Professional Documents
Culture Documents
Maintenance Manual
Hydraulic Excavator
SY16C
V. 07/2017 EN
Translation of the original user manual
Contact
Sany Allee 1
50181 Bedburg
Germany
E-Mail: service@sanyeurope.com
Web: www.sanyeurope.com
Table of contents
5.3 Slewing gear lubrication points 40 7.4 Checking and adjusting the fan belt 48
5.4 Swivel cylinder lubrication points 40 7.5 Replacing the engine oil and engine oil filter 50
5.5 Boom suspension lubrication points 40 7.6 Replacing the engine air filter 53
5.7 Lubrication points for the excavator arm 41 7.8 Checking and adjusting the valve clearance 55
suspension system
7.9 Inspecting the alternator 55
5.8 Lubrication points for the boom cylinder 41
7.10 Checking and cleaning the outside of the 56
5.9 Bucket suspension system lubrication 42 coolant tank and radiator
points
7.11 Changing the coolant 58
5.10 Bucket cylinder lubrication points 42
7.12 Checking the water pump 61
5.11 Blade lubrication points 42
8 Fuel system 62
Table of contents
5
8.6 Checking the fuel filter and fuel prefilter for 70 10.1 Overview 82
leaks
10.2 Maintenance overview 84
8.7 Purging the air from the fuel system 70
10.3 Lubricating the slewing ring 85
8.8 Cleaning the fuel tank 71
11 Tracks 86
8.9 Replacing fuel lines 71
11.1 Overview 86
9 Hydraulic system 72
11.2 Maintenance overview 88
9.1 Overview 72
11.3 Checking and adjusting the track tension 89
9.2 Maintenance overview 74
11.4 Bleeding the drive motors after changing 91
9.3 Changing the hydraulic oil 75 the gearbox oil
9.4 Checking and cleaning the breather valve 76 11.5 Checking the drive motor oil level and 92
Table of contents
6
12.1 Replacing the excavator teeth 94 14.5.1 Disassembling the hydraulic system and 118
conducting maintenance work on it
12.2 Bucket 97
14.5.2 Replacing the battery 118
12.3 Adjusting the blade width 100
14.5.3 Charging the battery 119
13 Error detection 101 14.5.4 Fuses 120
13.2 Maintenance personnel 101 14.5.6 Starting assistance from additional batter- 122
ies or generators
13.3 Service personnel 101
15 Additional equipment 124
13.4 Error codes 101
15.1 Quick change system 125
14 Error elimination 103
15.1.1 Installing the quick change mechanism 125
14.1 Procedure 103
15.1.2 Disassembling the quick change mecha- 126
14.2 Errors 105 nism
14.2.1 Engine errors 105 15.1.3 Fitting a bucket with the quick change 127
16.1 Preparing the machine 128 18.2.1 Fluid capacities of the machine 141
17 Disposal 135
19 Diagrams 148
18 Annex 136
Header Markings
The header contains the number of pages, the chapter heading Markings are used to make the text easier to follow. The follow-
(in bold) and the heading of the respective subchapter. The ing markings are used:
chapter numbers with an orange background are provided on
[F1] Keys, softkeys, switches, buttons
the outer edge as an aid to orientation.
[F1]+[F2] Press key combinations at the same
Handling instructions time
The handling instructions show how to perform a task step by [F1] [F2] Press key combinations in succession
step. The handling instructions include: «Menu» Menu names, system messages
▪ No, one or more than one operational requirement. A point- «Menu» «Submenu» Menu sequences
ed arrow (➢) introduces an operational requirement. (1) Position numbers that are found in the
▪ Operational steps. Every operational step includes instruc- figures
tions. The operational steps are numbered in the order they
Safety instructions
are to be completed.
Most accidents are caused by failure to follow the safety instruc-
▪ No, one or more than one interim result. An empty arrow (⇨)
tions. In this user manual, dangers are pointed out by safety
introduces an interim result. Interim results are followed by
instructions. The safety instructions are structured as follows.
additional operational steps.
▪ At least one final result. A double arrow (») introduces a final
result.
If the carrying out the handling instructions or an operational
step is connected with a danger, relative safety instructions will
make reference to this prior to the handling instructions or the
operational step.
Introduction Structure of the instructions
1 10
mark in a yellow warning triangle), a signal word (DANGER, Yellow For a possibly dangerous situation.
WARNING, CAUTION or ATTENTION) and a corresponding If this situation is not averted, it
colour (red, orange, yellow or blue). may result in minor, reversible
injuries.
Blue If refers to possible threats of
machine damage.
Other information
Introduces important information, such as manufac-
turer recommendations for the smooth operation of
the machine.
Intended use Safety
11 2
Incorrect use ▪ Abruptly switching from drive into reverse at high speeds
includes: using the travel control levers and pedals
▪ Carrying passengers ▪ Driving through water that is deeper than the track rollers
▪ Lifting people ▪ Fastening lifting devices, such as ropes, to the equipment
▪ Using the machine as a lifting platform and lifting objects with them
▪ Using the machine in contaminated areas
Safety Incorrect use
2 12
▪ Professional suitability according to national standards If maintenance or assembly personnel have to oper-
▪ Safety briefing ate the machine, the same obligations as for the op-
The operator has the following responsibilities: erating personnel additionally apply.
