SANY SY115C9 Guide

SANY HEAVY MACHINERY LIMITED
www.sanygroup.com
Quailty Changes the World
Crawler Hydraulic
Excavator
SY115C9
SY135C8
SY135C9
SY155H
Safety, Operation and Manitenance Manual
318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District,
Shanghai, P.R. of China 201413
Tel: [phone]
Service hotline:[phone]
E-mail: [e-mail]
Documentation No.: B06T01ENAM1-SY115C9/135C/155H
11644389

SY115C9/135C/155H
Crawler Hydraulic Excavator
Read and follow the safety precautions and instructions in this manual and on the ma-
chine decals. Failure to do can cause serious injury, death or property damage. Keep this
manual with the machine for reading and future reference.
WARNING
Operation and Maintenance Manual
Safety, Operation and Maintenance Manual - Aug 2012
SY115C9/135C/155H Crawler Hydraulic Excavator

2012 by Sany Group. All right reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as de-
scribed herein. All information included within this publication was accurate at the time
of publication. Product improvements ,revisions, etc., may result in differences between
your machine and what is presented here. Sany Group assumes no liability. For more in-
formation, Contact Sany Group.
©
Sany Group
Sany Heavy Machinery Limited
318A, Lianggang Avenue, Lingang Industrial Park,
Fengxian District, Shanghai, P. R. of China 201413
http://www.sanygroup.com
Tel: [phone]
Service hotline: [phone]
E-mail: [e-mail]
Safety, Operation and Maintenance Manual - Aug 2012
SY115C9/135C/155H Crawler Hydraulic Excavator

Table of Contents
Safety, Operation and Maintenance Manual - Aug 2012 I
SY115C9/135C/155H Crawler Hydraulic Excavator
1 Introduction
1.1 Overview.................................................................................................................. 1-3
1.2 Your Documentation Package ................................................................................. 1-4
1.2.1 Recommendations on using the documentation............................................ 1-5
1.2.2 Documentation storage.................................................................................. 1-5
1.2.3 Manual organization....................................................................................... 1-5
1.2.3.1 Introduction ........................................................................................... 1-6
1.2.3.2 Safety.................................................................................................... 1-6
1.2.3.3 System functions................................................................................... 1-6
1.2.3.4 Operation .............................................................................................. 1-6
1.2.3.5 Maintenance ......................................................................................... 1-6
1.2.3.6 Troubleshooting .................................................................................... 1-7
1.2.3.7 Specifications........................................................................................ 1-7
1.2.3.8 Optional Equipment .............................................................................. 1-7
1.2.4 Page numbers................................................................................................ 1-7
1.3 Your Sany Machine.................................................................................................. 1-8
1.3.1 Machine applications ..................................................................................... 1-8
1.3.2 Machine directions......................................................................................... 1-8
1.3.3 Breaking in a new machine............................................................................ 1-9
1.3.4 Machine information....................................................................................... 1-9
1.3.4.1 Product identification plate.................................................................... 1-9
1.3.4.2 Engine identification plate................................................................... 1-10
1.3.4.3 Right and left drive motors ...................................................................1-11
1.3.4.4 Swing motor .........................................................................................1-11
1.3.4.5 Hydraulic pump ....................................................................................1-11
1.3.4.6 Chassis serial number ........................................................................ 1-12
1.3.4.7 Machine monitor ................................................................................. 1-12
1.4 Table for serial number and distributor information................................................ 1-13
1.5 Correction Request Form - Technical Publications................................................ 1-14
1.6 Contact Information ............................................................................................... 1-15
2 Safety
2.1 Safety Information.................................................................................................... 2-5
2.2 Safety Messages ..................................................................................................... 2-7
Table of Contents

