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

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

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

1 Introduction
11 Overview 1-3
12 Your Documentation Package 1-4
121 Recommendations on using the documentation 1-5
122 Documentation storage 1-5
123 Manual organization 1-5
1231 Introduction 1-6
1232 Safety 1-6
1233 System functions 1-6
1234 Operation 1-6
1235 Maintenance 1-6
1236 Troubleshooting 1-7
1237 Specifications 1-7
1238 Optional Equipment 1-7
124 Page numbers 1-7
13 Your Sany Machine 1-8
131 Machine applications 1-8
132 Machine directions 1-8
133 Breaking in a new machine 1-9
134 Machine information 1-9
1341 Product identification plate 1-9
1342 Engine identification plate 1-10
1343 Right and left drive motors 1-11
1344 Swing motor 1-11
1345 Hydraulic pump 1-11
1346 Chassis serial number 1-12
1347 Machine monitor 1-12
14 Table for serial number and distributor information 1-13
15 Correction Request Form – Technical Publications 1-14
16 Contact Information 1-15
2 Safety
21 Safety Information 2-5
22 Safety Messages 2-7
Table of Contents
Table of Contents
Safety, Operation and Maintenance II Manual – Sep 2012
SY115C9/135C/155H Crawler Hydraulic Excavator
221 Hazard alert wording 2-8
222 Other alert wording 2-9
223 Safety decals 2-9
2231 Textual safety decals 2-10
2232 Graphical safety decals 2-10
2233 Safety decal locations 2-11
23 General Precautions 2-19
231 Safety rules 2-19
232 Abnormalities 2-19
233 Personal protective equipment 2-19
234 Fire extinguisher and first aid kit 2-21
235 Safety equipment 2-21
236 Cleaning your machine 2-22
237 Keeping the cab clean 2-23
238 Engaging the hydraulic lockout control 2-23
239 Handholds and steps 2-24
2310 Overhead work 2-25
2311 No sitting on attachment 2-25
2312 Articulated parts 2-25
2313 Preventing burns 2-25
23131 Hot coolant 2-25
23132 Hot oil 2-26
2314 Preventing fire and explosion 2-26
23141 Fire caused by fuel or oils 2-26
23142 Fire caused by flammable materials 2-27
23143 Fire caused by electric lines 2-27
23144 Fire caused by hydraulic lines 2-28
23145 Fire caused by illumination equipment 2-28
23146 Fire caused by heat shield 2-28
2315 In the event of fire 2-28
2316 Windshield cleaning detergent 2-29
2317 Preventing ejection of part 2-29
2318 Falling object protection 2-30
2319 Attachment installation 2-30
2320 Attachment combination 2-31
2321 Cab windows glasses 2-31
Table of Contents
Safety, Operation and Maintenance Manual – Sep 2012 III
SY115C9/135C/155H Crawler Hydraulic Excavator
2322 Unauthorized modification 2-31
2323 Job site investigation 2-31
2324 Operation on soft ground 2-32
2325 Overhead power cables 2-33
2326 Ensuring a good visibility 2-34
2327 Ventilating enclosed area 2-35
2328 Asbestos hazard 2-35
2329 Alternate exit 2-36
24 Safe Operation Precautions 2-37
241 Safe starting 2-37
2411 Safe mounting 2-37
2412 Seat adjustment 2-38
2413 Seat belt 2-38
2414 Before starting the engine 2-38
2415 Engine starting rules 2-39
2416 Safe starting 2-39
2417 Starting engine in cold season 2-40
2418 Engine starting aid 2-40
2419 After starting the engine 2-41
242 Operation 2-42
2421 Inspection before operation 2-42
2422 Prior-operation precautions 2-42
2424 Travel directions 2-43
2423 Rules for steering safety 2-43
2425 Rules for traveling safety 2-45
2426 Safe traveling 2-46
2427 Operation on an incline 2-47
2428 Operation in snowy weather 2-48
2429 Restricted operations 2-48
243 Parking the machine 2-51
2431 Select a parking place 2-51
2432 Machine shutdown 2-51
244 Transportation 2-52
2441 Loading and unloading the machine 2-52
2442 Transporting the machine 2-53
245 Battery 2-54
Table of Contents
Safety, Operation and Maintenance IV Manual – Sep 2012
SY115C9/135C/155H Crawler Hydraulic Excavator
246 Lifting objects with the machine 2-56
25 Precautions for Maintenance 2-57
251 Prior-maintenance precautions 2-57
252 Select a working area 2-57
