SANY SY500H Operation And Maintenance Manual
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SANY SY500H Operation And Maintenance Manual

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Operation and Maintenance Manual
SY500H Excavator
service@sanyamerica.com
SANY Part Number SSY005084272

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Summary of Contents for SANY SY500H

  • Page 1 Operation and Maintenance Manual SY500H Excavator service@sanyamerica.com SANY Part Number SSY005084272...
  • Page 2 Page Intentionally Blank...
  • Page 3 Read and understand all safety precautions and instructions in this manual and on the machine labels before operating or maintaining the machine. Failure to follow safety messages could result in death or serious injury. Keep this manual with the machine for reference. SY500H Excavator OMM 13914116...
  • Page 4 State of California to cause cancer, birth defects, or other reproductive harm. Wash hands after handling. © 2020 by SANY. All rights reserved. No part of this publication may be reproduced, used, distributed, or disclosed except for normal operation and maintenance of the machine as described herein. All information included within this publication was accurate at the time of publication.

  • Page 5: Table Of Contents

    SANY Contact Information ........
  • Page 6 Fresh/Recirculated-Air Selection Buttons ........3-10 SY500H Excavator OMM...
  • Page 7 Function Icons ........... . . 3-26 SY500H Excavator OMM...
  • Page 8 Opening the Right Rear Access Door ........4-8 SY500H Excavator OMM...
  • Page 9 Right ..............4-21 SY500H Excavator OMM...
  • Page 10 Genuine SANY Replacement Parts ........
  • Page 11 Check the Aftertreatment Exhaust Piping ........5-23 SY500H Excavator OMM...
  • Page 12 Check the Swing Bearing Fasteners ........5-53 SY500H Excavator OMM...
  • Page 13 Remove Optional Equipment ............7-6 SY500H Excavator OMM...
  • Page 14 Page Intentionally Blank 5-10 SY500H Excavator OMM...
  • Page 15 SANY Contact Information ........

  • Page 16: Introduction

    Continuing improvements in the design of this machine can lead to changes which may not be covered in this manual. Contact a SANY dealer for the latest available information on the machine or to answer any questions regarding information in this manual.

  • Page 17: Organization Of This Manual

    The excavator can also operate a variety of optional equipment. Hazard alerts used throughout the manual are explained. SANY assumes no responsibility for any consequence General and product-specific safety information is caused by use outside this specified range. provided for this manual.

  • Page 18: Serial Number Locations

    Swing Motor Identification Plate Identification plates are located in various places on the excavator. These list model and serial numbers that will be needed by a SANY dealer when ordering replacement parts or providing assistance for your machine. Product Identification Plate...

  • Page 19: Main Control Valve Identification Plate

    Remove the cover plate to access the travel The identification plate (1) is on the top of the hydraulic motor’s identification plate. main control valve. Hydraulic Pump Identification Plate 0004793 Figure 1-7 The identification plate (1) is on the side of the hydraulic pump. SY500H Excavator OMM...

  • Page 20: Sany Contact Information

    Peachtree City, GA 30269 DPF – Diesel Particulate Filter www.sanyamerica.com ECM – Engine Control Module Phone: 470 552 SANY (7269) HEST – High Exhaust System Temperatures Find a dealer go to: www.sanyamerica.com/find-a-dealer LCD – Liquid Crystal Display MSDS – Material Safety Data Sheet OEM –...

  • Page 21: Record Of Serial Number And Dealer Information

    Machine Serial Number Engine Serial Number Right Travel Motor Serial Number Left Travel Motor Serial Number Swing Drive Motor Serial Number Main Control Valve Serial Number Hydraulic Pump Serial Number Dealer Name: Address: Phone Numbers: SY500H Excavator OMM...

  • Page 22: Correction Request Form

    INTRODUCTION Correction Request Form If you find a problem with this manual, make a copy of this page, complete the form below, and send it to SANY. Date of This Notification Your Name Company Name Department Street Address City, State, and ZIP/Postal Code...

  • Page 23: Safety

    Precautions in High-Voltage Areas ..........2-7 SY500H Excavator OMM...

  • Page 24: General Safety

    Any faults found shall be reported to a injury, or even death. In this manual and on the machine SANY dealer. Stop all work immediately if any decals, different signal words or illustrations are used to operator aid is not working properly.

  • Page 25: Mount And Dismount The Machine

    Observe the following: repaired or replaced immediately. • Check the wiring on the machine for damage when doing a prestart check. Contact a SANY dealer to repair or replace any damaged wiring. • Make sure the battery is operating in its recommended range.

  • Page 26: Fire Extinguisher

    If a fire occurs on the machine: maintenance function. 1. Immediately press the emergency stop to shut down Contact a SANY dealer for replacement decals if needed. the machine. Never continue operating the machine. NOTE: When replacing decals, make sure they are 2.

  • Page 27: Lockout/Tagout Procedure

    Never weld on the accumulator. Always use hot water and mild, nonflammable, Never strike the accumulator. grease-cutting soaps or cleaning agents to clean the If the accumulator needs service, contact a SANY dealer. machine. Never use flammable or caustic cleaning Electrical System agents.

  • Page 28: Disconnect The Battery

    • When traveling or moving the machine on a Hearing Protection snow-covered incline, allow the machine to come to a stop slowly. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection to protect against loud noise. SY500H Excavator OMM...

  • Page 29: Avoid Backover Accidents

    Recycling used oil, coolants, and filters helps conserve natural resources and is good for the environment. Obey all regulations when disposing of harmful items such as oil, fuel, filters, batteries, hydraulic oil, and used parts. SY500H Excavator OMM...
  • Page 30 SAFETY Page Intentionally Blank SY500H Excavator OMM...

  • Page 31: Machine Controls

    Stationary Regeneration Switch ......... . . 3-13 SY500H Excavator OMM...
  • Page 32 Screen Backlight Setting ..........3-34 SY500H Excavator OMM...
  • Page 33 Quick Coupler Tool ..........3-39 SY500H Excavator OMM...

  • Page 34: Exterior Components

    MACHINE CONTROLS Exterior Components 0000002 Figure 3-1 Arm cylinder Carrier rollers Boom Idler Boom cylinders Tracks Counterweight removal system 10 Arm Drive sprocket Bucket Track frame 12 Bucket cylinder SY500H Excavator OMM...