Obligations of maintenance
personnel/specialised personnel
Maintenance/specialist personnel have the following responsibil-
ities:
▪ Performing all maintenance work thoroughly and on-time
according the maintenance schedule
Safety Hazards around the machine
2 14
▪ Use a marshaller to inform the operator as to the current ▪ Smoking and naked flames are not permitted while working
distance from the power cables. on the battery
▪ Wear rubber shoes and protective gloves.
Storms
▪ Cover seat with a rubber cover. When operating the machine during a storm, there is a danger
▪ Avoid contact with machine parts that can conduct electrici- that the machine's control system will be damaged. Therefore,
ty. cease all operation during a storm.
▪ Do not enter or exit the machine under power cables, but When operating the lifting tackle, the person guiding the load
rather only after the specified safety clearance has been outside of the cabin is in particular danger of being struck by
reached. lightning. Therefore, stop operating the lifting tackle immediately
Flammable / explosive environment during storms and find a protected area.
The machine's operating fluids, such as fuel, oil, lubricant and
Poor visibility
coolant, are highly inflammable and combustible. When operat- When operating the machine in poor visibility (for example, due
ing the machine near an open flame or flying sparks, there is to darkness, fog or high amounts of dust in the air), special
therefore a danger of fire or explosion for the machine. This can safety measures must be taken:
lead to death or serious injuries. The machine can be damaged. ▪ Switch on work spotlights
Prevention: ▪ Mark obstacles
▪ Do not operate the machine in a flammable or explosive ▪ Have a marshaller provide signals
environment (for example, in environments with flammable
Extreme climatic conditions
dust)
Operation must be stopped under extreme climatic conditions if
▪ Only operate the machine in well ventilated spaces
the protection provided by weather-resistant clothing is insuffi-
▪ Smoking and naked flames are not permitted while refuelling
cient.
Safety Hazard points on the machine
2 16
General dangers
Location Hazard may be able swing out further and thus reach the cabin. Serious
(1) Cab fuse box Electric shock injuries or damage to the machine can result from this. When
(2) Fuel injection, engine con- Electric shock combining lifting equipment, work must be conducted cautiously
trol system until the operator becomes familiar with the modified behaviour
Retrofitting
The machine may only be retrofitted with authorised lifting
equipment. If in doubt, related questions can be addressed to
SANY. If the machine is equipped with a quick-change unit, the
lifting equipment may be exchanged by the operator. To avoid
injuries and damage to the machine, the operating instructions
for the lifting equipment and the operating instructions for the
machine must be observed.
On the right side win- Lifting range Hydraulic oil tank Hydraulic oil level
dow of the cabin. For
further information, see
Lifting range
On the front right-hand Lifting position
On the lower right side Machine marking
side under the cabin
on the exterior of the
cabin
For further information, At the bottom on the Additional equipment
see Rating plate front side of the cabin, information
close to the point of
On the pedal for the Overview of boom
entry
boom swivel swivel movement
Safety Safety markings
2 26
Lubrication
Symbol Meaning
Change the engine oil
Maintenance personnel only
Check the coolant and top up if necessary
WARNING
As required
Check Maintenance work I C R L A
As required Outer air filter I C R
Inner air filter I R
Coolant R
Cooling fins I C
Track tension I A
Track shoes fastening I A
Bucket I R A
Bucket teeth I R
Lubrication Overview
5 34
Lubricating bearings
• When lubricating plain bearings, repeat the lubri-
cation procedure more frequently with less
grease.
• When lubricating pivot bearings, repeat the lubri-
cation procedure less frequently with more
grease.
• Check the bearing clearance when lubricating
bearings.
Lubrication chart
Maintenance steps After [h] Every [h]
50 100 500 50 100 200 250 500 1000 2000 2500
Swing motor oil I, A IA R R R R r
Drive motor oil R R
Hydraulic oil R R
Boom swing pin L L L L L L L L
Boom swing cylinder pin L L L L L L L L
Boom pins L L L L L L L L
Boom socket-head bolts L L L L L L L L
Boom/arm connecting pin L L L L L L L L
Arm cylinder pin L L L L L L L L
Arm/bucket connecting pin L L L L L L L L
Bucket socket-head pins L L L L L L L L
Slewing gear
Blade pin L L L L L L L L
Blade cylinder pin L L L L L L L L
Door pin L L L L L L L L
Track tensioner I, A I, A I, A I, A I, A I, A I, A I, A
Lubrication chart Lubrication
37 5
Lubrication
Machine signage 5. If air pockets are formed, pull off the adhesive label and
Safety marking is part of the machine and is used to protect the reattach it.
safety of operator and maintenance personnel. If the daily in- 6. Press down on the adhesive label with a rubber roller or a
spection of safety provisions reveals that adhesive labels are plane spatula.
missing or are no longer legible, they must be replaced without » Adhesive label has been replaced.
Engine WARNING
Overview Cleaning with compressed air
The engine is a three-cylinder in-line engine with direct fuel Compressed air and flying parts can lead to eye injuries, cuts
injection. It is equipped with electronically controlled fuel man- and bruises.
agement, charge-air cooler, thermostatically controlled cooling Injury to persons standing nearby or damage to the engine is
system and electronic engine speed regulation. possible.