Table of Contents
Safety, Operation and Maintenance Manual - Aug 2012II
SY115C9/135C/155H Crawler Hydraulic Excavator
2.2.1 Hazard alert wording...................................................................................... 2-8
2.2.2 Other alert wording ........................................................................................ 2-9
2.2.3 Safety decals ................................................................................................. 2-9
2.2.3.1 Textual safety decals........................................................................... 2-10
2.2.3.2 Graphical safety decals....................................................................... 2-10
2.2.3.3 Safety decal locations ..........................................................................2-11
2.3 General Precautions.............................................................................................. 2-19
2.3.1 Safety rules.................................................................................................. 2-19
2.3.2 Abnormalities ............................................................................................... 2-19
2.3.3 Personal protective equipment .................................................................... 2-19
2.3.4 Fire extinguisher and first aid kit .................................................................. 2-21
2.3.5 Safety equipment......................................................................................... 2-21
2.3.6 Cleaning your machine ............................................................................... 2-22
2.3.7 Keeping the cab clean ................................................................................. 2-23
2.3.8 Engaging the hydraulic lockout control ........................................................ 2-23
2.3.9 Handholds and steps .................................................................................. 2-24
2.3.10 Overhead work........................................................................................... 2-25
2.3.11 No sitting on attachment ........................................................................... 2-25
2.3.12 Articulated parts ......................................................................................... 2-25
2.3.13 Preventing burns ....................................................................................... 2-25
2.3.13.1 Hot coolant........................................................................................ 2-25
2.3.13.2 Hot oil................................................................................................ 2-26
2.3.14 Preventing fire and explosion .................................................................... 2-26
2.3.14.1 Fire caused by fuel or oils ................................................................. 2-26
2.3.14.2 Fire caused by flammable materials ................................................. 2-27
2.3.14.3 Fire caused by electric lines.............................................................. 2-27
2.3.14.4 Fire caused by hydraulic lines .......................................................... 2-28
2.3.14.5 Fire caused by illumination equipment.............................................. 2-28
2.3.14.6 Fire caused by heat shield ................................................................ 2-28
2.3.15 In the event of fire ...................................................................................... 2-28
2.3.16 Windshield cleaning detergent................................................................... 2-29
2.3.17 Preventing ejection of part ........................................................................ 2-29
2.3.18 Falling object protection............................................................................. 2-30
2.3.19 Attachment installation............................................................................... 2-30
2.3.20 Attachment combination ............................................................................ 2-31
2.3.21 Cab windows glasses ................................................................................ 2-31

Table of Contents
Safety, Operation and Maintenance Manual - Aug 2012 III
SY115C9/135C/155H Crawler Hydraulic Excavator
2.3.22 Unauthorized modification ......................................................................... 2-31
2.3.23 Job site investigation.................................................................................. 2-31
2.3.24 Operation on soft ground ........................................................................... 2-32
2.3.25 Overhead power cables............................................................................. 2-33
2.3.26 Ensuring a good visibility ........................................................................... 2-34
2.3.27 Ventilating enclosed area........................................................................... 2-35
2.3.28 Asbestos hazard ........................................................................................ 2-35
2.3.29 Alternate exit .............................................................................................. 2-36
2.4 Safe Operation Precautions................................................................................... 2-37
2.4.1 Safe starting ................................................................................................ 2-37
2.4.1.1 Safe mounting..................................................................................... 2-37
2.4.1.2 Seat adjustment .................................................................................. 2-38
2.4.1.3 Seat belt.............................................................................................. 2-38
2.4.1.4 Before starting the engine................................................................... 2-38
2.4.1.5 Engine starting rules ........................................................................... 2-39
2.4.1.6 Safe starting........................................................................................ 2-39
2.4.1.7 Starting engine in cold season............................................................ 2-40
2.4.1.8 Engine starting aid .............................................................................. 2-40
2.4.1.9 After starting the engine ...................................................................... 2-41
2.4.2 Operation ..................................................................................................... 2-42
2.4.2.1 Inspection before operation ................................................................ 2-42
2.4.2.2 Prior-operation precautions................................................................. 2-42
2.4.2.4 Travel directions.................................................................................. 2-43
2.4.2.3 Rules for steering safety ..................................................................... 2-43
2.4.2.5 Rules for traveling safety .................................................................... 2-45
2.4.2.6 Safe traveling ..................................................................................... 2-46
2.4.2.7 Operation on an incline ....................................................................... 2-47
2.4.2.8 Operation in snowy weather ............................................................... 2-48
2.4.2.9 Restricted operations .......................................................................... 2-48
2.4.3 Parking the machine .................................................................................... 2-51
2.4.3.1 Select a parking place......................................................................... 2-51
2.4.3.2 Machine shutdown .............................................................................. 2-51
2.4.4 Transportation .............................................................................................. 2-52
2.4.4.1 Loading and unloading the machine................................................... 2-52
2.4.4.2 Transporting the machine ................................................................... 2-53
2.4.5 Battery.......................................................................................................... 2-54

