MOperador SY215C Serie HO6898 - Crawler Hydraulic Excavator

www.sanyhi.
com Quality Changes the World
Crawler Hydraulic
Excavator
SY195C-9
SY205C-9
SY215C-9
SY225C-9
SY235C-9
SANY HEAVY MACHINERY LIMITED SY265C-9
318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District,

Shanghai, P.R. of China 201413
Tel: (86) 21 5700 8518

Service hotline:(86) 4006 098 318
E-mail: crd@sany.com.cn
Pub. No.: B06T01ENAN3-SY195/205/215/225/235/265C9
12265744
Safety, Operation and Maintenance Manual

SY195/205/215/225/235/265C9
Crawler Hydraulic Excavator
Safety, Operation and Maintenance Manual
WARNING
Read and follow the safety precautions and instructions in this manual and on the ma-
chine decals. Failure to do so may cause serious injury, death or property damage. Keep
this manual with the machine for reading and future reference.
Sany Group
Shanghai Sany Heavy Machinery Limited
318A, Lianggang Avenue, Lingang Industrial Park,
Fengxian District, Shanghai, P.R. of China 201413
http://www.sanygroup.com
Tel: 0086-10-60738666
Fax: 0086-10-60738831
© 2013 by Sany Group. All rights reserved. No part of this publication may be repro-
duced, used, distributed or disclosed except during normal operation of the machine as
described 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, please contact Sany Group.
SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator Table of Contents
Exemption Clauses
SPECIFIC DECLARATION
The crawler hydraulic excavator is a multi-purpose construction machine that is primarily used for
digging or loading earth and stones. It can also be used for grading, slope-trimming, lifting, break-
ing, demolishing and trenching applications. The excavator is widely used in road and railway
construction, bridge building, city construction, as well as airport, sea port and water conserva-
tion construction. It can also perform the function of bull dozer, loader and crane. Application oth-
er than the specified range are excluded from the scope. Sany assumes no responsibility for any
consequence caused by unauthorized applications.
Sany assumes no responsibility for consequences caused by the following factors:
● Misuse of the excavator due to failure to observe the information provided hereunder in this
manual;
● Unauthorized restructuring or modification to the excavator;
● Use of non-genuine parts, or untested or unapproved parts or tools.
● Machine failure or damage resulted from natural disasters (such as earthquake, typhoon,
etc.), wars and other force majeure.
Sany cannot anticipate all potential hazards that may occur on work site. Therefore, excavator
operator and owner shall attach great importance to the issue of safety.
Local government may impose higher standards for use of a hydraulic excavator. If local regula-
tions have conflicts to the safety rules described herein, whichever the stricter applies.
Obligations of Sany
● Offer quality excavators along with correct information.
● Abide by after-sales service commitment and keep a record for all maintenance work and re-
pair work.
● Provide training for excavator operators and service persons as required.
Obligations of owners or authorized persons
● Only trained personnel who fully understand the Parts Book and the Safety, Operation and
Maintenance Manual are allowed to operate and service the hydraulic excavator.
● Make sure that the excavator operator and service person are qualified for this job and know
their responsibilities.
● Regularly inspect the safety awareness of related persons at work.
● Should any fault threatening safety occurs, shut down the excavator immediately.
● Sany service personnel have the right to carry out safety inspection to the excavator when re-
quired.
Safety, Operation & Maintenance Manual - October 2013 3