253 Preparing the machine 2-58
254 Preparing yourself 2-59
255 Lock-out and tag-out 2-60
256 Using proper tools 2-60
257 Maintenance with engine running 2-61
258 Working under the machine 2-61
259 Track maintenance 2-62
2510 Track tension adjustment precautions 2-63
2511 Recoil spring 2-63
2512 Welding operation 2-64
2513 High-pressure hoses 2-64
2514 Pressurized fluid 2-65
2515 Hot cooling system 2-66
2516 Air-conditioning system 2-66
2517 High voltage precautions 2-67
2518 Accumulator 2-67
2519 Avoiding fire and explosion 2-68
2520 Regular replacement of safety-related parts 2-69
2521 Maintenance operation 2-70
2522 Proper disposal of wastes 2-71
3 System Functions
31 Machine Overview 3-5
32 Machine Controls 3-6
33 Monitor 3-7
331 Monitor introduction 3-7
332 System information and operation 3-10
3321 Main Page 3-10
3322 System Information 3-12
3323 Time Setup 3-13
3324 Main Menu 3-14
3325 Engine & Throttle Signals 3-15
Table of Contents
Safety, Operation and Maintenance Manual – Sep 2012 V
SY115C9/135C/155H Crawler Hydraulic Excavator
3326 Main Pump Signals 3-15
3327 Input Switch Signals 3-16
3328 Output Switch Signals 3-16
3329 Machine Configuration 3-17
33210 Failure codes 3-17
33211 Maintenance Information 3-18
33212 Engine Speed Calibration 3-23
33213 Language Selection 3-25
33214 GPS Monitoring Information 3-26
33215 System Setup 3-27
33216 Machine configuration setup 3-28
33217 Coolant Temperature 3-29
33218 Service Call 3-30
34 Switches 3-31
3421 Start switch 3-32
3422 Fuel control dial 3-33
3423 Work lamp switch 3-33
3424 Wiper switch 3-35
3425 Washer switch 3-36
3426 Head lamp switch 3-36
3427 Horn switch 3-37
3428 Cab lamp 3-37
3429 Cigar lighter 3-37
34210 Preheat switch (only for SY135C8M) 3-38
34211 Alternator indicator 3-38
35 Control levers and pedals 3-39
351 Hydraulic lockout control 3-40
352 Travel controls 3-41
353 Joystick controls 3-42
36 Roof Hatch 3-44
361 Opening the roof hatch 3-44
362 Closing the roof hatch 3-44
37 Windshield 3-45
371 Opening the window 3-45
372 Closing the window 3-48
373 Removing the lower window 3-50
Table of Contents
Safety, Operation and Maintenance VI Manual – Sep 2012
SY115C9/135C/155H Crawler Hydraulic Excavator
38 Alternate Exit 3-51
39 Door Catch 3-52
310 Cover/cap with a Latch 3-52
3101 Opening/closing the cover with lock 3-53
3102 Opening/closing the cap with lock 3-54
311 Cup Holder 3-55
312 Storage Box 3-56
313 Literature Bag 3-56
314 Ashtray 3-57
315 Air Conditioning System 3-58
3151 Control panel 3-58
3152 Operation method 3-64
3153 A/C operation precautions 3-72
316 Radio 3-74
3161 Control panel 3-74
3162 Radio operation 3-76
317 Auxiliary Power Supply 3-80
318 Fuses 3-80
319 Fusible Link 3-81
320 Controller 3-82
321 Toolbox 3-82
322 Grease pump frame 3-82
323 Fire extinguisher 3-83
4 Operation
41 Before Starting the Engine 4-5
411 Routine checks 4-5
412 Checks before starting 4-7
4121 Fuel tank – check/drain 4-7
4122 Water separator – check/drain 4-7
4123 Drain valve – regulate 4-8
4124 Hydraulic oil – check/refill 4-9
4125 Coolant – check/refill 4-10
4126 Oil in engine oil pan – check/refill 4-11
4127 Electric wires – check 4-12
4128 Fuel tank – check/refuel 4-13
Table of Contents
Safety, Operation and Maintenance Manual – Sep 2012 VII
SY115C9/135C/155H Crawler Hydraulic Excavator
4129 Work lamp switch – check 4-14
41210 Horn – check 4-15
413 Adjustment before operation 4-15
4131 Operator seat 4-15
4132 Rear view mirrors 4-17
4133 Seat belt 4-19
414 Before Starting the Engine 4-20
42 Engine Starting 4-22
421 Engine Preheating 4-25
422 Warm-up operation 4-26
423 Selecting a working mode 4-26
43 Engine Shutdown 4-27
44 Machine Operation 4-28
441 Before moving the machine 4-28
442 Moving the machine forward 4-29
443 Moving the machine backward 4-30
444 Parking the machine 4-31
45 Steering Operation 4-32
4541 Steering with travel controls 4-32
4542 Steering with machine stopped 4-32