• Wear safety goggles.
WARNING • Do NOT aim the compressed air stream at anyone.
Fire danger resulting from spilled consumables in the engine • Do NOT aim the compressed air stream at loose objects.
compartment • Do NOT aim the compressed air stream at seals, rubber
Heat in the engine compartment can ignite spilled consuma- hoses or electrical parts.
bles and lead to severe burns and engine damage. • NEVER use the compressed air stream for cleaning the
• Determine the cause of the consumables spill immediate- engine.
ly.
• Immediately eliminate the cause, for example, leakage.
WARNING
• Remove the spilled consumables immediately.
Danger to be injured or pulled in by rotating parts.
Carry out cleaning and maintenance operations only in deac-
tivated conditions.
Overview Engine
45 7
Maintenance overview
Maintenance steps After [h] Every [h]
50 50 250 500 1000 2000 4000
Visual inspection - leaks I I I I I I
Engine oil R I, A I, A R R R R
Engine oil filter R R R R R
Coolant I, A I, A I, A I, A R R
Swing motor oil I, A R R R
Drive motor oil I, A I, A R R
Cooling fins I, C I, C I, C I, C I, C I, C
Engine air filter I, C I, C R R R R
Alternator I I
Starter I I
Valve play, engine I, A ,A
Tightening torque
WARNING
4. Check the seals on the filter element seat for wear. Worn
seals on the filter element seat can cause oil leaks.
5. Apply engine oil to the seal and the thread.
1. Fill the new filter element with clean engine oil.
2. Install the new filter element on its seat.
3. Turn the filter element 3/4 to 1 turn. The installation requires
contact between the holder surface and the filter element
seat.
4. After replacing the filter element, open the engine bonnet
and fill engine oil through the filler opening until the oil level
is between the H and L marks on the dipstick.
5. Switch on the machine and leave the engine to idle for
5 minutes.
6. Switch the machine off again.
7. Check the oil level. The oil level must be between the H and
L marks on the dipstick. Top-up the engine oil if necessary.
» The filter element has now been replaced.
Replacing the engine air filter Engine
53 7
(1) Latch (3) Filter housing 6. Check that the inner filter is clean.
(2) Vacuum valve ⇨ Replace the inner filter if it has become dirty.
Engine Replacing the engine air filter
7 54
WARNING
• DO NOT open the filler opening of the cooling system if diator and in the coolant ducts. Therefore, the cooling system
the motor is still warm. must be cleaned when changing the coolant.
WARNING
The expansion tank for the coolant is located behind the rear 7. Fill the coolant tank with distilled water until the tank is full.
maintenance door. 8. Close the radiator cap again.
➢ The machine must be in the maintenance position. 9. Start the engine and run it at a low speed while watching
➢ The engine has cooled down. the coolant temperature indicator.
➢ Maintenance doors are open. ⇨ Coolant heats up to 90 °C.
➢ A container is ready for the drained coolant. The volume of 10.After the coolant temperature reaches 90 °C, allow the en-
the container should be greater than the volume of the gine to run for 10 minutes.
coolant. 11.Turn off the engine.
➢ Hose for transferring the coolant and the distilled water is 12.Open the radiator drain valve and drain the water.
ready for use. 13.Clean the radiator with a detergent, following the instruc-
➢ Water jerrycan containing at least 20 l tap water is ready for tions for the detergent.
use. 14.Close the drain valve.
1. Open the rear side maintenance door. 15.Open the radiator cap.
2. Loosen screws on the cover on the right-hand side and re- 16.Fill the tank with coolant (see mixture table) until the fluid
move cover. reaches the filler opening.
3. Carefully open the radiator cap. 17.Leave the radiator cap open.
⇨ Pressure is released. 18.Start the engine and run it at a low speed for 5 minutes and
4. Remove the radiator cap and place the prepared container then at a high speed for another 5 minutes.
under the drain valve of the coolant tank. ⇨ Air escapes from the radiator.
5. Open the drain valve for the radiator. 19.Empty the expansion tank into containers and dispose of
⇨ Coolant drains out. Properly dispose of the coolant. the coolant properly.
6. Close the drain valve. 20.Clean the expansion tank.
Engine Changing the coolant
7 60
NOTICE
Damage to the fuel system due to dirt particles
When installing the fuel filter, dirt particles can enter the fuel
system and cause damage. This can disturb the operating
procedure.
• Do not fill the fuel filter with fuel before installing it.
• Clean the area before installation.
• Work in clean conditions.
Maintenance overview
Maintenance steps After [h] Every [h]
50 50 100 250 500 1000 2000 4000
Fuel-water separator prefilter I, C I, C I, C I, C I, C I, C I, C
Fuel filter R R R R
See also
Tightening torques [➙ 137]
Replacing the fuel prefilter Fuel system
67 8
See also
Tightening torques [➙ 137]
Fuel system Check the fuel pre-filter and drain off any water that it may
8 68
Maintenance overview
Maintenance steps After [h] Every [h] Every [a]
50 50 250 500 1000 2000 4000 6
Hydraulic screwed connections C, A C, A C, A C, A
Hydraulic oil return filter R R R
Hydraulic oil suction filter R R
Hydraulic oil R
Hydraulic pipes R
(1) Oil filler cap (3) Sight glass 8. Check the seal on the drain plug and replace it if damaged
16.Check the fill level in the sight glass; top up the hydraulic oil
if required.