Table of Contents SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator
● Besides the checks specified by Sany, local laws and regulations on excavator shall also be
observed.
● Ensure timely maintenance and repair of the hydraulic excavator.
● Make a detailed plan for proper use of the hydraulic excavator.
Obligations of all operating personnel
● Any abnormalities that could bring improper operation of the hydraulic excavator or potential
hazards should be reported to your supervisor. The abnormalities should be corrected timely
if possible.
● All workers around the hydraulic excavator must know and obey all warning signals, and be
alert to safety of oneself and others.
● All operators must know the operating items and procedures.
● Be alert to any hazardous situation and immediately inform operator and signalman of the
hazards such as high voltage cables, irrelevant people and worse ground condition.
Obligations of manager
● The operator must have been trained and fully understand the provision of the Safety, Opera-
tion and Maintenance Manual. The operator must be healthy and licensed. Otherwise he/she
is not allowed to operate the hydraulic excavator.
● Make sure that the operator has good sense, cooperation awareness and psychological qual-
ity, or he/she is not allowed to operate or service the hydraulic excavator.
● Make sure that the signal person has good visibility and hearing ability, knows standard com-
mand signals and can give signals clearly and correctly. The signal person shall also have
enough experience to recognize hazardous factors and timely tell the operator to avoid the
hazards.
● Make sure that the assistant person can positively identify the model and working condition of
hydraulic excavator and choose a suitable hydraulic excavator.
● Each operating personnel of a project shall bear certain safety responsibilities and is required
to timely report unsafe factors to the supervisor.
4 Safety, Operation & Maintenance Manual - October 2013

Table of Contents
1 Introduction
1.1 Overview .................................................................................................................. 1-3
1.2 Your Documentation Package ................................................................................. 1-4
1.2.1 CD system requirements ............................................................................... 1-4
1.2.2 Recommendations on using the documentation ............................................ 1-4
1.2.3 Documentation storage .................................................................................. 1-5
1.2.4 Manual organization....................................................................................... 1-5
1.2.4.1 Introduction ........................................................................................... 1-5
1.2.4.2 Safety .................................................................................................... 1-5
1.2.4.3 System functions................................................................................... 1-5
1.2.4.4 Operation .............................................................................................. 1-5
1.2.4.5 Maintenance ......................................................................................... 1-5
1.2.4.6 Troubleshooting .................................................................................... 1-6
1.2.4.7 Specifications ........................................................................................ 1-6
1.2.4.8 Optional Equipment .............................................................................. 1-6
1.3 Your Sany Machine .................................................................................................. 1-7
1.3.1 Machine applications ..................................................................................... 1-7
1.3.2 Machine directions ......................................................................................... 1-7
1.3.3 Breaking in a new machine ............................................................................ 1-8
1.3.4 Machine information....................................................................................... 1-8
1.3.4.1 Product identification plate .................................................................... 1-9
1.3.4.2 Engine identification plate ..................................................................... 1-9
1.3.4.3 Drive motors identification plate .......................................................... 1-12
1.3.4.4 Swing motor identification plate .......................................................... 1-12
1.3.4.5 Hydraulic pump identification plate ..................................................... 1-12
1.3.4.6 Chassis serial number ........................................................................ 1-13
1.3.5 Table for serial number and distributor information ...................................... 1-14
1.4 Correction Request Form - Technical Publications ................................................ 1-15
1.5 Contact Information ............................................................................................... 1-16
2 Safety
2.1 Foreword.................................................................................................................. 2-5
2.2 Safety Messages ..................................................................................................... 2-7
2.2.1 Hazard alert wording ...................................................................................... 2-8
2.2.2 Other alert wording ........................................................................................ 2-9
Safety, Operation & Maintenance Manual - October 2013 I

