Sany SY155W Wheeled Hydraulic Excavator Operation and Maintenance Manual – PDF DOWNLOAD

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Sany SY155W Wheeled Hydraulic Excavator Operation and Maintenance Manual – PDF DOWNLOAD

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DESCRIPTION:

Sany SY155W Wheeled Hydraulic Excavator Operation and Maintenance Manual – PDF DOWNLOAD

1 Foreword
1.1 Overview

• This Operation and Maintenance Manual is a guide for you to operate your machine properly. It contains technical and safety information necessary for operation of your machine. Please read and understand each section of the manual. Only eligible and experienced operators with an official license (according to local laws) are al‐ lowed to operate the machine.
• Always operate your machine according to national and/or local laws and regulations. The operation safety information and description in this manual are just suggestive and attentive. Sany cannot anticipate every possible circumstance that might involve a potential hazard during operation and maintenance. The Safety messages in this manual and on the product are,
• there‐ fore, not all inclusive. If a procedure, work method or operating technique that is not specifically recommended in this manual is used, you must be sure that it is safe for you and for others. Modifying or abusing the machine according to your own will might impair the machine’s performance, or result in more serious potential hazard.
• For instance, the specific volume of fuel oil exceeds set limit or the machine is overloaded. Please drive and operate the machine carefully. Improper operation or application may cause personal injury or damage. Sany assumes no responsibility for such losses. Machines covered by this manual are used for various operations under normal conditions.
• Do not use the machine in flammable or explosive environment, or in areas containing asbestos dust. Please select a Sany excavator with a configuration suitable for high‐plateau operation when operating in areas 2,000 m above sea level. This machine has gone through electromagnetic capacity test according to EN 13309‐200C.
• All unapproved electronic attachments (such as communication devices) are therefore to be tested before installation and application. Make sure that the electromagnetic attachments will not cause electromagnetic interference. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written.
• Sany reserves the right to change this information at any time without prior notice. Please consult Sany dealer to obtain the latest information or if you have any question on the information provided in this manual。 Machine with standard configuration suitable for work under 2000m altitude, atmospheric temperature ranging from ‐20℃ to 40℃.

TABLE OF CONTENTS:

Sany SY155W Wheeled Hydraulic Excavator Operation and Maintenance Manual – PDF DOWNLOAD

