirrors and adjust their positions
so that the area behind the machine could
be seen clearly from operator’s seat.
8. Check the safety belt and holds for dam-

age or wear. Replace it with a new one in
case of any damage.
9. Check the bucket with hook (if equipped)

for any damage.
10. Check the hoisting hook, guide plate and

hook seat for any damage. Contact Sany
distributor for repair in case of any prob-
lem.

4.1.2 Inspection before starting
The items in this section must be checked ev-

ery day before starting the engine.
4.1.2.1 Water and sediment in fuel tank -

drain
1. Open the access door on the right side of

the machine.
2. Place a vessel under drain hose to contain

drained fuel.
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
4. When clean fuel is seen, close the drain Fig. 4-1

valve (2).
5. Close the access door.

4.1.2.2 Water and sediment in water sepa-

rator - check/drain
1. Open the access cover on the right side of

the machine.
2. Check water level and volume of sediment

through the transparent cover (1). If water
or sediment is built up at the bottom, place
a container under drain hose (3) to receive
drainage.
3. Open drain valve (2) to discharge water.

CB20160512003
4. Close drain valve (2) once fuel is seen
coming out of drain hose (3). Fig. 4-2
NOTE:
●● If cover (2) is dirty and opaque, clean it

when replacing fuel filter element (1).
●● When the drain valve (3) has been re-

moved during cleaning, its O-ring (4) must
be greased and the valve must be tight-
ened till it contacts the bottom.
4
CC13040702
Fig. 4-3

4.1.2.3 Hydraulic oil level - check/refill
CAUTION
●● 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.
●● Before removing the filler cap, turn it
slowly to release internal pressure.
1. Adjust the work equipment to the position

shown in the right illustration. Stop the CC13041001-1
engine. Fig. 4-4
2. Operate the joysticks and travel control

levers in all directions 15 seconds after
engine shutdown to release internal pres-
sure. 1
3. Open the access door on the right side to

check the oil level gauge (2). 2
Before operation: level between H and L 3

(Oil temperature: 10~30°C or 50~86°F)
After operation: level close to H

(Oil temperature: 55~80°C or 131~176°F) CZ335-1103126
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.
NOTE: Do not add oil to a level above the H

mark. If the oil level is above the H mark, stop H
the engine and wait for the oil to cool down.
Place a container under the drain plug (3) be-
neath the hydraulic tank and discharge exces-
sive oil from the tank via the drain plug.
L
CZ335-1103127
Fig. 4-6

4.1.2.4 Coolant level - check/refill
CAUTION
●● The coolant is hot and the radiator is

under high pressure upon shutdown of
the engine. Removing the radiator cap
(1) at the moment may cause burns. Do
1
not remove the cap until coolant tem-
perature has dropped. Turn the filler
cap slowly to release internal pressure.
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).
3. Tighten the cap after refilling the tank.
4. An empty reserve tank (2) might be caused 0-13014
by coolant leakage. Correct the fault im- Fig. 4-8

mediately after inspection. If no problem
has been found, check coolant level in the
radiator. Add coolant to reserve tank (2) if
its level is low.
5. If reserve tank (2) is dirty inside and the

level cannot be seen clearly, clean the
tank. For more information, see "Cooling
system interior - clean" on page 5-84.

4.1.2.5 Oil level in oil pan - check/add
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.
1. Open the engine hood.

1
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
4. Oil level should be between the H and

L marks on dipstick (2). Add oil through
opening (1) if oil level is below the L mark.
Recommended oil: Caltex CH-4 15W-40
5. If oil level is above H mark, the drain valve L H

(3) on the bottom of oil pan is to be opened
to discharge extra oil. Check oil level
CZ335-1103131
again.
Fig. 4-10
6. Tighten the filler opening cap and properly
close the engine hood if oil level is normal.
NOTE:
●● If you need to check oil level after opera-

tion of the engine, shut off the engine and
wait at least for 15 minutes before check-
ing.
●● If your machine is on a slope, move it to a

level ground prior to inspection. 3
CZ335S-1103057
Fig. 4-11

4.1.2.6 Electric wires - check
NOTICE
●● If fuses blow frequently or any short

circuits are detected in the system, in-
vestigate the cause and make repairs,
or contact your Sany distributor.
●● Keep battery surface clean and check
the vent on battery cover. Flush the
cover to clean the vent if the vent is
blocked by dirt or dust.
Check whether the fuse is damaged; whether

the fuse with proper capacity is used; whether
any wire connection is off; whether wire sheath
is broken.
Check for loose terminals. Fix it if any.
Moreover, pay special attention to electric

wires when checking battery, engine, start
motor and alternator. Make sure to check for
flammable materials around battery. Immedi-
ately remove them if any.
4.1.2.7 Fuel level - Check and add
WARNING
●● Be careful not to splash fuel on the tank

when filling the fuel tank to reduce fire
risk.
●● Clean splashed fuel completely if any.
Remove contaminated earth or sand if
fuel flows onto the ground.
●● Fuel is flammable and dangerous. No
open fire is allowed in the vicinity of
fuel.
E F
1. Turn the engine start switch to ON position
and check the fuel level on the monitor
screen. Turn the switch to OFF position CZ215-1303002
after checking. Fig. 4-12

2. When fuel level is low, remove the fuel tank

cap (1) and fill the tank till the float meter (2)
reaches the highest point. 1
●● When fuel level is below 10%, alarm on the

monitor will sound.
CZ335-1103134
Fig. 4-13
NOTE:
●● Pressure in the fuel tank may drop if the

vent hole (3) on the cap is blocked, which
may hinder the flow of fuel. Clean the vent 3
whenever necessary.
●● Lock the filler cap after is has been fully

screwed on; otherwise, the lock may be
damaged.
●● Always keep the sealing in the filler cap

clean. Metal chips or sands on the sealing
CZ335-1103136
may cause fuel leakage.
Fig. 4-14

4.1.2.8 Work lamp switches - check
Check the work lamps for normal functioning.
Check for any dirt or damage.
If any lamp does not work, the bulb may be

burned or broken circuit may be present.
Please contact Sany distributor for repair.
1. Turn the start switch to ON position.
2. Switch on the work lamp switch and check CC13040203

if the lamps light up. Fig. 4-15
4.1.2.9 Horn - check
2. The horn sounds immediately when the

horn button is pressed. Make sure that the
horn sounds normally. In case of dead horn
or abnormal sound, please contact Sany
distributor for repair.
CC13040209
Fig. 4-16

4.1.3 Adjustment before operation
4.1.3.1 Operator seat adjustment
It is necessary to adjust seat position before D

operating or after changing operator.
Adjust the seat so as to enable the operator

to easily manipulate the control levers, pedals
and switches from the seat.
(A) Forward and backward adjustment

E
Pull the lever (1) upward, slide the seat to

desired position, and release the lever. A
Adjusting length: 200mm (10mm per step) C
(B) Adjust the seat forward and backward

as a whole
Pull the lever (2), slide the seat to desired 1

position, and release the lever. In this case,
the operator seat moves along with both 3 2 4
armrest boxes and pilot lockout control.
B CZ335-1103139
(C) Suspension adjustment (if equipped) Fig. 4-17
Turning the lever (3) counterclockwise will

bring you a hard suspension which is suit-
able for heavy operator; turning the lever (3)
clockwise will bring you a soft suspension
which is suitable for light operator.
NOTE: To achieve the best adjustment, adjust

the reading (kg) on dial (4) to weight of opera-
tor.

(D) Backrest adjustment
Lift lever (5), move the backrest to an

optimum position at where operation can
be easily conducted, and release the lever.
Do not allow the backrest to interfere with

the cover plate of air conditioner behind it. 5
Be careful with the control levers, which
shall not be touched by armrest.
CZ335-1103140
Fig. 4-18
(E) Armrest angle adjustment
6
Turning the plate (7) beneath armrest (6)
can adjust the angle of armrest to desired
position.
The armrest can be placed vertically so

7
that the operator can leave the seat easily.
Adjustable angle: 40°
CC13031516
Fig. 4-19

4.1.3.2 Rear view mirrors
CAUTION
B A
●● Adjust the rear view mirrors before

operation. Failure to do so may cause
poor visibility, resulting in personal in-
jury.
Rear mirror (A)
Adjust installation of rear mirror (A) so that

people to rear left of machine can be seen
clearly. CZ335-1103238
Fig. 4-20
●● Install rear mirror (A) to the position as
shown in the right illustration.
●● Turn the rod (1) around rod (4) to a suit-

2
able position and fix rod (1).
1
●● When adjusting mirror angle, if the mirror

cannot move smoothly, you may loosen
3
bolt (2) and bolt (3) to release the mirror.
Torque of bolt (2): 4

CZ335-1103143
Fig. 4-21
4.0~5.4 N·m (0.41~0.55 kgf·m)
●● Adjustment of rear mirror is accomplished

when side of machine can be seen in the
mirror, as shown in the right illustration.
CZ335-1103144
Fig. 4-22

Rear mirror (B)
Adjust installation of rear mirror (B) so that 5

people to rear right of machine can be seen
clearly. 6
M
●● Install rear mirror (B) to the position as

shown in the right illustration. CZ335-1103145
Fig. 4-23
M: 120 mm
●● When adjusting mirror angle, if the mirror

cannot move smoothly, you may loosen
bolt (5) and bolt (6) to release the mirror.
Torque of bolt (5): 4.0~5.4 N·m
(0.41~0.55 kgf·m)
●● Adjustment of rear mirror is accomplished

when side of machine can be seen in the
CZ335-1103146
mirror, as shown in the right illustration.
Fig. 4-24

4.1.3.3 Seat belt
WARNING
●● Check the condition of the seat belt and

the buckle before you fasten it. Replace
the belt if excessive wear or damage is
observed.
●● Replace the seat belt every 3 years re-
gardless of its condition.
●● Be sure to fasten your seat belt during
machine operation.
●● Do not twist the seat belt.
Buckle up and release
The seal belt has a coiler, and belt length

needs no adjustment.
1. Buckle up
4 3 2 1
Hold clip (2) and pull the belt out of coiler
(1). Check that there is no twist on the belt
and insert catch (3) into buckle (4).
SS
PRE
Check if the belt has been fastened by

pulling it slightly. CZ335-1103147
Fig. 4-25
2. Release
Press button on buckle (4) to release catch

(3). The belt will retract into the coiler
automatically.
Hold clip (2) so that the belt retract slowly

into the coiler.

4.1.4 Operation before engine startup
WARNING
●● Before starting the engine, check if the

hydraulic lockout control is secured in
●● If the hydraulic lockout control is not in
the locked position, accidental touch-
ing of control lever or pedal when start-
ing the engine may lead to unexpected
movement of machine, which may
cause serious accidents.
●● When rising from the operator seat,
make sure the hydraulic lockout control
is in the locked position, whether the
engine is running or not.
1. Check if the hydraulic lockout control is in

2. Check if all control levers and pedals

are neutralized. They shall remain in
NEUTRAL position if not operated.
CC13031403
Fig. 4-26
ON
OFF
STA
T
HEA
RT
CC13031804
Fig. 4-27

4. Check the condition of the machine

through the gauges on the monitor display.
●● When a fault arises, the alarm indicator will

light up.
●● If a fault code is displayed on the monitor,

check the fault immediately.
●● If no fault code appears, the alarm indica-

tor may light up because:
coolant temperature is too high; or
engine oil pressure is too high or too low.

4.2 Engine Starting
WARNING
●● Only start the engine from the operator

seat.
●● Never start the engine by shorting the
starter circuit, which may cause serious
injury or fire.
●● Sound the horn and start the engine
after confirming that the machine sur-
roundings are clear of personnel or ob-
stacles.
●● Never use any aerosol starting aid,
which may cause an explosion.
●● Exhaust gas is poisonous. Provide ad-
equate ventilation when starting the en-
gine in a confined space.
●● Before starting the engine, check if the fuel

control dial is in MIN position for low idling
speed. If it is in MAX position, starting the
START X
engine can lead to sudden acceleration MA
ON
and machine damage.
OFF
●● Do not hold the ignition key in the START

AT
HE
position for more than 10 seconds. MIN
●● If you fail to start the engine, wait at least

one minute before restarting. CC13031502
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.

1. Check that the hydraulic lockout control is

in the locked position. If it is in free posi-
tion, do not start the engine.
CC13031403
Fig. 4-29
2. Turn the fuel control dial to the MIN posi-

tion.
MA
X
MIN
CC13031401
Fig. 4-30
NOTE:
ON
OFF
When ambient temperature is below 10°C,
STA
T
HEA
heat the engine before startup. For details

RT
about preheating the engine see "Engine Pre-

heating" on page 4-25.
CC13031804
Fig. 4-31

4. Turn the start switch to the START position

and start the engine.
ON
OFF
STA
T
HEA
RT
CC13031801
Fig. 4-32
5. Release the switch when the engine is

started. It returns to ON position automati-
cally.
ON
OFF
NOTE: When ambient temperature is low, the
STA
T
HEA
engine may fail to start after the start switch is
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
6. When the engine is started, do not operate

any control lever or pedal until oil pressure
is within normal operating range.
NOTE: If oil pressure remains abnormal after

four or five minutes, shut down the engine and
check oil level. Take necessary actions in case
of oil leakage.

4.2.1 Engine Preheating
When ambient temperature is below 10°C,

heat the engine before startup.
Preheating procedures are different depending

on the engine equipped on the machine.
1. Machines equipped with MITSUBISHI

engine
●● Turn the fuel control dial to MIN position,
and turn on the preheat switch (1). Turn
the engine start switch to the HEAT posi-
tion. When preheating indicator (2) lights START
X
MA
up, engine preheating begins.
N
T OFF O
HEA
MIN
Preheating takes from 10 to 30 seconds

depending on ambient temperature:
Temperature (°C) 0~10 -10~0 <-10 2 1

CC13040301
Preheating time 10s 20s 30s
Fig. 4-34
●● Do not preheat the engine for more than
30 seconds. Try starting the engine when
preheating process is over. Switch off the
preheat switch when the engine is started.
2. Machines equipped with ISUZU engine
●● Turn the fuel control dial to MIN position,

and turn the engine start switch to the ON
position. When preheating indicator lights
up, engine preheating begins.
●● When heating process is over, turn the

start switch to the START position in order
to start the engine.
●● If the engine fails to start, wait for one min-

ute at minimum and repeat the preheating
and startup procedure.

4.2.2 Warm-up operation
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.
6. Check exhaust color, noise or vibration for abnormality. Repair it if any.

4.3 Engine Shutdown
CAUTION
●● Engine service life will be reduced if it

is not shut down at idling speed. Never
stop the engine at high speed except
for emergency. Failure to do so can
cause failures such as fatigue cracking
in cylinder head or burning of turbo-
charger bearing.
1. Run the engine at idle speed for about five

minutes to cool it down gradually.
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

4.4 Machine Operation
WARNING
●● Check the area around the machine and

sound the horn before moving the ma-
chine.
●● Nobody is allowed to enter the area
around the machine.
●● Remove any barriers from the travel
route.
●● There is a blind area behind the ma-
chine. Take extra care when reversing
the machine.
Before operating the travel control levers or

pedals, make sure the idlers (1) are in the
front and sprockets (2) are under the tail (3)
of the machine. If the sprocket is in the front,
the travel direction of the machine will be op- 3
posite to the moving direction of travel control
lever(s) or pedal(s). (The forward and back-
ward directions are reversed. So do the left
and right turning directions.)
1 2
CC13031518
Fig. 4-36

4.4.1 Before moving the machine
1. Adjust the fuel control dial to a desired

position to increase engine speed. MA
X
MIN
CC13031507
Fig. 4-37

unlocked position and retract the work
equipment. Keep the bucket 40~50cm off
the ground.
NOTE: Raise the boom a little if necessary to

provide good visibility to the right side of the
operator cab.
CC13031404
Fig. 4-38
40~50cm
CC13050601
Fig. 4-39

4.4.2 Move the machine
Forward moving
Push both of the travel control levers or press

the upper part of the control pedals at the
same time with equal force to move the ma-
chine forward.
CC13031508
Fig. 4-40
Backward moving
Pull both of the travel control levers or press

the lower part of the control pedals at the
same time with equal force to move the ma-
chine backward.
NOTE:
●● If the sprockets are in the front of the ma-

chine, the moving direction of the machine
is opposite when the travel control levers
(pedals) are operated. CC13031509
Fig. 4-41
●● To ensure straight travel, operate the travel
control levers or pedals at the same with
equal force.
●● When ambient temperature is low, travel

speed may become abnormal. In this case,
warm up the machine completely before
operation.

4.4.3 Stopping the machine
CAUTION
●● Do not stop the machine suddenly.

●● Before stopping the machine, leave
yourself enough space so that you can
leave the machine easily.
Release the left and right travel control levers

(or pedals) at the same time to stop the ma-
chine. N
The control levers or pedals will return to neu-

tral position (N) once they are released.
N
CZ335-1103169
Fig. 4-42

4.5 Machine Turning
●● Check the direction of the track frame

before operating the travel control. If the
sprockets are in front of the cab, when
the travel controls are operated, machine
movement is opposite to that when ma-
chine direction is normal.
●● Avoid sudden change of direction. Stop

the machine before turning, especially for
a pivot turn.
4.5.1 Direction change when the ma-

chine is stopped
Left turn
●● Push the right travel control lever, or press

the upper part of the right control pedal.
The machine turns left as the right side
track moves forward;
CC13031510
Fig. 4-43
or,
●● Pull the left travel control, or press the

lower part of the left control pedal. The ma-
chine turns left as the left side track moves
backward.
CC13031511
Fig. 4-44

Right turn
●● Push the left travel control lever, or press

the upper part of the left control pedal. The
machine turns right as the left side track
moves forward;
CC13031512
Fig. 4-45
or,
●● Pull the right travel control, or press the

lower part of the right control pedal. The
machine turns right as the right side track
moves backward.
CC13031513
Fig. 4-46

4.5.2 Pivot turning
Left turn
●● Push the right travel control lever and pull

the left control lever at the same time; or
CC13031514
Fig. 4-47
Right turn
●● Push the left travel control lever and pull

the right control lever at the same time; or
CC13031515
Fig. 4-48
4.6 Selecting a Working Mode
Select a suitable working mode via the moni-

tor.
For more information on working mode see re-

lated sections on monitor.

4.7 Work Equipment Control
CAUTION
●● Operating the control levers while the

engine is idling may cause engine
speed to rise abruptly. Be careful with
the operation of control levers.
Work equipment is controlled with the left

and right joysticks.
The joysticks will return to the neutral

position once released, and the work
equipment will hold at the same time.
●● Arm control
Move the LEFT joystick forward and back-

ward to control the movement of the arm.
CZ335-1103175
Fig. 4-49
●● Swing control
Move the LEFT joystick to the left and right

to control the swing of upper structure.
CZ335-1103176
Fig. 4-50

●● Boom control
Move the RIGHT joystick forward and

backward to control the movement of the
boom.
CZ335-1103177
Fig. 4-51
●● Bucket control
Move the RIGHT joystick to the left and

right to control the movement of the
bucket.
When both joysticks are back to the neutral

position and no operation is performed within
five seconds, auto deceleration function will be
activated and engine speed will be lowered to CZ335-1103178
idling even if the fuel control dial is set to full Fig. 4-52

speed.
An accumulator is installed in the control cir-

cuit of the machine. It enables the operator to
lower the work equipment to the ground even
if the engine has been stopped. Turn the start
switch to ON position and place the lockout
control to unlocked position within 15 seconds
after engine shutdown, move the joysticks to
lower the work equipment to ground.
This method can also be used to release the

residual pressure of hydraulic system, or to
lower the boom after the machine has been
loaded onto a trailer.

4.8 Restricted Operations
CAUTION
●● Do not operate the joysticks while the

machine is traveling. Stop the machine
first before operating the joysticks.
●● Operation of the control levers while
the engine is idling may cause engine
speed to increase abruptly.
4.8.1 Operation with swinging force
Do not use the swinging force to compact the

ground or break objects. Doing this is danger-
ous. In addition, the service life of machine
would be reduced considerably.
CZ335-1103181
Fig. 4-53
4.8.2 Operation with traveling force
Do not cut your bucket into ground and use

the traveling force to excavate, which could
damage your machine or work equipment.
CZ335-1103182
Fig. 4-54

4.8.3 Operation when hydraulic cylin-

der reaches its stroke end
If the cylinder's piston reaches its end of

stroke, using the work equipment under ex-
ternal impact could damage hydraulic cylinder
and cause personal injury. Avoid operating the
machine when its hydraulic cylinder is fully re-
tracted or extended.
CZ335-1103183
Fig. 4-55
4.8.4 Operation with bucket landing

force
●● Do not use the bucket's landing force for

excavating, digging, breaking or pile-driv-
ing operation, which may otherwise reduce
the service life of the machine consider-
ably.
●● To avoid damage of hydraulic cylinders, do

not use the bucket to strike or compact the
ground while its cylinder is fully extended
or retracted.
CZ335-1103184
Fig. 4-56
4.8.5 Hard rocky ground
Do not try to directly excavate hard rocky

ground. Perform excavation after breaking the
rocks through other means. By doing so, dam-
age to your machine could be minimized, in
addition to cost reduction.

