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SY135C9
SANY SY135C9 - User Manual
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SANY HEAVY MACHINERY LIMITED
www.sanygroup.com
Quailty Changes the World
Crawler Hydraulic
Excavator
SY1
15C9
SY135C8
SY135C9
SY155H
Safety
, Operation and Manitenance Manual
318A, Lianggang
Avenue, Lingang Industrial Park, Fengxian District,
Shanghai, P
.R. of China 201413
T
el: (86) 21 5700 8518
Service hotline:(86) 4006 098 318
E-mail: crd@sany
.com.cn
Documentation No.: B06T01ENAM1-SY1
15C9/135C/155H
11644389
2
Table of Contents
Main Page
Default Chapter
4
Table of Contents
4
1 Introduction
18
Overview
20
Introduction
20
Your Documentation Package
21
Recommendations on Using the Documentation
22
Documentation Storage
22
Manual Organization
22
Introduction
23
Safety
23
System Functions
23
Operation
23
Maintenance
23
Troubleshooting
24
Specifi Cations
24
Optional Equipment
24
Page Numbers
24
Your Sany Machine
25
Machine Applications
25
Machine Directions
25
Breaking in a New Machine
26
Machine Information
26
Product Identifi Cation Plate
26
Engine Identifi Cation Plate
27
Right and Left Drive Motors
28
Swing Motor
28
Hydraulic Pump
28
Chassis Serial Number
29
Machine Monitor
29
Table for Serial Number and Distributor Information
30
Correction Request Form - Technical Publications
31
Contact Information
32
2 Safety
34
Safety Information
38
Safety
38
Safety Messages
40
Hazard Alert Wording
41
Other Alert Wording
42
Safety Decals
42
Textual Safety Decals
43
Graphical Safety Decals
43
Safety Decal Locations
44
General Precautions
52
Safety Rules
52
Abnormalities
52
Personal Protective Equipment
52
Fire Extinguisher and Fi Rst Aid Kit
54
Safety Equipment
54
Cleaning Your Machine
55
Keeping the Cab Clean
56
Engaging the Hydraulic Lockout Control
56
Handholds and Steps
57
Overhead Work
58
No Sitting on Attachment
58
Articulated Parts
58
Preventing Burns
58
Hot Coolant
58
Hot Oil
59
Preventing Fi Re and Explosion
59
Fire Caused by Fuel or Oils
59
Fire Caused by Fl Ammable Materials
60
Fire Caused by Electric Lines
60
Fire Caused by Hydraulic Lines
61
Fire Caused by Illumination Equipment
61
Fire Caused by Heat Shield
61
In the Event of Fi Re
61
Windshield Cleaning Detergent
62
Preventing Ejection of Part
62
Falling Object Protection
63
Attachment Installation
63
Attachment Combination
64
Cab Windows Glasses
64
Unauthorized Modifi Cation
64
Job Site Investigation
64
Operation on Soft Ground
65
Overhead Power Cables
66
Ensuring a Good Visibility
67
Ventilating Enclosed Area
68
Asbestos Hazard
68
Alternate Exit
69
Safe Operation Precautions
70
Safe Starting
70
Safe Mounting
70
Seat Adjustment
71
Seat Belt
71
Before Starting the Engine
71
Engine Starting Rules
72
Safe Starting
72
Starting Engine in Cold Season
73
Engine Starting Aid
73
After Starting the Engine
74
Operation
75
Inspection before Operation
75
Prior-Operation Precautions
75
Travel Directions
76
Rules for Steering Safety
76
Rules for Traveling Safety
78
Safe Traveling
79
Operation on an Incline
80
Operation in Snowy Weather
81
Restricted Operations
81
Parking the Machine
84
Select a Parking Place
84
Machine Shutdown
84
Transportation
85
Loading and Unloading the Machine
85
Transporting the Machine
86
Battery
87
Lifting Objects with the Machine
89
Precautions for Maintenance
90
Prior-Maintenance Precautions
90
Select a Working Area
90
Preparing the Machine
91
Preparing Yourself
92
Lock-Out and Tag-Out
93
Using Proper Tools
93
Maintenance with Engine Running
94
Working under the Machine
94
Track Maintenance
95
Track Tension Adjustment Precautions
96
Recoil Spring
96
Welding Operation
97
High-Pressure Hoses
97
Pressurized Fl Uid
98
Hot Cooling System
99
Air-Conditioning System
99
High Voltage Precautions
100
Accumulator
100
Avoiding Fi Re and Explosion
101
Regular Replacement of Safety-Related Parts
102
Maintenance Operation
103
Proper Disposal of Wastes
104
3 System Functions
106
Machine Overview
110
System Functions
110
Machine Controls
111
Monitor
112
Monitor Introduction
112
System Information and Operation
115
Main Page
115
System Information
117
Time Setup
118
Main Menu
119
Engine & Throttle Signals
120
Main Pump Signals
120
Input Switch Signals
121
Output Switch Signals
121
