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User Manual

Maintenance Manual
Hydraulic Excavator
SY16C

V. 07/2017 EN
Translation of the original user manual
Contact

SANY Europe GmbH

Sany Allee 1
50181 Bedburg
Germany

E-Mail: service@sanyeurope.com

Web: www.sanyeurope.com

Tel.: -49 2272 90531 100

Fax: -49 2272 90531 109

Service Number: 00800 88888 318

Spare parts number: 534119


Table of contents
3

Table of contents

1 Introduction 8 2.6 Hazard points on the machine 16

2.6.1 General dangers 16


1.1 Foreword 8
2.6.2 Mechanical dangers 17
1.2 Structure of the instructions 8
2.6.3 Hydraulic dangers 18
2 Safety 11
2.6.4 Electrical dangers 19
2.1 Intended use 11 2.6.5 Dangers from lifting equipment 20

2.2 Incorrect use 11 2.7 Personal protective equipment 21

2.3 Operator duties 13 2.8 Safety systems and protective devices 22

2.4 Obligations of maintenance person- 13 2.9 Safety markings 23


nel/specialised personnel
3 Preparation 28
2.5 Hazards around the machine 14
3.1 Overview 28
2.5.1 Ground 14
3.2 Bringing the machine into the maintenance 29
2.5.2 Power cables 14
position
2.5.3 Flammable / explosive environment 15
3.3 Maintenance while the machine is running 30
2.5.4 Storms 15
4 Maintenance schedule 31
2.5.5 Poor visibility 15

2.5.6 Extreme climatic conditions 15 4.1 Initial inspection 31


Table of contents
4

4.2 Regular maintenance 32 6 Machine signage 43

4.3 As required 33 7 Engine 44

5 Lubrication 34 7.1 Overview 44

5.1 Overview 34 7.2 Maintenance overview 46

5.2 Lubrication chart 36 7.3 Engine visual inspection 47

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

5.6 Boom cylinder lubrication points 41 7.7 Checking the starter 55

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

8.1 Overview 62 9.5 Cleaning or replacing the hydraulic oil suc- 77


tion filter screen
8.2 Maintenance overview 64
9.6 Replacing the hydraulic oil return filter 79
8.3 Replacing the fuel filter 65
9.7 Changing the hydraulic oil pilot filter 80
8.4 Replacing the fuel prefilter 67
9.8 Replacing hydraulic hoses 81
8.5 Check the fuel pre-filter and drain off any 68
water that it may contain 10 Slewing ring 82

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

changing the oil 14.4 Troubleshooting and eliminating errors 116

12 Work equipment 94 14.5 Carrying out measures to eliminate errors 118

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

13.1 Operator 101 14.5.5 Replacing a work spotlight bulb 122

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

14.2.2 Further errors 110 mechanism

14.3 Inspection before error elimination 114 16 Interface description 128


Table of contents
7

16.1 Preparing the machine 128 18.2.1 Fluid capacities of the machine 141

16.2 Hydraulic circuit 130 18.2.2 Specifications for consumables 141

18.2.3 Information about the use of grease 142


16.2.1 Components 130
18.2.4 Information about the use of fuel 142
16.2.2 Connecting additional equipment to the 132
hydraulic circuit Glossary 143

16.2.3 Checking connected parts 133 Index 146

17 Disposal 135
19 Diagrams 148

18 Annex 136

18.1 Tightening torques 137

18.1.1 Screws with strength classes 8.8, 10.9, 137


12.9

18.1.2 Tightening torques for hydraulic screws 137

18.1.3 Screws with strength classes 10.9 and 12.9 138


for the excavator

18.1.4 Hydraulic hose screw connections for the 138


excavator

18.1.5 Other screw connections for the excavator 139

18.2 Operating material overview 141


Introduction Foreword
1 8

Introduction This is a translation of the original instructions. In


case of doubt, the German wording shall take prec-
Foreword edence.
Please read and understand the user manual before machine
startup, operator control, maintenance or repair. Structure of the instructions
The advices of the user manual must be followed. These in- Structure of the instructions
structions are a requirement for safe machine operation and for This user manual consists of:
the safety of personnel. ▪ Operating manual for the machine operator
Failure to observe the safety regulations can lead to property ▪ Maintenance manual for the maintenance technician
damage, serious injuries or death. ▪ Diagrams for the maintenance technician
The user manual helps with: ▪ Installation instructions for the assembly personnel or Load-
▪ Using the machine in an optimal manner ing information for the carrier.
▪ Preventing accidents The user manual will be supplied in hard copy in the local lan-
▪ Avoiding machine malfunctions due to improper operation guage of the operating company . The loading instructions are
▪ Avoiding unintended use provided in the form of a card. A CD ROM is included that also
▪ Increasing reliability contains the original user manual in German. This user manual
▪ Minimising repair costs and downtime also includes functions that are marked as options. These func-
▪ Extending the machine's service life tions are not included in every machine.
A printed copy of the user manual must be made available near Chapter structure
the machine. The operating and maintenance instructions are divided into
chapters and subchapters.
Structure of the instructions Introduction
9 1

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

Signal word Colour Meaning


CAUTION
Red For an immediate thread of dan-
Type and source of the danger ger. If the danger is not averted,
Description of the imminent danger, for example an imminent threat of death or serious injuries.
injury.
Orange For a possibly dangerous situation.
• 1. Measures for averting the danger
If this situation is not averted, it
• 2. Measures for averting the danger
may result in death or serious

Safety instructions are classified by a danger sign (exclamation injuries.

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

Safety ▪ Using the machine in explosive atmospheres


▪ Driving at inappropriate speeds over uneven ground
Intended use ▪ Driving on public roads
The machine may only be used for the following operations:
▪ Driving over obstacles such as mounds of earth, large
▪ Loosening, picking up, transporting and releasing soil,
stones, tree stumps, etc.
stones and other materials
▪ Travelling on slopes where the tracks cannot find sufficient
▪ Excavating
grip
▪ Clearing, if the machine is equipped with a blade.
▪ Travelling on slopes above 30° (58 %)
▪ Lifting and transporting individual loads using sling gear,
▪ Demolition work
although manual help is required to attach and release the
▪ Overhead work
load
▪ Using the boom to help negotiate a slope where the tracks
The machine can be used under the following conditions:
cannot find sufficient grip
▪ Ambient temperature: -20 °C to + 40 °C
▪ Turning the machine on slopes, driving downhill or turning
▪ Height above sea level: up to 2000 m
the boom while driving downhill
The intended use also includes observance of the user manual
▪ Braking abruptly
and compliance with the maintenance and test conditions.
▪ Driving while operating the equipment or lifting objects

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

▪ Using the equipment while the hydraulic cylinder is com-


pletely retracted or extended
▪ Using the momentum/rotary motion of the equipment for
demolition work or lifting
▪ Entering the bucket with full force into the ground below for
digging
▪ Using the full force of the bucket to strike an object in order
to break it up
▪ Using the weight of the equipment for demolition work
▪ Using the bucket for bedrock excavation work
▪ Operating the machine with unapproved spare parts
▪ Converting or altering the machine without prior agreement
from SANY
In the case of improper use, SANY is not liable for any personal
injuries or damage to the environment and the machine itself.
Operator duties Safety
13 2

▪ Observance of the maintenance schedule


Operator duties
▪ Maintenance and servicing obligation
The machine operator must be at least 18 years old and be in
possession of the qualifications required locally by law: Operating the machine

▪ 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.

▪ Operating the machine


▪ Daily check of the machine for visible damage and defects.
▪ Immediately reporting damage and defects found as well as
any changes in operational performance to the appropriate
maintenance personnel
▪ Checking fill levels and topping up the operating fluids
▪ Lubricating moving parts
▪ If present, filling up the lubricating grease at a central lubri-
cation system

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

▪ Observe local regulations.


Hazards around the machine
▪ Before beginning digging or excavating work, check if gas,
Not all dangers resulting from the machine environment can be
water or power lines are installed in the ground.
prevented.
Power cables
Ground
Due to the machine's height, it can collide with power supply
When the machine is on non-load-bearing, soft or uneven
lines. This can lead to death or serious injuries. The machine
ground, driving over obstacles or on steep surfaces (slope
can be damaged.
above 15°), it can topple over and lead to death or serious inju-
The following safety clearances from power cables must be
ry. The machine can be damaged.
maintained. This clearance must not fall below the minimum
Prevention:
clearance.
▪ Only operate the machine on load-bearing ground.
▪ Check the load-bearing capacity of bridges and paths before Nominal voltage [V] Safety clearance [m]
travelling on them. Up to 1000 1
▪ Check the height and width of tunnels before driving through Above 1000 to 110 000 3
them. Above 110000 to 220 000 4
▪ Do not park the machine on slopes. Above 220000 to 380000 5
▪ Do not drive the machine over obstacles high enough to In the case of unknown nominal volt- 5
cause the machine to become unbalanced. age
Gas, water or power lines installed underground can be dam- If working under power cables cannot be avoided, the following
aged during digging or excavating work. This can lead to seri- safety measures must be taken:
ous injuries or machine damage. ▪ Observe the applicable local regulations.
Prevention:
Hazards around the machine Safety
15 2

▪ 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

Hazard points on the machine


Not all dangers resulting from the machine can be prevented.