  • Page 35: Seat And Seat Belt

    The headrest (1) can be raised or lowered. To unbuckle the seat belt, press the red button on the Seat Heater seat belt buckle (6). Press the heat switch (2) to turn the seat heater on and off. SY500H Excavator OMM...

  • Page 36: Seat And Console Adjustment Lever

    NOTE: Closing the red cover over the emergency stop Pull the seat cushion adjustment lever (12), adjust the switch forces the switch back to its original seat cushion forward or backward, and release the lever. position for normal machine operation. SY500H Excavator OMM...

  • Page 37: Operator Controls

    Windshield wiper switch (page 3-15) 15 Hydraulic lockout control lever (page 3-8) Windshield washer switch (page 3-15) 16 Left joystick (page 3-9) Headlight switch (page 3-15) 17 Travel control pedals (page 3-21) Travel alarm silence switch (page 3-14) SY500H Excavator OMM...

  • Page 38: Left Control Console

    NOTICE! If any part of the machine moves when the hydraulic lockout control lever is in the locked (closed) position, shut down the engine immediately. Contact a SANY dealer for assistance. 0004673 Figure 3-5 0004670...

  • Page 39: Left Joystick

    Figure 3-7 Move the hydraulic lockout control lever to the unlocked (open) position (3) to enable hydraulic controls. Left Joystick 0004690 Figure 3-8 The left joystick (1) has three buttons. See “Left Joystick Buttons” on page 3-18. SY500H Excavator OMM...

  • Page 40: Climate Control Panel

    Press the automatic temperature control selection button Contact a SANY dealer for further information. (AUTO) (5) to activate the automatic temperature control system. The climate control panel will automatically...

  • Page 41: Radio Control Panel

    AM1/AM2 and FM1/FM2 bands. Each band can have Press and release the button to leave the time set screen different preset stations selected. and return to time display for 5 seconds. The time display will return to the radio display. SY500H Excavator OMM 3-11...

  • Page 42: Liquid Crystal Display (Lcd)

    • Regeneration disable switch (9) 0004674 Figure 3-11 • Stationary regeneration switch (10) If the radio signal is weak or noisy, adjust the antenna (1) by loosening the wing nut (2) and moving the antenna to the appropriate position. 3-12 SY500H Excavator OMM...

  • Page 43: Right Joystick

    WARNING If the red stop engine icon illuminates, shut down the engine as soon as it is safe to do so and immediately contact a SANY dealer for service support. Failure to do so could result in engine 0004677 Figure 3-14 damage.

  • Page 44: Regeneration Disable Switch

    Travel Alarm Silence Switch 0004679 Figure 3-21 The third work light (3) is under the right front access door. 0004691 Figure 3-18 3-14 SY500H Excavator OMM...

  • Page 45: Windshield Wiper Switch

    The battery disconnect switch (1) is behind the left rear access door. See “Left Rear Access Door” on page 4-8. When the switch is moved to the OFF (2) position, electrical power is disconnected from all machine systems. SY500H Excavator OMM 3-15...

  • Page 46: Batteries

    There are two 12V batteries (2) connected in series to provide 24V power to the machine’s electrical system. The batteries are under a protective cover (1) behind the left rear access door. See “Left Rear Access Door” on page 4-8. 3-16 SY500H Excavator OMM...

  • Page 47: Monitor Console

    Airflow vents (4) on the monitor console can be opened, closed, and rotated. Sunlight Sensor NOTICE! To make sure the automatic functions of the air conditioning function properly, the sunlight sensor must be clean. Never obstruct the sunlight sensor, or it could malfunction. SY500H Excavator OMM 3-17...

  • Page 48: Joystick Controls

    NOTE: See “BHL Mode” on page 3-20 for additional 0004682 Figure 3-31 information. The right joystick has two buttons and a switch: • The top left button (1) is for power boost, which temporarily provides extra hydraulic pressure. 3-18 SY500H Excavator OMM...

  • Page 49: Sae Mode

    MACHINE CONTROLS SAE Mode Front Front Right Left Arm OUT Boom DOWN Swing Swing Bucket Bucket Uncurl Left Right Curl Boom UP Arm IN 00001410 Figure 3-33 SY500H Excavator OMM 3-19...

  • Page 50: Bhl Mode

    MACHINE CONTROLS BHL Mode Front Front Left Right Boom DOWN Arm OUT Swing Swing Bucket Bucket Left Right Curl Uncurl Boom UP Arm IN 0000141 Figure 3-34 3-20 SY500H Excavator OMM...

  • Page 51: Travel Controls

    • Travel control levers (2) higher, previously set level or the newly set level. • Travel control pedals (3) SY500H Excavator OMM 3-21...

  • Page 52: Stop Valve

    NOTE: The stop valve is shown in the closed position. To open the valve, turn the valve knob (2) counterclockwise until the stop (4) makes contact with the stop pin (3). 3-22 SY500H Excavator OMM...

  • Page 53: Fuses And Relays

    The fuse and relay panel is behind the left front access door, inside the electrical panel. Open the electrical panel door (1) and remove the fuse and relay panel cover (2) to access the fuses and relays. SY500H Excavator OMM 3-23...

  • Page 54: Fuse And Relay Locations

    R13 – DEF sensor relay (24V/10A) F14 – Horn (15A) R14 – DEF pump motor relay (24V/10A) F15 – Overload alarm (5A) R15 – DEF heater relay (24V/15A) F16 – Alarm lamp (10A) R16 – Fuel relay (24V/10A) 3-24 SY500H Excavator OMM...

  • Page 55: Monitor

    10 Diesel exhaust fluid (DEF) level gauge Periodic maintenance prompt 11 Fuel level gauge Installed equipment (bucket tool shown) 12 System service icons Engine coolant temperature gauge 13 Work mode Function icons 14 Throttle control dial setting SY500H Excavator OMM 3-25...

  • Page 56: Home Screen Display Icons

    See “Home Screen Function Icons and Buttons” on page 3-27. Function Buttons The function buttons (8) are used for selecting and programming machine functions. See “Home Screen Function Icons and Buttons” on page 3-27. 3-26 SY500H Excavator OMM...

