SY335 Maintenance EN PDF

User Manual
Maintenance Manual
Hydraulic Excavator
SY335
V.01/2015
Contact
Sany Allee 1
50181 Bedburg
E-Mail service@sany-germany.de
Web: www.sany-germany.de
Tel.: -49 2272 90531 100
Fax: -49 2272 90531 109
Service Number: 00800 88888 318

Table of contents
3
Table of contents
2.4.4 Fire danger 20
1 Introduction 11
2.4.5 Dangers from lifting equipment 21
1.1 Foreword 11
2.5 Residual machine dangers 23
1.2 Structure of the instructions 11
2.6 Residual dangers from the machine en- 24
2 Safety 14
vironment
2.1 Intended use 14
2.6.1 Ground 24
2.2 Incorrect use 14
2.6.2 Power cables 24
2.3 Target group 15
2.6.3 Flammable / explosive environment 25
2.3.1 End user duties 15
2.6.4 Storms 26
2.3.2 Operator duties 15
2.6.5 Poor visibility 26
2.3.3 Duties of workshop / specialist personnel 16
2.6.6 Extreme climatic conditions 26
2.4 General dangers 17
2.7 Prevention 27
2.4.1 Mechanical dangers 17
2.7.1 Personal protective equipment 27
2.4.2 Hydraulic dangers 19
2.7.2 Explosion-proof lighting system 28
2.4.3 Electrical dangers 20
2.7.3 Arranging the workspace 29
Table of contents
4
2.8 Safety equipment 29 3.1.1 Display items and operation 41
2.8.1 Emergency stop 29 3.2 Entering the password 45
2.8.2 Emergency exit 30 3.3 Main menu 46
2.8.3 Safety lever 30 3.3.1 Selecting an option 46
2.8.4 Camera 31 3.3.2 Viewing machine status information 47
2.8.5 Visual and acoustic driver warning system 31 3.3.3 DPF information 48
2.8.6 Horn 31 3.3.4 Viewing error messages 48
2.8.7 Fire extinguisher 31 3.3.5 Viewing and changing the machine perfor- 49
mance (throttle)
2.8.8 Rear-view mirrors 32
3.4 System settings 49
2.8.9 Seat belt 32
3.4.1 Selecting an option 50
2.8.10 Steps, handles and railing 32
3.4.2 Viewing and changing the system language 50
2.8.11 Overload warning for lifting operation 33
3.4.3 Setting the system time 51
2.9 Safety markings 33
3.4.4 Set the screen brightness 51
3 Configuring the machine control system 40
3.5 Machine configuration 51
3.1 Monitoring and control unit 40
Table of contents
5
3.5.1 Setting the hours of operation 52 5.4 Maintenance work every 250 hours of ope- 57
ration
3.5.2 Viewing and changing the system configu- 52
ration 5.4.1 Engine 57
3.5.3 Viewing and changing the work equipment 53 5.5 Maintenance work every 500 hours of ope- 57
ration
3.5.4 Viewing the machine configuration 53
5.5.1 Engine cooling 57
4 Preparation 54
5.5.2 Fuel system 58
4.1 Bringing the machine into the maintenance 54
position 5.5.3 Hydraulic system 58
4.2 Maintenance while the machine is running 55 5.5.4 Slewing ring 58
5 Maintenance schedule 56 5.5.5 Tracks 58
5.1 Maintenance work at first inspection 56 5.5.6 Cab 58
5.1.1 Engine 56 5.6 Maintenance work every 1000 hours of 58

operation
5.2 Daily maintenance work 56
5.6.1 Engine 58
5.3 Maintenance work every 100 hours of ope- 57
ration 5.6.2 Hydraulic system 59
5.3.1 Work equipment 57 5.6.3 Slewing ring 59

Table of contents
6
5.7 Maintenance work every 2000 hours of 59 5.10.5 Cab 61

operation
6 Engine 62
5.7.1 Engine 59
6.1 Engine 62
5.7.2 Hydraulic system 60
6.2 Checking the high pressure line connec- 63
5.7.3 Tracks 60 tions for the injection system
5.8 Maintenance work every 4000 hours of 60 6.3 Checking and adjusting the compressor 63
operation belts
5.8.1 Engine 60 6.4 Checking, tightening and replacing the fan 65
5.8.2 Hydraulic system 60 belts
5.9 Maintenance work every 10000 hours of 60 6.5 Engine oil, replacing the engine oil filter and 66
operation checking the engine oil return valve
5.10 Maintenance work as needed 61 6.6 Replacing the engine air filter 70
5.10.1 Engine 61 6.7 Regeneration of diesel particulate filter 72
5.10.2 Engine cooling 61 6.8 Checking the starter 72
5.10.3 Tracks 61 6.9 Inspecting the compressor 73
5.10.4 Work equipment 61 6.10 Checking and adjusting the valve clearance 73
Table of contents
7
6.11 Checking the exhaust system connections 73 leaks
6.12 Inspecting the alternator 73 8.3 Cleaning the fuel tank 84
6.13 Checking the connections for the air filter, 73 8.4 Replacing fuel lines 84
turbocharger, aftercooler and engine
9 Hydraulic system 86
clamps
9.1 Checking and cleaning the breather valve 86
7 Engine cooling 74
9.2 Changing the hydraulic oil 87
7.1 Checking and cleaning the outside of the 74
9.3 Cleaning the hydraulic tank filter screen 89
coolant tank and radiator
7.2 Changing the coolant 75 9.4 Replacing the hydraulic oil filter element 90
7.3 Checking the water pump 78 9.5 Checking the hydraulic system accumulator 92
Fuel system 79 9.6 Replacing hydraulic hoses 93

8
10 Slewing ring 95
8.1 Replacing the fuel filter and fuel prefilter 79
8.1.1 Replacing the fuel prefilter 80 10.1 Checking the level of lubricating grease in 95
the swing gear
8.1.2 Replacing the fuel filter 81
10.2 Lubricating the swing bearing 96
8.1.3 Purging the air from the fuel system 83
10.3 Checking the swing motor’s level of hydrau- 97
8.2 Checking the fuel filter and fuel prefilter for 84
Table of contents
8
lic oil and changing the hydraulic oil 12.1.2 Lubrication points for the boom cylinder 108
10.3.1 Check the hydraulic oil level 98 12.1.3 Lubrication points for the boom, boom 108
cylinder and arm cylinder
10.3.2 Changing the hydraulic oil 98
12.1.4 Lubrication points for the arm-to-boom 109
11 Tracks 100
connection
11.1 Checking and tightening the track shoe 100
12.1.5 Lubrication points for the arm-to-bucket 109
fastening screws
connection
11.2 Checking and adjusting the track tension 100
12.2 Replacing the excavator teeth 109
11.2.1 Checking the track tension 101
12.3 Exchanging the bucket 112
11.2.2 Adjusting the track tension 101
12.4 Adjusting the bucket clearance 115
11.3 Checking the engine oil level of the track 103
13 Driver's cab 117
drive
13.1 Mixing the windscreen washer fluid 117
11.4 Changing the engine oil of the track drive 105
13.2 Checking the gas spring of the cab roof 117
12 Work equipment 107
hatch
12.1 Lubricating the work equipment 107
13.3 Air conditioner 118
12.1.1 Lubrication points for the swing bearing 108
13.3.1 Checking the refrigerant level 118
Table of contents
9
13.3.2 Replacing the fresh air filter / air circulation 119 15.2 Hydraulic circuit 140
filter
15.2.1 Components 141
14 Error elimination 121
15.2.2 Connecting additional equipment to the 143
14.1 Procedure 121 hydraulic circuit
14.2 Inspection before error elimination 122 16 Annex 146
14.3 Errors 124 16.1 Fluid capacities of the machine 146
14.3.1 Engine errors 124 16.2 Specifications for consumables 146
14.3.2 Further errors 131 16.3 Specifications 148
14.4 Carrying out measures to eliminate errors 135 16.4 Digging range 150
14.4.1 Disassembly and maintenance work on site 135 16.5 Lifting range 151
14.4.2 Replacing the batteries 136 16.6 Tightening torques 153
14.4.3 Charging the battery 137 16.6.1 Screws with strength classes 8.8, 10.9, 153
12.9
14.5 Towing the machine 137
16.6.2 Tightening torques for hydraulic screws 153
15 Interface description 139
16.6.3 Screws with strength classes 10.9 and 12.9 154
15.1 Preparing the machine 139
for the excavator
Table of contents
10
16.6.4 Hydraulic hose screw connections for the 155

excavator
16.6.5 Other screw connections for the excavator 156
16.7 Loading information 157
16.8 Diagrams 160
Glossary 161
Index 162
Foreword Introduction
11 1
Introduction This is a copy of the original instructions. In case of

doubt, the German wording shall take precedence.
Foreword
Please read and understand the operating instructions before Structure of the instructions
machine startup, operation, maintnance or repair. Structure of the instructions
Directions in the operating instructions must be followed. These These operating instructions consist of the:
directions are a precondition for safe operation of the machine ▪ Operator manual
and for personnel safety. ▪ Maintenance manual
Not observing the safety regulations can lead to material dama- ▪ Diagrams
ge, serious injuries or death. ▪ Assembly instructions or loading instructions
The operating instructions help to: The operating instructions are delivered in paper form in the end
▪ Make optimal use of the machine’s capabilities user’s local language. The loading instructions are provided on
▪ Avoid accidents a card. A CD-ROM is supplied which also contains the original
▪ Avoid machine errors due to incorrect use operating instructions in German. These operating instructions
▪ Avoid unintended use also include functions that are marked as optional. Not every
▪ Increase reliability machine has these functions.
▪ Minimise repair costs and downtime
Structure of the chapters
▪ Increase the service life of the machine
Operating and maintenance instructions are divided into chap-
The machine must have an accessible printed copy of the ope-
ters and sub-chapters.
rating instructions.
Introduction Structure of the instructions
1 12
Headings Markings
The number of pages, the chapter title (in bold) and the title of Markings are used to make the text easier to read. The following
each sub-chapter are indicated in the heading. On the outer markings are used:
edge, the chapter numbers are colour-coded to serve as a point
[F1] Keys, softkeys, switches, buttons
of reference.
[F1]+[F2] Press the key combinations simulta-
Instructions neously
Instructions show how to carry out a task step by step. Instruc-
[F1] [F2] Press the key combinations one be-
tions consist of:
hind the other
▪ No requirements, one requirement or several requirements.
«Menu» Menu designations, system messages
A pointed arrow (➢) introduces a requirement.
▪ Action steps. Every action step contains instructions. Ac- «Menu» «Sub-menu» Menu sequence
tions steps are number in the order they are to be executed. (1) Item numbers that can also be found
▪ No interim results, one interim result or more than one inte- in the diagrams
rim result. An unfilled arrow (⇨) introduces an interim result.
Safety instructions
Following interim results, there are further action steps.
Most accidents are caused by ignoring safety instructions. In
▪ At least one end result. A double pointed arrow (») intro-
these operating instructions, attention is drawn to the dangers
duces an end result.
through safety instructions. A safety instruction is structured as
If carrying out an instruction or an individual action step entails
follows.
risks, corresponding safety instructions indicate this before the
instructions or action steps.
Structure of the instructions Introduction
13 1
Signal word Colour Meaning

CAUTION
DANGER! Red For an imminent danger. If not
Type and source of the danger
avoided, death or serious injuries
Description of the potential danger (for example, potential
will result.
injuries).
• Prevention measures WARNING! Orange For a potentially dangerous situa-
• Prevention measures tion. If not avoided, death or seri-

ous injuries may result.
Safety instructions are classified by hazard signs (exclamation
CAUTION! Yellow For a potentially dangerous situa-
mark in a yellow warning triangle), a signal word (DANGER,
tion. If not avoided, slight, rever-
WARNING, CAUTION or NOTICE) and a corresponding colour
sible injuries may result.
scheme (red, orange, yellow or blue).
NOTICE! Blue Informs of potential machine da-
mage.
Other information
Introduces important information (for example, manu-

facturer recommendations for smooth machine opera-
tion).
Safety Intended use
2 14
Safety ▪ Carrying passengers

▪ Lifting people
Intended use ▪ Using the machine as a lifting platform
The SANY Crawler Hydraulic Excavator may only be used for ▪ Using the machine in contaminated areas
the following operations: ▪ Using the machine in explosive atmospheres
▪ Loosening, picking up, transporting and releasing soil, sto- ▪ Driving at inappropriate speeds over uneven ground
nes and other materials ▪ Driving on public roads
▪ Excavating ▪ Driving over obstacles such as mounds of earth, large sto-
▪ Smashing and breaking ground level materials (if the ma- nes, tree stumps, etc.
chine is equipped with the hammer operation option) ▪ Travelling on steep ground where the tracks cannot find
▪ Lifting and transporting individual loads using sling gear sufficient grip
(however, help is required to attach and release the load) ▪ Travelling on slopes above 35° (70%)
▪ Clearing (if the machine is equipped with a dozer blade) ▪ Demolition work
The following ambient conditions must be observed: ▪ Overhead work
▪ Ambient temperature: -20 – +40 °C ▪ Using the boom to help negotiate steep slopes where the
▪ Altitude: up to 2000 m tracks cannot find sufficient grip
Intended use also includes observing the operating instructions ▪ Turning the machine on steep slopes, driving down steep
and complying with maintenance and inspection conditions. slopes or rotating the boom while driving downhill
▪ Opening or closing the cab door while travelling on steep
Incorrect use
slopes
Incorrect use includes:
▪ Braking abruptly
Target group Safety
15 2
▪ Driving while operating the equipment or lifting objects Target group

▪ Abruptly switching from drive into reverse at high speeds The responsibilities of the various target groups must be defined
using the control lever and pedals and observed for the operation of the machine.
▪ Driving through water that is deeper than the level of the
End user duties
track support rollers
The end user of the machine is obligated to operate the machi-
▪ Fastening lifting devices, such as ropes, to the equipment
ne in a fault-free and undamaged state only. Maintenance and
and lifting objects with these
inspection are detailed in the operating instructions.
▪ Using the equipment while the hydraulic cylinder is comple-
The end user has the following tasks:
tely retracted or extended
▪ Defining the responsibility of the individual target groups
▪ Using the momentum/rotary motion of the equipment for
▪ Monitoring the observance of these responsibilities
demolition work or lifting
▪ Allowing only qualified personnel to work on the machine
▪ Using the full force of the bucket to hit the ground for dig-
▪ Ensuring that only qualified personnel are present in the
ging
danger zone of the machine
▪ Using the full force of the bucket to hit an object so as to
▪ Ensuring that recognized work safety rules are observed
crush it
▪ Using the weight of the equipment for demolition work Operator duties
▪ Using the bucket for bedrock excavation work The operator of the machine must have the qualifications requi-
SANY assumes no liability for harm to persons, the environment red by the applicable local laws:
or the machine resulting from incorrect use. ▪ Technical qualifications according to national regulations
▪ Safety instruction
The operator has the following responsibilities:
Safety Target group
2 16
▪ Operating the machine

▪ Inspecting the machine daily for obvious damage or defects
▪ Immediately reporting damage and defects found as well as
any changes in operational performance to the appropriate
workshop / specialist personnel
▪ Filling the consumables
▪ Lubricating the moving parts
▪ Filling the lubricating grease of a central lubricating system
(if available)
Duties of workshop / specialist personnel

The workshop / specialist personnel have the following respon-
sibilities:
▪ Performing all maintenance work carefully and on-time
according the maintenance schedule.
▪ Complying with the maintenance schedule.
▪ Carrying out maintenance and servicing duties.
General dangers Safety
17 2
Location Danger
General dangers
(1) Next to the counterweight Crushing danger, danger of
Not all dangers resulting from the machine can be prevented.
being knocked over by the
turning machine
(2) Next to the machine Crushing danger, danger of
being knocked over by the
turning machine
(3) Under the bucket Danger from swinging
loads and falling objects
(4) Under the boom cylinder Danger of persons banging
their heads
Mechanical dangers
There are the following mechanical danger zones:
Danger areas
Safety General dangers
2 18
Location Danger
(1) In front of and behind the Danger of being crushed
machine when the machine starts to
move
(2) Tracks Danger of being pulled
along by the chain when
the machine starts to move
(3) Chain drive, rollers and Danger of crushing arm,
support rollers, drive spro- hand or finger
cket
(4) Drain plug, lubricating Danger of injury from plug
grease, chain flying out
(5) Idler Danger of serious or deadly
Mechanical danger zones injury from screw plug

popping out
(6) Next to the machine Danger of being injured by
the boom or counterweight
while the machine is turning
(7) Under the raised bucket Danger from falling objects
19 2
Hydraulic dangers
Besides the pressure-generating components, the high-
pressure hoses and their corresponding connections are notab-
le hydraulic danger zones.
Before maintenance work on the hydraulic accumulator, the
pressure must first be released.
There are the following hydraulic danger zones:
Hydraulic danger zones
Location Danger
(1) Hydraulic hose connections High pressure, leaking
between slewing ring and hydraulic oil
chassis
(2) Boom cylinder connections Leaking hydraulic oil
2 20
Location Danger Location Danger