4.8.6 Operation with machine weight
Do not use the weight of machine to excavate.
CZ335-1103185
Fig. 4-57
4.8.7 Sudden shift of control levers/

pedals
●● Do not maneuver any control lever or pedal A 3

abruptly to change the action of machine.
2
1
●● Do not suddenly change the position of B
control lever or pedal from forward (A) to
reverse (B), or vice versa.
●● Do not stop the machine by suddenly re-

leasing the control lever or pedal while CZ335-1103186
traveling at high speed. Fig. 4-58

4.9 Permissible depth of water

When driving the machine out of water, an in-
clination of slope exceeding 15° will have the
rear of the upper structure immersed in water,
thus the fan could be damaged due to water.
Be extremely careful when driving the machine

out of water.
CZ335-1103189
Fig. 4-59
●● Do not drive your machine into water

where water level could reach the center of
carrier roller (1).
●● Add grease to parts that have been soaked

long in water, till old grease is completely
squeezed out of the bearing (especially the
area around the pin of bucket).
●● Do not operate your machine in water un- 1

less the foundation of worksite is strong CZ335-1103190
enough so that the level of water could not Fig. 4-60
reach the center of carrier roller.
●● If the swing bearing, swing gear and cen-

tral swing joint are soaked in water, the
drain plug should be opened to remove
mud and water. Clean the swinging area
and reinstall the plug. Lubricate the mesh
gear and swing bearing inside the swing
unit.

4.10 Traveling on a Slope

Always operate or steer your machine properly
as described below. In this way, you can stop
your machine safely at any time when it skids
or becomes unstable.
WARNING
●● Turning the machine or operating work

equipment on a slope may cause the
machine to loose balance and roll over.
Such operations should be avoided.
CZ335-1102046
●● It is very dangerous to swing a loaded
bucket toward the downhill direction. If Fig. 4-61
you have to do this, build a platform on
the slope so that you can operate your
machine on a level ground.
●● Never travel on a steep slope or re-
verse down a slope, which can possibly
cause your machine to roll over.
●● Never turning your machine on a slope
or travel laterally on a slope. Always
reposition your machine on a level
ground. Level ground may be a little far
but can ensure your safety.
●● If you are unable to drive your machine
up a slope due to skidding or weak CZ335-1103192
force, never attempt it using the pulling Fig. 4-62
force of arm.
●● The engine will be insufficiently lubri-
cated on an incline over 30 degrees.
1. Keep your machine at low travel speed

with the travel control levers and fuel
control dial when you drive the machine
downhill. When you drive the machine
down a slope over 15 degrees, adjust the
work equipment to an attitude as shown
by the right illustration and reduce engine
speed. CZ335-1102039
Fig. 4-63

2. When driving the machine up a steep

slope, move the work equipment to the
forward direction. Keep the work equip-
ment about 20-30cm above the ground
and travel at a low speed.
CZ335-1102040
Fig. 4-64
4.10.1 Traveling downhill
Place the travel control levers to the neutral

position, which can make the brake function
automatically.
4.10.2 When engine stalls on a slope
If the engine stops while traveling on a slope,

place the travel control lever to its neutral po-
sition, lower the bucket to the ground and park
the machine before restarting the engine.
4.10.3 Cab door on a slope
●● If the engine stalls out on a slope, do not

perform swinging operation with the left
joystick. The upper turntable will swing
naturally under its weight.
●● When your machine is on a slope, do not

open or close your cab door because it
would cause sudden change of force ap-
plied on the machine. Always secure the
cab door in either open or closed position.

4.11 Escaping from Mud

Operate the machine carefully on muddy
ground and avoid being trapped in mud. If the
machine is trapped in mud, drive it out as per
the following instruction.
4.11.1 When one track is trapped
When the boom or arm is used to lift your ma-

chine, bucket bottom must contact ground,
and the boom and arm form an angle of 90-
110 degrees.
This also applies to a forward shovel.
When one of the tracks is trapped in mud,

push the bucket to lift the trapped track. Put
wood planks or log under the track in order to CZ335-1103195
drive the machine out of mud. Fig. 4-65
4.11.2 When both tracks are trapped
When both tracks are trapped in mud, insert

wood planks under the tracks using the meth-
od as described above and cut your bucket
into the ground in front of your machine.
Retract the arm as you do in normal excava-

tion and drive your machine out of mud.
CZ335-1103196
Fig. 4-66

4.12 Recommended Application

Besides the following applications, the scope
of application could be expanded by using
various additional attachments.
4.12.1 Backhoe operation
Backhoe operation is suitable for digging an

area which is lower than your machine.
When your machine is in a state shown in

90°
the right illustration, maximum digging force
can be obtained through the thrusting force of 90°
each hydraulic cylinder.
Make use of this angle effectively to help you
CZ335-1103197
Fig. 4-67
achieve the maximum working efficiency.

45° 30°
The digging range of arm is from 30 to 45°, as

relative to the machine.
The angle may vary according to digging

depth, but it is better to keep it within the
above range if possible. Do not operate the
hydraulic cylinders to their full stokes.
CZ335-1103198
Fig. 4-68

4.12.2 Trenching work
●● You can dig a trench efficiently by install-

ing a bucket suitable for this job and adjust
your tracks to parallel the to-be-dug trench
line.
●● When digging a wider trench, excavate first

both sides of the trench and then remove
the middle part.
●● The travel motors should be in the rear

during longitudinal excavation. In this way, CZ335-1103199
the stability and lifting capability of your Fig. 4-69

machine are maximized.
●● In excavating operation, the track should

be adjusted vertical to road shoulder or
cliff, with sprockets behind the cab, so that
the machine can retreat easily in case of
an emergency.
CZ335-1102049
Fig. 4-70
4.12.3 Loading operation
In a place where the swinging angle is small,

working efficiency can be improved by parking
the dump truck at where the operator could
see easily.
It is more convenient to load more material if

the truck is loaded from rear rather than from
its sides.
CZ335-1103200
Fig. 4-71

4.13 Parking
WARNING
●● Inadvertent of the control levers may

cause the machine to move suddenly
and result in serious accidents.
●● Make sure the hydraulic lockout control
is placed in the locked position before
leaving the cab.
Always park your machine on a hard, level

ground that is free from hazards. If you have
to park your machine on a slope, chock the
tracks with blocks as shown by the illustration
on the right. You can also thrust the bucket
tips into the ground as additional safety mea- 120°
sures.
CZ335-1102055
Fig. 4-72
1. Place the travel control levers to neutral

position to stop your machine.
N
CZ335-1103169
Fig. 4-73

2. Turn the fuel control dial to MIN position for

low idle to reduce engine speed.
MA
X
MIN
CC13031401
Fig. 4-74
3. Lower the bucket horizontally till its bottom

touches the ground.
CZ335-1103207
Fig. 4-75

locked position.
CC13031403
Fig. 4-76

5. Use the monitor to check the engine cool-

ant temperature and oil pressure.
●● If fault indicator blinks and oil pressure is

abnormal, shut down the engine immedi-
ately.
●● If the coolant temperature gauge stays in

the red range, wait until the indicator enters
C H
the yellow range before engine shutdown.
CC13050802-2
Fig. 4-77
6. Turn the start switch from ON position to

OFF position and shut off the engine.
4.14 Inspection after Each Work-

day
1. Inspect the machine and check the work
equipment, the exterior of machine, and
the undercarriage. Check for leaks of oil or
coolant. Repair it in case of any problem.
2. Refill the fuel tank to maximum level.
3. Check the engine compartment for any

paper or other debris. Remove them, if
any, in order to prevent fire.
4. Clean the mud on the undercarriage if any.
5. If the ambient temperature is below -35°C,

discharge the coolant in the radiator and
engine (Sany Heavy Machine uses the
type of anti-freeze liquid that freezes at
-35°C).

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
(3) Engine hood 5

7
(4) Battery cover
1
(5) Left access door
(6) Right access door
CZ335-1103208
(7) A/C fresh air cleaner cover
Fig. 4-78
6
CZ335-1103209
Fig. 4-79

4.16 Operation in Cold Weather

The engine may fails to start and the cool-
ant may freeze under low temperature. In this
case, the following instructions must be fol-
lowed.
4.16.1 Fuel and lubricant
Select fuel and lubricant with low viscosity for

all components when ambient temperature is
low.
For more information on viscosity, see "Rec-

ommended Fuel, Coolant and Lubricant"
on page 5-15.
4.16.2 Coolant
WARNING
●● Antifreeze is flammable. Keep it away

from fire. Do not smoke when handling
antifreeze.
●● Antifreeze is toxic. Wash with plenty of
water and seek medical treatment im-
mediately if antifreeze gets into your
eyes or on your skin.
●● Never drain antifreeze directly into the
sewer or onto the ground.
Please use Sany genuine, efficient TEEC-L35

antifreeze as the coolant. Choosing any other
type of coolant is not recommended.

4.16.3 Battery
Battery capacity decreases as the ambient

temperature drops. Keep battery capacity at
100% level. Do not let the battery stay long
under low temperature so as to avoid the dif-
ficulty in starting your machine.
Cover the battery or remove it from your ma-

chine when ambient temperature is low. Store
the battery in a warm place and reinstall it be-
fore operating the machine.
4.16.4 After each workday
When temperature is very low, mud and wa-

ter on the undercarriage may freeze at night,
which may make the machine hard to move
the next day. Observe the following instruc-
tions:
●● Remove all mud and water from your ma-

chine. Clean especially the piston rods of
hydraulic cylinders in order to prevent mud,
dirt or water from penetrating the cylinders
and spoiling the seals.
●● Park your machine on a hard, level ground.

Park it on wood planks if possible, which
can prevent your machine from being fro-
zen unto the ground.
●● Open the drain valve to discharge accu-

mulated water of the fuel system so as to
prevent it from freezing.
●● Refill the fuel tank to tis maximum level to

reduce condensation in the tank when am-
bient temperature drops.
●● After operation in water or mud, remove

water from the undercarriage as described
below in order to extend service life of the
undercarriage.

CAUTION
●● It is dangerous to run the track freely.

Keep a safe distance from the track.
1. Run the engine at idle speed and swing

the upper structure 90º so that the work
equipment is at the track side.
2. Lift one side of the tracks just off the CZ335-1103210

ground and make it run freely. Repeat the Fig. 4-80
this for both tracks.
4.16.5 After cold season
When the season changes and the weather

gets warm, perform the following operation:
●● Change fuel and lubricant with that of

specified viscosity.
For more information see "Recommended

Fuel, Coolant and Lubricant" on page 5-15.

4.17 Long-Term Storage

4.17.1 Before storage
When storing your machine for more than one

month, adjust your machine to the attitude as
shown in the right illustration in order to pro-
tect cylinder piston rod against rusting.
●● Clean all parts of your machine and then

store your machine indoors. If you have
to store your machine outdoors, choose a
level ground and cover your machine with
canvas.
●● Refill your fuel tank to its maximum level in CZ335-1103211

order to avoid accumulation of water.
Fig. 4-81
●● Lubricate your machine and change its oil

before storing it.
●● Apply grease to the exposed part of the

piston rod of hydraulic cylinder.
●● Disconnect the negative terminal of the

battery and reinstall its cover, or remove
the battery from your machine and store it
in a separate place.
●● For machines equipped with optional

equipment, the control pedal of optional
equipment shall be placed to locked posi-
tion.
●● To prevent rusting, please use Sany’s gen-

uine TEEC-L35 anti-freeze.

4.17.2 During storage
WARNING
●● When anti-rusting greasing operation is

performed indoors, proper ventilation
shall be provided to avoid gas poison-
ing.
●● During storage, operate your machine and

drive it for a short distance once a month.
This can help apply a new oil film on parts
and components. Meanwhile, charge the
battery of your machine.
●● Before operating the work equipment, wipe

off all the grease from the piston rod of hy-
draulic cylinder.
●● If your machine is equipped with air condi-

tioner, switch on the air conditioner for 3-5
minutes once a month, which can lubricate
all parts of its compressor. The engine shall
run at low idle speed when air conditioner
is working. In addition, check its refrigerant
twice a year.

4.17.3 After storage
If your machine has been stored for a long pe-

riod but no rusting prevention had been made
each month, contact authorized Sany dis-
tributors before operating the machine again.
Before operating the machine again after a
long-term storage, observe the following in-
structions:
●● Wipe off the grease from the piston rod of

hydraulic cylinder.
●● Apply lubricant or grease to all necessary

locations.
●● Water in the air can mix with oils of the ma-

chine when it has been stored for a long
time. Check the oils before and after start-
ing the engine. Replace the oil if neces-
sary.
4.17.4 Engine startup after long-term

storage
Before starting the engine of your machine

that has been stored for a long period of time,
it is important to fully preheat your machine.
For more information see "Warm-up opera-

tion" on page 4-26.

4.18 Transportation Information

Transportation of this machine must be in ac-
cordance with related laws and regulations.
Make sure the transportation is safe.
4.18.1 Transport methods
●● Choose a method that is suitable for the

weight and dimensions provided in "Speci-
fication" section.
●● The weight and dimensions provided in the

Specifications section may vary due to dif-
ferent type of track shoe, arm or other ad-
ditional equipment.
●● For transport of machines installed with

cab protective structure, contact your Sany
distributor for more information.

4.18.2 Loading and unloading
The following instructions must be followed

when loading/unloading the machine to/from a
trailer.
●● Use an access ramp with enough width,

length, thickness and strength. The maxi-
mum loading and unloading angle of the
ramp must not exceed 15 degrees.
●● When piling the earth to build a platform,

the platform must be fully compacted to
CZ335-1103227
prevent landslide.
Fig. 4-82
●● To prevent the machine from skidding on
the ramp, clean its track shoes and the
ramp before loading and unloading.
●● The machine is likely to skid when the ac-

cess ramp is contaminated with water,
snow, grease or ice.
CZ335-1103228
Fig. 4-83

4.18.2.1 Loading
WARNING
●● Deactivate auto-idle function when

loading or unloading the machine. If
auto-idle mode is active, engine speed
may change abruptly.
●● Keep travel speed at low level. Do not
switch travel speed when loading or un-
loading the machine.
1. Choose a hard and level surface to load

the machine. Keep the machine a safe
distance away from roadside.
2. Brake the trailer and put blocks (1) under

its wheels.
2
Place access ramps (2) the left and right
sides respectively. The two ramps shall
1
parallel to each other and have equal 4
3
distance to the centerline (3) of the trailer.
Mounting angle (4) shall not exceed 15º. If CZ335-1103229
the ramps bend too much under the weight Fig. 4-84
of machine, supports must be placed under
the ramps to prevent them from bending.
3. Set the travel speed to LOW speed.

MA
4. Set engine speed to MIN with the fuel
X
control dial.
MIN
CC13031401
Fig. 4-85

5. If work equipment is installed on the

machine, placed it in front of the machine.
Move the machine straight forward up the
ramps. If no work equipment is installed,
reverse the machine up the ramps.
90°-110°
Lower the bucket onto the trailer to support
the machine immediately after getting
aboard.
Follow the instructions and signals from a

commander, especially in reverse travel. CZ335-1103231
Fig. 4-86
WARNING
●● Do not reposition your machine on the

access ramps, which could cause your
machine to tip over.
●● Do not maneuver any control levers ex-
cept the travel controls on the access
ramps.
●● If necessary, reposition your machine
on a level ground or on the trailer.
CZ335-1103232
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.
Align your machine with the ramp and

travel slowly.
Lower the work equipment as low as pos-

sible.
Once the machine is on the ramps, only

the travel control can be maneuvered. Do
not operate any other control levers.

7. Drive the machine slowly forward till all

tracks are on the trailer and have full
contact with trailer floor.
8. When the machine passes the rear wheels

of the trailer, the machine could lean
forward. So drive the machine slowly and
carefully in order to avoid impact with the
trailer.
9. Slightly raise the bucket, retract the arm

and maintain it in lower position, and slowly CZ335-1103233
swing the upper structure by 180º. Fig. 4-88
10. Fully extend the bucket cylinder and arm

cylinder, and slowly lower the boom.
11. Place a wood block under the end of the

bucket cylinder in order to prevent it from
touching the trailer floor, which could result
in damage to the cylinder.
CZ335-1102060
Fig. 4-89

4.18.2.2 Securing the machine
●● Place a wood block under the end of the

bucket linkage to prevent the bucket cylin-
der from touching the trailer floor.
●● Locked the engine hood. Unlocked engine

hood may swing open during transit.
Secure the machine to the trailer according to

the following steps:
1. Fully extend the bucket cylinder and arm

cylinder, and slowly lower the boom.
CZ335-1104086
Fig. 4-90

locked position.
3. Stop the engine and remove the key from

the start switch.
4. Close all doors, windows and covers

properly. Lock the covers, caps and doors.
CC13031403
Fig. 4-91

5. Chock the tracks on both ends in order to

prevent the machine from moving during
transportation. Tie down the machine
with chains or wire ropes with sufficient
strength.
Care must be taken to keep the machine

in a proper position to ensure that the
machine will not slip sideways.
CZ335-1103237
Fig. 4-92
Rear view mirror
The rear view mirror is located in the position

B A
When the rear view mirrors have to be re-
moved and installed afterwards for transporta-
tion purpose, follow the instructions below:
Removal
1. Loosen bolt (2) and remove the rear view

mirror (1) from the bar (3).
CZ335-1103142
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).
2. Install the rear view mirror (1) to the bar (3),

and tighten the bolt (2). 5
NOTE: The rear view mirror must be readjust- 4 3
ed after installation. For more information see

"Rear view mirrors" on page 4-17. CZ335-1103239
Fig. 4-94

4.18.2.3 Unloading
1. Always load/unload the machine on a hard,

level ground. Keep the machine a safe
distance from roadside.
2. Brake the trailer and put blocks (1) under

its wheels.
2
●● Place access ramps (2) on the left and
right sides respectively. The two ramps
1
shall parallel to each other and have equal 4
3
distance to the centerline (3) of the trailer.
Mounting angle (4) shall not exceed 15º. If CZ335-1103229
the ramps bend too much under the weight Fig. 4-95
of machine, supports must be placed under
the ramps to prevent them from bending.
3. Remove the chains and wire ropes fasten-

ing the machine.
4. Start the engine and warm it up fully.
5. Place the hydraulic lockout control to

unlocked position.
CC13031404
WARNING
Fig. 4-96
●● Deactivate auto-idle function when

loading or unloading the machine. If
auto-idle mode is active, engine speed
may change abruptly. MA
X
●● Keep travel speed at low level. Do not
switch travel speed when loading or un-
MIN
loading the machine.
6. Use the function key on the monitor to set

travel speed to low. Turn off auto idling.
CC13031401
7. Set engine speed to MIN with the fuel
control dial. Fig. 4-97

8. Raise the work equipment, retract the arm

below the boom, and drive the machine
slowly.
9. Stop the machine when it comes to the

rear wheels of the trailer and is positioned
horizontally.
NOTE:
CZ335-1103242
●● Keep an angle of 90 - 110° between the
Fig. 4-98
arm and the boom when unloading the ma-
chine.
●● The machine could be damaged if it is un-

loaded with retracted arm.
●● When the machine runs on the access

ramp, do not penetrate the bucket into 90°-110°
ground, which could damage the hydraulic
cylinder.
CZ335-1103243
Fig. 4-99
10. While the machine is on the ramps, keep

an angle of 90 - 110º between the arm and
the boom. Lower the bucket to the ground
and move the machine slowly.
11. When the machine is going down the

ramps, slowly operate the boom and arm,
and carefully drive the machine off the
ramps.
CZ335-1103244
Fig. 4-100

4.18.2.4 Lifting the machine
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
Use proper wire ropes according to the weight of the load
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.

