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SANY SY115C9 Safety, Operation And Manitenance Manual

SANY SY115C9 Safety, Operation And Manitenance Manual

Crawler hydraulic excavator

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www.sanygroup.com

SANY HEAVY MACHINERY LIMITED

318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District,

Shanghai, P.R. of China 201413

Tel: (86) 21 5700 8518

Service hotline:(86) 4006 098 318

E-mail: crd@sany.com.cn

Documentation No.: B06T01ENAM1-SY115C9/135C/155H

11644389

Crawler Hydraulic

Excavator

SY115C9

SY135C8

SY135C9

SY155H

Safety, Operation and Manitenance Manual

Quailty Changes the World

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Troubleshooting

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Summary of Contents for SANY SY115C9

Page 1 Quailty Changes the World Crawler Hydraulic Excavator SY115C9 SY135C8 SY135C9 SY155H SANY HEAVY MACHINERY LIMITED 318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P.R. of China 201413 Tel: (86) 21 5700 8518 Service hotline:(86) 4006 098 318 E-mail: crd@sany.com.cn Documentation No.: B06T01ENAM1-SY115C9/135C/155H...
Page 2 SY115C9/135C/155H Crawler Hydraulic Excavator SY115C9/135C/155H 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.
Page 3 Tel: (86) 21 5700 8518 Service hotline: (86) 4006 098 318 E-mail: crd@sany.com.cn 2012 by Sany Group. All right reserved. No part of this publication may be reproduced, © used, distributed or disclosed except during normal operation of the machine as de- scribed herein.
Page 4: Table Of Contents
1.2.3.6 Troubleshooting ..................1-7 1.2.3.7 Speciﬁ cations ..................1-7 1.2.3.8 Optional Equipment ................1-7 1.2.4 Page numbers....................1-7 1.3 Your Sany Machine ....................1-8 1.3.1 Machine applications ..................1-8 1.3.2 Machine directions ..................1-8 1.3.3 Breaking in a new machine ................1-9 1.3.4 Machine information..................
Page 5 Table of Contents SY115C9/135C/155H Crawler Hydraulic Excavator 2.2.1 Hazard alert wording ..................2-8 2.2.2 Other alert wording ..................2-9 2.2.3 Safety decals ....................2-9 2.2.3.1 Textual safety decals ................2-10 2.2.3.2 Graphical safety decals ............... 2-10 2.2.3.3 Safety decal locations ................2-11 2.3 General Precautions ....................
Page 6 SY115C9/135C/155H Crawler Hydraulic Excavator Table of Contents 2.3.22 Unauthorized modiﬁ cation ................. 2-31 2.3.23 Job site investigation.................. 2-31 2.3.24 Operation on soft ground ................2-32 2.3.25 Overhead power cables ................2-33 2.3.26 Ensuring a good visibility ................2-34 2.3.27 Ventilating enclosed area ................2-35 2.3.28 Asbestos hazard ..................
Page 7 Table of Contents SY115C9/135C/155H Crawler Hydraulic Excavator 2.4.6 Lifting objects with the machine ..............2-56 2.5 Precautions for Maintenance ................. 2-57 2.5.1 Prior-maintenance precautions ..............2-57 2.5.2 Select a working area .................. 2-57 2.5.3 Preparing the machine ................2-58 2.5.4 Preparing yourself ..................2-59 2.5.5 Lock-out and tag-out ..................
Page 8 SY115C9/135C/155H Crawler Hydraulic Excavator Table of Contents 3.3.2.6 Main Pump Signals ................3-15 3.3.2.7 Input Switch Signals ................3-16 3.3.2.8 Output Switch Signals ................ 3-16 3.3.2.9 Machine Conﬁ guration ............... 3-17 3.3.2.10 Failure codes ................... 3-17 3.3.2.11 Maintenance Information ..............3-18 3.3.2.12 Engine Speed Calibration ..............
Page 9 Table of Contents SY115C9/135C/155H Crawler Hydraulic Excavator 3.8 Alternate Exit......................3-51 3.9 Door Catch......................3-52 3.10 Cover/cap with a Latch ..................3-52 3.10.1 Opening/closing the cover with lock............3-53 3.10.2 Opening/closing the cap with lock.............. 3-54 3.11 Cup Holder ......................3-55 3.12 Storage Box ......................
Page 10 SY115C9/135C/155H Crawler Hydraulic Excavator Table of Contents 4.1.2.9 Work lamp switch - check ..............4-14 4.1.2.10 Horn - check ..................4-15 4.1.3 Adjustment before operation ................ 4-15 4.1.3.1 Operator seat ..................4-15 4.1.3.2 Rear view mirrors ................4-17 4.1.3.3 Seat belt ....................4-19 4.1.4 Before Starting the Engine ................
Page 11 Table of Contents SY115C9/135C/155H Crawler Hydraulic Excavator 4.9.3 Permissible depth of water................4-42 4.10 Traveling on Slope ....................4-42 4.10.1 Traveling downhill ..................4-44 4.10.2 Engine stalls on an incline ................. 4-44 4.10.3 Cab door on an incline ................4-44 4.11 Removing Machine from Mud ................
Page 12 SY115C9/135C/155H Crawler Hydraulic Excavator Table of Contents 4.18.3.3 Lifting the machine ................4-67 5 Maintenance 5.1 Maintenance Information ..................5-5 5.2 General Service ....................... 5-9 5.2.1 Oil, fuel and coolant ..................5-9 5.2.1.1 Oil ......................5-9 5.2.1.2 Fuel ..................... 5-10 5.2.1.3 Coolant ....................5-11...
Page 13 Table of Contents SY115C9/135C/155H Crawler Hydraulic Excavator 5.8.2.9 Air conditioner - inspect/service ............5-52 5.8.2.10 Gas spring - inspect ................5-54 5.8.2.11 Air in hydraulic system - purge ............5-55 5.8.2.12 Hydraulic circuit internal pressure - release ........5-58 5.8.3 Checks before starting ................. 5-59 5.8.4 Every 100 service hours ................
Page 14 SY115C9/135C/155H Crawler Hydraulic Excavator Table of Contents 5.8.9.3 Accumulator (control oil circuit) - replace ..........5-96 5.8.9.4 High-pressure tube clamps and rubber - check ........5-97 5.8.9.5 Compressor working condition - inspect ..........5-97 5.8.10 Every 8000 service hours ................5-98 5.8.10.1 High-pressure tube clamps - replace ..........
Page 15 Table of Contents SY115C9/135C/155H Crawler Hydraulic Excavator 7 Speciﬁ cations 7.1 Machine Dimensions ....................7-3 7.2 Working Ranges ..................... 7-4 8 Optional Equipment 8.1 General Safety ......................8-3 8.1.1 Selection precautions..................8-3 8.1.2 Reading the instruction books................ 8-3 8.1.3 Removal and installation precautions ............8-3 8.1.4 Operation precautions..................
Page 16 SY115C9/135C/155H Crawler Hydraulic Excavator Table of Contents 8.7 Quick Coupler and Control System ............... 8-26 8.7.1 Quick coupler installation ................8-26 8.7.2 Operating precautions ................. 8-28 8.8 Refueling System....................8-29 8.8.1 Introduction ....................8-29 8.8.2 Components....................8-30 8.9 Central Lubrication System..................8-31 8.9.1 Scheme and components ................
Page 17 Table of Contents SY115C9/135C/155H Crawler Hydraulic Excavator Safety, Operation and Maintenance Manual - Aug 2012...
Page 18: Introduction
1.2.3.6 Troubleshooting ..................1-7 1.2.3.7 Speciﬁ cations ..................1-7 1.2.3.8 Optional Equipment ................1-7 1.2.4 Page numbers....................1-7 1.3 Your Sany Machine ....................1-8 1.3.1 Machine applications ..................1-8 1.3.2 Machine directions ..................1-8 1.3.3 Breaking in a new machine ................1-9 1.3.4 Machine information..................
Page 19 Introduction SY115C9/135C/155H Crawler Hydraulic Excavator 1.3.4.6 Chassis serial number ................ 1-12 1.3.4.7 Machine monitor ................. 1-12 1.4 Table for serial number and distributor information ..........1-13 1.5 Correction Request Form - Technical Publications ..........1-14 1.6 Contact Information ....................1-15...
Page 20: Overview
♦ Sany-built machines are widely used throughout the industry for various types of applications. ♦ Sany is a leading manufacturer of con- struction equipment worldwide. This operator’s manual provides safety, opera- tion, maintenance, troubleshooting and techni- cal speciﬁ cations. In order to properly use your equipment, it is important to read this manual carefully before beginning any operations.
Page 21: Your Documentation Package
— A VCR on safety, operation and maintenance of your excavator is delivered with the machine. CD system requirements In order to use the Sany CD, be sure of the following: Hardware: ● Intel® Pentium II® running at 500 MHz or above ●...
Page 22: Recommendations On Using The Documentation
● Use the CD to print and replace any miss- ing pages or those made unreadable due to damage, grease, dirt, etc. ● Insert Sany replacement pages immedi- ately into the appropriate book; destroy old versions of those pages. ● Replace outdated CD’s with new ones;...
Page 23: Introduction
Introduction SY115C9/135C/155H Crawler Hydraulic Excavator tact your Sany distributor before operating or repairing the machine. 1.2.3.1 Introduction This section provides an overview of what is covered in the rest of this manual, including machine label information and Sany contact information.
Page 24: Troubleshooting
1.2.3.8 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.
Page 25: Your Sany Machine
Introduction SY115C9/135C/155H Crawler Hydraulic Excavator 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 CZ335-1101001 Fig. 1-2 (A) Front In this manual, the front, back, left or right di-...
Page 26: 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.
Page 27: Engine Identiﬁ Cation Plate
Introduction SY115C9/135C/155H Crawler Hydraulic Excavator 1.3.4.2 Engine identiﬁ cation plate On cover of engine cylinder head. SY115C9/SY135C8/SY135C9/SY155H CONFORMED TO NATIONAL STAGE II NON-ROAD DIESL ENGINE EMISSION CONTROL STANDARD ENGINE FAMILY: G20097L0433GTA ENGINE MODEL: 4BG1-TABGC-03-C2 ENGINE POWER: 72.7 kW/ 2200 r/min...
Page 28: Right And Left Drive Motors
SY115C9/135C/155H Crawler Hydraulic Excavator Introduction 1.3.4.3 Right and left drive motors On each drive motor: Model: _____________________________ ID No.: _____________________________ CZ235-3100801 Fig. 1-6 1.3.4.4 Swing motor On top of swing motor: Model: ______________________________ ID No.: ______________________________ CZ235-3100802 Fig. 1-7 1.3.4.5 Hydraulic pump...
Page 29: Chassis Serial Number
Introduction SY115C9/135C/155H Crawler Hydraulic Excavator 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. 1-9 1.3.4.7 Machine monitor Location of machine monitor is shown in the right illustration.
Page 30: Table For Serial Number And Distributor Information
SY115C9/135C/155H Crawler Hydraulic Excavator Introduction 1.4 Table for serial number and distributor information This location is for you to record information relating to your machine. It is advised that you keep this manual with your machine at all times for reference.
Page 31: Correction Request Form - Technical Publications
Introduction SY115C9/135C/155H Crawler Hydraulic Excavator 1.5 Correction Request Form - Technical Publications If you ﬁ nd a problem with this manual, please make a copy of this page, ﬁ ll out: the information and send it to us attention Technical Publications. See Contact Information” on next page.
Page 32: Contact Information
SY115C9/135C/155H Crawler Hydraulic Excavator Introduction 1.6 Contact Information Thank you for purchasing a Sany machine. In the event that you should need to contact us for any reason, you can reach us as follows: Sany Heavy Machinery Limited 318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P. R. of China...
Page 33 Introduction SY115C9/135C/155H Crawler Hydraulic Excavator 1-16 Safety, Operation and Maintenance Manual - Aug 2012...
Page 34: Safety
SY115C9/135C/155H Crawler Hydraulic Excavator Safety Safety 2 Safety 2.1 Safety Information....................2-5 2.2 Safety Messages ..................... 2-7 2.2.1 Hazard alert wording ..................2-8 2.2.2 Other alert wording ..................2-9 2.2.3 Safety decals ....................2-9 2.2.3.1 Textual safety decals ................2-10 2.2.3.2 Graphical safety decals ...............
Page 35 Safety SY115C9/135C/155H Crawler Hydraulic Excavator 2.3.14 Preventing ﬁ re and explosion ..............2-26 2.3.14.1 Fire caused by fuel or oils ..............2-26 2.3.14.2 Fire caused by ﬂ ammable materials ..........2-27 2.3.14.3 Fire caused by electric lines .............. 2-27 2.3.14.4 Fire caused by hydraulic lines ............2-28 2.3.14.5 Fire caused by illumination equipment ..........
Page 36 SY115C9/135C/155H Crawler Hydraulic Excavator Safety 2.4.2.4 Travel directions .................. 2-43 2.4.2.3 Rules for steering safety ..............2-43 2.4.2.5 Rules for traveling safety ..............2-45 2.4.2.6 Safe traveling ..................2-46 2.4.2.7 Operation on an incline ............... 2-47 2.4.2.8 Operation in snowy weather ............... 2-48 2.4.2.9 Restricted operations ................
Page 37 Safety SY115C9/135C/155H Crawler Hydraulic Excavator 2.5.21 Maintenance operation ................2-70 2.5.22 Proper disposal of wastes ................2-71 Safety, Operation and Maintenance Manual - Sep 2012...
Page 38: Safety Information
Drive and operate the machine carefully. Improper operation or application may cause personal injury or machine dam- age. Sany assumes no responsibility for such losses. Safety, Operation and Maintenance Manual - Sep 2012...
Page 39 Never use the machine in ﬂ ammable or explosive environment, or in areas containing asbestos dust. Select a Sany excavator that is suitable for high-plateau operation when operating in areas 2,000 m above the sea level. This machine has gone through electromag- netic capacity test according to EN 13309- 200C.
Page 40: Safety Messages
If the ma- chine is sold to a third party, give this manual to new owner. The machine provided by Sany to its buyer is in line with all speciﬁ cations and standards of buyer's country. If the machine is purchased...
Page 41: Hazard Alert Wording
Safety SY115C9/135C/155H Crawler Hydraulic Excavator 2.2.1 Hazard alert wording Hazard alert words are used in this manual and on some machine decals to inform the operator of imminent or potential hazards that lead to death, personal injury or property dam- age.
Page 42: Other Alert Wording
SY115C9/135C/155H Crawler Hydraulic Excavator Safety An example alert wording and alert text WARNING ● The hydraulic lockout control must be placed in the LOCK position before you leave the operator cab. ● An unlocked hydraulic lockout control lever can cause serious injury or death if maneuvered unexpectedly.
Page 43: Textual Safety Decals
Safety SY115C9/135C/155H Crawler Hydraulic Excavator 2.2.3.1 Textual safety decals Textual safety decals use brief text to indicate hazardous situation and safety measures. CAUTION Fig. 2-1 is an example of textual safety decals. TO RELEASE PRESSURE, LOOSEN ONLY ONE TURN. A820601990968 Code Fig.
Page 44: Safety Decal Locations
If a tool, procedure, work method or operating tech- nique that is not speciﬁ cally recommended by Sany is used, you must be sure that it is safe for you and for others. Application or operation not specified in this manual shall not be performed at any time.
Page 45 Safety SY115C9/135C/155H Crawler Hydraulic Excavator CZ335-1102001 Fig. 2-3 2-12 Safety, Operation and Maintenance Manual - Sep 2012...
Page 46 SY115C9/135C/155H Crawler Hydraulic Excavator Safety (1) Read the manual ● Warning! ● Read the Manual before operation, main- tenance, disassembly, reassembly and transportation of your machine. A820601990971 Fig. 2-4 (2) Lock the front window ● Always lock the front window if it is open.
Page 47 Safety SY115C9/135C/155H Crawler Hydraulic Excavator (4) High voltage ● Electrocution hazard. ● Keep a safe distance from power transmis- sion lines. A820601990974 Fig. 2-7 (5) Remove key after power-off Before leaving your machine, lower the work equipment to ground, engage the hydraulic lockout control and remove the ignition key.
Page 48 SY115C9/135C/155H Crawler Hydraulic Excavator Safety (7) Away from swinging range ● This decal shows the possibility of being hit by the machine. Be away from the swing- ing range. ● Keep a safe distance from the machine when it is working.
Page 49 Safety SY115C9/135C/155H Crawler Hydraulic Excavator (10) Squirting hazard ● Read the instruction before removing the cap of any pressure vessel. To prevent squirting, turn the cap slowly to release in- ternal pressure before removing it. A820699000948 Fig. 2-13 (11) Fan cutting hazard WARNING ●...