(3) Transition between high- High pressure, leaking (1) Cab fuse box Electric shock
pressure hose and boom hydraulic oil (2) Fuel injection, engine con- Electric shock
(4) High-pressure hose from High pressure, leaking troller
boom to arm hydraulic oil During normal operation, all electrical components of the ma-
(5) Connections from hydraulic High pressure, leaking chine are protected against environmental factors and being
hose to work equipment hydraulic oil touched. During maintenance and repair, exposed components
(6) High-pressure hose from High pressure, leaking constitute electrical danger zones.
arm to bucket hydraulic oil
Fire danger
(7) High-pressure hose from High pressure, leaking
Parts of the machine (such as the exhaust manifold or bonnet)
boom to arm hydraulic oil
become very hot during operation. Dry leaves, pieces of wood
Electrical dangers or other flammable materials that collect on the machine can
There are the following electrical danger zones: ignite and cause a dangerous fire.
Prevention:
▪ Clean the machine of deposits.
A short circuit in the electrical system can cause a dangerous
fire.
Prevention:
▪ Every day at the end of operation — or after 8 to 10 hours
Electrical danger zones
of operation at the latest — check that the electrical connec-
21 2
tions are securely installed and clean and, if necessary, ▪ Check the consumables tank only with special non-
secure and clean them once again (or have them secured explosive lighting.
and cleaned). A defect or missing heat shield can cause a dangerous fire.
Hot hydraulic fluid or gear oil can spray out of leaking hoses and ▪ Check the heat shield for damage.
ignite flammable materials on or around the machine. Loose ▪ Do not operate the machine without a heat shield.
hydraulic or gear oil hoses or connections can cause a dange-
Dangers from lifting equipment
rous fire through frictional heat.
The following dangers can result from lifting equipment:
Prevention:
▪ Check the hoses, connections and seals daily before start- Converting
ing the engine. The machine may only be converted with authorized lifting
Contact between consumables and hot machine parts when equipment. If in doubt, related questions can be addressed to
topping up can cause a dangerous fire. SANY. If the machine is equipped with a quick change system,
Prevention: the lifting equipment may be exchanged by the operator. To
▪ Work in a clean manner, collect spilled consumables and avoid injuries and machine damage, the operating instructions
dispose in an environmentally sound manner. for the lifting equipment and the operating instructions for the
▪ Carefully close the tank cover and check daily that it is fitted machine must be observed.
securely. Combining lifting equipment

▪ Fill consumables only when engine is switched off. When combining lifting equipment, the excavator may behave
During inspection of the consumables tank, sparks can trigger unusually. For example, combined lifting equipment may be
explosions and fires. able swing out further and reach the cab. Serious injuries or
Prevention:
2 22
machine damage can result. When combining lifting equipment,

work must be conducted cautiously until the operator becomes
familiar with the altered behaviour of the excavator.
Residual machine dangers Safety
23 2
Location Danger
Residual machine dangers
(1) Boom, counterweight Bruising and crushing from
Not all dangers resulting from the machine can be prevented.
the turning machine
(2) Battery compartment Acid burns
(3) Hydraulic cylinder Head injuries from impact
(4) Tank filler necks Poisoning by inhaling,
serious to deadly burns
from ignition of the fumes
(5) Steps / stairs Injuries from slipping and
falling, particularly in case
of rain, snow and ice
(6) Exhaust system Burns, poisoning by in-
haling the poisonous ex-
haust fumes
(7) Bonnet Burns
(8) Window Head injuries if inserted
windscreen is poorly
secured and falls down
Residual dangers at machine
Safety Residual dangers from the machine environment
2 24
Location Danger ▪ Check the load-bearing capacity of bridges and paths befo-
(9) Crawler track, work Bruising, crushing from re travelling on them.
equipment being caught or being pul- ▪ Check the height and width of tunnels before driving
led along through them.
Gear oil, hydraulic fluid Burns, scalding ▪ Do not park the machine on slopes.
Gear oil cables, hydraulic Eye injuries, bruises, high- ▪ Do not drive the machine over obstacles high enough to
cables are under pressure pressure injection cause the machine to become unbalanced.
Gas, water or power lines installed underground can be dama-
Residual dangers from the machine ged during digging or excavating work. This can lead to serious
environment injuries or machine damage.
Not all dangers resulting from the machine environment can be Prevention:
prevented. ▪ Observe local regulations.
▪ Before beginning digging or excavating work, check if gas,
Ground
When the machine is on non-load-bearing, soft or uneven water or power lines are installed in the ground.
ground, driving over obstacles or on steep surfaces (slope Power cables

above 15°), it can topple over and lead to death or serious inju- Due to its height, the machine can collide with power cables.
ry. The machine can be damaged. This can lead to death or serious injuries. The machine can be
Prevention: damaged.
▪ Only operate the machine on load-bearing ground.
Residual dangers from the machine environment Safety
25 2
The following safety clearances from power cables must be ▪ Do not enter or exit the machine under power cables, but
maintained. This clearance must not fall below the minimum rather only after the specified safety clearance has been
clearance. reached.
Nominal voltage [V] Safety clearance [m] Flammable / explosive environment

Up to 1,000 1 The consumables of the machine, such as fuel, oil, lubricating
grease and coolant, can ignite easily and are flammable. As a
Over 1,000 to 110,000 3
result, there is a danger of the machine catching fire or explo-
Over 110,000 to 220,000 4
ding when operating the machine near an open flame or flying
Over 220,000 to 380,000 5 sparks. This can lead to death or serious injuries. The machine
When nominal voltage is unknown 5 can be damaged.
Prevention:
If working under power cables cannot be avoided, the following
▪ Do not operate the machine in a flammable or explosive
safety measures must be taken:
environment (for example, in environments with flammable
▪ Observe applicable local regulations.
▪ Use a marshaller to inform the operator as to the current dust)
▪ Only operate the machine in well ventilated spaces
distance from the power cables.
▪ Smoking and naked flames are not permitted while
▪ Wear rubber shoes and protective gloves.
▪ Cover the operator seat with a rubber cover. refuelling
▪ Smoking and naked flames are not permitted while working
▪ Avoid contact with machine parts that can conduct current.
on the battery
Safety Residual dangers from the machine environment
2 26
Storms
When operating the machine during a storm, there is a danger
of damaging the machine controls. Therefore, cease operating
during storms. When operating the lifting tackle, the person
guiding the load outside of the cab is in particular danger from
lightning. Therefore, cease operating the lifting tackle immedia-
tely during storms and find a protected area.
Poor visibility
When operating the machine in poor visibility (for example, due
to darkness, fog or high amounts of dust in the air), special
safety measures must be taken:
▪ Switch on work spotlights
▪ Activate windscreen wiper
▪ Mark obstacles
▪ Have a marshaller provide signals
Extreme climatic conditions

Cease operating under extreme climatic conditions if the protec-
tion provided by air conditioning, heating and weather-resistant
clothing is insufficient.
Prevention Safety
27 2
Personal protective equipment

Prevention Depending on the required function, the personal protective
To ensure safe operation and eliminate residual dangers, per- equipment comprises various components.
sonnel must observe the following: ▪ Safety helmet: The safety helmet reduces the danger
▪ Follow the operating instructions
and severity of head injuries. The safety helmet must be
▪ Follow the safety instructions in the operating instructions worn during machine operation, maintenance and repair.
▪ Follow the safety markings on the machine
▪ High-visibility protective clothing: High-visibility
▪ Follow the operating instructions protective clothing protects the body from injuries or limits
▪ Maintain constant heightened awareness while operating the severity of injuries resulting from contact with fire, heat,
the vehicle
cold and corrosive substances. The reflective portions of
▪ Wear personal protective equipment the clothing also make the wearer more visible to others.
▪ Replace damaged parts of the protective equipment High-visibility protective clothing must be worn during ma-
▪ Do not let hair hang down
chine operation, maintenance and repair.
▪ Remove all jewellery ▪ Safety shoes: Safety shoes protect feet from injuries or
▪ Wear close-fitting clothing
limit the severity of injuries resulting from:
▪ Do not listen to music or the radio (unless the operating – Impacts with hard objects
instructions contain regulations related to this) – Stepping on sharp parts
▪ Arrange the workspace in an ergonomic manner
– Heavy falling objects
Safety shoes must be worn during machine operation,
maintenance and repair.
Safety Prevention
2 28
▪ Safety goggles / protective mask: Safety goggles / ▪ Ear protection: Ear protection protects the ears against
protective mask protect the eyes against injuries. Safety noise. Wearing ear protection is recommended at a volume
goggles / protective mask must be worn when hammering of 80 dB(A) and mandatory at 85 dB(A) or higher.
and grinding parts, when driving out bolts during installation ▪ Weather-resistant clothing: Weather-resistant
work, when working on hydraulic pumps and on gear units, clothing (for example, a weather-resistant jacket) protects
when welding and when working with corrosive substances against environmental factors such as wetness or cold.
(battery acid). Weather-resistant clothing must be put on when leaving the
▪ Breathing mask: The breathing mask prevents acute or cab.
chronic health problems that can result from the inhalation ▪ Protective clothing for welding, welding glas-
of harmful substances (such as asbestos). The breathing ses, welding smoke filter or power-assisted fil-
mask must be worn when working in environments with tering device: Welding is associated with strong currents
harmful substances (for example, when working with indust- or explosive gases, toxic exhaust fumes, dangerous light
rial waste). and heat generation, and molten metal spatter. Welding fu-
▪ Safety gloves: Safety gloves protect hands against inju- mes often contain carcinogenic substances. Protective
ries or limit the severity of injuries resulting from contact clothing adapted to the welding process and material used
with hot, cold, sharp-edged or corrosive materials. Safety protects against severe and irreparable damage to health.
gloves must be worn when working on hydraulic pumps and
Explosion-proof lighting system
on gear units and when working with hot, cold, sharp-edged
Flammable gases can develop in the consumables tank. As a
or corrosive materials.
result, only explosion-proof lighting may be used to inspect the
consumables tank.
Safety equipment Safety
29 2
Arranging the workspace equipment must be complete and intact. Its functionality must be
To increase safety and to avoid long-term harm to health, ope- checked daily.
rators must adjust the settings of the operator seat, the outer The safety equipment requiring operator intervention is descri-
mirrors and the air conditioning to their needs before commen- bed below.
cing work.
Emergency stop
The following settings can be adjusted:
▪ Operator seat
– Inclination of the backrest
– Inclination of the armrest
– Headrest
– Suspension
▪ Air conditioner
– Fresh air supply
– Ventilation
– Temperature
▪ Rear-view mirrors
Emergency stop
Safety equipment In an emergency, the operator can bring the machine to a safe
The machine is equipped with safety equipment. The safety state by pressing the lever on the left-hand side of the seat
equipment may not be manipulated or disabled. The machine downwards. Pressing the lever downwards safely switches all
may only be operated with intact safety equipment. The safety machine movements off.
Safety Safety equipment
2 30
The lever must always be pressed downwards when leaving the 1. Pull the ring until the complete seal holding the panel is re-
cab. moved.
2. Press firmly against one corner of the glass to push it out-
Emergency exit
ward.
For safely exiting the machine in an emergency, the rear
» The emergency exit is now open.
window may be used as an emergency exit if it is not possible to
The rear window can also be broken with the emergency ham-
exit through the door.
mer.
Note:
▪ The rear window may only be removed in case of
emergency and not under other circumstances.
▪ After the rear window is used as an emergency exit, the
window must be replaced since the seal has been de-
stroyed and the window has been taken out of the frame.
Safety lever
The safety lever must be pushed downward whenever exiting
Emergency exit the operator seat.

The safety lever prevents inadvertent activation of the controls
(1) Emergency exit (3) Cutting wheel
for motion control, the turning mechanism and the equipment.
(2) Emergency exit marking (4) Emergency hammer
The rear window is equipped with an emergency hammer and a
cutting wheel.
Safety equipment Safety
31 2
Horn
The horn warns persons in the machine environment of motions
by the machine and the lifting equipment and thus reduces the
risk of injury.
Fire extinguisher
The cab is equipped with a fire extinguisher inside the cab on
the rear wall. A sign indicates the location of the fire extinguis-
her.
Safety lever
(1) Unlocking position (2) Locking position
Camera
The machine is equipped with a camera on the counterweight
so that the area behind the counterweight can be viewed. The
camera image can be viewed on the display as needed.
Visual and acoustic driver warning system

The machine emits an acoustic warning signal (beeping sound)
when being driven.
Safety Safety equipment
2 32
Saving oneself always has priority.
Rear-view mirrors
The machine is equipped with several rear-view mirrors.
The rear-view mirrors broaden the machine operator’s view of
the area beside and behind the machine. The rear-view mirrors
can be folded in and must be folded out during operation. Ope-
rators must always adjust the mirrors to suit their needs before
starting.
Seat belt
Fire extinguisher
The operator seat is equipped with a seat belt.
(1) Rear window (3) Fire extinguisher The seat belt is a restraining system that prevents the operator
(2) Fire extinguisher marking from being thrown about or even being thrown out of the machi-
Fires originating in the cab are to be fought with the fire extin- ne as the result of an unexpected machine motion. The seat belt
guisher found in the cab. If it is not possible to fight the fire, the stretches upon impact and so limits the force of deceleration.
operator must leave the cab immediately via the specified es-
cape route.
Steps, handles and railing
An access step and handles (operator cab) as well as steps, a
handle and a railing are attached to enable safe climbing in and
Safety markings Safety
33 2
out of the machine. The machine may only be climbed into or Overload warning for lifting operation
out of using the steps and handles / railing. The machine is equipped with an overload warning for lifting
operation. The operator receives optical and acoustic warnings
if the suspended load approaches or is over the allowable limit.
The overload warning can be switched off in normal operating
mode.
Safety markings
The following safety markings are found on the machine:
Prohibition signs
Sign Location Meaning
On the diesel filler Naked flames are

opening prohibited.
On the bonnet Do not step on

Access step and handles
(1) Handle (3) Access step

(2) Access step (4) Railing
Safety Safety markings
2 34
Warning signs Mandatory signs
Sign Location Meaning Sign Location Meaning
Engine, exhaust Hot surface warning Near the hydraulic Use safety goggles /
system, hydraulic sign. pump on the cover protective mask
pump
Near the hydraulic Use safety gloves
On the battery Warning of dangers
from the battery. pump on the cover.
On the machine at Warning of the risk of On the inside of the Use the seat belt
the stairs falling. window in the opera-
tor cab
On the front and on Warning of suspen-
the right-hand and ded loads. On the inside of the Comply with the ope-
left-hand sides of the window in the opera- rating instructions
machine tor cab
On the right-hand and Do not loiter in the

left-hand sides of the danger area.
boom
On the steps Slip danger

35 2
Fire prevention and rescue signs

Sign Location Meaning On the fastening The machine can be
Next to the fire extin- Indicates the storage eyelets fastened securely
guisher location of the fire here
extinguisher On the anchorage The machine can be
On the rear window Emergency exit points lifted here
At the machine’s Centre of gravity of

General information centre of gravity the machine

Maintenance information
Inside the operator Noise level in the
cab operator cab Sign Location Meaning
Hydraulic oil tank Specifications for the

Next to the rating Noise level next to hydraulic oil
plate the machine
Fuel tank Only fill with diesel

fuel
2 36
Sign Location Meaning Sign Location Meaning
Water separator Water separator On the right side Lifting range

window of the cab; for
more information, see
In the toolbox next to Indicates the lubrica- Safety markings
the grease gun; for tion points on the [Page 38]
more information see machine
On the right side Overview of the joy-
Safety markings
window of the cab stick and pedal /
[Page 37]
throttle motions
On the lower right Machine marking

side on the exterior of
the operator cab
For more information,
see Safety markings
[Page 37]
37 2
Rating plate Lubrication schedule
(1) Machine designation (5) Weight

(2) Manufacturer (6) Power
(3) CE mark (7) Serial number Lubrication schedule
(4) Product type (8) Year of manufacture

Symbol Meaning
Refill the fuel
Lubricate
Change the hydraulic oil for the first time.

Maintenance personnel only.
2 38
Lifting range
Symbol Meaning
Check the engine oil and top up if necessary
Change the engine oil
Check the cooling fluid and top up if necessary
Replace the cooling fluid
Change the gear oil and top up if necessary
Change the gear oil
Check the hydraulic oil and top up if necessary

Lifting chart
Change the hydraulic oil or perform an oil analysis. Symbol Meaning

Maintenance personnel only. Value applies to the lifting of loads over the front.
Value applies to the lifting of loads over the side.