General dangers

working area Location Hazard


The presence of others around the machine for longer than is (1) Tank filler neck Poisoning due to inhalation,
necessary is not permitted. Within the work area, the danger serious to fatal burns due to
exists of body parts suffering bruises, contusions or potentially ignition of the vapours
severe levels of compression, as well as the possibility of being (2) Exhaust system Burns, poisoning due to
knocked to the ground when the machine is turning. inhaling poisonous fumes
Hazard points on the machine Safety
17 2

Location Hazard Mechanical dangers


(3) Rear side maintenance Burning
cover
(4) Chain, work equipment Bruising, crushing from
being caught or being
pulled along
(5) Battery compartment Acid burns
(6) Below the bucket Danger from falling objects
(7) Boom Hazard of bumping your
head
Safety Hazard points on the machine
2 18

Location Danger Hydraulic dangers


(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 crawler chain
when the machine starts to
move
(3) Drive motor, running rollers Danger of crushing arm,
and rollers, drive motor hand or finger
(4) Drain plug, lubricating Danger of injury from plug
grease, chain flying out
(5) Idler Danger of serious or deadly
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) Below the raised bucket Danger from falling objects
Hazard points on the machine Safety
19 2

Location Hazard Location Hazard


(1) Connections for the transi- High pressure, leaking (6) Connections and high- High pressure, leaking
tion between high-pressure hydraulic oil pressure hoses for work hydraulic oil
hose and boom equipment
(2) Hydraulic hose connections High pressure, leaking (7) Connections and high- High pressure, leaking
between slewing gear and hydraulic oil pressure hoses for bucket hydraulic oil
chassis cylinder
(3) Boom swivel cylinder con- High pressure, leaking (8) Connections and high- High pressure, leaking
nections and high-pressure hydraulic oil pressure hoses for arm hydraulic oil
hoses cylinder
(4) Connections and high- High pressure, leaking In addition to the pressure-generating components, the high-
pressure hoses for blade hydraulic oil pressure hoses and their respective connections constitute
cylinder particular hydraulic hazard zones.
(5) Connections and high- High pressure, leaking Prior to performing maintenance work on the hydraulic accumu-
pressure hoses for boom hydraulic oil lator, the pressure must first be released.
cylinder
Electrical dangers
Safety Hazard points on the machine
2 20

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

In normal operation, all electrical machine components are of the excavator.

protected against environmental influences and contact. During


maintenance and repair operations, components left open are
electrical hazard zones.

Dangers from lifting equipment


The following dangers can result from the lifting equipment:

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.

Combining lifting equipment


When combining lifting equipment, the excavator may behave in
an unusual manner. For example, combined lifting equipment
Personal protective equipment Safety
21 2

hammering or grinding parts, knocking out bolts during as-


Personal protective equipment
sembly work, when working on hydraulic pumps, when weld-
The personal protective equipment includes different compo-
ing and when working with caustic substances (battery acid).
nents depending of the respective activities.
▪ Protective gloves: Protective gloves protect the hands
▪ Safety helmet: The safety helmet reduces the risk and
against injury or reduce the severity of injury sustained
severity of head injury. A safety helmet must be worn during
through contact with hot, cold, sharp-edged or corrosive ma-
machine operation, maintenance and repair work.
terials. Protective gloves must be worn when working on hy-
▪ Protective clothing: Protective clothing protects the
draulic pumps and when handling hot, cold, sharp or caustic
body from injury, or reduces the severity of injuries sustained
materials.
as a result of contact with fire, heat, cold and corrosive sub-
▪ Ear protectors: Ear protectorsprotect the ears against
stances. A protective suit must be worn during machine op-
exposure to noise. Wearing ear protectors is recommended
eration, maintenance and repair work.
above a sound level of 80 dB(A) and is obligatory above 85
▪ Safety shoes: Safety shoes protect feet from injury or limit
dB(A).
the severity of injuries resulting from:
– Colliding with hard objects.
– Walking on sharp parts.
– Falling of heavy objects.
Safety footwear must be worn during machine operation,
maintenance and repair work.
▪ Protective goggles/ protective mask: The safety
goggles/ protective mask protect the eyes against injury.
Protective goggles/ protective masks must be worn when
Safety Safety systems and protective devices
2 22

Safety systems and protective devices


Careful operation is the most import factor in avoiding accidents.
To assist the operator, the machine is equipped with various
safety systems and protective devices . These help to prevent
accidents. Some of these devices actively support the operator.
Others are only used when an emergency occurs. The functions
are explained in the corresponding sections for the machine
description.
▪ Emergency stop
▪ Emergency exit (with cabin option)
▪ Safety bar
▪ Visual and acoustic driver warning system
▪ Horn
▪ Rear-view mirror
▪ Seat belt
▪ Handles
▪ Load-holding valves
▪ Safety markings
Safety markings Safety
23 2

Sign Location Meaning


Safety markings
Vicinity of fan belt Warning: danger of
Prohibition signs
entanglement
Sign Location Meaning
Cooler Warning: risk of contact
On the rear side Open flame prohibited.
with hot fluids and va-
maintenance door
pours

Warning signs On the front side under The container is pressu-


the cabin rised
Sign Location Meaning
Engine, exhaust, hyd- Warning of hot
Boom Do not remain in the
raulic pump surfaces.
danger area of the
On the battery Warning of danger due
boom longer than nec-
to batteries.
essary.
Exhaust Warning: risk of contact Rear maintenance door Do not remain in the
with substances that danger area of the
cause irritation or are counterweight longer
harmful to health than necessary
Vicinity of engine fan Warning: risk of injury
due to engine fan
Safety Safety markings
2 24

Mandatory signs Fire protection and emergency signs

Sign Location Meaning General information

Near the hydraulic Use protective goggles / Sign Location Meaning


pump on the cover protective mask Cabin interior Noise level in the cabin

Near the hydraulic Use protective gloves


pump on the cover Next to the rating plate Noise level next to the
machine
Inside on the window of Use the safety belt
the cabin On the fastening eyelets The machine can be
fastened securely here
Inside on the window of Observe the operating
the cabin manual On the load points The machine can be
attached here

Sign Location Meaning


At the machine’s centre Centre of gravity of the
Inside on the window of Use the safety belt
of gravity machine
the cabin or in the foot-
well Safety bar Safety bar and emer-
Inside on the window of Observe the operating gency stop
the cabin or in the foot- manual
well
Safety markings Safety
25 2

Sign Location Meaning In the cabin Blade steering move-


On the right side win- Overview of the joystick ment
dow of the cabin and pedal / drive lever
motions

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

Maintenance information Lubrication schedule

Sign Location Meaning


Hydraulic oil tank Specifications for the
hydraulic oil

Fuel tank Only fill with diesel fuel

Water separator Water separator

In the toolbox next to Indicates the lubrication


the grease gun; for points on the machine
Symbol Meaning
more information see
Top up the fuel
Lubrication schedule

Lubrication

Replace the hydraulic oil for the first time


Maintenance personnel only
Check the engine oil and top up if necessary
Safety markings Safety
27 2

Symbol Meaning
Change the engine oil
Maintenance personnel only
Check the coolant and top up if necessary

Changing the coolant

Check the gearbox oil and have it topped up by


maintenance personnel if necessary
Change the gear oil
Maintenance personnel only
Check the hydraulic oil and top up if necessary

Change the hydraulic oil or perform an oil analysis


Maintenance personnel only
Preparation Overview
3 28

Preparation Handling safety components


• Never check or repair the safety components.
Overview
• Only the SANY service department may replace
the safety components.
WARNING
• The safety components are marked in the spare
Danger to be injured or pulled in by rotating parts.
part catalogue.
Carry out cleaning and maintenance operations only in deac-
tivated conditions.

The work may only be performed by authorised, spe-


cialised personnel.
All legal provisions and good engineering practice
must be complied with when performing any type of
task.

Wear personal protective equipment when performing


maintenance work.
Bringing the machine into the maintenance position Preparation
29 3

➢ The machine is safely parked.


Bringing the machine into the
1. Lower the work equipment onto the ground.
maintenance position
1. Move speed preselection switch to the "Tortoise" position.
1. Let the engine idle for 5 minutes.
2. Turn the ignition key to the OFF position.
⇨ The engine stops.
3. Turn the ignition key to the ON position.
4. Move the joystick controls in all directions 2 to 3 times.
⇨ The pressure in the hydraulic system is released.
5. Pull out the ignition key.
6. Move the safety bar to the locked position.
7. Disconnect the power supply using the battery isolator
For maintenance tasks, the machine must be driven into an switch.
area suitable for maintenance. This area must satisfy the follow- 8. Attach the “Maintenance” sign to the ignition lock and drive
ing conditions: levers or pedals.
▪ Even ground surface capable of bearing the load » The machine must be in the maintenance position.
▪ Spacious
▪ Well ventilated
▪ Well lit
▪ Clean and dry
Upon reaching the maintenance area, the machine must be
brought into the maintenance position.
Preparation Maintenance while the machine is running
3 30

Maintenance while the machine is


running

WARNING

Danger of serious injuries and loss of limbs


Reaching into moving parts can lead to loss of limbs and
damage 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 immediately.
▪ Operate the control levers only after consulting with and
warning the other person first.
▪ The safety lever must be in the locking position in order to
prevent the machine and the work equipment from moving.
▪ Take care when moving near rotating parts such as fans.
Initial inspection Maintenance schedule
31 4

Maintenance schedule Initial inspection


The specified maintenance intervals are SANY recommenda- One-time inspection Maintenance work I C R L A
tions. The information in the manuals from the component man- Initial inspection after 50 Engine oil R
ufacturers is authoritative. hours Engine oil filter R
Checks according to national requirements are independent of
this information.
The maintenance schedule includes the work which must be
initially undertaken on the machine as well as regular mainte-
nance work. The respective work steps that must be performed
are specified in the table:

I (Inspection) - Kontrolle L (Lubricate) - Schmieren


C (Clean) - Reinigung A (Adjust) – Einstellen
R (Replace) – Ersetzen
Maintenance includes
▪ Initial inspection,
▪ Work operations according to requirement, which arise from
reasons for concern noticed during daily or weekly mainte-
nance,
▪ regular maintenance work.
Maintenance information for stored machines can be obtained
from the SANY service manuals.
Maintenance schedule Regular maintenance
4 32

Regular inspec- Maintenance work I C R L A


Regular maintenance
tion
Regular inspec- Maintenance work I C R L A Fan belt I
tion Swing motor oil R
Every 50 hours Water build-up in the fuel I C Every 2000 Drive motor oil R
system hours Coolant R
Lubrication points L
Hydraulic oil suction filter R
Every 250 hours Engine oil I A
Alternator I
Climate control I L
Starter I
Every 500 hours Engine oil filter R
Valve play, engine I A
Engine oil R
Every 4000 Water pump I
Swing motor oil I A hours Hydraulic oil R
Drive motor oil I A
Every 6 years Hydraulic pipes R
Slewing gear L
Every 10000 SANY Service
Fuel filter R hours
Fuel pre-filter I
Cooling fins I C
Hydraulic screwed connec- I
tions
Every 1000 Hydraulic oil return filter R
hours Hydraulic oil filter R
As required Maintenance schedule
33 4

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

Lubrication Detailed information can be found in the maintenance schedule


and in the sections on the individual components.
Overview Proceed as follows when lubricating manually using a grease
Only use the lubricants indicated in the specification gun:
attached to this manual. ➢ The machine is in the maintenance position.
➢ Lubricating points are de-pressurised.
No dirt may enter the lubricant tank. ➢ Lubricant that meets the specification is ready.
1. Remove the protective cap.
2. Remove old grease and clean the grease nipple.
A new machine must be lubricated every 10 hours during the
3. Use the grease gun to fill with grease until it starts coming
first 50 hours of operation.
out of the grease nipple.
Following operation in water, the moist roll pins of the machine
4. Close the grease nipple again using the protective cap.
must be lubricated.
» The lubrication procedure is now complete.
If the lubricated parts emit unusual sounds, additional lubrication
beyond regular maintenance is necessary.
Components must be regularly lubricated to ensure proper ma-
chine operation.
The following must be observed:
▪ Lubrication point
▪ Lubrication interval
▪ Lubricant specifications
Overview Lubrication
35 5

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.

After carrying out lubrication, protect the grease nip-


ple against dirt by fitting the protective cap.
Lubrication Lubrication chart
5 36

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

Inspection Clean Replace Lubricate Adjust


[h] – Machine’s operating hours * Operating hours/years of the components
[a] - Years of operation
Lubrication Lubrication chart
5 38

(1) Boom swivel pins (7) Arm/bucket connecting


pins
(2) Boom swivel cylinder pin (8) Bucket cylinder pins
(3) Slewing gear (right-hand (9) Arm pin
side)
(4) Track tensioning (10) Arm cylinder pins
(5) Blade pin (11) Boom cylinder pins
(6) Blade cylinder pins (12) Boom pin
Lubrication chart Lubrication
39 5

Lubrication schedule Symbol Meaning


Check the engine oil and top up if necessary.

Replace the engine oil.


Maintenance personnel only.
Check the coolant and top up if necessary.

Changing the coolant.

Check the gearbox oil and have it topped up by


maintenance personnel if necessary.
Replace the gearbox oil.
Maintenance personnel only.
Symbol Meaning Check the hydraulic oil and top up if necessary
Top-up the fuel.
Change the hydraulic oil or perform an oil analysis.
Top up DEF Maintenance personnel only.

Lubrication

Replace the hydraulic oil for the first time.


Maintenance personnel only.
Lubrication Slewing gear lubrication points
5 40

Slewing gear lubrication points Boom suspension lubrication points

Swivel cylinder lubrication points


Boom cylinder lubrication points Lubrication
41 5

Boom cylinder lubrication points Lubrication points for the excavator


arm suspension system

Excavator arm suspension system

Lubrication points for the boom


cylinder
Lubrication Bucket suspension system lubrication points
5 42

Bucket suspension system lubrication Bucket cylinder lubrication points


points

Blade lubrication points


Bucket suspension system
Machine signage
43 6

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.

delay. Maximum label adhesion is reached after 24 hours.

A list of adhesive labels has been reproduced in the safety Sec-


tion of the manual. The signage plan is located in the folder
containing the plans.

Only use original (genuine) adhesive labels.


Surface and adhesive meet the requirements for
outdoor use. The size and design of the labels com-
plies with DIN ISO 3864-1.

➢ A new adhesive label is ready to be applied. The ideal ap-


plication temperature is in the region of 18 °C.
1. Remove damaged adhesive label.
2. Remove residues of old adhesive with a suitable cleaning
agent. The surface must be free of grease or silicone.
3. With the sticker film lying down, pull off the silicone paper at
a flat angle.
4. First affix the adhesive label with adhesive tape.
Engine Overview
7 44

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

Wear personal protective equipment when performing


maintenance work.
Engine Maintenance overview
7 46

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

Inspection Clean Replace Lubricate Adjust


[h] – Machine’s operating hours * Operating hours/years of the components
[a] - Years of operation
Engine visual inspection Engine
47 7

Engine visual inspection


Before each start, the engine must be inspected visually.
Check for the following:
▪ Leaking oil, fuel or coolant
▪ Loose screws
▪ Worn or loose belts
▪ Loose pipe connections
▪ Damaged electrical cables
▪ Damaged hoses
Damage to the engine may only be rectified by appropriately
trained personnel. It is therefore important to report any damage
discovered to maintenance personnel without delay.
Eliminating defects:
▪ Determine the causes of leaks and eliminate them.
▪ Exchange worn or damaged cables, lines, belts and hoses.
▪ Loose screws and bolts must be tightened with the specified
tightening torque. See also Tightening torques [Page 137]
Engine Checking and adjusting the fan belt
7 48

3. Replace worn and damaged belts.


Checking and adjusting the fan belt
» The belts have now been checked.
Checking the belt
In case of a problem, contact your SANY agent.

Adjusting the belts

(1) Belt play (3) Middle of belt


(2) Pulley
(1) Belt (2) Adjusting screw
The fan belt is located under the cover in the footwell.
➢ The machine must be in the maintenance position.
1. Loosen the fastening screws.
➢ The belt tension meter is ready for use.
2. Loosen the adjusting plate.
➢ The machine must be in the maintenance position.
3. Adjust the belt tension with the adjusting screw.
1. With a force of 98 N, press the belt tension meter onto the
4. Fasten the adjusting plate.
middle of the belt.
5. Tighten the fastening screws.
⇨ The belt must be able to deflect 9 - 12 mm.
1. Run the engine at a low speed for 5 minutes.
2. Visually inspect the belt for wear and damage
Checking and adjusting the fan belt Engine
49 7

2. Check the tension once again.


» The belts have now been adjusted.

Tightening torque

Tightening torque, generator


belt twistlock nut [Nm]
Tightening torque, generator
belt mounting nut [Nm]
Engine Replacing the engine oil and engine oil filter
7 50

Changing the engine oil


Replacing the engine oil and engine oil
filter
Avoid environmental damage resulting from consum-
ables. Observe applicable laws for the disposal of
materials harmful to the environment.

WARNING

Hot surfaces or consumables


Burns if touched
• Wear protective gloves
• Work only on parts which have cooled down (1) Oil dipstick position (3) Oil dip stick
(2) Engine oil tank cap (4) Oil drain plug
NOTICE ➢ The machine must be in the maintenance position.
➢ A container is ready to catch the engine oil.
Machine damage caused by unsuitable operating fluids, dam-
1. Remove the bottom cover.
age caused by too high a fill level.
2. Place the container under the drain valve.
The use of unsuitable operating fluids can damage the ma-
3. Carefully open the drain valve and drain the oil.
chine. Too high a fill level can lead to fluid spraying out or
4. Close the drain valve again after draining.
overflowing, and to overheating and damage.
5. Dispose of the drained oil in an environmentally friendly
• Use only recommended consumables.
manner.
• Do not fill beyond maximum fill level.
Replacing the engine oil and engine oil filter Engine
51 7

6. Re-attach the bottom cover. Replacing the engine oil filter


7. Open the rear side maintenance door.
8. Carefully remove the coolant expansion tank out of the
holder.
9. Open the engine oil tank cap.
10.Top up the engine oil.
11.Close the engine oil tank cap.
12.Place the coolant expansion tank in the holder.
13.Switch on the machine and let the engine idle for 1 minute.
14.Switch the machine off again.
15.Check the oil level. The oil level must be between the H and
L marks on the dipstick. Top up the engine oil when neces-
sary. (1) Filter holder (3) Filter element
» The engine oil has now been changed. (2) Seal
➢ The machine must be in the maintenance position.
➢ Filter element spanner is ready for use.
➢ The maintenance door on the right-hand side is open.
1. Turn the filter element to the left using the filter element
spanner.
2. Remove the filter element and dispose of it in an environ-
mentally friendly manner.
3. Clean the filter element seat.
Engine Replacing the engine oil and engine oil filter
7 52

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

Replacing the engine air filter


If the air filter is contaminated, the engine cannot be supplied
with enough air due to a pressure drop. The engine will not run
at full power. An indicator shows when the air filter needs to be
changed.
If the rubber seal is worn or significantly deformed, the vacuum
valve should be replaced.
(1) Filter housing (3) Outer filter element
(2) Inner filter element
The filter is located under the tailgate.
➢ The machine must be in the maintenance position.
1. Open the maintenance door and release the latch.
2. Remove the cover.
3. Loosen the outer filter element by turning it in both direc-
tions and remove it.
4. Remove the inner filter element.
5. Clean the outer filter element.
⇨ After its fourth cleaning, replace the outer filter element.