Page 50 SY115C9/135C/155H Crawler Hydraulic Excavator Safety (13) Moving belt ● A rotating belt is dangerous. ● Stop the belt before maintenance. STOP A820699001017 Fig. 2-17 (14) Possible to fall ● It is possible to fall. ● Stay away from the edge.
Page 51 Safety SY115C9/135C/155H Crawler Hydraulic Excavator (16) Not seating CAUTION A820699001023 Fig. 2-19 (17) Water separator draining precautions NOTICE Direction to drain. Direction to close. Tighten it properly. Never tighten it with extra force. Over-tightening could damage the water separator. A820601990962 Fig.
Page 52: General Precautions
In case of any abnormalities found during operation and maintenance, such as noise, vi- bration, odor, incorrect gauge display, smoke, or oil leakage, contact your Sany distributor and take necessary measures. Never operate the machine before the faults are corrected.
Page 53 Safety SY115C9/135C/155H Crawler Hydraulic Excavator ● Dust mask Wear all necessary PPEs as well as other equipment required by your employer, local government, and local laws and regulations. Never take a risk. WARNING Observe the following items before per- forming any operations. Failure to do so could cause machine damage, personal injury or death.
Page 54: Fire Extinguisher And Fi Rst Aid Kit
SY115C9/135C/155H Crawler Hydraulic Excavator Safety 2.3.4 Fire extinguisher and ﬁ rst aid kit To prevent injury or ﬁ re, observe the following precautions: ● First aid kit and ﬁ re extinguisher should be available nearby. ● Read and understand the instruction at- tached to fire extinguisher.
Page 55: Cleaning Your Machine
Safety SY115C9/135C/155H Crawler Hydraulic Excavator WARNING Observe the following items before per- forming any operations. Failure to do so could cause machine damage, personal injury or death. ● Make sure all covers and caps are in proper place. Repair or replace any of them immediately once found dam- aged.
Page 56: Keeping The Cab Clean
SY115C9/135C/155H Crawler Hydraulic Excavator Safety 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.
Page 57: Handholds And Steps
Safety SY115C9/135C/155H Crawler Hydraulic Excavator 2.3.9 Handholds and steps 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.
Page 58: Overhead Work
SY115C9/135C/155H Crawler Hydraulic Excavator Safety 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.
Page 59: Hot Oil
Safety SY115C9/135C/155H Crawler Hydraulic Excavator 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 pro- ceed. When the engine has cooled down, loosen the cover or screw plug slowly to relieve internal pressure.
Page 60: Fire Caused By Fl Ammable Materials
SY115C9/135C/155H Crawler Hydraulic Excavator Safety ● Shut down the engine before refueling. ● Never leave the machine when reﬁ lling the fuel or engine oil. ● Never let fuel overflow onto overheated surface or electrical components. ● Remove overﬂ owed fuel or engine oil after CZ335-1102015 reﬁ...
Page 61: Fire Caused By Hydraulic Lines
Safety SY115C9/135C/155H Crawler Hydraulic Excavator ● 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.
Page 62: Windshield Cleaning Detergent
SY115C9/135C/155H Crawler Hydraulic Excavator Safety 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 The grease in track tensioning device is under high pressure. Improper handling may result in serious injury, blindness or death.
Page 63: Falling Object Protection
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.
Page 64: Attachment Combination
Improper modification can affect ma- chine's strength and operator's view. Contact your Sany distributor before making any modi- fication. Sany assumes no responsibility for the accidents, failure or damage caused by unauthorized modiﬁ cation.
Page 65: Operation On Soft Ground
Safety SY115C9/135C/155H Crawler Hydraulic Excavator a ditch or on road shoulders. Keep your machine a safe distance away from the ditch or road shoulder. Designate a signal man, when necessary, to avoid accidental injury. ● When underground water mains, gas lines,...
Page 66: Overhead Power Cables
SY115C9/135C/155H Crawler Hydraulic Excavator Safety 2.3.25 Overhead power cables Never drive or operate your machine near power cables, which may bring electrocution hazard and cause machine damage, personal injury or death. The following steps are to be followed while working at where power cables could be nearby.
Page 67: Ensuring A Good Visibility
Safety SY115C9/135C/155H Crawler Hydraulic Excavator 2.3.26 Ensuring a good visibility The machine is equipped with rearview mirrors to improve the visibility of the operator. How- ever, some areas cannot be seen from the operator seat. When operating your machine in a position that gives you poor visibility, un- certainty of job site may cause machine dam- age and personal injury.
Page 68: Ventilating Enclosed Area
SY115C9/135C/155H Crawler Hydraulic Excavator Safety WARNING Exposure to hazardous chemicals or dusts pose a serious danger if released or mis- handled. Performing demolition work or handling hazardous materials often release substances that could pose a hazard. Seri- ous injury or death may result unless prop- er precautions are observed while working with these materials.
Page 69: Alternate Exit
Safety SY115C9/135C/155H Crawler Hydraulic Excavator market parts could contain asbestos. There- fore, use only the parts and components sup- plied by Sany. 2.3.29 Alternate exit ● If you are unable to open the cab door in case of emergency, use the safety hammer to break the rear window to escape.
Page 70: Safe Operation Precautions
SY115C9/135C/155H Crawler Hydraulic Excavator Safety 2.4 Safe Operation Precautions 2.4.1 Safe starting 2.4.1.1 Safe mounting When you mount or dismount the machine: ● Always face the machine and maintain a three-point contact (one hand and two feet CZ335-1102023 or two hands and one foot).
Page 71: Seat Adjustment
Safety SY115C9/135C/155H Crawler Hydraulic Excavator 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.
Page 72: Engine Starting Rules
SY115C9/135C/155H Crawler Hydraulic Excavator Safety ● Check the instrument panel. Check if the control levers are all in neutral position. ● Check if the hydraulic lockout control is in the LOCK position. ● Adjust the rear view mirrors so as to see clearly from the operator seat what is hap- pening behind the machine.
Page 73: Starting Engine In Cold Season
Safety SY115C9/135C/155H Crawler Hydraulic Excavator To understand proper starting steps of the ma- chine, see “Engine Starting” on page 4-22. ● Being seated in the operator's position, ad- just the seat so you can easily access all controls from a seated position.
Page 74: After Starting The Engine
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.
Page 75: Operation
Safety SY115C9/135C/155H Crawler Hydraulic Excavator and all readings are within normal working range. 2.4.2 Operation 2.4.2.1 Inspection before operation ● When conducting inspection, move the machine to a spacious area without barri- ers and operate slowly. Any other person is not allowed to approach the machine.
Page 76: Travel Directions
SY115C9/135C/155H Crawler Hydraulic Excavator Safety 2.4.2.4 Travel directions WARNING Improper operation of travel control lever/ pedal can cause serious injury or death. ● Conﬁ rm 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.
Page 77 Safety SY115C9/135C/155H Crawler Hydraulic Excavator at the rear of the machine. In turning or swivel operation, be alert not to hit other machines or personnel. ● Sound the horn to warn personnel in the area before traveling. ● Check for the presence of personnel and/ or obstacles again in the machine sur- roundings before traveling.
Page 78: Rules For Traveling Safety
SY115C9/135C/155H Crawler Hydraulic Excavator Safety 2.4.2.5 Rules for traveling safety ● To prevent machine breakdown and avoid damage of work equipment, never operate the machine beyond its maximum load or rated capacity. ● When driving or operating the machine, keep the machine a safe distance away from people, building or other machine so as to avoid collision.
Page 79: Safe Traveling
Safety SY115C9/135C/155H Crawler Hydraulic Excavator 2.4.2.6 Safe traveling ● Check the travel direction of the machine before driving it. Make sure you know how to operate the control levers and pedals. ● Press the upper part of the control pedal or push the control lever forward to move the machine in the direction of the idlers.
Page 80: Operation On An Incline
SY115C9/135C/155H Crawler Hydraulic Excavator Safety ● Drive straight up and down a steep slope. It is very dangerous to turn on or drive across a slope. CZ335-1102041 Fig. 2-63 ● 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.
Page 81: Operation In Snowy Weather
Safety SY115C9/135C/155H Crawler Hydraulic Excavator 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.
Page 82 SY115C9/135C/155H Crawler Hydraulic Excavator Safety ● Never dig too much under the machine, which may cause the ground to collapse due to cave-in, hence the accidents. CZ335-1102048 Fig. 2-67 ● In excavating operation, the track should be adjusted vertical to road shoulder or...
Page 83 Safety SY115C9/135C/155H Crawler Hydraulic Excavator ● Never tear down any structure over your machine. The falling of broken objects or collapse of building could damage your machine and cause personal injury or death. CZ335-1102051 Fig. 2-70 ● Never break anything with the impact force...
Page 84: Parking The Machine
SY115C9/135C/155H Crawler Hydraulic Excavator Safety 2.4.3 Parking the machine 2.4.3.1 Select a parking place ● Park your machine on a solid and ﬂ at sur- face. ● Park the machine in an ares free of such hazards as falling stones or landslide. If the terrain is low, park it in a relatively higher place.
Page 85: Transportation
Safety SY115C9/135C/155H Crawler Hydraulic Excavator LOCK position. 7. Remove ignition key. 8. Close the windows and the cab door. Locked 9. Lock all access doors, boxes and cham- bers. CZ335-1102057 When leaving your machine, face the machine Fig. 2-76 and maintain a three-point contact with it. Nev- er jump off the machine.
Page 86: Transporting The Machine
SY115C9/135C/155H Crawler Hydraulic Excavator Safety ● Place the work equipment straight forward. ● 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.
Page 87: Battery
Safety SY115C9/135C/155H Crawler Hydraulic Excavator 2.4.5 Battery Electrolyte contains sulfuric acid, which gives off ﬂ ammable and explosive gases. Improper handling may cause personal injury or fire. Observe the instructions below when handling battery: ● Never smoke or use ﬁ re near a battery.
Page 88 SY115C9/135C/155H Crawler Hydraulic Excavator Safety charging process. ● A battery being charged may give off ﬂ am- mable gases. Before charging a battery, remove it from the undercarriage, put it in well-ventilated area and remove the cap. ● If acid squirts out of battery vent during charging, stop charging immediately.
Page 89: Lifting Objects With The Machine
Safety SY115C9/135C/155H Crawler Hydraulic Excavator 2.4.6 Lifting objects with the machine 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.
Page 90: Precautions For Maintenance
SY115C9/135C/155H Crawler Hydraulic Excavator Safety 2.5 Precautions for Maintenance 2.5.1 Prior-maintenance precautions To prevent accidents: ● Understand maintenance procedure before operation. ● Keep a clean and dry working area. ● Never spray water or steam in the cab. ● Never add lubricant and carry out other maintenance work when your machine is moving.
Page 91: Preparing The Machine
Safety SY115C9/135C/155H Crawler Hydraulic Excavator 2.5.3 Preparing the machine Before maintaining the machine: ● Park the machine on solid and ﬂ at ground. ● Lower the bucket to the ground. ● Place blocks under the tracks to prevent CZ335-1102073 movement of the machine.
Page 92: Preparing Yourself
SY115C9/135C/155H Crawler Hydraulic Excavator Safety 2.5.4 Preparing yourself Only approved personnel can maintain or repair the machine. An observer may be as- signed if necessary. ● Wear protective clothing and shoes neces- sary for the job. ● Wear rubber apron and rubber gloves when handling corrosive materials.
Page 93: Lock-Out And Tag-Out
Safety SY115C9/135C/155H Crawler Hydraulic Excavator 2.5.5 Lock-out and tag-out ● When maintenance is underway, starting the engine or moving the control levers or pedals could lead to serious accident. ● Before maintenance, attach a Never OP- ERATE tag or similar sign to the machine's start switch or control levers to warn others that this machine is under maintenance.
Page 94: Maintenance With Engine Running
SY115C9/135C/155H Crawler Hydraulic Excavator Safety 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.
Page 95: Track Maintenance
Safety SY115C9/135C/155H Crawler Hydraulic Excavator ● 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 hy- draulic pipe or accidental touch of control lever, the work equipment or machine may fall suddenly, causing injury or death.
Page 96: Track Tension Adjustment Precautions
It includes a high pres- sure spring, which may ﬂ y out and cause seri- ous injury or death if removed improperly. If it has to be removed, contact your Sany dis- tributor. CZ335-1102081 Fig. 2-99...
Page 97: Welding Operation
If any bolt on hose is loose, stop operation and tighten it to speciﬁ ed 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: ●...
Page 98: Pressurized Fl Uid
SY115C9/135C/155H Crawler Hydraulic Excavator Safety 2.5.14 Pressurized ﬂ uid 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.
Page 99: Hot Cooling System
Safety SY115C9/135C/155H Crawler Hydraulic Excavator 2.5.15 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.
Page 100: High Voltage Precautions
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- CZ335-1102084 gine controller.
Page 101: Avoiding Fi Re And Explosion
Safety SY115C9/135C/155H Crawler Hydraulic Excavator 2.5.19 Avoiding ﬁ re and explosion DANGER Never smoke when handling the fuel or maintaining the fuel system. The gases in empty fuel tank can cause explosion eas- ily. Never carry out ﬂ ame-cutting or weld- ing operation on fuel pipe, fuel tank or fuel vessels, which can lead to ﬁ...
Page 102: Regular Replacement Of Safety-Related Parts
SY115C9/135C/155H Crawler Hydraulic Excavator Safety 2.5.20 Regular replacement of safety- related parts WARNING Safety-related parts are important for safe- ty of you and your machine. Failure to re- place them at speciﬁ ed intervals may lead to personal injury, death or serious dam- age.
Page 103: Maintenance Operation
● 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...
Page 104: Proper Disposal Of Wastes
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, ﬁ lter and batteries etc.. CZ335-1102086 ●...
Page 105 Safety SY115C9/135C/155H Crawler Hydraulic Excavator 2-72 Safety, Operation and Maintenance Manual - Sep 2012...
Page 106: System Functions
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions System Functions 3 System Functions 3.1 Machine Overview ....................3-5 3.2 Machine Controls ..................... 3-6 3.3 Monitor ........................3-7 3.3.1 Monitor introduction ..................3-7 3.3.2 System information and operation ............... 3-10 3.3.2.1 Main Page ................... 3-10 3.3.2.2 System Information ................
Page 107 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.4.2.2 Fuel control dial ................... 3-33 3.4.2.3 Work lamp switch ................3-33 3.4.2.4 Wiper switch ..................3-35 3.4.2.5 Washer switch ..................3-36 3.4.2.6 Head lamp switch ................3-36 3.4.2.7 Horn switch ..................3-37 3.4.2.8 Cab lamp .................... 3-37 3.4.2.9 Cigar lighter ..................
Page 108 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.16.2 Radio operation..................3-76 3.17 Auxiliary Power Supply ..................3-80 3.18 Fuses ........................3-80 3.19 Fusible Link......................3-81 3.20 Controller ......................3-82 3.21 Toolbox ........................ 3-82 3.22 Grease pump frame ..................... 3-82 3.23 Fire extinguisher ....................3-83...
Page 109 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator Safety, Operation and Maintenance Manual - Aug 2012...
Page 110: Machine Overview
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3 SYSTEM FUNCTIONS 3.1 Machine Overview CZ335-1103001 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...
Page 111: Machine Controls