39 2
Symbol Meaning
Load suspension point
Values apply to the lifting of loads with the dozer

blade raised
Values apply to the lifting of loads with the dozer

blade lowered
Limitation on the load to be lifted due to the hyd-

raulic system
Configuring the machine control system Monitoring and control unit
3 40
Configuring the machine control

system
The machine control system is configured with the monitoring
and control unit. Depending on the display, information about
the machine can be viewed or changes can be made to the
machine control system.
Monitoring and control unit

To operate the machine, it is important to be familiar with the
operation and display of the monitoring and control unit. Only in
this way can appropriate actions be taken if errors arise.
Monitoring and control unit
(1) Status LED (3) Display

(2) Key with changing func-
tions
Status display
In normal operating mode, the status display lights up green.
Display
The display shows the operating states, system information or
programming information. This is dependent on the display
Monitoring and control unit Configuring the machine control system
41 3
status selected. The displayed information appears as symbols Main display screen
or text. The main display screen appears after the initialisation display
The display is automatically switched on when the ignition key is screen. All information necessary for operation is displayed. The
in the “ON” position. When the display is switched on, the LED display is automatically switched on when the ignition key is in
at the top right of the screen lights up green. the “ON” position.
Function keys
The 5 function keys (F1 to F5) switch the display to different
modes or confirm entries. Each function is directly shown on the
display screen next to the key. Function keys can have different
functions on different display screens.
Display items and operation
Initialisation display screen

If the ignition key is turned to “ON” when starting the machine,
the SANY logo appears on the screen for about 2 seconds.
A prompt then appears on the display indicating that the opera-
Operator 1
ting instructions must be read prior to using the machine. This
message must be confirmed by pressing funktion key [F5].
Configuring the machine control system Monitoring and control unit
3 42
(1) Counter for hours of ope- (7) Hydraulic oil temperature

ration
(2) Switch operating mode: (8) Display next page
press [F1]
(3) Speed selection (9) Cooling water temperature
(4) Switch to automatic idle (10) Fuel level
mode
(5) Switch between slow travel (11) Operating mode
/ fast travel
(6) Display error messages: (12) System time
press [F3]
Operator 2
(1) Counter for hours of ope- (8) Display previous page

ration
(2) Show camera image (9) Cooling water temperature
(3) Speed selection (10) Fuel level
(4) Switch to automatic idle (11) DPD display
mode
Monitoring and control unit Configuring the machine control system
43 3
(5) Switch between slow travel (12) Operating mode display Hydraulic oil temperature display
/ fast travel In total, there are 5 sections in order to display a temperature
(6) Automatic clearing of die- (13) System time between 0 ― 120° C.
sel particulate filter on/off: Fuel level display

press [F4] In total, there are 9 sections for a scale of 0 ― 100%.
(7) Hydraulic oil temperature If the fuel level is below 8%, the warning light lights up.
Operating mode display System time display

When displaying the operating mode, a distinction is made The current time is displayed.
between the standard operating mode (S), heavy-duty operating
Error code display
mode (H), light operating mode (L) or breaking/demolition ope-
If an error occurs, the operator can press the error code key to
rating mode (B).
call a screen containing information on the error code.
Speed selection display
Hours of operation display
If the speed selection switch is turned, the information displayed
The hours of operation for the excavator are displayed using the
between the area of 0 ― 11 is updated.
format: hhhhh:mm.
Cooling water temperature display
Switch operating mode
In total, there are 5 sections in order to display a temperature
The display indicates that using the assigned function key [F1],
between 0 ― 120° C.
the operator can switch between the four modes: the standard
operating mode (S), heavy-duty operating mode (H), light opera-
ting mode (L) or breaking/demolition operating mode (B). The
Configuring the machine control system Entering the password
3 44
machine is automatically in the standard mode after start-up. The display indicates that using the assigned function key [F3],
The symbol changes according to the mode selected. the operator can switch between slow travel and fast travel. The
symbol changes according to the mode selected.
Switch to automatic idle mode
Call system mode
The display indicates that using the assigned function key [F3]
on the second operator screen, the operator can switch into the
system mode to configure the system and display further sys-
Automatic idle mode / full load tem data.
(1) Full load (2) Automatic idle mode The switch into the system mode requires the entry of a pass-
The display indicates that using the assigned function key [F2], word.
the operator can switch between automatic idle mode and full
DPD display
load. The symbol changes according to the mode selected.
Switch between slow travel / fast travel
DPD display
Slow travel / fast travel (1) Level (2) Automatic / manual
(1) Slow travel (2) Fast travel The status of the diesel particulate filter is displayed on the
second operator screen.
Entering the password Configuring the machine control system
45 3
▪ Automatic or manual mode

▪ The DPD level is shown on a display with five bars.
Entering the password

The settings of the monitoring and control unit can only be
changed by authorised persons. They must enter a password to
do so.
Pressing the [F5] key (system information) on the standard
display brings up the password entry screen. The password
consists of five digits.
Password entry screen
Password entry
The dialog box for password entry appears automatically once a
function requiring a password is called.
➢ The screen shows the dialog box for password entry.
1. Press [F2] to start the entry.
2. Press [F3] or [F4] to change the first value.
3. Press [F2] to confirm the set value.
4. Press [F3] or [F4] to enter a further number.
Configuring the machine control system Main menu
3 46
5. Press [F2] to confirm the set value. Futher information is protected by an additional password. For
6. Repeat the step until the last number has been set. more on this, contact your SANY agent.
7. Press [F5] to confirm the code. The display offers a list with options for selection:
8. Press [F1] to return to the main display screen. ▪ Status information
» The password is set. ▪ Maintenance information
▪ Error information
Main menu ▪ View and change the system components
▪ View and change the system configuration
▪ View and change the work equipment
When an option is selected, a brief explanation of the selected
option appears on the lower left-hand side of the display.
Selecting an option
➢ The password has been entered.
1. Press [F3] to move the cursor up or [F4] to move it down
through the list of options.
2. Move the cursor to the desired option.
⇨ The selected option is highlighted.
Main menu screen ⇨ Options not selected appear grey.

Access to the main menu is password-protected. 3. Press [F5] to confirm the selection.
4. Press [F4] to enter system settings for the selected option.
Main menu Configuring the machine control system
47 3
5. Press [F1] to return to the main menu. Information Unit

» The option has now been selected.
Hydraulic oil temperature ℃
Viewing machine status information Throttle angle --

The following information can be viewed:
Battery voltage V
Main pump pressure information Engine speed rpm
Information Unit Engine load %
F pump pressure kgf/cm2

Pilot pressure signals
F pump pressure kgf/cm2
Information Unit
F proportioning valve flow mA
Pilot pressure, turning kgf/cm2
R proportioning valve flow mA
Pilot pressure, lifting the boom kgf/cm2
Pressure reducing valve flow mA
Pilot pressure, lowering the boom kgf/cm2
Engine information Pilot pressure, retracting arm kgf/cm2
Information Unit Pilot pressure, extending arm kgf/cm2
Coolant temperature ℃ Pilot pressure, closing bucket kgf/cm2
Oil pressure kPa Pilot pressure, opening bucket kgf/cm2
Fuel level %
Configuring the machine control system Main menu
3 48
Information Unit Information Unit

Pilot pressure, direction of travel L kgf/cm2 Camshaft position --
Pilot pressure, direction of travel R kgf/cm2 Engine speed rpm

Pressure, feed-forward circuit kgf/cm2 Coolant temperature ℃
Engine oil pressure kPa

DPF information
DPF differential pressure kPa
Load state %
Ambient air pressure kPa
Loading air pressure kPa
Loading air temperature ℃
Fuel temperature ℃
DOC inlet temperature ℃
DPF inlet temperature ℃
Air supply temperature ℃

DPF information
The DPF information can be called up from the operator screen Viewing error messages
via [F2]. The current error messages can be viewed here.
System settings Configuring the machine control system
49 3
Information Unit
Current gear N
Engine speed rpm
Gear setting V
Throttle position V
The following settings can be changed:

▪ Press [F1] to switch operating mode.
▪ Press [F2] to switch between idle and full throttle.
▪ Press [F3] to switch between high and low travel speed.
Error codes
▪ Press [F4] or [ESC] to return to the main menu.
▪ Error code
▪ Explanation of error System settings
Access to system control is password-protected.
Viewing and changing the machine
The display offers a list with options for selection:
performance (throttle)
The following information can be viewed: ▪ Set the system language
▪ Set the system time
▪ Set the screen brightness
▪ Set the units
▪ Change the time settings
Configuring the machine control system System settings
3 50
Selecting an option Viewing and changing the system language

➢ The password has been entered.
1. Press [F3] to move the cursor up or [F4] to move it down
through the list of options.
2. Move the cursor to the desired option.
⇨ The selected option is highlighted.
⇨ Options not selected appear grey.
3. Press [F5] to confirm the selection.
4. Press [F4] to enter system settings for the selected option.
5. Press [F1] to return to the main menu.
» The option has now been selected.
Screen for viewing and changing the system language

In this menu you can view the current system language or select
a different system language. See also Selecting an option [Page
50].
Machine configuration Configuring the machine control system
51 3
Setting the system time 5. Repeat the previous steps until all parameters have been
set correctly.
6. Press [F5] to confirm the time setting.
» The system time has now been set.
Set the screen brightness

The brightness of the screen background and keys are display-
ed via a progress indicator. The current value is displayed in
yellow.
1. Press [F2] to start the entry.
2. Press [F3] or [F4] to set the brightness.
3. Press [F2] to confirm the selected value or press [F3] or
Screen for setting the system time
[F4] to set the cursor to the next brightness level.
The current time (system time) is shown on the display in white.
4. Press [F5] to confirm the brightness.
The time and date set by the user are shown on the display in
yellow.
» The screen brightness has now been set.
➢ ‘Set system time’ has been selected.
1. Press [F2] to start the selected parameters or to confirm. Machine configuration
2. Press [F3] or [F4] to select a parameter. The following parameters can be selected:
3. Press [F2] to confirm the selected parameter. ▪ Servicing hours
4. Press [F3] or [F4] to change the parameter.
Configuring the machine control system Machine configuration
3 52
▪ Machine equipment Viewing and changing the system

▪ Machine numbers configuration
▪ Work equipment
Setting the hours of operation

The current total hours of operation are shown on the display in
white.
The total hours of operation set by the user are shown on the
display in yellow. The minimum time period which can be recor-
ded is 1 minute.
➢ ‘Set hours of operation’ has been selected.
1. Press [F2] to start the selected parameters or to confirm.
2. Press [F3] or [F4] to select a parameter.
The configuration of the machine numbers is protected by an
3. Press [F2] to confirm the selected parameter.
additional password. The current number is shown on the dis-
4. Press [F3] or [F4] to change the parameter.
play in white. The number set by the user is shown on the dis-
5. Repeat the previous steps until all parameters have been
play in yellow.
set correctly.
1. Press [F2] to start the selected parameters or to confirm.
6. Press [F5] to confirm the time setting.
2. Press [F3] or [F4] to select a parameter.
3. Press [F2] to confirm the selected parameter.
» The hours of operation have now been set.
4. Press [F3] or [F4] to change the number
Machine configuration Configuring the machine control system
53 3
5. Repeat the previous steps until all parameters have been Viewing the machine configuration
set correctly.
6. Press [F5] to confirm the setting.
» The machine numbers have now been set.
Viewing and changing the work equipment

In this menu, you can call the current work equipment or select
different work equipment.
The selection of the work equipment is protected by an additio-
nal password. See also Selecting an option [Page 50].
Screen for calling the machine configuration

The following information can be viewed:
▪ Machine model
▪ Machine serial number
▪ Engine model
▪ Hydraulic system
▪ Control system
▪ Hardware version
▪ Software version
Preparation Bringing the machine into the maintenance position
4 54
Preparation 6. Turn the ignition key to the ON position.

7. Move the joystick controls in all directions 2 to 3 times.
Bringing the machine into the ⇨ The pressure in the hydraulic system is released.
maintenance position 8. Pull out the ignition key.
For maintenance, the machine must be driven into an area 9. Push the safety lever downwards.
suitable for maintenance. This area must satisfy the following 10.Disconnect the power supply using the battery isolator
conditions: switch.
▪ Even ground surface capable of bearing the load 11.Attach the “Maintenance” sign to the ignition lock and travel
▪ Spacious control levers or pedals.
▪ Well ventilated » The machine is in the maintenance position.
▪ Well lit
▪ Clean and dry
Upon reaching the maintenance area, the machine must be
brought into its maintenance position.
➢ Machine is now safely parked.
1. Lower the work equipment to the ground.
2. Secure both tracks with chocks at front and rear.
3. Turn the speed selection switch to 1.
4. Run the engine idly for 5 min.
5. Turn the ignition key to the OFF position.
⇨ The engine stops.
Maintenance while the machine is running Preparation
55 4
Maintenance while the machine is ▪ Take care when moving near rotating parts such as fans.
running
WARNING
Danger of serious injuries and loss of limbs
Reaching into moving parts can lead to loss of limbs and da-
mage to the machine.
• Do not reach into moving parts.
• Do not insert any objects into moving parts or allow them
to drop into moving parts.
If you need to start the machine for maintenance purposes,

comply with the following points:
▪ The maintenance must be carried out by at least 2 people.
▪ One person must monitor the machine from the operator
seat in order to be able to switch off the engine immedia-
tely.
▪ Operate the control levers only after consulting with and
warning the other person first.
▪ The safety lever must be pressed down in order to prevent
movements of the machine and the work equipment.
Maintenance schedule Maintenance work at first inspection
5 56
Maintenance schedule Engine

The following maintenance measures apply for a new machine
The specified maintenance intervals are SANY recommenda-
after a running-in period of 50 hours of operation.
tions. The information in the manuals from the component ma-
nufacturers is authoritative. Work See chapter
Checks according to national requirements are independent of
Changing the engine oil and Engine oil, replacing the engi-
this information.
engine oil filter ne oil filter and checking the
Handling safety components engine oil return valve [Page
• Never check or repair the safety components. 66]
• Only the SANY service department may replace Changing the fuel filter Replacing the fuel filter and
the safety components. fuel prefilter [Page 79]
• The safety components are marked in the spare
part catalogue. Daily maintenance work
The daily maintenance work must be carried out by the operator
before starting the engine. The chapter “Before starting the
engine” of the operating instructions must be observed.
Maintenance work at first inspection
The following maintenance measures apply for a new machine
after a running-in period of 50 hours of operation.
See also
 Replacing the hydraulic oil filter element [➙ 90]
Maintenance work every 100 hours of operation Maintenance schedule
57 5
Maintenance work every 100 hours of Work See chapter

operation Checking the engine oil return Engine oil, replacing the engi-
valve ne oil filter and checking the
Work equipment
engine oil return valve [Page
Work See chapter 66]
Lubricating the work Lubricating the work Changing the engine oil Engine oil, replacing the engi-
equipment equipment [Page 107] ne oil filter and checking the
engine oil return valve [Page
Maintenance work every 250 hours of
66]
operation
Checking the fan belt tension Checking, tightening and re-
Engine placing the fan belts [Page 65]
Work See chapter

Checking and adjusting the Checking and adjusting the
operation
compressor belts compressor belts [Page 63]
Engine cooling
Changing the engine oil filter Engine oil, replacing the engi-
ne oil filter and checking the Work See chapter
engine oil return valve [Page Checking and cleaning the Checking and cleaning the
66] cooling fins outside of the coolant tank and
radiator [Page 74]
Maintenance schedule Maintenance work every 1000 hours of operation
5 58
Fuel system Tracks
Work See chapter Work See chapter
Changing the fuel filter Replacing the fuel filter and Checking the track drive oil Checking the engine oil level
fuel prefilter [Page 79] level and filling of the track drive [Page 103]
Changing the fuel prefilter Replacing the fuel filter and

Cab
fuel prefilter [Page 79]
Work See chapter
Hydraulic system
Replacing the fresh air filter Replacing the fresh air filter /
Work See chapter and air circulation filter air circulation filter [Page 119]
Checking the breather valve Checking and cleaning the

breather valve [Page 86]
operation
Slewing ring
Engine
Work See chapter
Work See chapter
Lubricating the swing bearing Lubricating the swing bearing
Ensuring the exhaust system Checking the exhaust system
[Page 96]
is fitted securely connections [Page 73]
Checking swing motor gear- Checking the swing motor’s
box oil and filling level of hydraulic oil and chan-
ging the hydraulic oil [Page 97]
Maintenance work every 2000 hours of operation Maintenance schedule
59 5
Hydraulic system Maintenance work every 2000 hours of

Work See chapter operation
Replacing the hydraulic filter Replacing the hydraulic oil Engine
filter element [Page 90]
Work See chapter
Checking the pressure accu- Checking the hydraulic system
Inspecting the alternator Inspecting the alternator [Page
mulator accumulator [Page 92]
73]
Slewing ring Checking the starter Checking the starter [Page 72]
Work See chapter
Lubricating the swing bearing Lubricating the swing bearing

[Page 96]
Maintenance schedule Maintenance work every 4000 hours of operation
5 60
Hydraulic system Maintenance work every 4000 hours of

Work See chapter operation
Replacing the hydraulic filter Replacing the hydraulic oil Engine
filter element [Page 90]
Work See chapter
Checking the nitrogen pres- Checking the hydraulic system
Checking the starter Checking the starter [Page 72]
sure in the bladder accumula- accumulator [Page 92]
Checking the injection system Checking the high pressure
tor
line connections for the injec-
Releasing the hydraulic pres- Equalizing the pressure of the
tion system [Page 63]
sure hydraulic circuit
Changing the hydraulic oil Changing the hydraulic oil Hydraulic system
[Page 87]
Work See chapter
Tracks Replacing the bladder accu- Contact a SANY maintenance

mulator technician
Work See chapter
Changing the oil of the track Changing the engine oil of the Maintenance work every 10000 hours
drive track drive [Page 105] of operation
For a thorough overhaul of the machine, contact SANY.
Maintenance work as needed Maintenance schedule
61 5
Maintenance work as needed Tracks

The following maintenance work must be carried out if there is a
Work See chapter
need or signs of wear appear during the daily check of the ma-
Checking the connection on Checking and tightening the
chine.
the track shoe track shoe fastening screws
Engine [Page 100]
Work See chapter Readjusting the track tension Checking and adjusting the
track tension [Page 100]
Regeneration of diesel particu- Regeneration of diesel particu-
late filter late filter [Page 72]
Work equipment
Engine cooling Work See chapter
Work See chapter Replacing the excavator teeth Replacing the excavator teeth
[Page 109]
Checking and cleaning the Checking and cleaning the
cooling fins outside of the coolant tank and Replacing the bucket Exchanging the bucket [Page
radiator [Page 74] 112]
Cab
Work See chapter
Checking the gas pressure Checking the gas spring of the

spring of the roof hatch cab roof hatch [Page 117]
Engine Engine
6 62
Engine ▪ Damaged hoses

Damage to the engine may only be rectified by appropriately
Engine trained personnel. It is therefore important to report any damage
discovered to maintenance personnel without delay.
WARNING Eliminating defects:
Fire danger resulting from spilled consumables in the engine ▪ Determine the causes of leaks and eliminate them.
compartment ▪ Exchange worn or damaged cables, lines, belts and hoses.
Heat in the engine compartment can ignite spilled consumab- ▪ Loose screws and bolts must be tightened with the spe-
les and lead to severe burns and engine damage. cified tightening torque. See also Tightening torques [Page
• Determine the cause of the consumables spill immedia- 153]
tely.
• Immediately eliminate the cause, for example, leakage.
• Remove the spilled consumables immediately.
The engine must be visually inspected before every start.