NOTE: The lifting method may vary accord-

ing to the attachment or optional equipment
installed on the machine. For a suitable lift
method please contact your Sany distributor.
When lifting the machine, operate on a level

ground according to the following steps.
Standard machine
WARNING
●● A wire rope closing to hook tip may slip

off the hook during lifting and cause se-
vere accident. The strongest part lies in
the middle of hook.
●● Do not lift if the wire rope and hook
form a larger suspension angle. If two
or more wire ropes are used for lifting
an object, the bearing capacity of each
rope increases with the suspension
angle.
●● Using a single rope may lead to revolv-
ing load during lifting. A loosened rope
or a rope slipping away from the origi-
nal position can cause dangerous acci-
dent.
1. Start the engine and swing the upper

structure to position the work equipment at
the side of the sprockets (1).
2. Fully extend the bucket cylinder and the

arm cylinder, and lower the work equip-
ment to the ground, as shown in the right
illustration.
CZ335-1103245
Fig. 4-101

3. Move the hydraulic lockout control to

locked position.
4. Shut off the engine. Check the surrounding

of the cab before leaving the machine.
Close the cab door and windows properly.
CC13031403
Fig. 4-102
5. Run a wire rope between the first two track

rollers and between the last two track A
rollers. For machines installed with roller

guard, the cable shall go through under the
tracks.
6. Adjust the wire rope lifting angle (A) to 30 -

40º, and lift the machine slowly.
7. When the machine is above the ground,

make sure that the hook condition and
the lifting condition are normal, and lift the CZ335-1103246
machine slowly. Fig. 4-103

SY500H-10 Crawler Hydraulic Excavator Maintenance
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

Maintenance SY500H-10 Crawler Hydraulic Excavator

5 MAINTENANCE
5.1 Maintenance Information

Never conduct any inspection and mainte-
nance work other than the scope specified in
this manual.
Service hour meter reading
Check the service hour meter reading on a

daily basis and determine whether the ma-
chine requires the specified maintenance.
Genuine Sany parts
Always use genuine Sany replacement parts

listed in the Parts Manual.
Genuine Sany lubricants
Always use genuine Sany oil and grease. Se-

lect oil and grease of suitable viscosity accord-
ing to ambient temperature.
Windshield washer fluid
Use automotive windshield washer fluids only.

Make sure it is not contaminated by foreign
substances.
Using clean engine oil and lubricants
Always use clean oil and grease and keep the

container clean. Keep oil and grease free of
any impurities.
Checking the drained oil and used filter el-

ements
After oil change and filter element replace-

ment, check the used oil and filter element for
signs of metal particles and foreign material.
If large amount of metal particles and/or im-
purities are observed in the used oil and filter
element, take immediate action or inform your
boss in time.

Fuel strainer
If a fuel strainer is equipped in the fuel tank

filler opening, do not remove it when filling the
tank.
Welding instruction
●● Turn off the start switch and one minute

later disconnect the negative (-) post of
battery.
●● Connect grounding cable in a place where

is more than 1 meter from the welding lo-
cation. The meters and gauges will fail if
the grounding cable is connected to the in-
strument, connectors or other attachments.
If any sealing part or bearing is present be-
tween the welding location and the ground-
ing point, change the grounding point to
avoid such parts.
●● Never use a grounding point in the vicinity

of the work equipment pin or hydraulic cyl-
inder.
●● Never apply more than 200V continuously.
Preventing things from falling into machine
●● When opening the access window or tank

filler for inspection, make sure that the
nuts, bolts or tools are not left inside the
machine. Failure to do so may result in un-
expected failure or damage to the machine,
or accidents. In case that any materials fall
into the machine, remove it immediately.
●● Do not carry unnecessary items in your

pockets except those necessary for inspec-
tion.

Dusty work site
Observe the following items before working in

a dusty place.
●● When inspecting your machine or chang-

ing the oil, park your machine in a dust-
free place in order to prevent dust from
getting into the oil.
●● Clean the air filter cartridge immediately if

the filter's alarm indicates clogging.
●● Clean the fins and other heat exchanger

parts frequently to avoid them being
clogged.
●● Clean and replace the fuel filter frequently.
●● Clean the electrical components, espe-

cially the start motor and the alternator, to
prevent dust from building up on them.
Lubricants of different brands
Never mix lubricants of different brands and/or

grades together. If you need to use the lubri-
cant of another brand or grade, drain the old
lubricant completely and replace with the new
brand.
Securing access cover
When servicing the machine with the access

covers open, use a locking lever to secure the
cover to certain position. Otherwise, the cover
can be swung close by wind and cause bodily
injury.
Purging air from hydraulic system
When any hydraulic units have been repaired

or replaced or any hydraulic lines have been
removed or installed, always bleed the air from
the system.

Connecting hydraulic hoses
●● In removal of parts with O-rings or gaskets,

clean the installation surfaces and replace
with new parts. Remember to install the O-
rings or gaskets.
●● Do not twist or bend the hydraulic hoses

when assembling. Failure to do so could
cause damage to the hoses and consider-
ably reduce their service life.
After inspection and maintenance
If no checks have been made after inspection

and maintenance, unexpected failure may oc-
cur, causing severe injury or damage. The fol-
lowing items must be observed:
●● Checks when machine is running
●● For more information, see "Mainte-

nance with engine running" on page
2-69.
●● Whether the checked or maintained

parts work normally.
●● Whether oil leakage occurs when the

engine speed increases and the oil is
under pressure.
●● Checks after the operation (when the en-

gine has been shut down)
●● Whether you have missed the items to

be checked or maintained.
●● Whether all the checks and mainte-

nance have been performed correctly.
●● Whether any tools and parts are left

in the machine. It is very dangerous
to have a foreign object blocked in the
linkage.

●● Whether leakage of water or oil oc-

curs; whether all the bolts have been
screwed tightly.
Closing engine hood properly
When the engine hood is closed after inspec-

tion and maintenance, hold the lever and lift
the engine hood slightly in order to check
whether the lock is securely engaged. An un-
locked hood may be opened and cause acci-
dents.

5.2 Oil, fuel and coolant

5.2.1 Oil
●● The oils in engine and hydraulic units keep

deteriorating when operating your machine
under extreme conditions, such as high
pressure and high temperature.
●● Always use recommended type of oil which

shall also be applicable under extreme am-
bient temperatures.
●● Within the specified oil change interval, the

oil must be changed even if it is not dirty.
●● Lubricant shall be handled carefully in or-

der to prevent impurities such as water,
metal particles and dust.
●● Most troubles of the machine are caused

by impurities. Pay special attention to the
prevention of any impurities when storing
or filling the oil.
●● Fill the amount of oil as specified. Failure

to do so could result in abnormality.
●● Do not mix oils of different grades or

brands together.
●● Contact your Sany distributor when the oil

in your work equipment has been contami-
nated by water or air.
●● To know the condition of your machine,

regular oil quality analysis is recommend-
ed. Contact your Sany distributor if you
need such service.
●● In replacement of machine oil filter ele-

ment, acceptable clean oil shall be filled
into the new filter element prior to installa-
tion.

●● Please use the oils approved by Sany.
●● Do not use the hydraulic oil that has not

been approved by Sany, which can block
filter cartridge.
●● Remove the remaining oil as much as pos-

sible from the lines and cylinders when
changing the hydraulic oil. A small amount
of different residual is acceptable.
5.2.2 Fuel
●● To prevent the moisture in air from con-

densing in the fuel tank, the tank must be
fully refueled after each workday.
●● The fuel injection pump is a precise com-

ponent, which may not work normally if the
fuel contains water or other foreign sub-
stances.
●● The sediment and water in the fuel tank

must be drained before starting the engine
or after 10 minutes since injection of oil.
●● Flush the fuel tank and the fuel system

in case of any impurities found in the fuel
tank.
●● The air in fuel path must be eliminated in

case that the engine runs out of fuel or the
filter cartridge has been replaced.
●● Always use the type of fuel specified in the

"Maintenance" section.
●● The fuel can freeze below the specified

temperature (especially lower than -15°C
(5°F)).
●● When the fuel is used above the specified

temperature, its viscosity and output power
will decrease .

●● Pay special attention to prevention of impurities when storing or refilling the fuel.
NOTE:
●● Always use diesel oil as the fuel.
●● 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
●● The coolant is an important fluid against corrosion and freezing.
Anti-freezing coolant is also necessary in regions where freezing prevention is unnecessary.
●● 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.
Water-antifreeze mixing ratio
Min. tempera- °C -10 -15 -20 -25 -30 -35 -40

ture °F 14 5 -4 -13 -22 -31 -40
Mixing ratio (%) 30 36 41 46 50 54 58
Table 5-1
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
●● Grease is used to prevent distortion and noise of joints.
●● 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.
5.2.5 Oil and fuel storage
●● 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.
5.2.6 Filter element
●● 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.
All filter elements must be replaced regularly.
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.
●● Do not unpack the filter element when it is not used.
●● Always use genuine Sany filter elements.

5.2.7 Electrical system
●● 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.

5.3 Wear Parts

●● Wear parts, such as filter element, bucket tips, etc. are to be replaced at the time of periodic
maintenance or before their abrasion limits.
●● The wear parts shall be changed correctly in order to use the machine economically.
●● For part change, Sany genuine parts of excellent quality shall be used.
●● When ordering parts, please check the part number in the parts book.
Component Part Number Part Qty Interval

Every 500
Engine oil filter B222100000494 Filter element 2
service hours
Every 500
Fuel filter, first 60249072 Water separator 1
service hours
Every 500
Fuel filter, secondary 60151839 Filter element 2
service hours
Every 500
Fuel filter, primary 60250941 Filter element 2
service hours
B222100000640 Safety filter element 1 Cleaned 6
Air cleaner times or every
B222100000641 Main filter element 1
12 months
Every 1000
Pilot filter element A222100000119 Filter element 1
service hours
Every 1000
Filter element, breather valve 60186788 Filter element 1
service hours
Every 1000
Oil drain filter element 60210416 Filter element 1
service hours
Every 1000
Oil return filter element 60014122 Filter element 1
service hours
Every 2000
Oil suction filter 60251436 Filter element 1
service hours
60250669 Fresh air filter 1 Every 6
Filter, air conditioner
B222100000711 Recirculation filter 1 months
60265885 Bucket tips 5
60266484 Pins 5
60266485 Snap spring 5
Rockwork 12827269 Side cutters 2 —
A210110000424 Bolts 6
60013102 Washers 6
A210307000078 Nuts 6
Table 5-2

5.4 Recommended Fuel, Coolant and Lubricant
●● 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.

5.4.1 Table of recommended fuel, oil and coolant
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.

5.4.2 Table of capacities

Engine Oil Hydraulic Cooling
Specific capacity Swing Drive Final Drive Fuel Tank
Pan* System System
L 50 14 2×10 400 60 680
SY500
US gal 13.2 3.7 2×2.6 105.7 15.9 179.6
Table 5-5

5.5 Tightening Torque Table
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.
5.5.1 Table of bolt tightening torques
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

5.5.2 Table of hydraulic hose tightening torques
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

5.6 Safety-Related Parts

●● To ensure safety when operating or driving the machine, the user of the machine shall carry
out regular maintenance. In addition, the user shall also replace the parts listed in the table
in order to further improve safety condition. These parts are closely related to safety and fire
prevention.
●● 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.
●● Consult your Sany distributor to replace the Safety-related parts.
No. Safety-related parts for periodic replacement Quantity Frequency

1 Fuel hose (fuel tank - water separator) 1
2 Fuel hose (water separator - primary filter) 1
3 Fuel return hose (engine - fuel tank) 1
4 Fuel hose (primary filter - engine) 1
5 Pump outlet hose (pump - control valve) 2
6 Work equipment hose (boom cylinder oil inlet) 4
7 Work equipment hose (Bucket cylinder line - boom root) 2 Every 2 years
8 Work equipment hose (bucket cylinder oil inlet) 2 or 4000 hours,
9 Work equipment hose (arm cylinder line - boom root) 2 whichever occurs
10 Work equipment hose (arm cylinder oil inlet) 2 first.
11 Swing drive hose (swing motor oil inlet) 2

12 Main oil suction hose 1
13 Travel control hose (control valve - swivel joint) 4
14 Travel control hose (swivel joint - travel motor) 4
15 Pump pressure hose 1
16 Accumulator (control oil) 1
17 High-pressure tube clamps 1
Every 8000 hours
18 Cover - fuel squirt prevention 1
19 Seat belt 1 Every 3 years
Table 5-8

5.7 Maintenance Schedule

Standard calendar or service hours should be used as the criteria for inspection and maintenance
intervals, which ever occurs first.
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.
Maintenance schedule list

Initial 50 hours of operation................................................................... 5-25
When Required........................................................................................ 5-26

Track shoe bolts - inspect/tighten.................................................................................. 5-26
Track tension - inspect/adjust........................................................................................ 5-27
Bucket - replace............................................................................................................ 5-30
Bucket tips (lateral pin) - replace................................................................................... 5-33
Bucket clearance - adjust.............................................................................................. 5-35
Window washer fluid level - check/refill......................................................................... 5-37
Air conditioner - inspect/service.................................................................................... 5-38
Ceiling window gas spring - inspect.............................................................................. 5-40
Inspection Prior to Startup..................................................................... 5-42
Every 100 service hours......................................................................... 5-43

Lubrication..................................................................................................................... 5-43

Air filter element - inspect/clean/replace....................................................................... 5-46
Compressor belt tension - inspect/adjust...................................................................... 5-50
Swing bearing - lubricate............................................................................................... 5-51
Pipe clamps of hydraulic system - check...................................................................... 5-52

Swing pinion gear grease level - inspect/fill.................................................................. 5-53
Engine pan oil and filter element - change/replace....................................................... 5-55
Primary fuel filter element - replace............................................................................... 5-57
Secondary fuel filter element - replace.......................................................................... 5-60

Radiator and oil cooler fins - inspect/clean.................................................................... 5-63

Air conditioner fresh air/recirculation filter - clean......................................................... 5-65
Swing drive oil level - check/refill................................................................................... 5-67
Final drive oil level - check/refill..................................................................................... 5-68
Engine coolant pump (fan shaft) - lubricate................................................................... 5-69
Every 1000 service hours....................................................................... 5-70

Hydraulic oil return filter element /oil drain filter element/pilot filter element- replace... 5-70
Swing drive oil - change................................................................................................ 5-72
Engine exhaust pipe clamps - check............................................................................. 5-73
Fan belt tension - check/replace................................................................................... 5-73
Nitrogen pressure in accumulator (breaker) - check..................................................... 5-73
Breather valve - check/replace...................................................................................... 5-74
Filling lubricating grease of Rotary Reduction Gear...................................................... 5-75

Final drive oil - change.................................................................................................. 5-76
Hydraulic oil suction filter element – clean/replace....................................................... 5-77
Nitrogen pressure in accumulator (control oil circuit) - check........................................ 5-78
Cooling system interior - clean...................................................................................... 5-82
Alternator - inspect........................................................................................................ 5-84
Engine valve clearance - check/adjust.......................................................................... 5-84

Water pump - inspect.................................................................................................... 5-85
Start motor - check........................................................................................................ 5-85
Oil in hydraulic tank - change........................................................................................ 5-86
Accumulator - replace................................................................................................... 5-88
High-pressure tube clamps and rubber - check............................................................ 5-89
Compressor working condition - inspect....................................................................... 5-89

High-pressure tube clamps - replace............................................................................ 5-90
Every 10000 service hours..................................................................... 5-90

5.8 Maintenance Procedures

5.8.1 Initial 50 hours of operation
Always prepare your machine as required and

lock out/tag out your machine before proceed-
ing. See “Engine shutdown procedure” on
page 2-67 and “Lock out and tag out” on
page 2-68.
●● Change engine oil and replace oil filter ele-

ment. For details see "Engine pan oil and
filter element - change/replace" on page
5-54.

5.8.2 When Required
5.8.2.1 Track shoe bolts - inspect/tighten

page 2-68.
If your machine is operated with loose track
shoe bolts (1), the bolts can break. Tighten
any loose bolts immediately.
Tightening
Three-grouser track shoe
1. Tighten the bolts to torques below:
SY500H: 1319N·m - 1417 N·m

1
2. Make sure that the nuts and track shoe
are in close contact with the link mating
surface.
CZ335-1104014
3. Further tighten them by 120° ± 10°.
Fig. 5-1
Tightening sequence
Tighten the bolts in the sequence shown in the

right illustration. After tightening, make sure
that the nuts and track shoe are in close con-
tact with the link mating surface. 1 3
4 2
CZ335-1104015
Fig. 5-2

5.8.2.2 Track tension - inspect/adjust
The wear of undercarriage pin rolls and pin

bushings may vary according to operating
condition and soil type. Therefore, the ten-
sion of track shall be checked often in order to
maintain standard tension.

page 2-68.
Inspection
1. Run the engine at low idle speed. Travel

the machine forward a distance that is
equivalent to the length of an unfolded
2
track. Park your machine.
s
2. Place a straight edge on top of the track

grousers between the idler (1) and the
front carrier roller (2), as shown in the right
illustration.
1
3. Measure the maximum amount of deflec-
CZ335-1104016
tion in the track. The deflection is mea-
sured from the highest point of the track Fig. 5-3
grouser to the bottom of the straight edge.
Standard value of deflection (a):

10~30mm (0.4~1.2in)

Adjustment
WARNING
●● The screw plug may shoot out under

high pressure. Never loosen the screw
plug more than one turn.
●● Do not loosen any other components
except the screw plug. Never face the
installation direction of the screw plug.
Increasing track tension
To increase track tension, prepare a grease 1

gun. 2
1. Add grease with the grease gun through

the grease fitting (2). (Grease fitting (2)
and screw plug (1) are integral.)
2. Slowly travel the machine forward (7~8 m

{23 ft~26 ft 3 in}) in order to check whether
the track tension is suitable. CZ335-1104018
Fig. 5-4
3. Check the track tension again. Readjust
the tension if it is still beyond the standard
range.
4. Continue to add grease till the distance

(S) becomes null (0). If the tension is still
loose, it is probably because the pin roll
and bushing are overworn. The pin rolls or
bushings must be swapped or replaced.
Contact your Sany distributor for repair.
CZ335-1104019
Fig. 5-5

Reducing track tension
WARNING
1
●● The screw plug may shoot out under 2

high pressure. Never loosen the screw
plug more than one turn.
●● Do not loosen any other components
except the screw plug. Never face the
installation direction of the screw plug.
CZ335-1104020
●● To decrease the track tension, slowly turn Fig. 5-6

the valve (1) counterclockwise with a long
socket wrench. The grease will come out
of the grease fitting.
●● Loosening the valve (1) only one turn is

enough to decrease the track tension. 1
●● If the grease does not come out smoothly,

travel your machine back and forth for a
short distance.
●● When suitable deflection of the track is

obtained, turn the valve (1) clockwise to
CZ335-1104021
47N·m {15kgf·m}.
Fig. 5-7
●● To check whether you have obtained the
desired track tension, run the engine at low
idle speed, travel the machine forward (at
a distance that is equivalent to the length
of an unfolded track), and then park the
machine.
●● Check the track tension again. Readjust

the tension if it is still beyond the standard
range.
CZ335-1104022
Fig. 5-8

5.8.2.3 Bucket - replace
WARNING
●● Driving a pin shaft with a hammer can

cause flying metal pieces that could
lead to severe injury. Wear goggles,
safety hat, protective gloves and other
protective gears during such an opera-
tion.
●● If the pin shaft is hit with strong force, it
could fly out and cause personal injury.
Make sure that the surrounding area is
clear of people before doing the job.
●● Do not stand behind the bucket when
removing the pin shaft. Do not place
your foot under the bucket when work-
ing at one side.
●● Do not get your finger pinched while re-
moving or installing the pin shaft.
●● Never put your finger inside a pin hole
for aligning.
1. Park the machine on a hard and level

ground and lower the bucket onto the
ground.
If the bucket is put down wither greater

force, resistance to the pin will increase
and it will be not easy to remove the pin.
2. Lock out and tag out the machine as

required. See “Lock out and tag out” on
page 2-68.
CZ335-1103207
Fig. 5-9

3. Remove the nuts on the bolts of the retain-

ing plate of arm pin (1) and link pin (2).
Remove the bolts and take out arm pin
(1) and link pin (2), and then remove the Arm
Linkage
bucket.
NOTE: 1
●● Make sure the pin roll is free from mud or

sand after removal.
2
●● Both ends of the bushing are installed with
CZ335-1103201
seals against dust. Be careful not to dam-
age them. Fig. 5-10
4. Align the arm with the pin hole (3) of the

replacement bucket as well as the link 3
rod with the hole (4). Insert the greased
pins (1) and (2) into hole (3) and hole (4) 4
respectively.
WARNING
When you reconnect the bucket, designate a

commanding person and follow his commands
during operation. CZ335-1103202
Fig. 5-11

NOTE: When mounting the bucket, place the

O-ring (5) of bucket to the position, as shown
in the right illustration. After the pin roll is in-
serted, align it to the standard notch.
5. Reinstall the nuts and bolts onto the plate

retaining the pin rolls. Add grease to the
pin rolls.
5 5
NOTE: CB13031501
Fig. 5-12
●● Inject sufficient amount of grease till the
grease is squeezed out of the end face.
●● Replace any broken seals when replacing

a bucket. The use of broken seals could
allow sand or dust to penetrate through to
the pin roll and cause its abnormal wear.