  • Page 57: System Service Icons

    NOTE: The icon (2) illuminates red when this function is disabled. 3. Press function button F3 (6) to choose between slow travel speed mode (turtle shown) (3) or fast travel speed mode (rabbit). Main Menu Screen SY500H Excavator OMM 3-27...
  • Page 58 3. Press function button F3 (7) to confirm your selection and proceed to the next screen. 4. Press function button F5 (6) to return to the Home screen without selecting any icon. NOTE: Function button F4 is for use only by SANY technicians. 0004957,0004714 Figure 3-47...

  • Page 59: Password Screen

    Password Screen 5. Press function button F5 (2) to return to the Main Menu screen without entering a password. Work Parameters Screens These screens are for use by SANY technicians only and require a password. Maintenance Information Screen 0004957, 0004747...
  • Page 60 3. There are a total of five Maintenance Information (info.) screens designed for each interval of recommended maintenance: 0005067 Figure 3-50: 50 Hours 0005069 Figure 3-52: 500 Hours 0005070 Figure 3-53: 10000 Hours 0005068 Figure 3-51: 250 Hours 0005071 Figure 3-54: 2000 Hours 3-30 SY500H Excavator OMM...

  • Page 61: Error Codes Screen

    1. Press function button F1 (4) twice on the Main Menu screen to navigate to the Error Codes icon (1). 2. Press function button F3 (3) to see the Error Codes screen showing specific error codes and description(s). SY500H Excavator OMM 3-31...

  • Page 62: System Setting Menu Screen

    • The display shows an error code for a too-low fuel level. NOTE: Contact a SANY dealer for more information about specific error codes and what actions to take. 3. Press function button F5 (2) to return to the Main Menu screen.

  • Page 63: Date/Time Setting Screen

    MACHINE CONTROLS Date/Time Setting Screen NOTE: Contact a SANY dealer if you do not have time zone information (the number of time zones east or west of 0 degrees longitude). 5. Press function button F5 (5) to return to the System Setting screen without making any changes.

  • Page 64: Screen Backlight Setting

    NOTE: Use this screen to adjust the screen brightness for better readability of the monitor. 1. Proceed to the Screen Backlight icon (1) on the System Setting screen, then press function button F3 (3). 0004957,0004708 Figure 3-60 3-34 SY500H Excavator OMM...

  • Page 65: System Language Setup Screen

    OFF and back to ON to confirm the selection. 4. Press function button F5 (2) to return to the System Setting screen without making any changes. NOTE: This screen defaults to highlight the Chinese language option regardless of the language option in effect. SY500H Excavator OMM 3-35...

  • Page 66: Machine Configuration Screen

    MACHINE CONTROLS Machine Configuration Screen 2. Press function button F5 (1) to return to the Main Menu screen without making any changes. NOTE: This screen is for use by SANY technicians only and requires a password. Tool Icons Tool Select Screen...

  • Page 67: Breaker

    NOTE: The available range is 0 gpm to 132 gpm (0 Lpm to 500 Lpm). 0004957,0004710 Figure 3-66 NOTE: The numerical values for liters per minute (Lpm) 1. Select Shear option. See “Tool Icons” on page 3-36. and gallons per minute (gpm) will change, and the SY500H Excavator OMM 3-37...

  • Page 68: Lifting Tool

    The available range is 0 gpm to 53 gpm (0 Lpm to 200 Lpm). NOTE: The numerical values for gpm and Lpm will change, and the progress box will fill or empty to graphically indicate the selected hydraulic oil flow rate. 3-38 SY500H Excavator OMM...

  • Page 69: Quick Coupler Tool

    NOTE: Use this screen to display the hydraulic oil pressures for this device and to operate the quick coupler for work tool attachment and removal. 2. Press function button F2 (3) to activate the quick coupler function. SY500H Excavator OMM 3-39...
  • Page 70 MACHINE CONTROLS Page Intentionally Blank 3-40 SY500H Excavator OMM...

  • Page 71: Machine Operation

    Opening the Windshield ........... . 4-11 SY500H Excavator OMM...
  • Page 72 Parking and Storing the Machine ..........4-26 SY500H Excavator OMM...
  • Page 73 Unloading the Machine ............4-36 SY500H Excavator OMM...

  • Page 74: Work Area

    • Maintain complete control of the machine at all times. • Before leaving the cab, make sure all control devices are set to the neutral position and that the 0000453 Figure 4-1 engine is shut down. • Give warning signals when necessary. SY500H Excavator OMM...

  • Page 75: Cleaning The Cab Interior

    • Check the undercarriage (track, sprockets, tension break-in. rollers, and guards) for damage, wear, loose Contact a SANY dealer for details to properly break in the fasteners, and fluid leaks. Make repairs as engine. necessary.

  • Page 76: Electrical Components Check

    Opening the Cab Door or a component placing a high electrical load on the system. Contact a SANY dealer for more information. Failure to follow this notice could damage the machine or cause it to operate improperly.

  • Page 77: Closing The Cab Door

    (2) to prevent them from closing unexpectedly. Guide the support rod into the appropriate support bracket slot to secure the door in the open position. NOTE: Move the support rod out of the support bracket slot to close the access door. SY500H Excavator OMM...

  • Page 78: Right Front Access Door

    Closing the Right Front Access Door Pull the door down, hook the door latch onto the door, and secure by locking the door latch. 0004820 Figure 4-10 SY500H Excavator OMM...

  • Page 79: Opening The Left Rear Access Door

    See “Access Door shield (1). Support Rod” on page 4-7. Close the access door. To secure the door, close the left rear access door. See “Closing the Left Rear Access Door” on page 4-9. SY500H Excavator OMM...

  • Page 80: Expansion Tank Access Door

    To open the fresh-air access door (1), insert the key into the lock (2) and turn the key clockwise. Closing the Fresh-Air Access Door With the key in the lock, push and hold the door in closed position and turn the key counterclockwise to secure. 4-10 SY500H Excavator OMM...

  • Page 81: Closing The Engine Access Door

    Avoid sudden movement of the machine or work equipment. Always place the hydraulic lockout control lever in the locked (closed) position before opening or closing the windshield. Failure to follow this warning could result in death or serious injury. SY500H Excavator OMM 4-11...

