Sany SY115C9/135C/155H Crawler Hydraulic Excavator Operation & Maintenance Manual – PDF

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Sany SY115C9/135C/155H Crawler Hydraulic Excavator Operation & Maintenance Manual – PDF DOWNLOAD

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Sany SY115C9/135C/155H Crawler Hydraulic Excavator Operation & Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 444
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Sany SY115C9/135C/155H Crawler Hydraulic Excavator Operation & Maintenance Manual – PDF DOWNLOAD

1 Introduction
1 1 Overview 1-3
1 2 Your Documentation Package 1-4
1 2 1 Recommendations on using the documentation 1-5
1 2 2 Documentation storage 1-5
1 2 3 Manual organization 1-5
1 2 3 1 Introduction 1-6
1 2 3 2 Safety 1-6
1 2 3 3 System functions 1-6
1 2 3 4 Operation 1-6
1 2 3 5 Maintenance 1-6
1 2 3 6 Troubleshooting 1-7
1 2 3 7 Speci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 1-9
1 3 4 1 Product identication plate 1-9
1 3 4 2 Engine identication plate 1-10
1 3 4 3 Right and left drive motors 1-11
1 3 4 4 Swing motor 1-11
1 3 4 5 Hydraulic pump 1-11
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
2 Safety
2 1 Safety Information 2-5
2 2 Safety Messages 2-7
Table of Contents
Table of Contents
II Safety, Operation and Maintenance Manual – Sep 2012
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 2-19
2 3 1 Safety rules 2-19
2 3 2 Abnormalities 2-19
2 3 3 Personal protective equipment 2-19
2 3 4 Fire extinguisher and rst aid kit 2-21
2 3 5 Safety equipment 2-21
2 3 6 Cleaning your machine 2-22
2 3 7 Keeping the cab clean 2-23
2 3 8 Engaging the hydraulic lockout control 2-23
2 3 9 Handholds and steps 2-24
2 3 10 Overhead work 2-25
2 3 11 No sitting on attachment 2-25
2 3 12 Articulated parts 2-25
2 3 13 Preventing burns 2-25
2 3 13 1 Hot coolant 2-25
2 3 13 2 Hot oil 2-26
2 3 14 Preventing re and explosion 2-26
2 3 14 1 Fire caused by fuel or oils 2-26
2 3 14 2 Fire caused by flflammable 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 2-28
2 3 14 6 Fire caused by heat shield 2-28
2 3 15 In the event of re 2-28
2 3 16 Windshield cleaning detergent 2-29
2 3 17 Preventing ejection of part 2-29
2 3 18 Falling object protection 2-30
2 3 19 Attachment installation 2-30
2 3 20 Attachment combination 2-31
2 3 21 Cab windows glasses 2-31
Table of Contents
Safety, Operation and Maintenance Manual – Sep 2012 III
SY115C9/135C/155H Crawler Hydraulic Excavator
2 3 22 Unauthorized modi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 2-35
2 3 29 Alternate exit 2-36
2 4 Safe Operation Precautions 2-37
2 4 1 Safe starting 2-37
2 4 1 1 Safe mounting 2-37
2 4 1 2 Seat adjustment 2-38
2 4 1 3 Seat belt 2-38
2 4 1 4 Before starting the engine 2-38
2 4 1 5 Engine starting rules 2-39
2 4 1 6 Safe starting 2-39
2 4 1 7 Starting engine in cold season 2-40
2 4 1 8 Engine starting aid 2-40
2 4 1 9 After starting the engine 2-41
2 4 2 Operation 2-42
2 4 2 1 Inspection before operation 2-42
2 4 2 2 Prior-operation precautions 2-42
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 2-48
2 4 3 Parking the machine 2-51
2 4 3 1 Select a parking place 2-51
2 4 3 2 Machine shutdown 2-51
2 4 4 Transportation 2-52
2 4 4 1 Loading and unloading the machine 2-52
2 4 4 2 Transporting the machine 2-53
2 4 5 Battery 2-54
Table of Contents
IV Safety, Operation and Maintenance Manual – Sep 2012
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 2-60
2 5 6 Using proper tools 2-60
2 5 7 Maintenance with engine running 2-61
2 5 8 Working under the machine 2-61
2 5 9 Track maintenance 2-62
2 5 10 Track tension adjustment precautions 2-63
2 5 11 Recoil spring 2-63
2 5 12 Welding operation 2-64
2 5 13 High-pressure hoses 2-64
2 5 14 Pressurized flfluid 2-65
2 5 15 Hot cooling system 2-66
2 5 16 Air-conditioning system 2-66
2 5 17 High voltage precautions 2-67
2 5 18 Accumulator 2-67
2 5 19 Avoiding re and explosion 2-68
2 5 20 Regular replacement of safety-related parts 2-69
2 5 21 Maintenance operation 2-70
2 5 22 Proper disposal of wastes 2-71
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 3-12