5.8.2.4 Bucket tips (lateral pin) - replace
Replace the bucket tip before the tip adapter

is worn.
WARNING
●● Make sure the work equipment is stable

when you are replacing bucket tips.
Shut down the engine and engage the
hydraulic lockout control so as to pre-
vent accidents caused by misoperation.
●● The pin may fly out can cause personal
injury if too much force is applied onto
it. Make sure that nobody is in the sur-
rounding area.
●● Flying debris may be present when you
change bucket tips. Be sure to wear
safety goggles, gloves and other per-
sonal protective gears.

page 2-68.
1. Place a block beneath the bucket and keep

the bucket bottom level.
CZ335-1104023
Fig. 5-13

2. Make sure the work equipment is stable

and the hydraulic hydraulic lockout control
is in the locked position.
CC13031403
Fig. 5-14
3. Place a metal stick against one end of the

pin (1) and hammer the metal stick in order
to drive the pin (1) out and remove the
2
bucket tip (2).
1
NOTE:
●● The metal stick shall have a smaller diam-

eter than the pin.
●● If the tip cannot be removed safely in this

way, Consult your Sany distributor for re- CZ335-1104025
placement. Fig. 5-15
4. Remove the tip and check the retainer

for any damage. Replace it if necessary.
The retainers and tips worn short must be
replaced with new ones. 2
5. Clean the installation surface. Insert the

retainer spring into the mounting hole of
the adapter. Mount the new bucket tip (2)
to the adapter. Push part of the pin (1) into
the tip and hammer it in completely in order 1
to lock the bucket tip onto its adapter.
CZ335-1104026
Fig. 5-16

5.8.2.5 Bucket clearance - adjust
WARNING
●● Make sure the work equipment is stable

when you are adjusting bucket clear-
ance. Shut down the engine and engage
the hydraulic lockout control so as to
prevent accidents caused by misopera-
tion.
The bucket clearance must be readjusted after

your machine has been operated for a period
of time. When the clearance is excessively
large or small, it is necessary to install or re-
move the shims.
1. Park your machine on a level ground.

Lower the bucket to the ground, in an at-
titude shown in the right illustration.
2. Run the engine at low speed. Fix the

bucket on the ground. Slowly turn the
upper structure counterclockwise until the
inside of the left side of the bucket contacts
closely with the left end surface of the arm.
3. Shut down the engine. Place the hydraulic

lockout control to the locked position. Tag CZ335-1103207
out the machine as required. See “Lock Fig. 5-17

out and tag out” on page 2-68.

8
7
4. Move the O-ring (1) and measure the
clearance. It is easy to obtain accurate 6
result with a feeler gauge.
5
5. Loosen the two bolts (3), shim (4) and
keep plate (2). Drive out the pin (5) so as
3、4
to separate bucket (6) from arm (8).
6. Add shim (7) according to the wearing 1 2

degree. The clearance must be less than CZ365-1304029
the thickness of one shim. Fig. 5-18
7. Reinstall the pin (5) to its original position.

Replace in turn the keep plate (2), shim (4)
and bolts (3).

5.8.2.6 Window washer fluid level - check/refill

page 2-68.
When washer fluid level is low, fluid ejection

will contains air bubbles. Check fluid level of
washer reservoir (as shown) and add washer
fluid to it as required.
Take care to prevent invasion of dust when

you refill the reservoir.
Mixing ratio of pure detergent and water
Select a mixture ratio according to ambient CB20160512001

temperature. Therefore, the detergent is to be
Fig. 5-19
diluted with water according the ratios listed
below.
Operating
Mixture Ratio Temperature
Regions
General 1:2 - 10°C (14°F)
Cold regions
1:1 - 20°C (- 4°F)
in winter
Frigid regions Pure deter-

- 30°C (- 22°F)
in winter gent
Table 5-9
Note: There are two types of detergent: one

for -10°C {4°F} (common) and one for -30°C
{-22°F} (frigid regions), which can be selected
according to the operating region.

5.8.2.7 Air conditioner - inspect/service
Refrigerant level - check
WARNING
●● Refrigerant can cause blindness or

frostbite when it contacts your eyes or
skin. So do not contact refrigerant. Nev-
er loosen any component in refrigerant
line.
●● Keep any naked fire away from the leak-
ing point of refrigerant gas.
Insufficient refrigerant (R134a) will severely

impair the cooling performance. Running the
air conditioner when refrigerant level is low
may cause damage to the compressor.
Operate the air conditioner for strong refrig-

eration when the engine is running at a high
speed.
Observe through the glass (2) on the condens-

er reservoir (1) in order to inspect the condi- CB2016051101
tion of refrigerant gas flowing to the tube.
Fig. 5-20
●● Refrigerant flows without foam: OK
●● Refrigerant flow contains foam that pass

continuously: Insufficient 2
OK
●● Colorless and transparent: None

Insufficient
NOTE: The existence of foams indicates low

refrigerant level. Please consult your Sany dis- 1 None
tributor to add refrigerant.
CZ215-1104007
Fig. 5-21

Inspection during idle period
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.
Air conditioner components inspection and maintenance schedule
Components Description Service Interval
Twice a year
Refilling
(spring and autumn)
Refrigerant (gas)
Tube connections and internal leakage of
Daily
parts and components
Condenser Radiator fins plugged Every 500 hours
Compressor Function Every 4000 hours
Loose and bent Every 250 hours
V-belt Deterioration, wear, scratch and cracking Every 250 hours
Noise, odor smell or abnormal heat When necessary
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
Loose connections and loose or detached

Joining bolts Every 6 months
nuts and bolts
Installation condition, loose connections, air

Connection tubes When necessary
leakage or any damage
Reservoir dryer temperature Temperature difference indicates a blocked

Every year
difference dryer.
Table 5-10

5.8.2.8 Ceiling window gas spring - inspect
WARNING
●● The gas spring contains high-pressur-

ized nitrogen. Wrong operation can
cause explosion and result in machine
damage and personal injury or death.
●● Keep the gas spring away from naked
fire.
●● Do not drill or weld on the gas spring.
●● Do not hammer the gas spring or ex-
pose it under any impact.
The gas springs are located in top of the cab (at

both the left and right sides).
Contact your Sany distributor for inspection,

repair and replacement when
●● The ceiling window cannot be opened eas-

ily; or when
●● Oil or gas leaks from the gas spring.
CZ335-1104036
Fig. 5-22

How to release pressure in the hydraulic circuit
WARNING
●● The hydraulic circuit is always under

pressure. Relieve the pressure in hy-
draulic circuit when checking or replac-
ing the hoses or fittings.
●● When the engine is stopped, oil and en-
gine components are still hot and can
cause serious burns. Wait until they
have cooled down before operating.
●● Oil may squirt out when removing the
oil filler cap. Therefore, slowly remove
the cap in order to release the internal
pressure.
1. Park your machine on a hard, level ground.
CZ335-1103207
Fig. 5-23
2. Turn the start switch to the ON position

1
within 15 seconds after engine shutdown
and move the hydraulic lockout control to
unlocked position. Move the joysticks and Press
the travel control levers in all directions to
relieve the internal pressure.
3. Remove the butterfly nut (1) on the

breather valve of the hydraulic tank and
press the air vent to relieve the internal
pressure.
CZ215-1304004
Fig. 5-24

5.8.3 Inspection Prior to Startup
For more information about the following items, see "Inspection before starting" on page 4-7.
●● Drain the water and sediment from the fuel tank.
●● Check the water separator for water and sediment. Drain the water.
●● Check the oil level in the hydraulic tank. Add oil.
●● Check the coolant level. Add coolant.
●● Check the oil level in the engine oil pan. Add oil.
●● Check the wires.
●● Check the fuel level. Add fuel.
●● Check the work lamp switch.
●● Check the function of the horn.
●● 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 Every 100 service hours
5.8.4.1 Lubrication
NOTICE
●● If the lubricated components produce abnormal noise, additional lubrication is required

besides regular maintenance.
●● After operating in water, the machine's wet pin rolls are to be greased.
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

(1) Boom cylinder root pin (2 points)
CZ425-1104015
Fig. 5-26
(2) Boom root pin (2 points)
CZ425-1104016
Fig. 5-27
(3) Boom cylinder piston rod end (2 points)

(4) Arm cylinder root pin (1 point)
CZ425-1104017
Fig. 5-28

(5) Boom-arm joining pin (1 point)

(6) Arm cylinder piston rod end (1 point)
(7) Bucket cylinder root pin (1 point)
CZ425-1104018
Fig. 5-29
(8) Arm-linkage joining pin (1 point)

(9) Arm-Bucket joining pin (1 point)
CZ425-1104019
Fig. 5-30
(10) Linkage joining pin (2)

(11) Bucket cylinder piston rod end (1)
(12) Bucket-linkage joining pin (1)
CZ425-1104020
Fig. 5-31

5.8.5.1 Air filter element - inspect/clean/replace
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.
Outer filter element - Clean and replace
●● 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.

1. Open the rear-left access cover of the

machine and loosen the clip or clasp (1)
before removing the cover (2).
CB20160512004
Fig. 5-32
2. Hold the outer filter element (3), shake

it slightly and turn it in both directions in
order to pull it out.
4
3. Check the inner filter element (4) to see if it
displaces or tilts. Push it back to position in 3
case of displacement or tilting. 5
4. Cover the inner element (4) with a piece of

clean cloth to avoid entering of dirt.
5. Clean the dirt inside the cover and the CZ335-1104006
Fig. 5-33

inside (5).
6. Blow the outer filter element with com-

pressed air (less than 0.2MPa) along the
inside and outside pleats.
NOTE:
●● Do not tap the air filter element with any

object when cleaning it.
CZ335-1104008
●● Do not use air filter elements with dam- Fig. 5-34

aged pleats, gaskets or seals.
●● Using a filter element that has been used

for more than a year or an O-ring that has
been cleaned could result failure. Never
use them again.
7. Use a light to illuminate the filter element.

Replace the filter element in case of holes
or reduced thickness found in the filter
material.
CZ335-1104107
Fig. 5-35

Replacement of the inner filter element
1. Remove the outer filter element (3) and

then the inner filter element (4).
2. Cover the air connecting side with a piece 4

of clean cloth to prevent dust form entering
the filter element. 3
3. Clean the inside of the air cleaner body

and then remove the covering cloth.
4. Place the new inner filter element (4) onto

the connecting side. CZ215-1304005
Fig. 5-36
5. Install the outer filter element (3).
Push the filter element straight forward into

the air cleaner housing. You can hold and
shake it slightly to make the task easier.
6. Install the cover (2). Make sure the arrow

mark points upward. Lock the clip (or 2
clasp) (1). Check the gap between the
housing and the cover. Reinstall the cover
if the gap is excessive.
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.
●● When the outer filter element and the cover

have been installed, improper installation
of the inner filter element could damage
the outer element.
●● Fake parts will allow dirt to pass through

and damage the engine due to insufficient
precision in the sealing area. Therefore,
fake parts shall not be used under any cir-
cumstances.

5.8.5.2 Compressor belt tension - inspect/adjust

lock out/tag out your machine before proceed- 2
page 2-68. A
Inspection
Press the middle of the belt between the drive

pulley (1) and the compressor pulley (2) with
your finger (about 58.8N {6kgf}). Measure 1
the deflection (A), which should be be 5-8mm CZ335-1104054
{0.20-0.31in.}. Fig. 5-38
Adjustment
1. Loosen the bolts (4) and (3). 6

4
2. Move the compressor (5) and its bracket (6)

in order to adjust belt tension.
3. Tighten the bolts (4) and (3) after position-

ing the compressor (5).
3
5
4. Check again the belt tension after adjust-
ment. CZ215-1104019
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.

5.8.5.3 Swing bearing - lubricate
WARNING
●● Applying grease to the swing bearing

is dangerous. Do not swing the upper
structure when grease is being applied.
1. Lower the work equipment to the ground

and then shut down the engine. Place the
hydraulic lockout control to the locked posi-
tion. Tag out the machine as required. See
“Lock out and tag out” on page 2-68.
2. Add grease through the two grease fittings

while the upper structure is kept still.
3. Start the engine, move the hydraulic

lockout control to the unlocked position,
and raise the bucket 20-30 mm above the CZ335-1104065
ground. Swing the upper structure by 90°. Fig. 5-40
4. Repeat steps 1 through 3 and add grease.
NOTE:
●● The grease is used to prevent distortion

and noise of joints.
●● It is necessary to add grease to any com-

ponent that appears inflexible or noisy after
operation for a long period.
●● Wipe off the used grease that has been

squeezed out when greasing.
●● Make sure to wipe off all used grease in

different locations. Using a grease that has
been contaminated by sand or debris can
lead to wear of rotating components.

5.8.5.4 Pipe clamps of hydraulic system - check
●● 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.

The 100 hour and 250 hour services shall be

carried out in the mean time.
5.8.6.1 Swing pinion gear grease level -

inspect/fill

page 2-68.
●● Prepare a dipstick.
1. Remove the two bolts (1) from the swing

frame. Remove the cover (2).
2
CZ335-1104068
Fig. 5-41
2. Put the dipstick (3) into the grease through

the inspection hole. Check the grease level
(S), which should be 14 mm {0.6 in} at 3
minimum. If grease level is lower than this
value, you need to add grease.
3. Check if the grease turns milk-white. Milk- S

white grease indicates that the grease has
been contaminated. Consult your Sany
distributor to change the grease.
Grease capacity: 35L (9.24 US gal) CZ335-1104069
Fig. 5-42

4. Use the bolts (1) to reinstall the cover (2).
CZ335-1104070
Fig. 5-43

5.8.6.2 Engine pan oil and filter element -

change/replace
CAUTION
●● When the engine has just been stopped,

the parts and oil are still hot and can
cause serious burns. Wait for them to
cool down before you proceed.
●● For capacity of engine oil pan see "Table

of capacities" on page 5-18.
●● Prepare a filter element wrench.

ing. See “Engine shutdown procedure prior
to maintenance” on page 2-66 and “Lock
1
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.
2. To prevent oil from splashing onto your

body, slowly open the drain valve to dis-
charge oil. Close the drain valve when you Oil pan
finish.
clean cloth
Container
CZ335-1104057
Fig. 5-45

3. Open the right access door of the machine

and turn the filter element (2) counterclock-
wise with filter element spanner in order to
disassemble the filter element.
4. Clean the filter element seat (3). Fill the

new filter element with clean engine oil.
Apply engine oil (or a film of grease) to
the filter sealing surface and the threads
before installing the filter element to its
seat.
CB20160512005
Remark: Check the filter element seat (3) for Fig. 5-46

presence of used seal. The presence of used
seal in the filter element seat (3) can cause oil
leakage.
5. The installation requires contact of the

sealing surface with that of the filter ele-
ment seat (3). Turn the filter element 3/4-1
turn.
6. Open the engine hood and add engine oil

through the filler. After 15 minutes, check if L H
oil level is between the H and L marks on
the dipstick.
CZ335-1103131
7. Run the engine idly for a short time and Fig. 5-47

then turn off the engine. Check again the
oil level, which shall be between the H and
L marks of the dipstick. For more informa-
tion, see "Oil level in oil pan - check/
add" on page 4-11.
8. Reinstall the bottom cover.
NOTICE
●● To ensure oil quality and 500 service

hour change interval, buy genuine en-
gine oil from your Sany distributor.

5.8.6.3 Primary fuel filter element - replace
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.
See “Engine shutdown procedure” on page 2-67 and “Lock out and tag out” on page 2-68.
●● Prepare a container to store the fuel drained.
●● Prepare a filter spanner.

1. Open the right access door of the machine.
2. Place a container under the primary fuel

filter to collect the fuel to be drained.
3. Loosen the drain valve (1) to discharge

all water and sediment from bowl (2). Also
discharge the fuel in filter element (3).
4. Turn the handle (5) counterclockwise with

a filter wrench to remove it. Take the filter
and O-ring (4) out.Turn the filter cartridge
(3) counterclockwise with a filter wrench to CB20160512006
remove it.
Fig. 5-48
5. Install a new filter and O-ring (4). (O-ring (4)
must be replaced.)
6. The sealing surface shall have close

contact with that of the filter element (3).
Further tighten it by 1/4-1/2 turn.
If the bowl is tightened too much, the O-ring

seal will be damaged and oil leak could
result. If the bowl is not tightened enough,
fuel will leak through the gap of O-ring
seal. To prevent such problems, proper
tightening is required.
NOTE: If the handle is tightened too much, the

O-ring seal will be damaged and oil leak could
result. If the handle is not tightened enough,
fuel will leak through the gap of O-ring seal.
To prevent such problems, proper tightening is
required.
7. Clean the filter seat and fill a new filter

element with clean fuel. Apply a film of
machine oil to the sealing surfaces before
installing the new filter element to its seat.

8. Check the drain valve (1) to see if it has been tightened enough.
9. Bleed the air after replacement of the filter element (3).
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.

5.8.6.4 Secondary fuel filter element - replace
WARNING
NOTE:
●● Prepare a container to hold the fuel drained.
●● Prepare a filter element spanner.

2. Place a container under the filter element.
3. Loosen the drain valve (1) to discharge all

water and sediment from filter cartridge (2).
Also discharge the fuel in filter element.
4. Turn counterclockwise the filter cartridge(2)

with the filter element spanner to remove
it.
5. Take the filter and O-ring out.

CB20160512008
6. Clean the filter element seat. Apply a Fig. 5-49

film of oil to the surface of the new filter
cartridge before mounting it to the filter
element seat.
7. Install a new filter and O-ring. (O-ring must

be replaced.)
NOTE:
●● Do not fill the new filter cartridge with fuel.
8. During installation, tighten the filter car-

tridge until its sealing surface contacts that
of the filter seat. Then, tighten it further
by 3/4 turn.If the filter cartridge is over-
tightened, the seals may be broken and
oil leakage could result. If the cartridge is
too loose, fuel will leak from the sealing
location. Therefore, the filter element must
be tightened to a suitable torque.
9. Bleed the air after filter element replace-

ment.

5.8.6.5 Tertiary fuel filter element – replace
WARNING
NOTE:
●● Prepare a container to hold the fuel drained.
●● Prepare a filter element spanner.


1
2. Place a container under the filter element.
3. Turn counterclockwise the filter cartridge

(1) with the filter element spanner to
remove it.
4. Replace the internal seal (2) with a new

one.
5. Clean the filter element seat. Apply a CZ425-1104039

film of oil to the surface of the new filter Fig. 5-50
cartridge before mounting it to the filter
element seat.
NOTE:
●● Do not fill the new filter cartridge with fuel.
●● Remove the cover 3) and install the car-

tridge.
6. During installation, tighten the filter car-

tridge until its sealing surface contacts that
of the filter seat. Then, tighten it further by CB20160512007
3/4 turn.
Fig. 5-51
If the filter cartridge is over-tightened, the
seals may be broken and oil leakage could
result. If the cartridge is too loose, fuel will
leak from the sealing location. Therefore,
the filter element must be tightened to a 3
suitable torque.
7. Bleed the air after filter element replace-

ment.
CZ335-1104191
Fig. 5-52

Air bleeding procedure:
8. Fill the fuel tank till the float reaches its

maximum level.
9. Loosen the plug on top of the second-

ary fuel filter. Release the knob of hand
pump (3) and pull it out. Pump oil until all
foam disappears and diesel oil stream is
continuous and cohesive to give powerful
injection.
CB20160512009
NOTE:
Fig. 5-53
●● It is necessary to remove the plug on top
of the primary fuel filter and the secondary
fuel filter.
●● When fuel level is low, operate the pump in

the same way to bleed air.
10. After replacing the filter cartridge start the

engine and run it at low idle for 10 minutes.
Check for fuel leakage on the sealing

surface of the filter cartridge. If fuel leaks,
check if the cartridge is well tightened. If
fuel leakage does not stop, repeat steps 1
through 3 to remove the filter cartridge. If
damage or foreign objects are found on the
sealing surface, the cartridge with a new
one and follow steps 4 through 13 to install
it.