2.2.3 Safety decals ............................................................................................... 2-10

2.2.3.1 Textual safety decals........................................................................... 2-10
2.2.3.2 Graphical safety decals....................................................................... 2-10
2.2.4 Safety decal locations ...................................................................................2-11
2.3 General Precautions .............................................................................................. 2-21
2.3.1 Safety rules .................................................................................................. 2-21
2.3.2 Abnormal cases ........................................................................................... 2-21
2.3.3 Personal protective equipment .................................................................... 2-22
2.3.4 Fire extinguisher and first aid kit .................................................................. 2-23
2.3.5 Safety equipment ......................................................................................... 2-24
2.3.6 Machine cleaning ........................................................................................ 2-25
2.3.7 Keeping cab clean ....................................................................................... 2-25
2.3.8 Lock the hydraulic controls before leaving the cab ...................................... 2-26
2.3.9 Handholds and steps .................................................................................. 2-27
2.3.10 Elevated work ............................................................................................ 2-28
2.3.11 No sitting on attachment ........................................................................... 2-28
2.3.12 Articulated parts ......................................................................................... 2-28
2.3.13 Prevention of burns and scalds.................................................................. 2-29
2.3.13.1 Hot coolant ........................................................................................ 2-29
2.3.13.2 Hot oil ................................................................................................ 2-29
2.3.14 Fire and explosion hazard.......................................................................... 2-30
2.3.14.1 Fire caused by fuel or oils ................................................................. 2-30
2.3.14.2 Fire caused by flammable materials ................................................. 2-31
2.3.14.3 Fire caused by electric lines.............................................................. 2-31
2.3.14.4 Fire caused by hydraulic lines .......................................................... 2-31
2.3.14.5 Fire caused by illumination equipment.............................................. 2-32
2.3.14.6 Fire caused by heat shield ................................................................ 2-32
2.3.15 In the event of fire ...................................................................................... 2-32
2.3.16 Windshield cleaning detergent ................................................................... 2-33
2.3.17 Ejecting parts ............................................................................................ 2-33
2.3.18 Falling object protection ........................................................................... 2-34
2.3.19 Attachment installation ............................................................................... 2-34
2.3.20 Attachment combination ............................................................................ 2-35
2.3.21 Cab windows glasses ................................................................................ 2-35
2.3.22 Unauthorized modification ......................................................................... 2-35
2.3.23 Worksite investigation ................................................................................ 2-36
2.3.24 Operation on loose ground ........................................................................ 2-37
2.3.25 Overhead power cables ............................................................................. 2-38
II Safety, Operation & Maintenance Manual - October 2013

2.3.26 Visibility ...................................................................................................... 2-39

2.3.27 Ventilation .................................................................................................. 2-39
2.3.28 Asbestos .................................................................................................... 2-40
2.3.29 Alternate exit .............................................................................................. 2-41
2.4 Safe Operation Precautions................................................................................... 2-42
2.4.1 Safe starting ................................................................................................ 2-42
2.4.1.1 Safe mounting ..................................................................................... 2-42
2.4.1.2 Operator seat ...................................................................................... 2-42
2.4.1.3 Seat belt .............................................................................................. 2-43
2.4.1.4 Before starting the engine ................................................................... 2-43
2.4.1.5 Engine starting rules ........................................................................... 2-44
2.4.1.6 Machine starting.................................................................................. 2-44
2.4.1.7 Starting engine in cold season ............................................................ 2-45
2.4.1.8 Engine starting aid .............................................................................. 2-45
2.4.1.9 After starting the engine ...................................................................... 2-46
2.4.2 Operation ..................................................................................................... 2-47
2.4.2.1 Inspection before operation ................................................................ 2-47
2.4.2.2 Prior-operation precautions ................................................................ 2-48
2.4.2.3 Travel direction confirmation ............................................................... 2-49
2.4.2.4 Safety rules for turning ........................................................................ 2-50
2.4.2.5 Safety rules for traveling ..................................................................... 2-52
2.4.2.6 Safe traveling ..................................................................................... 2-53
2.4.2.7 Machine operation on slope ................................................................ 2-54
2.4.2.8 Operation in snowy weather ............................................................... 2-55
2.4.2.9 Restricted operation ............................................................................ 2-56
2.4.3 Parking the machine .................................................................................... 2-58
2.4.3.1 Select a parking place......................................................................... 2-58
2.4.3.2 Machine shutdown .............................................................................. 2-59
2.4.4 Transportation .............................................................................................. 2-60
2.4.4.1 Loading and unloading........................................................................ 2-60
2.4.4.2 Transportation ..................................................................................... 2-61
2.4.5 Battery.......................................................................................................... 2-62
2.4.6 Towing .......................................................................................................... 2-64
2.4.7 Lifting objects with the machine ................................................................... 2-65
2.5 Precautions for Maintenance ................................................................................. 2-66
2.5.1 Pre-maintenance precautions ...................................................................... 2-66
2.5.2 Select a working area .................................................................................. 2-66
2.5.3 Prepare the machine ................................................................................... 2-67
Safety, Operation & Maintenance Manual - October 2013 III