1 Introduction
11 Overview 1‐3
12 Safety Information 1‐5
13 Page instruction 1‐7
14 Introduction 1‐7
141 machine directions… 1‐8
15 Product information 1‐9
151 machine series number 1‐9
2 Safety
21 Safety information 2‐5
211 location of safety decals 2‐5
212 description of safety decals 2‐7
22 General Precautions 2‐17
221 safety rules 2‐17
222 in emergency 2‐17
223 PPEs for operators 2‐18
224 fire extinguishers and first aid kit 2‐19
225 saftey equipment 2‐20
226 keep the machine clean 2‐21
227 keep the cabin clean 2‐21
228 keep safety lever locked 2‐22
229 handrails and steps 2‐23
2210 e l e v a t e d w o r k 2‐24
2211 keep away from attachment 2‐24
2212 articulated parts 2‐24
2213 heat protection 2‐25
22131 when coolant is hot 2‐25
22132 when fuel is hot 2‐25
2214 fire and explosion prevention 2‐26
22141 fire caused by fuel or engine oil 2‐26
22142 fire caused by flammables 2‐27
142 unning-in of a new machine … 1‐8
152 engine series number 1‐10
SY155W Wheeled Hydraulic Excavator Contents
Operation and Maintenance Manual 11-2015 IV
22143 fire caused by electrical lines 2‐27
22146 fire caused by heat shield 2‐27
2217 a v o i d f l y o u t o f c o m p o n e n t s 2‐28
2218 falling & ejecting parts 2‐29
2219 installation of attachments 2‐30
2220 combination of attachments 2‐30
2221 wind shield of cabin 2‐30
2222 unauthorized modificatioin 2‐30
2223 jobsite investigation 2‐31
2224 operation on a loose ground 2‐31
2225 away from high voltage cables 2‐32
2226 visibility………………………… 2‐33
2227 ventilation at workplace 2‐34
2228 asbestos dust 2‐34
2229 emergency exit of cabin 2‐35
23 safe machine operation 2‐36
231 safe operation precautions 2‐36
2311 step‐onto the machine safely 2‐36
2312 operator seats 2‐36
2313 fasten theseatbelt 2‐37
2314 inspection before starting the engine 2‐37
2315 turn on the machine safely 2‐38
2316 start the engine in cold season 2‐39
2317 auxiliary equipment for machine start up 2‐39
2318 after starting the engine 2‐39
232 operation 2‐40
2321 inspection before operation 2‐40
2322 precautions before operation 2‐40
2323 confirm direction of machine 2‐41
2324 safety rules for changing the direction of machine 2‐42
2325 safety rules for traveling 2‐44
2326 safe traveling 2‐45
22144 fire caused by hydr a ulic pipe 2‐27
22145 fire caused by illumination equipment 2‐27
2216 winds hield cleaning ditergen 2‐28
2215 actions to take at a fires 2‐28
Contents SY155W Wheeled Hydraulic Excavator
V Operation and Maintenance Manual 11-2015
2327 operation on slopes 2‐48
2328 oper at ion on a s n owy d a y 2‐48
2329 forbidden operations 2‐49
233 Parking the machine 2‐51
2331 Select a parking place 2‐51
2332 Machine shutdown 2‐52
234 Transportation 2‐53
2341 transportation of machine 2‐53
2342 Loading and unloading 2‐53
235 Battery 2‐54
236 Towing 2‐56
237 Lifting objects with the machine 2‐57
24 Precautions for Maintenance 2‐58
241 Prior‐maintenance precautions 2‐58
242 Get prepared 2‐58
243 Select a working area 2‐59
244 Procedures of shutting down engines before maintenance 2‐59
245 Lockout and tag‐out measures 2‐60
246 Use proper tools 2‐60
247 Maintenance with engine running 2‐61
248 Work under the machine 2‐62
249 Track maintenance 2‐62
2410 Hot cooling system 2‐63
2411 High‐pressure hoses 2‐63
2412 Pressurized fluid 2‐64
2413 welding operation 2‐64
2416 accumulator2‐66
2417 fire and explosion prevention 2‐66
2420 waste treatment 2‐67
3 Technic specifications
31 machine dimensions 3‐3
2414 air-con system maintenance 2‐65
2415 high voltage precautions2‐65
2418 regular replacement of safety related parts 2‐66
2419 maintenance operation 2‐67
SY155W Wheeled Hydraulic Excavator Contents
VI
32 digging range 3‐4