3 3 2 3 Time Setup 3-13
3 3 2 4 Main Menu 3-14
3 3 2 5 Engine & Throttle Signals 3-15
Table of Contents
Safety, Operation and Maintenance Manual – Sep 2012 V
SY115C9/135C/155H Crawler Hydraulic Excavator
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 Con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 3-23
3 3 2 13 Language Selection 3-25
3 3 2 14 GPS Monitoring Information 3-26
3 3 2 15 System Setup 3-27
3 3 2 16 Machine conguration setup 3-28
3 3 2 17 Coolant Temperature 3-29
3 3 2 18 Service Call 3-30
3 4 Switches 3-31
3 4 2 1 Start switch 3-32
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 3-37
3 4 2 10 Preheat switch (only for SY135C8M) 3-38
3 4 2 11 Alternator indicator 3-38
3 5 Control levers and pedals 3-39
3 5 1 Hydraulic lockout control 3-40
3 5 2 Travel controls 3-41
3 5 3 Joystick controls 3-42
3 6 Roof Hatch 3-44
3 6 1 Opening the roof hatch 3-44
3 6 2 Closing the roof hatch 3-44
3 7 Windshield 3-45
3 7 1 Opening the window 3-45
3 7 2 Closing the window 3-48
3 7 3 Removing the lower window 3-50
Table of Contents
VI Safety, Operation and Maintenance Manual – Sep 2012
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 3-56
3 13 Literature Bag 3-56
3 14 Ashtray 3-57
3 15 Air Conditioning System 3-58
3 15 1 Control panel 3-58
3 15 2 Operation method 3-64
3 15 3 A/C operation precautions 3-72
3 16 Radio 3-74
3 16 1 Control panel 3-74
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
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/rell 4-9
4 1 2 5 Coolant – check/rell 4-10
4 1 2 6 Oil in engine oil pan – check/rell 4-11
4 1 2 7 Electric wires – check 4-12
4 1 2 8 Fuel tank – check/refuel 4-13
Table of Contents
Safety, Operation and Maintenance Manual – Sep 2012 VII
SY115C9/135C/155H Crawler Hydraulic Excavator
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 4-20
4 2 Engine Starting 4-22
4 2 1 Engine Preheating 4-25
4 2 2 Warm-up operation 4-26
4 2 3 Selecting a wor king mode 4-26
4 3 Engine Shutdown 4-27
4 4 Machine Operation 4-28
4 4 1 Before moving the machine 4-28
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 4-33
4 5 4 4 Pivot turn 4-33
4 5 1 Swing operation 4-34
4 6 Work Equipment Control and Operation 4-35
4 7 Working mode 4-37
4 8 Restricted Operations 4-38
4 8 1 Operation with swinging force 4-38
4 8 2 Operation with traveling force 4-38
4 8 3 Operation when hydraulic cylinder reaches its stroke end 4-39
4 8 4 Operation with bucket landing force 4-39
4 8 5 Operation with machine weight 4-40
4 8 6 Hard rocky ground 4-40
4 8 7 Sudden shift of travel speed during fast traveling 4-41
4 9 General Operation 4-41
4 9 1 Traveling operation 4-41
4 9 2 High-speed tr avel 4-41
Table of Contents
Safety, Operation and Maintenance VIII Manual – Sep 2012
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 4-44
4 11 1 One track trapped 4-44
4 11 2 Both tracks trapped 4-45
4 12 Recommended Applications 4-45
4 12 1 Backhoe operation 4-45
4 12 2 Trench work 4-46
4 12 3 Loading operation 4-46
4 13 Parking Operation 4-47
4 14 Checks after Each Workday 4-49
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 4-54
4 17 1 Before storage 4-54
4 17 2 During storage 4-55
4 17 3 After storage 4-56
4 17 4 Starting the engine after long-term storage 4-56
4 18 Transportation Information 4-57
4 18 1 Transport methods 4-57
4 18 2 Loading/unloading machine to/from a trailer 4-57
4 18 2 1 Loading the machine 4-59
4 18 2 2 Securing the machine 4-61
4 18 2 3 Rear view mirrors 4-62
4 18 2 4 Unloading the machine 4-63
4 18 3 Lifting the machine or its components 4-65
4 18 3 1 Lifting precautions 4-65
4 18 3 2 Choosing a wire rope 4-66
Table of Contents
Safety, Operation and Maintenance Manual – Sep 2012 IX
SY115C9/135C/155H Crawler Hydraulic Excavator
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
5 2 2 Grease 5-12
5 2 3 Oil and fuel storage 5-13
5 2 4 Filter element 5-13
5 2 5 Electrical system 5-14
5 2 6 Hydraulic system 5-14
5 3 Replacement Parts 5-16
5 4 Recommended Fluids 5-17
5 4 1 Fluid capacities 5-19
5 4 2 Recommended oils: 5-20
5 5 Tightening Torque Specication 5-22