2.5.4 Prepare yourself........................................................................................... 2-68

2.5.5 Lockout and tag-out measures ................................................................... 2-69
2.5.6 Use proper tools........................................................................................... 2-69
2.5.7 Maintenance with engine running ................................................................ 2-70
2.5.8 Work under the machine .............................................................................. 2-71
2.5.9 Track maintenance....................................................................................... 2-72
2.5.10 Track tension adjustment ........................................................................... 2-73
2.5.11 Recoil spring .............................................................................................. 2-73
2.5.12 Welding operation ...................................................................................... 2-74
2.5.13 High-pressure hoses .................................................................................. 2-74
2.5.14 Pressurized fluid ........................................................................................ 2-75
2.5.15 Hot cooling system..................................................................................... 2-76
2.5.16 Air-conditioning system maintenance ........................................................ 2-76
2.5.17 High voltage precautions ........................................................................... 2-77
2.5.18 Accumulator ............................................................................................... 2-77
2.5.19 Fire and explosion prevention .................................................................... 2-78
2.5.20 Regular replacement of safety-related parts .............................................. 2-79
2.5.21 Maintenance operation ............................................................................. 2-79
2.5.22 Proper disposal of wastes .......................................................................... 2-80
3 System Functions
3.1 Machine general drawing......................................................................................... 3-3
3.2 Monitoring System ................................................................................................... 3-4
3.2.1 Monitor functions............................................................................................ 3-4
3.2.2 Monitor operation ........................................................................................... 3-7
3.3 Switches ................................................................................................................ 3-24
3.3.1 Start switch .................................................................................................. 3-25
3.3.2 Fuel control dial............................................................................................ 3-26
3.3.3 Work lamp switch ......................................................................................... 3-26
3.3.4 Head lamp switch......................................................................................... 3-28
3.3.5 Windshield wiper switch ............................................................................... 3-29
3.3.6 Washer switch .............................................................................................. 3-30
3.3.7 Horn switch .................................................................................................. 3-30
3.3.8 Cab lamp switch........................................................................................... 3-30
3.3.9 Cigarette lighter............................................................................................ 3-31
3.3.10 Preheat switch (If equipped) ...................................................................... 3-31
3.3.11 Preheat indicator ........................................................................................ 3-32
3.3.12 Charging indicator ...................................................................................... 3-32
IV Safety, Operation & Maintenance Manual - October 2013

3.4 Control Levers and Pedals .................................................................................... 3-33

3.4.1 Hydraulic lockout control .............................................................................. 3-34
3.4.2 Travel control levers ..................................................................................... 3-35
3.4.3 Joysticks ...................................................................................................... 3-36
3.5 Cab Windows and Cab Door ................................................................................ 3-38
3.5.1 Ceiling window ............................................................................................. 3-38
3.5.2 Front window................................................................................................ 3-39
3.5.3 Cab door window ......................................................................................... 3-45
3.6 Cup Holder............................................................................................................. 3-46
3.7 Ash Tray ................................................................................................................. 3-46
3.8 Manual Pocket ....................................................................................................... 3-46
3.9 Drink Box ............................................................................................................... 3-47
3.10 Alternate exit ........................................................................................................ 3-47
3.11 Fire Extinguisher .................................................................................................. 3-47
3.12 Electronic Control Module.................................................................................... 3-48
3.13 Fusible Link.......................................................................................................... 3-48
3.14 Air Conditioning System....................................................................................... 3-49
3.14.1 Control panel.............................................................................................. 3-49
3.14.2 Operation method ...................................................................................... 3-55
3.14.3 Air conditioner operation precautions ........................................................ 3-58
3.15 Radio ................................................................................................................... 3-59
3.15.1 Control panel.............................................................................................. 3-59
3.15.2 Operation ................................................................................................... 3-61
3.16 Cab door catch .................................................................................................... 3-65
3.17 Lockable Caps and Covers.................................................................................. 3-65
3.17.1 Lockable caps ............................................................................................ 3-66
3.17.2 Lockable covers ......................................................................................... 3-67
3.18 Toolbox ................................................................................................................ 3-68
3.19 Grease Pump Frame ........................................................................................... 3-68
4 Operation
4.1 Before Starting the Engine....................................................................................... 4-5
4.1.1 Walk-around inspection ................................................................................. 4-5
4.1.2 Inspection before starting............................................................................... 4-7
4.1.2.1 Water and sediment in fuel tank - drain ................................................ 4-7
4.1.2.2 Water and sediment in water separator - check/drain .......................... 4-8
4.1.2.3 Hydraulic oil level - check/refill ............................................................ 4-9
4.1.2.4 Coolant level - check/refill ................................................................... 4-10
Safety, Operation & Maintenance Manual - October 2013 V