» The hydraulic oil has now been changed.
See also
Tightening torques [➙ 137]
Set pressure for outlet 0.017 MPa (at 1 l/min) Cleaning or replacing the hydraulic oil
➢ The machine must be in the maintenance position. suction filter screen
➢ A torque wrench must be ready for use.
1. Open the maintenance door on the right-hand side.
2. Clean the hydraulic tank and breather valve.
3. Remove the breather valve. If the nuts and bolts are hard to
undo, do not use excessive force otherwise the breather
valve could be damaged.
4. Visually inspect the filter element for contamination and
remove it if contaminated.
5. If the filter element is contaminated, clean it with a brush
and then flush it out with the Kesaixin detergent. (1) Drain screw (3) Filter cover
6. If this does not remove the dirt, blow compressed air (2) Filter (4) Oil filler cap
through the filter element from inside to outside. ➢ The machine must be in the maintenance position.
7. If the dirt cannot be eliminated or the filter element is dam- ➢ Cover on the left-hand side has been removed.
aged or worn, replace the filter element with a new one. ➢ A container is ready to catch drained hydraulic oil.
8. Allow the filter element to dry in a well-ventilated location. 1. Carefully open the oil filler cap.
9. Re-install the filter element. ⇨ The pressure is now released from the hydraulic reser-
with the torque specified in the Appendix. See also Tighten- 2. Place the container under the drain plug and remove the
» The breather valve has now been inspected and cleaned. ⇨ Oil drains out. Properly dispose of the collected oil.
Hydraulic system Cleaning or replacing the hydraulic oil suction filter screen
9 78
(1) Filter (3) Filter cover 11.Check the fuel level in the sight glass. The fill level should
(2) Drain screw (4) Oil filler cap be at the MAX mark.
12.Fasten the oil filler cap.
➢ The machine must be in the maintenance position.
» The hydraulic oil return filter screen has now been replaced.
➢ Cover on the left-hand side has been removed.
➢ A container is ready to catch drained hydraulic oil.
1. Carefully open the oil filler cap.
⇨ The pressure is now released from the hydraulic reser-
voir.
2. Place the container under the drain plug and remove the
drain plug.
⇨ Oil drains out. Properly dispose of the collected oil.
3. Loosen the 5 screws on the filter cover.
4. Remove the filter cover.
Hydraulic system Changing the hydraulic oil pilot filter
9 80
(1) Swing motor oil filler neck (3) Slewing ring CAUTION
(2) Rotation engine (4) Slewing ring grease nipple Injuries due to falling by slipping on leaked operating fluid
Slipping on leaked operating fluid can lead to injuries due to
falling. Leaked operating fluid can harm the environment.
• Collect the leaked operating fluid only using suitable con-
tainers.
• Absorb the leaked operating fluids with suitable binding
agents.
Overview Slewing ring
83 10
Maintenance overview
Maintenance steps After [h] Every [h]
50 50 100 250 500 1000 2000 4000
Swing motor oil I, A R R R
Slewing gear L L L L
See also
Fluid capacities of the machine [➙ 141]
Tracks WARNING
Overview Severe bruising caused by screw plugs being ejected from
lubricating grease containers
WARNING Due to the high pressure under which lubricating grease may
Burns from the hot engine and from hot, pressurised engine be kept, the screw plug that keeps the lubricating grease con-
oil tained may be ejected at speed and cause severe bruising to
Burns can be caused by contact with hot engine parts and those who are hit.
engine oil and by hot, pressurised engine oil spraying out. • When making adjustments, never stand directly in front of
• Allow the engine to cool before refilling. the screw plug.
• Slowly unscrew the screw plugs in order to release the • Turn the screw plug by no more than one revolution.
internal pressure.
CAUTION
Machine tipping over when raising from the side using the
bucket
Risk of injury if the machine loses its equilibrium and finally
topples over when lifting at the side using the bucket.
• Only raise the machine on sound and level ground below.
• Raise the machine slowly and carefully.
Overview Tracks
87 11
Maintenance overview
Maintenance steps After [h] Every [h]
50 50 250 500 1000 2000 4000
Track tension C, A C, A C, A C, A C, A C, A
Track shoes fastening C, A C, A C, A C, A C, A C, A
Drive motor oil I, A I, A R R
(1) Crawler chain (3) Distance the lubricating grease does not run out by itself, you
(2) Centre track roller may need to drive the machine slowly backwards and
forwards.
Checking the track tension
2. Inspect the track tension.
➢ The machine must be in the maintenance position.
3. Repeat steps 1 ― 2 until a sag of 10 ― 20 mm is reached.
➢ A ruler must be ready for use.
1. Lift the machine on one side by using the bucket. Increasing the track tension
If the maximum sag is more than 20 mm, the track tension must
2. With the ruler on the middle load-bearing roller of the crawl-
be increased.
er, measure the distance between the crawler chain and the
➢ The machine must be in the maintenance position.
load-bearing roller.