5.8.6.6 Radiator and oil cooler fins -

inspect/clean
WARNING
●● If you are struck by compressed air,

high pressure water or steam, or they
are used to blow away dust or contami-
nants, bodily injury could result. Always
wear goggles, dust mask or other pro-
tective gears.
CAUTION
●● When compressed air is used for clean-

ing, a safe distance must be kept so as
to avoid damaging the radiator fins.
●● In a dusty place, check the radiator fins
everyday regardless of the specified
maintenance intervals.

page 2-67 and “Lock out and tag out” on 1
page 2-68.
1. Open the engine hood (1).
CZ425-1104026
Fig. 5-54

2. Open the left access door of the machine

and clean the condenser fins (2) of air
conditioner.
3. Inspect the coolant tank, the intercooler

fins (3) ,the water cooler fins (4) and the
fuel cooler fins(6). If there are dirt and/or
tree leaves attaching to the fins, sweep
them with compressed air.
Steam or water can also be used besides

compressed air. CB20160512010
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.
4. Inspect the rubber hoses. Replace the

hoses in case of cracking or aging. Check
the hose clamps for looseness.
5. Remove the cover plate (5) under radiator.

Eliminate the dirt, debris and tree leaves
that have been swept to the external edge. 5
6. Reinstall the cover plate (5). Lock the

engine hood and the left access door.
CZ425-1104029
Fig. 5-56

5.8.6.7 Air conditioner fresh air/recirculation filter - clean
WARNING
●● When compressed air is used, dust in

air is harmful to health. Always wear
goggles, dust mask or other protective
gears.
The filter shall be cleaned every 500 hours,

but operating your machine in a dusty place
requires cleaning the filter more frequently.
A dust-clogged air filter reduces air flow and

causes the A/C unit to produce noise.

lock out/tag out your machine before proceed- 1

page 2-68.
Cleaning the recirculation filter
1. Remove the screw (1) from the access

cover in the rear of the cab, loosen the
locking nut (2) and remove the internal air
CZ335-1104075
filter (3).
Fig. 5-57
2. Use compressed air to clean the filter. If
the filter bears oil or too much dirt, clean it
with moderate detergent. After the filter has
been flushed with water, it must be dried
completely before reuse. This filter shall
be replaced every year with a new one. If 2
a plugged air filter cannot be cleaned with
compressed air or flushing water, replace it
immediately. 3
CZ335-1104076
Fig. 5-58

Cleaning the fresh air filter
1. Unlock and open the cover (4) on the left

side of the cab. Remove the locking nut (5)
and take out the fresh air filter (6).
4
2. Use compressed air to clean the filter. If

the filter bears oil or too much dirt, clean it
with moderate detergent. After the filter has
been flushed with water, it must be dried
completely before reuse. This filter shall
be replaced every year with a new one. If CZ335-1104077
a plugged air filter cannot be cleaned with Fig. 5-59
compressed air or flushing water, replace it
immediately.
3. After cleaning, restore the filter (6), tighten

the nut (5) and lock the cover.
4 5
CZ335-1104078
Fig. 5-60
NOTE: The fresh air filter must be installed

correctly. To install the filter, the long end (L) of
S
the filter (6) must be inserted first into the filter
box. By inserting the short end (S), the cover L
(4) will not be closed.
6
4
CZ335-1104079
Fig. 5-61

5.8.6.8 Swing drive oil level - check/refill
WARNING

cool down before you proceed. 1
Always prepare your machine as required and 2

page 2-68.
1. Remove the dipstick (2) and wipe off the oil

on it. CB13050901-2
Fig. 5-62
2. Insert the dipstick (2) back into the tube.
3. Take out the dipstick (2) and check whether

the oil level is between the H and L marks.
4. If the oil level is lower than the L mark on

the dipstick (2), remove the filler cap (1)
H
and add oil.
L
CZ335-1204006
Fig. 5-63
5. If the oil level goes beyond the H mark on

the dipstick (2), loosen the drain valve (3)
and to drain the excessive oil.
●● If the oil level is too high, Consult your 3

Sany distributor for inspection.
●● Place a container under the drain valve

before draining machine oil.
6. After checking the oil level or refilling the

oil, insert the dipstick (2) into the tube and CZ335-1104084
restore the filler cap (1). Fig. 5-64

5.8.6.9 Final drive oil level - check/refill
WARNING
●● When the engine is shut down, the oil is

still hot. Wait until the oil is cool enough
before operation.
●● Residual pressure in the tank can cause
oil to squirt out or the screw plug to fly
out. Slowly loosen the screw plug in or-
der to release the pressure.
●● When the screw plug is being loosened,
do not stand in front of the screw plug.
1. Park the machine on a hard and flat

ground and adjust position so that the
1
drain plug (3) is closest to the ground. Stop
2
the engine and place the lockout control to
the locked position. Tag out the machine 3
before proceeding. See “Lock out and

tag out” on page 2-68. Oil level
2. Use a proper screwdriver to remove the

dirt in the hexagonal socket of screw plug.
3. Remove the plug (2) with a spanner. Check CZ235-1104017

oil level and for contamination. When oil Fig. 5-65
level reaches the plug hole, the volume of
oil is fine. When the level is low, refill gear
oil via the plug hole (1).
4. Clean the plug (2) with diesel oil and

reinstall the plug.
5. Check the other final drive through in the

same way.

5.8.6.10 Engine coolant pump (fan shaft) -

lubricate
Sweep the dust and soil from grease filler

opening, as indicated by the arrow, before you
replenish specified grease.
Grease: NLGI No.2 (lithium base)
CB20160512011
Fig. 5-66

The 100, 250 and 500 hour services shall be

5.8.7.1 Hydraulic oil return filter element /

oil drain filter element/pilot filter
element- replace
WARNING

For machines equipped with a hydraulic

breaker, the hydraulic oil deteriorates faster
than that of machines operating with a bucket.
For more information, see "Hydraulic oil and
filter - change/replace" on page 8-15.
1. Park your machine on a hard, level ground.

Adjust the work equipment to an attitude
ready for service. Lower the work equip-
ment to ground and stop the engine. Tag
out the machine before proceeding. See
“Lock out and tag out” on page 2-68. CZ335-1104086
Fig. 5-67

2. Remove the butterfly nut 【1】 of the

1
breather valve on top of the hydraulic tank.
Press the bleeder valve to release internal
pressure. Press
3. Loosen the four bolts and remove the cap

【2】. When the cap is being removed, it
may eject due to the action of the spring
【3】 . In this case, hold down the cap
when removing the bolts.
4. Remove the spring 【3】, valve 【4】 and CZ215-1304004
filter element 【5】. Fig. 5-68
●● Check the bottom of the filter box and re-

move the dirt if any. Keep the hydraulic oil
free from any dirt. 2
3
5. Clean the disassembled parts with clean-
ing oil.
4
6. Install a new filter element.

5
7. Restore the valve 【4】 and spring 【3】.
8. Install the cap 【2】 to its position. Hold

down the cap and tighten the bolts. CZ425-1104036
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.
10. To bleed the air, start the engine and run it

at low idle for 10 minutes.
11. Stop the engine.
CZ365-140625001
Fig. 5-70

12. Replacement of pilot filter element 【7】.

replacement procedure is similar to the
aboe step 3 through step 8.
5.8.7.2 Swing drive oil - change 2015020501
Fig. 5-71
WARNING


1
page 2-68.
●● Oil capacity: 10.5 L
1. Place a container under the drain valve 1)

to collect the gear oil drained.
2. Loosen the drain valve (1) to drain the gear

oil. Tighten the drain valve upon comple- CB13051401-2
tion of the draining. Fig. 5-72
NOTE:
●● If the gear oil flows out in a thin thread pat-

tern, stop draining.
●● When ambient temperature is low, you can

swing the work equipment to slightly in-
crease the oil temperature before draining
the oil. However, the work equipment shall
not be swung during draining, which may
otherwise damage the swing unit.

3. Remove the filler cap (2) and add oil as

required through the filler opening.
2
4. Check the oil level with the dipstick (3). For
more information, see "Swing drive oil 3
level - check/refill" on page 5-68.
5. Apply sealant onto the thread of the filler

opening and tighten the filler cap.
NOTE: Improper tightening of the filler cap

may cause the gear oil in the swing drive to CB13050901-2
leak. Fig. 5-73
5.8.7.3 Engine exhaust pipe clamps - check
Consult your Sany distributor to check the

fastening conditions of the air cleaner - turbo-
charger - post cooler - engine clamps.
5.8.7.4 Fan belt tension - check/replace
Check the tension of fan belt. Replace the fan

belt in case of cracks or damage. Contact your
Sany distributor if you have any troubles.
5.8.7.5 Nitrogen pressure in accumulator

(breaker) - check
(If equipped)
Special tools will be used in order to check the

accumulator and inject nitrogen.
Please Consult your Sany distributor, if possi-

ble, to conduct related inspection and inflating
operation.

5.8.7.6 Breather valve - check/replace
WARNING
●● The engine must be shut down when

you service the breather valve.
●● Hot components and oil can cause
burns. Wait until they are cool enough
before you proceed.

page 2-68.
1. Clean the top of the hydraulic tank before
removal. Clean especially the area around
the breather valve (as shown). The job site
shall be free from fire sources and dust.
2. Remove the butterfly nut (1) of breather

valve and press the bleeder valve to
release internal pressure.
3. Remove lock nut (2) and cover (3) and

take off the filter element (4).
CZ335-1104080
4. Clean the filter element is covered by too Fig. 5-74

much dirt, clean it with a brush. And then
flush the element with Tonson detergent
outwardly.
5. Place it in a ventilated place after cleaning. 1

Dry it completely before reassembly.
3
2
NOTE:
4
●● When assembling the hexagonal nut (2),

tighten it to the specific torque (10-14 N·m).
Never tighten it with extra force in order to
have better sealing.
●● Replace the breather valve filter element CC13031501
if it has used for a year or cleaned for 6 Fig. 5-75

times. If the filter element (4) is serious
worn, replace it immediately.

5.8.7.7 Filling lubricating grease of Rotary Reduction Gear
1. Lower the work equipment to the groundand then shut down the engine. Place thehydraulic
lockout control to the locked position.
2. Filling lubricating grease from “filling lubricating adapter” until overflow.
NOTE:
●● Wipe off the used grease that has been squeezed out when greasing.
●● Part excavator’s“filling lubricating adapter”has hose,filling lubricating grease from hose’s

adapter.


The 100, 500 and 1000 hour services will be
5.8.8.1 Final drive oil - change
WARNING
●● After the engine has just been shut

down, the oil and components are still
hot and can cause burns. Wait until they
are cool enough before you proceed.
●● Residual pressure in the tank can cause
oil to squirt out or the screw plug to fly
out. Slowly loosen the screw plug to re-
lease pressure. Never stand in front of
the plug.
●● Refilling capacity: Refer to "Table of ca-

pacities" on page 5-18.
ground and adjust position so that the
1
drain plug (3) is closest to the ground. Stop
2
the engine and place the lockout control to
the locked position. Tag out the machine 3
before proceeding. See “Lock out and

tag out” on page 2-68. Oil level
2. Use a proper screwdriver to remove the

dirt in the hexagonal socket of screw plug.
3. Place a container under the drain port (3)to
collect the oil. Loosen the level port plug (2) CZ235-1104017
and the drain port plug to discharge oil.
Fig. 5-76
4. When the oil in the final drive is drained,
clean the drain port plug with clear diesel
fuel and install the plug.
5. Remove the fill port plug (1) and add speci-
fied gear oil through the filler opening until
oil flows out from the level port.
6. Clean the plug with clear diesel fuel and
re-install the plug.
NOTE: Check the O-ring on screw plug and
replace the O-ring if it is damaged.

5.8.8.2 Hydraulic oil suction filter element

– clean/replace
WARNING


1
page 2-67 and “Lock out and tag out” on Press
page 2-68.
1. Remove the butterfly nut (1) of the breather
valve on the hydraulic tank and press the
bleeder valve to relieve internal pressure.
CZ215-1304004
Fig. 5-77
2. Loosen the four bolts and remove the cap

(2). When the cap is being removed, it may 2
fly out due to the action of the spring (3). In 3
this case, hold down the cap when remov- 4
ing the bolts.
5
3. Hold the top end of the rod (4) and pull it
upward to remove the spring (3) and the
suction filter element (5).
6
4. Clean the suction filter element (5). Flush it

with cleaning oil. Replace the suction filter CZ425-1104042
elemen if it is damaged. Fig. 5-78
5. During installation, fix the suction filter ele-

ment (5) to the projected part (6) of the oil
tank before assembling.
6. When assembling, use the bulged part of

the cap (2) to hold the spring (3) before
tightening the bolts.
5.8.8.3 Nitrogen pressure in accumulator

(control oil circuit) - check
WARNING
●● The accumulator contains pressurized

nitrogen, which may explode due to im-
proper operation and result in machine
damage and personal injury.
●● Be away from fire sources. Do not
strike or roll the accumulator. Keep it
free from any impact.
●● Release the gas completely when you
handle the accumulator. Consult your
Sany distributor to do this job.
NOTE: In continuous operation with low nitro-

gen pressure in the accumulator, the remain-
ing pressure in hydraulic circuit will not be re-
leased once failure occurs to your machine.
Functions of the accumulator
The accumulator stores the pressure of the

control circuit. Even if the engine is turned off,
the control oil circuit allows you to achieve the
following operations:
●● Operate the control lever to lower the work

equipment. The work equipment will fall
due to gravity.
●● The pressure in hydraulic circuit can be re- CB2016051303
leased. Fig. 5-79
The installation location of the accumulator is


Checking the functions of accumulator
CAUTION
●● During inspection, make sure the sur-

rounding area is clear of personnel or
any barriers.
Check nitrogen pressure in the accumulator

through the following steps:

ground.
2. Keep the work equipment 1.5m (4'11'')

above the ground at maximum reach (with
the arm cylinder and the bucket cylinder 1.5m
fully retracted).
The step 3 through step 5 shall be con- CZ335-1104095

ducted within 15 seconds. Fig. 5-80
The accumulator’s pressure drops gradu-

ally after engine shutdown. Check the
accumulator immediately after the engine
is shut down.
3. Keep the work equipment at its maximum

operating radius, turn the start switch to
OFF position and stop the engine.
5. Place the hydraulic lockout control to

unlocked position. Operate the joysticks
and lower the work equipment. Check if
the work equipment touches the ground.
CC13031404
Fig. 5-81

6. If the work equipment fall under its own

weight to the ground, this shows the ac-
cumulator functions normally.
If the work equipment fails to fall to the

ground, this shows pressure in the accu-
mulator has dropped. Consult your Sany
distributor for such inspection.

locked position and turn the start switch to
the OFF position. CZ335-1104099
Fig. 5-82

Releasing pressure from hydraulic circuit
1. Low the work equipment to the ground.
2. Place the lockout control to the locked

position.
The steps 4 through step 6 shall be carried

out within 15 seconds.
Pressure of the accumulator will drop

gradually after the engine is stopped.
Therefore, the pressure can only be CC13031403
Fig. 5-83
released when the engine has just be

turned off.
ON
OFF
STA
T
HEA
RT
CC13031804
Fig. 5-84
3. Turn off the engine.
5. Place the lockout control to unlocked posi-

tion and then cycle the control levers in all
directions to release the pressure in control
circuit.
6. Place the lockout control to the locked

position (L) and then turn the start switch CC13031404
to OFF position. Fig. 5-85

5.8.8.4 Cooling system interior - clean
WARNING
●● Coolant in the radiator is still hot and

under high pressure when the engine is
shut down. Removing the radiator cap
at this time may cause severs burns.
Loosen the cover slowly when the cool-
ant has cooled down to relieve internal
pressure before removing it.
●● When the engine is started for cleaning
purpose, place the hydraulic lockout
control in the locked position to prevent
unexpected machine movement.
●● Antifreeze is flammable. Keep it away
from fire.
●● Antifreeze is toxic. Never allow it to
contact your eyes and/or your skin.
Wash with plenty of water and seek
medical treatment immediately if anti-
freeze contacts your eyes or skin.
●● Never dump the coolant directly into
the sewer system or onto the ground.
Contact your Sany distributor when you
need to change the coolant.
1. Park your machine on a level ground

and then shut off the engine. Tag out the
machine before you proceed. See “Lock
2. Remove slowly the radiator cap (1) to

relieve pressure only when the coolant is
cool enough for you to touch the radiator
cap with your bare hand.
CB2015051301
Fig. 5-86

3. Remove the bottom cover under the radia-

tor and place a container to collect the
coolant under the drain valve (2). Open the
drain valve (2) to drain the coolant.
4. Close the drain valve (2) after draining

the coolant. Add tap water to the radiator.
When the radiator is full, start the engine
at a low speed in order to heat up to 90°C
(194°F)at minimum. Continue to run the
engine for about 10 minutes.
CB2016051302
5. Stop the engine and open the drain valve
Fig. 5-87
(2) to discharge water. Use detergent to
clean the radiator after draining the water.
Refer to the detergent instruction for clean-
ing method.
6. Close the drain valve (2). Add coolant to

the radiator till it overflows from the filler
opening.
7. Run the engine at low speed for about 5

minutes and then at high speed for another
3 minutes to bleed the air from the coolant.
(The radiator cap (1) shall be left open at
the moment.)
8. Stop the engine. Wait about 3 minutes

before adding water through the filler
opening. Screw on the radiator cap tightly.
9. Install the bottom cover.

5.8.8.5 Alternator - inspect
Contact your Sany distributor to inspect the alternator.
Check the engine every 1000 service hours if the engine is started frequently.
5.8.8.6 Engine valve clearance - check/adjust
Special tools are necessary for inspection and maintenance. Consult your Sany distributor to do
this job.

The 100, 250, 500, 1000 and 2000 hour ser-

vices shall be carried out in the meantime.
5.8.9.1 Water pump - inspect
Check the water pump for water leakage or oil

leakage. In case of any problem, Contact your
Sany distributor for disassembly, repair or re-
placement.
CZ335-1104104
Fig. 5-88
5.8.9.2 Start motor - check
Consult your Sany distributor to check the

start motor. Check it every 1000 service hours
if the engine is started frequently.

5.8.9.3 Oil in hydraulic tank - change
WARNING

●● Press the breather valve venting button
to release the internal pressure before
removing the oil filler cap.
NOTE:
For machines equipped with a hydraulic

breaker, the hydraulic oil deteriorates faster
than that of machines operating with a bucket.
For more information, see "Hydraulic oil and
filter - change/replace" on page 8-15.
●● Refilling capacity: Refer to "Table of ca-

pacities" on page 5-18.
●● Prepare a lever (used for 36 mm socket

wrenches)
1. Unscrew the bolts of the bottom cover

plate and remove the cover plate.
2. Swing the upper structure in order to posi-

tion the drain plug beneath the hydraulic
tank between the tracks.
3. Retract the arm and bucket cylinders and

lower the boom in order to enable the
bucket tips to touch the ground.
4. Place the lockout control to the locked CZ335-1104102

position and turn off the engine. Fig. 5-89

5. Remove the cap of the oil filler (1). 1
6. Place a container under the drain plug.

Remove the drain plug (2) with the lever to
drain the oil. Check the O-ring on the drain
plug (2) and replace it timely if broken.
Tighten the plug (2) after draining.
NOTE: Do not get oil on your body when re-

moving the drain plug (2).
7. Add hydraulic oil as required through the 2

CZ335-1104103-2
filler (1). Check the oil level, which shall be Fig. 5-90
between the H and L marks of dipstick.
●● For more information on applicable hydrau-

lic oil, see "Recommended Fuel, Coolant
and Lubricant" on page 5-15.
●● For more information on oil level inspec-

tion, see "Swing drive oil - change" on
page 5-73.