4.1.2.5 Oil level in oil pan - check/add .............................................................4-11

4.1.2.6 Electric wires - check .......................................................................... 4-13
4.1.2.7 Fuel level - Check and add ................................................................. 4-14
4.1.2.8 Work lamp switches - check ............................................................... 4-16
4.1.2.9 Horn - check........................................................................................ 4-16
4.1.3 Adjustment before operation ........................................................................ 4-17
4.1.3.1 Operator seat adjustment ................................................................... 4-17
4.1.3.2 Rear view mirrors ................................................................................ 4-19
4.1.3.3 Seat belt .............................................................................................. 4-21
4.1.4 Operation before engine startup .................................................................. 4-22
4.2 Engine Startup ....................................................................................................... 4-24
4.2.1 Engine Preheating ...................................................................................... 4-27
4.2.2 Warm-up operation ...................................................................................... 4-28
4.3 Engine Shutdown................................................................................................... 4-29
4.4 Machine Operation ................................................................................................ 4-30
4.4.1 Before moving the machine ......................................................................... 4-31
4.4.2 Move the machine........................................................................................ 4-32
4.4.3 Stopping the machine .................................................................................. 4-33
4.5 Machine Turning .................................................................................................... 4-34
4.5.1 Direction change when the machine is stopped ......................................... 4-34
4.5.2 Pivot turning ................................................................................................. 4-36
4.6 Work Equipment Control........................................................................................ 4-37
4.7 Restricted Operations ............................................................................................ 4-39
4.7.1 Operation with swinging force ...................................................................... 4-39
4.7.2 Operation with traveling force ...................................................................... 4-39
4.7.3 Operation when hydraulic cylinder reaches its stroke end ......................... 4-40
4.7.4 Operation with bucket landing force............................................................. 4-40
4.7.5 Hard rocky ground ...................................................................................... 4-40
4.7.6 Operation with machine weight .................................................................... 4-41
4.7.7 Sudden shift of control levers/ pedals ......................................................... 4-41
4.8 Permissible depth of water .................................................................................... 4-42
4.9 Traveling on a Slope .............................................................................................. 4-43
4.9.1 Traveling downhill ....................................................................................... 4-44
4.9.2 When engine stalls on a slope ..................................................................... 4-44
4.9.3 Cab door on a slope..................................................................................... 4-44
4.10 Escaping from Mud .............................................................................................. 4-45
4.10.1 When one track is trapped ......................................................................... 4-45
4.10.2 When both tracks are trapped.................................................................... 4-45
VI Safety, Operation & Maintenance Manual - October 2013