➢ Grease gun is ready for use.
3. If the maximum sag is between 10 ― 20 mm (guide value),
1. Fill lubricating grease into the lubricating valve using the
the track tension is in the normal range.
grease gun.
4. If the maximum sag is below 10 mm or above 30 mm, the
2. Start the machine and slowly drive forwards 7 ― 8 m.
track tension must be adjusted.
Tracks Checking and adjusting the track tension
11 90
See also
Tightening torques [➙ 137]
Bleeding the drive motors after changing the gearbox oil Tracks
91 11
Check the oil level ➢ A torque wrench must be ready for use.
➢ The machine must be in the maintenance position. ➢ The drive motor has cooled down.
➢ Filler screw plug and drain plug are positioned as shown in ➢ Filler screw plug and drain plug are positioned as shown in
the figure above. the figure.
➢ The screw plugs must not have any dirt clinging to them. ➢ The screw plugs must not have any dirt clinging to them.
1. Loosen the filler screw plug. 1. Place the container under the drain plug.
2. Loosen the drain plug and remove it.
Checking the drive motor oil level and changing the oil Tracks
93 11
» The engine oil will drain out. Properly dispose of the drained
engine oil.
» Tighten the drain plug to a torque of 70 ±20 Nm.
1. Remove the filler screw plug.
2. Add engine oil through the filler screw plug opening until the
engine oil runs out through the screw plug opening.
3. Check the sealing ring of the filler screw plug; replace if
necessary.
4. Tighten the filler screw plug to a torque of 70 ±20 Nm.
» The drive motor engine oil is now changed.
See also
Tightening torques [➙ 137]
Work equipment Replacing the excavator teeth
12 94
WARNING
Removing an excavator tooth that has been bolted Bolting on an excavator tooth
on
WARNING
Turning the bucket 3. Releasing the excavator arm from the bucket
4. Clean and lubricate the holding pins and boreholes.
5. Turn the bucket through 180°.
6. Align the excavator arm to the bucket that is to be fitted.
⇨ The holes drilled in the excavator arm are aligned with
those drilled in the bucket.
7. Connect the excavator arm and the bucket using the retai-
ning pins.
8. Fasten the seals.
» The bucket is now turned.
(1) Drilled holes in the bucket (2) Drilled holes in the arm
cylinder
In order to remove earth from above the machine, the bucket
may be turned towards the front.
➢ The bucket is suitable for forward-facing use.
➢ The bucket is lowered to safely to the ground.
➢ Machine is parked.
1. Loosen the seals.
Work equipment Adjusting the blade width
12 100
If the machine exhibits error functions or poor performance, the available. By entering a password, the service technician can
operator must also immediately stop operation and determine use the user interfaces on the display to receive additional in-
The software offers a wide range of troubleshooting possibilities. The technical documents from the supplier are also available.
The start screen graphically represents all error messages. The These include troubleshooting information for the engine, gear-
operator can access more information by selecting the corres- box, hydraulics and spreader.
Starter OK
Errors
Causes Remedy
Check the machine according to the following table and elimi-
Fuel used up Refill fuel and purge air
nate errors. Contact your SANY technician to eliminate recurring
Low opening pressure of fuel Adjust/replace fuel injection
problems.
injection
Engine errors
Fuel valve for the injection Replace the fuel valve
Engine does not start pump faulty
Starter faulty Control rod of the injection Repair or replace control rod
Battery is depleted Charge or replace battery Plunger of the injection pump Replace plunger assembly
worn or stuck
Battery cable loose or corroded Tighten loose cable, remove
corroded part Improper starting procedure Start the engine correctly
Blown fuse Replace fuse Air in the fuel system Purge air in fuel system
Starter or start relay faulty Replace start switch or relay Fuel filter clogged Replacing the fuel filter
Diesel engine faulty Repair/replace diesel engine Air purifier clogged Clean/replace air filter
High viscosity of engine oil Use engine oil with suitable Engine shuts down right after starting
viscosity
Causes Remedy
Low idle speed Charge battery
Fuel filter clogged Replacing the fuel filter
Air purifier clogged Clean/replace air filter
Clutch grinds Repair/replace clutch
Error elimination Errors
14 106
Causes Remedy
Idle mode faulty at low speed
Air purifier clogged Clean/replace air filter
Causes Remedy
Fuel pump faulty Repair/replace fuel pump
Low idle speed control faulty Repair/replace low idle speed
Low triggering pressure for fuel Adjust/replace fuel injection
control
injection, operation of injection
Fuel system leaking or blocked Repair fuel system
not effective
Air in the fuel system Purge air in fuel system
Injection pump faulty Repair/replace injection pump
Water in the fuel system Replace the fuel
Exhaust leaks, Replace corresponding parts
Fuel filter clogged Replacing the fuel filter
air leaks
Injection pump faulty Repair/replace injection pump
Exhaust valve clogged Clean exhaust pipe
Poor alignment of air valve Adjust the air valve clearance
Poor alignment of air valve Adjust valve clearance
clearance
clearance
Broken sealing ring for the Replace corresponding parts
Soft or broken air valve spring Replace gas spring
cylinder, worn cylinder insert,
Broken sealing ring for the Replace corresponding parts
stuck or broken piston ring or
cylinder, worn cylinder insert,
defective contact between air
stuck or broken piston ring or
valve and insert
defective contact between air
Insufficient fuel supply valve and insert
Causes Remedy
Fuel filter clogged Replacing the fuel filter
Water in the fuel system Replace the fuel
Errors Error elimination
107 14
Defective valve oil seal or worn Replace corresponding parts Escaping gas noises
valve spindle and valve guide
Causes Remedy
tube
Exhaust pipe fitting loose or Tighten exhaust pipe fitting or
Wear, break or incorrect setting Set the piston ring correctly or
exhaust pipe broken replace exhaust pipe
of piston ring replace
Fuel injection loose Replace sealing ring and tight-
Scratches on or wear of the Replace cylinder insert
en fuel injection
cylinder insert
Fitting of exhaust manifold Tighten fitting of exhaust mani-
Low oil pressure loose fold
Cylinder sealing ring broken Replace cylinder sealing ring
Causes Remedy
Too little oil Fill with oil Consistent noises
Incorrect oil viscosity Only use oil specified in the
Causes Remedy
appendix.