4543 Steering during traveling 4-33
4544 Pivot turn 4-33
451 Swing operation 4-34
46 Work Equipment Control and Operation 4-35
47 Working mode 4-37
48 Restricted Operations 4-38
481 Operation with swinging force 4-38
482 Operation with traveling force 4-38
483 Operation when hydraulic cylinder reaches its stroke end 4-39
484 Operation with bucket landing force 4-39
485 Operation with machine weight 4-40
486 Hard rocky ground 4-40
487 Sudden shift of travel speed during fast traveling 4-41
49 General Operation 4-41
491 Traveling operation 4-41
492 High-speed travel 4-41
Table of Contents
Safety, Operation and Maintenance VIII Manual – Sep 2012
SY115C9/135C/155H Crawler Hydraulic Excavator
493 Permissible depth of water 4-42
410 Traveling on Slope 4-42
4101 Traveling downhill 4-44
4102 Engine stalls on an incline 4-44
4103 Cab door on an incline 4-44
411 Removing Machine from Mud 4-44
4111 One track trapped 4-44
4112 Both tracks trapped 4-45
412 Recommended Applications 4-45
4121 Backhoe operation 4-45
4122 Trench work 4-46
4123 Loading operation 4-46
413 Parking Operation 4-47
414 Checks after Each Workday 4-49
415 Locking the Machine 4-50
416 Operation in Cold Weather 4-50
4161 Operation instruction 4-50
41611 Fuel and lubricant 4-50
41612 Battery 4-51
4162 After each workday 4-52
4163 After cold season 4-53
417 Long-Term Storage 4-54
4171 Before storage 4-54
4172 During storage 4-55
4173 After storage 4-56
4174 Starting the engine after long-term storage 4-56
418 Transportation Information 4-57
4181 Transport methods 4-57
4182 Loading/unloading machine to/from a trailer 4-57
41821 Loading the machine 4-59
41822 Securing the machine 4-61
41823 Rear view mirrors 4-62
41824 Unloading the machine 4-63
4183 Lifting the machine or its components 4-65
41831 Lifting precautions 4-65
41832 Choosing a wire rope 4-66
Table of Contents
Safety, Operation and Maintenance Manual – Sep 2012 IX
SY115C9/135C/155H Crawler Hydraulic Excavator
41833 Lifting the machine 4-67
5 Maintenance
51 Maintenance Information 5-5
52 General Service 5-9
521 Oil, fuel and coolant 5-9
5211 Oil 5-9
5212 Fuel 5-10
5213 Coolant 5-11
522 Grease 5-12
523 Oil and fuel storage 5-13
524 Filter element 5-13
525 Electrical system 5-14
526 Hydraulic system 5-14
53 Replacement Parts 5-16
54 Recommended Fluids 5-17
541 Fluid capacities 5-19
542 Recommended oils: 5-20
55 Tightening Torque Specification 5-22
56 Safety-Related Parts 5-24
57 Maintenance Schedule 5-25
571 List of maintenance schedule 5-25
572 Hydraulic Breaker Service Interval 5-27
58 Maintenance Procedures 5-28
581 Maintenance after initial 50 service hours 5-28
5811 Engine oil and filter – change/replace 5-28
5812 Fuel filter – replace 5-28
582 When Required 5-29
5821 Air cleaner – clean/replace 5-29
5822 Cooling system – clean 5-37
5823 Track shoe bolts – inspect/tighten 5-41
5824 Track tension – inspect/adjust 5-42
5825 Bucket tips (lateral pin) – replace 5-45
5826 Bucket Replacement 5-47
5827 Bucket clearance – adjust 5-49
5828 Window washer fluid – check/refill 5-51
Table of Contents
Safety, Operation and Maintenance X Manual – Sep 2012
SY115C9/135C/155H Crawler Hydraulic Excavator
5829 Air conditioner – inspect/service 5-52
58210 Gas spring – inspect 5-54
58211 Air in hydraulic system – purge 5-55
58212 Hydraulic circuit internal pressure – release 5-58
583 Checks before starting 5-59
584 Every 100 service hours 5-60
5841 Lubrication 5-60
585 Every 250 service hours 5-63
5851 Compressor belt tension – inspect/adjust 5-63
5852 Oil in engine oil pan and oil filter – change/replace 5-65
5853 Primary fuel filter – replace 5-67
5854 Secondary fuel filter – replace 5-71
586 Every 500 service hours 5-74
5861 Swing bearing – lubricate 5-74
5862 Swing pinion gear grease – check/refill 5-75
5863 Coolant tank and radiator fins – inspect/clean 5-76
5864 Air conditioner filters – clean 5-77
5865 Swing drive oil – check/refill 5-80
5866 Final drive oil – check/fill 5-81