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.2 Machine Controls CZ155-1103001 Fig. 3-2 (1) Air conditioner control panel (11) Indicator lights (2) Radio control panel (12) Start switch (3) Hydraulic lockout control (13) Fuel control dial (4) Left joystick control (14) Work lamp switch...
Page 112: Monitor
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.3 Monitor When the start switch is turned to the ON position, the monitor is energized by the battery and initializes. An operating monitor looks like below: Alert indicator Alert and signal indicators Signal indicator...
Page 113 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator LCD display The LCD display allows you to view system information like operating parameters, time, Sany Hydraulic Excavator and function icons. As shown in Fig. 3-5, the following information will be displayed on the monitor.
Page 114 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions Common icons and function keys Function key Icon Function Range Select a working mode S → H → L → B Switch to idle/non-idle Idle/non/idle Switch to high/low speed Lo → Hi Access an option/setup...
Page 115: System Information And Operation
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 2. Navigation keys Navigation key Function Enter Enter an option/setup item. Return to previous page. Select previous item (select the last item after the ﬁ rst one). Select next item (select the ﬁ rst item after the last one).
Page 116 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions to be done. 10. GPRS signal. 11. Press [F4] to access failure codes. 12. Press [F5] to access “System Information”. 13. System clock (h:m:s) 14. System calendar (Y/M/D) 15. Fuel control dial position (1-11) Keypad input [F1]: Select a working mode (S, H, L or B).
Page 117: System Information
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.3.2.2 System Information Pass code is required to access system infor- mation. System Information Screen output Please enter the password: 1. A 5-digit pass code is required to access system information, with each indicated by ＊　＊　＊　＊　＊...
Page 118: Time Setup
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.3.2.3 Time Setup Set up the time of system clock. Time Setup Screen output 1. Date and time. Y/M/D h/m/s 2. Enter time setup. 2010 09 30 13 32 55 08 E 3. Return to "System Information".
Page 119: Main Menu
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.3.2.4 Main Menu A list of system functions that can be selected to access different options. Main Menu Screen output Operating parameters Machine configuration 1. Menu of system functions. Failure codes 2. A short description of the item selected, in-...
Page 120: Engine & Throttle Signals
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.3.2.5 Engine & Throttle Signals Displaying operating parameters of engine. Screen output Engine & Throttle Signals 1. Real-time display of engine signals col- Fuel level %: lected by the controller. Oil pressure kPa: 2. Press [F1] to view "Main Pump Signals" on Hyd oil temp °C:...
Page 121: Input Switch Signals
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.3.2.7 Input Switch Signals Displaying input switch signals. Input Switch Signals Screen output ○ Start input ○ Boom UP 1. Real-time display of input switch signals. ○ Shutdown input ○ Boom DOWN 2. Press [F1] to view "Output Switch Signals".
Page 122: Machine Conﬁ Guration
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.3.2.9 Machine Conﬁ guration Displaying major components of the machine. Machine Configuration Screen output Machine model: SY135C8B 1. Machine conﬁ guration information. 2. Press [F5] to return to the "Main Menu". Machine number: 018998...
Page 123: Maintenance Information
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.3.2.11 Maintenance Information Every 50 service hours Maintenance Information Screen output Every 50 Service Hours 1. Maintenance interval. ① Grease the swing bearing. Slowly rotate the bearing as you grease it. 2. Maintenance items.
Page 124 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions Every 250 service hours Screen output Maintenance Information 1. Maintenance interval. 2. Maintenance items. Every 250 Service Hours ① Replace the fuel filter element. 3. Press [F1] to call “System Setup”. Enter ② Clean the primary filter element of air cleaner;...
Page 125 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator Every 500 service hours Screen output Maintenance Information 1. Maintenance interval. Every 500 Service Hours 2. Maintenance items. ① Perform maintenance for every 250 service hours. 3. Press [F1] to call “System Setup”. Enter ②...
Page 126 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions Every 1000 service hours Screen output 1. Maintenance interval. Maintenance Information 2. Maintenance items. Every 1000 Service Hours 3. Press [F1] to call “System Setup”. Enter ① Perform maintenance for every 500 service hours.
Page 127 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator Every 2000 service hours Screen output 1. Maintenance interval. Maintenance Information 2. Maintenance items. Every 2000 Service Hours 3. Press [F1] to call “System Setup”. Enter ① Perform maintenance for every 1000 service hours.
Page 128: Engine Speed Calibration
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.3.2.12 Engine Speed Calibration Auto setup of gear positions and correspond- ing engine speed. Engine Speed Calibration Screen output Throttle gear N： 1. Press [F1] to select a working mode: Target speed rpm： 1000 S →...
Page 129 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator Remark: ● Gear position calibration 1. Gear position calibration can be performed without running the engine. 2. Auto gear position calibration procedure: 1) Press [F1] to select working mode H. 2) Turn the fuel control dial to position 0. (The monitor displays 0 for gear position.) 3) Press the calibration start key [F3] to activate auto calibration mode.
Page 130: Language Selection
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.3.2.13 Language Selection Selecting a system language. Language Selection Screen output 1. List of language options. 2. Press [F1] to scroll down the list. 中文 3. Press [F2] to select a language. 4. Press [F5] to return to the “Main Menu”.
Page 131: Gps Monitoring Information
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.3.2.14 GPS Monitoring Information Displaying GPS monitoring information. Screen output GPS Monitoring Info 121.0W Longitude ° 1. Real-time display of GPS monitoring 31.40N Latitude ° information. 28.79P Elevation 4.037 Speed Km/h 2. Press [F5] to return to the “Main Menu”.
Page 132: System Setup
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.3.2.15 System Setup Access to “Machine Setup” requires a pass code. System Setup Screen output Please enter the password: 1. A 5-digit pass code is required to access “Machine Setup”, with each indicated by ＊　＊　＊　＊　＊...
Page 133: Machine Conﬁ Guration Setup
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.3.2.16 Machine conﬁ guration setup Setting up serial number of the machine. Machine Config. Setup Screen output 1. Machine serial number and operating hours. Machine serial No.: 018998 √ Operating hours: 000012 2. Select an item to set up.
Page 134: Coolant Temperature
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.3.2.17 Coolant Temperature Displaying the coolant temperature. Coolant Temperature Screen output Coolant temp ℃： 80 1. Coolant temperature. 2. Press [F5] to return to the “Main Menu”. Keypad input [F5]: Return to the "Main Menu".
Page 135: Service Call
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.3.2.18 Service Call Sending a call to machine service center. Call Service Screen output Call command: 0004 1. Call state. 1. Use the key F1 to start or finish altering the call comand. 2. Call command.
Page 136: Switches
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.4 Switches CZ135B-1103007 Fig. 3-29 (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) Cigar lighter (5) Washer switch...
Page 137 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.4.2.1 Start switch NOTICE If the engine does not stop at low idle speed, the service life of engine will be reduced. Except for emergency, never shut off the engine while it is running at...
Page 138: Fuel Control Dial
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.4.2.2 Fuel control dial Fuel control dial is used to adjust engine speed and output power. Turn the dial clock- wise to increase engine speed; turn it counter- （b） clockwise to decrease engine speed.
Page 139 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator b. Two(2) work lamps on the boom 2. Work lamp external structure (1) Work lamp seat (2) Two-wire socket jacket (3) Nut (4) Work lamp screw CZ335-1103040 3. Work lamp internal wiring Fig. 3-35...
Page 140: Wiper Switch
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.4.2.4 Wiper switch NOTICE Wiper Switch When you use the wiper, press the washer switch to spray some detergent in order to prevent damaging the wiper due to fric- tion. CZ335-1103042 Fig. 3-38 When it is raining or the windshield is dirty, you can press the wiper switch to activate the windshield wiper.
Page 141: Washer Switch
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.4.2.5 Washer switch CAUTION Before pressing the button, make sure that the windshield of cab is closed. Press washer switch to spray cleaning deter- gent. Washer Switch With the switch depressed, the washer keeps spraying detergent.
Page 142: Horn Switch
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.4.2.7 Horn switch The horn switch is located on top of right joy- Horn switch stick. Press the switch to sound the horn. Depress the switch to keep the horn hooting. CZ335S-1103034 Fig. 3-44 3.4.2.8 Cab lamp...
Page 143: Preheat Switch (Only For Sy135C8M)
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.4.2.10 Preheat switch (only for SY135C8M) This is engine preheat switch, which will be used together with the preheat start switch. ● Pressing the preheat switch (6) and turning the key counterclockwise to HEAT position, the engine will start to preheating.
Page 144: Control Levers And Pedals
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.5 Control levers and pedals CZ335-1103052 Fig. 3-49 (1) Hydraulic lockout control (3) Left joystick control (2) Travel controls (4) Right joystick control Safety, Operation and Maintenance Manual - Aug 2012 3-39...
Page 145: Hydraulic Lockout Control
In this case, immediately engage the hydraulic lock- out control and stop the engine. Contact your Sany distributor to solve this problem. 3-40 Safety, Operation and Maintenance Manual - Aug 2012...
Page 146: Travel Controls
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.5.2 Travel controls WARNING ● Do not put your foot on any pedal during operation, except for travel. Unintended ped- aling could lead to sudden move of your machine and cause severe accidents. ● Take extra care when driving or steering the machine with pedals. Do not put your foot on any pedal when they are not used.
Page 147: Joystick Controls
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.5.3 Joystick controls WARNING ● Never expose any part of your body outside the window, which may other- wise put you in danger of being hurt by the boom if the joystick is moved un- expectedly.
Page 148 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions Right joystick control ⑤ Right joystick operation ⑧ Forward Boom DOWN ⑤ Backward Boom UP ⑥ ⑥ Left Bucket DIG ⑦ Right Bucket DUMP ⑧ Table 3-4 CZ335S-1103042 Fig. 3-54 CZ335-1103058 Fig. 3-55 Remark:...
Page 149: Roof Hatch
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.6 Roof Hatch WARNING Secure the lockout control to the LOCK position when leaving the operator's seat. Serious accidents can be caused if any control lever or pedal is maneuvered by mistake when the lockout control is in FREE position.
Page 150: Windshield
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.7 Windshield Front window can be pulled up onto the cab roof. WARNING Always leave the lockout control in the LOCK position when opening or closing the windshield, bottom window or cab door. Serious accidents can be caused if...
Page 151 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3. Check the wiper blade, which shall be stored in the right bracket. CZ335-1103062 Fig. 3-59 4. Hold the left and right handholds (A) of the windshield and pull the two levers (B) in order to release the locks on top of the windshield.
Page 152 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 5. In the cab, hold the lower handhold (C) with your left hand and the upper handhold (D) with your right hand, and push the win- dow upward. Continue to push the window toward the latch (E)in the rear of the cab till it is locked securely.
Page 153: Closing The Window
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 6. Check the lever (B), which shall be secured in “locked” position. ● Check the arrow on the catch (F), which should be aligned with the arrow on lever (B). The lock is engaged.
Page 154 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 4. Hold the lower handhold (C) with your left hand and upper handhold (D) with your right hand, push the window forward and lower the window slowly. CZ335-1103070 Fig. 3-68 CZ135B-1103009 Fig. 3-69 5. When the bottom of windshield reaches...
Page 155: Removing The Lower Window
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 6. Check the lever (B), which should be secured in “locked” position. ● Check the arrow on the catch (F), which should be aligned with the arrow on lever (B). The lock is engaged.
Page 156: Alternate Exit
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.8 Alternate Exit If you are unable to open the cab door in case of emergency, use the hammer to break the rear window and escape. Sign of alternate exit Never use the hammer for other purposes.
Page 157: Door Catch
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.9 Door Catch CAUTION ● Park your machine on a level ground before unlocking the cab door. ● Never unlock the door on a slope. The door may shut suddenly and cause in- jury.
Page 158: Opening/Closing The Cover With Lock
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.10.1 Opening/closing the cover with lock NOTICE ● Make sure to turn the cover (1) to shield the key hole after removing the key. Otherwise, invasion of foreign bodies could make the switch sluggish or fail- ing.
Page 159: Opening/Closing The Cap With Lock
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator Closing the cover 1. Screw on the cover(2) and insert the key into the key hole. 2. Turn the start switch key to “locked” posi- tion (B), and remove the key. 3. Turn the cover (1) to shield key hole.
Page 160: Cup Holder
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.11 Cup Holder A cup holder has been designed and installed to the left side of operator in order to hold bev- erage. CZ335-1103086 Fig. 3-80 ● As shown in the illustration, the cup holder can be folded to prevent damage when it is not used.
Page 161: Storage Box
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.12 Storage Box ● Located to the rear right of operator seat, the storage box is used to keep your drinks warm in winter and cool in summer. Closed ● Cool or warm air is sent into the storage box according to the setting of air-condi- tioner.
Page 162: Ashtray
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.14 Ashtray ● The ashtray is above the cigar lighter. ● Make sure that the cigarette is extin- guished before closing the ash tray. Closed CZ335-1103091 Fig. 3-85 Open CZ335-1103092 Fig. 3-86 Safety, Operation and Maintenance Manual - Aug 2012...
Page 163: Air Conditioning System
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.15 Air Conditioning System 3.15.1 Control panel Monitor FULL AUTO AIRCONDITIONER CZ215-1103037 Fig. 3-87 Remark: (1) Power-off switch (2) Fan switch After the automatic control switch (5), fresh (3) Temperature switch air/recirculation switch (6) and air conditioner...
Page 164 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions (2) Fan control switch The switch (2) is used to regulate the volume of air ﬂ ow, which can be set to any of six lev- els. The amount of air flow is displayed on the LCD panel.
Page 165 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator LCD display and function LCD display (℃ ) Set Temperature 18.0 Maximum cooling 18.5 ~ 31.5 Adjust temperature inside operator cab to selected temperature 32.0 Maximum heating Table 3-6 (4) Air outlet selector switch This switch (4) is used to select the position of each air outlet.
