SANY SY500H Manuals

Manuals and User Guides for SANY SY500H. We have 1 SANY SY500H manual available for free PDF download: Operation And Maintenance Manual

SANY SY500H Operation And Maintenance Manual (196 pages)

Brand: SANY | Category: Excavators | Size: 63.1 MB

Table of Contents
5
Introduction
16
About this Manual
16
Documentation Package
16
Operation and Maintenance Manual
16
Parts Manual
16
Maintenance Log
16
Organization of this Manual
17
Introduction
17
Safety
17
Machine Controls
17
Machine Operation
17
Maintenance
17
Specifications
17
Optional Equipment
17
Machine Applications
17
Machine Directions
17
Serial Number Locations
18
Product Identification Plate
18
Frame Serial Number
18
Swing Motor Identification Plate
18
Engine Identification Plate
18
Main Control Valve Identification Plate
19
Hydraulic Pump Identification Plate
19
Travel Motor Identification Plate
19
SANY Contact Information
20
Glossary of Acronyms
20
Record of Serial Number and Dealer Information
21
Correction Request Form
22
Safety
23
General Safety
24
Hazard Alerts in this Manual
24
Operator Safety Information
24
Mount and Dismount the Machine
25
Machine Safety
25
Authorized Use of this Machine
25
Unauthorized Use of this Machine
25
Unauthorized Machine Modifications
25
Escape Tool
25
Fire Safety
25
Electrical Fires
25
Fire Extinguisher
26
In Case of Fire
26
Crushing Hazard
26
Diesel Engine Exhaust
26
Machine Decals
26
Maintenance Safety
26
Lockout/Tagout Procedure
27
Clean the Machine
27
Fluid Systems
27
Adding Fluids to the Machine
27
Refueling
27
High-Pressure Fluid Lines
27
Accumulator
27
Electrical System
27
Battery Safety
27
Disconnect the Battery
28
Job Safety
28
Personal Protective Equipment (PPE)
28
Hearing Protection
28
Travel and Operation Precautions
28
Inclined Areas
28
Snow or Frozen Surfaces
28
Avoid Backover Accidents
29
Dust and Chemical Hazards
29
Environmental Precautions
29
Precautions in High-Voltage Areas
29
Machine Controls
31
Exterior Components
34
Seat and Seat Belt
35
Headrest
35
Seat Heater
35
Lumbar Adjustment
35
Armrest Angle Adjustment
35
Backrest Angle Adjustment
35
Seat Belt
35
Buckle the Seat Belt
35
Unbuckle the Seat Belt
35
Seat and Console Adjustment Lever
36
Weight Adjustment
36
Seat Forward and Backward Adjustment
36
Seat Cushion Adjustments
36
Emergency Stop Switch
36
Operator Controls
37
Left Control Console
38
Hydraulic Lockout Control Lever
38
Left Joystick
39
Climate Control Panel
40
Climate Control System Operation
40
OFF Button
40
Fan Speed Control Switch
40
Temperature Selection Control Switch
40
Vent Mode Selection Button
40
Automatic Temperature Control Selection Button
40
Air Conditioning Power Button
40
LCD Screen
40
Fresh/Recirculated-Air Selection Buttons
40
Radio Control Panel
41
Radio Operation
41
Universal Serial Bus (USB) Port
41
Auto Scan/Preset Station (AS/PS) Button
41
FM/AM Selector Button
41
Audio Selection (SEL) Button
41
Time Display/Time Set Button
41
Liquid Crystal Display (LCD)
42
Power Button
42
Volume Control Buttons
42
Tuning Buttons
42
Antenna
42
Right Control Console
42
Switches
42
Right Joystick
43
Key Switch
43
Throttle Control Dial
43
Stationary Regeneration Switch
43
Regeneration Disable Switch
44
Travel Alarm Silence Switch
44
Work Light Switch
44
Windshield Wiper Switch
45
Windshield Washer Switch
45
Headlight Switch
45
Battery Disconnect Switch
45
Batteries
46
Monitor Console
47
Power Supply Socket
47
Cup/Ashtray
47
Airflow Vents
47
Sunlight Sensor
47
Joystick Controls
48
Left Joystick Buttons
48
Right Joystick Buttons/Switch
48
SAE/BHL Joystick Operating Modes
48
Pattern Change (SAE/BHL) Valve
48
SAE Mode
49
BHL Mode
50
Travel Controls
51
Auto-Idle
51
Stop Valve
52
Return Flow Selector Valve
52
Fuses and Relays
53
Accessory Light Outlet (24V)
53
Fuse and Relay Locations
54
Monitor
55
Home Screen
55
Home Screen Display Icons
56
Date and Time
56
Hour Meter
56
Fault Icon
56
Periodic Maintenance Prompt
56
Installed Equipment
56
Engine Coolant Temperature Gauge
56
Function Icons
56
Function Buttons
56
Engine Speed Gauge (Tachometer)
56
System Service Icons
57
Home Screen Function Icons and Buttons
57
Main Menu Screen
57
Password Screen
59
Work Parameters Screens
59
Maintenance Information Screen
59