Table of Contents
Safety, Operation and Maintenance Manual - Aug 2012IV
SY115C9/135C/155H Crawler Hydraulic Excavator
2.4.6 Lifting objects with the machine................................................................... 2-56
2.5 Precautions for Maintenance................................................................................. 2-57
2.5.1 Prior-maintenance precautions.................................................................... 2-57
2.5.2 Select a working area .................................................................................. 2-57
2.5.3 Preparing the machine ................................................................................ 2-58
2.5.4 Preparing yourself........................................................................................ 2-59
2.5.5 Lock-out and tag-out .................................................................................. 2-60
2.5.6 Using proper tools........................................................................................ 2-60
2.5.7 Maintenance with engine running ................................................................ 2-61
2.5.8 Working under the machine......................................................................... 2-61
2.5.9 Track maintenance....................................................................................... 2-62
2.5.10 Track tension adjustment precautions ....................................................... 2-63
2.5.11 Recoil spring .............................................................................................. 2-63
2.5.12 Welding operation ...................................................................................... 2-64
2.5.13 High-pressure hoses.................................................................................. 2-64
2.5.14 Pressurized fluid ........................................................................................ 2-65
2.5.15 Hot cooling system..................................................................................... 2-66
2.5.16 Air-conditioning system ............................................................................. 2-66
2.5.17 High voltage precautions ........................................................................... 2-67
2.5.18 Accumulator ............................................................................................... 2-67
2.5.19 Avoiding fire and explosion ........................................................................ 2-68
2.5.20 Regular replacement of safety-related parts.............................................. 2-69
2.5.21 Maintenance operation ............................................................................. 2-70
2.5.22 Proper disposal of wastes.......................................................................... 2-71
3 System Functions
3.1 Machine Overview ................................................................................................... 3-5
3.2 Machine Controls..................................................................................................... 3-6
3.3 Monitor..................................................................................................................... 3-7
3.3.1 Monitor introduction ....................................................................................... 3-7
3.3.2 System information and operation ............................................................... 3-10
3.3.2.1 Main Page........................................................................................... 3-10
3.3.2.2 System Information ............................................................................. 3-12
3.3.2.3 Time Setup.......................................................................................... 3-13
3.3.2.4 Main Menu .......................................................................................... 3-14
3.3.2.5 Engine & Throttle Signals .................................................................. 3-15

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Safety, Operation and Maintenance Manual - Aug 2012 V
SY115C9/135C/155H Crawler Hydraulic Excavator
3.3.2.6 Main Pump Signals ............................................................................ 3-15
3.3.2.7 Input Switch Signals ........................................................................... 3-16
3.3.2.8 Output Switch Signals ........................................................................ 3-16
3.3.2.9 Machine Configuration ....................................................................... 3-17
3.3.2.10 Failure codes ................................................................................... 3-17
3.3.2.11 Maintenance Information................................................................... 3-18
3.3.2.12 Engine Speed Calibration ................................................................. 3-23
3.3.2.13 Language Selection .......................................................................... 3-25
3.3.2.14 GPS Monitoring Information.............................................................. 3-26
3.3.2.15 System Setup.................................................................................... 3-27
3.3.2.16 Machine configuration setup ............................................................. 3-28
3.3.2.17 Coolant Temperature ........................................................................ 3-29
3.3.2.18 Service Call....................................................................................... 3-30
3.4 Switches ................................................................................................................ 3-31
3.4.2.1 Start switch ......................................................................................... 3-32
3.4.2.2 Fuel control dial................................................................................... 3-33
3.4.2.3 Work lamp switch................................................................................ 3-33
3.4.2.4 Wiper switch........................................................................................ 3-35
3.4.2.5 Washer switch..................................................................................... 3-36
3.4.2.6 Head lamp switch................................................................................ 3-36
3.4.2.7 Horn switch ......................................................................................... 3-37
3.4.2.8 Cab lamp ............................................................................................ 3-37
3.4.2.9 Cigar lighter......................................................................................... 3-37
3.4.2.10 Preheat switch (only for SY135C8M)................................................ 3-38
3.4.2.11 Alternator indicator ............................................................................ 3-38
3.5 Control levers and pedals...................................................................................... 3-39
3.5.1 Hydraulic lockout control.............................................................................. 3-40
3.5.2 Travel controls.............................................................................................. 3-41
3.5.3 Joystick controls........................................................................................... 3-42
3.6 Roof Hatch............................................................................................................. 3-44
3.6.1 Opening the roof hatch ............................................................................... 3-44
3.6.2 Closing the roof hatch ................................................................................. 3-44
3.7 Windshield ............................................................................................................. 3-45
3.7.1 Opening the window ................................................................................... 3-45
3.7.2 Closing the window ..................................................................................... 3-48
3.7.3 Removing the lower window ...................................................................... 3-50