5.8.9.4 Accumulator - replace
Replace the accumulator every two years or

4000 service hours, whichever occurs first.
WARNING
●● The accumulator contains pressurized

nitrogen, which may explode due to im-
proper operation and result in machine
damage and personal injury.
●● Be away from fire sources. Do not
strike or roll the accumulator. Keep it
free from any impact.
●● Release the gas completely when you
handle the accumulator. Consult your
Sany distributor to do this job.
If your machine is kept operating when the

performance of accumulator decreases, the
pressure in the hydraulic system will not be
released. Consult your Sany distributor to re-
place the accumulator.
CB2016051303
Fig. 5-91

5.8.9.5 High-pressure tube clamps and rubber - check
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.
5.8.9.6 Compressor working condition - inspect
The following two items are to be inspected:
1. Whether the compressor and the magnetic clutch are switched on/off when switching on/off
the air conditioner.
2. Whether the clutch or compressor produces abnormal noise.
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.
5.8.10.1 High-pressure tube clamps - replace
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.

E
G
PA
K
AN
BL

SY500H-10 Crawler Hydraulic Excavator Troubleshooting
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

Troubleshooting SY500H-10 Crawler Hydraulic Excavator

6 TROUBLESHOOTING
6.1 Troubleshooting Preparation
6.1.1 Checks before troubleshooting
Item Judgement value Remedy
1. Check fuel level and type of fuel — Add fuel

2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
4. Check hydraulic oil strainer — Clean, drain
Lubricating 5. Check swing drive oil level — Add oil
oil, coolant 6. Check engine oil level (in oil pan) — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
—
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
Hydraulic, 1. Check for abnormal noise and smell — Repair

mechanical 2. Check for oil leakage — Repair
equipment 3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20~30V Replace

2. Check battery electrolyte level — Add or replace
3. Check for discolored, burnt, exposed wiring — Replace
4. Check for missing wiring clamps and hanging wiring — Repair
5. Check for water leaking on wiring (be particularly — Disconnect con-
Electrics, careful attention to water leaking on connectors or nector and dry
electrical terminals) —
equipment 6. Check for blown or corroded fuses After running for Replace
7. Check alternator voltage (engine running at 1/2 several minutes: Replace
throttle or above) 27.5~29.5V Replace
8. Check operating sound of battery relay —
(when switch is turned ON/OFF)
Table 6-1

6.1.2 Troubleshooting precautions
CAUTION
●● Park the machine on a hard, level

ground. Make sure safety pins, blocks
and machine brake are functional.
●● Workers in the same team must use the
same signal system. Keep other per-
sonnel a safe distance away from the
machine.
●● If the radiator cap is removed when the
engine is hot. Hot coolant may squirt
out and cause burns, wait for the en-
gine to cool down before troubleshoot-
ing.
●● Take care not to touch any hot parts or
be seized by any rotating parts.
●● Before disconnecting any electrical wir-
ing, always disconnect the negative (–)
post of battery.
●● Before removing the plug or cap from
any vessel that contains pressurized
oil, water or air, release the internal
pressure.
●● When installing a measuring equip-
ment, be sure to connect it properly.
●● The aim of troubleshooting is to pinpoint

the basic cause of the failure, to carry out
repairs swiftly, and to prevent reoccurrence
of the failure.
●● When carrying out troubleshooting, it is

important to understand the structure and
function.
●● However, a short cut to effective trouble-

shooting is to ask the operator various
questions to form some idea of possible
causes of the failure that would produce
the reported symptoms.

1. When carrying out troubleshooting, do not

hurry to disassemble the components.
If components are disassembled immedi-

ately any failure occurs:
●● Parts that have no connection with the

failure or other unnecessary parts will
be disassembled.
●● It will become impossible to find the

cause of the failure.
It will also cause a waste of man-hours,

parts, or oil or grease, and at the same
time, will also lose the confidence of the
user or operator.
For this reason, when carrying out

troubleshooting, it is necessary to carry out
thorough prior investigation and to carry
out troubleshooting in accordance with the
fixed procedure.
2. Points to ask user or operator:
●● Have any other problems occurred

apart from the problem that has been
reported?
●● Was there anything strange about the

machine before the failure occurred?
●● Did the failure occur suddenly, or were

there problems with the machine condi-
tion before this?
●● Under what conditions did the failure

occur?
●● Had any repairs been carried out be-

fore the failure? When were these re-
pairs carried out?
●● Has the same kind of failure occurred

before?
3. Check before troubleshooting
●● Check or any external leakage of oil

from the piping or hydraulic equipment.

●● Check the travel of the control levers.
●● Check the stroke of the control valve

spool.
●● Other maintenance items can be

checked externally, so check any item
that is considered to be necessary.
4. Confirming failure
●● Confirm the extent of the failure your-

self, and judge whether to handle it as
a real failure or as a problem with the
method of operation, etc.
●● When operating the machine to reen-

act the troubleshooting symptoms, do
not carry out any investigation or mea-
surement that may make the problem
worse.
5. Troubleshooting
●● Use the results of the investigation

and inspection in Items 2 – 4 to narrow
down the causes of failure, then use
the troubleshooting flowchart to locate
the position of the failure exactly.
●● The basic procedure for troubleshoot-

ing is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or

information.
6. Measures to remove root cause of failure
●● Even if the failure is repaired, if the root

cause of the failure is not repaired, the
same failure will occur again. To pre-
vent this, always investigate why the
problem occurred. Then, remove the
root cause.

6.1.3 Electrical circuits troubleshooting

precautions
1. Always turn the power off before discon-

necting or connect connectors.
2. Before carrying out troubleshooting, check

that all the related connectors are properly
inserted.
●● Disconnect and connect the related

connectors several times to check.
3. Always connect any disconnected connec-

tors before going on to the next step.
●● If the power is turned ON with the con-

nectors still disconnected, unnecessary
abnormality displays will be generated.
4. When carrying out troubleshooting of

circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
●● If there is any change, there is probably

defective contact in that circuit.

6.1.4 Hydraulic components handling

precautions
With the increase in pressure and precision

of hydraulic equipment, the most common
cause of failure is dirt (foreign material) in the
hydraulic circuit. When adding hydraulic oil, or
when disassembling or assembling hydraulic
equipment, it is necessary to be particularly
careful.
1. Be careful of the operating environment
Avoid adding hydraulic oil, replacing filters,

or repairing the machine in rain or high
winds, or places where there is a lot of
dust.
2. Disassembly and maintenance work in the

field
ZX215-1000023
If disassembly or maintenance work is Fig. 6-1

carried out on hydraulic equipment in the
field, there is danger of dust entering the
equipment. It is also difficult to confirm the
performance after repairs, so it is desir-
able to use unit exchange. Disassembly
and maintenance of hydraulic equipment
should be carried out in a specially
prepared dust-proof workshop, and the
performance should be confirmed with
special test equipment.
3. Do not let any dirt or dust get in during

refilling operations.
Be careful not to let any dirt or dust get

in when refilling with hydraulic oil. Always
keep the oil filler and the area around it
clean, and also use clean pumps and oil
containers. If an oil cleaning device is
used, it is possible to filter out the dirt that
has collected during storage, so this is an
even more effective method. ZX215-1000025
Fig. 6-2

4. Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it

flows easily. In addition, the sludge can
also be drained out easily from the circuit
together with the oil, so it is best to change
the oil when it is still warm. When changing
the oil, as much as possible of the old
hydraulic oil must be drained out. (Drain
the oil from the hydraulic tank; also drain
the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
5. Flushing operations
After disassembling and assembling

the equipment, or changing the oil, use
flushing oil to remove the contaminants, Flushing oil
sludge, and old oil from the hydraulic cir-
cuit. Normally, flushing is carried out twice:
primary flushing is carried out with flushing
oil, and secondary flushing is carried out
with the specified hydraulic oil.
ZX215-1000026
Fig. 6-3
6. Cleaning operations
After repairing the hydraulic equipment

(pump, control valve, etc.) or when run-
ning the machine, carry out oil cleaning
to remove the sludge or contaminants in
the hydraulic oil circuit. The oil cleaning
equipment is used to remove the ultra fine
(about 3μ) particles that the filter built into
the hydraulic equipment cannot remove, so
it is an extremely effective device. ZX215-1000027
Fig. 6-4

6.2 Measures Taken When Failure Occurs
6.2.1 Failure-like phenomena
Note that the following phenomena are not

machine failures:
●● The arm speed may drop suddenly when

retracting the arm with the work equipment
lowering unloaded and the arm in a nearly
vertical position.
CZ335-1103213
Fig. 6-5
●● When the bucket tips are nearly parallel

to the ground, the bucket speed may drop
suddenly.
●● The brake valve produces noise when

starting or stopping swinging operation.
●● The travel motor produces noise when the

machine travels downhill at low speed.
CZ335-1103214
Fig. 6-6

6.2.2 Towing the machine
WARNING
●● Make sure that the wire cables used for

towing the machine are strong enough,
which may otherwise result in acci-
dents.
●● While towing the machine, do not use
wire cables with broken wires (A), re-
duced diameter (B) or knot (C) in order
A
to prevent rupture of the wire cables.
●● Always wear protective gloves when B
handling wire cables.
●● Never tow the machine on a slope. C
●● Never stand between the towing ma-

chine and faulty machine when per-
forming towing operation. CZ335-1102063
●● Operate the machine slowly and avoid Fig. 6-7

imposing sudden load on wire cable.
NOTE: The towing operation must be per-

formed within the maximum towing capacity.

●● If the machine is trapped in mud and can-

not move out of the mud with its own force,
or the towing force of excavator is occu-
pied by heavy object, wire cables can be
used as shown in the right illustration.
●● Place wood blocks or other protective

materials between where the wire cable
contacts the machine in order to prevent
friction between the wire cable and the ma-
chine.
CZ335-1103216
●● Keep the wire cable parallel to the ground Fig. 6-8
and align its direction with that of the track
frame.
●● Move at a speed of 1Km/h when towing

the machine. Tow the machine to a place
suitable for repair. Never tow the machine
over a long distance.
●● Towing of the machine is only allowed in

case of emergency.
CZ335-1103217
Fig. 6-9

6.3 Engine Failures

6.3.1 Engine troubleshooting table
Check the engine according to the following table if any failure occurs to it. Contact your Sany
distributor to repair the engine.
Failure Causes Remedy
●● Battery dead ●● Recharge/replace the battery.

●● Battery that has disconnected or loose ●● Remove the corroded part.
cable, or is corroded.
Starter failure
●● Fuse breaks. ●● Replace the fuse.
or reluctant
●● Failure of start switch or start relay. ●● Replace the start switch or relay.
rotation.
When the engine fails to start
●● Failure of start motor. ●● Repair/replace the start motor.

●● Engine oil viscosity high. ●● Use engine oil with suitable viscos-
ity.
●● Fuel exhausted. ●● Refill the fuel and purge the air.

●● Fuel injector opening pressure low. ●● Adjust/replace the fuel injector.
●● Failure of injection pump delivery valve ●● Replace the fuel delivery valve.
●● Failure of control rack of injection pump ●● Repair or replace the control rack.
●● Worn or stuck plunger of injection pump ●● Replace the plunger assembly.
●● Improper starting operation ●● Start the engine in regular steps.
Starter is OK.
●● Air trapped in the fuel system ●● Purge air from the fuel system.
●● Fuel filter plugged ●● Replace filter element or cartridge.
●● Air cleaner plugged ●● Clean/replace air cleaner element.
●● Clutch sideslip ●● Repair or replace the clutch.
●● Turbocharger intake hose clamp loose ●● Tighten the clamps with force.
●● Turbocharger intake hose cracking ●● Replace the hose
Engine shuts ●● Idle speed low ●● Battery dead

down immediately ●● Fuel filter plugged ●● Replace filter element or cartridge.
after starting. ●● Air cleaner plugged ●● Clean/replace air cleaner element.
●● Failure of low idle controller ●● Repair/replace idle control system.

●● Fuel system leaks or is blocked. ●● Repair the fuel system.
●● Air trapped in the fuel system ●● Pure the air from fuel system.
●● Fuel system contains water. ●● Change the fuel.
Low idle speed ●● Fuel filter element plugged ●● Replace filter element or cartridge.
instable ●● Failure of injection pump ●● Repair/replace related parts.
●● Bad adjustment of air valve clearance ●● Readjust air valve clearance.
●● Broken cylinder gasket, worn cylinder liner, ●● Replace relevant parts.
stuck or ruptured piston ring, or defective
contact between air valve and its seat

●● Fuel filter plugged ●● Replace filter element or cartridge.

●● Fuel contaminated by water ●● Change the fuel.
●● Failure of fuel delivery pump ●● Repair/replace fuel delivery pump
●● Fuel injector activating pressure low; injec- ●● Readjust/replace fuel injector.
tion effect not good
●● Failure of injection pump ●● Repair/replace related parts.
●● Exhaust system leaks. ●● Replace relevant parts.
Power insufficient
●● Air intake system leaks.
●● Turbocharger assembly damaged ●● Replace turbocharge assembly.
●● Exhaust valve blocked ●● Clean the exhaust pipe.
●● Bad adjustment of air valve clearance ●● Adjust valve clearance.
●● Soft or broken spring of air valve ●● Replace gas spring.
●● Insufficiency of coolant ●● Refill coolant.
●● Fan belt skids due to looseness or crack- ●● Replace fan belt.
ing.
●● Radiator cap damaged or radiator core ●● Replace radiator cap or clean radia-
plugged tor core.
Engine overheat-
●● Coolant pump damaged ●● Repair/replace coolant pump.
ed
●● Coolant leaks due to broken cylinder head ●● Replace seal cap.
or cylinder block seal cap
●● Thermostat damaged ●● Replace thermostat.
●● Cooling system blocked by foreign object ●● Remove foreign object.
●● Poor adjustment of fuel injection timing ●● Readjust fuel injection timing.
●● Fuel contaminated by water ●● Change the fuel.
●● Sluggish fuel injection timing ●● Readjust fuel injection timing.
White exhaust
●● Failure of turbocharger ●● Repair/replace.
gas
●● Defective valve oil seal or worn valve stem ●● Replace valve oil seal, valve and
and valve guide tube valve guide tube.
●● Wear, rupture or incorrect setup of piston ●● Replace the piston or reset it cor-
ring rectly.
●● Scratch or wear of cylinder liner ●● Replace cylinder liner.
●● Fuel injector activating pressure low or bad ●● Readjust/replace fuel injector.
injection effect
Black exhaust gas ●● Poor adjustment of fuel injection timing ●● Readjust fuel injection timing.
●● Fuel drips after injection due to damage of ●● Replace fuel delivery valve.
fuel injection pump delivery valve
●● Excessive injection of the injection pump ●● Readjust fuel injection amount.

●● Fuel leaks. ●● Repair/replace related parts of the

fuel system.
●● Low idle improper ●● Readjust low idle.
●● Fuel injector activating pressure low, or ●● Adjust/replace fuel injector.
bad injection effect
●● Fuel injection timing incorrect ●● Readjust fuel injection timing.
●● Fuel drips after injection due to damage of ●● Replace fuel delivery valve.
Excessive con-
fuel injection pump delivery valve.
sumption of fuel
●● Air leaks from the intake side of turbo- ●● Repair the intake side of turbo-
charger. charger.
●● Turbocharger assembly damaged ●● Replace turbocharger assembly.
●● Bad valve clearance ●● Readjust valve clearance.
●● Soft or broken valve spring ●● Replace valve spring.
●● Inappropriate engine oil used ●● Use appropriate engine oil.
●● Excessive oil ●● Drain excessive oil.
●● Oil leaks through oil seal and/or gasket. ●● Replace oil seal and/or gasket.
Excessive con- ●● No preheating operation ●● Follow the procedure specified
sumption of en- ●● Defective valve oil seal, or wear of valve ●● Replace related parts.
gine oil stem and valve guide tube
●● Wear, rupture or improper setup of piston ●● Replace piston ring or reset it prop-
ring erly.
●● Scratch or wear of cylinder liner ●● Replace cylinder liner.
●● Oil insufficient ●●
Refill oil.
●● Bad oil viscosity ●●
Use lubricant with proper viscosity.
●● Oil leaks through oil seal and/or gasket. ●●
Replace oil seal and/or gasket.
●● Oil filter element plugged ●●
Replace oil filter element or car-
Oil pressure low tridge.
●● Stuck safety valve and/or soft bypass ●● Replace spring of safety valve and/
valve spring or bypass valve.
●● Oil pump screen plugged ●● Clean the screen of oil pump.
●● Wear of oil pump related parts ●● Replace related parts of oil pump.
●● Exhaust pipe connector loose or exhaust ●● Tighten exhaust pipe connector or
pipe broken replace exhaust pipe.
Strange engine noise
●● Fuel injector loose ●● Replace gasket and tighten fuel in-

Gas leaking
jector .
noise
●● Exhaust manifold connector loose ●● Tighten the connector of exhaust
manifold.
●● Cylinder gasket broken ●● Replace cylinder gasket.
●● Fan belt loose ●● Readjust belt tension.
C o n t i n u o u s ●● Cooling fan loose ●● Tighten the cooling fan.
noise ●● Worn or damaged coolant pump bearing ●● Replace coolant pump bearing.
●● Bad valve clearance ●● Readjust valve clearance.
Table 6-2

6.3.2 Coolant temperature high
WARNING
●● Never remove the radiator cap when the

coolant is still hot. If you remove the
cap at this moment, hot water or steam
may squirt out and cause burns. When
coolant cools down, cover the cap with
a piece of thick cloth and slowly turn
the cap to open it.
NOTICE
●● Do not stop the engine immediately.

Sudden rise of coolant temperature can
cause engine parts to burn.
●● Refill the coolant slowly in several
times. Quick filling of low-temperature
coolant can cause engine cracks.
When the coolant temperature gauge shows

a temperature higher than 100°C, the coolant
temperature alert indicator will be on. Stop op-
erating your machine and keep engine running
at a speed a little higher than idle in order to
reduce temperature. When the pointer of cool-
ant temperature gauge returns to the middle
position, the alert indicator is off. Now, stop the
engine and perform the following steps.

1. Check radiator hoses for coolant leak.
2. Check V-belt for rupture. Check the belt

tension.
3. Check coolant level. Refill coolant if neces-

sary.
●● Remove the radiator cap (1) and refill

coolant to the opening. Tighten the cap
properly.
CB2016051305
Fig. 6-10
4. Check the front of radiator for any contami-

nants.
5. If your machine has coolant leak or often

encounters higher coolant temperature, the
cooling system has a problem.

6.3.3 Engine oil pressure low
When the engine is just started, the oil pres-

sure gauge indicates high pressure before the
engine is preheated. Check oil pressure after
the engine is fully preheated.
When engine oil pressure is abnormal, which

is shown on the monitor, stop operating your
machine, shut down the engine immediately,
and proceed as the following.
NOTICE
●● Shut down the engine immediately.

Keep running the engine can cause
damage to the engine.
1. Check for oil leak. 1
2. Check engine oil level. Refill oil if neces-

sary.
●● Remove the dipstick (1). Wipe off the

oil on it with cloth.
●● Fully insert the dipstick (1) into oil and

then slowly pull it out.
CZ215-1105004
●● If oil level between the marks L and H,
Fig. 6-11
the amount of oil is good.
●● If oil level is low, add oil immediately. If

engine oil is contaminated, change the
oil immediately.
●● Replace the dipstick(1) after checking.
3. If engine oil level is normal but the oil

L H
pressure gauge reads wrong, the low oil
pressure alert indicator and oil filter indica-
tor will be on. Contact your Sany distributor CZ335-1103131
to solve the problem.
Fig. 6-12

6.3.4 When fuel runs out
When fuel exhausts, refuel the tank and purge

air from the fuel system before restarting the
engine.
WARNING
●● Never use a lighter, smoke, or use other

fire sources when purging the air. A fire
source can cause fire.
●● Completely remove engine oil or fuel
splashed onto the exhaust pipe and
other places. These oil and fuel can
cause fire or slipping accident.
●● The space for air-purging operation is
limited. Take care not to be cut by the
edges
One method：
1. Turn the handle(1) of hand pump counter-

clockwise to unlock it.
CB2016051306
Fig. 6-13

2. Loosen the fuel filter vent plug(2) and

cover the vent with cloth.
CB2016051307
Fig. 6-14
3. Operate the hand pump to deliver fuel until

no foam is seen in the vent.
CB2016051308
Fig. 6-15
4. Screw on the vent plug (2) when no foam

is observed.
CB2016051309
Fig. 6-16

5. Keep pumping the fuel until high resistance

is felt.
With the fuel temperature is low, the

pressure of hand pump may not grow. It is
important to operate the hand pump many
a time continuously .
6. After eliminating the air, completely remove

the splashed fuel before starting the
engine.
CZ215-1105008
7. Make sure that no fuel leaks any more. Fig. 6-17
WARNING
●● Check the fuel filter and its shell for

fuel leak. The leak of fuel is possible to
cause fire.
Another method:
1. Make sure to turn off the cut-off vavel(A).
CB2016051310
Fig. 6-18

2. Loosen the fuel filter vent plug(B) and

cover the vent with cloth.
CB2016051311
Fig. 6-19
3. Open the rainhat(C) and the switch(D). The

electromagnetic pump is in operation.
4. Shut off the switch(D) and the rainhat(C)

until no foam is seen in the vent.
5. Open the cut-off vavel(A).
WARNING
CB2016051312
●● The electromagnetic pump is prohibited
working, when the engine is in Fig. 6-20
operation. And keep the valve open.