V-belt loose Adjust V-belt
Oil leak from oil seal and/or Replace oil seal and/or sealing
Cooler fan loose Fasten cooler fan
sealing ring ring
Coolant pump bearing worn or Replace coolant pump bearing
Oil filter clogged Replace oil filter
damaged
Incorrect valve clearance Adjust valve clearance
Error elimination Errors
14 110
Causes Remedy
Loose track Tighten track
High travelling speed on une- Travel slowly on uneven
ven ground in the direction of ground in the direction of the
the idler idler
Errors Error elimination
111 14
Condensing effect of the condenser is insufficient Hot capacitor and high pressure pipe
Both the high pressure and low pressure gauges display Air conditioning system not working
values that are too low
Causes Remedy
Causes Remedy Temperature in the cabin is too Set the air exchange in the
Too little refrigerant Refill refrigerant low cabin in order to raise the tem-
Low pressure line blo- Clean/replace malfunctioning perature.
cked/damaged component
Internal compressor error Replace compressor
Causes Remedy
Too little refrigerant Refill refrigerant
Low pressure line blo- Clean/replace malfunctioning
cked/damaged component
Internal compressor error Replace compressor
Error elimination Inspection before error elimination
14 114
Check the battery terminal - Tighten or Check the alternator volta- Following ope- Replace
and cabling for loose fitting replace ge (engine throttled) ration for se-
and signs of corrosion veral minutes:
cabling of the alternator for replace Sound of the battery relay - Replace
loose fitting and signs of when the battery switch is
corrosion activated.
Electrics
WARNING
1A black 10 A red
2A grey 15 A blue
3A purple 20 A yellow
5A light brown 25 A clear
7,5 A brown 30 A green
Carrying out measures to eliminate errors Error elimination
121 14
Relay
ID User
K2 Horn
K4 Work lights
K8 Engine delay
K9 Driver warning (standard: closed)
Error elimination Carrying out measures to eliminate errors
14 122
WARNING
4. Connect the other end of the black jumper cable to the ne-
gative pole of the machine battery.
5. Start the engine.
6. Once the engine is running, remove the jumper cables in
reverse order.
» The engine has been started.
Additional equipment Quick change system
15 124
Additional equipment circuit or new equipment connected to it, the pressure in the
The machine can be equipped with additional equipment. The hydraulic circuit must be released completely and the hydraulic
operating manual for the additional equipment must be under- oil must have cooled down.
stood and followed. Depending on the equipment and any specific company agree-
ments, the equipment manufacturer’s specialist personnel may
Unauthorized modifications
be responsible for installing the additional equipment. In that
Any change made to the machine without SANY's approval can
case, the machine’s maintenance personnel connects the
give rise to dangers.
equipment to the hydraulic circuit and operates the machine.
Modifications may only be carried out with the approval of
The manual for the additional equipment being attached must
SANY. SANY is not responsible for accidents or damage
be read and understood, especially the safety chapter. The
caused by unauthorized additional equipment or modifications.
design of the additional equipment being attached may vary
The machine can be equipped with the following additional
depending on the model of the machine’s hydraulic cylinder.
equipment:
Port sizes and the design of additional pressure accumulators
▪ Bucket (earth shovel/rock shovel)
may vary depending on the manufacturer of the additional
▪ Bucket teeth
equipment. Your SANY agent will help you to select the best
▪ Quick change mechanism
additional equipment.
▪ Hydraulic hammer
▪ Refuelling system Unauthorized modifications
▪ Central lubrication system Any change made to the machine without SANY's approval can
Additional equipment such as a quick change system, bucket or give rise to dangers.
hydraulic hammer must be connected to the machine's hydraulic Modifications may only be carried out with the approval of
circuit. Before equipment can be removed from the hydraulic SANY. SANY is not responsible for accidents or damage
caused by unauthorized additional equipment or modifications.
Quick change system Additional equipment
125 15
CAUTION
Quick change system
Risk of injury and machine damage from changes in operation
This function is an option. The quick change mechanism and the work equipment atta-
ched to it enlarge the swing radius of the excavator arm, which
could cause the work equipment to reach the cab, thus inju-
ring the operator and/or damaging the machine.