Table of Contents
Safety, Operation and Maintenance Manual - Aug 2012VI
SY115C9/135C/155H Crawler Hydraulic Excavator
3.8 Alternate Exit.......................................................................................................... 3-51
3.9 Door Catch............................................................................................................. 3-52
3.10 Cover/cap with a Latch ........................................................................................ 3-52
3.10.1 Opening/closing the cover with lock........................................................... 3-53
3.10.2 Opening/closing the cap with lock.............................................................. 3-54
3.11 Cup Holder........................................................................................................... 3-55
3.12 Storage Box ......................................................................................................... 3-56
3.13 Literature Bag ...................................................................................................... 3-56
3.14 Ashtray................................................................................................................. 3-57
3.15 Air Conditioning System....................................................................................... 3-58
3.15.1 Control panel.............................................................................................. 3-58
3.15.2 Operation method ...................................................................................... 3-64
3.15.3 A/C operation precautions.......................................................................... 3-72
3.16 Radio ................................................................................................................... 3-74
3.16.1 Control panel.............................................................................................. 3-74
3.16.2 Radio operation.......................................................................................... 3-76
3.17 Auxiliary Power Supply ........................................................................................ 3-80
3.18 Fuses................................................................................................................... 3-80
3.19 Fusible Link.......................................................................................................... 3-81
3.20 Controller ............................................................................................................. 3-82
3.21 Toolbox ................................................................................................................ 3-82
3.22 Grease pump frame............................................................................................. 3-82
3.23 Fire extinguisher .................................................................................................. 3-83
4 Operation
4.1 Before Starting the Engine....................................................................................... 4-5
4.1.1 Routine checks ............................................................................................. 4-5
4.1.2 Checks before starting................................................................................... 4-7
4.1.2.1 Fuel tank - check/drain.......................................................................... 4-7
4.1.2.2 Water separator - check/drain .............................................................. 4-7
4.1.2.3 Drain valve - regulate............................................................................ 4-8
4.1.2.4 Hydraulic oil - check/refill ...................................................................... 4-9
4.1.2.5 Coolant - check/refill ........................................................................... 4-10
4.1.2.6 Oil in engine oil pan - check/refill .........................................................4-11
4.1.2.7 Electric wires - check .......................................................................... 4-12
4.1.2.8 Fuel tank - check/refuel....................................................................... 4-13

Table of Contents
Safety, Operation and Maintenance Manual - Aug 2012 VII
SY115C9/135C/155H Crawler Hydraulic Excavator
4.1.2.9 Work lamp switch - check ................................................................... 4-14
4.1.2.10 Horn - check...................................................................................... 4-15
4.1.3 Adjustment before operation........................................................................ 4-15
4.1.3.1 Operator seat ...................................................................................... 4-15
4.1.3.2 Rear view mirrors................................................................................ 4-17
4.1.3.3 Seat belt.............................................................................................. 4-19
4.1.4 Before Starting the Engine........................................................................... 4-20
4.2 Engine Starting ...................................................................................................... 4-22
4.2.1 Engine Preheating ...................................................................................... 4-25
4.2.2 Warm-up operation ...................................................................................... 4-26
4.2.3 Selecting a working mode ........................................................................... 4-26
4.3 Engine Shutdown................................................................................................... 4-27
4.4 Machine Operation ................................................................................................ 4-28
4.4.1 Before moving the machine ......................................................................... 4-28
4.4.2 Moving the machine forward........................................................................ 4-29
4.4.3 Moving the machine backward .................................................................... 4-30
4.4.4 Parking the machine .................................................................................... 4-31
4.5 Steering Operation................................................................................................. 4-32
4.5.4.1 Steering with travel controls ............................................................... 4-32
4.5.4.2 Steering with machine stopped........................................................... 4-32
4.5.4.3 Steering during traveling ..................................................................... 4-33
4.5.4.4 Pivot turn............................................................................................. 4-33
4.5.1 Swing operation ........................................................................................... 4-34
4.6 Work Equipment Control and Operation................................................................ 4-35
4.7 Working mode........................................................................................................ 4-37
4.8 Restricted Operations ............................................................................................ 4-38
4.8.1 Operation with swinging force...................................................................... 4-38
4.8.2 Operation with traveling force ...................................................................... 4-38
4.8.3 Operation when hydraulic cylinder reaches its stroke end ......................... 4-39
4.8.4 Operation with bucket landing force............................................................. 4-39
4.8.5 Operation with machine weight.................................................................... 4-40
4.8.6 Hard rocky ground ...................................................................................... 4-40
4.8.7 Sudden shift of travel speed during fast traveling ....................................... 4-41
4.9 General Operation ................................................................................................ 4-41
4.9.1 Traveling operation ...................................................................................... 4-41
4.9.2 High-speed travel......................................................................................... 4-41