6.3.5 When engine rotates reversely
WARNING
●● Reverse rotation of engine can burn the

engine within several minutes or cause
severe injury. Shut down the engine
immediately once reverse rotation is
found. The exhaust gas from air cleaner
is possible to cause fire.
The follow symptoms will appear when the

engine rotates in opposite direction.
●● Harsh clash at the beginning.
●● Heavy smoke coming out air cleaner
●● Low oil pressure alert appearing on the

monitor
Check and clean the air cleaner and intake
hoses after shutting down the engine. Replace
any defective air cleaner or hose immediately.

6.4 Failures of the Electrical System
6.4.1 Electrical system troubleshooting table
Trouble-shoot the electrical system according to the following tables. Contact your Sany distribu-
tor solve the problem.
●● Battery low ●● Recharge/replace battery.

●● Engine start switch internal failure ●● Replace
●● Pilot switch failure ●● Repair/replace
●● Start motor failure ●● Repair/replace
●● Open circuit of wire harness ●● Check/repair
Engine fails to start
●● Fuse failure (F1) ●● Replace
●● Short circuit of wire (grounding failure) ●● Check/repair
●● Alternator internal failure ●● Repair/replace
●● Start relay failure ●● Replace
●● Brake failure ●● Repair/replace
●● Open circuit of wire harness ●● Check/repair
●● Sensor internal failure ●● Replace
Rough engine speed
●● Sensor internal failure ●● Replace
Unable to power off the ●● Battery relay failure ●● Replace
machine ●● Breakdown of surge diode ●● Replace
●● Boom-up signal failure ●● Check/repair
●● Boom-down signal failure ●● Check/repair
●● Arm-in signal failure ●● Check/repair
●● Arm-out signal failure ●● Check/repair
●● Bucket-dig signal failure ●● Check/repair
Auto idle fails.
●● Bucket-dump signal failure ●● Check/repair
●● Swing signal failure ●● Check/repair
●● Travel signal failure ●● Check/repair
●● Attachment signal failure ●● Check/repair
●● Controller failure ●● Replace
●● Preheat fuse failure ●● Replace
●● Preheat relay failure ●● Replace
Preheating function fails.
●● Preheat controller failure ●● Replace
●● Hydraulic lockout control failure ●● Repair/replace
All devices fail. ●● Short circuit of wire (grounding failure) ●● Check/repair
●● Failure of internal coil of pilot lockout valve ●● Replace
●● Sensor failure ●● Replace
●● Short circuit of harness (grounding failure) ●● Check/repair
Boom slow and weak
●● Open circuit of harness ●● Check/repair


Arm slow and weak
Bucket slow and weak ●● Open circuit of harness ●● Check/repair
●● Bucket confluence solenoid valve failure ●● Replace
Travel slow and weak
●● Fuse failure ●● Replace
●● Open circuit of wire ●● Check/repair
Monitor black-out
●● Monitor failure ●● Replace
●● Resistor failure ●● Replace
●● Open circuit of wire ●● Check/repair
Monitor displays nothing.
●● Monitor or controller failure ●● Replace
●● Dual travel speed solenoid valve failure ●● Replace
Dual-travel speed failure ●● Open circuit of wire ●● Check/repair
●● Coolant temperature sensor failure ●● Replace
Engine coolant tempera- ●● Open circuit of wire ●● Check/repair
ture reading incorrect ●● Short circuit of wire (grounding failure) ●● Check/repair
●● Wire short-circuited with 24V ●● Check/repair
●● Fuel level sensor failure ●● Replace
Fuel level reading incor- ●● Open circuit of wire ●● Check/repair
rect ●● Short circuit of wire (grounding failure) ●● Check/repair
●● Wire short-circuited with 24V ●● Check/repair
●● Wiper motor internal failure ●● Repair/replace
Wiper failure ●● Open circuit of wire ●● Check/repair
●● 5V power supply failure ●● Repair/replace
Arm-in pilot pressure ●● Open circuit of signal line ●● Check/repair
reading incorrect ●● Short circuit of signal line ●● Check/repair
Arm-out pilot pressure ●● Open circuit of signal line ●● Check/repair


Boom-up pilot pressure ●● Open circuit of signal line ●● Check/repair
Boom-down pilot pres- ●● Open circuit of signal line ●● Check/repair
sure reading incorrect ●● Short circuit of signal line ●● Check/repair
Bucket-dig pilot pressure ●● Open circuit of signal line ●● Check/repair
Bucket-dump pilot pres- ●● Open circuit of signal line ●● Check/repair
sure reading incorrect ●● Short circuit of signal line ●● Check/repair
Swing pilot pressure ●● Open circuit of signal line ●● Check/repair
Travel pilot pressure ●● Open circuit of signal line ●● Check/repair
Table 6-3

6.4.2 Failure codes
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
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
Right travel pilot pressure sensor abnor- Right travel pilot pressure collecting volt lower than 0.25
29
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
CAN communication monitoring component overtime or
42 CAN bus abnormal
reset characters changed for 3s
Table 6-4

6.5 Battery
WARNING
●● It is dangerous to charge a battery

mounted on the machine. Remove the 2
battery before charging it. 1
●● Turn the ignition key to the OFF posi-

tion to shut down the engine when you
check or handle the batteries.
●● Always wear goggles and rubber gloves
1
when you handle the batteries. 2
●● To remove the battery, disconnect the

negative post (-) first. To install the bat-
tery, connect the positive post (+) first. CZ335-1103219
If you tool contact the positive post and Fig. 6-21

chassis at the same time, sparks may
occur. Take extra care.
●● A loose terminal can result in improper
contact, which may cause sparks and
explosion.
●● Check which terminal is positive (+) or
negative (-) when you install or remove
it.
6.5.1 Battery removal and installation
●● Disconnect the grounding cable (generally

the one in connection with the negative
terminal (-)) before removing the battery.
●● Sparks can occur if your tool touches the

positive terminal and the chassis.
●● Secure the battery with clamping plates

when changing the battery.
●● Disconnect the negative post before the

positive post when you are to remove the
battery.
●● Connect the positive post before the

negative post when you are to install the
battery.

6.5.2 Battery charging
Improper handling of the battery can cause

explosion when it is being charged. Be sure to
follow the battery operation and charging in-
structions and proceed as the following:
●● Regulate the charger to the voltage appli-

cable to the battery. Incorrect voltage can
over heat the charger and cause explo-
sion.
●● Connect the charger's positive clip (+) to

the battery's positive terminal (+). Connect
the charger's negative clip (-) to the bat-
tery's negative terminal (-). The wire clips
must be fixed.
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.
●● If the battery electrolyte freezes, do not

charge the battery, or use an alternate
power supply to start the engine. Charging
a frozen battery may cause electrolyte to
catch on fire and the battery to explode.

6.5.3 Starting engine with jumper cable
WARNING
●● Never let the positive post (+) contact

with the negative post (-) when connect-
ing the cables.
●● Keep the normal machine away from
the faulty one to prevent sparks around
the battery which may ignite the hydro-
gen released from the battery.
●● Avoid mistakes in connection of the
jumper cable. Its final connection with
upper structure of the machine can pro-
duce sparks. In this case, the battery CZ335-1103221
shall be connected to a location that is
Fig. 6-23
far enough from the battery. (However,
the work equipment should be avoided
as it is not a good conductor.)
●● When removing the jumper cables,
take care not to allow the cables clips
to contact with each other or with the
chassis.
NOTE:
●● The start system of the machine is sup-

plied with a 24V power source. Two 12V
batteries are connected serially to supply
power under normal operating conditions.
●● The sizes of jumper cables and clips shall
match the battery.
●● The battery of the starting machine shall
have the same capacity as the engine to
be started.
●● Check the cables and clips for damage or
corrosion.
●● Make sure that the cables and clips are
connected securely.
●● Check if the hydraulic lockout controls of
both machines are in the locked position.
●● Check if all control levers are neutralized.

6.5.3.1 Connecting jumper cables
Turn the start switches of the normal machine

and the faulty one to OFF position.
Connect the jumper cables in the numbered

sequence, as shown in the diagram.
1. Connect the clip of jumper cable (A) to the

positive terminal (+) of battery (C) of the
A
faulty machine.
2 1
2. Connect the clip on the other end of jumper 3
cable (A) to the positive terminal (+) of

battery (D) of the normal machine.
D C
3. Connect the clip of jumper cable (B) to 4
the negative terminal of battery (D) of the B
normal machine. E
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.

6.5.3.2 Starting engine
CAUTION
●● Check the machine and make sure the

hydraulic lockout control is placed in
the locked position and the all the con-
trol levers are neutralized.
1. Make sure the clips are securely con-

nected with terminals of the battery.
2. Start the engine of the good machine and

run it at high idle.
3. Turn the start switch of the faulty machine

to "START" position and start the engine.
If the engine fails to start, wait for two

minutes before attempting to restart it.
6.5.3.3 Disconnecting jumper cables
After the engine is started, disconnect the

jumper cables in steps reversed to their con-
nection.
1. Disconnect the clip of the jumper cable

(B) from the swivel frame (E) of the faulty
machine. A
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.

6.6 Failures of the Hydraulic System
●● 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
●● Bad adjustment or main relief valve failure ●● Replace

Work equipment moving
●● Pilot relief valve failure ●● Replace
slowly, or travel and swing
●● Regulator failure ●● Repair/replace
speed slow
●● Plunger pump failure ●● Check/repair
●● Pilot pump relief valve failure ●● Replace
Work equipment, final drive
●● Hydraulic pump failure ●● Check/repair
or swing drive not functioning
●● Coupling failure ●● Check/repair
●● Refill hydraulic oil
●● Hydraulic oil level low
●● Use suitable hyd
●● Bad hydraulic oil
Abnormal noise in hydraulic oil
●● Hydraulic tank cap vent plugged
pump ●● Clean/replace
●● Hydraulic tank filter screen plugged
●● Clean/replace
●● Plunger pump failure
●● Check/repair
Auto idle not functioning ●● Pilot valve failure ●● Replace
●● Controller failure ●● Repair/replace
●● Right pilot valve (boom circuit) failure ●● Check/repair
●● Pressure sensor failure ●● Replace
●● Boom control valve (spool) failure ●● Repair/replace
Boom speed slow ●● Boom control valve (retaining valve) failure ●● Repair/replace
●● Boom control valve (Safety valve and feed ●● Repair/replace
valve) seal failure
●● Boom cylinder failure ●● Check/repair
●● Left pilot valve (arm circuit) failure ●● Check/repair
●● Arm control valve (spool) failure ●● Repair/replace
Arm speed slow ●● Arm control valve (regeneration valve) failure ●● Repair/replace
●● Arm control valve (Safety valve and feed valve) ●● Repair/replace
or seal failure
●● Arm cylinder failure ●● Check/repair


●● Right pilot valve (bucket circuit) failure ●● Check/repair
●● Bucket control valve (spool) failure ●● Repair/replace
Bucket speed slow ●● Bucket control valve (regeneration valve) failure ●● Repair/replace
●● Bucket control valve (Safety valve and feed ●● Repair/replace
valve) or seal failure
●● Bucket cylinder failure ●● Check/repair
●● Pilot valve failure ●● Check/repair
One cylinder of work equip-
ment not working
●● Work equipment control valve (spool) failure ●● Repair/replace
●● Work equipment cylinder failure ●● Repair/replace
●● Retaining valve (of boom or arm) failure ●● Repair/replace
Work equipment cylinder drift-
●● Work equipment control valve (safety valve and ●● Repair/replace
ing excessively
feed valve) seal failure
●● Work equipment valve spool failure ●● Repair/replace
●● Arm regeneration valve failure
●● Repair/replace
Work equipment sluggish ●● Control valve (safety valve and feed valve) fail-
●● Repair/replace
ure
Other work equipment moves
when single cylinder is in re- ●● Control valve seal failure ●● Replace
lief.
Travel speed drops remark-
ably during swing or travel ●● Straight travel valve failure ●● Repair/replace
operation.
●● Travel pilot valve failure ●● Repair/replace
●● Regulator failure ●● Repair/replace
Machine runs out during trav- ●● Proportional solenoid valve sluggish ●● Repair/replace
el ●● Travel valve spool sluggish ●● Repair/replace
●● Central swivel joint sluggish ●● Repair/replace
●● Travel motor failure ●● Repair/replace
●● Travel pilot pressure sensor failure ●● Replace
Travel speed slow
●● Travel control valve (spool) failure ●● Repair/replace
●● Travel control valve (feed valve) failure ●● Repair/replace
●● Travel motor failure ●● Check/repair


●● Travel pilot pressure sensor failure ●● Replace
Machine steering difficult or ●● Travel control valve (spool) failure ●● Repair/replace
power insufficient ●● Travel control valve (feed) failure ●● Repair/replace
●● Travel motor (safety valve) failure ●● Repair/replace
●● Travel motor (check valve) failure ●● Repair/replace
●● High/low travel speed shift valve failure ●● Replace
Unable to shift travel speed
●● Travel control pedal valve failure ●● Repair/replace
●● Travel motor safety valve failure ●● Repair/replace
Travel fails (on one side) ●● Travel motor balance valve failure ●● Repair/replace
●● Pilot pressure sensor failure ●● Replace
●● Swing motor (parking brake) failure ●● Check/repair
●● Misadjustment or failure of swing motor (safety ●● Adjust/replace
Unable to swing
In both directions valve)

●● Swing motor failure ●● Check/repair
●● Swing drive failure ●● Check/repair
●● Pilot valve failure ●● Repair/replace
In one direction ●● Swing control valve (spool) failure ●● Repair/replace
●● Swing motor (feed valve) seal failure ●● Replace
●● Swing motor (parking brake) failure ●● Check/repair
●● Misadjustment or failure of swing motor (safety ●● Adjust/replace
valve)
Swing speed slow

Acceleration perfor- ● ● Brake control line blocked ●● Remove obstruc-
mance bad tion or replace the
pipeline.

Swing speed slow
●● Swing motor (pressure compensation valve) fail- ●● Repair/replace

Bad acceleration per-
ure
formance on one side
or swing speed slow
●● Leak on one side the shuttle valve of swing pilot ●● Repair/replace
pressure sensor

●● Bad adjustment or failure of swing motor (safety ●● Adjust/replace

Too much overrun in
swing stoppage
In both directions valve)

In one direction ●● Swing control valve (spool) failure ●● Repair/replace
●● Swing pilot valve failure ●● Repair/replace
Too much jerk in swing stop-
●● Swing anti-jerk valve failure ●● Repair/replace
page
●● Swing relief valve failure ●● Repair/replace
●● Back pressure valve failure ●● Repair/replace
High abnormal noise in swing ●● Swing motor (safety valve) failure ●● Repair/replace
stoppage ●● Swing motor (feed valve) failure ●● Repair/replace
●● Swing system mechanical failure ●● Check/repair
When swing brake ●● Swing brake control line failure ●● Check/repair
Excessive hydraulic
engaged ●● Swing motor (parking brake) failure ●● Repair/replace

drift of swing
●● Swing control valve (spool) failure ●● Repair/replace

When swing brake
●● Swing motor (relief valve) failure ●● Repair/replace
disengaged
●● Swing motor (feed valve) failure ●● Repair/replace
Table 6-5

6.7 Other Common Failures
●● Loose fastener ●● Check and retighten.

Structure member
●● Bigger clearance between arm and ●● Reduce the clearance to a value
noise loud
bucket end faces due to wear that is smaller than 1mm.
●● Spring deformed and weak due to re-
Bucket tip falls off dur-
peated use of bucket tip pin ●● Replace bucket tip pin
ing operation.
●● Bucket tip pin not matching the adaptor
●● Loose track ●● Tighten the track
Track kinks. ●● Traveling at high speed on rough road ●● Travel slowly on rough road in the
in the direction of sprocket direction of idler.
●● Improper electrical connection or con-
nector contact
Fan not working ●● Air flow control switch, relay or tem- ●● Repair/replace.
perature control switch damaged
●● Fuse exploded or battery voltage low
●● Air intake side blocked
Fan running but pro- ●● Evaporator or condenser fin plugged,
●● Clean/replace.
ducing less air flow giving ineffective heat conduction
●● Fan vane seized or damaged
●● Compressor clutch not picking up due ●● Repair
to wire break or defective contact of
electrical circuit
Compressor not work- ●● Loose compressor belt ●● Adjust the tension of compressor
ing or working with belt
difficulty ●● Wire break or failure of compressor ●● Replace clutch coil
clutch coil
●● Insufficient or excessive refrigerant ●● Refill/drain the refrigerant to a suit-
able level
●● Refrigerant leaks. ●● Eliminate the leaking point.
Refrigerant insufficient ●● Insufficient refilling ●● Refill suitable amount of refriger-
ant.
High/low pressure ●● Ambient temperature: 30~50°C
reading in normal op- ●● High pressure gauge: 1.47~1.67MPa (15~17kgf/cm²)
eration ●● Low pressure gauge: 0.13~0.20MPa (1.4~2.11kgf/cm²)
●● Expansion valve opening excessively. ●● Replace expansion valve.
Low pressure gauge
●● Defective contact of expansion valve ●● Install thermo-bulb correctly.

Low pressure thermo-bulb
tube surface ●● Excessive refrigerant in the system ●● Drain refrigerant to the specified
reads higher.
frosted level.

Both high and

Low pressure gauge reads lower.
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
low pressure refill refrigerant.

gauges read ●● Excessive refrigerant refilled. ●● Drain refrigerant to the specified
higher than level.
standard
value.
Bad condens- ●● Condenser blocked by dust and debris ●● Clean the condenser.
higher.
ing effect of ●● Condenser fan damaged ●● Check/replace condenser fan.

condenser.
Both high and
low pressure
gauges read
lower.
High
pressure Low pres- ●● Refrigerant insufficient ●● Refill refrigerant as required.
gauge sure could be ●● Low pressure line blocked/damaged ●● Clean/replace faulty component.
reads negative. ●● Compressor internal failure ●● Replace compressor.
lower.
Condenser
and high
pressure tube
hot
Bad refrigerating effect ●● Hot water valve damaged and left open Replace hot water valve.
due active heater
Table 6-6

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SY500H-10 Crawler Hydraulic Excavator Specifications
Specifications
7 Specifications
7.1 Machine Dimensions................................................................................................ 7-3
7.2 Working Ranges....................................................................................................... 7-4
7.3 Technical Specifications............................................................................................ 7-5

Specifications SY500H-10 Crawler Hydraulic Excavator

7 SPECIFICATIONS
7.1 Machine Dimensions
A
D I
E C
L
H
G F J
B K
CJ13032601-3
Fig. 7-1
Item Unit SY500H

A Shipping length mm 12095
B Total width mm 3360
C Shipping height mm 3790
D Top width mm 3290
E Height to top of cab mm 3470
F Width of std. track mm 600

G Gauge mm 2740
H Min. ground clearance excluding track shoe grouser mm 560
I Tail swing radius mm 3765
J Track grounding length mm 4415
K Length of track mm 5440
Ground clearance of upper-structure (excluding track shoe
L grouser) mm 1355

7.2 Working Ranges
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
e Max. horizontal reach mm 11860
f Min. swing radius mm 5240

g Max. height at min. swing radius mm 9100

7.3 Technical Specifications

Item Unit SY500H
Operating weight kg 49500
3
Bucket capacity m 2.2(Rock)
Engine model 6WG1
Engine power kW / rpm 300/1800
Travel speed (high/low) km/h 5.4/3.4
Swing speed rpm 8.0

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SY500H-10 Crawler Hydraulic Excavator Optional Equipment
Optional Equipment
8 Optional Equipment
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

Optional Equipment SY500H-10 Crawler Hydraulic Excavator
8.4.1 Quick coupler control.................................................................................... 8-24

8.4.2 Precautions for quick coupler safe operation ............................................... 8-26
8.5 Fueling System....................................................................................................... 8-28
8.5.1 Introduction................................................................................................... 8-28
8.5.2 Fueling system makeup................................................................................ 8-28

8 OPTIONAL EQUIPMENT
8.1 Safety Information
Observe the following precautions when se-
lecting, installing and operating attachments or
optional equipment of the machine.
8.1.1 Optional equipment selection
●● Please consult Sany distributor before in-

stalling any optional equipment to your ma-
chine. You may need to install front guard,
top guard or other protective structures to
your machine according to the type of at-
tachment or other optional equipment se-
lected.
●● You are only allowed to install Sany-ap-

proved optional equipment. Sany assumes
no responsibility to accidents, loss or fail-
ures caused by any optional equipment not
approved by Sany.
8.1.2 Read equipment instruction
●● Make sure you have read and understand

the instruction manuals of your machine
as well as the optional equipment before
installing and operating any optional equip-
ment.
●● If the instruction manual of the machine

and/or the optional equipment is lost,
please contact the make of the optional
equipment or Sany distributor to obtain a
new one.
8.1.3 Optional equipment removal and

installation precautions
The following items must be observed in order

to ensure safety when removing or installing
the optional equipment.