(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

7. If necessary, dispose of the filter element in accordance


with pertinent regulations.
8. Insert the inner filter element so that the open end fits in the
holder.
9. Insert the new or clean outer filter element so that the open
end fits in the holder.
10.Position the cover so that the vacuum valve is facing
downwards.
11.Tighten the latch diagonally. The filter elements have been
inserted correctly if there is not a gap between the housing
and cover when the latch is closed.
» Air filter has been cleaned/replaced.
Checking the starter Engine
55 7

Checking the starter


Contact your SANY agent to check the starter.

Checking and adjusting the valve


clearance
Since special tools are necessary for inspection and mainte-
nance, contact your SANY agent for this.

Inspecting the alternator


Contact your SANY agent to inspect the alternator.
Engine Checking and cleaning the outside of the coolant tank and
7 56

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.
• Wear safety goggles.
• Do NOT aim the compressed air stream at anyone.
• Do NOT aim the compressed air stream at loose objects.
• Do NOT aim the compressed air stream at seals, rubber (1) Radiator (3) Radiator cap
hoses or electrical parts. (2) Radiator fins
• NEVER use the compressed air stream for cleaning the The radiator is located behind the right side cover.
engine. ➢ The machine must be in the maintenance position.
1. Open the rear side maintenance door.
2. Loosen screws on the cover on the right-hand side and re-
move cover.
3. Visually inspect the coolant tank and radiator.
4. Remove any dirt, debris or leaves.
Checking and cleaning the outside of the coolant tank and Engine
57 7

5. Clean the outside of the coolant tank and radiator. The


pressure must not exceed 3 bar.
6. Check that the rubber hoses and tube clamps are firmly in
place and visually inspect them for damage and wear; re-
place if needed.
7. Attach the cover on the right-hand side
8. Close the maintenance door.
» The coolant tank and radiator have now been inspected.
Engine Changing the coolant
7 58

Changing the coolant NOTICE


Damage to the cooling system from frost
WARNING
Freezing water expands and can damage the coolant ducts.
Burns from escaping steam or hot coolant • Do not clean the cooling system if there is a risk of frost.
The escape of steam or hot coolant can lead to burns on eyes,
hands and skin. Cooling system performance is reduced by deposits in the ra-

• 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

Eye and skin injuries from coolant


Contact with coolant can damage eyes and skin.
• Wear safety goggles and protective gloves.
• If eyes or skin come in contact with coolant, wash the af-
fected body parts thoroughly with water and seek medical
attention if necessary.

Avoid environmental damage resulting from consum-


ables. Observe applicable laws for the disposal of
(1) Radiator (3) Expansion tank
materials harmful to the environment.
(2) Drain valve (4) Radiator cap
Changing the coolant Engine
59 7

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

21.Fill the compensation tank with coolant up to the MAX mark.


22.Turn off the engine, wait 3 minutes and check the coolant
level; top up coolant if necessary.
23.Close the radiator cap again.
24.Attach the cover on the right-hand side
25.Close rear maintenance door.
» The coolant has now been replaced.
Checking the water pump Engine
61 7

Checking the water pump

(1) Water pump


➢ The machine is in the maintenance position.
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.
Fuel system Overview
8 62

Fuel system WARNING


Eye injuries and bruises resulting from the release of pressur-
Overview ized fuel
The fuel system is under high pressure. When replacing the
WARNING filters, fuel spraying out can cause eye injuries and bruises.
Burns from the hot engine and igniting consumables • Do not work on the fuel system until the engine has been
Contact with hot engine parts can lead to severe burns. turned off for more than 30 seconds.
Spilled consumables (e.g. released by damaged filter seals)
can be ignited by heat in the engine compartment and lead to
CAUTION
burns and engine damage.
Injuries due to falling by slipping on leaked operating fluid
• Allow the engine to cool for at least 15 min before any
Slipping on leaked operating fluid can lead to injuries due to
work.
falling. Leaked operating fluid can harm the environment.
• Wear protective gloves.
• Collect the leaked operating fluid only using suitable con-
• Determine the cause of the consumables spill immediately
tainers.
and remedy it.
• Absorb the leaked operating fluids with suitable binding
• Tighten filters only with the torque specified.
agents.
• Remove the spilled consumables immediately.
Overview Fuel system
63 8

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.

To prevent machine damage, replace the filters using


original replacement parts only.

Avoid environmental damage resulting from consum-


ables. Observe applicable laws for the disposal of
materials harmful to the environment.
Fuel system Maintenance overview
8 64

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

Inspection Clean Replace Lubricate Adjust


[h] – Machine’s operating hours * Operating hours/years of the components
[a] - Years of operation
Replacing the fuel filter Fuel system
65 8

2. Use the filter wrench to turn the filter cover anticlockwise


Replacing the fuel filter
and remove it. Set it aside for re-use later.
The filters can only function properly when they are free of im-
3. Use the filter wrench to turn the filter element anticlockwise,
purities. If impurities get into the filters during maintenance, they
remove it and dispose of it properly.
must be removed by rinsing with engine oil before installing.
4. Install the filter cover on the bottom of the new filter (replace
the O-ring as well).
5. Apply engine oil to the sealing surfaces.
6. 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.
7. Fill the new filter element with clean fuel through the 8
openings in the filter cover.
8. Clean the filter with a cloth.
9. Place the filter on the filter seat and tighten it until the seal-
(1) Shut-off valve (3) Fuel filter ing surface of the filter element touches the sealing surface
(2) Fuel pre-filter (4) Transfer pump of the filter seat. Then tighten the filter with the tightening
➢ A container must be ready to catch the used fuel. torque specified in the Appendix. See also Tightening tor-
➢ A filter wrench must be ready for use. ques [Page 137].
➢ Maintenance door is open. 10.Purge the air from the fuel system.
1. Place the container under the fuel filter. » The fuel filter is replaced.
Fuel system Replacing the fuel filter
8 66

Bleeding the fuel system


To prevent engine damage, air must be purged from
the fuel system after replacing the fuel filter.

See also
 Tightening torques [➙ 137]
Replacing the fuel prefilter Fuel system
67 8

Replacing the fuel prefilter


The filters can only function properly when they are free of im-
purities. If impurities get into the filters during maintenance, they
must be removed by rinsing with engine oil before installing.

(1) Filler openings (2) Cover

Bleeding the fuel system


To prevent engine damage, air must be purged from
the fuel system after replacing the fuel filter.

(1) Fuel filter (2) Fuel pre-filter

See also
 Tightening torques [➙ 137]
Fuel system Check the fuel pre-filter and drain off any water that it may
8 68

Check the fuel pre-filter and drain off


any water that it may contain
Before starting, the fuel pre-filter must be checked and drained.

(1) Valve outlet (4) Drain hose


(2) Threads (5) Drain valve
(3) O-ring (6) Housing
➢ The machine is safely parked.
(1) Fuel filter (2) Fuel pre-filter ➢ The collection container is ready.
1. Place a collection container beneath the fuel pre-filter.
2. Turn the shut-off valve upwards in anticlockwise direction.
⇨ Fuel supply is interrupted.
3. Unscrew the housing of the fuel pre-filter.
4. Remove water and fuel from the housing and clean the
housing.
5. Screw the housing of the fuel pre-filter in tightly.
Check the fuel pre-filter and drain off any water that it may Fuel system
69 8

6. Turn the shut-off valve downwards in clockwise direction.


⇨ Fuel flows into the housing of the fuel pre-filter.
7. Repeat steps 2 to 6 until water is no longer visible in the
fuel pre-filter
8. Bleeding the fuel system
⇨ The fuel pre-filter has now been checked and cleaned.
Fuel system Checking the fuel filter and fuel prefilter for leaks
8 70

Checking the fuel filter and fuel


prefilter for leaks
1. Start the engine and let it idle at a low speed for 10 min.
2. Switch off the engine and wait at least 30 seconds until the
pressure in the fuel system falls.
3. Check the filter covers and installation surfaces for leaks.
» The filters have now been checked for leaks. If there are
any leaks, check that the filters are firmly in place. If neces-
sary, remove the affected filter and install it again. If the
seal is damaged, the filter cartridge of the affected filter
must be replaced with a new filter cartridge.

Purging the air from the fuel system


1. Fill the fuel tank up to the MAX mark with fuel.
2. Turn the ignition key to the ON position.
3. Run the engine idly at a low speed for 2 – 3 min.
⇨ The air is automatically removed.
4. Turn the ignition key to the OFF position.
» The fuel system has now been purged.
Cleaning the fuel tank Fuel system
71 8

Cleaning the fuel tank


➢ The machine must be in the maintenance position.
1. Place a container underneath the drain valve on the right
side of the machine to collect the fuel as it flows out.
2. Open the drain valve.
⇨ Deposits, water and fuel flow out of the fuel tank.
3. When clean fuel starts to emerge, close the drain valve
once again.
» The fuel tank has now been cleaned.