Page 166 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions (D): air outlet for feet (1) CZ335-1103100 Fig. 3-94 Air Outlet LCD Display Air Outlet Mode Remark Front outlet for face Auto operation disabled ○ Front and back outlets for ○ ○ face Front and back outlets for ○...
Page 167 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator (5) Automatic control switch This switch (5) can be used to set air ﬂ ow, out- lets and fresh air or circulation automatically according to the preset temperature. AUTO ● Pressing the automatic control switch (5), CZ335-1103101 the indicator above the switch comes on.
Page 168 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions (7) LCD display LCD display (7) shows the preset temperature (a), air flow (b) and outlet position (c) during operation. ● By pressing the OFF switch (1), the display of preset temperature (a), air ﬂ ow (b) and outlet position (c) disappears, and the op- eration stops.
Page 169: Operation Method
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.15.2 Operation method You can control the air conditioner automati- cally or manually. Select a control manner you want. Automatic operation 1. Turn on the automatic control switch (5). AUTO ● The LCD panel will display the temperature (a) and air flow (b).
Page 170 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions Remark: When air outlet (c) is in (d) or (e) mode and the temperature of engine coolant is low, the air ﬂ ow will be restricted to prevent blowing the cooling air. CZ335-1103107 Fig. 3-103...
Page 171 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 2. Turn on the air conditioner switch (8). CZ335-1103104 Fig. 3-107 3. Press the temperature switch (3) to set the internal temperature of the operator cab. CZ335-1103096 Fig. 3-108 4. Press the air outlet selector switch (4) to set it to the desired mode.
Page 172 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 5. Press the fresh air/recirculation switch (6) to select the recirculation or fresh air intake mode of the operator cab. CZ335-1103102 Fig. 3-111 Stopping manual operation Press the switch OFF (1) to stop the manual operation.
Page 173 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 2. Press the air outlet selector switch (4) in order to display on the LCD panel the im- age as shown in the right illustration. CZ335-1103226 Fig. 3-115 3. Turn on the air conditioner switch (8).
Page 174 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions Defroster operation 1. Press the fan switch (2) to regulate the air flow. Meanwhile, check the temperature (a) and air flow (b) displayed on the LCD panel (7). CZ335-1103095 Fig. 3-118 CZ335-1103103 Fig. 3-119 2.
Page 175 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3. Press the fresh air/recirculation switch (6) to open the air inlet. CZ335-1103102 Fig. 3-122 4. Press the temperature switch (3) and set the temperature on the LCD panel (7) to the maximum (32℃ ).
Page 176 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions ● Air outlet for face (B) ● Defrosting outlet (C) CZ335-1103099 Fig. 3-127 ● The air outlet (D) toward feet is ﬁ xed and nonadjustable. CZ335-1103100 Fig. 3-125 ● Turn on the air conditioner switch (8) when...
Page 177: A/C Operation Precautions
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.15.3 A/C operation precautions Remark: ● 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 .
Page 178 ● In case that any device or sensor of the air conditioner is found abnormal, “A/C con- troller failure” will be displayed on the air conditioner control penal. Please contact Sany distributor to investigate and repair it. Safety, Operation and Maintenance Manual - Aug 2012 3-73...
Page 179: Radio
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.16 Radio 3.16.1 Control panel PRESET STATION SANY AS/PS AM/FM TIME TIME ADJ TUNING CZ335-1103111 Fig. 3-128 (1) Power switch (6) Preset stations (1, 2, 3, 4, 5, 6) (2) Sound effect switch (7) LCD...
Page 180 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions ● Depress the button (4) for more than 5 seconds in order to display the region: ASIA: EU. FM/AM band selector Press the switch (4) to select the desired band. Pressing the button each time toggles the band between FM and AM.
Page 181: Radio Operation
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.16.2 Radio operation Presetting radio station 1. Press the power switch (1) in order to show the frequency on display (7). 2. Press one of the tuning buttons (8) to locate PRESRT STATION SANY...
Page 182 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions ＜ key: Decrease the frequency. ＞ key: Increase the 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.
Page 183 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator Setting the time correctly 3. Press the button (3) to display the time. The display will return to show radio frequency after 5 seconds and the time cannot be reset. In this case, press the...
Page 184 SY115C9/135C/155H Crawler Hydraulic Excavator System Functions Antenna Before moving your machine into any build- ing, it is necessary to put away the antenna in order to prevent intervention. Put away the antenna by the following steps: Loosen the antenna's mounting bolt (1) in order to place the antenna in position (A).
Page 185: Auxiliary Power Supply
System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3.17 Auxiliary Power Supply 24V Power Remove the cigar lighter. Its socket can be used as auxiliary power supply. M a x a p p l i c a b l e p o w e r s u p p l y i s 2 4 0 W (24V×10A).
Page 186: Fusible Link
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions Fuse capacity and corresponding circuit Capacity Circuit Start circuit Charging indicator Horn circuit Work lamp Wiper & washer Radio Cab lamp Air conditioner Access lamp Monitor Controller Head lamp CZ135B-1103013 Cigar lighter Table 3-8 Fig.
Page 187: Controller
3.20 Controller Be careful not to get the controller contami- nated by water, mud or juice, which can cause failure. Never disassemble the controller in case of any failure. Please contact Sany distributor for repair. CZ135B-1103014 Fig. 3-136 3.21 Toolbox Store your tools in this box.
Page 188: Fire Extinguisher
SY115C9/135C/155H Crawler Hydraulic Excavator System Functions 3.23 Fire extinguisher Fire extinguisher is equipped in the rear of op- erator cab. The following precautions must be observed in order to deal with unexpected ﬁ re. ● Read instruction label on ﬁ re extinguisher and know how to use fire extinguisher in event of ﬁ...
Page 189 System Functions SY115C9/135C/155H Crawler Hydraulic Excavator 3-84 Safety, Operation and Maintenance Manual - Aug 2012...
Page 190: Operation
SY115C9/135C/155H Crawler Hydraulic Excavator Operation Operation 4 Operation 4.1 Before Starting the Engine..................4-5 4.1.1 Routine checks ..................... 4-5 4.1.2 Checks before starting ................... 4-7 4.1.2.1 Fuel tank - check/drain ................4-7 4.1.2.2 Water separator - check/drain .............. 4-7 4.1.2.3 Drain valve - regulate ................4-8 4.1.2.4 Hydraulic oil - check/reﬁ...
Page 191 Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4.4.2 Moving the machine forward ................ 4-29 4.4.3 Moving the machine backward ..............4-30 4.4.4 Parking the machine ..................4-31 4.5 Steering Operation....................4-32 4.5.4.1 Steering with travel controls ............... 4-32 4.5.4.2 Steering with machine stopped ............4-32 4.5.4.3 Steering during traveling ..............
Page 192 SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.15 Locking the Machine .................... 4-50 4.16 Operation in Cold Weather .................. 4-50 4.16.1 Operation instruction .................. 4-50 4.16.1.1 Fuel and lubricant ................4-50 4.16.1.2 Battery ....................4-51 4.16.2 After each workday ..................4-52 4.16.3 After cold season ..................4-53 4.17 Long-Term Storage ....................
Page 193 Operation SY115C9/135C/155H Crawler Hydraulic Excavator Safety, Operation and Maintenance Manual - Sep 2012...
Page 194: Before Starting The Engine
The leak of oil or fuel may cause the machine to catch on fire. Careful inspection is necessary. Contact your Sany distributor if any fault of your ma- chine must be corrected. Check and clean the following items each day before starting the engine: 1.
Page 195 10. Check the bucket with hook (if equipped) for any damage. Check the hoisting hook, guide plate and hook seat for any damage. Contact Sany distributor for repair in case of any prob- lem. Safety, Operation and Maintenance Manual - Sep 2012...
Page 196: Checks Before Starting
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.1.2 Checks before starting The items in this section must be checked ev- ery day before starting the engine. 4.1.2.1 Fuel tank - check/drain 1. Remove lower cover plate of fuel tank. 2. Place a vessel under drain valve (1) to contain drained fuel.
Page 197: Drain Valve - Regulate
Operation SY115C9/135C/155H Crawler Hydraulic Excavator ing the additional fuel ﬁ lter (1) if the trans- parent cover (2) is dirty or it is hard to see the interior through it. ● When drain valve (3) has been removed during cleaning, its O-ring must be greased and the valve must be tightened till it con- tacts the bottom.
Page 198: Hydraulic Oil - Check/Reﬁ Ll
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.1.2.4 Hydraulic oil - check/reﬁ ll WARNING ● Components and oil art still hot and can cause burns after the engine has been just shut down. Wait for them to cool down before working on them.
Page 199: Coolant - Check/Reﬁ Ll
Operation SY115C9/135C/155H Crawler Hydraulic Excavator Remark: The oil level may change as the oil tempera- ture varies. (Refer to the following ranges.) ● Before operation: L+12.5~L+32.5 (Oil temperature: 10 - 30°C (50 - 86°F)) ● During operation: higher than the mid- mark.
Page 200: Oil In Engine Oil Pan - Check/Reﬁ Ll
SY115C9/135C/155H Crawler Hydraulic Excavator Operation after inspection. If no problem is found, check coolant level in radiator. Add coolant to auxiliary tank (2) if its level is low. 5. If auxiliary tank (2) is dirty inside and the level cannot be seen clearly, clean the tank by following the steps speciﬁ...
Page 201: Electric Wires - Check
NOTICE ● If any fuse burns frequently or any wire shows the sign of short circuit, contact your Sany distributor to ﬁ nd the cause and eliminate the trouble. ● Keep battery surface clean and check the vent on battery cover. Flush the cover to clean the vent if the vent is plugged by dirt or dust.
Page 202: Fuel Tank - Check/Refuel
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.1.2.8 Fuel tank - check/refuel WARNING ● Never make fuel splash or overflow during refueling, which can cause ﬁ re. ● Clean the fuel completely in case of splashing. Remove the fuel if it flows onto ground or sand.
Page 203: Work Lamp Switch - Check
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. CZ335-1103137 1. Turn the start switch to the ON position. Fig. 4-18 2.
Page 204: Horn - Check
Horn Button 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. CZ335-1103138 Fig. 4-21 4.1.3 Adjustment before operation ●...
Page 205 Operation SY115C9/135C/155H Crawler Hydraulic Excavator (B) Backrest adjustment Lift lever (2), move the backrest to an optimum position at where operation can be easily con- ducted, and release the lever. Make sure the backrest does not interferes with the cover plate of the air conditioner at rear when adjusting the inclination of backrest.
Page 206: Rear View Mirrors
SY115C9/135C/155H Crawler Hydraulic Excavator Operation (E) Adjust the seat forward and backward as a whole Pull the lever (5), slide the seat to desired po- sition, and release the lever. In this case, the operator seat moves along with both armrest boxes and pilot hydraulic lockout control.
Page 207 Operation SY115C9/135C/155H Crawler Hydraulic Excavator Rear mirror (A) Adjust installation of rear mirror (A) so that people to rear left of machine can be seen clearly. Install rear mirror (A) to the position as shown in the right illustration. Turn the rod (1) around rod (4) to a suitable CZ335-1103143 position and ﬁ...
Page 208: Seat Belt
SY115C9/135C/155H Crawler Hydraulic Excavator Operation When adjusting mirror angle, if the mirror can- not 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...
Page 209: Before Starting The Engine
Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4.1.4 Before Starting the Engine WARNING ● Before starting the engine, check the hydraulic lockout control whether it is secured in "locked" position. ● If the hydraulic lockout control is not secured in position, accidental touch-...
Page 210 SY115C9/135C/155H Crawler Hydraulic Excavator Operation 3. Insert your key into start switch (2), turn the key to ON position (B), and then check the following: CZ335-1103150 Fig. 4-34 Two seconds after the key is turned to ON po- sition, default screen will be displayed under normal condition, as shown in the right illustra- tion.
Page 211: Engine Starting
Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4.2 Engine Starting WARNING ● Always start the engine from the opera- tor seat. ● Never start the engine in a way that may cause short circuit, which can lead to serious injury or ﬁ re.
Page 212 SY115C9/135C/155H Crawler Hydraulic Excavator Operation 1. Check if the hydraulic lockout control (1) is in the LOCK position (L). If it remains in FREE position (F), the engine cannot be started. CZ335-1103149 Fig. 4-37 2. Turn the fuel control dial (2) to MIN posi- tion.
Page 213 Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4. Turn the ignition key to START position (C). CZ335-1103155 Fig. 4-40 5. Release the key (3) after starting the engine. The key will be back to the ON position (B) by itself. Remark: When ambient temperature is low, the engine may fail to start after the start switch is kept at START position for more than 10 seconds.
Page 214: Engine Preheating
0~10 -10~0 <-10 Preheating period 2. For models SY115C9, SY135C8, SY 135C9 and SY155H Turn fuel control dial to the MIN position (b). Turn ignition key to the HEAT position (a). The preheat indicator (c) will be on and the engine begins preheating.
Page 215: Warm-Up Operation
Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4.2.2 Warm-up operation WARNING ● In case of emergency, abnormal running of engine, or other faults, turn the start switch to OFF position and shut off the engine. ● Never operate any control lever or pedal suddenly when temperature of hydraulic oil is low.
Page 216: Engine Shutdown
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.3 Engine Shutdown Remark: ● Shutting off the engine suddenly may con- siderably reduce service life of its compo- nents. ● Never shut off the engine suddenly except for emergency. ● Never shut off the engine suddenly if the engine is too hot.
Page 217: Machine Operation
Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4.4 Machine Operation WARNING ● Check the surrounding of machine for safety and sound the horn before moving the machine. ● Nobody is allowed to enter the area around the machine. ● Remove any barriers from the travel route.
Page 218: Moving The Machine Forward
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.4.2 Moving the machine forward 1. Place the hydraulic lockout control to the FREE position (F), and retract the work equipment till it is 40-50 cm above the ground, as shown in the right illustration.
Page 219: Moving The Machine Backward
Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4.4.3 Moving the machine backward 1. Place the hydraulic lockout control to the FREE position (F), and retract the work equipment till it is 40-50 cm above the ground, as shown in the right illustration.
Page 220: Parking The Machine
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.4.4 Parking the machine Never park your machine suddenly. Before parking your machine, leave yourself enough space so that you could leave the ma- chine easily. Place the left and right travel control levers (1) to neutral position before parking your ma- chine.
Page 221: Steering Operation
Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4.5 Steering Operation Check the direction of track frame (position of sprocket) before maneuvering the travel con- trols. When the operator faces the sprockets, moving direction of travel controls is opposite to travel direction of machine.