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Safety, Operation and Maintenance Manual - Aug 2012VIII
SY115C9/135C/155H Crawler Hydraulic Excavator
4.9.3 Permissible depth of water........................................................................... 4-42
4.10 Traveling on Slope............................................................................................... 4-42
4.10.1 Traveling downhill ..................................................................................... 4-44
4.10.2 Engine stalls on an incline ......................................................................... 4-44
4.10.3 Cab door on an incline............................................................................... 4-44
4.11 Removing Machine from Mud .............................................................................. 4-44
4.11.1 One track trapped ...................................................................................... 4-44
4.11.2 Both tracks trapped.................................................................................... 4-45
4.12 Recommended Applications ................................................................................ 4-45
4.12.1 Backhoe operation ..................................................................................... 4-45
4.12.2 Trench work ............................................................................................... 4-46
4.12.3 Loading operation ...................................................................................... 4-46
4.13 Parking Operation................................................................................................ 4-47
4.14 Checks after Each Workday ................................................................................ 4-49
4.15 Locking the Machine............................................................................................ 4-50
4.16 Operation in Cold Weather .................................................................................. 4-50
4.16.1 Operation instruction.................................................................................. 4-50
4.16.1.1 Fuel and lubricant ............................................................................. 4-50
4.16.1.2 Battery............................................................................................... 4-51
4.16.2 After each workday .................................................................................... 4-52
4.16.3 After cold season ....................................................................................... 4-53
4.17 Long-Term Storage .............................................................................................. 4-54
4.17.1 Before storage ........................................................................................... 4-54
4.17.2 During storage ........................................................................................... 4-55
4.17.3 After storage............................................................................................... 4-56
4.17.4 Starting the engine after long-term storage ............................................... 4-56
4.18 Transportation Information................................................................................... 4-57
4.18.1 Transport methods..................................................................................... 4-57
4.18.2 Loading/unloading machine to/from a trailer.............................................. 4-57
4.18.2.1 Loading the machine......................................................................... 4-59
4.18.2.2 Securing the machine ....................................................................... 4-61
4.18.2.3 Rear view mirrors.............................................................................. 4-62
4.18.2.4 Unloading the machine ..................................................................... 4-63
4.18.3 Lifting the machine or its components ....................................................... 4-65
4.18.3.1 Lifting precautions............................................................................. 4-65
4.18.3.2 Choosing a wire rope ........................................................................ 4-66

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Safety, Operation and Maintenance Manual - Aug 2012 IX
SY115C9/135C/155H Crawler Hydraulic Excavator
4.18.3.3 Lifting the machine............................................................................ 4-67
5 Maintenance
5.1 Maintenance Information ......................................................................................... 5-5
5.2 General Service ....................................................................................................... 5-9
5.2.1 Oil, fuel and coolant ....................................................................................... 5-9
5.2.1.1 Oil.......................................................................................................... 5-9
5.2.1.2 Fuel ..................................................................................................... 5-10
5.2.1.3 Coolant ................................................................................................5-11
5.2.2 Grease ......................................................................................................... 5-12
5.2.3 Oil and fuel storage...................................................................................... 5-13
5.2.4 Filter element ............................................................................................... 5-13
5.2.5 Electrical system ......................................................................................... 5-14
5.2.6 Hydraulic system.......................................................................................... 5-14
5.3 Replacement Parts ................................................................................................ 5-16
5.4 Recommended Fluids............................................................................................ 5-17
5.4.1 Fluid capacities ............................................................................................ 5-19
5.4.2 Recommended oils: .................................................................................... 5-20
5.5 Tightening Torque Specification............................................................................. 5-22
5.6 Safety-Related Parts.............................................................................................. 5-24
5.7 Maintenance Schedule .......................................................................................... 5-25
5.7.1 List of maintenance schedule ...................................................................... 5-25
5.7.2 Hydraulic Breaker Service Interval............................................................... 5-27
5.8 Maintenance Procedures....................................................................................... 5-28
5.8.1 Maintenance after initial 50 service hours.................................................... 5-28
5.8.1.1 Engine oil and filter - change/replace.................................................. 5-28
5.8.1.2 Fuel filter - replace ............................................................................. 5-28
5.8.2 When Required ............................................................................................ 5-29
5.8.2.1 Air cleaner - clean/replace .................................................................. 5-29
5.8.2.2 Cooling system - clean....................................................................... 5-37
5.8.2.3 Track shoe bolts - inspect/tighten ....................................................... 5-41
5.8.2.4 Track tension - inspect/adjust ............................................................. 5-42
5.8.2.5 Bucket tips (lateral pin) - replace ........................................................ 5-45
5.8.2.6 Bucket Replacement........................................................................... 5-47
5.8.2.7 Bucket clearance - adjust.................................................................... 5-49
5.8.2.8 Window washer fluid - check/refill...................................................... 5-51