33 technical parameters 3‐5
4 Operation
41 Machine operation 4‐5
42 Controls and instruments description 4‐6
421 monitor 4‐6
422 monitor operation 4‐10
423 switches 4‐19
4231 starting up switch 4‐20
4232 throttle knob 4‐20
4233 work lamp switch 4‐21
4234 horn switch 4‐22
4235 cabin lamps 4‐22
4236 cigarette lighter and auxiliary 4‐22
4237 headlamps switch 4‐23
4238 climbing switch 4‐23
4239 reversing alarm release switch 4‐23
424 Joystick and pedal 4‐24
4241 safety lock lever 4‐25
4242 joysticks 4‐26
4243 brake pedal 4‐28
4244 accelerating pedal 4‐28
425 Steering Bar Switch And Indicator 4‐29
4251 Combination Switch (Left Lever) 4‐30
4252 Travel Combination Switch (Right Lever) 4‐31
4253 Parking Brake 4‐32
4254 Operating Mode Indicator 4‐32
4255 High Beam 4‐33
4256 Damping Lock On Indicator 4‐33
4257 Park/Work/Travel Mode Select Button 4‐33
4258 Warning Light Switch 4‐34
4259 Damping Cylinder Lock switch 4‐34
426 Top Window 4‐35
427 Windshield 4‐36
428 Cabin Windows and Doors 4‐42
Operation and Maintenance Manual 11-2015
Contents SY155W Wheeled Hydraulic Excavator
VII
429 Cup Holder 4‐43
4210 Ash Tray 4‐43
4211 Document Storage 4‐43
4212 Beverage Holder 4‐44
4213 Emergency Exit 4‐44
4214 Fire extinguisher 4‐45
4215 Controller 4‐45
4216 Fuse link 4‐45
4217 Air Conditioning System 4‐46
42171 Control panel 4‐46
4218 Radio 4‐48
42181 Control panel 4‐48
42182 Control buttons and LCD display 4‐48
42183 Radio Operations 4‐50
4219 Door lock 4‐53
4220 Lockable cover 4‐53
42201 Open and close the lockable lid 4‐54
42202 Opening and closing lockable cover 4‐55
43 Operation and control of the machine 4‐56
431 Before start the engine 4‐56
4311 Inspection 4‐56
4312 Check before the start of the engine 4‐57
4313 Adjustment before operation 4‐65
4314 Operation before start the engine 4‐70
432 Start the engine 4‐71
433 Engine preheating 4‐74
434 Warming‐up operation 4‐75
435 Machine operation 4‐76
4351 Turn off the engine 4‐76
4352 Machine walking 4‐78
4353 Working device control and operation 4‐86
436 Prohibited operations 4‐88
437 The maximum of water depth during operating 4‐91
438 Operating on slopes 4‐92
4381 Engine stalled on the slopes 4‐93
4382 The operation of cab door on slopes 4‐93
Operation and Maintenance Manual 11-2015
SY155W Wheeled Hydraulic Excavator Safety
VII
439 Recommended use 4‐94
4391 Back shovel operation 4‐94
4392 Trenching 4‐95
4393 Loading 4‐95
4310 Parking 4‐96
4311 Check the machine after daily work 4‐98
4312 Locking 4‐99
4313 Cold weather operation 4‐100
43131 Cold weather operation instruction 4‐100
43132 After daily work completed 4‐101
43133 After the cold season 4‐101
4314 Long‐term storage 4‐102
43141 Before storing the machine 4‐102
43142 During the storing period 4‐102
43143 After the storing period 4‐103
43144 Start the engine after long storage 4‐103
44 Transportation4‐104
441 Drive on a road 4‐104
442 Transport method 4‐104
443 Trailers for loading and unloading machine 4‐104
4431 Loading 4‐105
4432 Fix the machine 4‐108
4433 Unloading 4‐110
5 Maintenance
51 Maintenance guide 5‐3
52 oil, fuel and coolant 5‐5
521 oil 5‐5
522 fuel 5‐5
523 coolant 5‐6
524 grease 5‐7
525 oil and fuel storage 5‐7
526 filters 5‐8
53 electrical system 5‐8
54 wear parts 5‐9
Operation and Maintenance Manual 11-2015
Safety SY155W Wheeled Hydraulic Excavator
IX
55 recommended fuel, coolant and lubricant 5‐10
56 tightening torque table 5‐14
57 safety critical parts 5‐16
58 maintenance schedule 5‐17
59 maintenance procedures 5‐19
591 initial 50 hours of operation (only the first 50 hours) 5‐19
592 Check and tighten the nut 5‐19
5921 Check and tighten the nut of wheel 5‐19
5922 Check and tighten the nut of transmission axle 5‐19
5923 Bucket – replace 5-20
