SANY SY500H - User Manual

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SY500H Excavator

Operation and Maintenance Manual

SANY Part Number SSY005084272

Main Page

Table of Contents5
Introduction16
About this Manual16
Documentation Package16
Operation and Maintenance Manual16
Parts Manual16
Maintenance Log16
Organization of this Manual17
Introduction17
Safety17
Machine Controls17
Machine Operation17
Maintenance17
Specifications17
Optional Equipment17
Machine Applications17
Machine Directions17
Serial Number Locations18
Product Identification Plate18
Frame Serial Number18
Swing Motor Identification Plate18
Engine Identification Plate18
Main Control Valve Identification Plate19
Hydraulic Pump Identification Plate19
Travel Motor Identification Plate19
SANY Contact Information20
Glossary of Acronyms20
Record of Serial Number and Dealer Information21
Correction Request Form22
Safety23
General Safety24
Hazard Alerts in this Manual24
Operator Safety Information24
Mount and Dismount the Machine25
Machine Safety25
Authorized Use of this Machine25
Unauthorized Use of this Machine25
Unauthorized Machine Modifications25
Escape Tool25
Fire Safety25
Electrical Fires25
Fire Extinguisher26
In Case of Fire26
Crushing Hazard26
Diesel Engine Exhaust26
Machine Decals26
Maintenance Safety26
Lockout/Tagout Procedure27
Clean the Machine27
Fluid Systems27
Adding Fluids to the Machine27
Refueling27
High-Pressure Fluid Lines27
Accumulator27
Electrical System27
Battery Safety27
Disconnect the Battery28
Job Safety28
Personal Protective Equipment (PPE)28
Hearing Protection28
Travel and Operation Precautions28
Inclined Areas28
Snow or Frozen Surfaces28
Avoid Backover Accidents29
Dust and Chemical Hazards29
Environmental Precautions29
Precautions in High-Voltage Areas29
Machine Controls31
Exterior Components34
Seat and Seat Belt35
Headrest35
Seat Heater35
Lumbar Adjustment35
Armrest Angle Adjustment35
Backrest Angle Adjustment35
Seat Belt35
Buckle the Seat Belt35
Unbuckle the Seat Belt35
Seat and Console Adjustment Lever36
Weight Adjustment36
Seat Forward and Backward Adjustment36
Seat Cushion Adjustments36
Emergency Stop Switch36
Operator Controls37
Left Control Console38
Hydraulic Lockout Control Lever38
Left Joystick39
Climate Control Panel40
Climate Control System Operation40
OFF Button40
Fan Speed Control Switch40
Temperature Selection Control Switch40
Vent Mode Selection Button40
Automatic Temperature Control Selection Button40
Air Conditioning Power Button40
LCD Screen40
Fresh/Recirculated-Air Selection Buttons40
Radio Control Panel41
Radio Operation41
Universal Serial Bus (USB) Port41
Auto Scan/Preset Station (AS/PS) Button41
FM/AM Selector Button41
Audio Selection (SEL) Button41
Time Display/Time Set Button41
Liquid Crystal Display (LCD)42
Power Button42
Volume Control Buttons42
Tuning Buttons42
Antenna42
Right Control Console42
Switches42
Right Joystick43
Key Switch43
Throttle Control Dial43
Stationary Regeneration Switch43
Regeneration Disable Switch44
Travel Alarm Silence Switch44
Work Light Switch44
Windshield Wiper Switch45
Windshield Washer Switch45
Headlight Switch45
Battery Disconnect Switch45
Batteries46
Monitor Console47
Power Supply Socket47
Cup/Ashtray47
Airflow Vents47
Sunlight Sensor47
Joystick Controls48
Left Joystick Buttons48
Right Joystick Buttons/Switch48
SAE/BHL Joystick Operating Modes48
Pattern Change (SAE/BHL) Valve48
SAE Mode49
BHL Mode50
Travel Controls51
Auto-Idle51
Stop Valve52
Return Flow Selector Valve52
Fuses and Relays53
Accessory Light Outlet (24V)53
Fuse and Relay Locations54
Monitor55
Home Screen55
Home Screen Display Icons56
Date and Time56
Hour Meter56
Fault Icon56
Periodic Maintenance Prompt56
Installed Equipment56
Engine Coolant Temperature Gauge56
Function Icons56
Function Buttons56
Engine Speed Gauge (Tachometer)56
System Service Icons57
Home Screen Function Icons and Buttons57
Main Menu Screen57
Password Screen59
Work Parameters Screens59
Maintenance Information Screen59
Error Codes Screen61
System Setting Menu Screen62
Date/Time Setting Screen63