Replacing fuel lines


➢ The machine is in the maintenance position.
➢ The engine has cooled down.
➢ Fuel line and tube clamps are ready for use.
1. Remove and dispose of the tube clamps.
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 Overview
9 72

Hydraulic system WARNING


Overview Burns and poisoning from the hydraulic oil
The hydraulic oil is poisonous if it enters the body through an
WARNING injury, and can burn the skin or eyes upon contact.
Hot surfaces or operating fluids! • Avoid contact with eyes or skin.
The hydraulic circuit is always pressurised. Burns can result • Wear safety goggles.
from hot hydraulic oil spraying out or from contact with the • Wear protective gloves.
engine or with its operating fluids before it cools down.
• Allow the engine to cool for at least 15 min
NOTICE
• Allow hydraulic oil to cool to temperatures below 40 °C
Hydraulic system damage due to unsuitable operating fluids or
• Release the pressure in the hydraulic system
too low a fill height of hydraulic oil
• Open the filler neck slowly and carefully
Unsuitable hydraulic oil and filling the hydraulic oil to a level
• Perform work only on cooled parts
that is too low or too high can cause damage to the machine.
• Wear protective gloves
• Use only recommended hydraulic oil.
• Monitor the oil level and top up or drain hydraulic oil as
required.
• Determine the cause of oil leaks immediately and remedy
them.
Overview Hydraulic system
73 9

Observe the laws on the disposal of environmentally


dangerous substances.
Hydraulic system Maintenance overview
9 74

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

Inspection Clean Replace Lubricate Adjust


[h] – Machine’s operating hours * Operating hours/years of the components
[a] - Years of operation
Changing the hydraulic oil Hydraulic system
75 9

4. Move the safety bar to the locked position.


Changing the hydraulic oil
5. Switch off the engine and remove the ignition key.
6. Carefully open the oil filler cap.
⇨ The pressure is now released from the hydraulic reser-
voir.
7. Place the container under the drain plug and remove the
drain plug with the lever.
⇨ Oil drains out. Properly dispose of the collected oil.

(1) Oil filler cap (3) Sight glass 8. Check the seal on the drain plug and replace it if damaged

(2) Drain screw or worn.


9. Tighten the drain plug to the torque specified in the appen-
➢ The machine must be in the maintenance position.
dix. See also Tightening torques [Page 137].
➢ Cover on the left-hand side has been removed.
10.Fill hydraulic oil into the filler opening. Fluid capacities for
➢ A torque wrench must be ready for use.
the machine.
➢ 36 mm socket wrench is ready for use.
11.Check the fuel level in the sight glass. It should be at the
➢ Lever for socket wrench is ready for use.
MAX mark.
➢ A container is ready to catch drained hydraulic oil.
12.Close the oil filler cap.
1. Start the engine.
13.Move the safety bar to the unlocked position.
2. Swing the upper carriage in order to position the drain plug
14.Start the engine and let it idle at a low speed for 10 minutes
beneath the hydraulic tank between the tracks.
to remove air from the hydraulic line.
3. Retract the arm, boom and bucket cylinders so that the ex-
15.Turn off the engine
cavator teeth touch the ground.
Hydraulic system Checking and cleaning the breather valve
9 76

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]

Checking and cleaning the breather


valve
Dirt on the breather valve’s filter element must be removed to
ensure an even flow of air through the breather valve. The filter
element and breather valve must be cleaned using only a brush
and the specified detergents.

(1) Butterfly nut (5) Breather valve


(2) Seal (6) Filter element
(3) Hexagon bolt (7) Housing
(4) Seal

Breather valve parameters


Filter fineness: 10 μm
Ambient temperature: -40℃ - 120℃
Set pressure for inlet 0.004 MPa (at 1 l/min)
Cleaning or replacing the hydraulic oil suction filter screen Hydraulic system
77 9

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-

10.Re-install the breather valve. Tighten the hexagonal nut voir.

with the torque specified in the Appendix. See also Tighten- 2. Place the container under the drain plug and remove the

ing torques [Page 137]. drain plug with the lever.

» 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

3. Loosen the 5 screws on the cover.


4. Remove the cover.
5. Use the filter wrench to remove the filter screen.
6. Clean the filter screen and flush it with cleaning oil. Replace
the filter screen if damaged.
7. Attach the cleaned or new filter screen.
8. Tighten the 5 screws on the filter cover.
9. Tighten the drain plug to the torque specified in the appen-
dix. See also Tightening torques [Page 137].
10.Fill hydraulic oil into the filler opening. Fluid capacities for
the machine.
11.Check the fuel level in the sight glass. The fill level should
be at the MAX mark.
12.Fasten the oil filler cap.
» The filter screen suction line has now been cleaned.
Replacing the hydraulic oil return filter Hydraulic system
79 9

5. Use the filter wrench to remove the filter screen.


Replacing the hydraulic oil return filter
6. Dispose of the filter screen correctly.
7. Insert a new filter screen.
8. Tighten the 5 screws on the filter cover.
9. Tighten the drain plug to the torque specified in the appen-
dix. See also Tightening torques [Page 137].
10.Fill hydraulic oil into the filler opening. Fluid capacities for
the machine.

(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

Changing the hydraulic oil pilot filter


➢ The machine must be in the maintenance position.
➢ Filter element spanner is ready for use.
➢ The maintenance door on the right-hand side is open.
1. Turn the filter element to the left using the filter element
spanner.
2. Remove the filter element and dispose of it in an environ-
mentally friendly manner.
3. Clean the filter housing.
4. Insert a new filter into the filter housing.
5. Replace the seal and O-ring.
6. Clean the filter element seat.
» Pilot filter is replaced.
Replacing hydraulic hoses Hydraulic system
81 9

2. Clean the hose connections.


Replacing hydraulic hoses
3. Screw new hydraulic hoses to the hose connections.
4. Tighten the screws with the required tightening torque. See
WARNING
also Tightening torques for hydraulic screws [Page 137].
Hot surfaces or operating fluids!
» The hydraulic hose has been replaced.
The hydraulic circuit is always pressurised. Burns can result
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

Avoid environmental damage resulting from consum-


ables. Observe applicable laws for the disposal of
materials harmful to the environment.

➢ The machine is in the maintenance position.


➢ Hydraulic hose and torque wrench are ready for use.
➢ The hydraulic circuit has been purged.
1. Remove the hydraulic hose and dispose of it properly.
Slewing ring Overview
10 82

Slewing ring WARNING


Overview 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.
• Wear protective gloves and safety goggles.
• Slowly unscrew the cap of the level indicator and tank and
release the internal pressure.

(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

Avoid environmental damage resulting from consum-


ables. Observe applicable laws for the disposal of
materials harmful to the environment.
Slewing ring Maintenance overview
10 84

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

Inspection Clean Replace Lubricate Adjust


[h] – Machine’s operating hours * Operating hours/years of the components
[a] - Years of operation
Lubricating the slewing ring Slewing ring
85 10

8. Repeat steps 5 – 7 until the lubricating grease oozes out of


Lubricating the slewing ring
the seals.
9. Wipe away any excess lubricating grease and dispose of it
properly.
» The slewing ring

See also
 Fluid capacities of the machine [➙ 141]

(1) Greasing nipples


➢ The machine must be in the maintenance position.
1. Wipe away old lubricating grease and dispose of it properly.
2. Add lubricating grease through the two lubrication nipples.
3. Wipe away any excess lubricating grease and dispose of it
properly.
4. Start the engine.
5. Lift the bucket 20 ― 30 cm above the ground and rotate the
upper carriage 45°.
6. Lower the bucket to the ground.
7. Lubricating the swing bearing again
Tracks Overview
11 86

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

Avoid environmental damage resulting from consum-


ables. Observe applicable laws for the disposal of
materials harmful to the environment.

(1) Track shoe (3) Idler


(2) Drive motor (4) Track tensioner
Tracks Maintenance overview
11 88

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

Inspection Clean Replace Lubricate Adjust


[h] – Machine’s operating hours * Operating hours/years of the components
[a] - Years of operation
Checking and adjusting the track tension Tracks
89 11

» The track tension has now been checked.


Checking and adjusting the track
tension Reducing the track tension
➢ The machine must be in the maintenance position.
➢ Long socket wrench is ready for use.
➢ A torque wrench must be ready for use.
1. Using a long socket wrench, turn the lubricating valve anti-
clockwise no more than one quarter turn.
⇨ Lubricating grease runs out of the lubricating valve. If

(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

3. Bring the machine into the maintenance position.


4. Inspect the track tension.
Repeat steps 1 ― 4 until the sag is between 20 ±10 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 bush-
ings, contact your SANY agent.

The pin rolls and bushings of the under


carriage are worn down differently depend-
ing on the work conditions and the ground.

See also
 Tightening torques [➙ 137]
Bleeding the drive motors after changing the gearbox oil Tracks
91 11

Bleeding the drive motors after


changing the gearbox oil

1. Run the engine at low speed.


2. Open drive motor bleed screw plug.
⇨ Motor oil runs out.
3. Close the air vent screw plug.
(1) Air vent screw plug 4. Run the engine at low engine speed and turn the upper car-
riage 90°.
5. Lift the machine using the bucket.
⇨ Chain has no contact with the ground
6. When lifted, run the crawler for two minutes.
7. Lower the crawler.
8. Repeat steps 1 ― 7 with the 2nd drive motor.
9. Run both tracks backwards and forwards evenly.
Tracks Checking the drive motor oil level and changing the oil
11 92

» Drive motor has been bled. ⇨ Pressure is released.