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Safety, Operation and Maintenance Manual - Aug 2012X
SY115C9/135C/155H Crawler Hydraulic Excavator
5.8.2.9 Air conditioner - inspect/service .......................................................... 5-52
5.8.2.10 Gas spring - inspect .......................................................................... 5-54
5.8.2.11 Air in hydraulic system - purge .......................................................... 5-55
5.8.2.12 Hydraulic circuit internal pressure - release...................................... 5-58
5.8.3 Checks before starting................................................................................. 5-59
5.8.4 Every 100 service hours .............................................................................. 5-60
5.8.4.1 Lubrication .......................................................................................... 5-60
5.8.5 Every 250 service hours .............................................................................. 5-63
5.8.5.1 Compressor belt tension - inspect/adjust............................................ 5-63
5.8.5.2 Oil in engine oil pan and oil filter - change/replace ............................. 5-65
5.8.5.3 Primary fuel filter - replace .................................................................. 5-67
5.8.5.4 Secondary fuel filter - replace ............................................................. 5-71
5.8.6 Every 500 service hours .............................................................................. 5-74
5.8.6.1 Swing bearing - lubricate .................................................................... 5-74
5.8.6.2 Swing pinion gear grease - check/refill ............................................... 5-75
5.8.6.3 Coolant tank and radiator fins - inspect/clean..................................... 5-76
5.8.6.4 Air conditioner filters - clean................................................................ 5-77
5.8.6.5 Swing drive oil - check/refill................................................................. 5-80
5.8.6.6 Final drive oil - check/fill...................................................................... 5-81
5.8.7 Every 1000 service hours ............................................................................ 5-82
5.8.7.1 Hydraulic oil filter - replace.................................................................. 5-82
5.8.7.2 Swing drive oil - change...................................................................... 5-84
5.8.7.3 Engine exhaust pipe clamps - check .................................................. 5-85
5.8.7.4 Fan belt tension - check/replace ......................................................... 5-85
5.8.7.5 Nitrogen pressure in accumulator (breaker) - check........................... 5-85
5.8.8 Every 2000 service hours ............................................................................ 5-86
5.8.8.1 Final drive oil - change........................................................................ 5-86
5.8.8.2 Hydraulic tank filter screen - clean...................................................... 5-88
5.8.8.3 Nitrogen pressure in accumulator (control oil circuit) - check ............. 5-89
5.8.8.4 Hydraulic circuit internal pressure - release........................................ 5-92
5.8.8.5 Oil in hydraulic tank - change.............................................................. 5-93
5.8.8.6 Alternator - inspect .............................................................................. 5-95
5.8.8.7 Engine valve clearance - check/adjust................................................ 5-95
5.8.9 Every 4000 service hours ............................................................................ 5-95
5.8.9.1 Coolant pump - inspect ....................................................................... 5-95
5.8.9.2 Start motor - check.............................................................................. 5-95