Attention must be paid to the following:
▪ Leaks of oil, fuel or cooling fluid
▪ Loose screws
▪ Worn or loose belts
▪ Loose connectors
▪ Damaged electrical cables
Checking the high pressure line connections for the injection Engine
63 6
Checking the high pressure line 1. Check the high pressure pipe for cracks and damage.
connections for the injection system 2. Check the pipe connections.

3. Check that the pipe’s fastening clips are firm and tighten if
needed.
4. To replace any faulty parts, contact your SANY agent.
» The high pressure line connections for the injection system
have now been checked.
Checking and adjusting the

compressor belts
Inspecting the belts
➢ The machine is in the maintenance position.
➢ The belt tension meter is ready for use.
Checking the high pressure line 1. With a force of 58.8 N, press the belt tension meter onto the
middle of the belt between the drive pulley and the com-
(1) Fastening clips (3) High pressure line
pressor pulley.
(2) Supply pump
⇨ The belt must be able to deflect 5-8 mm.
The high pressure line runs between the supply pump and injec-
2. Check the belt for wear.
tion nozzle and is under high pressure. The high pressure line is
3. Check the pulleys for wear.
held in place by 5 fastening clips.
Engine Checking, tightening and replacing the fan belts
6 64
4. Replace worn or damaged belts or pulleys, or contact your Adjusting the belts
SANY agent for replacement of faulty parts.
» The belts have now been inspected.
Reference values for belt tension
New belt Used belt
637±108 (N) 441±88.2 (N)
Compressor
(1) Belt (4) Compressor pulley

(2) Drive pulley (5) Screw
(3) Bracket
Checking, tightening and replacing the fan belts Engine
65 6
1. Loosen the screws. Tightening the fan belt

2. Insert the tension adjustment stick between the brackets.
3. Use the stick to move the bracket in order to deflect the belt
5 - 8 mm.
4. Tighten the screws in order to fix the bracket, and then pull
out the stick.
» The belts are now adjusted.
A newly fitted V-belt must be checked and adjusted

after one hour of operation.
Checking, tightening and replacing the

fan belts
Fan belt
1. With a force of 98 N, press the belt tension meter onto the
middle of the belt. (1) Adjusting screw (3) Nut
⇨ The belt must be able to deflect 7 ― 10 mm. (2) Screw
2. Visually inspect the belt for wear and damage 1. Loosen the screw and nut.
3. Replace worn and damaged belts. 2. Tighten or loosen the fan belt with the adjusting screw.
In case of problems, contact your SANY maintenance technici- 3. Re-tighten the screw and nut.
an. 4. Run the engine at low speed for 5 min.

5. Check the tension once again.
Engine Engine oil, replacing the engine oil filter and checking the
6 66
» The fan belt is tightened.

NOTICE
Engine oil, replacing the engine oil Motor damage from unsuitable consumables or from overfil-
filter and checking the engine oil ling.
return valve The use of unsuitable consumables can damage the motor.
Overfilling the consumable levels leads to spattering or over-
Avoid environmental damage resulting from consum-
flowing fluids, to overheating and to damage.
ables. Observe applicable laws for the disposal of
• Use only recommended consumables.
materials harmful to the environment.
• Do not fill beyond maximum fill level.
Changing the engine oil
WARNING
Hot surfaces or consumables
Burns if touched
• Wear protective gloves
• Work only on parts which have cooled down
Oil pan
Engine oil, replacing the engine oil filter and checking the Engine
67 6
(1) Oil drain plug Changing the engine oil filter

WARNING
➢ A container is ready to catch the engine oil.
1. Remove the bottom cover. Hot surfaces or consumables
2. Place the container under the drain valve. Burns if touched
3. Carefully open the drain valve and drain the oil. • Wear protective gloves
4. Close the drain valve again after draining. • Work only on parts which have cooled down
5. Dispose of the drained oil in an environmentally sound
manner.
NOTICE
6. Re-attach the bottom cover.
Motor damage from unsuitable consumables or from overfil-
7. Open the bonnet.
ling.
8. Open the engine oil tank cap.
The use of unsuitable consumables can damage the motor.
9. Refill the engine oil.
Overfilling the consumable levels leads to spattering or over-
10.Switch on the machine and run the engine idly for 1 min.
flowing fluids, to overheating and to damage.
11.Switch the machine off again.
• Use only recommended consumables.
12.Check the oil level. The oil level must be between the H and
• Do not fill beyond maximum fill level.
L marks on the dipstick. Top up the engine oil if needed.
» The engine oil has now been changed.
Engine Engine oil, replacing the engine oil filter and checking the
6 68
5. Check the seals on the filter element seat for wear. Worn
seals on the filter element seat can cause oil leaks.
6. Fill the new filter element with clean engine oil.
7. Apply engine oil to the seal and the thread.
8. Install the new filter element on its seat.
9. Turn the filter element 3/4 to 1 turn. The installation requires
contact between the holder surface and the filter element
seat.
10.After replacing the filter element, open the bonnet and fill
Engine engine oil through the filler opening until the oil level is
(1) Filter seat (2) Filter between the H and L marks of the dipstick.
➢ Filter element spanner is ready for use. 11.Switch on the machine and leave the engine to idle for
➢ The machine is in the maintenance position. 5 minutes.
1. Open the maintenance door on the right-hand side. 12.Switch the machine off again.
2. Turn the filter element to the left using the filter element 13.Check the oil level. The oil level must be between the H and
spanner. L marks on the dipstick. Top up the engine oil if needed.
3. Remove the filter element and dispose of it in an environ- » The filter element has now been replaced.
mentally sound manner.

4. Clean the filter element seat.
Replacing the engine air filter Engine
69 6
Checking the engine oil return valve
WARNING

Burns if touched
Engine
(1) Return valve (4) Return hose

(2) Pipe clip (5) Tube clamp
(3) Return pipe
➢ The engine has cooled down.
➢ Pliers are ready for use.
Engine Replacing the engine air filter
6 70
➢ 6 mm, 14 mm and 22 mm torque wrench are ready for use. full power of the engine will not be available. An indicator shows
➢ Clean cloth is ready for use. when the air filter needs to be changed.
1. Open the bonnet.
2. Remove the tube clamp with the pliers.
3. Remove the pipe clip with the 6 mm wrench.
4. Remove the return hose and return pipe.
5. Remove and check the return valve.
⇨ Clean the valve if it is clogged or blocked.
⇨ Replace the valve if it is damaged.
6. Mount the return valve and tighten it with a torque of 20 –
29 Nm.
7. Mount the return hose and return pipe.
8. Tighten the pipe clip with a torque of 3 Nm.
» The return valve has now been inspected and cleaned.
Replacing the engine air filter

The filter cartridge and filter element must be replaced after one
year of use, after 500 hours of operation or after 6 cleanings.
If the rubber seal is worn or significantly deformed, the vacuum
valve should be replaced. When the air filter is dirty, the engine Air filter
cannot be supplied with enough air due to a pressure drop. The

Regeneration of diesel particulate filter Engine
71 6
(1) Latch (3) Filter housing 5. Dispose of the filter elements in accordance with regulati-
(2) Vacuum valve ons.
6. Insert a new inner filter element, placing the open end for-
wards into the bracket.
7. Insert a new outer filter element, placing the open end for-
wards into the bracket.
8. Attach the cover with the vacuum relief valve pointing down.
9. Lock the latch diagonally. The filter elements are inserted
correctly if there is no gap between the housing and cover
when the latch is closed.
» The air filter has now been changed.
Replacing the filter element
(1) Cover (3) Inner filter element

(2) Outer filter element (4) Filter housing
1. Open the small maintenance door on the left-hand side and
release the latch.
2. Remove the cover.
3. Release and take out the outer filter element by turning it in
both directions.
4. Take out the inner filter element.
Engine Regeneration of diesel particulate filter
6 72
Regeneration of diesel particulate If the particle density exceeds a set value and automatic DPF
filter regeneration has been deactivated, the display indicates the

need for manual DPF regeneration.
WARNING
Manual regeneration of the diesel particulate filter
Risk of explosion and fire ➢ The machine is parked on ground that is even and load-
Explosions or fires resulting from the high temperatures of bearing.
DPF regeneration in explosive or high fire risk environments ➢ The area around the machine is free of flammable or explo-
may cause life-threatening injuries and burns. sive materials.
• Always deactivate DPF regeneration when working in ex- 1. Start the engine.
plosive or high fire risk environments. 2. Press the manual regeneration switch.
⇨ The DPF symbol on the display lights up.
Fuel combustion results in residues of soot and unburnt hydro-
⇨ The engine speed increases.
carbons. The diesel particulate filter (DPF) is regenerated by
⇨ Depending on the particle density, manual regeneration
burning the residues.
takes 30 – 50 min.
Once the particle density in the carbon-particulate filter has
3. The DPF symbol goes out.
reached a set value, passive regeneration of the diesel particu-
» Manual regeneration has now been carried out.
late filter is automatically initiated.
Once the machine has been operated for a preset time or the Checking the starter
DPF pressure falls below a preset value, active DPF regenerati- Contact your SANY agent to check the starter.
on is initiated. Regeneration is indicated by an indicator light.
Inspecting the compressor Engine
73 6
Inspecting the compressor Contact your SANY agent to remedy any damage.
Inspecting the alternator
1. Inspect the clutch and compressor for unusual noises.
Contact your SANY agent to inspect the alternator.
2. Switch the air conditioner on and off and check whether the
compressor and magnetic clutch switch on and off with the Checking the connections for the air
air conditioner. filter, turbocharger, aftercooler and
⇨ In case of any problem and to replace any parts,
engine clamps
contact your SANY agent.
Contact your SANY agent to check the connections for the air
» The compressor has now been inspected.
filter, turbocharger, aftercooler and engine clamps.
Checking and adjusting the valve

clearance
Since special tools are necessary for inspection and maintenan-
ce, contact your SANY agent for this.
Checking the exhaust system

connections
The exhaust system must be checked for the following:
▪ Completeness
▪ Secure installation of all parts
▪ Rust and damage to the connections
Engine cooling Checking and cleaning the outside of the coolant tank and
7 74
Engine cooling
Checking and cleaning the outside of
the coolant tank and radiator
WARNING
Cleaning with compressed air
Compressed air and flying parts can lead to eye injuries, cuts
and bruises.
Injury to persons standing nearby or damage to the engine is
possible.
Radiator
• Wear safety goggles.
• Do NOT aim the compressed air stream at anyone. (1) Radiator (2) Expansion tank
• Do NOT aim the compressed air stream at loose objects. ➢ The machine is in the maintenance position.
• Do NOT aim the compressed air stream at seals, rubber 1. Open the bonnet and the large maintenance door on the
hoses or electrical parts. left-hand side.
• NEVER use the compressed air stream for cleaning the 2. Loosen the screw.
engine. 3. Lift the plate.
4. Clean the plate.
5. Visually inspect the coolant tank and radiator.
Changing the coolant Engine cooling
75 7
6. Clean the outside of the coolant tank and radiator. The

pressure may not exceed 3 bar.
7. Check that the rubber hoses and tube clamps are firmly in
place and visually inspect them for damage and wear; re-
place if needed.
8. Remove the bottom cover and remove any dirt, debris or
leaves.
9. Re-install the cleaned cover and tighten the screw.
10.Close the bonnet and the maintenance lid on the left-hand
side. Under the upper carriage
» The coolant tank and radiator have now been inspected. (1) Drain valve
The expansion tank for the coolant is located behind the large
Changing the coolant
maintenance door on the left-hand side.
The coolant is an important protective agent against rust and
frost. The mixture ratio of coolant to water is determined by the
ambient temperature. See the following table for more specific
information about this ratio.
Cooling system interior
(1) Compensation tank

Engine cooling Changing the coolant
7 76
Minimum ambient temperature Volume ratio Undiluted coolant will freeze at -15 ℃, so store undiluted coo-
lant at temperatures over -15 ℃.
°C %
-10 30
WARNING
-15 36
Burns from escaping steam or hot coolant
-20 41 The escape of steam or hot coolant can lead to burns on eyes,
-25 46 hands and skin.
-30 50 • DO NOT open the filler opening of the cooling system if

the motor is still warm.
-35 54
-40 58
WARNING
A density meter must always be used when checking the mix-
ture ratio. Eye and skin injuries from coolant
When determining the mixture ratio, subtract 10 ℃ from the Contact with coolant can damage eyes and skin.
actual temperature. • Wear safety goggles and protective gloves.
Even in regions where frost protection is unnecessary, the mix- • If eyes or skin come in contact with coolant, wash the af-
ture ratio must not be lower than 30% (antifreeze volume/total fected body parts thoroughly with water and seek medical
volume of coolant ×100) in order to protect the cooling system attention if necessary.
from rust.
Changing the coolant Engine cooling
77 7
Avoid environmental damage resulting from consum- ➢ Water jerrycan containing at least 20 l distilled water is
ables. Observe applicable laws for the disposal of ready for use.
materials harmful to the environment. 1. Open the bonnet.

2. Carefully open the radiator cap.
The performance of the cooling system is lessened by deposits ⇨ Pressure is released.
in the radiator and cooling ducts. Therefore the cooling system 3. Remove the radiator cap and place the prepared container
must be cleaned when changing the coolant. under the drain valve of the coolant tank.
4. Open the drain valve of the radiator.
NOTICE
⇨ Coolant drains out. Properly dispose of the coolant.
Damage to the cooling system from frost 5. Close the drain valve.
Freezing water expands and can damage the coolant ducts. 6. Fill the coolant tank up with distilled water until the tank is
• Do not clean the cooling system if there is a risk of frost. full.
7. Start the engine and run it at low speed while watching the
coolant temperature display.
⇨ Coolant water heats up to 90 °C.
➢ A container is ready for the drained coolant. The volume of
8. After the coolant temperature reaches 90 °C, allow the en-
the container should be greater than the volume of the coo-
gine to run for 10 min.
lant.
9. Turn off the engine.
➢ Density meter is ready for use.
10.Open the drain valve of the coolant tank and drain the wa-
➢ Hose for transferring the coolant and the distilled water is
ter.
ready for use.
Engine cooling Checking the water pump
7 78
11.Clean the radiator with a detergent, following the instruc- Checking the water pump
tions for the detergent.
12.Close the drain valve.
13.Fill the tank with coolant (see mixture table) until the fluid
overflows from the filler opening.
14.Start the engine and run it at low speed for 5 min and then
at high speed for another 5 min.
⇨ Air escapes from the radiator
15.Open the large maintenance door on the left-hand side.
16.Look at the level of the coolant in the expansion tank. The
level must be between Maximum and Minimum. Top up
coolant if needed.
17.Turn off the engine and wait 3 min. Check the coolant level, Water pump
top up coolant if needed.
(1) Water pump
18.Close the radiator cap again.
» The coolant has now been changed.
1. Visually inspect the water pump for leaks.
2. In case of any problem and to remove, repair or replace the
water pump, contact your SANY agent.
» The water pump has now been inspected.
Replacing the fuel filter and fuel prefilter Fuel system
79 8
Fuel system WARNING

Eye injuries and bruises resulting from the release of pressu-
WARNING
rized fuel
Burns from the hot engine and igniting consumables
The fuel system is under high pressure. When replacing the
Contact with hot engine parts can lead to severe burns. Spil-
filters, fuel spraying out can cause eye injuries and bruises.
led consumables (e.g. released by damaged filter seals) can
• Do not work on the fuel system until the engine has been
be ignited by heat in the engine compartment and lead to
turned off for more than 30 seconds.
burns and engine damage.
• Allow the engine to cool for at least 15 min before any
To prevent machine damage, replace the filters using
work.
original replacement parts only.
• Wear protective gloves.
• Determine the cause of the consumables spill immediately
and remedy it. Avoid environmental damage resulting from consum-
• Tighten filters only with the torque specified. ables. Observe applicable laws for the disposal of
• Remove the spilled consumables immediately. materials harmful to the environment.
Replacing the fuel filter and fuel

prefilter
The filters can only function properly when they are free of im-
purities. If impurities enter the filter housing during maintenance,
Fuel system Replacing the fuel filter and fuel prefilter
8 80
they must be removed by rinsing the housing with clean fuel (1) Transfer pump (4) Filter cover
before installing. (2) Fuel pre-filter (5) Drain valve
(3) O-ring
Only rinse the filter housing with clean operating fluid.
Replacing the fuel prefilter
Filter cover
(1) Filler openings (2) Cover

➢ A container must be ready to catch the used fuel.
➢ A filter wrench must be ready for use.
➢ A torque wrench must be ready for use.
1. Open the maintenance cover on the right-hand side.
2. Place a container beneath the fuel pre-filter.
Replacing the fuel filter and fuel prefilter Fuel system
81 8
3. Open the drain valve. torque specified in the Appendix. See also Tightening tor-
⇨ Water and deposits flow out. ques [Page 153].
4. Drain any fuel which has collected in the filter element. 13.Close the drain valve.
5. Use the filter wrench to turn the filter cover anticlockwise » The fuel pre-filter has now been replaced.
and remove it. Set it aside for re-use later. To prevent engine damage, air must be purged from the fuel
6. Use the filter wrench to turn the filter element anticlockwise, system after the fuel pre-filter has been replaced.
remove it and dispose of it properly.
Replacing the fuel filter
7. Install the filter cover on the bottom of the new filter (replace
the O-ring as well).
8. Apply engine oil to the sealing surfaces.
9. Press the sealing surface of the filter cover on to the sealing
surface of the filter element and tighten the filter element by
1/4 - 1/2 turn.
⇨ The filter is now assembled.
10.Fill the new filter element with clean fuel through the 8 ope-
nings in the filter cover.
11.Remove excess fuel with a lint-free cloth.
12.Place the filter on the filter seat and tighten it until the seal-
ing surface of the filter element touches the sealing surface
of the filter seat. Then tighten the filter with the tightening
Fuel system Replacing the fuel filter and fuel prefilter
8 82
(1) Transfer pump (4) Filter housing ⇨ Water and deposits flow out.
(2) Fuel filter (5) Drain valve 4. Drain out any fuel which has collected in the filter element.
(3) O-ring 5. Use the filter wrench to turn the filter cover anticlockwise
and remove it. Set it aside for re-use later.
6. Use the filter wrench to turn the filter element anticlockwise,
remove it and dispose of it properly.
7. Install the filter cover on the bottom of the new filter (replace
the O-ring as well).
8. Apply engine oil to the sealing surfaces.
9. Press the sealing surface of the filter cover onto the sealing
surface of the filter element and tighten the filter element by
1/4 - 1/2 turn.
⇨ The filter has now been assembled.
Filter cover 10.Fill the new filter element with clean fuel through the 8 ope-
nings in the filter cover.
(1) Filler openings
11.Clean the filter with a cloth.
➢ A container is ready to catch the used fuel.
12.Place the filter on the filter seat and tighten it until the seal-
➢ Filter wrench is ready for use.
ing surface of the filter element touches the sealing surface
1. Open the maintenance lid on the right-hand side.
of the filter seat. Then tighten the filter with the tightening
2. Place the container under the fuel filter.
torque specified in the Appendix. See also Tightening tor-
3. Open the drain valve.
ques [Page 153].
Checking the fuel filter and fuel prefilter for leaks Fuel system
83 8
13.Close the drain valve.