  • Page 82: Closing The Windshield

    1. Before closing the windshield, park the machine on and the seal are clean. Accumulated dirt may level ground, lower the work equipment to the make the windshield difficult to remove or install. ground, and stop the engine. 4-12 SY500H Excavator OMM...

  • Page 83: Cab Light

    ON position for the cab light to operate. 0004742 Figure 4-26 1. Turn the key switch to the ON position. 2. Push function button F4 on the monitor to activate the backup camera and view activity behind the machine. SY500H Excavator OMM 4-13...

  • Page 84: Monitor Settings

    2. Press function button F1 (12) to move to and highlight the System Setting icon (13). 3. Press function button F3 (14) to activate System Setting. Language Selection See “System Language Setup Screen” on page 3-35. 4-14 SY500H Excavator OMM...

  • Page 85: System Clock Calibration

    (open) Failure to follow this notice could damage the position. If it does, contact a SANY dealer. Failure machine or cause it to operate improperly. to follow this warning could result in death or serious injury.

  • Page 86: Cold Weather Start

    (open) position. If it does, contact a SANY dealer. Failure 10. Turn the key switch to START. The starter motor will to correct this could result in death or serious crank the engine.

  • Page 87: Machine Warm-Up

    MACHINE OPERATION Machine Warm-up Cold Weather Operation The following recommendations are for operating SANY WARNING machines in low temperatures (below 32°F [0°C]): NOTE: See “Key Switch” on page 3-13 for details on • In case of emergency, irregular engine operation,...

  • Page 88: Jump-Start The Engine

    HEST and regeneration Failure to follow this notice could damage the lamps will turn off. machine or cause it to operate improperly. 1. Make sure that the key switches of both machines are at OFF. 4-18 SY500H Excavator OMM...

  • Page 89: Traveling Operations

    7. Attempt to start the engine of the machine with the drained battery. Retry every 3 minutes if the engine will not start. NOTE: Contact a SANY dealer if the engine will not start after five attempts. 8. Perform steps 2 through 5 in reverse order to...

  • Page 90: Track Direction

    When the cab faces the opposite direction of the arrows on the undercarriage, the machine moves forward when the control levers are pulled, and backward when they are pushed. SANY does not recommend traveling with the undercarriage reversed. Right Turn 0004692 Figure 4-33 2.

  • Page 91: Forward Travel

    (3) to rotate the machine to the left. stresses or possible tip-over. • Position the bucket 16 in. to 20 in. (20 cm to 30 cm) above the ground while traveling. SY500H Excavator OMM 4-21...

  • Page 92: Operating In Water

    • There are two operating modes available for the joystick controls, the Society of Automotive NOTES: Use cribbing to provide a firm surface if Engineers (SAE) mode and the backhoe loader necessary. (BHL) mode. 4-22 SY500H Excavator OMM...

  • Page 93: Sae Control Pattern

    NOTE: The bucket function is the same for SAE and BHL operating modes. To curl the bucket, move the right joystick to the left. To dump the bucket, move the right joystick to the right. 0000699 Figure 4-42 SY500H Excavator OMM 4-23...

  • Page 94: Bhl Control Pattern

    NOTE: The bucket function is the same for SAE and BHL operating modes. To curl the bucket, move the right joystick to the left. To dump the bucket, move the right joystick to the right. 0000699 Figure 4-46 4-24 SY500H Excavator OMM...

  • Page 95: Recommended Applications

    The digging range of the arm is between Loading Operations 30° and 45°. The angle may vary according to the digging depth. 0000706 Figure 4-52 Loading material from the rear of the truck is more convenient than from the side. SY500H Excavator OMM 4-25...

  • Page 96: End Of Workday Checks

    (closed) position (2). • Fuel tank (6) 6. Close and lock the windows. 7. Exit the cab. • Right rear access door (7) 8. Turn the battery disconnect switch to the OFF position. 9. Fill the fuel tank. 4-26 SY500H Excavator OMM...

  • Page 97: Short-Term Storage

    • Right rear access door (7) 9. Apply spray lubricant to any exposed cylinder rods. 10. Change the engine oil. 11. Turn the battery disconnect switch to OFF or remove the batteries and store them in a separate location. SY500H Excavator OMM 4-27...

  • Page 98: Maintenance During Storage

    3. Start the machine and test all operations. Failure to follow these warnings could result in death or serious injury. Counterweight Removal NOTE: Removing the counterweight for transport is not required. However, it may be necessary to comply with weight limits. 4-28 SY500H Excavator OMM...
  • Page 99 MACHINE OPERATION The SY500H excavator is equipped with a built-in counterweight removal system (1). 0004739 Figure 4-59 Lift + Counterweight = 0000711 Figure 4-60 There are two parts to the SY500H counterweight assembly, the lift (2) and the counterweight (3).
  • Page 100 5. Press function button F4. 6. Move the hydraulic lockout control lever to the unlocked (open) position. See “Hydraulic Lockout Control Lever” on page 3-8. 0004759 Figure 4-62 7. Access the control valves (7) in the right rear access door. 4-30 SY500H Excavator OMM...
  • Page 101 8. Push the right handle (8) of the control valve to raise the counterweight (9) off the frame. 0000716 Figure 4-64 9. Pull the left handle (10) of the control valve and tilt the counterweight away from the machine. SY500H Excavator OMM 4-31...
  • Page 102 NOTE: Make sure the ground is firm under the counterweight. Do not let the counterweight sink more than 1 ft. (32 cm) into the ground, or the machine may not be able to pick up the counterweight. 4-32 SY500H Excavator OMM...

  • Page 103: Counterweight Installation

    2. Tighten the mounting fasteners to 2249–2545 ft-lb distance between the machine and the (3050–3450 N•m). counterweight should not exceed 4 ft. (1.2 m). 0000720 Figure 4-68 4. If reassembly is required for the linkage, follow the pattern shown. SY500H Excavator OMM 4-33...