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Safety, Operation and Maintenance Manual - Aug 2012 XI
SY115C9/135C/155H Crawler Hydraulic Excavator
5.8.9.3 Accumulator (control oil circuit) - replace ............................................ 5-96
5.8.9.4 High-pressure tube clamps and rubber - check.................................. 5-97
5.8.9.5 Compressor working condition - inspect ............................................. 5-97
5.8.10 Every 8000 service hours .......................................................................... 5-98
5.8.10.1 High-pressure tube clamps - replace ................................................ 5-98
5.8.11 Every 10000 service hours......................................................................... 5-98
6 Troubleshooting
6.1 Troubleshooting Preparation.................................................................................... 6-3
6.1.1 Checks before troubleshooting ...................................................................... 6-3
6.1.2 Troubleshooting procedure ............................................................................ 6-4
6.1.3 Troubleshooting precautions.......................................................................... 6-6
6.1.4 Electrical circuits troubleshooting precautions............................................... 6-9
6.1.5 Hydraulic components handling precautions ............................................... 6-10
6.2 Pseudo Failures..................................................................................................... 6-12
6.3 Towing the Machine ............................................................................................... 6-13
6.4 Towing Hook for Light Loads ................................................................................. 6-15
6.5 Severe Operating Conditions................................................................................. 6-15
6.6 Engine Failures...................................................................................................... 6-16
6.6.1 Engine troubleshooting table ....................................................................... 6-16
6.6.2 Coolant temperature high ............................................................................ 6-19
6.6.3 Engine oil pressure low................................................................................ 6-20
6.6.4 When fuel exhausts ..................................................................................... 6-22
6.6.5 When engine rotates reversely ................................................................... 6-24
6.7 Failures of the Electrical System ........................................................................... 6-25
6.7.1 Electrical system troubleshooting table........................................................ 6-25
6.7.2 Failure codes ............................................................................................... 6-28
6.8 Battery .................................................................................................................. 6-30
6.8.1 Battery removal and installation................................................................... 6-30
6.8.2 Battery charging........................................................................................... 6-31
6.8.3 Jump-starting the engine ............................................................................. 6-32
6.8.3.1 Connecting the jumper cables ............................................................ 6-33
6.8.3.2 Starting the engine.............................................................................. 6-34
6.8.3.3 Disconnecting the jumper cables ........................................................ 6-34
6.9 Failures of the Hydraulic System........................................................................... 6-35
6.10 Other Common Failures ...................................................................................... 6-39

Table of Contents
Safety, Operation and Maintenance Manual - Aug 2012XII
SY115C9/135C/155H Crawler Hydraulic Excavator
7 Specifications
7.1 Machine Dimensions ............................................................................................... 7-3
7.2 Working Ranges ..................................................................................................... 7-4
8 Optional Equipment
8.1 General Safety ........................................................................................................ 8-3
8.1.1 Selection precautions..................................................................................... 8-3
8.1.2 Reading the instruction books........................................................................ 8-3
8.1.3 Removal and installation precautions ........................................................... 8-3
8.1.4 Operation precautions.................................................................................... 8-4
8.2 Hydraulic Control Elements and Oil Circuit ............................................................. 8-6
8.2.1 Location of the components........................................................................... 8-6
8.2.1.1 Stop valve ............................................................................................. 8-6
8.2.1.2 Selector valve ....................................................................................... 8-7
8.2.1.3 Control pedal......................................................................................... 8-7
8.2.2 Hydraulic circuit.............................................................................................. 8-8
8.2.2.1 Hydraulic circuit switching..................................................................... 8-8
8.2.2.2 Shifting to breaker / general optional equipment .................................. 8-8
8.2.2.3 Connecting hydraulic oil circuit ............................................................. 8-9
8.2.2.4 Hydraulic oil passage.......................................................................... 8-10
8.2.3 Optional equipment removal and installation................................................8-11
8.2.3.1 Removal...............................................................................................8-11
8.2.3.2 Optional equipment installation .......................................................... 8-13
8.2.4 Hydraulic oil and hydraulic tank filter - change/replace ............................... 8-15
8.2.5 Long-term storage........................................................................................ 8-16
8.2.6 Hydraulic specifications ............................................................................... 8-16
8.3 Optional equipment Guide..................................................................................... 8-17
8.3.1 Work equipment combination ...................................................................... 8-17
8.3.2 Bucket tips selection .................................................................................... 8-19
8.3.2.1 Rockwork bucket tips .......................................................................... 8-19
8.3.2.2 Earthwork bucket tips.......................................................................... 8-19
8.4 Recommended Operations.................................................................................... 8-20
8.4.1 Hydraulic breaker......................................................................................... 8-20
8.4.2 Hydraulic breaker operation......................................................................... 8-21
8.5 Restricted Operations ............................................................................................ 8-22
8.6 Hydraulic Breaker Lubrication................................................................................ 8-25