14.Purge the air from the fuel system.
» The fuel filter has now been replaced.
To prevent engine damage, air must be purged from the fuel
system after replacing the fuel filter.
Purging the air from the fuel system
(1) Transfer pump (3) Start button for transfer

pump
(2) Drain valve
1. Fill the fuel tank up to the “Max” marking with fuel.
2. Pump fuel backwards and forwards with the transfer pump
until strong resistance is discernible.
3. Turn the ignition key to the ON position.
(1) Transfer pump
4. Run the engine idly at low speed for 10 min.
Fuel system Checking the fuel filter and fuel prefilter for leaks
8 84
» The fuel system has now been purged. ➢ Machine is now safely parked.
Checking the fuel filter and fuel 2. Remove the lower sealing cover of the fuel tank.
prefilter for leaks 3. Place a container underneath the drain valve to collect the
1. Start the engine and run it idly at low speed for 10 min.
fuel as it flows out.
2. Switch off the engine and wait at least 30 seconds until the
4. Unscrew the drain valve.
pressure in the fuel system falls.
⇨ Deposits, water and fuel flow out of the fuel tank.
3. Check the filter covers and installation surfaces for leaks.
5. When clean fuel emerges, close the drain valve once again.
» The filters have now been checked for leaks. If there are
6. Retighten the lower sealing cover.
leaks, check that the filters are firmly in place. If necessary,
7. Close the maintenance lid.
remove the affected filter and install it again. If the seal is
» The fuel tank has now been cleaned.
damaged, the filter element of the affected filter must be re-
placed with a new filter element. Replacing fuel lines
Cleaning the fuel tank Avoid environmental damage resulting from consum-
materials harmful to the environment. ➢ The machine is in the maintenance position.
Before starting, the fuel tank must be visually examined and
➢ Fuel line and tube clamps are ready for use.
cleaned.
1. Remove and dispose of the tube clamps.
Replacing fuel lines Fuel system
85 8
2. Remove the fuel line and dispose of it properly.

3. Install the new fuel line.
4. Fasten the fuel line with new tube clamps.
» The fuel line has now been replaced.
Hydraulic system Checking and cleaning the breather valve
9 86
Hydraulic system
Checking and cleaning the breather
valve
WARNING
The hydraulic circuit is always pressurised. Burns can result
from hot hydraulic oil spraying out or from contact with the
engine before it cools down or with its operating fluids.
• Allow the engine to cool for at least 15 min
• Allow hydraulic oil to cool to temperatures below 40 °C
• Release the pressure in the hydraulic system
• Open filler opening slowly and carefully Breather valve
(1) Butterfly nut (5) Breather valve
(2) Seal (6) Filter element
Dirt on the breather valve’s filter element must be removed to (3) Hexagon bolt (7) Housing
ensure an even flow of air through the breather valve. The filter (4) Seal
element and breather valve must be cleaned using only a brush
and the specified detergents.
Changing the hydraulic oil Hydraulic system
87 9
Breather valve parameters 9. Re-install the filter element.

Filter fineness: 10 μm 10.Re-install the breather valve. Tighten the hexagonal nut
Ambient temperature: -40 ℃ - 120 ℃ with the torque specified in the Appendix. See also Tighten-
Set pressure for inlet 0.004 MPa (at 1 l/min) ing torques [Page 153].
Set pressure for outlet 0.017 MPa (at 1 l/min) » The breather valve has now been inspected and cleaned.
➢ Torque wrench is ready for use. Changing the hydraulic oil
2. Clean the hydraulic tank and breather valve.
WARNING
3. Remove the breather valve. If the nuts and bolts are hard to Hot surfaces or consumables
undo, do not use excessive force otherwise the breather va- The hydraulic circuit is always pressurised. Burns can result
lve could be damaged. from hot hydraulic oil spraying out or from contact with the
4. Visually inspect the filter element for contamination and engine before it cools down or with its operating fluids.
remove it if contaminated. • Allow the engine to cool for at least 15 min
5. If the filter element is contaminated, clean it with a brush • Allow hydraulic oil to cool to temperatures below 40 °C
and then flush it out with the Kesaixin detergent. • Release the pressure in the hydraulic system
6. If this does not remove the dirt, blow compressed air • Open filler opening slowly and carefully
through the filter element from inside to outside. • Work only on parts which have cooled down
7. If the dirt cannot be eliminated or the filter element is dama- • Wear protective gloves
ged or worn, replace the filter element with a new one.
8. Allow the filter element to dry in a well-ventilated location.
Hydraulic system Changing the hydraulic oil
9 88
Avoid environmental damage resulting from consum- Machines equipped with a hydraulic hammer require the hyd-
ables. Observe applicable laws for the disposal of raulic oil to be changed at shorter intervals.

➢ Torque wrench is ready for use.
➢ 36 mm socket wrench is ready for use.
➢ Lever for socket wrench is ready for use.
➢ A container is ready to catch drained hydraulic oil.
1. Undo the bolts on the bottom cover plate and remove the
cover plate.
2. Start the engine.
3. Swing the upper structure in order to position the drain plug
beneath the hydraulic tank between the tracks.
4. Retract the boom, arm and bucket cylinders so that the
excavator teeth touch the ground.
5. Push the safety lever down and turn off the engine.
6. Disconnect the power supply using the battery isolator
switch.
7. Undo the butterfly nut on the breather valve.
Hydraulic tank
⇨ The pressure is released from the hydraulic tank.
(1) Breather valve (3) Sightglass
8. Remove the oil filler cap.
(2) Oil filler cap (4) Drain plug
Cleaning the hydraulic tank filter screen Hydraulic system
89 9
9. Place the container under the drain plug and remove the
drain plug with the lever.
⇨ Oil drains out. Properly dispose of the collected oil.
10.Check the seal on the drain plug and replace it if damaged
or worn.
11.Tighten the drain plug with the torque specified in the Ap-
pendix. See also Tightening torques [Page 153].
12.Fill hydraulic oil into the filler opening. Fluid capacities of the
machine. Hydraulic tank
13.Open the maintenance door on the right-hand side and (1) Breather valve (5) Rod
check the level in the sight glass. It should be at the Max. (2) Cover fastened with (6) Spring
mark. screws
14.Purge the air from the hydraulic circuit. (3) Fastening of filter screen
» The hydraulic oil has now been changed. on tank floor
(4) Filter screen
Cleaning the hydraulic tank filter
screen
Avoid environmental damage resulting from consum- ⇨ The pressure is released from the hydraulic tank.
ables. Observe applicable laws for the disposal of 2. Undo the 4 screws while holding the cap down firmly
materials harmful to the environment. (otherwise it will be pushed up by the spring).
Hydraulic system Replacing the hydraulic oil filter element
9 90
3. Remove the cover. Replacing the hydraulic oil filter

4. Hold the top end of the filter rod and pull the rod up. element
5. Remove the spring and the screen.
6. Clean the filter screen and flush it with cleaning oil. Replace WARNING
the filter screen if damaged.
7. Fasten the filter screen to the floor of the hydraulic tank.
8. Use the bulged part of the cap to push the spring down be-
fore tightening the 4 screws.
» The filter screen has now been cleaned.
• Open filler opening slowly and carefully

Replacing the hydraulic oil filter element Hydraulic system
91 9
5. Remove dirt from the base of the filter box, while ensuring
that the oil stays clean.
6. Clean the removed parts with cleaning oil.
7. Install a new filter element. Properly dispose of the old filter
element.
8. Install filter, valve and spring.
9. When assembling, use the bulged part of the cap to push
the spring down before tightening the 4 screws with a tor-
Hydraulic tank que of 113 N.
(1) Breather valve (4) Valve 10.Start the engine and run it idly at low speed for 10 min to
(2) Cover secured with screws (5) Filter remove air from the hydraulic line.
(3) Spring (6) Filter housing 11.Turn off the engine.

» The hydraulic oil filter element has now been replaced.
⇨ The pressure is released from the hydraulic tank.
2. Undo the 4 screws while holding the cap down firmly
(otherwise it will be pushed up by the spring).
3. Remove the cover.
4. Remove spring, valve and filter element and take out the
filter.
Hydraulic system Checking the hydraulic system accumulator
9 92
Checking the hydraulic system

accumulator
WARNING
Explosion danger from pressurized nitrogen gas
The hydraulic circuit is always pressurized. An explosion of
the nitrogen gas or pressurized hydraulic oil shooting out can
lead to serious injuries and machine damage.
• NEVER disassemble the accumulator yourself.
• Contact your SANY agent to have the pressure in the ac-
cumulator released completely.
Top view of pressure accumulator
• No hammering or welding on the accumulator.
(1) Pressure accumulator
• No rolling or striking of the accumulator.
The pressure accumulator stores the pressure of the hydraulic
• No open flames near the accumulator.
circuit. Even when the engine is switched off, the following tasks
can be carried out:
▪ The equipment can be lowered with the aid of gravity.
▪ The pressure in the hydraulic circuit can be released.
➢ The equipment is fully extended, meaning that the arm is
extended completely and the bucket is turned forward as far
as it goes and is 1.5 m above the ground.
Replacing hydraulic hoses Hydraulic system
93 9
1. Start the engine. Replacing hydraulic hoses

2. Turn off the engine and read the pressure in the hydraulic
accumulator within 15 seconds. WARNING
3. Start the engine. Hot surfaces or consumables
4. Pull the safety lever up and lower the equipment to the The hydraulic circuit is always pressurised. Burns can result
ground using the control lever. from hot hydraulic oil spraying out or from contact with the
⇨ If the equipment can be lowered to the ground by gravi- engine before it cools down or with its operating fluids.
ty, the pressure accumulator is functioning properly. • Allow the engine to cool for at least 15 min
⇨ If the equipment cannot be lowered or stops halfway, • Allow hydraulic oil to cool to temperatures below 40 °C
the pressure in the pressure accumulator of the hydrau- • Release the pressure in the hydraulic system
lic circuit has already fallen too far. In that case, the • Open filler opening slowly and carefully
pressure accumulator must be replaced by a SANY • Work only on parts which have cooled down
agent. • Wear protective gloves
5. Push the safety lever down and turn the ignition key to OFF.
» The hydraulic system pressure accumulator has now been
checked.
Replacing the hydraulic system pressure materials harmful to the environment.
accumulator
After 2 years or 4000 hours of operation, the pressure accumu- ➢ The machine is in the maintenance position.
lator must be replaced by a SANY agent. ➢ Hydraulic hose and torque wrench are ready for use.
➢ The hydraulic circuit has been purged.
Hydraulic system Replacing hydraulic hoses
9 94
1. Remove the hydraulic hose and dispose of it properly.

2. Clean the hose connections.
3. Screw new hydraulic hoses to the hose connections.
4. Tighten the screws with the required tightening torque. See
also Tightening torques for hydraulic screws [Page 153].
» The hydraulic hose has been replaced.
Checking the level of lubricating grease in the swing gear Slewing ring
95 10
Slewing ring ➢ The machine is in the maintenance position.

➢ The dipstick is ready for use.
Checking the level of lubricating 1. Remove the two bolts from the swing frame.
grease in the swing gear 2. Remove the cover.
3. Insert the dipstick through the opening into the lubricating
grease and pull it out again.
4. Check the colour of the lubricating grease.
⇨ If the lubricating grease is milk-white, it is contamina-
ted. Contact a SANY agent to change the lubricating
grease.
5. Check the level of the lubricating grease. At the point where
the pinion gear passes, the oil level should be at least
14 mm.
6. Install the cap and tighten the fastening screws.
» The oil level has now been checked.
Swing frame
(1) Swing frame (3) Dipstick

(2) Fastening screws
Slewing ring Lubricating the swing bearing
10 96
Lubricating the swing bearing 3. Wipe away any excess lubricating grease and dispose of it
properly.
4. Start the engine and lift the bucket 20 ― 30 cm above the
ground.
5. Rotate the upper carriage by 45°.
6. Lower the bucket to the ground.
» The swing bearing is lubricated.
Lubrication nipple


1. Wipe away old lubricating grease and dispose of it properly.
2. Add lubricating grease through the two lubrication nipples.
Fluid capacities of the machine.
Checking the swing motor’s level of hydraulic oil and changing Slewing ring
97 10
Checking the swing motor’s level of

hydraulic oil and changing the
hydraulic oil
WARNING
Burns from hot oil under pressure
Components and oil are hot and can lead to burns. The oil is
under pressure and can spray out and lead to burns. Even
cooled oil can lead to burns upon contact with skin.
• Allow the engine to cool.
• Avoid skin contact with the oil.
Rotating engine
• Wear protective gloves and safety goggles.
(1) Filler opening (2) Oil dipstick
• Slowly unscrew the cap of the level indicator and tank and
release the internal pressure.

Slewing ring Checking the swing motor’s level of hydraulic oil and
10 98
⇨ If the oil level is above the grooved area, hydraulic oil

must drained.
» The hydraulic oil level has now been checked.
Changing the hydraulic oil
Refill the hydraulic oil

1. Open the filler opening.
2. Add hydraulic oil through the filler opening.
Rotating engine 3. Close the filler opening.
4. Check the hydraulic oil level and repeat steps 1-3 if needed
(1) Drain valve
until the fill level is in the grooved area.
Check the hydraulic oil level » The hydraulic oil has now been topped up.
➢ The machine is in the maintenance position. If the hydraulic oil needs to be changed in low outside tempera-
1. Remove the oil dipstick and wipe it clean with a cloth. tures, the flow rate of the hydraulic oil may have fallen so much
2. Insert the dipstick completely. that the hydraulic oil flows only very slowly. In that case, the
3. Pull out the dipstick and look at the oil level. The fill level hydraulic oil temperature can be increased by moving the
must be in the grooved area. equipment.
⇨ If the oil level is below the grooved area, the hydraulic
Draining the hydraulic oil
oil must topped up.
Checking the swing motor’s level of hydraulic oil and changing Slewing ring
99 10
➢ A container is ready to catch the drained hydraulic oil.

1. Place the container under the drain valve and open the
drain valve.
⇨ Hydraulic oil drains out. Properly dispose of the drained
hydraulic oil.
2. Close the drain valve.
3. Check the hydraulic oil level and repeat steps 1 ― 2 if nee-
ded until the fill level is in the grooved area.
» The hydraulic oil has now been drained.
Tracks Checking and tightening the track shoe fastening screws
11 100
Tracks (1) Track shoe (2) Fastening screws

➢ The machine is in the maintenance position when in the
Checking and tightening the track forward position.
shoe fastening screws ➢ Torque wrench is ready for use.
The fastening screws must be firmly joined to the track shoe. 1. Inspect track shoes for loose screws.
2. Use the torque wrench to tighten loose screws in the spe-
cified order with the torque specified in the Appendix. See
also Tightening torques [Page 153].
» The fastening screws have now been inspected and tighte-
ned.
Checking and adjusting the track

tension
The pin rolls and bushings of the lower structure are worn down
differently depending on the work conditions and the ground.
Track shoe bolts

Checking and adjusting the track tension Tracks
101 11
Checking the track tension 3. If the maximum sag is between 10 ― 30 mm (guide value),
the track tension is in the normal range.
4. If the maximum sag is below 10 mm or above 30 mm, the
track tension must be adjusted.
» The track tension has now been checked.
Adjusting the track tension
WARNING
Severe bruising from escaping lubricating grease from the
Checking the track tension
screw plug
(1) Support roller (3) Maximum sag As a result of the high pressure being exerted on the lubri-
(2) Wooden beam (4) Idler cating grease, opening the screw plug can cause lubricating
➢ The machine is in the maintenance position. grease to fly out and lead to severe bruising.
➢ Ruler and straight wooden beam are ready for use. • During adjustment, never stand directly in front of the
1. Place the wooden beam on the track shoes between the screw plug.
idler and the front support roller, as shown in the figure. • Turn the screw plug no more than one complete turn.
2. Using the ruler, measure the maximum amount of sag in the
track. The sag is the distance between the highest point of
the track shoes and the underside of the wooden beam.
Tracks Checking and adjusting the track tension
11 102
Increasing the track tension 1. Fill lubricating grease into the lubricating valve using the
grease gun.
2. Start the machine and slowly drive forward 7 ― 8 m.
3. Bring the machine into maintenance position.
4. Inspect the track tension.
5. Repeat steps 1 ― 4 until the sag is between 10 ― 30 mm. If
the sag cannot be set as required, it could be because the
pin rolls and bushings are worn down. To replace the pin
rolls and bushings, contact your SANY agent.
Reducing the track tension

If the maximum sag is below 10 mm, the track tension must be
reduced by draining lubricating grease.
Increasing the track tension
(1) Screw plug (3) Track lubrication point

(2) Lubricating valve
If the maximum sag is above 30 mm, the track tension must be
increased.
➢ Grease gun is ready for use.
Checking the engine oil level of the track drive Tracks
103 11
may need to drive the machine slowly backwards and

forwards.
2. Inspect the track tension.
3. Repeat steps 1 ― 2 until a sag of 10 ― 30 mm is reached.
4. Tighten the lubricating valve clockwise with the torque spe-
cified in the Appendix. See also Tightening torques [Page
153].
5. Start the machine and slowly drive forward 7 ― 8 m.
6. Bring the machine into maintenance position.
Reducing the track tension 7. Inspect the track tension.
(1) Screw plug (2) Lubricating valve 8. Repeat steps 1 ― 7 until a sag of 10 ― 30 mm is reached. If
➢ The machine is in the maintenance position. the optimum sag cannot be set, it could be because the pin
➢ Long socket wrench is ready for use. rolls and bushings are worn down. To replace the pin rolls
➢ Torque wrench is ready for use. and bushings, contact your SANY agent.
➢ Grease gun is ready for use.