Page 222: Steering During Traveling
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.5.4.3 Steering during traveling When turning to the left side: Place the left travel control lever in the neutral position to turn your machine to the left side during traveling. (A) Turning left during forward travel...
Page 223: Swing Operation
Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4.5.1 Swing operation ● When the rear part of the machine is posi- tioned away from the track, check whether the surrounding area of the machine is safe before carrying out swinging opera- tion. ● When the engine's speed decreases due...
Page 224: Work Equipment Control And Operation
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.6 Work Equipment Control and Operation CAUTION Operation of the control levers while the engine is idling may cause engine speed to increase abruptly. Be careful with the operation of joystick controls. Work equipment is controlled through the joy- sticks.
Page 225 Operation SY115C9/135C/155H Crawler Hydraulic Excavator ● Boom control Push or pull the right joystick to control boom operation. CZ335-1103177 Fig. 4-62 ● Bucket control Move the right joystick left or right to control bucket operation. When joystick control is in the neutral position,...
Page 226: Working Mode
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.7 Working mode The working modes selection switch (1) is used to select a mode suitable for your work- ing condition and purpose. In this way, effec- tive operation can be achieved. Sany Hydraulic Excavator...
Page 227: Restricted Operations
Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4.8 Restricted Operations ● Never maneuver the control levers of the work equipment when the machine is trav- eling. Stop the machine before maneuver- ing any control lever. ● The engine's speed could increase abrupt- ly if you maneuver any control lever when the automatic idling function is active.
Page 228: Operation When Hydraulic Cylinder Reaches Its Stroke End
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 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.
Page 229: Operation With Machine Weight
Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4.8.5 Operation with machine weight Never use the weight of machine to excavate. CZ335-1103185 Fig. 4-70 4.8.6 Hard rocky ground Never 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.
Page 230: Sudden Shift Of Travel Speed During Fast Traveling
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.8.7 Sudden shift of travel speed dur- ing fast traveling 1. Never maneuver any control lever or pedal abruptly to change the action of machine. 2. Never suddenly change the position of control lever or pedal from forward (A) to reverse (B), or vice versa.
Page 231: Permissible Depth Of Water
Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4.9.3 Permissible depth of water Note: When driving your machine out of water, an inclination of slope exceeding 15° would have the rear of its upper turntable immersed in water, thus the fan could be damaged due to water.
Page 232 SY115C9/135C/155H Crawler Hydraulic Excavator Operation ● Never travel on a steep slope, which could cause your machine to tip over. ● The bucket must be lifted 20-30 cm above the ground during traveling. ● Never travel reversely down a slope.
Page 233: Traveling Downhill
Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4.10.1 Traveling downhill Place the travel control levers to the neutral position, which can make the brake function automatically. 4.10.2 Engine stalls on an incline 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.
Page 234: Both Tracks Trapped
SY115C9/135C/155H Crawler Hydraulic Excavator Operation bucket. When one of the tracks is trapped in the mud, use the bucket to lift the track, place wood planks or logs under the track and then drive your machine out of the mud.
Page 235: Trench Work
Operation SY115C9/135C/155H Crawler Hydraulic Excavator The digging range of arm is from 30 to 45°, as 45° 30° 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. Never operate the hy- draulic cylinders to their full stokes.
Page 236: Parking Operation
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.13 Parking Operation Park your machine on a hard, level ground that is free from dangers. If you have to park your machine on a slope, chock the tracks with blocks. You can also penetrate the bucket 120°...
Page 237 Operation SY115C9/135C/155H Crawler Hydraulic Excavator 2. Turn fuel control dial to low idle (MIN) posi- tion in order to reduce engine speed. CZ335-1103153 Fig. 4-89 3. Lower the bucket horizontally until its bot- tom is in contact with ground. CZ335-1103207 Fig.
Page 238: Checks After Each Workday
5. If the ambient temperature is below -35°C, make sure to drain the coolant of radiator and engine (Sany uses the type of anti- freeze liquid that freezes at -35°C. ) Safety, Operation and Maintenance Manual - Sep 2012...
Page 239: Locking The Machine
Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4.15 Locking the Machine The following locations must be locked. (1) Cab door Close the windows properly. (2) Injection cap of fuel tank (3) Engine hood (4) Battery cover (Battery is mounted behind CZ335-1103208 left access door on some models.) Fig.
Page 240: Battery
Never smoke while disposing antifreeze liquid. Note: Please use Sany genuine, efﬁ cient anti-freeze liquid as the coolant. In principle, we never recommend you choosing any other type of coolant. See “Cooling system - clean” on page 5-37 for more information about the mixing ratio of anti-freeze liquid when changing the coolant.
Page 241: After Each Workday
Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4.16.2 After each workday CAUTION Rotating track can cause severe injury. Always keep a safe distance from rotating track. Observe the following precautions to prevent the machine from being immobilized the next day due to frozen mud and ice on the under- carriage.
Page 242: After Cold Season
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.16.3 After cold season When the season changes and the weather gets warm, perform as described below. ● The fuel or lubricant of any components shall be replaced with the one of speciﬁ ed viscosity.
Page 243: Long-Term Storage
● For machines equipped with additional equipment, the control pedal of additional equipment shall be placed to LOCK posi- tion. ● To prevent rusting, please use Sany genu- ine, efﬁ cient anti-freeze liquid as coolant of the engine. 4-54 Safety, Operation and Maintenance Manual - Sep 2012...
Page 244: During Storage
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.17.2 During storage WARNING When your machine is stored indoors, it is important to prevent it from rusting, Open the doors and windows to allow good ven- tilation. This can also prevent gas poison- ing.
Page 245: After Storage
Note: If your machine has been stored for a long pe- riod but no rusting prevention had been made each month, please contact Sany distributor before operating your machine again. Before using your machine again after a long- term storage, perform as described below: ●...
Page 246: Transportation Information
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.18 Transportation Information Related laws and regulations must be ob- served when transporting the machine. Safety must be ensured. 4.18.1 Transport methods ● Choose a method that is suitable for the weight and dimension provided in the section“Speciﬁ...
Page 247 Operation SY115C9/135C/155H Crawler Hydraulic Excavator on the trailer. ● It is dangerous to load or unload your ma- chine with the work equipment. The use of an access ramp is necessary. ● On an access ramp, never maneuver any other control lever except the travel control lever.
Page 248: Loading The Machine
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 4.18.2.1 Loading the machine 1. The machine shall only be loaded and unloaded on a hard, level ground. It is necessary to keep a safe distance to roadside. 2. Choke the trailer and put blocks under its wheels to prevent its moving.
Page 249 Operation SY115C9/135C/155H Crawler Hydraulic Excavator 5. If the machine is installed with work equip- ment, the work equipment must be placed in front of the machine. Move the machine straight forward up the ramp. Without the 90°-110° work equipment, reverse the machine up the ramp.
Page 250: Securing The Machine
SY115C9/135C/155H Crawler Hydraulic Excavator Operation 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 ﬂ oor, which could result in damage to the cylinder.
Page 251: Rear View Mirrors
Operation SY115C9/135C/155H Crawler Hydraulic Excavator 2. Place the hydraulic lockout control to the LOCK position (L). 3. Stop the engine and remove the key from the start switch. 4. Close all doors, windows and covers properly. CZ335-1103251 Lock the covers, caps and doors.
Page 252: Unloading The Machine
SY115C9/135C/155H Crawler Hydraulic Excavator Operation Removal 1. Loosen bolt (2) and remove the rear view mirror (1) from the bar (3). 2. Loosen bolt (4) and remove the bar (3) and the clasp (5). CZ335-1103239 Fig. 4-109 Installation 1. Install the bar (3) and the clasp (5) to the handhold, and tighten bolt (4).
Page 253 Operation SY115C9/135C/155H Crawler Hydraulic Excavator 6. Set the travel speed selector switch to low speed (Lo). ● Press travel speed button (6) to change travel speed (Lo, Hi), which will be dis- Sany Hydraulic Excavator played at (5) on the display screen.
Page 254: Lifting The Machine Or Its Components
SY115C9/135C/155H Crawler Hydraulic Excavator Operation important to keep an angle of 90 - 110° 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 ramp, slowly operate the boom and arm,...
Page 255: Choosing A Wire Rope
Operation SY115C9/135C/155H Crawler Hydraulic Excavator hand, if the sling angle is 150 degrees, to lift a load of 19.6 kN(1000 kg), each rope has to bear 39.2 kN(1000 kg). 3. Never use a single rope to lift an object. It’s better to bind the object with two or more rope symmetrically.
Page 256: Lifting The Machine
The lifting procedure is applicable to machines of standard dimension. The lifting methods may vary according to actual additional and optional components installed. Contact Sany distributor for suitable lifting methods. For more information on the weight of machine see the section "Speciﬁ cation".
Page 257 Operation SY115C9/135C/155H Crawler Hydraulic Excavator Machine of standard dimension 1. Start the engine and swing the upper structure in order to position the work equipment at the side of the sprocket (1). 2. Fully extend the bucket cylinder and the...
Page 258 SY115C9/135C/155H Crawler Hydraulic Excavator Operation Safety, Operation and Maintenance Manual - Sep 2012 4-69...
Page 259 Operation SY115C9/135C/155H Crawler Hydraulic Excavator 4-70 Safety, Operation and Maintenance Manual - Sep 2012...
Page 260: Maintenance
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance Maintenance 5 Maintenance 5.1 Maintenance Information ..................5-5 5.2 General Service ....................... 5-9 5.2.1 Oil, fuel and coolant ..................5-9 5.2.1.1 Oil ......................5-9 5.2.1.2 Fuel ..................... 5-10 5.2.1.3 Coolant ....................5-11 5.2.2 Grease ......................5-12 5.2.3 Oil and fuel storage ..................
Page 261 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 5.8.2.1 Air cleaner - clean/replace ..............5-29 5.8.2.2 Cooling system - clean ............... 5-37 5.8.2.3 Track shoe bolts - inspect/tighten ............5-41 5.8.2.4 Track tension - inspect/adjust ............. 5-42 5.8.2.5 Bucket tips (lateral pin) - replace ............5-45 5.8.2.6 Bucket Replacement ................
Page 262 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.8.8.3 Nitrogen pressure in accumulator (control oil circuit) - check ..... 5-89 5.8.8.4 Hydraulic circuit internal pressure - release ........5-92 5.8.8.5 Oil in hydraulic tank - change .............. 5-93 5.8.8.6 Alternator - inspect ................5-95 5.8.8.7 Engine valve clearance - check/adjust ..........
Page 263 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator Safety, Operation and Maintenance Manual - Aug 2012...
Page 264: Maintenance Information
Genuine Sany replacement parts Always use genuine Sany replacement parts listed in the Parts Manual. Genuine Sany lubricants Always use genuine Sany engine oil and grease. Select engine oil and grease of suit- able viscosity according to ambient tempera- ture.
Page 265 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator Primary fuel ﬁ lter Primary Fuel Filter must be installed before ﬁ ll- ing the fuel. Welding instruction ● Turn off the engine start switch and wait for 1 minute before disconnecting the negative (-) terminal of the battery.
Page 266 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance free place in order to prevent dust from getting into the oil. ● Clean the air ﬁ lter cartridge immediately if the ﬁ lter's alarm indicates clogging. ● Clean the fins and other heat exchanger parts frequently to avoid them being clogged.
Page 267 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 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.
Page 268: General Service
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.2 General Service ● Use genuine Sany replacement parts, grease and oil. ● Never change or refill oil with a different type. When different oil is to be used, the used oil must be drained completely before ﬁ...
Page 269 ● Never 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.
Page 270: Fuel
Anti-freezing coolant is also necessary in regions where freezing prevention is un- necessary. Sany machines are prefilled with TEEC- L35 antifreeze, which has excellent perfor- mance in anticorrosion, anti-freezing and cooling, and can last for 1 year or 2000...
Page 271: Grease
Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator hours. As a basic principle, we do 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.
Page 272: Oil And Fuel Storage
Replace it with a new one. ● In replacement of ﬁ lter element, check the element for attached metal particles. Con- tact your Sany distributor if metal particles are found. ● Never open the package of a spare ele- ment when it is in storage.
Page 273: Electrical System
● Never install any other electrical compo- nents except those speciﬁ ed by Sany. ● External electromagnetic interference can cause failure of system controller. Contact your Sany distributor before installing radio receiver or other wireless devices.
Page 274 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance are at high temperature and high pressure, so wait for the oil temperature to go down before starting maintenance. Even when the temperature goes down, the circuit may still be under internal pressure, so when loosening the plug or screw, or the hose joint, do not stand in front of the part.
Page 275: Replacement Parts
● Replacement parts shall be replaced properly in order to use your machine economically. ● Select Sany genuine quality parts for replacement. ● Check the part number in the Parts Manual when ordering a part.
Page 276: Recommended Fluids
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance Component Part Number Part Interval Lateral pin 60100572 Bucket tips (10143975) (Pin) A229900005244 Tip adaptor Bucket A229900005241 Tip pin ─ (SY135C9) A229900007131 Left cutter A229900007130 Right cutter A210111000301 (Bolt) 60012073 (Nut) Lateral pin 60100572 Bucket tips...
Page 277 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator Ambient Temperature Recommended Fluid 122 °F ﬂ uids 50°C 5W-30 5W-40 10W-30 15W-40 (Note 1) HDZ32 (ISO VG32) Hydraulic HDZ46 (ISO VG46) -30 diesel Diesel fuel -10 light diesel 0 light diesel Coolant TEEC-135 (Note 2)
Page 278: Fluid Capacities
Note 1: 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 strongly recommend the use of engine oil 15W-40.
Page 279: Recommended Oils
Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 5.4.2 Recommended oils: 1. Engine oil Select the oil of proper viscosity according to the temperature range given in the oil change schedule. Engine oil grade: Above API CF-4 Recommended engine oil brand and type: Caltex CH-4 15W-40 2.
Page 280 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance to ensure the safety of the hydraulic sys- tem. ● Run the engine at idle speed for 7-10 minutes before increasing its rpm to 1000 - 1200. Never operate your exca- vator except running the engine unload-...