1. Visually inspect the engine oil level by opening the filler
Checking the drive motor oil level and
screw plug.
changing the oil
⇨ If the engine oil level reaches the lower edge of the filler
screw plug, the engine oil level is in the optimum range.
⇨ If the engine oil level does not reach the lower edge of
the filler screw plug, the engine oil level is too low.
⇨ If the engine oil spills out over the edge of the filler
screw plug, the engine oil level is too high. Properly
dispose of spilled engine oil.
» The drive motor engine oil level has now been checked.
The engine oil level must be checked on both drive motors.

Changing the oil


(1) Drive motor (3) Drain screw ➢ The machine must be in the maintenance position.
(2) Filler screw ➢ A container must be ready to catch the drained engine oil.

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

Preparing the machine


Work equipment
Replacing the excavator teeth

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
• Wear protective gloves.
• Prevent access to the work area.

Worn out excavator teeth must be replaced. Excavator teeth


can either be screwed on or bolted on.
Replacing the excavator teeth Work equipment
95 12

Removing an excavator tooth that has been bolted Bolting on an excavator tooth
on

Installing the excavator tooth


➢ The machine is prepared. ➢ The machine is prepared.
1. Hold the metal bolt to the pin. The diameter of the bolt must 1. Clean the fitting if necessary.
be a bit smaller than the pin. 2. Insert the excavator tooth into the fitting.
2. Hit the bolt with a hammer until the pin can be removed. ⇨ The pin holes of the fitting and the excavator tooth must
3. Remove and dispose of the excavator tooth. be on top of one another.
» The excavator tooth has now been removed. 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 now been installed.

Removing an excavator tooth that has been


screwed on
➢ The machine is prepared.
1. Unscrew screws.
Work equipment Replacing the excavator teeth
12 96

2. Remove and dispose of the excavator tooth.


» The excavator tooth has now been removed.

Screwing on an excavator tooth


➢ The machine is prepared.
1. Clean the fitting if necessary.
2. Insert the excavator tooth into the fitting.
⇨ The boreholes of the fitting and the excavator tooth
must be on top of one another.
3. Insert screws.
4. Tighten screws.
» The excavator tooth has now been installed.
Bucket Work equipment
97 12

Removing the bucket


Bucket

WARNING

Crushing resulting from falling bucket and injuries from pins


and fragments jumping out
When the bucket is released, it may fall and crush feet or
other body parts, when the pins are struck, they may fly out
and fragments that break off can fly around and may cause
injury.
• Lower the bucket carefully and store it securely
• Wear safety goggles
• Wear protective gloves
• Prevent access to the work area

(1) Excavator arm (4) Connecting bolts


(2) Arm pin (5) Connecting element
(3) Bucket
➢ The machine must be in the maintenance position.
➢ The bucket is lying on the ground below.
1. Remove the fastening bolts and nuts from the connecting
pins and arm pins.
Work equipment Bucket
12 98

2. Remove the arm pins and connecting pins.


⇨ 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.

Attaching the bucket

Cross-sectional view of bolt connections

(1) Connecting element (3) Arm pin


(2) Fastening screws (4) Lubrication point
1. Position the machine so that the pin holes of the excavator
arm and the deflection plate line up with the corresponding
holes on the bucket.
2. Switch off the engine and move the safety bar to the locked
position.
3. Lubricate the length of the bolt.
4. Position the bucket sealing ring to line up with the arm pin.
Replace defective seals, if necessary.
(1) Holes for connecting bolts (2) Arm pin holes 5. Apply lubricant using the grease gun until the lubricant
oozes out.
Bucket Work equipment
99 12

» The bucket is now attached. 2. Remove the bucket retaining pins.

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

2. Remove the blade ends and place in the respective


Adjusting the blade width
transport bracket.
3. Fix the blade ends in position with the securing pins.
⇨ Blade ends are now removed.
» Blade width is now reduced.

Increasing blade width


1. Remove the securing pins.
2. Take the blade ends out of the transport bracket and fit to
the blade.
3. Fix the blade ends in position with the securing pins.
⇨ Blade ends are now fitted .
» Blade width is now increased.

(1) Locking pins (3) Transport brackets


(2) Blade ends
To transport the excavator, the ends of the blades can be re-
moved and placed for safe keeping in a transport bracket. Be-
fore using the blade, the ends should be re-fitted for as wide a
work surface as possible.

Reducing the blade width


1. Remove the securing pins.
Operator Error detection
101 13

Error detection Maintenance personnel


The maintenance technician carries out the work listed in the
Operator maintenance manual and also helps with troubleshooting. By
The first step in troubleshooting is to observe the indicator ele-
entering a password, the maintenance technician can obtain
ments in the cabin. The light in the right-hand operating area
more information via user interfaces in the display than the
indicates a fault without providing exact information about the
operator.
cause. The operator must stop operation and determine the
cause of the error. Further information is available on the dis- Service personnel
play. The service technician has further troubleshooting possibilities

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 cause of the error. formation.

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.

ponding function unit using the function keys.


Error codes
The operator has the possibility to remedy errors that are The error code shown on the display can be used to conduct an
described in the operating manual in the Troubleshooting chap- error analysis.
ter. Any other errors must be fixed by maintenance or service
personnel.
Error detection Error codes
13 102

(1) Engine coolant tempera- (3) Battery charge status


ture
(2) Engine oil pressure
Procedure Error elimination
103 14

Error elimination ▪ Hydraulic pressure gauge


▪ Identifying the replacement parts using the part instructions
Procedure Step 4: Construction site visit
The goal of error elimination is to determine the underlying
Construction site
cause of the error, carry out repairs quickly and prevent a recur-
Step 5: Questions for the operator in order to clarify the details
rence of the error.
of the error.
When eliminating errors, it is important to be familiar with design
▪ Was there anything unusual with the machine before the
and function of the machine.
error occurred?
Workshop ▪ Did the error occur suddenly or were there already problems
Step 1: Inspection and confirmation of the behaviour
with the machine?
Clarify the following points when an error message occurs:
▪ Under what circumstances did the error occur?
▪ Name of the customer
▪ Was repair work carried out before the error occurred? If so,
▪ Machine model and serial number
what kind of work and by whom?
Questions for localizing the problem:
▪ Has this type of error occurred before?
▪ Error status
▪ Besides the reported problem, have any other problems
▪ Work being carried out when the error occurred
occurred?
▪ Work environment
Step 6: Replicating the error
▪ Maintenance background and details
▪ Start and operate the machine. Evaluate the error.
Step 2: Determination of the cause of error
Do not carry out any inspections or measures that
Step 3: Securing replacement parts and tools for error elimina-
have the potential to make the problem worse.
tion, such as:
▪ T connector
Error elimination Procedure
14 104

Step 7: Determining the problem area and defining measures


for error elimination
Step 8: Carrying out measures to eliminate errors at the work
location or in the workshop
Errors Error elimination
105 14

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

Causes Remedy pump faulty

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

Engine overheats Causes Remedy


Causes Remedy Broken sealing ring for the Replace corresponding parts
Coolant lacking Refill the coolant cylinder, worn cylinder insert,
V-belt slips because of loose Replace V-belt stuck or broken piston ring or
fitting or tear formation defective contact between air
Radiator cap damaged or radi- Replace radiator cap or clean valve and insert
ator core clogged radiator core Defective valve oil seal or worn Replace valve oil seal, valve
Water pump damaged Repair/replace water pump valve spindle and valve guide and valve guide tube
Coolant leak because of bro- Replace cylinder head or cylin- tube
ken cylinder head or cylinder der block seal closure Wear, break or incorrect setting Set the pistons correctly or
block seal closure of piston ring replace
Thermostat damaged Replace thermostat Scratches on or wear of the Replace cylinder insert
Cooling system clogged by Remove impurities from the cylinder insert
impurities cooling system
Black exhaust fumes
Fuel injection timing set incor- Adjust fuel injection timing
Causes Remedy
rectly
Air purifier clogged Clean/replace air filter
White exhaust fumes Low triggering pressure for fuel Adjust/replace fuel injection
Causes Remedy injection or poor operation of
Water in the fuel system Replace the fuel injection
Fuel injection timing set incor- Adjust fuel injection timing
rectly
Error elimination Errors
14 108

Causes Remedy Causes Remedy


Fuel injection timing set incor- Adjust fuel injection timing Poor valve clearance Adjust valve clearance
rectly Soft or broken valve spring Replace valve spring
Fuel drips after injection be- Replace the fuel valve Broken sealing ring for the Replace corresponding parts
cause of damaged fuel valve cylinder, worn cylinder insert,
on the injection pump stuck or broken piston ring or
Excessive injection from the Adjust the amount of fuel to be defective contact between air
injection pump injected valve and insert

Excessive fuel consumption Excessive oil consumption

Causes Remedy Causes Remedy


Fuel leak Repair/replace fuel system Unsuitable oil Only use oil specified in the
Air purifier clogged Clean/replace air filter appendix.
Idle speed mode faulty Adjust idle speed mode Excess oil Drain the excess oil
Low triggering pressure for fuel Adjust/replace fuel injection Oil leak from oil seal and/or Replace oil seal and/or sealing
injection or poor operation of sealing ring ring
injection No preheating possible Carry out preheating process
Fuel injection timing set incor- Adjust fuel injection timing correctly
rectly
Fuel drips after injection be- Replace the fuel valve
cause of damaged fuel valve
on the injection pump
Errors Error elimination
109 14