596 every 500 service hours 5‐51
5961 swing bearing lubricate 5‐51
5962 engine pan oil and filter element‐change/replacement 5‐52
5963 Swing pinion gear grease level ‐ inspect/fill 5‐54
5964 Primary fuel filter element ‐replace 5‐55
5965 Secondary fuel filter element ‐ replace 5‐58
Operation and Maintenance Manual 11-2015
5924 Bucket tips – replace 5-23
5925 Bucket clearance – adjust 5-25
5926 Window washer fluid level – check/fill 5-27
5927 Refrigerant level – check 5-28
5928 Ceiling window gas spring – inspect 5-30
593 Check and tighten the nut 5‐32
594 Every 100 service hours 5‐33
5941 Lubricationt 5-33
5942 Blade lubrication 5-36
595 Every 250 service hours 5‐41
5951 Air filter element – inspect/clean/replace 5-41
5952 Compressor belt tension – inspect/adjust 5-44
5953 Check the vehicle axle and gearbox ,oil level, add oil and check
the front and rear wheel axle oil 5-45
5954 Lubricate the transmission shaftt 5-48
5955 Lubricate front axle oscillating shaft 5-49
5956 Lubrication front axle rotating hinge point 5-50
SY155W Wheeled Hydraulic Excavator Safety
X
599 every 4000 service hours 5‐80
5991 water pumps inspection 5‐80
5992 starting motor inspection 5‐80
5994 accumulator replace 5‐83
5995 High-pressure tube clamps and rubber – check5-84
5996 Compressor working condition – inspect 5‐85
5910 every 8000 service hours 5‐85
59101 high pressure pipe clamp‐replace 5‐85
5911 every 10000 service hours 5‐85
Operation and Maintenance Manual 11-2015
5965 Secondary fuel filter element ‐ replace 5‐58
5966 Radiator and oil cooler fins ‐ inspect/clean 5‐60
5967 Air conditioner fresh air/recirculation filter ‐ clean 5‐62
5968 Swing drive oil level ‐ check/fill 5‐64
597 every 1000 service hours5‐65
5971 Hydraulic oil suction filter element ‐ replace 5‐65
5972 Swing drive oil ‐ change 5‐67
5973 Cab door lock and front window lock catch ‐ inspect/tighten 5‐68
5974 Cab door hinge and front window slide rail ‐ inspect/add grease 5‐69
5975 Windshield wiper arm nut ‐ Inspect/tighten 5‐70
5976 Engine exhaust pipe clamps ‐ check 5‐70
5977 Fan belt tension ‐ check/replace 5‐70
5978 Nitrogen pressure in accumulator (breaker) ‐ check 5‐70
5979 Breather valve – service 5‐71
598 every 2000 service hours 5‐72
5981 Hydraulic oil suction filter element – clean/replace 5‐72
5982 Nitrogen pressure in accumulator ‐ check 5‐73
5983 Cooling system interior ‐ clean 5‐77
5984 Alternator ‐ inspect 5‐79
5985 Engine valve clearance ‐ check/adjust 5‐79
5993 Hydraulic tank oil – change 5‐80
Safety SY155W Wheeled Hydraulic Excavator
XI Operation and Maintenance Manual 11-2015
6 Troule-shootingg
61 about trouble shooting 6‐2
62 trouble shooting preparation 6‐3
622 trouble shooting precautions 6‐4
623 precautions on electrical circuits trouble‐shooting 6‐6
624 precautions on handling hydraulic components 6‐7
63 engine failures 6‐9
631 engine troubleshooting table 6‐9
632 coolant temperature high 6‐14
633 engine oil pressure low 6‐15
634 when fuels run out 6‐16
635 when engine rotates reversely 6‐17
64 Failures of the electrical system 6‐18
641 electrical system trouble shooting table 6‐18
642 failure codes on monitor 6‐22
643 battery 6‐24
6431 battery removal and installation 6‐24
6432 battery charging 6‐25
65 failures of hydraulic system 6‐29
66 other common failures 6‐33
6433 start engine with auxiliary cables 6‐26
621 check before trouble shooting 6‐3
Safety
1-1
Foreword
1 Foreword
11 Overview 1‐3
12 Safety information 1‐5
13 Page instruction 1‐7
14 Brief introduction1‐7
141 Machine directions1‐8
15 Machine information1‐9
151 Product identification plate1‐9
152 Engine identification plate 1‐10

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