Error Codes Screen
61
System Setting Menu Screen
62
Date/Time Setting Screen
63
Data Unit Setting Screen
63
Screen Backlight Setting
64
Time Format Setting Screen
64
System Language Setup Screen
65
Machine Configuration Screen
66
Tool Select Screen
66
Tool Icons
66
Bucket
66
Breaker
67
Shear Tool
67
Lifting Tool
68
Quick Coupler Tool
69
Machine Operation
71
Work Area
74
General Job Safety
74
Operator Responsibilities
74
Seat Belt Usage
74
Operation and Maintenance Manual Check
74
Daily Maintenance Record Check
74
Cleaning the Machine
74
Cleaning the Cab Interior
75
New Machine Break-In
75
Prestart Checks and Adjustments
75
Electrical Components Check
76
Lights and Warning Devices
76
Access Doors, Panels, and Covers
76
Cab Door
76
Opening the Cab Door
76
Closing the Cab Door
77
Emergency Escape Hatch
77
Access Door Support Rod
77
Right Front Access Door
78
Opening the Right Front Access Door
78
Closing the Right Front Access Door
78
Right Rear Access Door
78
Opening the Right Rear Access Door
78
Closing the Right Rear Access Door
78
Left Rear Access Door
78
Opening the Left Rear Access Door
79
Closing the Left Rear Access Door
79
Left Front Access Door
79
Opening the Left Front Access Door
79
Closing the Left Front Access Door
79
Fuel Filler Cap
79
Opening the Fuel Tank Filler Cap
79
Closing the Fuel Tank Filler Cap
79
Expansion Tank Access Door
80
Opening the Expansion Tank Access Door
80
Closing the Expansion Tank Access Door
80
Fresh-Air Access Door
80
Opening the Fresh-Air Access Door
80
Closing the Fresh-Air Access Door
80
Engine Access Door
80
Opening the Engine Access Door
80
Closing the Engine Access Door
81
Cab Door Windows
81
Windshield
81
Opening the Windshield
81
Closing the Windshield
82
Lower the Front Windshield
82
Cab Light
83
Mirrors
83
Backup Camera
83
Monitor Settings
84
First-Time Setup
84
Access the Main Menu
84
Language Selection
84
System Clock Calibration
85
Data Unit Setting
85
Engine Start Procedure
85
Cold Weather Start
86
Machine Warm-Up
87
Idling the Engine
87
Engine Shutdown Procedure
87
Cold Weather Operation
87
Manual Regeneration
87
Jump-Start the Engine
88
Traveling Operations
89
Before Traveling
89
Track Direction
90
Traveling with the Undercarriage Reversed
90
Right Turn
90
Left Turn
90
Forward Travel
91
Backward Travel
91
Zero-Degree Rotation
91
Left
91
Right
91
Operating on Inclines
91
Operating in Water
92
Releasing the Machine from Mud
92
One Track Stuck
92
Two Tracks Stuck
92
Work Equipment Controls
92
SAE Control Pattern
93
Swing
93
Arm
93
Boom
93
Bucket
93
BHL Control Pattern
94
Swing
94
Arm
94
Boom
94
Bucket
94
Recommended Applications
95
Backhoe Operation
95
Digging a Trench
95
Loading Operations
95
End of Workday Checks
96
Parking and Storing the Machine
96
Overnight Storage
96
Short-Term Storage
97
Long-Term Storage
97
Preparation
97
Maintenance During Storage
98
Return to Service
98
Transportation Information
98
Counterweight Removal
98
Counterweight Installation
103
Lifting the Machine
104
Loading the Machine
104
Unloading the Machine
106
Maintenance
109
Maintenance Information
112
Checks before Maintenance
112
Checks after Maintenance or Repairs
112
Hour Meter Reading
112
Genuine SANY Replacement Parts
112
SANY-Approved Lubricants
112
Weld, Drill, Cut, or Grind on the Machine
112
Clean Parts of the Machine
112
Securing Access Covers and Compartment Doors
113
Installation of Hydraulic Hoses
113
Inspection and Maintenance in Adverse Environments
113
Mud, Rain, or Snow Conditions
113
Near Ocean (Salt Air) Environments
113
Dusty Environment
113
Rocky Ground Surface
113
Cold Environments
113
Other Weather Environments
113
Fluids and Lubricants
114
Location, Capacity, and Type
114
Collect Oil Samples
114
Engine Oil Viscosity/Temperature Data
115
Lubricating Grease/Temperature Data
115
Industrial Gear Oil/Temperature Data
115
Hydraulic Oil/Ambient Temperature Data
116
Diesel Exhaust Fluid (DEF)
116
Engine Coolant
116
Lubricants
116
Grease
116
Fuel
117
Windshield Washer Fluid
117
Hydraulic Oil Description
117
Maintenance Schedule
118
Daily Maintenance and Inspection
118
When Required
118
After the First 50 Hours
118
Weekly or Every 50 Hours
118
Every 100 Hours
118
Every 250 Hours
118
Every 3 Months or 500 Hours
118