Machine Confi Guration
122
Failure Codes
122
Maintenance Information
123
Engine Speed Calibration
128
Language Selection
130
GPS Monitoring Information
131
System Setup
132
Machine Confi Guration Setup
133
Coolant Temperature
134
Service Call
135
Switches
136
Start Switch
136
Fuel Control Dial
138
Work Lamp Switch
138
Wiper Switch
140
Washer Switch
141
Head Lamp Switch
141
Horn Switch
142
Cab Lamp
142
Cigar Lighter
142
Preheat Switch (Only for SY135C8M)
143
Alternator Indicator
143
Control Levers and Pedals
144
Hydraulic Lockout Control
145
Travel Controls
146
Joystick Controls
147
Roof Hatch
149
Opening the Roof Hatch
149
Closing the Roof Hatch
149
Windshield
150
Opening the Window
150
Closing the Window
153
Removing the Lower Window
155
Alternate Exit
156
Door Catch
157
Cover/Cap with a Latch
157
Opening/Closing the Cover with Lock
158
Opening/Closing the Cap with Lock
159
Cup Holder
160
Storage Box
161
Literature Bag
161
Ashtray
162
Air Conditioning System
163
Control Panel
163
Operation Method
169
A/C Operation Precautions
177
Radio
179
Control Panel
179
Radio Operation
181
Auxiliary Power Supply
185
Fuses
185
Fusible Link
186
Controller
187
Toolbox
187
Grease Pump Frame
187
Fire Extinguisher
188
4 Operation
190
Before Starting the Engine
194
Routine Checks
194
Operation
194
Checks before Starting
196
Fuel Tank - Check/Drain
196
Water Separator - Check/Drain
196
Drain Valve - Regulate
197
Hydraulic Oil - Check/Refi Ll
198
Coolant - Check/Refi Ll
199
Oil in Engine Oil Pan - Check/Refi Ll
200
Electric Wires - Check
201
Fuel Tank - Check/Refuel
202
Work Lamp Switch - Check
203
Horn - Check
204
Adjustment before Operation
204
Operator Seat
204
Rear View Mirrors
206
Seat Belt
208
Before Starting the Engine
209
Engine Starting
211
Engine Preheating
214
Warm-Up Operation
215
Selecting a Working Mode
215
Engine Shutdown
216
Machine Operation
217
Before Moving the Machine
217
Moving the Machine Forward
218
Moving the Machine Backward
219
Parking the Machine
220
Steering Operation
221
Steering with Travel Controls
221
Steering with Machine Stopped
221
Steering During Traveling
222
Pivot Turn
222
Swing Operation
223
Work Equipment Control and Operation
224
Working Mode
226
Restricted Operations
227
Operation with Swinging Force
227
Operation with Traveling Force
227
Operation When Hydraulic Cylinder Reaches Its Stroke End
228
Operation with Bucket Landing Force
228
Operation with Machine Weight
229
Hard Rocky Ground
229
Sudden Shift of Travel Speed During Fast Traveling
230
General Operation
230
Traveling Operation
230
High-Speed Travel
230
Permissible Depth of Water
231
Traveling on Slope
231
Traveling Downhill
233
Engine Stalls on an Incline
233
Cab Door on an Incline
233
Removing Machine from Mud
233
One Track Trapped
233
Both Tracks Trapped
234
Recommended Applications
234
Backhoe Operation
234
Trench Work
235
Loading Operation
235
Parking Operation
236
Checks after each Workday
238
Locking the Machine
239
Operation in Cold Weather
239
Operation Instruction
239
Fuel and Lubricant
239
Battery
240
After each Workday
241
After Cold Season
242
Long-Term Storage
243
Before Storage
243
During Storage
244
After Storage
245
Starting the Engine after Long-Term Storage
245
Transportation Information
246
Transport Methods
246
Loading/Unloading Machine To/From a Trailer
246
Loading the Machine
248
Securing the Machine
250
Rear View Mirrors
251
Unloading the Machine
252
Lifting the Machine or Its Components
254
Lifting Precautions
254
Choosing a Wire Rope
255
Lifting the Machine
256
5 Maintenance
260
Maintenance Information
264
Maintenance
264
General Service
268
Oil, Fuel and Coolant
268
Oil
268
Fuel
270
Coolant
270
Grease
271
Oil and Fuel Storage
272
Filter Element
272
Electrical System
273
Hydraulic System
273
Replacement Parts
275
Recommended Fluids
276
Fluid Capacities
278
Recommended Oils
279
Tightening Torque Specifi Cation
281
Safety-Related Parts
283
Maintenance Schedule
284
List of Maintenance Schedule
284
Hydraulic Breaker Service Interval
286
Maintenance Procedures
287
Maintenance after Initial 50 Service Hours
287
Engine Oil and Fi Lter - Change/Replace
287
Fuel Fi Lter - Replace
287
When Required
288
Air Cleaner - Clean/Replace
288
Cooling System - Clean
296
Track Shoe Bolts - Inspect/Tighten