Checking the engine oil level of the
1. Using a long socket wrench, turn the lubricating valve antic-
track drive
lockwise no more than one complete turn.
The engine oil level must be checked on both track drives.
⇨ Lubricating grease runs out of the lubricating valve. If
the lubricating grease does not run out by itself, you
Tracks Checking the engine oil level of the track drive
11 104
WARNING
Burns from the hot engine and from hot, pressurised engine
oil
Burns can be caused by contact with hot engine parts and
engine oil and by hot, pressurised engine oil spraying out.
• Allow the engine to cool before refilling.
• Slowly unscrew the screw plugs in order to release the
internal pressure.
Track drive
Avoid environmental damage resulting from consum- (1) Track drive (3) Oil level inspection cap
ables. Observe applicable laws for the disposal of (2) Filler screw plug (4) Drain plug
➢ Torque wrench is ready for use.
➢ Correctly sized spanner is ready for use: 10 mm.
➢ Filler screw plug and drain plug are positioned as shown in
the illustration above.
➢ Screw plugs do not have any dirt clinging to them.
1. Undo the oil level inspection cap.
2. Visually check the engine oil level.
Changing the engine oil of the track drive Tracks
105 11
⇨ If the engine oil level reaches the 10 mm mark on the

WARNING
lower edge of the filler screw plug, the engine oil level is
in the optimum range. Burns from the hot engine and from hot, pressurised engine
⇨ If the engine oil level does not reach the lower edge of oil
the filler screw plug, the engine oil level is too low. Burns can be caused by contact with hot engine parts and
⇨ If the engine oil spills out over the edge of the filler engine oil and by hot, pressurised engine oil spraying out.
screw plug, the engine oil level is too high. Properly • Allow the engine to cool before refilling.
dispose of spilled engine oil. • Slowly unscrew the screw plugs in order to release the
3. Tighten the oil level inspection cap with the torque specified internal pressure.
in the Appendix. See also Tightening torques [Page 153].
» The track drive engine oil level has now been checked. Avoid environmental damage resulting from consum-
Changing the engine oil of the track
drive
The refill volume of engine oil depends on the engine type in
use.
Tracks Changing the engine oil of the track drive
11 106
2. Using the spanner, undo the drain plug and remove it.
⇨ The engine oil will drain out. Properly dispose of the
drained engine oil.
3. Tighten the drain plug to the torque specified in the Appen-
dix. See also Tightening torques [Page 153].
4. Using the spanner, undo the filler screw plug and oil level
inspection cap and remove them.
5. Add engine oil through the filler screw plug opening until the
engine oil runs out through the oil level inspection cap ope-
Track drive ning.
(1) Track drive (3) Oil level inspection cap 6. If the filler screw plug seal is damaged, replace it.
(2) Filler screw plug (4) Drain plug 7. Tighten the filler screw plug and oil level inspection cap to
➢ The machine must be in the maintenance position. the torque specified in the Appendix. See also Tightening
➢ A container must be ready to catch the drained engine oil. torques [Page 153].
➢ A torque wrench must be ready for use. » The engine oil of the track drive has now been changed.
➢ 10 mm spanner must be ready for use.

➢ Filler screw plug and drain plug must be positioned as
shown in the illustration.
➢ The screw plugs must not have any dirt clinging to them.
1. Place the container under the drain plug.
Lubricating the work equipment Work equipment
107 12
Work equipment 8. Secure the lubricating nipple with the cap to prevent the
entry of dirt.
» Lubricate work equipment.
Lubricating the work equipment
Overview
To operation the machine in a correct manner, the components
must be regularly lubricated.
If the lubricated parts emit unusual sounds, additional lubrication
beyond regular maintenance is necessary.
A new machine must be lubricated every 10 hours during the
first 50 hours of operation.
Following operation in water, the moist roll pins of the machine
must be lubricated.
1. Move the machine to the lubrication position.
3. Push the safety lever downwards.
4. Interrupt the power supply with the battery switch.
5. Remove the cap from the lubricating nipple.
6. Press lubricant into the lubricating nipple using a grease
gun.
7. Remove excess lubricant with a cloth.
Work equipment Lubricating the work equipment
12 108
(1) Rod socket-head bolts (6) Swing gear Lubrication points for the boom cylinder
(2) Rod bolts (7) Bucket connecting bolts
(3) Lubricating strip for boom (8) Connecting bolts
bolts, rod socket-head
bolts and boom socket-
head bolts
(4) Boom socket-head bolts (9) Bucket socket-head bolts
(5) Swing bearing
Boom bolts
Lubrication points for the swing bearing
Lubrication points for the boom, boom cylinder
and arm cylinder
Slewing ring
Lubricating strip for boom bolts, boom cylinder bolts and arm cylinder
Replacing the excavator teeth Work equipment
109 12
bolts Lubrication points for the arm-to-bucket

connection
Lubrication points for the arm-to-boom
connection
Bucket connection
Replacing the excavator teeth

Bearing boom / arm Worn out excavator teeth must be replaced.
Work equipment Replacing the excavator teeth
12 110
Preparing the machine Removing the excavator tooth
WARNING
Injuries from pins popping out and fragments flying around

When striking the pins, these can pop out and fragments that
break off can fly around. This can lead to injuries.
• Wear safety goggles
• Prevent access to the work area.
Setting down the bucket

1. Set the bucket down on a block as shown in the figure.
4. Interrupt the power supply with the battery switch.
» The machine has now been prepared. Removing the excavator tooth
Replacing the excavator teeth Work equipment
111 12
➢ The machine has now been prepared.

1. Hold the metal bolt to the pin. The diameter of the bolt must
be a bit smaller than the pin.
2. Hit the bolt with a hammer until the pin can be removed.
3. Extract and dispose of the excavator tooth.
» The excavator tooth has been removed.
Installing the excavator tooth
WARNING
Injuries from pins popping out and fragments flying around
Installing the excavator tooth
When striking the pins, these can pop out and fragments that
➢ The machine has now been prepared.
break off can fly around. This can lead to injuries.
1. Clean the fitting if necessary
2. Insert the excavator tooth into the fitting.
⇨ The pin hole of the fitting and the excavator tooth must
be on top of each other.
3. Insert the pin into the pin hole.
4. Drive the pin into the pin hole with a hammer until the pin is
completely in the hole.
» The excavator tooth has been installed.
Work equipment Exchanging the bucket
12 112
Exchanging the bucket Removing the bucket
WARNING
Crushing resulting from falling buckets and injuries from pins
and fragments popping out
If the bucket becomes loose, it can fall and crush feet or other
body parts. When striking the pins, these can pop out and
fragments that break off can fly around. This can lead to inju-
ries.
• Carefully lower the bucket and store securely.
• Wear safety goggles.
Bucket
(1) Arm (4) Connecting bolts

(2) Arm bolts (5) Connecting element
(3) Bucket
➢ The bucket must be on the ground.
Exchanging the bucket Work equipment
113 12
1. Remove the fastening screws and nuts from the connecting Installing the bucket
bolts and arm bolts.
2. Remove the arm bolts and connecting bolts.
⇨ The bolts are sealed with O-rings.
⇨ The bucket is now no longer attached to the arm.
3. Start the machine and lift the boom.
» The bucket has now been removed.
Bolt holes of the bucket
(1) Holes for connecting bolts (2) Holes for arm bolts
Work equipment Exchanging the bucket
12 114
5. Apply lubricant using the grease gun until the lubricant pus-
hes out.
» The bucket has now been installed.
Turning the bucket
Cross-sectional view of bolt connections
(1) Connecting element (3) Arm bolts

(2) Fastening screws (4) Lubrication point
1. Position the machine so that the bolt holes of the arm and
the deflection plate line up with the corresponding holes on
the bucket.
2. Turn off the engine and push the safety lever down. Bucket
3. Lubricate the length of the bolt.
(1) Boreholes on bucket (2) Boreholes on arm
4. Position the sealing ring to correspond to the arm pin. Re-
In order to excavate soil above the machine, the bucket may be
place defective seals if necessary.
turned to face forwards.
➢ The bucket must be suitable for forward operation.
Adjusting the bucket clearance Work equipment
115 12
➢ The bucket must be safely lowered to the ground. Example: The distance is to be set to 0.5 mm. The measured
➢ Machine is parked. distance is 3 mm. Therefore, two spacers of 1.0 mm and one of
1. Loosen the seals. 0.5 mm or one spacer of 2.0 mm and one of 0.5 mm must be
2. Remove holding pins from the bucket. removed.
3. Release the arm from the bucket.
4. Clean and lubricate the holding pins and boreholes.
5. Rotate the bucket through 180°.
6. Align the arm with the bucket to be attached.
⇨ The boreholes on the arm must be aligned with the bo-
reholes on the bucket.
7. Connect the arm and the bucket using the holding pins.
Adjusting the bucket clearance
8. Fasten the seals.
» The bucket has now been turned. (1) O-ring (3) Fastening screws
(2) Locking screw (4) Plate
➢ The feeler gauge is ready for use.
Adjusting the bucket clearance 1. Park the machine on even ground.
The bucket clearance is set by installing or removing spacers. 2. Lower the bucket to the ground.
There are three different spacers; those of 2.0 mm, 1.0 mm and 3. Allow the engine to rut at a low speed and slowly rotate the
0.5 mm. If the distance is to be for less than that of one spacer, upper carriage in an anticlockwise motion until the left inte-
no adjustment may occur. rior of the bucket touches the surface of the arm on the left-
hand side.
Work equipment Adjusting the bucket clearance
12 116

6. Move the sealing ring and measure the bucket clearance
with a feeler gauge.
7. Loosen the fastening screws on the plate and remove the
plate. Since the spacer has an opening, it is not necessary
to remove the screws for the adjustment.
8. The clearance distance is set by removing or adding the
appropriate number of spacers.
9. Affix the plate and tighten the fastening screws on the plate.
» The bucket clearance is now adjusted.
Mixing the windscreen washer fluid Driver's cab
117 13
Driver's cab Checking the gas spring of the cab

roof hatch
Mixing the windscreen washer fluid
The windscreen washer fluid is made up of detergent and water. WARNING
There are two types of detergent: one for temperatures down to
Risk of fatal injury from exploding gas spring
-10 ℃ (standard) and one for temperatures down to -30 ℃. The
The gas spring is under high pressure. If incorrectly operated,
detergent also acts as antifreeze.
the nitrogen gas can explode out, leading to serious injuries
Depending on the outside temperature, the detergent is used
and death.
either undiluted or mixed with water. See the table in the Ap-
• No hammering or striking of the gas spring
pendix for the mixture ratios. See also Specifications for con-
• No drilling or welding on the gas spring
sumables [Page 146].
• No open flames
Cab roof
(1) Gas springs

Driver's cab Air conditioner
13 118
The gas springs are fastened on both sides between the roof
WARNING
hatch and the cab roof, and must be replaced in the following
cases: Eye and skin injuries from coolant
▪ If the roof hatch can only be opened or closed with great Contact with coolant can damage eyes and skin.
force. • Wear safety goggles and protective gloves.
▪ If the roof hatch falls closed by itself. • If eyes or skin come in contact with coolant, wash the af-
fected body parts thoroughly with water and seek medical
Air conditioner attention if necessary.
The air conditioner must be switched on at least once per month
for 3 ― 4 min in order to lubricate the components of the com-
pressor.
Checking the refrigerant level

If there is not enough refrigerant, the functioning of the air condi-
tioner will be impaired and the compressor may be damaged.
(1) Sight glass (4) Empty (transparent, co-

lourless)
(2) Normal (5) Refrigerant container
(3) Low (formation of bubbles)
➢ Machine is parked.
Air conditioner Driver's cab
119 13
➢ Engine is running idly at high speed. Replacing the air circulation filter
1. Set the air conditioner to high refrigeration.
3. Open the maintenance door on the left-hand side.
4. Check the condition of the refrigerant in the sight glass on
the condenser reservoir.
⇨ If the refrigerant is flowing without bubbles, the refrige-
Air filter (screen type)
rant level is adequate.
(1) Locking nut (3) Fastening screw
⇨ If the refrigerant contains bubbles, the refrigerant level
(2) Air circulation filter
is too low. Contact your SANY agent to top up the refri-
gerant.
1. Remove the screw from the filter door. The door is located
⇨ If the sight glass is colourless and transparent: there is
at bottom right on the back wall of the cab.
no refrigerant. Contact your SANY agent to top up the
2. Unscrew the locking nuts and remove the air circulation
refrigerant.
filter.
» The refrigerant level has now been checked.
3. Insert a new filter and secure it with the locking screws.
Replacing the fresh air filter / air circulation 4. Close the filter door and secure it with the screw.
filter 5. Dispose of the used filter in accordance with national regu-
An air filter clogged with dirt will impair the functioning of the air
lations.
conditioner and cause noise.
» The air circulation filter has now been replaced.
Driver's cab Air conditioner
13 120
Replacing the fresh air filter
Fresh air filter
(1) Filter door (3) Locking nut

(2) Filter
1. Open the filter door.
2. Unscrew the locking nut from the cover and remove the
cover.
3. Remove the used filter and replace it with a new filter. Make
sure the filter is positioned correctly.
4. Re-install the cover and tighten the locking nuts.
5. Close the filter door and lock it.
6. Dispose of the used filter in accordance with national regu-
lations.
» The fresh air filter has now been replaced.
Procedure Error elimination
121 14
Error elimination Step 3: Securing replacement parts and tools for error eliminati-
on, such as:
Procedure ▪ T connector
The goal of error elimination is to determine the underlying cau- ▪ Hydraulic pressure gauge
se of the error, carry out repairs quickly and prevent a recur- ▪ Identifying the replacement parts using the part instructions
rence of the error. Step 4: Construction site visit
When eliminating errors, it is important to be familiar with design
Construction site
and function of the machine.
Step 5: Questions for the operator in order to clarify the details
Workshop of the error.
Step 1: Inspection and confirmation of the behaviour ▪ Was there anything unusual with the machine before the
Clarify the following points when an error message occurs: error occurred?
▪ Name of the customer ▪ Did the error occur suddenly or were there already prob-
▪ Machine model and serial number lems with the machine?
Questions for localizing the problem: ▪ Under what circumstances did the error occur?
▪ Error status ▪ Was repair work carried out before the error occurred? If so,
▪ Work being carried out when the error occurred what kind of work and by whom?
▪ Work environment ▪ Has this type of error occurred before?
▪ Maintenance background and details ▪ Besides the reported problem, have any other problems
Step 2: Determination of the cause of error occurred?
Step 6: Replicating the error
Error elimination Inspection before error elimination
14 122
▪ Start and operate the machine. Evaluate the error. Item Reference Measure
value
Do not carry out any inspections or measures that
have the potential to make the problem worse. Check the hydraulic oil - Fill with oil
level
Step 7: Determining the problem area and defining measures Check the hydraulic oil - Replace filter
for error elimination filter
Step 8: Carrying out measures to eliminate errors at the work Check the hydraulic oil - Fill with oil
location or in the workshop level of the swing motor
Inspection before error elimination Check the engine oil level - Fill with oil
of the diesel engine
Lubricating grease, coolant
Check the coolant level - Refill the coo-
Item Reference Measure lant
value
Check the engine air filter Clean/replace
Check type of fuel. Replace with
Check the hydraulic oil Clean the
recommended
filter screen screen.
fuel.
Checking the engine oil Fill with oil
Check the fuel level - Refill the fuel
level of the track drive
Check the fuel level for - Replace the
impurities fuel
Inspection before error elimination Error elimination
123 14
Electrical Item Reference Measure
Item Reference Measure value
value Check cabling Replace or
Check the battery termi- - Tighten or repair
nals and cabling for loose replace Check electrical system for - Disconnect
fitting and signs of corrosi- moisture and dry
on Check the fuses - Replace
Check the terminals and - Tighten or Check the alternator volta- Following Replace
cabling of the alternator for replace ge (engine throttled) operation for
loose fitting and signs of several minu-
corrosion tes: 27.5 –
Check the terminals and - Tighten or 29.5 V
cabling of the starter for replace Sound of the battery relay - Replace
loose fitting and signs of when the battery switch is
corrosion activated.
Check the battery voltage 20 – 30 V Replace
(engine switched off)
Check the electrolyte level Refill or re-

of the battery place battery
Error elimination Errors
14 124
Hydraulic, mechanical equipment Engine errors
Item Reference Measure Engine does not start

value Starter faulty
Inspection for unusual - Repair
Causes Remedy
noises and smells
Battery is depleted Charge or replace battery
Check for oil leaks - Repair
Battery cable loose or corro- Tighten loose cable, remove
Vent hydraulic system - Vent
ded corroded part
Blown fuse Replace fuse