Data Unit Setting Screen63
Screen Backlight Setting64
Time Format Setting Screen64
System Language Setup Screen65
Machine Configuration Screen66
Tool Select Screen66
Tool Icons66
Bucket66
Breaker67
Shear Tool67
Lifting Tool68
Quick Coupler Tool69
Machine Operation71
Work Area74
General Job Safety74
Operator Responsibilities74
Seat Belt Usage74
Operation and Maintenance Manual Check74
Daily Maintenance Record Check74
Cleaning the Machine74
Cleaning the Cab Interior75
New Machine Break-In75
Prestart Checks and Adjustments75
Electrical Components Check76
Lights and Warning Devices76
Access Doors, Panels, and Covers76
Cab Door76
Opening the Cab Door76
Closing the Cab Door77
Emergency Escape Hatch77
Access Door Support Rod77
Right Front Access Door78
Opening the Right Front Access Door78
Closing the Right Front Access Door78
Right Rear Access Door78
Opening the Right Rear Access Door78
Closing the Right Rear Access Door78
Left Rear Access Door78
Opening the Left Rear Access Door79
Closing the Left Rear Access Door79
Left Front Access Door79
Opening the Left Front Access Door79
Closing the Left Front Access Door79
Fuel Filler Cap79
Opening the Fuel Tank Filler Cap79
Closing the Fuel Tank Filler Cap79
Expansion Tank Access Door80
Opening the Expansion Tank Access Door80
Closing the Expansion Tank Access Door80
Fresh-Air Access Door80
Opening the Fresh-Air Access Door80
Closing the Fresh-Air Access Door80
Engine Access Door80
Opening the Engine Access Door80
Closing the Engine Access Door81
Cab Door Windows81
Windshield81
Opening the Windshield81
Closing the Windshield82
Lower the Front Windshield82
Cab Light83
Mirrors83
Backup Camera83
Monitor Settings84
First-Time Setup84
Access the Main Menu84
Language Selection84
System Clock Calibration85
Data Unit Setting85
Engine Start Procedure85
Cold Weather Start86
Machine Warm-Up87
Idling the Engine87
Engine Shutdown Procedure87
Cold Weather Operation87
Manual Regeneration87
Jump-Start the Engine88
Traveling Operations89
Before Traveling89
Track Direction90
Traveling with the Undercarriage Reversed90
Right Turn90
Left Turn90
Forward Travel91
Backward Travel91
Zero-Degree Rotation91
Left91
Right91
Operating on Inclines91
Operating in Water92
Releasing the Machine from Mud92
One Track Stuck92
Two Tracks Stuck92
Work Equipment Controls92
SAE Control Pattern93
Swing93
Arm93
Boom93
Bucket93
BHL Control Pattern94
Swing94
Arm94
Boom94
Bucket94
Recommended Applications95
Backhoe Operation95
Digging a Trench95
Loading Operations95
End of Workday Checks96
Parking and Storing the Machine96
Overnight Storage96
Short-Term Storage97
Long-Term Storage97
Preparation97
Maintenance During Storage98
Return to Service98
Transportation Information98
Counterweight Removal98
Counterweight Installation103
Lifting the Machine104
Loading the Machine104
Unloading the Machine106
Maintenance109
Maintenance Information112
Checks before Maintenance112
Checks after Maintenance or Repairs112
Hour Meter Reading112
Genuine SANY Replacement Parts112
SANY-Approved Lubricants112
Weld, Drill, Cut, or Grind on the Machine112
Clean Parts of the Machine112
Securing Access Covers and Compartment Doors113
Installation of Hydraulic Hoses113
Inspection and Maintenance in Adverse Environments113
Mud, Rain, or Snow Conditions113
Near Ocean (Salt Air) Environments113
Dusty Environment113
Rocky Ground Surface113
Cold Environments113
Other Weather Environments113
Fluids and Lubricants114
Location, Capacity, and Type114
Collect Oil Samples114
Engine Oil Viscosity/Temperature Data115
Lubricating Grease/Temperature Data115
Industrial Gear Oil/Temperature Data115
Hydraulic Oil/Ambient Temperature Data116
Diesel Exhaust Fluid (DEF)116
Engine Coolant116
Lubricants116
Grease116
Fuel117
Windshield Washer Fluid117
Hydraulic Oil Description117
Maintenance Schedule118
Daily Maintenance and Inspection118
When Required118
After the First 50 Hours118
Weekly or Every 50 Hours118
Every 100 Hours118
Every 250 Hours118
Every 3 Months or 500 Hours118
Every 6 Months or 1000 Hours119
Annually or Every 2000 Hours119