300
Track Tension - Inspect/Adjust
301
Bucket Tips (Lateral Pin) - Replace
304
Bucket Replacement
306
Bucket Clearance - Adjust
308
Window Washer Fl Uid - Check/Refi Ll
310
Air Conditioner - Inspect/Service
311
Gas Spring - Inspect
313
Air in Hydraulic System - Purge
314
Hydraulic Circuit Internal Pressure - Release
317
Checks before Starting
318
Every 100 Service Hours
319
Lubrication
319
Every 250 Service Hours
322
Compressor Belt Tension - Inspect/Adjust
322
Oil in Engine Oil Pan and Oil Fi Lter - Change/Replace
324
Primary Fuel Fi Lter - Replace
326
Secondary Fuel Fi Lter - Replace
330
Every 500 Service Hours
333
Swing Bearing - Lubricate
333
Swing Pinion Gear Grease - Check/Refi Ll
334
Coolant Tank and Radiator Fi Ns - Inspect/Clean
335
Air Conditioner Fi Lters - Clean
336
Swing Drive Oil - Check/Refi Ll
339
Final Drive Oil - Check/Fi Ll
340
Every 1000 Service Hours
341
Hydraulic Oil Fi Lter - Replace
341
Swing Drive Oil - Change
343
Engine Exhaust Pipe Clamps - Check
344
Fan Belt Tension - Check/Replace
344
Nitrogen Pressure in Accumulator (Breaker) - Check
344
Every 2000 Service Hours
345
Final Drive Oil - Change
345
Hydraulic Tank Fi Lter Screen - Clean
347
Nitrogen Pressure in Accumulator (Control Oil Circuit) - Check
348
Hydraulic Circuit Internal Pressure - Release
351
Oil in Hydraulic Tank - Change
352
Alternator - Inspect
354
Engine Valve Clearance - Check/Adjust
354
Every 4000 Service Hours
354
Coolant Pump - Inspect
354
Start Motor - Check
354
Accumulator (Control Oil Circuit) - Replace
355
High-Pressure Tube Clamps and Rubber - Check
356
Compressor Working Condition - Inspect
356
Every 8000 Service Hours
357
High-Pressure Tube Clamps - Replace
357
Every 10000 Service Hours
357
6 Troubleshooting
362
Troubleshooting Preparation
362
Checks before Troubleshooting
362
Troubleshooting Procedure
363
Troubleshooting Precautions
365
Electrical Circuits Troubleshooting Precautions
368
Hydraulic Components Handling Precautions
369
Pseudo Failures
371
Towing the Machine
372
Towing Hook for Light Loads
374
Severe Operating Conditions
374
Engine Failures
375
Engine Troubleshooting Table
375
Coolant Temperature High
378
Engine Oil Pressure Low
379
When Fuel Exhausts
381
When Engine Rotates Reversely
383
Failures of the Electrical System
384
Electrical System Troubleshooting Table
384
Failure Codes
387
Battery
389
Battery Removal and Installation
389
Battery Charging
390
Jump-Starting the Engine
391
Connecting the Jumper Cables
392
Starting the Engine
393
Disconnecting the Jumper Cables
393
Failures of the Hydraulic System
394
Other Common Failures
398
7 Specifi Cations 7.1 Machine Dimensions
402
Working Ranges
405
8 Optional Equipment
410
General Safety
410
Selection Precautions
410
Reading the Instruction Books
410
Removal and Installation Precautions
410
Optional Equipment
410
Operation Precautions
411
Hydraulic Control Elements and Oil Circuit
413
Location of the Components
413
Stop Valve
413
Selector Valve
414
Control Pedal
414
Hydraulic Circuit
415
Hydraulic Circuit Switching
415
Shifting to Breaker / General Optional Equipment
415
Connecting Hydraulic Oil Circuit
416
Hydraulic Oil Passage
417
Optional Equipment Removal and Installation
418
Removal
418
Optional Equipment Installation
420
Hydraulic Oil and Hydraulic Tank Fi Lter - Change/Replace
422
Long-Term Storage
423
Hydraulic Specifi Cations
423
Optional Equipment Guide
424
Work Equipment Combination
424
Bucket Tips Selection
426
Rockwork Bucket Tips
426
Earthwork Bucket Tips
426
Recommended Operations
427
Hydraulic Breaker
427
Hydraulic Breaker Operation
428
Restricted Operations
429
Hydraulic Breaker Lubrication
432
Quick Coupler and Control System
433
Quick Coupler Installation
433
Operating Precautions
435
Refueling System
436
Introduction
436
Components
437
Central Lubrication System
438
Scheme and Components
438
System Working Principle
440
Setting the Lubrication Time of Electric Grease Pump
441
Technical Description
442
Adding Grease with Electric Pump
443
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SANY SY135C9 Specifications
General
Operating Weight
13, 500 kg
Bucket Capacity
0.52 m³
Travel Speed
5.5 km/h
Gradeability
35°
Engine Model
Yanmar 4TNV98
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