Errors
Check the machine according to the following table and elimina- Starter or start relay faulty Replace start switch or relay
te errors. Contact your SANY technician to eliminate recurring Diesel engine faulty Repair/replace diesel engine
problems.
High viscosity of engine oil Use engine oil with suitable
viscosity
Starter OK
Causes Remedy
Fuel used up Refill fuel and purge air
Low opening pressure of fuel Adjust/replace fuel injection

injection
Errors Error elimination
125 14
Engine shuts down right after starting

Causes Remedy
Fuel valve of the injection Replace the fuel valve Causes Remedy
pump faulty Low idle speed Charge battery
Control rod of the injection Repair or replace control rod Fuel filter clogged Replacing the fuel filter
pump faulty Air purifier clogged Clean/replace air filter
Plunger of the injection pump Replace plunger assembly
Idle mode faulty at low speed
worn or stuck
Causes Remedy
Improper starting procedure Start the engine correctly
Low idle speed control faulty Repair/replace low idle speed
Air in the fuel system Purge air in fuel system
control
Fuel filter clogged Replacing the fuel filter
Fuel system leaking or blo- Repair fuel system
Air purifier clogged Clean/replace air filter
cked
Clutch slips Repair/replace clutch
Air in the fuel system Purge air in fuel system
Turbocharger air intake hose Tighten clips
Water in the fuel system Replace the fuel
clips are loose
Fuel filter clogged Replacing the fuel filter
Turbocharger intake hose is Replace hose
damaged
Diesel particulate filter (DPF) Clean DPF / start manual

is clogged regeneration
14 126
Causes Remedy Causes Remedy
Injection pump faulty Repair/replace injection pump Injection pump faulty Repair/replace injection pump
Poor alignment of air valve Adjust the air valve clearance Exhaust leaks, Replace corresponding parts
clearance air leaks
Broken sealing ring for the Replace corresponding parts Turbocharger assembly da- Replace turbocharger as-
cylinder, worn cylinder insert, maged sembly
stuck or broken piston ring or Exhaust valve clogged Clean exhaust pipe
defective contact between air
Poor alignment of air valve Adjust valve clearance
valve and insert
clearance
Insufficient fuel supply Soft or broken air valve spring Replace gas spring
Causes Remedy Broken sealing ring for the Replace corresponding parts
Fuel filter clogged Replacing the fuel filter cylinder, worn cylinder insert,
stuck or broken piston ring or
Water in the fuel system Replace the fuel
valve and insert
Fuel pump faulty Repair/replace fuel pump
Diesel particulate filter (DPF) Clean DPF / start manual
Low triggering pressure for Adjust/replace fuel injection is clogged regeneration
fuel injection, operation of
injection not effective
127 14
Engine overheats White exhaust fumes
Coolant lacking Refill the coolant Water in the fuel system Replace the fuel
V-belt slips because of loose Replace V-belt Fuel injection timing set incor- Adjust fuel injection timing
fitting or tear formation rectly
Radiator cap damaged or Replace radiator cap or clean Broken sealing ring for the Replace corresponding parts
radiator core clogged radiator core cylinder, worn cylinder insert,
Water pump damaged Repair/replace water pump stuck or broken piston ring or
Coolant leak because of bro- Replace cylinder head or
valve and insert
ken cylinder head or cylinder cylinder block seal closure
block seal closure Turbocharger faulty Repair/replace
Thermostat damaged Replace thermostat Defective valve oil seal or Replace valve oil seal, valve
worn valve spindle and valve and valve guide tube
Cooling system clogged by Remove impurities from the
guide tube
impurities cooling system
Wear, break or incorrect set- Set the pistons correctly or
Fuel injection timing set incor- Adjust fuel injection timing
ting of piston ring replace
rectly
Scratches on or wear of the Replace cylinder insert
cylinder insert
14 128
Black exhaust fumes

Causes Remedy
Causes Remedy Low triggering pressure for Adjust/replace fuel injection
Air purifier clogged Clean/replace air filter fuel injection or poor operation
Low triggering pressure for Adjust/replace fuel injection of injection
fuel injection or poor operation Fuel injection timing set incor- Adjust fuel injection timing
of injection rectly
Fuel injection timing set incor- Adjust fuel injection timing Fuel drips after injection be- Replace the fuel valve
rectly cause of damaged fuel valve
Fuel drips after injection be- Replace the fuel valve on the injection pump
cause of damaged fuel valve Air leaks on the inlet side of Repair the inlet side of the
on the injection pump the turbocharger turbocharger
Excessive injection from the Adjust the amount of fuel to be Turbocharger assembly da- Replace turbocharger as-
injection pump injected maged sembly
Excessive fuel consumption Poor valve clearance Adjust valve clearance
Causes Remedy
Fuel leak Repair/replace fuel system
Idle speed mode faulty Adjust idle speed mode

129 14
Soft or broken valve spring Replace valve spring Defective valve oil seal or Replace corresponding parts
Broken sealing ring for the Replace corresponding parts worn valve spindle and valve
cylinder, worn cylinder insert, guide tube
stuck or broken piston ring or Wear, break or incorrect set- Set the piston ring correctly or
defective contact between air ting of piston ring replace
valve and insert Scratches on or wear of the Replace cylinder insert
Diesel particulate filter (DPF) Clean DPF / start manual cylinder insert
is clogged regeneration Diesel particulate filter (DPF) Clean DPF / start manual
Excessive oil consumption

is clogged regeneration
Causes Remedy Low oil pressure
Unsuitable oil Only use oil specified in the Causes Remedy

Appendix. Too little oil Fill with oil
Excess oil Drain the excess oil Incorrect oil viscosity Only use oil specified in the
Oil leak from oil seal and/or Replace oil seal and/or sealing Appendix.
sealing ring ring Oil leak from oil seal and/or Replace oil seal and/or sealing
No preheating possible Carry out preheating process sealing ring ring
correctly Oil filter clogged Replace oil filter
14 130
Consistent noises
Causes Remedy
Safety valve sticks and/or soft Replace spring for safety valve Causes Remedy
spring for bypass valve and/or bypass valve V-belt loose Adjust V-belt
Oil pump screen clogged Clean the oil pump screen Cooler fan loose Fasten cooler fan
Oil pump worn Repair/replace oil pump Coolant pump bearing worn or Replace coolant pump bearing
damaged
Unusual engine noises
Incorrect valve clearance Adjust valve clearance
Escaping gas noises
Engine turning over backwards
Causes Remedy
Exhaust pipe fitting loose or Tighten exhaust pipe fitting or WARNING

exhaust pipe broken replace exhaust pipe
Burns from igniting exhaust fumes or burning engine
Fuel injection loose Replace sealing ring and tigh-
The exhaust fumes from the air filter or the engine can ignite
ten fuel injection
and lead to severe burns.
Fitting of exhaust manifold Tighten fitting of exhaust ma- • Turn off the engine immediately
loose nifold
Signs that the engine is starting to turn over backwards:
Cylinder sealing ring broken Replace cylinder sealing ring
▪ Loud popping noises after starting
▪ Smoke comes out of the air filter
▪ Speedometer and oil pressure gauge do respond
131 14
▪ Signal display for low oil pressure lights up Bucket tip falls off
Remedy: Causes Remedy
▪ Turn off the engine immediately
Spring deformed and too yiel- Replace pin of bucket tip
▪ Check and clean the air filter and the supply hoses
ding due to wear on the pin of
▪ Replace defective air filter and hoses
the bucket tip
Further errors Pin of bucket tip does not Replace pin of bucket tip
Loud noise of a component match the fitting
Causes Remedy Track buckling

Loose fastening element Tighten Causes Remedy
Too great a clearance Reduce clearance to less than Loose track Tighten track
between arm and bucket due 1 mm
High travelling speed on une- Travel slowly on uneven
to wear
ven ground in the direction of ground in the direction of the
the idler idler
14 132
Fan does not function Compressor does not function or is stiff
Incorrect connection to electri- Repair/replace Compressor coupling engage Repair

cal system due to cable break or defective
Air flow switch, relay or tempe- Repair/replace open circuit contact
rature switch damaged Loose compressor V-belt Adjust tension of compressor
Fuse fails or low battery volta- Repair/replace V-belt
ge Cable break or failure of the Replace coupling coil

compressor coupling coil
Fan runs but air flow is too weak
Too much or too little refrige- Refill/drain refrigerant
Causes Remedy rant
Air inlet blocked Clean/replace
Too little refrigerant
Evaporator or condenser fins Clean/replace
clogged Causes Remedy
Air admittance vent blocked or Clean/replace Cooling system leaking Repair
damaged Low refrigerant level Refill refrigerant

133 14
Standard display value during normal operating Display value of low pressure gauge too low
mode
Display values that are both too high and too low on the low pressure
gauge cause the standard value to drop
Causes
Causes Remedy
Ambient temperature: 30～50 ℃
Too little refrigerant Refill refrigerant
High pressure gauge: 1.47～1.67 MPa
Low pressure gauge 0.13～0.20 MPa Low pressure gauge displays a negative value
Causes Remedy
Display value of low pressure gauge too high
Low pressure hose blocked; Repair. Replace the container
Low pressure line surface frozen
expansion valve blocked by if blocked by ice
Causes Remedy
ice or dirt
Expansion valve too open Replace expansion valve
Evaporator frozen
Defective contact of the ther- Correctly install thermometer
mometer bulb for the expansi- bulb Causes Remedy
on valve Thermostat has switched off Replace thermostat
Too much refrigerant Drain refrigerant

Inlet of the expansion valve cold and frozen
Causes Remedy
Expansion valve blocked Clean/replace expansion valve

14 134
Outlet of the expansion valve is not cold. Low Display value of the high pressure gauge too low
pressure gauge may display negative values
Both the high pressure and low pressure gauges display values that are
too low
Causes Remedy
Causes Remedy
Thermometer tube or bulb for Replace expansion valve
the expansion valve leaking Too little refrigerant Refill refrigerant
Low pressure line blo- Clean/replace malfunctioning

Display value of high pressure gauge too high
cked/damaged component
Display values that are both too high and too low raise the standard
value Internal compressor error Replace compressor
Causes Remedy Low pressure gauge displays a negative value
Air in the air circulation system Purge air in air circulation Causes Remedy
system and refill refrigerant
Too little refrigerant Refill refrigerant
Too much refrigerant Drain refrigerant
Condensing effect of the condenser is insufficient cked/damaged component
Causes Remedy Internal compressor error Replace compressor
Condenser clogged up by dust Clean condenser

and dirt
Condenser fan damaged Check/replace condenser fan

Carrying out measures to eliminate errors Error elimination
135 14
Hot capacitor and high pressure pipe For this reason, when carrying out measures to eliminate error,
Causes Remedy care must be taken to conduct a comprehensive investigation
Too little refrigerant Refill refrigerant beforehand and to carry out the measures according to the
defined procedures.
Even if the error is eliminated, the same error can reoccur. To
cked/damaged component
avoid this, investigate and eliminate the cause of the error.
Internal compressor error Replace compressor
Disassembly and maintenance work on site
Negative cooling effect of an active heater If disassembly or maintenance work on the hydraulic equipment
Causes Remedy is carried out on site, there is a danger of dust entering the
equipment. Avoid refilling the hydraulic oil, replacing the filters
Hot water valve damaged or Close/replace hot water valve
or carrying out machine repairs during rain, strong wind or in
left open
environments with excessive dust.
Disassembly or maintenance of hydraulic equipment should be
Carrying out measures to eliminate
carried out in a workshop and its performance must be confir-
errors
med using test equipment.
Do not disassemble the components too hurriedly.
If the components are disassembled immediately after the error
occurred, the following happens:
▪ Parts not connected to the error or other parts are need-
lessly disassembled.
▪ It is not possible to fine the cause of error.
Error elimination Carrying out measures to eliminate errors
14 136
Replacing the batteries 7. Secure the battery with clamping plates.

8. Connect the positive pole of the one battery to the negative
WARNING pole of the second battery.
Risk of explosion if the battery poles are confused 9. Connect the connecting cables to the positive pole of the
Explosions resulting from overheating when a battery is second battery.
connected incorrectly may lead to serious injuries or death. 10.Connect the grounding cables to the negative pole of the
Sparks can ignite materials in the environment and lead to first battery.
burns. » The battery has now been replaced.
• Compare color markings for the plus and minus pole of
the battery with manufacturer’s instructions.
• Work carefully to avoid confusing the plus pole with the
minus pole.

1. Open the maintenance door under the steps.
2. Disconnect grounding cables and connecting cables.
3. Disconnect connecting cables between the batteries.
4. Remove the clamping plate.
5. Remove battery.
⇨ The battery has been removed.
6. Insert new battery.
Towing the machine Error elimination
137 14
Charging the battery Towing the machine
WARNING WARNING
Risk of explosion if the battery poles are confused Danger of injury from using unsuitable or defective wire ropes
Explosions resulting from overheating when a battery is Incorrectly towing the machine or using wire ropes in a man-
connected incorrectly may lead to serious injuries or death. ner contrary to the specifications can lead to serious injury or
Sparks can ignite materials in the environment and lead to even death.
burns. • Wear protective clothing when handling.
• Compare color markings for the plus and minus pole of • Use wire rope suitable for towing and without signs of ma-
the battery with manufacturer’s instructions. terial defects.
• Work carefully to avoid confusing the plus pole with the • Never tow the machine on a slope.
minus pole. • During the towing process, never stand between the to-
wing machine and the machine being towed.
Remove the battery and follow the instructions for the charging
• Operate the machine slowly and avoid applying sudden
device.
loads to the wire rope.
Since fast charging can reduce the service life of a
If the machine becomes stuck or can no longer move on its
battery, always observe the instructions for fast
own, it must be towed. Towing is only permitted in case of
charging.
emergency and for short distances.
The maximum towing force of the machine is 247,000 N.
Error elimination Towing the machine
14 138
1. Place wire ropes around the lower structure as shown in the

figure.
2. Wedge wood blocks or other protective materials between
the wire rope and lower structure.
⇨ Minimise friction between lower structure and wire rope.
3. Route wire ropes parallel to the ground and position them
towards the lower structure.
4. Hook the wire ropes into the towing equipment.
5. Tow the machine at a maximum speed of 1 km/h.
» The machine has been towed.
Preparing the machine Interface description
139 15
Interface description CAUTION
Preparing the machine Injury from additional equipment falling or the machine tipping
Raised loads can come loose and fall down, injuring people.
When installing or disassembling, the machine can become
unbalanced and tip over, injuring people standing nearby or
damaging the machine.
• Carry out installation and disassembly work only on
ground that is even and capable of bearing the load
• Move loads over 25 kg with a lifting device only
• Secure loads in accordance with regulations
• Do not stand under raised loads
• Be mindful of the centre of gravity of the machine and the
Hydraulic tank breather valve weight of the additional equipment
• Secure the machine and the work area
(1) Breather valve
• Do not drive the machine during installation and disas-
The machine must be prepared before installing or disassemb-
sembly work
ling additional equipment.
➢ Machine is parked on even ground capable of bearing the

load.
➢ The work area is secured with barriers.
Interface description Hydraulic circuit
15 140
➢ A lifting device is ready to move objects weighing more than 11.Replace any damaged O-ring seals.
25 kg. » The machine has now been prepared.
1. Lower the work equipment to the ground.
Hydraulic circuit
Removing and connecting additional equipment on the machi-
3. Turn the ignition key to the ON position.
ne's hydraulic circuit is the job of the maintenance personnel.
4. Pull the safety lever up and operate every control lever and
Before equipment can be removed from the hydraulic circuit or
pedal 2 ― 3 times within 15 seconds.
new equipment connected to it, the pressure in the hydraulic
⇨ The pressure remaining in the hydraulic lines is relie-
circuit must be released completely and the hydraulic oil must
ved.
have cooled down to at least 40 °C.
7. Turn the butterfly nut to open the breather valve at the top
of the hydraulic tank.
⇨ Pressure in the hydraulic system is relieved completely.
8. Check the temperature of the hydraulic oil.
⇨ If necessary, wait until the hydraulic oil has cooled to a
temperature below 40 °C.
9. Open the screw plugs on the arm's hydraulic supply and
return lines.
10.Check the hose connections for dirt and oil and clean if
needed.
Hydraulic circuit Interface description
141 15
Components
WARNING
• Open filler opening slowly and carefully
Components
(1) Hydraulic valve block (4) Control pedal

(2) Right joystick (5) Shut-off valve
(3) Left joystick
Shut-off valve
The shut-off valve is used for cutting off the flow of hydraulic oil.
The valve must be closed before disassembling or installing
additional equipment.
15 142
Position Alignment Function
RELEASED Lever is parallel to Valve is open

the pipe Hydraulic oil can
flow freely
BLOCKED Lever is perpendi- Valve is closed

cular to the pipe Hydraulic oil flow is
cut off
Selection valve
The selection valve regulates the direction of flow of the hydrau-
Selection valve
lic oil. The position of the selection valve depends on the additi-
onal equipment that has been retrofitted and the work mode (1) Lever (2) Selection valve
selected. The manual of the additional equipment must be ob-
served.
143 15
Additional filter Pressure accumulator
Pressure accumulator
(1) Pressure accumulator