Causes Remedy Unusual engine noises

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

Engine turning over backwards Further errors


Loud noise of a component
WARNING
Causes Remedy
Burns from igniting exhaust fumes or burning engine
Loose fastening element Tighten
The exhaust fumes from the air filter or the engine can ignite
Excessive clearance between Reduce clearance to less than
and lead to severe burns.
excavator arm and bucket due 1 mm
• Turn off the engine immediately
to wear
Signs that the engine is starting to turn over backwards:
Digging tooth drops off
▪ Loud popping noises after starting
Causes Remedy
▪ Smoke comes out of the air filter
Spring deformed and too yiel- Replace pin of bucket tip
▪ Speedometer and oil pressure gauge do respond
ding due to wear on the pin of
▪ Signal display for low oil pressure lights up
the bucket tip
Remedy:
Pin of bucket tip does not Replace pin of bucket tip
▪ Turn off the engine immediately
match the fitting
▪ Check and clean the air filter and the supply hoses
▪ Replace defective air filter and hoses Track buckling

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

Fan does not function Compressor does not function or is stiff

Causes Remedy Causes Remedy


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
Fan blades blocked or dama- Clean/replace Cooling system leaking Repair
ged Low refrigerant level Refill refrigerant
Error elimination Errors
14 112

Indicator value of low pressure gauge too high Evaporator frozen

Low pressure line surface frozen Causes Remedy


Thermostat has switched off Replace thermostat
Causes Remedy
Expansion valve too open Replace expansion valve Inlet of the expansion valve cold and frozen
Defective contact of the ther- Correctly install thermometer
Causes Remedy
mometer bulb for the expansi- bulb
Expansion valve blocked Clean/replace expansion valve
on valve
Outlet of the expansion valve is not cold. Low
Too much refrigerant Drain refrigerant
pressure gauge may display negative values
Indicator value of low pressure gauge too low
Causes Remedy
Indicator values that are both too high and too low on the Thermometer tube or bulb for Replace expansion valve
low pressure gauge cause the standard value to drop
the expansion valve leaking
Causes Remedy
Indicator value of high pressure gauge too high
Too little refrigerant Refill refrigerant
Indicator values that are both too high and too low raise the
Low pressure gauge displays a negative value standard value

Causes Remedy Causes Remedy


Low pressure hose blocked; Repair. Replace the container Air in the air circulation system Purge air in air circulation sys-
expansion valve blocked by ice if blocked by ice tem and refill refrigerant
or dirt Too much refrigerant Drain refrigerant
Errors Error elimination
113 14

Condensing effect of the condenser is insufficient Hot capacitor and high pressure pipe

Causes Remedy Causes Remedy


Condenser clogged up by dust Clean condenser Too little refrigerant Refill refrigerant
and dirt Low pressure line blo- Clean/replace malfunctioning
Condenser fan damaged Check/replace condenser fan cked/damaged component
Internal compressor error Replace compressor
Indicator value of the high pressure gauge too low

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

Low pressure gauge displays a negative value

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

Position Reference Measure


Inspection before error elimination
value
Lubricating grease, coolant
Check the engine oil level - Top up the oil
Position Reference Measure of the diesel engine
value Check the hydraulic oil - Top up the oil
Check type of fuel. Replace with level of the swing motor
recommended Check the coolant level - Top up the
fuel. coolant
Check the fuel level - Top up the fuel
Engine
Check the fuel level for - Replace the
impurities fuel Position Reference Measure
value
Check the level of hydraulic - Top up the oil
oil. Check the engine air filter Clean/replace

Check the hydraulic oil filter - Replace the


filter
Check drive motor engine - Top up the oil
oil fill level
Troubleshooting and eliminating errors Error elimination
115 14

Electrics Position Reference Measure

Position Reference Measure value

value Check the fuses - Replace

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:

Check the terminals and - Tighten or 27.5 – 29.5 V

cabling of the alternator for replace Sound of the battery relay - Replace
loose fitting and signs of when the battery switch is
corrosion activated.

Check the terminals and - Tighten or Hydraulic, mechanical equipment


cabling of the starter for replace
Position Reference Measure
loose fitting and signs of
value
corrosion
Inspection for unusual - Repair
Check the battery voltage 20 – 30 V Replace
noises and smells
(engine switched off)
Check for oil leaks - Repair
Check the electrolyte level Refill or re-
Vent hydraulic system - Vent
of the battery place battery
Check the hydraulic oil filter Clean the
Check electrical system for - Disconnect
screen screen.
moisture and dry
Error elimination Troubleshooting and eliminating errors
14 116

Troubleshooting and eliminating errors Engine

Fault Possible cause Fault diagnostics Troubleshooting


The engine does not start Battery does not activate Check the position of the battery Activate the battery with the
switch battery switch
Battery error / the battery is not Check that the battery poles are If the battery is defective,
connected correctly free of dirt deposits and correctly contact maintenance personnel
connected
Battery is depleted Check the battery voltage (engi- Charge or replace battery
ne switched off) 20 – 30 V
The fuse has tripped. Check the fuse F1 Replace defective fuse
No fuel Top up the fuel
Incorrect start process Start the machine correctly
Engine stops right after starting Battery is depleted Check the battery voltage (engi- Charge or replace battery
ne switched off) 20 – 30 V
Engine overheats Coolant level too low Check the level of the coolant Let the engine cool and fill the
compensation vessel coolant
Low engine oil pressure Too little engine oil The alarm on the display lights Checking the engine oil and
up refilling
Troubleshooting and eliminating errors Error elimination
117 14

Electrics

Fault Possible cause Fault diagnostics Troubleshooting


Work spotlight goes out The fuse has tripped Check the fuse F7 Replace defective fuse
Bulb is defective Open the affected lamp and Replace the bulb
check the bulb
Horn does not work The fuse has tripped Check the fuse F10 Replace defective fuse

Fault Possible cause Fault diagnostics Troubleshooting


All other faults Contact maintenance personnel
Error elimination Carrying out measures to eliminate errors
14 118

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 Replacing the battery
occurred, the following happens:
WARNING
▪ Parts not connected to the error or other parts are needless-
ly disassembled. Risk of explosion if the battery poles are confused
▪ It is not possible to fine the cause of error. Explosions resulting from overheating when a battery is
For this reason, when carrying out measures to eliminate error, connected incorrectly may lead to serious injuries or death.
care must be taken to conduct a comprehensive investigation Sparks can ignite materials in the environment and lead to
beforehand and to carry out the measures according to the burns.
defined procedures. • Compare color markings for the plus and minus pole of
Even if the error is eliminated, the same error can reoccur. To the battery with manufacturer’s instructions.
avoid this, investigate and eliminate the cause of the error. • Work carefully to avoid confusing the plus pole with the
minus pole.
Disassembling the hydraulic system and
conducting maintenance work on it
If disassembly or maintenance work on the hydraulic equipment
is carried out on site, there is a danger of dust entering the
equipment. Avoid refilling the hydraulic oil, replacing the filters
or carrying out machine repairs during rain, strong wind or in
environments with excessive dust.
Carrying out measures to eliminate errors Error elimination
119 14

9. Connect the grounding cable to the negative pole.


» The battery has now been replaced.

Charging the battery

WARNING

Risk of explosion if the battery poles are confused


Explosions resulting from overheating when a battery is
connected incorrectly may lead to serious injuries or death.
Sparks can ignite materials in the environment and lead to
burns.
• Compare color markings for the plus and minus pole of
➢ The machine must be in the maintenance position.
the battery with manufacturer’s instructions.
1. Remove cover in footwell.
• Work carefully to avoid confusing the plus pole with the
2. Remove front cover on left-hand side.
minus pole.
3. Disconnect grounding cables and connecting cables.
4. Remove clip. Remove the battery and follow the instructions for the charging
5. Remove battery. device.
⇨ The battery has been removed.
Since fast charging can reduce the service life of a
6. Insert new battery.
battery, always observe the instructions for fast
7. Secure the battery with clamps.
charging.
8. Connect the connection cable to the positive pole.
Error elimination Carrying out measures to eliminate errors
14 120

Fuses (1) Fuse box

flat vehicle fuses Fuses


The machine is protected by standard-size flat vehicle fuses. ID Rated current User
The fuses must be replaced once they have tripped. In a defec- F1 Starter
tive fuse, the wire at the top of the fuse is defective.
F2 Solenoid valve
F3 Charging circuit
F4 Fuel pump
F5 Display
F6 Pilot pressure
(1) Fuse intact (2) Fuse must be exchanged
F7 Working lights
F8 Driver warning system
F9 Ground speed
F10 Horn
Colour codes for the fuses:

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

» The light bulb has been replaced.


Replacing a work spotlight bulb
Starting assistance from additional batteries
or generators
In the event of nearly or fully discharged batteries, a generator
or a battery can be used for starting assistance.