Every 6 Months or 1000 Hours
119
Annually or Every 2000 Hours
119
Hydraulic Breaker Maintenance Interval
119
After Maintenance Is Completed
119
Maintenance Procedures
120
Engine
120
Check the Crankcase Breather Tube
120
Check the Engine Air Precleaner
120
Check the Engine Air Filter System
120
Replace the Engine Air Filter
121
Check the Engine Oil Level
122
Collect an Engine Oil Sample
122
Replace the Engine Oil and Filter
123
Check the Engine Belts
125
Check the Alternator
125
Check the Starter
125
Check the Air Intake and the Charge Air Piping
125
Cooling System
126
Replace the Engine Coolant
126
Check the Engine Coolant Level
127
Check the Radiator, Charge Air Cooler, and Air Conditioner Condenser Fins
128
Air Conditioning System
129
Check the Air Conditioner
129
Check the Air Conditioner Compressor Belt
129
Adjust the Air Conditioner Compressor Belt
129
Replace the Fresh-Air Filter
130
Replace the Cab Recirculation Filter
131
Exhaust System
131
Check the Aftertreatment Exhaust Piping
131
Check the Engine Exhaust Pipe Clamps
131
Replace the Diesel Exhaust Fluid (DEF) Pump Filter
132
Check the Diesel Exhaust Fluid (DEF)
133
Fill the Diesel Exhaust Fluid (DEF) Tank
133
Replace the Diesel Exhaust Fluid (DEF) Tank Filter
134
Stationary Regeneration
135
Fuel System
136
Check the Fuel Level
136
Check the Fuel Lines
136
Drain the Fuel Tank
136
Check the Fuel Tank Strainer
136
Replace the Primary and Secondary Fuel Filter
137
Drain the Primary Fuel Filter
138
Hydraulic System
138
Check the Accumulator Function
138
Relieve Hydraulic System Pressure
139
Collect a Hydraulic Oil Sample
140
Replace the Case Drain Filter
140
Check the Hydraulic Oil Level
141
Check the Hydraulic Hoses
141
Check the Hydraulic Hose/Line Connections
142
Add Hydraulic Oil
142
Replace Hydraulic Oil
143
Replace the Hydraulic Pilot Filter Element
145
Check the Hydraulic Pump
146
Replace the Hydraulic System Breather Filter
146
Check the Hydraulic Tank
148
Replace the Hydraulic Tank Return Filter
148
Clean the Hydraulic Suction Strainer
149
Check the Pump Mounting Fasteners
150
Electrical System
151
Check the Batteries
151
Replace the Battery
151
Check the Fuses
153
Check the Electrical System
153
Check the Operating Functions
153
Check the Backup Camera
154
Final Drive
154
Check the Final Drive
154
Collect a Final Drive Oil Sample
155
Check and Add Final Drive Oil
155
Check the Final Drive Motor Mounting Fasteners
155
Replace the Final Drive Oil
156
Track Assemblies
158
Check the Track Assemblies
158
Check the Track Fasteners
158
Check the Idler
158
Check the Track Tension
159
Increase the Track Tension
160
Decrease the Track Tension
160
Swing Drive
161
Lubricate the Swing Bearing
161
Check the Swing Bearing Fasteners
161
Check the Swing Drive
161
Collect a Swing Drive Oil Sample
162
Replace the Swing Drive Oil
162
Check the Swing Grease Bath Level
163
Bucket
164
Replace the Bucket
164
Replace the Bucket Teeth
165
Miscellaneous Procedures
166
Check the Cab Door, Doors, and Locks
166
Check the Cooling Fan
166
Check the Decals
166
Check the Escape Tool
166
Check the Fire Extinguisher
166
Check the Front Window Locks
167
Check the Grab Handles and Steps
167
Collect Oil Samples
167
Check the Operation and Maintenance Manual
167
Check the Seat Belt
167
Check the Sheet Metal
168
Structural Inspection
168
Clean and Check the Upper Structure and Undercarriage
168
Check the Windshield Washer Fluid
168
Windshield Wiper
169
Lubricate the Work Equipment
170
Machine Storage
171
Short-Term Storage (Less than 30 Days)
171
Long-Term Storage (Longer than 30 Days)
171
Specifications
173
Machine Dimensions
174
Operating Ranges
176
Technical Specifications
177
Lift Chart
178
Lift Chart (Continued)
179
Optional Equipment
181
Optional Equipment Selection
182
Read Equipment Instructions
182
Removal and Installation Precautions
182
Operation Precautions
182
Equipment Control Valves
183
Stop Valves
183
Return Flow Selector Valve
184
Optional Equipment Controls
184
Right and Left Joystick
184
Monitor
184
Install Optional Equipment
185
Remove Optional Equipment
186

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SANY SY500H Operation And Maintenance Manual (196 pages)

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