587 Every 1000 service hours 5-82
5871 Hydraulic oil filter – replace 5-82
5872 Swing drive oil – change 5-84
5873 Engine exhaust pipe clamps – check 5-85
5874 Fan belt tension – check/replace 5-85
5875 Nitrogen pressure in accumulator (breaker) – check 5-85
588 Every 2000 service hours 5-86
5881 Final drive oil – change 5-86
5882 Hydraulic tank filter screen – clean 5-88
5883 Nitrogen pressure in accumulator (control oil circuit) – check 5-89
5884 Hydraulic circuit internal pressure – release 5-92
5885 Oil in hydraulic tank – change 5-93
5886 Alternator – inspect 5-95
5887 Engine valve clearance – check/adjust 5-95
589 Every 4000 service hours 5-95
5891 Coolant pump – inspect 5-95
5892 Start motor – check 5-95
Table of Contents
Safety, Operation and Maintenance Manual – Sep 2012 XI
SY115C9/135C/155H Crawler Hydraulic Excavator
5893 Accumulator (control oil circuit) – replace 5-96
5894 High-pressure tube clamps and rubber – check 5-97
5895 Compressor working condition – inspect 5-97
5810 Every 8000 service hours 5-98
58101 High-pressure tube clamps – replace 5-98
5811 Every 10000 service hours 5-98
6 Troubleshooting
61 Troubleshooting Preparation 6-3
611 Checks before troubleshooting 6-3
612 Troubleshooting procedure 6-4
613 Troubleshooting precautions 6-6
614 Electrical circuits troubleshooting precautions 6-9
615 Hydraulic components handling precautions 6-10
62 Pseudo Failures 6-12
63 Towing the Machine 6-13
64 Towing Hook for Light Loads 6-15
65 Severe Operating Conditions 6-15
66 Engine Failures 6-16
661 Engine troubleshooting table 6-16
662 Coolant temperature high 6-19
663 Engine oil pressure low 6-20
664 When fuel exhausts 6-22
665 When engine rotates reversely 6-24
67 Failures of the Electrical System 6-25
671 Electrical system troubleshooting table 6-25
672 Failure codes 6-28
68 Battery 6-30
681 Battery removal and installation 6-30
682 Battery charging 6-31
683 Jump-starting the engine 6-32
6831 Connecting the jumper cables 6-33
6832 Starting the engine 6-34
6833 Disconnecting the jumper cables 6-34
69 Failures of the Hydraulic System 6-35
610 Other Common Failures 6-39
Table of Contents
Safety, Operation and Maintenance XII Manual – Sep 2012
SY115C9/135C/155H Crawler Hydraulic Excavator
7 Specifications
71 Machine Dimensions 7-3
72 Working Ranges 7-4
8 Optional Equipment
81 General Safety 8-3
811 Selection precautions 8-3
812 Reading the instruction books 8-3
813 Removal and installation precautions 8-3
814 Operation precautions 8-4
82 Hydraulic Control Elements and Oil Circuit 8-6
821 Location of the components 8-6
8211 Stop valve 8-6
8212 Selector valve 8-7
8213 Control pedal 8-7
822 Hydraulic circuit 8-8
8221 Hydraulic circuit switching 8-8
8222 Shifting to breaker / general optional equipment 8-8
8223 Connecting hydraulic oil circuit 8-9
8224 Hydraulic oil passage 8-10
823 Optional equipment removal and installation 8-11
8231 Removal 8-11
8232 Optional equipment installation 8-13
824 Hydraulic oil and hydraulic tank filter – change/replace 8-15
825 Long-term storage 8-16
826 Hydraulic specifications 8-16
83 Optional equipment Guide 8-17
831 Work equipment combination 8-17
832 Bucket tips selection 8-19
8321 Rockwork bucket tips 8-19
8322 Earthwork bucket tips 8-19
84 Recommended Operations 8-20
841 Hydraulic breaker 8-20
842 Hydraulic breaker operation 8-21
85 Restricted Operations 8-22
86 Hydraulic Breaker Lubrication 8-25
Table of Contents
Safety, Operation and Maintenance Manual – Sep 2012 XIII
SY115C9/135C/155H Crawler Hydraulic Excavator
87 Quick Coupler and Control System 8-26
871 Quick coupler installation 8-26
872 Operating precautions 8-28
88 Refueling System 8-29
881 Introduction 8-29
882 Components 8-30
89 Central Lubrication System 8-31
891 Scheme and components 8-31
892 System working principle 8-33
893 Setting the lubrication time of electric grease pump 8-34
894 Technical description 8-35
895 Adding grease with electric pump 8-36