Table of Contents
Safety, Operation and Maintenance Manual - Aug 2012 XIII
SY115C9/135C/155H Crawler Hydraulic Excavator
8.7 Quick Coupler and Control System ....................................................................... 8-26
8.7.1 Quick coupler installation............................................................................. 8-26
8.7.2 Operating precautions ................................................................................. 8-28
8.8 Refueling System.................................................................................................. 8-29
8.8.1 Introduction .................................................................................................. 8-29
8.8.2 Components................................................................................................. 8-30
8.9 Central Lubrication System.................................................................................... 8-31
8.9.1 Scheme and components ............................................................................ 8-31
8.9.2 System working principle ............................................................................. 8-33
8.9.3 Setting the lubrication time of electric grease pump .................................... 8-34
8.9.4 Technical description.................................................................................... 8-35
8.9.5 Adding grease with electric pump ................................................................ 8-36

Table of Contents
Safety, Operation and Maintenance Manual - Aug 2012XIV
SY115C9/135C/155H Crawler Hydraulic Excavator

Introduction
SY115C9/135C/155H Crawler Hydraulic Excavator Introduction
Safety, Operation and Maintenance Manual - Aug 2012 1-1
1 Introduction
1.1 Overview.................................................................................................................. 1-3
1.2 Your Documentation Package ................................................................................. 1-4
1.2.1 Recommendations on using the documentation............................................ 1-5
1.2.2 Documentation storage.................................................................................. 1-5
1.2.3 Manual organization....................................................................................... 1-5
1.2.3.1 Introduction ........................................................................................... 1-6
1.2.3.2 Safety.................................................................................................... 1-6
1.2.3.3 System functions................................................................................... 1-6
1.2.3.4 Operation .............................................................................................. 1-6
1.2.3.5 Maintenance ......................................................................................... 1-6
1.2.3.6 Troubleshooting .................................................................................... 1-7
1.2.3.7 Specifications........................................................................................ 1-7
1.2.3.8 Optional Equipment .............................................................................. 1-7
1.2.4 Page numbers................................................................................................ 1-7
1.3 Your Sany Machine.................................................................................................. 1-8
1.3.1 Machine applications ..................................................................................... 1-8
1.3.2 Machine directions ......................................................................................... 1-8
1.3.3 Breaking in a new machine............................................................................ 1-9
1.3.4 Machine information....................................................................................... 1-9
1.3.4.1 Product identification plate.................................................................... 1-9
1.3.4.2 Engine identification plate ................................................................... 1-10
1.3.4.3 Right and left drive motors ...................................................................1-11
1.3.4.4 Swing motor .........................................................................................1-11
1.3.4.5 Hydraulic pump ....................................................................................1-11

Introduction SY115C9/135C/155H Crawler Hydraulic Excavator
1-2 Safety, Operation and Maintenance Manual - Aug 2012
1.3.4.6 Chassis serial number ........................................................................ 1-12
1.3.4.7 Machine monitor ................................................................................. 1-12
1.4 Table for serial number and distributor information................................................ 1-13
1.5 Correction Request Form - Technical Publications................................................ 1-14
1.6 Contact Information ............................................................................................... 1-15

Introduction
Safety, Operation and Maintenance Manual - Aug 2012 1-3
SY115C9/135C/155H Crawler Hydraulic Excavator
1 INTRODUCTION
1.1 Overview
♦Sany-built machines offer high-quality per-
formance and star-grade, after-sales ser-
vice.
♦Sany-built machines are widely used
throughout the industry for various types of
applications.
♦Sany is a leading manufacturer of con-
struction equipment worldwide.
This operator’s manual provides safety, opera-
tion, maintenance, troubleshooting and techni-
cal specifications. In order to properly use your
equipment, it is important to read this manual
carefully before beginning any operations.
Items addressed in this manual are designed
to help you:
●Understand the structure and performance
of your crawler hydraulic excavator.
●Reduce improper operation and point out
possible hazardous situations.
●Increase equipment efficiency during op-
eration.
●Prolong the service life of equipment.
●Reduce maintenance costs.
Always keep this manual nearby and have all
personnel involved with any job-related proce-
dures read it periodically.
If you sell the machine, be sure to give this
manual to the new owner.
Continuing improvements in the design of this
machine can lead to changes in detail which
may not be covered in this manual. Always
consult your Sany distributor for the latest
available information or if you have questions
regarding information in this manual.
Fig. 1-1