●● The removal or installation operation shall

be performed on a hard, level ground.
●● When the job is shared by two or more

persons, a commander is to be assigned
and his/her instruction must be followed.
●● Crane shall be used when handling heavy

object above 25 kg. (Only eligible, expe-
rienced personnel with official license are
allowed to operate the crane.)
●● Never stand under any lifted objects by the

crane.
●● Do not operate your machine when an

object is being lifted with crane during re-
moval or installation. Support can be used
to prevent falling from the object when nec-
essary.
●● When a heavy part is to be removed, it is

necessary to consider the impact to ma-
chine balance after removal. To prevent the
machine from tipping over, support your
machine, if necessary, before removing the
heavy component.
●● Before or after the optional equipment has

been installed or removed, make sure that
it is stable without the danger to tip.
●● For more information about removal and

installation please consult Sany distributor.
8.1.4 Optional equipment operation

precautions
Keep the following procedures in mind when

installing a larger or heavy optional equipment.
Prior to the operation, move your machine to a
safe ground for trial operation. Make sure that
you know very well the movement, center of
gravity, and working range of your machine.

●● If the machine stays inclined, swinging op-

eration is not allowed in order to prevent
tipping of the machine.
●● Keep a safe distance to surrounding barri-

ers during operation.
●● Pay attention to the following points when

installing a heavy optional equipment.
●● Heavy optional equipment probably re-

quires a larger space for swinging op-
eration. There might be the danger of
impacting other objects if the swinging
range has not been calculated accu-
rately. A larger space must be prepared
before performing the swinging opera-
tion.
●● When the lifting of heavy optional

equipment is held, the distance mov-
ing downward is relatively longer due
to gravity. In this case, it should be
lowered to the ground instead of being
held in air.
●● Never swing, lower or stop your ma-

chine suddenly in order to prevent it
from tipping over.
●● Never extend or retract the boom cylin-

der suddenly in order to prevent impact
that may cause the machine to tip.

8.2 Hydraulic Control Elements and Oil Circuit

8.2.1 Component locations
CZ335-1105001-1
Fig. 8-1
(1) Stop valve (3) Control pedal

(2) Selector valve

8.2.1.2 Stop valve
The stop valve is used to stop the flow of hy-

draulic oil.
●● FREE position (A) allows flow of the hy-

draulic oil. A
●● LOCK position (B) stops flow of the hy-

draulic oil.
B
Switch the valve to locked position when re- CZ335-1105002

moving or installing an attachment. Fig. 8-2
8.2.1.3 Selector valve
The selector valve is used to change the flow

direction of hydraulic oil.
The change of direction is made according to

the working mode selected. The working mode
must be applicable to the installed attachment.
For more information, see "Hydraulic circuit"
on page 8-8.
CZ335-1105003
Fig. 8-3
8.2.1.1 Attachment control pedal
This pedal is used to control the attachment. A
Step on the front, center, or rear part of the N

pedal to perform the following operations:
B
●● Hydraulic breaker
Front part (A): Operate
Rear part (B): Stop

CZ335-1105004
NOTE: For other attachments you need to
consult attachment maker before installation. Fig. 8-4
You must be sure of pedal and attachment op-
eration prior to application.

8.2.2 Hydraulic circuit
●● 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.
8.2.2.1 Hydraulic circuit switching
●● 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.
Attachment Mode Hydraulic line Safety valve set pressure

Hydraulic path forms automati-
One-way hydraulic attachment cally at the control valve where Before delivery:
B
(e.g. breaker) the return oil does not pass 20.6Mpa {210kgf/ cm²}
through.
Before delivery:
Hydraulic path forms automati- 20.6/31.4 MPa {210/320kgf/cm²}
Dual-action hydraulic attach-
S cally at the control valve where NOTE:
ment (e.g. hydraulic shear)
the return oil passes through. Closing: 320 kgf/cm²
Opening: 210 kgf/cm²
Table 8-1
8.2.2.2 Switching between breaker and general attachment

●● When an attachment is installed and mode B is selected:
(1) Breaker hydraulic path (one-way hydraulic path) is formed.
(2) The overflow valve is set to low pressure.
When delivered from the factory: 20.6 MPa {210 kgf/cm2}
●● When an attachment is installed and mode S is selected.
(1) Shear hydraulic path (dual-action hydraulic path) is formed.
(2) The overflow valve is set to high pressure.
When delivered from the factory: 31.4 MPa {320 kgf/cm2, 3980PSI}

8.2.2.3 Connecting hydraulic oil circuit
Connect the hydraulic lines as per the follow-

ing steps when an attachment is installed.
1. Check the stop valve and make sure it is in

the locked position (B).
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
2. Remove the screw plug (1) from the end of

the stop valve line.
NOTE: Do not damage or discard removed

parts.
CZ335-1105005
Fig. 8-6
3. When plug (1) is removed, the attachment

maker is responsible for the connection of
attachment pipelines (2).
Coupler sizes and additional accumulator 2

may vary according to different attachment
makers. Please consult Sany distributor in
this regard.
CZ335-1105006
Fig. 8-7

8.2.2.4 Hydraulic oil path
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 Attachment removal and installation
8.2.3.1 Removal
1. Lower the work equipment to the ground

and shut down the engine.
2. Turn the start switch to ON position (B),

and move the hydraulic lockout control to
unlocked position.
3. Move all control levers in all directions and

press the control pedal for 2-3 times within
15 seconds after the lockout control is
move the unlocked position in order to re- CC13031404
lieve the internal pressure in the hydraulic Fig. 8-9
lines.

locked position.
CC13031403
Fig. 8-10
5. The breather valve (1) on top of the hy-

draulic tank is used to release the internal
pressure of the hydraulic lines. 1
To release the pressure completely, turn

and open the butterfly nut on the breather
valve (1) and press the relief button to
release the pressure.
CZ335-1105011
Fig. 8-11

6. When the hydraulic oil has cooled down,

turn the stop valve (mounted to the inlet
and outlet lines to the side of the arm) to
locked position (B).

draulic oil. (The arrow is parallel to arm A
length).

lic oil. (The arrow is perpendicular to B
arm length). CZ335-1105012
Fig. 8-12
7. Disconnect the hose at the side of the

attachment. Install the screw plugs to the
two outlets.
Note: The screw plugs are used to avoid intru-

sion of foreign objects. Store the disconnected
attachment properly when the screw plugs are
in place.
8. Remove the two retaining pins, remove

the attachment, and install the bucket. For
more information on bucket installation
procedures, see "Bucket - replace" on
page 5-30.
9. Check the oil level in the hydraulic tank

when the bucket is installed properly.
CZ335-1105013
Fig. 8-13

8.2.3.2 Installation
1. Remove the bucket.
2. Place the attachment on a flat surface.

Install the attachment to the arm with the
pin (1) followed by the pin (2). 1
3. Lower the equipment to the ground and

2
shut down the engine.
CZ335-1105014
Fig. 8-14
4. Turn the start switch to the ON position,

and place the hydraulic lockout control to
the unlocked position.
6. Move all control levers in all directions and

press the control pedal for 2-3 times within
15 seconds after the lockout control is
move the unlocked position in order to re-
lieve the internal pressure in the hydraulic
lines. CC13031404
Fig. 8-15

locked position.
CC13031403
Fig. 8-16

7. The breather valve (3) on top of the

hydraulic tank can be used to release the
internal pressure of the hydraulic lines. 3
To release the pressure completely, turn

and open the butterfly nut on the breather
valve (3) and press the relief button to
release the pressure.
10. Check the temperature of the hydraulic

oil, which should be cooled down to a safe
temperature. Remove the two screw plugs CZ335-1105011
from the inlet and outlet. Be careful not to Fig. 8-17
contaminate the hose connections with any
dirt or soil.
If the O-ring is broken, replace it with a

new one.
11. Connect the hose to the side of the attach-

ment.
When connecting the hose, check the oil

flow direction and be careful not to make
any mistakes.
8. Turn the rotor of the stop valve (mounted

to the inlet and outlet lines to the side of
the arm) to unlocked position (A).

draulic oil. (The arrow is parallel to arm
length). A

lic oil. (The arrow is perpendicular to
arm length). B
CZ335-1105012
9. Check the oil level in hydraulic tank after Fig. 8-18
installation of the attachment.

8.2.4 Hydraulic oil and filter - change/replace
●● 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)
Machine with Hydraulic Breaker Machine with Common Bucket

Hydraulic oil 600 2000/4000
Filter element 100 1000/2000
Table 8-2
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
hour service life
40
Change interval for
20 hour service life
0 500 1000 1500 2000 2500 3000 3500 4000

Hydraulic Excavator Operating Hours
CZ335-1105015
Table 8-3

8.2.5 Long-term storage
The following procedures shall be followed

when the equipment is to be stored for a long
period of time.
●● Turn the stop valve to locked position.
●● Screw the plug on the valve.
●● Place the latch pin to locked position.
Operating the pedal with no breaker or general

attachment installed may cause overheating
or other problems.

8.3 Recommended Operations
The following instructions must be followed

when operating an excavator with attachment.
NOTE: The types and models of attachments

depends on the model of your machine. Con-
sult your Sany distributor for attachment selec-
tion.
8.3.1 Hydraulic breaker
Major applications:
●● Crushing rocks
●● Demolition
●● Road construction
This attachment is used in a wide range of

applications, such as demolishing a building, CZ335-1105016
breaking road surface or slag, channeling, Fig. 8-19

crushing rocks, and breaking operation at
quarry.

8.3.2 Hydraulic breaker operation
1. Press the breaker chisel vertically and

firmly onto the object to be broken during
breaking operation.
90°
90°
CZ335-1105017
Fig. 8-20
2. Press the breaker chisel tightly onto the

working surface when striking and slightly
raise the front of the undercarriage about 5
mm (0.2 in) from the ground, as shown in
the right illustration.
NOTE: The excavator shall not be raised too

much.
CZ335-1105018
Fig. 8-21
3. If the same surface cannot be penetrated

or broken by the chisel within one minute
under continuous striking, change the
struck position and try to break it near the
edge.
CZ335-1105019
Fig. 8-22

4. The chisel's penetrating direction will mis-

align gradually to the working direction of
breaking hammer. It is important to align R
them by readjusting the bucket cylinder.
CZ335-1105020
Fig. 8-23
5. Always press the chisel properly on the

working surface in order to prevent striking
without resistance.
CZ335-1105021
Fig. 8-24

8.3.3 Restricted operations
Do not operate your machine in any of the fol-

lowing manners in order to ensure a longer
service life and safe operation.
●● Do not operate any of the oil cylinders to

its full stroke. A distance of 5 cm (2 in) is to
be reserved for backup.
1. Accumulating rocks with the breaker.
CZ335-1105022
Fig. 8-25
2. Breaking with swinging force.
CZ335-1105023
Fig. 8-26

3. Moving the chisel during striking operation.
CZ335-1105024
Fig. 8-27
4. Keep the chisel level or upward during strik-

ing operation.
CZ335-1105025
Fig. 8-28
5. Swing the chisel when the rock has been

penetrated.
CZ335-1105026
Fig. 8-29

6. Pecking operation.
CZ335-1105027
Fig. 8-30
7. Raise your machine above ground by fully

extending the bucket cylinder and by the
pushing force.
CZ335-1105028
Fig. 8-31

8.3.4 Hydraulic breaker greasing
Grease the breaker at specified point correctly.
CZ335-1105029
Fig. 8-32
NOTE:
●● Greasing in an improper manner could add

grease more than desired. As a result, soil
and sand may enter the hydraulic system,
which can damage the hydraulic compo-
nents when using the breaker.
●● So the breaker must be greased in appro-

priate attitude.
CZ335-1105030
Fig. 8-33
CZ335-1105031
Fig. 8-34

8.4 Quick Coupler
8.4.1 Quick coupler control
1. Remove the safety pin of the quick coupler.
Safety pin
Jaw
CZ335-1105032
Fig. 8-35
2. Depress the quick coupler button (1) (auto

reset) on the left joystick to reduce the 1
opening of the flexible jaw and the fixed
jaw slowly.
CZ335-1105033
Fig. 8-36
3. Allow the fixed jaw to slowly grip the sup-

port pin (2) of the bucket, as shown in the
right illustration.
2 3
CZ335-1105034
Fig. 8-37

4. Extend the bucket cylinder to slowly move

the flexible jaws toward the support pin (3)
of the bucket.
2
3
CZ335-1105035
Fig. 8-38
5. Make sure that the jaws of the quick

coupler grip completely the support pin (3)
of the bucket.
6. Release the operation button to enable the

quick coupler to grip the bucket's support
pin before conducting other operations.
7. Insert the safety pin after installation.
CZ335-1105036
Fig. 8-39

8.4.2 Precautions for quick coupler safe operation

1. Installation of the quick coupler may
contribute to longer swing radius when op-
eration the bucket of other attachments. As
a result, the work equipment may interfere
with the cab or boom of the machine.
If a quick coupler has been installed,

retract the bucket fully (bucket cylinder
fully extended) before retracting the arm.
To avoid interference with the boom, never
retract the arm fully (arm cylinder fully
extended) before retracting the bucket. CZ335-1105037
Fig. 8-40
2. Overloaded operation may impair your

machine and the attachment, thus reducing
their service life.
CZ335-1105038
Fig. 8-41
3. Do not apply pressure when the quick cou-

pler touches the ground. Use the coupler
only when it is connected with the bucket
or other attachment.
CZ335-1105039
Fig. 8-42

4. It is very dangerous to move a heavy

object with the quick coupler. Meanwhile,
the service life of quick coupler could be
reduced.
NOTE: Consult Sany local authorized dealer

if you need to install a quick coupler. Make
sure that you are using an attachment that
has been approved by Sany. Sany assumes
no responsibility for any failure and accident
resulted from installation of any attachment CZ335-1105040
unapproved by Sany.
Fig. 8-43

8.5 Fueling System
8.5.1 Introduction
SANY large excavators are equipped with a

fueling system, which uses a refueling pump
assembly. The refueling pump assembly is
intended specially for large mobile off-the-
road machinery, vehicles and vessels. It uses
on-board battery as the power source and is
not limited by terrain and power supply, which
makes it very suitable for construction side
and field.
For information regarding refueling amount,

see "Table of capacities" on page 5-18.
8.5.2 Fueling system makeup

1 2
●● The fueling system of SANY excavators in-

cludes mainly: a refueling pump assembly
(including relevant piping and valves) and
a control switch. 3
●● Open the battery cover (1) and you can

see the control switch (2) and the refueling
pump (3).
CZ335S-1105001
Fig. 8-44
●● The main structure of the refueling pump (3)

is shown in the right illustration.
Technical specifications:
Pump flow rate 45L/min

Rated voltage 24V
Rate speed 2900 rpm
Coupling thread 3/4’G
Weight 2.5kg
Packing dimension 190×130×90mm CZ335S-1105002
Fig. 8-45

SY500H-10 Crawler Hydraulic Excavator EC Declaration
EC Declaration
9 EC DECLARATION
9.1 DECLARATION OF CONFORMITY......................................................................... 9-2

EC Declaration SY500H-10 Crawler Hydraulic Excavator
9 EC DECLARATION
9.1 DECLARATION OF CONFORMITY

THIS IS HEREBY DECLARED THAT FOLLOWING DESIGNATED PRODUCT COMPLIED WITH
THE ESSENTIAL HEALTH AND SAFETY REQUIEMENTS OF MACHINE DIRECTIVE 2006/42/
EC ON THE APPROXIMATION OF THE LAWS OF THE MEMBER STATES RELATING TO IT.
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
THIS DECLARATION APPLIES TO ALL SPECIMENS MANUFACTURED IDENTICAL TO THE

MODEL SUBMITTED FOR TESTING/EVALUATION. ASSESSMENT OF COMPLIANCE OF THE
PRODUCT WITH THE REQUIRMENTS RELATING TO SAFETY STANDARDS LISTED ABOVE
WAS PERFORMED BY MANUFACTURER.
SIGNED ON BEHALF OF SANY HEAVY

MACHINERY LIMITED
SIGNATURE :
NAME : XIANFENG DUAN
POSITION : DESIGN ENGINEER
PLACE : KUNSHAN, CHINA
DATE : MAY 16, 2016

SY500H-10 Crawler Hydraulic Excavator: Operation and Maintenance Manual

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SY500H-10 Crawler Hydraulic Excavator: Operation and Maintenance Manual

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SY500H-10

Crawler Hydraulic Excavator

Sany Heavy Machinery Limited

Sany industrial park, economic and technology development zone,

Kunshan, jiangsu 215300, P.R.China

Service hotline: 0086-4006 098 318

●● Unauthorized restructuring or modification to the excavator;

●● Use of non-genuine parts, or untested or unapproved parts or tools.

●● Provide training for excavator operators and service persons as required.

●● Regularly inspect the safety awareness of related persons at work.

●● Ensure timely maintenance and repair of the hydraulic excavator.

●● Make a detailed plan for proper use of the hydraulic excavator.

●● All operators must know the operating items and procedures.

Operation & Maintenance Manual - May 2016 I

2.2.2.1 Textual safety decals.............................................................................. 2-9

II Operation & Maintenance Manual - May 2016

2.3.26 Ensuring a good view................................................................................. 2-38

Operation & Maintenance Manual - May 2016 III

2.5.5 Lock out and tag out ................................................................................... 2-68

IV Operation & Maintenance Manual - May 2016

3.2.2.16 Machine Conﬁguration Setting........................................................... 3-19

Operation & Maintenance Manual - May 2016 V

VI Operation & Maintenance Manual - May 2016

4.4 Machine Operation................................................................................................. 4-28

Operation & Maintenance Manual - May 2016 VII

4.17 Long-Term Storage............................................................................................... 4-53

VIII Operation & Maintenance Manual - May 2016

5.8.2.3 Bucket - replace................................................................................... 5-29

Operation & Maintenance Manual - May 2016 IX

5.8.8.3 Nitrogen pressure in accumulator (control oil circuit) - check.............. 5-79

X Operation & Maintenance Manual - May 2016

6.5.3.2 Starting engine..................................................................................... 6-33

Operation & Maintenance Manual - May 2016 XI

8.4 Quick Coupler......................................................................................................... 8-24

XII Operation & Maintenance Manual - May 2016

Operation & Maintenance Manual - May 2016 1-1

1.4 Noise and Vibration Statements............................................................................. 1-14

1-2 Operation & Maintenance Manual - May 2016

●● Sany-built machines are widely used

●● Sany is a leading manufacturer of con-

This operator manual provides safety, opera-

Items addressed in this manual are designed

●● Understand the structure and performance

●● Increase equipment efficiency during op-

●● Prolong the service life of equipment.

●● Reduce maintenance costs.

Always keep this manual nearby and have all

If you sell the machine, be sure to give this

Continuing improvements in the design of this

1.2 Your Documentation Package

●● Safety, Operation & Maintenance Manual

●● Parts Book — This publication consists of

●● CD — Along with this machine you will re-

1.2.1 CD system requirements

In order to use the Sany CD, be sure of the

●● Intel® Pentium II® running at 500 MHz or

●● At least 128 MB RAM

●● Minimum screen resolution of 800 x 600

●● Windows 2000, XP, Vista or Windows 7

●● Internet Explorer 6.0 or later version (pop-

●● Acrobat Reader 7.0 or later version

1-4 Operation & Maintenance Manual - May 2016

1.2.2 Recommendations on using the