Page 281: Tightening Torque Speciﬁ Cation
The tightening of torque is determined by the width of screw cap or nut. CZ335-1104001 In replacement of the bolts or nuts, use Sany Fig. 5-1 genuine parts of equivalent size. Tightening Torques Thread...
Page 282 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance Hydraulic hoses are tightened according to the torques given below. Fig. 5-2 Tightening Torques Nominal Thread Square Size Number Target Values Permissible Range (b)(mm) N·m kgf·m lbft N·m kgf·m lbft 9/16-18UNF 32.5 35-63 3.5-6.5 25.3-47 11/16-16UN 54.2...
Page 283: Safety-Related Parts
If any hose deteriorates, such as deforming or cracking, the hose clamps shall also be replaced while replacing the hose. O-ring, gasket and other similar parts shall also be replaced while replacing a hose. Consult your Sany distributor to replace the following safety-related parts on a regular basis. Safety-related parts subject to regular replacement Quantity...
Page 284: Maintenance Schedule
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.7 Maintenance Schedule If your machine is equipped with hydraulic breaker, the maintenance schedule for some parts may vary. For more information and proper maintenance see "Hydraulic Breaker Maintenance Schedule." 5.7.1 List of maintenance schedule Maintenance after initial 50 service hours ................
Page 285 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator Swing bearing - lubricate ......................5-74 Swing pinion gear grease - check/reﬁ ll ..................5-75 Coolant tank and radiator ﬁ ns - inspect/clean ................5-76 Air conditioner ﬁ lters - clean ...................... 5-77 Swing drive oil - check/reﬁ ll ....................... 5-80 Final drive oil - check/ﬁ...
Page 286: Hydraulic Breaker Service Interval
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.7.2 Hydraulic Breaker Service Interval For machines equipped with a hydraulic 5000 breaker, the hydraulic oil deteriorates faster than that of machines operating with a bucket. In this case, the following steps shall be fol- 4000 lowed in order to adjust the service intervals.
Page 287: Maintenance Procedures
5.8.1 Maintenance after initial 50 ser- vice hours The following maintenance is to be carried out after initial 50 service hours. Consult your Sany distributor for special tools used for checks and maintenance. 5.8.1.1 Engine oil and ﬁ lter - change/ replace For the procedures of changing engine oil and replacing oil ﬁ...
Page 288: When Required
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.8.2 When Required 5.8.2.1 Air cleaner - clean/replace WARNING ● If you check, clean and replace the ﬁ lter when the engine is running, dust may invade the engine and cause damage. Shut down the engine before doing this job.
Page 289 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator Replacement ● Replace ﬁ lter elements. If the ﬁ lter has been used for more than a year or cleaned for more than six times, re- place the outer ﬁ lter element (5) and inner ﬁ...
Page 290 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 2. Hold the primary air cleaner element (5), shake it slightly and turn it in both direc- tions in order to pull it out. 3. After removing the primary air cleaner ele- ment (5), check the secondary air cleaner element to see if it displaces or tilts.
Page 291 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 8. Use a light to illuminate the whole primary air cleaner element. Replace the primary air cleaner element in case of holes or reduced thickness found in the ﬁ lter mate- rial. 9. Remove the cloth or tape covering the inner ﬁ...
Page 292 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance Note: The latches (2) and housing of air cleaner could be damaged when you insert filter ele- ment with expanded rubber on the top or you did not push it in vertically but latch the cover (3) with force.
Page 293 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator Replacing ﬁ lter elements 1. Open the left rear door of the machine and loosen the four latches (2) before removing the cover (3). CZ135B-1104004 Fig. 5-14 2. Hold the outer filter element (5), shake it slightly and turn it in both directions in order to pull it out.
Page 294 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance Note: ● Never use the inner filter element after cleaning it. Replace the inner ﬁ lter element while the outer ﬁ lter element is replaced. ● When the outer ﬁ lter element and the cover...
Page 295 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator Note: The latches (2) and housing of air cleaner could be damaged when you insert filter ele- ment with expanded rubber on the top or you did not push it in vertically but latch the cover (3) with force.
Page 296: Cooling System - Clean
The coolant is also an important ﬂ uid against corrosion and freezing. Anti-freezing coolant is also necessary in regions where freezing prevention is unnecessary. Sany recommends TEEC-L35 antifreeze, which has excellent performance in anticorrosion, anti- freezing and cooling, and can last for one year or 2000 hours.
Page 297 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator Sany recommends TEEC-L35 antifreeze. This antifreeze has a concentration of 50% and needs no dilution. 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.
Page 298 ● To change the coolant or drain the ra- diator coolant when repairing your ma- chine, consult professional company or your Sany distributor to dispose the coolant containing antifreeze. Never drain the coolant to sewage or onto ground since the antifreeze is poison- ous.
Page 299 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 3. Remove the bottom cap and place a con- tainer to hold the coolant under the drain valve (2). Open the radiator bottom drain valve (2) to drain the coolant. 4. Close the drain valve (2) after draining the coolant.
Page 300: Track Shoe Bolts - Inspect/Tighten
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.8.2.3 Track shoe bolts - inspect/tighten If your machine is operated with loose track shoe bolts (1), the bolts can break. Tighten any loose bolts immediately. Always prepare your machine as required and lock/tag it out before proceeding. See “Preparing the machine”...
Page 301: Track Tension - Inspect/Adjust
Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 5.8.2.4 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 302 The pin rolls or CZ335-1104019 bushings must be swapped or replaced. Fig. 5-28 Contact your Sany distributor for repair. Safety, Operation and Maintenance Manual - Aug 2012 5-43...
Page 303 ● Never loosen the grease ﬁ tting (2). ● The grease is to be released through CZ335-1104020 the following steps. If the tension of track is still tight, contact your Sany Fig. 5-29 distributor for repair. ● If gravels or mud falls between the sprock- et and track link, remove it before you re- duce track tension.
Page 304: Bucket Tips (Lateral Pin) - Replace
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.8.2.5 Bucket tips (lateral pin) - replace Replace the bucket tip before the tip adapter is worn. WARNING ● Place the work equipment ﬁ rmly before replacing the bucket tips. Stop the en- gine and engage the hydraulic lockout control.
Page 305 CZ335-1104025 ● If the tip cannot be removed safely in this Fig. 5-34 way, consult Sany distributor for replace- ment. 4. Remove the tip and check the latch for any damage. Replace it if necessary. The latches and tips worn short must be replaced with new ones.
Page 306: Bucket Replacement
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.8.2.6 Bucket Replacement CAUTION ● 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 gear during such an opera- tion.
Page 307 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 1. Place the bucket on a level ground. Remark: Before removing the pin roll, slowly lower the bucket to a level where it just contacts the ground. CZ335-1103201 Fig. 5-37 If a larger force is used to lower the bucket to the ground, resistance could increase on the pin roll, causing difﬁ...
Page 308: Bucket Clearance - Adjust
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance Remark: When mounting the bucket, place the O-ring (3) of bucket (4) to the position, as shown in the right illustration, corresponding to the arm pin (A). After the pin roll is inserted, align it to the standard notch.
Page 309 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 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...
Page 310: Window Washer Fl Uid - Check/Reﬁ Ll
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.8.2.8 Window washer ﬂ uid - check/reﬁ ll Always prepare your machine as required and lock/tag it out before proceeding. See “Preparing the machine” on page 2-58 and “Lock-out and tag-out” on page 2-60. If the washer ﬂ uid contains air, check the ﬂ uid level in the reservoir (1).
Page 311: Air Conditioner - Inspect/Service
● Colorless and transparent: no refrigerant Remark: The appearance of bubbles indicates low re- Insufficient frigerant level. Please consult Sany distributor to add refrigerant. Running the air conditioner No refrigerant with low refrigerant level could damage its (Colorless, transparent) compressor.
Page 312 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance When the air conditioner will not be used for a long period of time, the air conditioner shall be operated for 3-4 minutes each month in order to lubricate the compressor com- ponents. Components Description...
Page 313: Gas Spring - Inspect
“Lock-out and tag-out” on page 2-60. The air springs are located on top of the cab (at both the left and right sides). Contact your Sany distributor for inspection, repair and replacement in case of the following conditions. ● The cab roof hatch cannot be opened eas- ily.
Page 314: Air In Hydraulic System - Purge
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.8.2.11 Air in hydraulic system - purge Always prepare your machine as required and lock/tag it out before proceeding. See “Preparing the machine” on page 2-58 and “Lock-out and tag-out” on page 2-60. 1. Purging air from the pump 1) Loosen air vent plug (1) and check for oil leak.
Page 315 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator stroke end. Keep it 100 mm (3.9 in) from stroke end. 2) Operate each cylinder 3-4 times to its stroke end. 3) Operate each cylinder 4-5 times to its stroke end in order to purge air com- pletely.
Page 316 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance tor, consult Sany distributor for replace- ment and air elimination. 5. Eliminate air from the travel motor (only when the oil has been discharged from the travel motor shell) 1) Run the engine at low speed. Loosen the air vent screw plug (4).
Page 317: Hydraulic Circuit Internal Pressure - Release
Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 5.8.2.12 Hydraulic circuit internal pressure - release WARNING ● The hydraulic circuit is always under pressure. In this case, the pressure in hydraulic circuit is to be released when checking or replacing the hoses or ﬁ t- tings.
Page 318: Checks Before Starting
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.8.3 Checks before starting For more information about the following items see “Checks before starting” on page 4-7. ● Drain water and sediment from fuel tank. ● Check water separator and drain water and sediment.
Page 319: Every 100 Service Hours
Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 5.8.4 Every 100 service hours 5.8.4.1 Lubrication NOTICE ● If the lubricated components produce abnormal noise, additional lubrication is re- quired besides regular maintenance. ● A new machine shall be greased every 10 hours within the initial 50 hours.
Page 320 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance (1) Boom cylinder root pin (2) CZ335-1104047 Fig. 5-54 (2) Boom root pin (2) (3) Boom cylinder piston rod end (2) (4) Arm cylinder root pin (1) CZ335-1104048 Fig. 5-55 (5) Boom-arm joining pin (2) CZ335-1104049 Fig.
Page 321 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator (6) Arm cylinder piston rod end (1) (7) Bucket cylinder root pin (1) CZ335-1104051 Fig. 5-57 (8) Arm-Bucket joining pin (1) CZ135B-1104016 Fig. 5-58 (9) Rod joining pin (2) (10) Bucket cylinder piston rod end (1)
Page 322: Every 250 Service Hours
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.8.5 Every 250 service hours 5.8.5.1 Compressor belt tension - inspect/ adjust Always prepare your machine as required Compressor pulley and lock/tag it out before proceeding. See “Preparing the machine” on page 2-58 and “Lock-out and tag-out” on page 2-60.
Page 323 V-belt. In addition, make sure that the V-belt must not rub against the bottom of the V-groove. ● Consult Sany distributor to replace the belt timely in case of the following conditions. ● The fan belt has been stretched and little margin is left for adjustment.
Page 324: Oil In Engine Oil Pan And Oil Fi Lter - Change/Replace
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.8.5.2 Oil in engine oil pan and oil ﬁ lter - change/replace WARNING When the engine has just been stopped, the parts and oil are still hot and can cause serious burn. Wait until they are Drain valve cool enough before doing the job.
Page 325 ﬁ lter - change/replace” on page 5-65. CZ335-1104059 8. Reinstall the bottom cover. Fig. 5-66 NOTICE Contact your Sany distributor to obtain genuine engine oil in order to guarantee oil quality and ensure 250 service hours. 5-66 Safety, Operation and Maintenance Manual - Aug 2012...
Page 326: Primary Fuel Fi Lter - Replace
● Be away from ﬁ re sources. Note: ● Sany genuine fuel filter is a special filter of effective ﬁ ltration. The ﬁ lter must be re- placed with a genuine one. The use of other parts may allow dirt or de- bris to get into the fuel system and cause the injection system failure.
Page 327 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator Always prepare your machine as required and lock/tag it out before proceeding. See “Preparing the machine” on page 2-58 and “Lock-out and tag-out” on page 2-60. 1. Open the door on the right side of machine.
Page 328 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance Note: ● Never remove the cover (B) while ﬁ lling the fuel. Always ﬁ ll fuel via the eight(8) external holes (A). ● Remove the cover (B) after filling. Install the fuel ﬁ lter. ● Always fill clean fuel. Take care to keep the fuel free from dust or dirt.
Page 329 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 14. After purging the air, push in the knob of pump (5) and tighten it. 15. After replacing the filter, start the engine and run the engine at low idle for 10 min- utes. Check the ﬁ lter seal and the cover for fuel leak.
Page 330: Secondary Fuel Fi Lter - Replace
● Be away from ﬁ re sources. Note: ● Sany genuine fuel filter is a special filter of effective ﬁ ltration. The ﬁ lter must be re- placed with a genuine one. The use of other parts may allow dirt or de- bris to get into the fuel system and cause the injection system failure.
Page 331 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator Always prepare your machine as required and lock/tag it out before proceeding. See “Preparing the machine” on page 2-58 and “Lock-out and tag-out” on page 2-60. 1. Open engine hood. 2. Place a fuel container under the ﬁ lter.
Page 332 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5. Tighten filter cartridge until the seal con- tacts ﬁ lter seat. Further turn it by 3/4 turn. If filter cartridge was over-tightened, the seal might be damaged and fuel leak could result. If filter cartridge was not tightened enough, fuel will leak through the gap of seal.
Page 333: Every 500 Service Hours
Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 5.8.6 Every 500 service hours Also perform maintenance for every 100 and 250 service hours is in the meantime. 5.8.6.1 Swing bearing - lubricate 1. Lower work equipment to ground, stop the engine and engage hydraulic lockout control.
Page 334: Swing Pinion Gear Grease - Check/Reﬁ Ll
3. Check the grease to see whether it is milk- CZ335-1104068 white. Milk-white grease indicates that the grease has been contaminated. Consult Fig. 5-76 Sany distributor in order to change the grease. Total grease volume: 15 L (3.97 US gal) CZ335-1104069 Fig. 5-77 4.
Page 335: Coolant Tank And Radiator Fi Ns - Inspect/Clean
Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 5.8.6.3 Coolant tank and radiator ﬁ ns - inspect/clean WARNING If you are directly impacted by compressed air, pressurized water or steam, or you use them to purge dirt or debris, personal injury could result. Make sure you are well protect- ed by wearing goggles, dust-proof mask or other protective gear.
Page 336: Air Conditioner Fi Lters - Clean
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance and air conditioner condenser) with power- ful steam (from high-pressure ﬂ ushing ma- chine). With steam cleaning (high-pressure machine flushing) at a near distance, the heat exchanger could deform and early plugging and cracking could be resulted.
Page 337 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator Cleaning the ﬁ lter screen 1. Remove the screw (1) from the access window located on the left rear bottom of the cab, loosen the locking nut (2) and remove the air recirculation ﬁ lter (3).
Page 338 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance Cleaning the fresh air ﬁ lter 1. Unlock the rear cover (4) on the left side of the cab with the start switch key. Open the cover (4) with your hand, remove the locking nut (5) and take out the fresh air ﬁ...
Page 339: Swing Drive Oil - Check/Reﬁ Ll
(G), loosen the drain valve (P) CZ335-1104083 to drain excessive oil. Fig. 5-89 ● If the oil level is too high, consult Sany distributor for inspection. ● Place a container under the drain valve before draining the oil.
Page 340: Final Drive Oil - Check/Fi Ll
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.8.6.6 Final drive oil - check/ﬁ ll WARNING ● When the engine is shut down, the oil is still hot. Wait until the oil is cool enough be- fore operation. ● Remaining pressure in the tank can cause oil to squirt out or the screw plug to ﬂ y out.
Page 341: Every 1000 Service Hours
Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 6. When the oil level is too high, consult Sany distributor for inspection. 7. Restore the screw plugs (F) and (L) after check and tighten them to: 58.8±19.6N.m. 5.8.7 Every 1000 service hours Also perform maintenance for every 100, 250 and 500 service hours in the meantime.
Page 342 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 1. Park your machine on a hard, level ground. Adjust the work equipment to an attitude ready for service, as shown in the right illustration. Lower the work equipment to ground and turn off the engine.
Page 343: Swing Drive Oil - Change
Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 5.8.7.2 Swing drive oil - change WARNING When the engine has just been stopped, the parts and oil are still hot and can cause serious burn. Wait until they are cool enough before doing the job.
Page 344: Engine Exhaust Pipe Clamps - Check
5-17. CZ135B-1104027 Fig. 5-96 5.8.7.3 Engine exhaust pipe clamps - check Consult Sany distributor to check the fastening conditions of the air cleaner - turbocharger - 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.
Page 345: Every 2000 Service Hours
Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 5.8.8 Every 2000 service hours Also perform maintenance for every 100, 500 and 1000 service hours in the meantime. 5.8.8.1 Final drive oil - change WARNING ● When the engine is just shut down, the oil and components are still hot and can cause burn.
Page 346 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance (P) in order to drain the oil. Remark: Check the O-ring on screw plug and replace the O-ring if broken. 5. Tighten the plug (P) and remove the plugs (F) and (L). 6. Fill oil through the opening of the plug (F).
Page 347: Hydraulic Tank Fi Lter Screen - Clean
Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 5.8.8.2 Hydraulic tank ﬁ lter screen - clean WARNING When the engine has just been stopped, the parts and oil are still hot and can cause serious burn. Wait until they are cool enough before doing the job.
Page 348: Nitrogen Pressure In Accumulator (Control Oil Circuit) - Check
● Be away from ﬁ re sources. ● Never punch or weld the accumulator. ● Never bump or roll the accumulator. Keep it free from any impacts. ● Vent the air completely when handling the accumulator. Consult your Sany distributor to do this job. Note:...
Page 349 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator Checking the functions of accumulator NOTICE During inspection, make sure the sur- rounding area is clear without personnel or any barriers. Check the nitrogen pressure through the fol- lowing steps: 1. Park your machine on a hard, level ground.
Page 350 CZ335-1104099 dropped already. Fig. 5-105 Consult Sany distributor for such inspec- tion. After checking through the a.m. steps, place the hydraulic lockout control to LOCK position and turn the start switch to OFF position.
Page 351: Hydraulic Circuit Internal Pressure - Release
Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 5.8.8.4 Hydraulic circuit internal pressure - release 1. Low the work equipment to ground. 2. Place the work equipment lockout control to the LOCK position (L). The step 4 through step 6 shall be carried out within 15 seconds.
Page 352: Oil In Hydraulic Tank - Change
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.8.8.5 Oil in hydraulic tank - change WARNING ● When the engine has just been stopped, the parts and oil are still hot and can cause serious burn. Wait until they are cool enough before doing the job.
Page 353 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 5. Remove the cap of the oil ﬁ ller (F) . 6. Place a container under the drain plug. Remove the drain plug (P) with the lever in order to drain the oil. Check the O-ring on the drain plug (P) and replace it timely if broken.
Page 354: Alternator - Inspect
SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance 5.8.8.6 Alternator - inspect Contact your Sany distributor to inspect the al- ternator. Check the engine every 1000 service hours if the engine is started frequently. 5.8.8.7 Engine valve clearance - check/ adjust Special tools are necessary for inspection and maintenance.
Page 355: Accumulator (Control Oil Circuit) - Replace
If your machine is kept operating when the performance of accumulator decreases, the pressure in the hydraulic system will not be re- leased. Consult Sany distributor to replace the accumulator. The accumulator's installation location is shown in the right illustration.
Page 356: High-Pressure Tube Clamps And Rubber - Check
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. Safety, Operation and Maintenance Manual - Aug 2012...
Page 357: Every 8000 Service Hours
500, 1000, 2000 and 4000 service hours in the meantime. 5.8.10.1 High-pressure tube clamps - re- place Contact your Sany distributor to replace the high-pressure tube clamps on the engine. 5.8.11 Every 10000 service hours Contact your Sany distributor for an overall maintenance if your machine has worked for 10,000 hours.
Page 358 SY115C9/135C/155H Crawler Hydraulic Excavator Maintenance Safety, Operation and Maintenance Manual - Aug 2012 5-99...
Page 359 Maintenance SY115C9/135C/155H Crawler Hydraulic Excavator 5-100 Safety, Operation and Maintenance Manual - Aug 2012...
Page 360 SY115C9/135C/155H 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 procedure ................6-4 6.1.3 Troubleshooting precautions ................6-6 6.1.4 Electrical circuits troubleshooting precautions ..........6-9 6.1.5 Hydraulic components handling precautions ..........6-10 6.2 Pseudo Failures .....................
Page 361 Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator 6.8.3.3 Disconnecting the jumper cables ............6-34 6.9 Failures of the Hydraulic System ................6-35 6.10 Other Common Failures ..................6-39 Safety, Operation and Maintenance Manual - Aug 2012...
Page 362: Troubleshooting Preparation
SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting 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 —...
Page 363: Troubleshooting Procedure
Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator 6.1.2 Troubleshooting procedure 1. Check and determine failure symptom. Ask for the following information upon ser- vice request of a client. ● Name of client ● Model and serial number of machine ● Detailed information on job site, etc.
Page 364 SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting ● Did you do any repair when the failure occurred? 6. Play back the failure. 7. Start the engine and operate the machine to make sure that the symptom does exist. Simply determine location of failure and make repair before performing trouble- shooting.
Page 365: Troubleshooting Precautions
Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator 6.1.3 Troubleshooting precautions WARNING Observe the following items before per- forming any troubleshooting operations. Failure to do so can cause machine dam- age, personal injury or death. ● Park your machine on a hard, level ground.
Page 366 SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting toms. 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.
Page 367 Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator 6) Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Check the oil level. 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers.
Page 368: Electrical Circuits Troubleshooting Precautions
SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting 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 prevent this, always investigate why the problem occurred.
Page 369: Hydraulic Components Handling Precautions
Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator 6.1.5 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.
Page 370 SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting 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.
Page 371: Pseudo Failures
Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator 6.2 Pseudo Failures Note that the following failures are pseudo ones: ● The arm speed may drop suddenly when retracting the arm with the work equipment lowering unloaded and the arm in a nearly vertical position.
Page 372: Towing The Machine
SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting 6.3 Towing the Machine WARNING Towing the machine improperly or using wire cables beyond the speciﬁ cation could lead to serious injury or death. ● Make sure that the wire cables used for towing the machine are strong enough, which may otherwise result in acci- dents.
Page 373 Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator ● 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.
Page 374: Towing Hook For Light Loads
SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting 6.4 Towing Hook for Light Loads WARNING ● Towing the machine improperly could cause severe accidents. The following items must be observed when towing the machine. ● Shackle must be used. ● Keep the wire cable parallel to the ground and align its direction with that of the track frame.
Page 375: Engine Failures
Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator 6.6 Engine Failures 6.6.1 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 ● Recharge/replace the bat- ●...
Page 376 SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting Failure Causes Remedy ● Sensor failure ● Replace ● Short circuit of harness (grounding failure) ● Check/repair Arm slow and weak ● Open circuit of harness ● Check/repair ● Controller failure ● Replace ● Sensor failure ●...
Page 377 Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator Failure Causes Remedy ● 5V power supply failure ● Repair/replace Boom-up pilot pressure ● Open circuit of signal line ● Check/repair reading incorrect ● Short circuit of signal line ● Check/repair ● Sensor failure ● Replace ●...
Page 378: Coolant Temperature High
SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting 6.6.2 Coolant temperature high CAUTION ● Never remove the radiator cap when the coolant is still hot. Hot water or steam may squirt and cause burns. ● Wait the coolant to cool down before re- moving the radiator cap.
Page 379: Engine Oil Pressure Low
Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator Always prepare your machine as required and lock out/tag out your machine before proceed- ing. See “Preparing the machine” on page 2-58 and “Lock-out and tag-out” on page 2-60. 1. Check radiator hoses for coolant leak.
Page 380 ● Replace the dipstick(1) after checking. 3. If engine oil level is normal but abnormal pressure of engine oil is altered, contact your Sany distributor in time to solve the problem. CZ335-1104059 Fig. 6-14 Safety, Operation and Maintenance Manual - Aug 2012...
Page 381: When Fuel Exhausts
Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator 6.6.4 When fuel exhausts When fuel exhausts, it is necessary to refuel the engine and purge air from the fuel system before restarting it. WARNING ● Never use a lighter, smoke, or use other ﬁ re sources when purging the air. A ﬁ re source can cause ﬁ...
Page 382 SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting 3. Repeatedly push the pump to transfer fuel until no foam is seen at the vent. CZ215-1105007 Fig. 6-17 4. Retighten plug (2) when you are sure no foam is seen. Plug tightening torque： 9.8±2.0N·m {1±0.2 kgf·m} CZ215-1105009 Fig.
Page 383: When Engine Rotates Reversely
Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator 6.6.5 When engine rotates reversely WARNING Reverse rotation of engine can burn the engine within several minutes or cause severe injury. Shut down the engine imme- diately once reverse rotation is found. The exhaust gas from air cleaner is possible to cause ﬁ...
Page 384: Failures Of The Electrical System
SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting 6.7 Failures of the Electrical System 6.7.1 Electrical system troubleshooting table Trouble-shoot the electrical system according to the following tables. Contact your Sany distribu- tor solve the problem. Failure Causes Remedy ● Recharge/replace the bat- ●...
Page 385 Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator Failure Causes Remedy ● Sensor failure ● Replace ● Short circuit of harness (grounding failure) ● Check/repair Arm slow and weak ● Open circuit of harness ● Check/repair ● Controller failure ● Replace ● Sensor failure ●...
Page 386 SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting Failure Causes Remedy ● 5V power supply failure ● Repair/replace Boom-up pilot pressure ● Open circuit of signal line ● Check/repair reading incorrect ● Short circuit of signal line ● Check/repair ● Sensor failure ● Replace ●...
Page 387: Failure Codes
Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator 6.7.2 Failure codes The failure code(1) displayed on the monitor can be used to make failure analysis. Sany Hydraulic Excavator 2010/07/27 15:32:4 8 CZ215-1103058 Fig. 6-20 Failure Symptom Alarm Trigger Condition Code Oil pressure lower than 200 and engine speed higher than...
Page 388 SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting Failure Symptom Alarm Trigger Condition Code Boom-up pilot pressure sensor Boom-up pilot pressure collecting volt lower than 0.25 and abnormal higher than 4.75 for 3s Boom-down pilot pressure sen- Boom-down pilot pressure collecting volt lower than 0.25 and sor abnormal higher than 4.75 for 3s...
Page 389: Battery
Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator 6.8 Battery WARNING ● It is dangerous to charge a battery while it is installed on the machine. Re- move the battery before charging it. ● Stop the engine and turn the start switch key to OFF position before checking or handling the battery.
Page 390: Battery Charging
SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting 6.8.2 Battery charging Improper handling can result in explosion when the battery is charged. Follow the in- struction, see “Battery” on page 6-30 and the instruction of charger, and proceed the proce- dure below: ● Regulate the charger to the voltage appli- cable to the battery.
Page 391: Jump-Starting The Engine
Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator 6.8.3 Jump-starting the engine WARNING ● Never let the positive terminal (+) con- tact with the negative terminal (-) when connecting the cable. ● Keep a normal machine away from the faulty machine in order to prevent sparks around the battery from burning the hydrogen released from the battery.
Page 392: Connecting The Jumper Cables
SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting "LOCKED" position. ● Check the control levers whether they are in the neutral position. 6.8.3.1 Connecting the jumper cables Turn the start switches of the normal machine and the faulty machine to the OFF position.