5 6 Safety-Related Parts 5-24
5 7 Maintenance Schedule 5-25
5 7 1 List of maintenance schedule 5-25
5 7 2 Hydraulic Breaker Service Interval 5-27
5 8 Maintenance Procedures 5-28
5 8 1 Maintenance after initial 50 service hours 5-28
5 8 1 1 Engine oil and lter – change/replace 5-28
5 8 1 2 Fuel lter – replace 5-28
5 8 2 When Required 5-29
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 5-47
5 8 2 7 Bucket clearance – adjust 5-49
5 8 2 8 Window washer fluid – check/rell 5-51
Table of Contents
Safety, Operation and Maintenance X Manual – Sep 2012
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 5-60
5 8 4 1 Lubrication 5-60
5 8 5 Every 250 service hours 5-63
5 8 5 1 Compressor belt tension – inspect/adjust 5-63
5 8 5 2 Oil in engine oil pan and oil lter – change/replace 5-65
5 8 5 3 Primary fuel lter – replace 5-67
5 8 5 4 Secondary fuel lter – replace 5-71
5 8 6 Every 500 service hours 5-74
5 8 6 1 Swing bearing – lubricate 5-74
5 8 6 2 Swing pinion gear grease – check/rell 5-75
5 8 6 3 Coolant tank and radiator ns – inspect/clean 5-76
5 8 6 4 Air conditioner lters – clean 5-77
5 8 6 5 Swing drive oil – check/rell 5-80
5 8 6 6 Final drive oil – check/ll 5-81
5 8 7 Every 1000 service hours 5-82
5 8 7 1 Hydraulic oil lter – replace 5-82
5 8 7 2 Swing drive oil – change 5-84
5 8 7 3 Engine exhaust pipe clamps – check 5-85
5 8 7 4 Fan belt tension – check/replace 5-85
5 8 7 5 Nitrogen pressure in accumulator (breaker) – check 5-85
5 8 8 Every 2000 service hours 5-86
5 8 8 1 Final drive oil – change 5-86
5 8 8 2 Hydraulic tank lter screen – clean 5-88
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 5-95
5 8 9 Every 4000 service hours 5-95
5 8 9 1 Coolant pump – inspect 5-95
5 8 9 2 Start motor – check 5-95
Table of Contents
Safety, Operation and Maintenance Manual – Sep 2012 XI
SY115C9/135C/155H Crawler Hydraulic Excavator
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 5-98
5 8 11 Every 10000 service hours 5-98
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 6-12
6 3 Towing the Machine 6-13
6 4 Towing Hook for Light Loads 6-15
6 5 Severe Operating Conditions 6-15
6 6 Engine Failures 6-16
6 6 1 Engine troubleshooting table 6-16
6 6 2 Coolant temperature high 6-19
6 6 3 Engine oil pressure low 6-20
6 6 4 When fuel exhausts 6-22
6 6 5 When engine rotates reversely 6-24
6 7 Failures of the Electrical System 6-25
6 7 1 Electrical system troubleshooting table 6-25
6 7 2 Failure codes 6-28
6 8 Battery 6-30
6 8 1 Battery removal and installation 6-30
6 8 2 Battery charging 6-31
6 8 3 Jump-starting the engine 6-32
6 8 3 1 Connecting the jumper cables 6-33
6 8 3 2 Starting the engine 6-34
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
Table of Contents
Safety, Operation and Maintenance XII Manual – Sep 2012
SY115C9/135C/155H Crawler Hydraulic Excavator
7 Speci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 8-4
8 2 Hydraulic Control Elements and Oil Circuit 8-6
8 2 1 Location of the components 8-6
8 2 1 1 Stop valve 8-6
8 2 1 2 Selector valve 8-7
8 2 1 3 Control pedal 8-7
8 2 2 Hydraulic circuit 8-8
8 2 2 1 Hydraulic circuit switching 8-8
8 2 2 2 Shifting to breaker / general optional equipment 8-8
8 2 2 3 Connecting hydraulic oil circuit 8-9
8 2 2 4 Hydraulic oil passage 8-10
8 2 3 Optional equipment removal and installation 8-11
8 2 3 1 Removal 8-11
8 2 3 2 Optional equipment installation 8-13
8 2 4 Hydraulic oil and hydraulic tank lter – change/replace 8-15
8 2 5 Long-term storage 8-16
8 2 6 Hydraulic specications 8-16
8 3 Optional equipment Guide 8-17
8 3 1 Work equipment combination 8-17
8 3 2 Bucket tips selection 8-19
8 3 2 1 Rockwork bucket tips 8-19
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
Table of Contents
Safety, Operation and Maintenance Manual – Sep 2012 XIII
SY115C9/135C/155H Crawler Hydraulic Excavator
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 8-31
8 9 2 System working principle 8-33
8 9 3 Setting the lubrication time of electric grease pump 8-34
8 9 4 Technical description 8-35
8 9 5 Adding grease with electric pump 8-36

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