  • Page 104: Lifting The Machine

    0004938,0004957 Figure 4-70 4. Press function button F2 (1) on the Main screen to set the auto-idle to OFF. 5. Press function button F3 (2) on the Main screen to set the travel speed to low. 4-34 SY500H Excavator OMM...
  • Page 105 The other mirror (5) is mounted to the cab. 15. Turn both of the outside mirrors inward so they are within the perimeter of the machine. 16. Turn the battery disconnect switch to OFF. 0000726 Figure 4-74 SY500H Excavator OMM 4-35...

  • Page 106: Unloading The Machine

    • Use a signal person to alert the operator to any potential hazards Failure to follow these warnings could result in death or serious injury. 0004961 Figure 4-78 • Engine access door (11) 4-36 SY500H Excavator OMM...
  • Page 107 8. Move the hydraulic lockout control lever to the unlocked (open) position. See “Hydraulic Lockout Control Lever” on page 3-8. 9. Raise the work equipment to clear the trailer. 10. Slowly drive the machine off the trailer. SY500H Excavator OMM 4-37...
  • Page 108 If disconnecting the battery, wait at least 1 minute before disconnecting the battery cables so the machine’s ECM can complete its updating procedure. Failure to follow this notice can damage the machine or cause it to operate improperly. 4-38 SY500H Excavator OMM...

  • Page 109: Maintenance

    Genuine SANY Replacement Parts ........
  • Page 110 Replace the Hydraulic Tank Return Filter ........5-40 SY500H Excavator OMM...
  • Page 111 Long-Term Storage (Longer Than 30 Days) ........5-63 SY500H Excavator OMM...

  • Page 112: Maintenance Information

    Contact a SANY dealer before beginning any • Contact a SANY dealer if you are unable to perform welding repairs. Any welding repairs on the the procedures listed in this manual or if additional machine must be performed by personnel who are procedures are required.

  • Page 113: Securing Access Covers And Compartment Doors

    The track should be set slightly looser than what is Adverse Environments required for other environments. While track sag is normally 0.75 in.–1.75 in. (19 mm–45 mm), SANY If the machine will be operating under adverse recommends that you loosen the track tension to 1.75 in.

  • Page 114: Fluids And Lubricants

    Collect Oil Samples 4. Obtain and send the oil sample for testing in accordance with the instructions included with the 1. Obtain an oil analysis sample kit from a SANY dealer. sample kit. 2. Operate the machine until the lubricant in the compartment being tested is up to normal operating temperature.

  • Page 115: Engine Oil Viscosity/Temperature Data

    NGLI #1 molybdenum disulfide lithium-based grease NOTE: Always use clean extreme pressure (EP) grease when greasing the machine. Avoid using low-viscosity greases. SANY recommends EP 2 or equivalent grease. See “Grease” on page 5-8. Industrial Gear Oil/Temperature Data Temperature Oil Type -4°F...

  • Page 116: Hydraulic Oil/Ambient Temperature Data

    • Start the engine and run it at idle speed for 7 to 10 minutes. Increase the engine speed to 1200 rpm Contact a SANY dealer for assistance if the and perform only no-load traveling for a machine will be operated in subzero temperatures...

  • Page 117: Fuel

    • Use only ultra-low sulfur fuel, with a limit of S<15 mg/kg for all normal operations. NOTICE! • SANY does not recommend the use of any diesel fuel with a cetane level less than 40. Failure to inspect hydraulic oil for contamination •...

  • Page 118: Maintenance Schedule

    • Check the windshield washer fluid. (See page 5-60.) maintenance tasks. • Replace the bucket teeth. (See page 5-57.) • Lubricate the swing bearing. (See page 5-53.) • Replace the bucket. (See page 5-56.) • Check the swing grease bath level. (See page 5-55.) 5-10 SY500H Excavator OMM...

  • Page 119: Every 6 Months Or 1000 Hours

    • Check the alternator. (See page 5-17.) • Check the starter. (See page 5-17.) • Check the engine valve clearance. (Contact a SANY dealer for more information.) • Replace the hydraulic oil. (See page 5-35.) • Replace the engine coolant. (See page 5-18.)

  • Page 120: Maintenance Procedures

    • Restriction • Material deterioration • General damage NOTE: If any of the above conditions exist, replace the crankcase breather tube. 3. Close the engine access door. See “Closing the Engine Access Door” on page 4-11. 5-12 SY500H Excavator OMM...

  • Page 121: Replace The Engine Air Filter

    3. Clean the inside of the air filter housing with a clean cloth if needed. 4. Install new air filters. 5. Close the air filter housing. 6. Close the left front access door. See “Closing the Left Front Access Door” on page 4-9. SY500H Excavator OMM 5-13...

  • Page 122: Check The Engine Oil Level

    11. Follow the instructions included with the sample kit to send the sample for testing. 0000736 Figure 5-10 5. Make sure the oil level is within the etched area (3) of the dipstick. 6. Insert the dipstick. 5-14 SY500H Excavator OMM...

  • Page 123: Replace The Engine Oil And Filter

    3. Open the engine access door (2). See “Engine 5. Place a suitable sized container under the engine oil Access Door” on page 4-10. drain valve (4). 6. Slowly open the drain valve to drain the oil. SY500H Excavator OMM 5-15...
  • Page 124 24. Shut down the engine, wait several minutes, then remove the dipstick from the engine and note the oil level. 25. If necessary, remove the oil filler cap, add oil as needed, then install the filler cap. 5-16 SY500H Excavator OMM...

  • Page 125: Check The Engine Belts

    Check the Engine Belts engine flywheel). • Starter turns engine over slowly. • Burning smell or smoke coming from the starter. If the starter is malfunctioning, contact a SANY dealer for additional information. Check the Air Intake and the Charge Air Piping...

  • Page 126: Cooling System

    Failure to 6. Remove the cap when all pressure has been do so could damage the environment. relieved. 10. Allow the coolant to completely drain into the container, then close the drain valve. 5-18 SY500H Excavator OMM...

  • Page 127: Check The Engine Coolant Level

    18. Close the engine access door. See “Engine Access Door” on page 4-10. Check the Engine Coolant Level WARNING Engine coolant is toxic and could result in death or serious injury. Avoid inhaling or ingesting engine coolant. 0004828 Figure 5-8 SY500H Excavator OMM 5-19...