Page 393: Starting The Engine
Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator 6.8.3.2 Starting the engine WARNING Check the lockout control, which must be in the "LOCKED" position regardless of that the machine is operating normally or has trouble. Check all control levers, which shall be in the "retaining" or neutral position.
Page 394: Failures Of The Hydraulic System
Troubleshooting 6.9 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...
Page 395 Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator Failure Causes Remedy ● Pilot valve failure ● Check/repair One cylinder of work equip- ● Pressure sensor failure ● Replace ment not working ● Work equipment control valve (spool) failure ● Repair/replace ● Work equipment cylinder failure ●...
Page 396 SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting Failure Causes Remedy ● Swing motor (parking brake) failure ● Check/repair ● Bad adjustment or failure of swing motor (safety ● Adjust/replace In both directions valve) ● ● Swing motor failure ● Check/repair ● Swing drive failure ●...
Page 397 Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator Failure Causes Remedy When swing brake ● Swing brake control line failure ● Check/repair engaged ● Swing motor (parking brake) failure ● Repair/replace ● Swing control valve (spool) failure ● Repair/replace When swing brake ● Swing motor (relief valve) failure ●...
Page 398: Other Common Failures
SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting 6.10 Other Common Failures Failure Causes Remedy ● Loose fastener ● Check and retighten. Structure member ● Bigger clearance between arm and buck- ● Reduce the clearance to a value that noise loud et end faces due to wear is smaller than 1mm.
Page 399 Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator Failure Causes Remedy Both high and low pressure gauge read- ● Refill refrigerant to the specified ● Refrigerant insufﬁ cient 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.
Page 400 SY115C9/135C/155H Crawler Hydraulic Excavator Troubleshooting Safety, Operation and Maintenance Manual - Aug 2012 6-41...
Page 401 Troubleshooting SY115C9/135C/155H Crawler Hydraulic Excavator 6-42 Safety, Operation and Maintenance Manual - Aug 2012...
Page 402: Speciﬁ Cations 7.1 Machine Dimensions
SY115C9/135C/155H Crawler Hydraulic Excavator Speciﬁ cations Speciﬁ cations 7 Speciﬁ cations 7.1 Machine Dimensions ....................7-3 7.2 Working Ranges ..................... 7-4 Safety, Operation and Maintenance Manual - Aug 2012...
Page 403 Speciﬁ cations SY115C9/135C/155H Crawler Hydraulic Excavator Safety, Operation and Maintenance Manual - Aug 2012...
Page 404 SY115C9/135C/155H Crawler Hydraulic Excavator Speciﬁ cations 7 SPECIFICATIONS 7.1 Machine Dimensions Fig. 7-1 Item Unit SY115C9 SY135C8/C9 SY135C8(M) SY155H Operating weight 12400 13,500 14,100 Bucket capacity 0.48 0.54 Engine model 4BG1-TABGC-03-C2 4D34-TLE2A BB-4BG1TRP Engine power kW/rpm 72.7 / 2200 70 / 2050 72.7 / 2200...
Page 405: Working Ranges
Speciﬁ cations SY115C9/135C/155H Crawler Hydraulic Excavator 7.2 Working Ranges Fig. 7-2 Safety, Operation and Maintenance Manual - Aug 2012...
Page 406 SY115C9/135C/155H Crawler Hydraulic Excavator Speciﬁ cations Item Unit SY115C9 SY135C8/C9 SY155H Max cutting height 7780 8645 8625 Max dumping height 5530 6175 6120 Max digging depth 5165 5500 5520 Max vertical digging depth 4925 4890 5005 Max horizontal reach 7605...
Page 407 Speciﬁ cations SY115C9/135C/155H Crawler Hydraulic Excavator Safety, Operation and Maintenance Manual - Aug 2012...
Page 408 SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment Optional Equipment 8 Optional Equipment 8.1 General Safety ......................8-3 8.1.1 Selection precautions..................8-3 8.1.2 Reading the instruction books................ 8-3 8.1.3 Removal and installation precautions ............8-3 8.1.4 Operation precautions..................8-4 8.2 Hydraulic Control Elements and Oil Circuit ............. 8-6 8.2.1 Location of the components ................
Page 409 Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator 8.3.2.2 Earthwork bucket tips ................8-19 8.4 Recommended Operations ..................8-20 8.4.1 Hydraulic breaker ..................8-20 8.4.2 Hydraulic breaker operation ................. 8-21 8.5 Restricted Operations .................... 8-22 8.6 Hydraulic Breaker Lubrication................8-25 8.7 Quick Coupler and Control System ............... 8-26 8.7.1 Quick coupler installation ................
Page 410: General Safety
Read the following precau- tions before selecting, installing and operating an optional equipment. 8.1.1 Selection precautions ● Consult your Sany distributor before install- ing an optional equipment to your machine. Front guard, top guard or other protective structures may be required according to the type of optional equipment to be used.
Page 411: Operation Precautions
Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator ● If the job has to be done by two or more persons, appoint a chief and follow his in- struction. ● Use a crane if you handle an object that weighs over 25 kg. (Only eligible, experi- enced personnel with official license are allowed to operate a crane.)
Page 412 SY115C9/135C/155H Crawler Hydraulic Excavator 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.
Page 413: Hydraulic Control Elements And Oil Circuit
Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator 8.2 Hydraulic Control Elements and Oil Circuit 8.2.1 Location of the components CZ135B-1105001 Fig. 8-1 (1) Stop valve (2) Selector valve (3) Control pedal 8.2.1.1 Stop valve Stop valve stops hydraulic oil ﬂ ow.
Page 414: Selector Valve
SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment 8.2.1.2 Selector valve Selector valve changes ﬂ owing direction of hy- draulic oil. The change of direction is made according to the working mode selected. The working mode must be applicable to the installed optional equipment.
Page 415: Hydraulic Circuit
(280 kgf/cm , 3980PSI). Readjustment may be necessary according to the type of optional equipment. In this case, please contact Sany distributor for adjustment. 8.2.2.1 Hydraulic circuit switching ● Set the working mode on the monitor according to the following standards according to the type of optional equipment.
Page 416: Connecting Hydraulic Oil Circuit
SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment (a) Shear hydraulic path (dual-action hy- draulic path) has been formed. (b) The overﬂ ow valve is set to high pres- sure. When delivered from the factory: 27.4MPa 280kgf/cm2, 3980PSI 8.2.2.3 Connecting hydraulic oil circuit Connect the hydraulic lines to the optional equipment according to the following steps.
Page 417: Hydraulic Oil Passage
Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator 8.2.2.4 Hydraulic oil passage The operating directions of the pedal and hydraulic path are shown below. CZ335-1105007 Fig. 8-8 By pushing the front of the pedal, the hydraulic oil flows to the left of the work equipment; by pushing the rear, the hydraulic oil ﬂ...
Page 418: Optional Equipment Removal And Installation
SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment 8.2.3 Optional equipment 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 place the lockout control to FREE position (F).
Page 419 Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator 5. The breather valve (F) on top of the hydraulic tank can be used to release the internal pressure of the hydraulic lines. To release the pressure completely, turn and open the butterﬂ y nut on the breather valve (F) and press the relief button to re- lease the pressure.
Page 420: Optional Equipment Installation
SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment 9. Check the oil level in the hydraulic tank af- ter the bucket has been installed properly. 8.2.3.2 Optional equipment installation 1. Remove the bucket. 2. Place the optional equipment to a flat surface. Install the optional equipment to the arm with the pin (A) followed by the pin (B).
Page 421 Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator 6. Place the lockout control to LOCK position (L). 7. The breather valve (F) on top of the hydraulic tank can be used to release the internal pressure of the hydraulic lines. To release the pressure completely, turn and open the butterﬂ...
Page 422: Hydraulic Oil And Hydraulic Tank Fi Lter - Change/Replace
SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment 8.2.4 Hydraulic oil and hydraulic tank ﬁ lter - change/replace The operation of hydraulic breaker could contaminate the hydraulic system and deteriorate the hydraulic oil. In this case, the hydraulic oil and hydraulic tank ﬁ lter should be changed more of- ten, as compared with the machine installed with bucket.
Page 423: Long-Term Storage
24.5MPa (250kgf/ , 3550PSI) and its activating pressure can be set to 20.1MPa (205 kgf/cm , 2911PSI). Please consult Sany dealer in your locality. 8-16 Safety, Operation and Maintenance Manual - Aug 2012...
Page 424: Optional Equipment Guide
SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment 8.3 Optional equipment Guide WARNING Read the optional equipment instruction manual and related sections about option- al equipment. ● Safety issue will be involved when in- stalling any optional equipment. There- fore, please consult Sany distributor before the installation.
Page 425 Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator Note: ● In excavation, the boom may intervene with the undercarriage when the boom is fully low- ered. Be careful with the operation of the boom. ● For excavating or loading hard soil or soft soil containing gravels, reinforced rock-digging bucket with higher strength and abrasion resistance is recommended.
Page 426: Bucket Tips Selection
SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment 8.3.2 Bucket tips selection Bucket tips may break off the adapter due to the working condition. In this case, suitable bucket tips must be determined. Currently, we offer bucket tips with a lateral pin. So the following types of bucket tips are recommended according to different working conditions.
Page 427: Recommended Operations
Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator 8.4 Recommended Operations The following instruction must be followed when operating an excavator with optional equipment. Note: Select the optimum model of optional equip- ment for your hydraulic excavator. ● The type of optional equipment to be in-...
Page 428: Hydraulic Breaker Operation
SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment 8.4.2 Hydraulic breaker operation 1. Press the breaker chisel vertically and ﬁ rmly onto the object to be broken during breaking operation. 2. Press the breaker chisel tightly onto the 90° working surface when striking and slightly raise the front of the undercarriage about 5 90°...
Page 429: Restricted Operations
Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator 4. The chisel's penetrating direction will devi- ate gradually to the working direction of breaking hammer. It is important to align them by readjusting the bucket cylinder. CZ335-1105020 Fig. 8-26 5. Always press the chisel properly on the working surface in order to prevent striking without resistance.
Page 430 SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment 2. Breaking with swinging force. CZ335-1105023 Fig. 8-29 3. Moving the chisel during striking operation. CZ335-1105024 Fig. 8-30 4. Keep the chisel level or upward during striking operation. CZ335-1105025 Fig. 8-31 Safety, Operation and Maintenance Manual - Aug 2012...
Page 431 Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator 5. Swing the chisel when the rock has been penetrated. CZ335-1105026 Fig. 8-32 6. Pecking operation. CZ335-1105027 Fig. 8-33 7. Raise your machine above ground by fully extending the bucket cylinder and by the pushing force.
Page 432: Hydraulic Breaker Lubrication
SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment 8.6 Hydraulic Breaker Lubrication Grease the breaker at the correct point. CZ335-1105029 Fig. 8-35 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 components when using the breaker.
Page 433: Quick Coupler And Control System
Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator 8.7 Quick Coupler and Control System 8.7.1 Quick coupler installation 1. Remove the safety pin of quick coupler, as shown in the right illustration. Safety pin CZ335-1105032 Fig. 8-38 2. Depress the quick coupler operation button (1) (auto reset) on the left joystick in order to slowly reduce the opening of the ﬂ...
Page 434 SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment 4. Extend the bucket cylinder to slowly move the flexible jaws of quick coupler toward the bucket's support pin (3). CZ335-1105034 Fig. 8-41 5. Make sure that the jaws of quick coupler grip completely the support pin (3) of the bucket.
Page 435: Operating Precautions
Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator 6. Release the operation button of quick coupler in order to enable the quick cou- pler to grip the bucket's support pin before conducting other operations. 7. Insert the safety pin after installation. CZ335-1105036 Fig.
Page 436: Refueling System
CZ335-1105040 you are using an optional equipment that has Fig. 8-47 been approved by Sany. Sany assumes no re- sponsibility for any failure and accident result- ed from installation of any optional equipment that has not been approved by Sany.
Page 437: Components
Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator 8.8.2 Components ● The fueling system of Sany excavators in- cludes mainly: a refueling pump assembly (including relevant piping and valves), a control switch and a fuel level control relay. ● Open the battery cover (1) and you can see the control switch and the refueling pump (2).
Page 438: Central Lubrication System
SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment 8.9 Central Lubrication System 8.9.1 Scheme and components 1. Models SY115C9, SY135C8/9 and SY155H adopt a 18-point lubrication scheme. A sketch on distribution of excavator lubricating points is shown below: 7、8 13、14、15 3、4 1、2 5、6...
Page 439 Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator ● Distributor section Boom System distributor is mainly composed of: Main distributor (1) MX-F3/3 Secondary distributors (3) MX-F510 MX-F3/5 MX-F3/4 CZ335-1105043 Fig. 8-53 The main distributor (A) and the secondary distributor (B) installed to the boom root are shown in the right illustration.
Page 440: System Working Principle
Optional Equipment 8.9.2 System working principle As Sany SY series excavators have a relatively central distribution of lubricating points that are close to each other, we choose to use a progressive central lubrication system which is shown in the illustration below.
Page 441: Setting The Lubrication Time Of Electric Grease Pump
Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator 8.9.3 Setting the lubrication time of electric grease pump The electronic controller built in the electric grease pump can realize related control over the time or cycle of the central lubrication system. When the time programming control is applied, the cab's central lubrication system indicator ﬂ...
Page 442: Technical Description
SY115C9/135C/155H Crawler Hydraulic Excavator Optional Equipment ● Setting the parameters The interval can be set to 0.5 - 8 hours; the lubrication cycle can be set to 1 - 16 minutes, as shown in the illustration below. If you need to adjust the time, use a ﬂ at-headed screw driver to disassemble the red edge frame, loosen the four cross-headed screws, and remove the transparent covers in turn.
Page 443: Adding Grease With Electric Pump
Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator 8.9.5 Adding grease with electric pump The electric grease pump of the central lubrication system lubricates your machine in the follow- ing three ways. 1. Standard Method: Manual or pneumatic grease gun is used to add grease through the ball-type nozzle (1), as shown in the following illustration.
Page 444 Please consult Sany distributor if you need to install the central lubrication system. Make sure that you are using accessories speciﬁ ed by Sany. Sany assumes no responsibility for failures and accidents caused by the installation of any accessories that have not been approved by Sany.
Page 445 Optional Equipment SY115C9/135C/155H Crawler Hydraulic Excavator 8-38 Safety, Operation and Maintenance Manual - Aug 2012...

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