• Become familiar with the changes in operation before
starting work.
• Retract the bucket cylinder before the arm cylinder.
• Extend the excavator arm first, then work with the excava-
tor.
• Use the quick change mechanism only when work
With the quick change system, one person can change an item • Do not apply pressure when the quick change mechanism
of work equipment by themselves. The operating manual for the is touching the ground.
2. Install the quick change mechanism on the excavator arm 3. Close off the hydraulic hoses of the supply and return lines
using the mounting and dowel pins. with screw plugs.
3. Install the quick change mechanism on an item of work ⇨ This prevents impurities from entering and contamina-
equipment (e.g. a bucket) using the mounting and dowel ting the hydraulic lines, causing malfunctions.
pins. 4. Remove the mounting pins, dowel pins and mounting bolt.
4. Install the locking pin. 5. Disassemble the additional equipment and store it properly.
5. Connect the hydraulic hoses on the side of the additional 6. Fit bucket or other work equipment.
equipment. 7. Check the hydraulic oil level.
6. Check the direction of flow of the hydraulic oil. » The quick change mechanism has now been disassembled.
7. Connect lines to the oil drain port of the additional
equipment.
8. Check that installation is correct.
9. Check the level of the hydraulic oil.
» The quick change mechanism has now been installed.
Fitting a bucket with the quick change 2. Press the button for activating the quick change mechanism
mechanism (automatic reset) on the left control lever.
⇨ The opening between the movable and fixed jaws on
the quick change mechanism becomes smaller.
3. Ensure that the fixed jaws on the quick change mechanism
slowly close around the retaining pin of the bucket.
4. Slowly extend the bucket cylinder.
⇨ Move the movable jaws of the quick change mecha-
nism to the retaining pin of the bucket.
5. Ensure that the fixed jaws on the quick change mechanism
slowly close completely around the retaining pin of the bu-
cket.
6. Release the button for activating the quick change mecha-
nism
⇨ The quick change mechanism now encloses the retai-
ning pin of the buckets.
(1) Quick change system (3) Bucket retaining pin 7. Insert the locking pin.
(2) Jaws of quick change (4) Locking pin » The bucket is now fitted.
system
➢ The machine is parked.
1. Remove the locking pin on the quick change mechanism.
Interface description Preparing the machine
16 128
➢ A lifting device is ready to move objects that weigh more » The machine is prepared.
than 25 kg.
1. Lower the work equipment onto the ground.
2. Turn off the engine.
3. Turn the ignition key to the ON position.
4. Move the safety bar into the unlocking position and press
every control bar and pedal 2 ― 3 times within 15 seconds.
⇨ This relieves any pressure remaining in the hydraulic
lines.
5. Move the safety bar into the locking position.
6. Turn the ignition key to the OFF position.
7. Press the breather valve button.
⇨ The pressure in the hydraulic system has been relieved
completely.
8. Check the temperature of the hydraulic oil.
⇨ If necessary, wait until the hydraulic oil has cooled
down to a temperature below 40 °C.
9. Open the screw plugs on the excavator arm's hydraulic
supply and return lines.
10.Check the hose connections for dirt and oil and clean if
needed.
11.Replace any damaged O-ring seals.
Interface description Hydraulic circuit
16 130
Components
Hydraulic circuit
Removing and connecting additional equipment on the machi-
ne's hydraulic circuit is the job of the maintenance personnel.
Before equipment can be removed from the hydraulic circuit or
new equipment connected to it, the pressure in the hydraulic
circuit must be released completely and the hydraulic oil must
have cooled down to at least 40 °C.
WARNING
Hot surfaces or operating fluids! (1) Selection valve (2) Control pedal
The hydraulic circuit is always pressurised. Burns can result Selection valve
from hot hydraulic oil spraying out or from contact with the
engine or with its operating fluids before it cools down.
• 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 the filler neck slowly and carefully
• Perform work only on cooled parts
• Wear protective gloves
Hydraulic circuit Interface description
131 16
The standard pressure of the safety valve in the standby valve 2. Have the manufacturer of the additional equipment connect
is set at the factory before the machine is delivered. the hydraulic line of the additional equipment to the hydrau-
▪ In standard mode, the set pressure is 24.5 MPa. lic circuit of the machine.
▪ In demolition mode, the set pressure is 17.20 MPa. 3. Purge the air from the hydraulic circuit.
Changes to the standard pressure setting must only be made by 4. Check the hydraulic system for leaks.
1. Remove and keep the screw plugs. ➢ The machine is now prepared.
1. Remove and keep the screw plugs.
Hydraulic circuit Interface description
133 16
Once standard additional equipment has been connected to the In the manual of the additional equipment, check whether the
hydraulic circuit, the following parts must be checked and/or set. equipment requires a high or low oil flow rate and insert the
locking pin in the corresponding position.
Interface description Hydraulic circuit
16 134
Selection valve
Disposal
The machine is disposed of by the Operator.
When disposing of additional equipment that was not manufac-
tured by SANY, the appropriate instructions in the third-part
documentation must be observed.
Personnel
The workshop personnel responsible for the disposal must have
been familiarised with the safety instructions.
Disposal regulations
During the disposal of the machine, regional laws and directives
must be observed.