  • Page 128: Check The Radiator, Charge Air Cooler, And Air Conditioner Condenser Fins

    Access Door” on page 4-8. 0004780 Figure 5-9 4. Remove the fasteners (2) that secure the protection screens (1) mounted in front of the radiator. 5. Remove the protection screens. 6. Clean the protection screens using compressed air. 5-20 SY500H Excavator OMM...

  • Page 129: Air Conditioning System

    4. Check for damaged pulleys, worn V-groove, and V-belt. Make sure the V-belt does not rub against the bottom of the V-groove. 5. Move the compressor (2) and its bracket (3) to adjust the belt tension. SY500H Excavator OMM 5-21...

  • Page 130: Replace The Fresh-Air Filter

    5. Install the fresh-air filter. 6. Install the three fasteners that secure the fresh-air 0004817 Figure 5-15 filter in place. 1. Unlock and open the fresh-air filter door (1). 7. Close and lock the fresh-air filter door. 5-22 SY500H Excavator OMM...

  • Page 131: Replace The Cab Recirculation Filter

    Hot engine and exhaust touched without burning. Hot engine and exhaust components can cause burns and injury. components can cause burns and injury. 1. Open the engine access door. See “Engine Access Door” on page 4-10. SY500H Excavator OMM 5-23...

  • Page 132: Replace The Diesel Exhaust Fluid (Def) Pump Filter

    1. Open the right front access door. See “Right Front Access Door” on page 4-8. 0004754 Figure 5-20 2. Locate the DEF pump (1). 3. Remove the DEF pump filter housing (2) from the bottom of the pump. 5-24 SY500H Excavator OMM...

  • Page 133: Check The Diesel Exhaust Fluid (Def)

    Check the DEF level (1) on the monitor Home screen. 0004755 Figure 5-24 2. Remove the DEF tank cap (2), then add DEF through the filler neck as needed. 3. Install the DEF tank cap and close the right front access door. SY500H Excavator OMM 5-25...

  • Page 134: Replace The Diesel Exhaust Fluid (Def) Tank Filter

    DEF sending unit from the tank. connector (8). 11. Remove the DEF tank cap (13), then add DEF through the filler neck as needed. 12. Install the DEF tank cap, then close the DEF compartment door. 5-26 SY500H Excavator OMM...

  • Page 135: Stationary Regeneration

    If the red stop engine icon (2) illuminates, shut down the engine as soon as it is safe to do so and immediately contact a SANY dealer to arrange for service support. Failure to do so could result in engine damage.

  • Page 136: Fuel System

    Drain the Fuel Tank 1. Prepare the machine for service. See “Maintenance 0004760 Figure 5-36 Safety” on page 2-4. 1. Unlock and remove the fuel tank filler cap (1). 5-28 SY500H Excavator OMM...

  • Page 137: Replace The Primary And Secondary Fuel Filter

    15 seconds, wait for 15 seconds, and then attempt to restart for 15 seconds. Repeat this process up to 10 times. If the engine still fails to start, contact a SANY dealer. 0004761 15. Check for leaks around both the primary and Figure 5-38 secondary fuel filters.

  • Page 138: Drain The Primary Fuel Filter

    • See “Accumulator” on page 2-5 for special precautions that need to be taken when working with or around the accumulator. Contact a SANY dealer for additional information. Failure to follow these warnings could result in death or serious injury.

  • Page 139: Relieve Hydraulic System Pressure

    (open) position (3). 7. The boom should lower. 6. Fully cycle each joystick, and travel control NOTE: If there is no movement, contact a SANY dealer. lever/pedals two to three times within 15 seconds to release hydraulic pressure remaining in the hydraulic 8.

  • Page 140: Collect A Hydraulic Oil Sample

    Hydraulic System Pressure” on page 5-31. 3. Open the right rear access door. See “Right Rear Access Door” on page 4-8. 0000774 Figure 5-47 11. Press the vent button (9) to relieve pressure in the hydraulic tank. 5-32 SY500H Excavator OMM...

  • Page 141: Check The Hydraulic Oil Level

    Figure 5-49 and hoses and the high-temperature engine components (for example, the exhaust system). Make sure there is no 12. Set the hydraulic lockout control lever (9) to the unlocked (open) position (10). friction between them. SY500H Excavator OMM 5-33...

  • Page 142: Check The Hydraulic Hose/Line Connections

    Figure 5-53 CAUTION 7. Remove the suction strainer cover (3). Hydraulic oil may be hot and under pressure, which could result in injury. Always wait for the machine to cool before attempting to open the hydraulic system. 5-34 SY500H Excavator OMM...

  • Page 143: Replace Hydraulic Oil

    2. Position the work equipment as shown on the 16. Recheck the hydraulic oil level at the sight glass. hydraulic tank decal. 17. If necessary, remove the suction strainer cover and repeat steps 9 through 15. SY500H Excavator OMM 5-35...
  • Page 144 Failure to do so could damage the environment. 0004777 Figure 5-58 8. Remove the bottom cover (3). 0000781 Figure 5-60 12. Install a new O-ring (5) on the drain plug. 13. Install and securely tighten the hydraulic tank drain plug. 5-36 SY500H Excavator OMM...

  • Page 145: Replace The Hydraulic Pilot Filter Element

    1000 service hours or at least once each year, whichever occurs first. NOTE: Make sure the machine is on firm, level ground before proceeding. 1. Position the work equipment as shown on the 0000788 Figure 5-64 hydraulic tank decal. SY500H Excavator OMM 5-37...

  • Page 146: Check The Hydraulic Pump

    1. Prepare the machine for service. See “Maintenance use a piece of cardboard or paper to search for Safety” on page 2-4. suspected leaks. Failure to follow this warning could result in death or serious injury. 5-38 SY500H Excavator OMM...
  • Page 147 4. To relieve pressure in the hydraulic system, press the 0000790 Figure 5-71 hydraulic tank vent button (3). 7. Install the new breather filter. 8. Install the breather filter cover (6). 9. Install the spacer and wing nut. SY500H Excavator OMM 5-39...