Operation of a hydraulic hammer results in higher oil tempera-
Additional filter
tures. To protect the oil cooler, a pressure accumulator can be
(1) Additional filter
retrofitted. It may only be connected by the manufacturer of the
Operation of a hydraulic hammer results in heavier and faster additional equipment.
fouling of the hydraulic oil. An additional filter can be retrofitted
to avoid the need for more frequent oil changes. The manual of Connecting additional equipment to the
hydraulic circuit
the hydraulic hammer must be observed.
The standard pressure of the safety valve in the standby valve
is set at the factory before the machine is delivered.
15 144
The set pressures for the safety valve in the standby valve and 1. Remove the screw plugs from the pipe ends of the shut-off
for the hydraulic line switch are determined by the work mode valve and store them securely.
selected. 2. Have the manufacturer of the additional equipment connect
▪ In mode (S) for bidirectional additional equipment, such as the hydraulic line of the additional equipment to the hydrau-
the hydraulic shear, the set pressure is 27.4 MPa. lic circuit of the machine.
▪ In mode (B), e.g. for the hydraulic hammer, the set pressure » The unidirectional additional equipment has now been
is 20.6 MPa. connected to the hydraulic circuit.
Changes to the standard pressure setting must only be made by
Connecting bidirectional additional equipment (e.g.
SANY. quick change mechanism)
Connecting unidirectional additional equipment, ▪ Select work mode S in machine configuration

e.g. hydraulic hammer ▪ Factory setting of the safety valve is 27.4 MPa.
▪ Select work mode B in machine configuration ▪ A (bidirectional) hydraulic circuit is formed automatically at
▪ Factory setting of the safety valve is 20.6 MPa. the control valve because the oil flowing back can flow
▪ A (unidirectional) hydraulic circuit is formed automatically at through.
the control valve because the oil flowing back cannot flow ➢ Overflow valve is set to high pressure.
through. ➢ The machine has now been prepared.
➢ Overflow valve is set to low pressure. ➢ Shut-off valve is in the BLOCKED position.
➢ The machine has now been prepared. 1. Remove the screw plugs from the pipe ends of the shut-off
➢ Shut-off valve is in the BLOCKED position. valve and store them securely.
⇨ Make sure that removed parts are not damaged.
145 15
2. Have the manufacturer of the additional equipment connect

the hydraulic line of the additional equipment to the hydrau-
lic circuit of the machine.
3. Connect lines to the oil drain port of the bidirectional additi-
onal equipment.
» The bidirectional additional equipment has now been
connected to the hydraulic circuit.
Annex Fluid capacities of the machine
16 146
Annex Operating fluid Specification
10W-30 (-20°- 40 °C)

Fluid capacities of the machine
15W-40 (-15°- 50 °C)
Fluid capacities in l in l
40 (0° - 40 °C)
Engine oil pan 21.5
Gearbox oil 85W/140*
Rotary actuator 4
Hydraulic oil Caltex
Idler 5.5
HDZ32 [ISO VG32]
Hydraulic system 239 (-25° - 30 °C)
Hydraulic tank 340 HDZ46 [ISO VG46]*
Cooling system 20 (-20° - 40 °C)
Fuel tank 540 Fuel (diesel) Light diesel oil (GB252.81)*
-30 diesel fuel*

Specifications for consumables (-30° - 20 °C)
Operating fluid Specification -10 light diesel
Engine oil CJ-4 15W-40*, (-10° - 50 °C)
oil grade above API CF-4 0 light diesel
5W30 (-30° – 30 °C) (0° - 50 °C)
5W40 (-30° – 40 °C)

Specifications for consumables Annex
147 16
Operating fluid Specification
Lubricating grease NLGI No.2*
Coolant Shell Full Effect

50/50 antifreeze*
*Recommended specification
Windscreen wiper fluid
Operating region Mixture ratio Frost protection

temperature
Standard: tempera- 1/3 detergent to -10 ℃

ture does not fall 2/3 water
below -10 °C
Cold regions: tem- 1/2 detergent to -20 ℃

perature does not 1/2 water
fall below -20 °C
Frigid regions: tem- Undiluted detergent -30 ℃

perature falls below
-30 °C
Annex Specifications
16 148
Item Unit Value

Specifications
Max. altitude for use m 2,000
Ambient conditions:
Ambient temperatures °C -20 - +40
Item Unit Value
Dimensions and weights

Specifications Annex
149 16
Dimensions and weights: Item Unit Value
Item Unit Value H Ground clearance (without mm 550

grouser)
Kerb weight kg 34,900
J Track length mm 5,065
A Length over boom mm 11,100
R Track length mm 5,065
B Overall width mm 3,290
J Track length mm 5,065
C Height over boom mm 3,675
D Width of upper structure mm 3,145 Capacity:
E Height over upper structure mm 3,190 Item Unit Value
L Ground clearance of upper mm 1,185 Bucket capacity m³ 1.50

structure Engine output / rotations kW / rpm 210 / 1,900
I Turning radius of upper struc- mm 3,300 Slow travel speed km/h 3.4
ture (without work equipment)
Fast travel speed km/h 5.8
Width of lower structure mm /
No. of upper structure revolutions rpm 9.5
K Length of lower structure mm 5,065
F Shoe width mm 800
G Width over tracks mm 2,590

Annex Digging range
16 150
Digging range
Digging range
Item Unit Value
a Max. digging height mm 10,135
b Max. dumping height mm 7,180
c Max. digging depth mm 7,327
d Max. vertical wall cut depth mm 6,480
Max. radius mm 11,105
e Max. digging reach on ground mm 11,068
f Min. work equipment radius mm 4,310
g Max. height at min. work mm 8,480

equipment radius
Lifting range Annex
151 16
The values marked with * indicate the maximum load due to the
Lifting range hydraulic system. The other values indicate the maximum load
due to the stability analysis.
Lifting range
The lifting range diagram shows the range of the excavator in
lifting mode. The point of reference is the lifting point. The lifting
range corresponds to the maximum values in the last column of
the lifting capacity tables.
Annex Lifting range
16 152
3000 4500 6000 7500 9000 max

kg/mm mm
7500 7175 *6880 7130 *6633 7660
6000 8082 *6839 6926 *5531 8550
4500 9886 *9215 8537 *6654 7750 *5041 6970 *4940 9110
3000 14943 *12995 11078 *8725 9125 *6408 7737 4939 7221 *4628 9400
1500 16560 *12177 12023 *8293 9610 *6173 7611 4824 7111 4517 9440
0 16672 *11830 12397 *8015 9703 6001 7519 4741 7268 4592 9230
-1500 *12590 *12590 15761 *11767 12065 *7900 9523 *5922 7731 *4889 8760
-3000 *17812 *17812 13970 *11875 10902 *7930 8426 *5961 7570 *5543 7980
-4500 *13436 *13436 *10960 *10960 8487 *8127 6989 *6979 6780
Tightening torques Annex
153 16
Screw Strength class / tightening torques [Nm]

Tightening torques
8.8 10.9 12.9
Screws with strength classes 8.8, 10.9, 12.9
M33 1800 2520 3060
Screw Strength class / tightening torques [Nm] M8x1 24 36 42
8.8 10.9 12.9 M10x1.25 49 71 84
M6 9 14 16 M12x1.25 86 126 149
M8 23 32 39 M12x1.5 83 122 140
M10 44 65 76 M14x1.5 135 198 234
M12 77 113 131 M16x1.5 207 306 351
M14 122 180 212 M18x1.5 315 441 522
M16 189 279 329 M20x1.5 432 621 720
M18 270 387 450 M22x1.5 576 828 963
M20 383 549 639 M25x2 729 1044 1215
M22 522 747 873 M27x2 1071 1530 1800
M24 657 945 1089 M30x2 1449 2070 2421
M27 990 1395 1620
Tightening torques for hydraulic screws
M30 1305 1890 2205
Annex Tightening torques
16 154
Nominal thread Square Tightening torques

Number (b) Setpoint values Permissible range
(a) (mm) Nm Nm
9/16-18UNF 19 44 35~63
11/16-16UN 22 74 54~93
13/16-16UN 27 103 84~132
1-14UNS 32 157 128~186
13/16-12UN 36 216 177~245
1-7/16-12UN-2B 41 215 176~234
Screw Strength class / tightening torque [Nm]

Screws with strength classes 10.9 and 12.9
for the excavator 10.9 12.9
Screw Strength class / tightening torque [Nm] M12 113±10 137±10
10.9 12.9 M14 177±19 210±20
M6 13.2±1.4 16.2±1.6 M16 279±30 339±30
M8 31±3 38.7±4 M18 382±39 450±40
M10 66±7 78±7 M20 549±59 664±59

Tightening torques Annex
155 16
Screw Strength class / tightening torque [Nm] Hoses
10.9 12.9 Screw Torque [Nm] Fitting Torque [Nm]
M22 697±70 864±85 M30 135 ± 20 M22 125 ± 10
M24 927±103 1100±100 M36 166 ± 26 M24 142 ± 20
M27 1320±140 1683±150 M42 240 ± 30 M26 180 ± 20
M30 1785±170 2200±200
M33 2295±200 2900±280 Pipes

M42 4700±450 5985±590 metric Torque [Nm] imperial Torque [Nm]
M48 7140±650 9100±900 M14 24.5 ± 5 G1/8“ 16.7 ± 2
Hydraulic hose screw connections for the M16 45 ± 7 G1/4“ 36.7 ± 2.5
excavator M18 51 ± 8 G3/8“ 73.5 ± 5
Hoses M20 58 ± 8 G1/2“ 107.8 ± 7.8
Screw Torque [Nm] Fitting Torque [Nm] M22 74 ± 14 G3/4“ 161.7 ± 14.7
M14 24.5 ± 5 M14 34.3 ± 5 M24 74 ±14 G1“ 220 ± 25
M18 51 ± 8 M16 54 ± 5 M26 105 ± 20
M22 74 ± 14 M18 70 ± 10
M26 105 ± 20 M20 93 ± 10

Annex Tightening torques
16 156
Plugs
metric Torque [Nm] imperial Torque [Nm]
M20 49 ± 5 G3/8 68.6 ± 20
M24 68.6 ± 10
Fittings
imperial Torque [Nm]
G3/4 (A) 161.7 ± 14.7
Other screw connections for the excavator
Tightening torque [Nm]
Filler opening, track drive
Track shoes 600-680; 120°±10°
External mirrors 4.0~5.4
Track tension lubricating valve 78.4
Hydraulic oil filter
Hydraulic oil drain plug

Loading information Annex
157 16
Machine identification
Loading information
Product designation: Hydraulic excavator
SY335 C9
Type designation: SY335 C9
WARNING Manufacturer: SANY Germany GmbH

SANY Allee 1
Risk of the machine slipping, turning or falling
DE-50181 Bedburg
To prevent risks arising from an incorrectly secured machine
• Use a non-slip mat. Specifications:
• Use only the specified lashing points.
Weight [t] 34,900
• Secure the upper carriage to prevent it swinging.
Position of the centre of 2430 / 1700 / 1250
• Secure the moving parts of the machine.
gravity [mm]
Select the lifting gear Position of the centre of gravity of the machine
If no lifting gear of the correct rating is available, use
An adhesive label indicates the centre of gravity of
lifting gear of the next higher rating.
the machine.
Illustrations
All illustrations are schematic representations only.
Annex Loading information
16 158
Lashing points
The machine must be lashed to the transport

trailer at all the lashing points that are provided.
The lashing points on the machine are indicated
by adhesive labels.
Loading information Annex
159 16
Interfaces: Lashing point specification for handling equipment:
Type of contact Metal / non-slip mat Lashing point tensile force 24350
Contact position Chain on the loading surface [daN]
Vertical lashing angle α 8.2° < α < 45° Lashing point load marking
Horizontal angle β 45° < β < 55°
Adhesion coefficient of fric- 0.6 Lashing point number 4
tion
Lashing equipment:
Specific lashing point load: Lashing equipment capacity 24350
Lashing point tensile force 24350 [daN]
[daN] Type of lashing equipment Chains with chain tensioner
Lashing point load marking
Lashing point number 4

Annex Diagrams
16 160
Diagrams
Hydraulic diagram
Electrical diagram
Glossary
161
Glossary
assembly instructions user manual

The assembly instructions help to assemble the machine Information that helps the operating, maintenance and as-
before operation. They specify all work steps required to in- sembly personnel to use the product safely and in the in-
stall the machine as intended by the manufacturer. tended manner. The operating instructions consist of the
operator manual, maintenance manual and assembly in-
Loading information structions as well as electrical and hydraulic diagrams.
Data sheet or information card with instructions for safe
loading and lashing the machine on a transport trailer.
maintenance manual
The maintenance manual is aimed at the end user’s service
personnel. Here the service personnel are provided with all
information for maintenance work on the machine to gua-
rantee safe operation.
Operator manual
The operator manual is aimed at the machine operator. It
contains all information necessary for using the machine
safely and in the intended manner.
Index
162
Index
A E
Air filter, 119 Ear protection, 28
Alternator, 73 Emergency exit, 30
Ambient conditions, 14 Emergency stop, 29, 29
End user, 15
B Engine, 62
Breathing mask, 28 Engine oil, 66
Bucket, 112 Engine oil filter, 67
Bucket clearance, 115 Excavator teeth, 109
Exhaust system, 73
C
Camera, 31 F
Compressor, 73 Fan belt, 65
Compressor belts, 63 Fire extinguisher, 31
Cutting wheel, 30 Fluid capacities, 146
Fuel pre-filter, 80
D
Danger, 13 G
Display, 40 Gas spring, 117
Driver warning system, 31
H
Handles, 32
High pressure line, 63
High-visibility protective clothing, 27
Horn, 31
Hours of operation, 52
Index
163
I R
Incorrect use, 14 Radiator fins, 74
Inspecting the machine daily, 16 Railing, 32
Intended use, 14 Rating plate, 37
Rear-view mirrors, 32
K Residual dangers, 27
Key with changing functions, 40 Return valve, 69
L S
Lifting range, 38 Safety gloves, 28
Lubrication schedule, 37 Safety goggles / protective mask, 28
Safety helmet, 27
M
Safety instruction, 15
Main display screen, 41
Safety instruction, structure, 12
Main menu, 46
Safety lever, 30
Maintenance schedule, 16, 56
Safety markings, 33
Maintenance work, 16
Safety shoes, 27
Monitoring and control unit, 40
Seat belt, 32
O Status LED, 40
Operating the machine, 16 Steps, 32
Operator, 15 T
Overload warning, 33
Towing, 137
P Track shoe, 100
Password, 45 Track tension, 101
Personal protective equipment, 27 Transfer pump, 80
Pressure accumulator, 92 W
Prevention, 27
Water pump, 78
Weather-resistant clothing, 28
Windscreen washer fluid, 117
Workshop personnel, 16

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User Manual

Tel.: -49 2272 90531 100

Fax: -49 2272 90531 109

Service Number: 00800 88888 318

2.8 Safety equipment 29 3.1.1 Display items and operation 41

2.8.1 Emergency stop 29 3.2 Entering the password 45

2.8.2 Emergency exit 30 3.3 Main menu 46

2.8.3 Safety lever 30 3.3.1 Selecting an option 46

2.8.4 Camera 31 3.3.2 Viewing machine status information 47

2.8.6 Horn 31 3.3.4 Viewing error messages 48

4.2 Maintenance while the machine is running 55 5.5.4 Slewing ring 58

5 Maintenance schedule 56 5.5.5 Tracks 58

5.1 Maintenance work at first inspection 56 5.5.6 Cab 58

5.1.1 Engine 56 5.6 Maintenance work every 1000 hours of 58

5.3.1 Work equipment 57 5.6.3 Slewing ring 59

5.7 Maintenance work every 2000 hours of 59 5.10.5 Cab 61

5.8.1 Engine 60 6.4 Checking, tightening and replacing the fan 65

5.8.2 Hydraulic system 60 belts

operation checking the engine oil return valve

5.10.1 Engine 61 6.7 Regeneration of diesel particulate filter 72

5.10.2 Engine cooling 61 6.8 Checking the starter 72

5.10.3 Tracks 61 6.9 Inspecting the compressor 73

6.11 Checking the exhaust system connections 73 leaks

6.12 Inspecting the alternator 73 8.3 Cleaning the fuel tank 84

Fuel system 79 9.6 Replacing hydraulic hoses 93

14.2 Inspection before error elimination 122 16 Annex 146

14.3 Errors 124 16.1 Fluid capacities of the machine 146

14.3.1 Engine errors 124 16.2 Specifications for consumables 146

14.3.2 Further errors 131 16.3 Specifications 148

14.4.2 Replacing the batteries 136 16.6 Tightening torques 153

16.6.4 Hydraulic hose screw connections for the 155

16.6.5 Other screw connections for the excavator 156

16.7 Loading information 157

16.8 Diagrams 160

Introduction This is a copy of the original instructions. In case of

Signal word Colour Meaning

• Prevention measures tion. If not avoided, death or seri-

Introduces important information (for example, manu-

Safety ▪ Carrying passengers

▪ Driving while operating the equipment or lifting objects Target group

▪ Operating the machine

Duties of workshop / specialist personnel

Mechanical danger zones injury from screw plug

Hydraulic danger zones

Location Danger Location Danger

Prevention: the lifting equipment may be exchanged by the operator. To

securely. Combining lifting equipment

machine damage can result. When combining lifting equipment,

ground, driving over obstacles or on steep surfaces (slope Power cables

Nominal voltage [V] Safety clearance [m] Flammable / explosive environment

Extreme climatic conditions

Personal protective equipment

Emergency exit the operator seat.

(1) Unlocking position (2) Locking position

Visual and acoustic driver warning system

Saving oneself always has priority.

Sign Location Meaning

On the diesel filler Naked flames are

On the bonnet Do not step on