WARNING

Deadly electric shock from incorrect connection of the starting


assistance battery
(1) Grounding cable (5) Power cable
Incorrectly connecting the battery for starting assistance can
(2) Bushing (6) Fastening screws
lead to serious injuries or death by electric shock.
(3) Lamp support bracket (7) Spotlight housing
• Only trained specialist personnel may carry out such ac-
(4) Connector
tions for starting assistance.
1. Park the machine.
2. Loosen the fastening screws of the spotlight housing. ➢ The ignition is switched off.
3. Pull the power connector out of the connector cable socket. ➢ All electrical devices are switched off.
4. Pull out the light bulb holder. 1. Connect one end of the red jumper cable to the positive
5. Replace the defective light bulb. pole of the machine battery.
6. Insert the light bulb with mount. 2. Connect the other end of the same cable to the plus pole of
7. Insert the power connector into the connector cable socket. the battery used for starting assistance.
8. Close the spotlight housing and secure with fastening 3. Connect one end of the black jumper cable to the negative
screws. pole of the battery used for starting assistance.
Carrying out measures to eliminate errors Error elimination
123 14

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

(1) Quick change system equipment is connected to it.

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.

quick change system must be followed.

Installing the quick change mechanism


➢ The machine is now prepared.
1. Set down the quick change mechanism on a flat surface.
Additional equipment Quick change system
15 126

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.

Disassembling the quick change mechanism


➢ The machine is now prepared.
1. Turn the shut-off valve on the supply and return lines of the
excavator arm to the BLOCKED position.
⇨ Hydraulic oil flow is cut off.
2. Detach the hydraulic hoses of the additional equipment and
close them off with screw plugs.
Quick change system Additional equipment
127 15

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

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

(1) Breather valve weight of the additional equipment


• Secure the machine and the work area
The machine must be prepared before installing or disassemb-
• Do not drive the machine during installation and disas-
ling additional equipment.
sembly work

➢ Machine is parked on even ground capable of bearing its


weight.
➢ The work area is secured with barriers.
Preparing the machine Interface description
129 16

➢ 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

(1) Selection valve (3) Position for one-way au-


xiliary devices
(2) Position for two-way au-
xiliary devices
The selection valve regulates the direction of flow of the hydrau-
lic oil. The position of the selection valve depends on the additi-
onal equipment that has been retrofitted. Please observe the
manual for the additional equipment.
Operation of a hydraulic hammer results in heavier and faster
soiling of the hydraulic oil. An additional filter can be retrofitted
to avoid the need for more frequent oil changes. Please observe
the manual for the hydraulic hammer. The selection valve must
be placed in the position for the hydraulic hammer.
Interface description Hydraulic circuit
16 132

⇨ Depending on the type of hoses to be connected, the


Connecting additional equipment to the
hydraulic circuit hose coupling must be removed.

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.

SANY. » The unidirectional additional equipment has now been


connected to the hydraulic circuit.
Connecting the unidirectional additional equipment
Connecting the bidirectional additional equipment

(1) Nut (3) Hose


(2) Screw plug (1) Nut (3) Hose

➢ The machine is now prepared. (2) Screw plug

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

⇨ Depending on the hoses to be connected, the hose Control pedal


coupling must be removed.
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.
4. Purge the air from the hydraulic circuit.
5. Check the hydraulic system for leaks.
» The bidirectional additional equipment has now been (1) Additional equipment posi- (3) Locking pin
connected to the hydraulic circuit. tion

Checking connected parts (2) Driving position

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

(1) Selection valve


In the manual of the additional equipment, check which direction
of flow is to be set for the hydraulic oil and set the selection
valve to the corresponding position.
Disposal
135 17

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

Screw Strength class / tightening torques [Nm]


Tightening torques
8.8 10.9 12.9
Screws with strength classes 8.8, 10.9, 12.9
M12x1.5 83 122 140
Screw Strength class / tightening torques [Nm] M14x1.5 135 198 234
8.8 10.9 12.9 M16x1.5 207 306 351
M6 9 14 16 M18x1.5 315 441 522
M8 23 32 39 M20x1.5 432 621 720
M10 44 65 76 M22x1.5 576 828 963
M12 77 113 131 M25x2 729 1044 1215
M14 122 180 212 M27x2 1071 1530 1800
M16 189 279 329 M30x2 1449 2070 2421
M18 270 387 450
Tightening torques for hydraulic screws
M20 383 549 639
M22 522 747 873 Nominal thread Square Tightening torque
Number (b) Setpoint Permissible
M24 657 945 1089
(a) (mm) values range
M27 990 1395 1620
Nm Nm
M30 1305 1890 2205
9/16-18UNF 19 44 35-63
M33 1800 2520 3060
11/16-16UN 22 74 54–93
M8x1 24 36 42
13/16-16UN 27 103 84–132
M10x1.25 49 71 84
M12x1.25 86 126 149
Annex Tightening torques
18 138

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

Pipes Other screw connections for the excavator


metric Torque [Nm] imperial Torque [Nm] Components Tightening
M14 24.5 ± 5 G1/8“ 16.7 ± 2 torque
M16 45 ± 7 G1/4“ 36.7 ± 2.5 Tightening torque, track shoes [Nm] ○ (rubber)
M18 51 ± 8 G3/8“ 73.5 ± 5 Tightening torque, outer mirrors [Nm] 4.0~5.4
M20 58 ± 8 G1/2“ 107.8 ± 7.8 Tightening torque, lubricating valve, track tension 60-80
M22 74 ± 14 G3/4“ 161.7 ± 14.7 [Nm]
M24 74 ±14 G1“ 220 ± 25 Tightening torque, hydraulic oil suction filter [Nm] 135 ±20
M26 105 ± 20 Tightening torque, hydraulic oil return filter [Nm] 60-80
Tightening torque, drain opening track drive [Nm] 70 ±20
Tightening torque, hydraulic oil drain plug [Nm] 70 ±10
Plugs
Tightening torque, filler neck, track drive [Nm] 17 ±2
metric Torque [Nm] imperial Torque [Nm]
Tightening torque, drain opening track drive [Nm] 70 ±20
M20 49 ± 5 G3/8 68.6 ± 20
Tightening torque, generator belt twistlock nut
M24 68.6 ± 10
[Nm]
Tightening torque, generator belt mounting nut
Fittings [Nm]
imperial Torque [Nm] Tightening torque, hydraulic pump fastening
G3/4 (A) 161.7 ± 14.7 screws [Nm]
Annex Tightening torques
18 140

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

Specifications for consumables


Operating material overview
The following list provides you with information about the opera- Operating fluids Specification

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

Information about the use of grease


Environmental conditions

Temperature range Measure


Permanent use under -10 °C Check the grease specification
for low temperature suitability.
Permanent use between -25 It is recommended to use Total
°C and -30 °C Multis MV2 also for general
purposes.

Information about the use of fuel


Fuel recommendation

Engine type Fuel


Stage IV engines Ultra-Low-Sulphur-Diesel (ULSD) with
maximum sulphur content of 15 ppm.
Diesel according to EN590 has a maxi-
mum sulphur concentration of 10 ppm.
Stage III engines Use of Ultra-Low-Sulphur-Diesel (ULSD)
is recommended, otherwise shorten the
oil change interval.
Glossary
143

Glossary

assembly instructions Maintenance technician


The assembly instructions help to assemble the machine Maintenance personnel have the following responsibilities: •
before operation. They specify all work steps required to in- Performing all maintenance work thoroughly and on-time
stall the machine as intended by the manufacturer. according to the maintenance schedule • Observance of
the maintenance schedule • Maintenance and servicing ob-
Load-holding valves ligation. Maintenance personnel are specialist personnel.
Load-holding valves prevent the load from falling if there is
an unexpected drop in the pressure of the hydraulic sys- Operator
tem. The machine operator is obliged to only operate the machi-
ne in a perfect and undamaged condition. Maintenance and
Loading information inspections are described in the operating instructions. The
Data sheet or information card with instructions for safe
Operator must perform the following duties: • Defining the
loading and lashing the machine on a transport trailer.
responsibilities of the individual target groups • Monitoring
the observance of these responsibilities • Allowing only
maintenance manual
qualified personnel to work on the machine • Allowing only
The maintenance manual is intended for the operator's
qualified personnel to operate the machine • Ensuring that
maintenance personnel. The maintenance technician can
local regulations are observed • Ensuring that only qualified
refer to this for all information regarding maintenance work
personnel are present in the danger zone of the machine •
on the machine to ensure that it can be operated safely.
Ensuring that recognised rules for work safety are observed
• Disposing of the machine as required by law
Glossary
144

Operator manual Service technician


The operator manual is aimed at the machine operator. It The service technician possesses special knowledge about
contains all information necessary for using the machine individual components of the machine which goes beyond
safely and in the intended manner. the knowledge of the maintenance technician. Certain work
operations must only be carried out by service personnel.
Protective devices The service personnel is generally not staff employed by
Protective devices are used for the safety of machine ope-
the owner/operator.
rator and other people in the surrounding area. Protective
equipment, for instance, includes fire extinguishers, rear- user
view mirror, reversing camera, lights, safety markings. The The operator of the machine must be at least 18 years old
documentation shows what protective equipment is fitted on and be in possession of the qualifications required by the
the machine. The operator is responsible to check protecti- applicable local laws: • Professional suitability in ac-
ve equipment during daily inspections and keep them in a cordance with national standards • Health and safety in-
clean state. struction The operator has the following responsibilities: •
Operating the machine • Daily check of the machine for vi-
Safety system sible damage and defects • Reporting damage and defects
The machine's safety system consists of safety compo-
found as well as any changes in operational performance
nents and steering. Safety system components may only be
immediately to the appropriate maintenance personnel •
maintained and replaced by the manufacturer. If errors that
Checking fill levels and topping up the operating fluids •
are captured by the safety system occur during operation,
Lubricating the moving parts • Falls Filling the lubricating
the machine is automatically switched to a safe mode.
grease of a central lubricating system (if available)
Glossary
145

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

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