  • Page 148: Check The Hydraulic Tank

    “Add Hydraulic Oil” on page 5-34. 5. Remove the spring (2), and then remove the 6. Check and tighten all hydraulic fittings as necessary. hydraulic oil return filter (3). 7. Close and secure the right rear access door. 5-40 SY500H Excavator OMM...

  • Page 149: Clean The Hydraulic Suction Strainer

    3. Relieve hydraulic system pressure. See “Relieve Hydraulic System Pressure” on page 5-31. 0004763 Figure 5-78 12. Install the cover (8) over the breather valve. 13. Install the decking (9) on top of the hydraulic tank. SY500H Excavator OMM 5-41...

  • Page 150: Check The Pump Mounting Fasteners

    6. Clean the suction strainer of all debris. NOTE: Replace the strainer if there is visible damage. 7. Replace the O-ring (2). 8. Install suction strainer (5) with rod (4) and spring (3). 0004793 Figure 5-83 3. Locate the hydraulic pump assembly (1). 5-42 SY500H Excavator OMM...

  • Page 151: Electrical System

    (ECM) can complete its updating Replace the Battery procedure. Failure to follow this notice can damage the machine or cause improper machine operation. CAUTION Before proceeding with any battery maintenance procedure, remember and follow these points. SY500H Excavator OMM 5-43...
  • Page 152 12. Install plastic terminal covers. 13. Install the battery cover. 0004716 Figure 5-86 14. Turn the battery disconnect switch to the ON 5. Remove the battery cover (1). position. 15. Close and secure the left rear access door. 5-44 SY500H Excavator OMM...

  • Page 153: Check The Fuses

    The electrical system should be inspected, starting with the fuse box. The fuse box is behind the left front door. • If a fuse is corroded, contact a SANY dealer for repair information regarding the electrical circuit in question. • Inspect all electrical equipment. If necessary, remove and replace faulty items, including loose connectors, worn or degraded wiring, etc.

  • Page 154: Check The Backup Camera

    5. Check for leaks. 6. If no issues are found, install the final drive motor cover. NOTE: Use thread lock compound when retightening loose fasteners and installing new fasteners. 5-46 SY500H Excavator OMM...

  • Page 155: Collect A Final Drive Oil Sample

    Failure to do so could result in death or serious injury. machine damage and improper machine operation. Check the Final Drive Motor Mounting Fasteners 1. Prepare the machine for service. See “Maintenance Safety” on page 2-4. 0004729 Figure 5-95 SY500H Excavator OMM 5-47...

  • Page 156: Replace The Final Drive Oil

    Slowly loosen applicable environmental regulations. Failure to the plug to gradually release the pressure. do so could damage the environment. Failure to follow these precautions could result in death or serious injury. 5-48 SY500H Excavator OMM...
  • Page 157 10. Remove the fill plug. the inspection and locate and repair the cause of the oil leaks. Failure to do so could result in machine damage and improper machine operation. 13. Repeat this procedure for the other final drive. SY500H Excavator OMM 5-49...

  • Page 158: Track Assemblies

    Check the idler (1) for cracks and distortion. Replace as necessary. 3. Inspect the mounting fasteners (1) that secure the support rollers to the side frame for rust, damage, or 0004869 loose parts. Figure 5-102 NOTE: Replace any damaged or defective fasteners. 5-50 SY500H Excavator OMM...

  • Page 159: Check The Track Tension

    8. Adjust the track tension as needed to obtain this 6. Measure the gap at location B from the top of the dimension. grouser to the string or straightedge. 7. Add dimensions A and B. SY500H Excavator OMM 5-51...

  • Page 160: Increase The Track Tension

    4. Slowly move the machine forward two machine lengths. 5. Stop the machine. 6. Recheck the track tension. See “Check the Track Tension” on page 5-51. 7. Repeat step 1 if the track tension is not within the specified range. 0000812 Figure 5-109 5-52 SY500H Excavator OMM...

  • Page 161: Swing Drive

    Lubricate the Swing Bearing 5. Repeat steps 1 through 4 until you have inspected all of the fasteners. NOTE: Contact a SANY dealer for missing or damaged fasteners. Check the Swing Drive 1. Prepare the machine for service. See “Maintenance Safety”...

  • Page 162: Collect A Swing Drive Oil Sample

    3. Shut down the machine. 4. Remove the dipstick from the swing drive. See “Replace the Swing Drive Oil” on page 5-54. 5. Insert the oil sample tube into the dipstick tube. 6. Collect a sample of swing drive oil. 5-54 SY500H Excavator OMM...

  • Page 163: Check The Swing Grease Bath Level

    Dispose of the drain oil in accordance with all Figure 5-119 applicable environmental regulations. Failure to 2. Locate the swing grease bath checkpoint (1). do so could result in damage to the environment. 9. Install the machine bottom cover. SY500H Excavator OMM 5-55...

  • Page 164: Bucket

    NOTE: Make sure the pins are free of mud or sand during installation. Both ends of the bushing are 1. Prepare the machine for service. See “Maintenance equipped with dust seals. Be careful not to Safety” on page 2-4. damage them. 5-56 SY500H Excavator OMM...

  • Page 165: Replace The Bucket Teeth

    1. Prepare the machine for checks and inspections. See page 2-4. 2. Turn the battery disconnect switch to OFF. See “Battery Disconnect Switch” on page 3-15. 0002350 Figure 5-1 SY500H Excavator OMM 5-57...

  • Page 166: Miscellaneous Procedures

    Failure to secure the machine could result in carefully and know how to use it in an emergency. damage to the machine. Inspect the condition of the fire extinguisher daily. If damaged, replace the extinguisher immediately. 5-58 SY500H Excavator OMM...

  • Page 167: Check The Front Window Locks

    Collect Oil Samples The fire extinguisher must be at least a 2.5 lb. 1. Acquire an oil analysis sample kit from a SANY Class ABC rated fire extinguisher (National Fire dealer. Protection Association [NFPA] 10 Standard for Portable Fire Extinguishers).

  • Page 168: Check The Sheet Metal

    3. Make sure the belt releases when the red button (4) is pressed at the end of the buckle (5). WARNING Contact a SANY dealer if the seat belt fails any of these checks or fails to fasten or unfasten, which could result in death or serious injury.