Hydraulic Breaker Maintenance Interval119
After Maintenance Is Completed119
Maintenance Procedures120
Engine120
Check the Crankcase Breather Tube120
Check the Engine Air Precleaner120
Check the Engine Air Filter System120
Replace the Engine Air Filter121
Check the Engine Oil Level122
Collect an Engine Oil Sample122
Replace the Engine Oil and Filter123
Check the Engine Belts125
Check the Alternator125
Check the Starter125
Check the Air Intake and the Charge Air Piping125
Cooling System126
Replace the Engine Coolant126
Check the Engine Coolant Level127
Check the Radiator, Charge Air Cooler, and Air Conditioner Condenser Fins128
Air Conditioning System129
Check the Air Conditioner129
Check the Air Conditioner Compressor Belt129
Adjust the Air Conditioner Compressor Belt129
Replace the Fresh-Air Filter130
Replace the Cab Recirculation Filter131
Exhaust System131
Check the Aftertreatment Exhaust Piping131
Check the Engine Exhaust Pipe Clamps131
Replace the Diesel Exhaust Fluid (DEF) Pump Filter132
Check the Diesel Exhaust Fluid (DEF)133
Fill the Diesel Exhaust Fluid (DEF) Tank133
Replace the Diesel Exhaust Fluid (DEF) Tank Filter134
Stationary Regeneration135
Fuel System136
Check the Fuel Level136
Check the Fuel Lines136
Drain the Fuel Tank136
Check the Fuel Tank Strainer136
Replace the Primary and Secondary Fuel Filter137
Drain the Primary Fuel Filter138
Hydraulic System138
Check the Accumulator Function138
Relieve Hydraulic System Pressure139
Collect a Hydraulic Oil Sample140
Replace the Case Drain Filter140
Check the Hydraulic Oil Level141
Check the Hydraulic Hoses141
Check the Hydraulic Hose/Line Connections142
Add Hydraulic Oil142
Replace Hydraulic Oil143
Replace the Hydraulic Pilot Filter Element145
Check the Hydraulic Pump146
Replace the Hydraulic System Breather Filter146
Check the Hydraulic Tank148
Replace the Hydraulic Tank Return Filter148
Clean the Hydraulic Suction Strainer149
Check the Pump Mounting Fasteners150
Electrical System151
Check the Batteries151
Replace the Battery151
Check the Fuses153
Check the Electrical System153
Check the Operating Functions153
Check the Backup Camera154
Final Drive154
Check the Final Drive154
Collect a Final Drive Oil Sample155
Check and Add Final Drive Oil155
Check the Final Drive Motor Mounting Fasteners155
Replace the Final Drive Oil156
Track Assemblies158
Check the Track Assemblies158
Check the Track Fasteners158
Check the Idler158
Check the Track Tension159
Increase the Track Tension160
Decrease the Track Tension160
Swing Drive161
Lubricate the Swing Bearing161
Check the Swing Bearing Fasteners161
Check the Swing Drive161
Collect a Swing Drive Oil Sample162
Replace the Swing Drive Oil162
Check the Swing Grease Bath Level163
Bucket164
Replace the Bucket164
Replace the Bucket Teeth165
Miscellaneous Procedures166
Check the Cab Door, Doors, and Locks166
Check the Cooling Fan166
Check the Decals166
Check the Escape Tool166
Check the Fire Extinguisher166
Check the Front Window Locks167
Check the Grab Handles and Steps167
Collect Oil Samples167
Check the Operation and Maintenance Manual167
Check the Seat Belt167
Check the Sheet Metal168
Structural Inspection168
Clean and Check the Upper Structure and Undercarriage168
Check the Windshield Washer Fluid168
Windshield Wiper169
Lubricate the Work Equipment170
Machine Storage171
Short-Term Storage (Less than 30 Days)171
Long-Term Storage (Longer than 30 Days)171
Specifications173
Machine Dimensions174
Operating Ranges176
Technical Specifications177
Lift Chart178
Lift Chart (Continued)179
Optional Equipment181
Optional Equipment Selection182
Read Equipment Instructions182
Removal and Installation Precautions182
Operation Precautions182
Equipment Control Valves183
Stop Valves183
Return Flow Selector Valve184
Optional Equipment Controls184
Right and Left Joystick184
Monitor184
Install Optional Equipment185
Remove Optional Equipment186

Brand	SANY
Model	SY500H
Category	Excavators
Language	English

SANY SY500H - User Manual

Table of Contents

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