Operating fluids
Fully drain operating fluids out of the machine and dispose of
them according to regional laws and directives.
Disassembly
Disassemble the machine in the reverse order of the sequence
given in the assembly instructions.
Materials
Separate materials according to material group and dispose of
them in accordance with regional laws and directives.
Annex Hydraulic circuit
18 136
Annex
Tightening torques Annex
137 18
Nominal thread Square Tightening torque Screw Strength class / tightening torque [Nm]
Number (b) Setpoint Permissible 10.9 12.9
(a) (mm) values range M27 1320±140 1683±150
Nm Nm M30 1785±170 2200±200
1-14UNS 32 157 128–186 M33 2295±200 2900±280
13/16-12UN 36 216 177–245 M42 4700±450 5985±590
1-7/16-12UN-2B 41 215 176–234 M48 7140±650 9100±900
Screws with strength classes 10.9 and 12.9 Hydraulic hose screw connections for the
for the excavator excavator
Screw Strength class / tightening torque [Nm] Hoses
10.9 12.9 Screw Torque [Nm] Fitting Torque [Nm]
M6 13.2±1.4 16.2±1.6 M14 24.5 ± 5 M14 34.3 ± 5
M8 31±3 38.7±4 M18 51 ± 8 M16 54 ± 5
M10 66±7 78±7 M22 74 ± 14 M18 70 ± 10
M12 113±10 137±10 M26 105 ± 20 M20 93 ± 10
M14 177±19 210±20 M30 135 ± 20 M22 125 ± 10
M16 279±30 339±30 M36 166 ± 26 M24 142 ± 20
M18 382±39 450±40 M42 240 ± 30 M26 180 ± 20
M20 549±59 664±59
M22 697±70 864±85
M24 927±103 1100±100
Tightening torques Annex
139 18
Components Tightening
torque
Tightening torque, battery terminals [Nm]
Tightening torque, carrier roller fastening screws
[Nm]
Tightening torque, track drive fastening screws
[Nm]
Operating material overview Annex
141 18
ting materials required for your machine. Engine oil SAE 15W-40 (-15 – 50 °C)
Only use the materials indicated here for the operation and Gearbox oil SAE 30 (-20 – 40 °C)
maintenance of your machine. Hydraulic oil L-HV32 Low-temp, wear-resistant hydrau-
Operating materials include: lic oil
▪ Energy sources such as natural gas, petrol, diesel fuel, (-30 – 10 °C)
electric current, compressed air L-HM46 A, wear-resistant hydraulic oil (-
▪ Coolant for cooling tools and machines, such as water, lubri- 10 – 50 °C)
cant such as oil and grease. L-HM68, wear-resistant, hydraulic oil
(10 – 50 °C)
Fluid capacities of the machine
Fuel (diesel) ASTM D 975 No.2 (-10 – 50 °C)
Tank contents and lubricant
GB252 Super-20 Diesel fuel
volumes
(-15 – 40 °C)
Engine oil [l] 2.8
GB252 Super -35 Diesel fuel
Rotary actuator [l]
(-20 – 30 °C)
Idler [l] 2 x 0.5
Lubricating grease NLGI No.2*
Hydraulic system [l]
Coolant TEEC-L35 antifreeze* (freezing point -
Hydraulic tank [l] 21
37 °C/ vaporization point 129 °C [below
Cooling system [l] 4.5
103,4 kPa])
Fuel tank [l] 23
*Recommended specification
Annex Operating material overview
18 142
Glossary
user manual
Information that helps the operating, maintenance and as-
sembly personnel to use the product safely and in the in-
tended manner. The operating instructions consist of the
operator manual, maintenance manual and assembly in-
structions as well as electrical and hydraulic diagrams.
Index
146
Index
A G
Adhesive labels, 43 Gearbox oil, 46
Air filter, 33, 33
Alternator, 55 I
Environmental conditions, 11 Intended use, 11
B L
Bucket, 97 Lubrication schedule, 26, 39
Bucket teeth, 33
M
C Maintenance personnel, 13
Coolant, 33 Maintenance schedule, 13, 31
Cooling fins, 33 Maintenance work, 13
D O
Daily check of the machine , 13 Operating the machine, 13
Danger, 10 Operator, 13
Drive motor, 91
P
E Personal protective equipment, 21
Engine, 44, 47 Persönliche Schutzausrüstung
Engine oil, 31, 50 Ear protectors, 21
Engine oil filter, 51 Protective clothing, 21
Environmental conditions, 11 Protective gloves, 21
Height above sea level, 11 Protective mask, 21
Excavator teeth, 94 Safety goggles, 21
Safety helmet, 21
F Safety shoes, 21
Fan belt, 48 Protective device, 22
Fault code, 101
Fuel, 63 Q
Fuel filter, 63 Quick change system, 125
Index
147
R
Radiator cap, 56
Radiator fins, 56, 56
S
Safety briefing, 13
Safety instruction, structure, 9
Safety system, 22
Error message, 101
Sicherheitskennzeichnung
Safety marking, 43
T
Tank content, 141
Tightening torque, 139
U
Unintended use, 11
W
Water pump, 61
Diagrams
19 148
Diagrams
Hydraulic plan