  • Page 169: Windshield Wiper

    (1) and wiper (2) to make sure there is no smearing across the windshield during operation. Replace the wiper blade with a new one if smearing does occur. 4. If necessary, adjust the spray nozzle to make sure the fluid spray is properly directed. SY500H Excavator OMM 5-61...

  • Page 170: Lubricate The Work Equipment

    1. Grease the arm cylinder head end pin fitting (1). 2. Grease the two boom foot pin fittings (2). 3. Grease the two boom cylinder rod end pin fittings (3). 5-62 SY500H Excavator OMM...

  • Page 171: Machine Storage

    8. Grease the bucket linkage fitting (8). If your storage area is near the ocean or other saltwater environment, it is important to be aware of salt damage. Contact a SANY dealer for additional storage procedures if this is the case. Short-Term Storage (Less Than 30 Days) See “Short-Term Storage”...
  • Page 172 MAINTENANCE Page Intentionally Blank 5-64 SY500H Excavator OMM...

  • Page 173: Specifications

    Lift Chart (Continued) ............6-7 SY500H Excavator OMM...

  • Page 174: Machine Dimensions

    SPECIFICATIONS Machine Dimensions 0000837 Figure 6-1 SY500H Excavator OMM...
  • Page 175 12 ft. 8 in. (3.85 m) 10) Track length on ground 14 ft. 6 in. (4.41 m) 11) Track length 17 ft. 11 in. (5.45 m) Boom length 22 ft. 11 in. (6.99 m) Arm length 12 ft. 9 in. (3.88 m) SY500H Excavator OMM...

  • Page 176: Operating Ranges

    27 ft. 1 in. (8.25 m) 4) Maximum vertical wall digging depth 22 ft. 1 in. (6.72 m) 5) Maximum digging reach 41 ft. 1 in. (12.54 m) 6) Maximum swing radius 17 ft. 2 in. (5.24 m) SY500H Excavator OMM...

  • Page 177: Technical Specifications

    46,535 lb-ft (207.0 kN) Fuel tank capacity 179.6 gal. (680.0 L) DEF tank capacity 15.0 gal. (56.6 L) Hydraulic tank capacity 126.8 gal. (480.0 L) Engine oil capacity 8.7 gal. (33.0 L) Cooling system capacity 13.2 gal. (50.0 L) SY500H Excavator OMM...

  • Page 178: Lift Chart

    (21,220) (*19,380) (*13,906) (*15,330) (10,301) -14.8 ft. *70,636 *70,636 *51,271 *51,271 *39,339 *31,202 *30,680 23,197 (-4.5 m) (*32,040) (*32,040) (*23,256) (*23,256) (*17,844) (*14,153) (*13,916) (10,522) -19.7 ft. *41,321 *41,321 *31,112 *31,112 (-6.0 m) (*18,743) (*18,743) (*14,114) (*14,112) SY500H Excavator OMM...

  • Page 179: Lift Chart (Continued)

    (-1.5 m) (*12,840) (8,134) (*9,940) (6,781) -9.8 ft. *27,172 18,071 *26,037 17,518 (-3.0 m) (*12,325) (8,197) (*11,810) (7,946) -14.8 ft. *27,179 16,905 *26,881 20,926 (-4.5 m) (*12,328) (7,668) (*12,193) (9,492) -19.7 ft. *26,912 *26,912 (-6.0 m) (*12,207) (*12,207) SY500H Excavator OMM...
  • Page 180 SPECIFICATIONS Page Intentionally Blank SY500H Excavator OMM...

  • Page 181: Optional Equipment

    Remove Optional Equipment ............7-6 SY500H Excavator OMM...

  • Page 182: Optional Equipment Selection

    OPTIONAL EQUIPMENT Optional Equipment Selection Operation Precautions Consult a SANY dealer before installing any optional NOTICE! equipment to the machine. Depending on the type of optional equipment selected, protective structures (such The following precautions must be strictly as front guards or top guards) may need to be installed observed when selecting, installing, and on the machine.

  • Page 183: Equipment Control Valves

    NOTE: Consult a SANY dealer for hydraulic flow and pressure adjustment needed for the attached equipment.

  • Page 184: Return Flow Selector Valve

    The monitor is used to select optional equipment and a shear is an example of a two-way flow attachment. adjust hydraulic pressures of some of the equipment. See “Tool Select Screen” on page 3-36. SY500H Excavator OMM...

  • Page 185: Install Optional Equipment

    10. Set the flow rates and pressures as required. 11. Check the hydraulic oil level and add hydraulic oil if necessary. See “Check the Hydraulic Oil Level” on page 5-33. NOTE: Consult a SANY dealer for hydraulic flow and pressure adjustment needed for the attached equipment. 0004809...

  • Page 186: Remove Optional Equipment

    Dispose of hydraulic oil in accordance with local environmental regulations. Failure to do so could damage the environment. 6. Place a suitably sized container under the stop valves to catch any hydraulic oil when hoses are disconnected. SY500H Excavator OMM...
  • Page 187 Contact Information SANY ......BHL Mode ......3-20...
  • Page 188 Hydraulic Pump Identification Plate ..1-5 Hydraulic Tank ..... . 5-40 SY500H Excavator OMM...
  • Page 189 Key Switch ......3-13 Left Turn ......4-20 SY500H Excavator OMM...
  • Page 190 Swing Bearing Fasteners ....5-53 Organization ......1-3 SY500H Excavator OMM...
  • Page 191 Mount and Dismount ....Controls Operator Information ....SY500H Excavator OMM...
  • Page 192 Return to Service ..... 4-28 SANY Contact Information ....1-6 Short-Term .
  • Page 193 Swing ......4-23, 4-24 Numerics 12V Power Supply Socket ....3-17 SY500H Excavator OMM...
  • Page 194 Page Intentionally Blank SY500H Excavator OMM...
  • Page 195 Page Intentionally Blank...
  • Page 196 318 Cooper Circle Peachtree City, Georgia 30269 www.sanyamerica.com/find-a-dealer Sales E-mail: sales@sanyamerica.com Service E-mail: service@sanyamerica.com Service Hotline: 470 552 SANY (7269) sanyamerica.com service@sanyamerica.com SANY Part Number SSY005084272...

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