4.11 Recommended Application .................................................................................. 4-46

4.11.1 Backhoe operation ..................................................................................... 4-46
4.11.2 Trenching work ........................................................................................... 4-47
4.11.3 Loading operation ...................................................................................... 4-47
4.12 Parking................................................................................................................. 4-48
4.13 Post-operation Inspection .................................................................................... 4-51
4.14 Locking ................................................................................................................ 4-52
4.15 Operation in Cold Weather .................................................................................. 4-53
4.15.1 Fuel and lubricant ...................................................................................... 4-53
4.15.2 Coolant....................................................................................................... 4-53
4.15.3 Battery........................................................................................................ 4-53
4.15.4 After operation in cold weather .................................................................. 4-54
4.15.5 After cold season ....................................................................................... 4-55
4.16 Long-Term Storage .............................................................................................. 4-55
4.16.1 Before storage ........................................................................................... 4-55
4.16.2 During storage ........................................................................................... 4-56
4.16.3 After storage............................................................................................... 4-56
4.16.4 Engine startup after long-term storage ...................................................... 4-56
4.17 Transportation Information ................................................................................... 4-57
4.17.1 Transport methods ..................................................................................... 4-57
4.17.2 Loading and unloading .............................................................................. 4-57
4.17.2.1 Loading ............................................................................................. 4-58
4.17.2.2 Securing the machine ....................................................................... 4-61
4.17.2.3 Unloading .......................................................................................... 4-63
4.17.2.4 Lifting the machine ............................................................................ 4-65
5 Maintenance
5.1 Maintenance Information ......................................................................................... 5-3
5.2 Oil, fuel and coolant ................................................................................................. 5-6
5.2.1 Oil................................................................................................................... 5-6
5.2.2 Fuel ................................................................................................................ 5-6
5.2.3 Coolant .......................................................................................................... 5-7
5.2.4 Grease ........................................................................................................... 5-8
5.2.5 Oil and fuel storage ........................................................................................ 5-8
5.2.5.1 Filter element ........................................................................................ 5-9
5.2.6 Electrical system ........................................................................................... 5-9
5.3 Wear Parts ............................................................................................................. 5-10
5.4 Recommended Fuel, Coolant and Lubricant ......................................................... 5-12
Safety, Operation & Maintenance Manual - October 2013 VII

5.4.1 Table of recommended fuel, oil and coolant ................................................ 5-13

5.4.2 Table of capacities ...................................................................................... 5-14
5.5 Tightening Torque Table......................................................................................... 5-15
5.6 Safety Critical Parts ............................................................................................... 5-17
5.7 Maintenance Schedule .......................................................................................... 5-18
5.8 Maintenance Procedures ....................................................................................... 5-20
5.8.2 Initial 50 hours of operation.......................................................................... 5-20
5.8.3 When Required ............................................................................................ 5-21
5.8.3.1 Track shoe bolts - inspect/tighten ....................................................... 5-21
5.8.3.2 Track tension - inspect/adjust ............................................................. 5-22
5.8.3.3 Bucket - replace .................................................................................. 5-25
5.8.3.4 Bucket tips - replace ........................................................................... 5-28
5.8.3.5 Bucket clearance - adjust.................................................................... 5-30
5.8.3.6 Window washer fluid level - check/fill.................................................. 5-32
5.8.3.7 Refrigerant level - check ..................................................................... 5-33
5.8.3.8 Ceiling window gas spring - inspect .................................................... 5-35
5.8.4 Inspection Prior to Startup ........................................................................... 5-37
5.8.5 Every 100 service hours .............................................................................. 5-38
5.8.5.1 Lubrication .......................................................................................... 5-38
5.8.6.1 Air filter element - inspect/clean/replace ............................................. 5-41
5.8.6.2 Engine pan oil and filter element - change/replace ............................. 5-44
5.8.6.3 Fan belt tension - inspect/adjust ......................................................... 5-46
5.8.6.4 Compressor belt tension - inspect/adjust ............................................ 5-47
5.8.6.5 Oil return check valve - check ............................................................. 5-48
5.8.6.6 Pipe clamps of hydraulic system - check ............................................ 5-49
5.8.7.1 Swing bearing - lubricate .................................................................... 5-50
5.8.7.2 Swing pinion gear grease level - inspect/fill ........................................ 5-51
5.8.7.3 Primary fuel filter element - replace .................................................... 5-52
5.8.7.4 Secondary fuel filter element - replace ............................................... 5-55
5.8.7.5 Prmiming pump strainer - Clean ......................................................... 5-58
5.8.7.6 Radiator and oil cooler fins - inspect/clean ......................................... 5-59
5.8.7.7 Air conditioner fresh air/recirculation filter - clean ............................... 5-61
5.8.7.8 Swing drive oil level - check/fill ........................................................... 5-63
5.8.7.9 Final drive oil level - check/fill ............................................................. 5-64
5.8.7.10 Breather valve - service .................................................................... 5-65
VIII Safety, Operation & Maintenance Manual - October 2013

5.8.8 Every 1000 service hours ............................................................................ 5-66

5.8.8.1 Hydraulic oil filter element - replace .................................................... 5-66
5.8.8.2 Swing drive oil - change ...................................................................... 5-68
5.8.8.3 Cab door lock and front window lock catch - inspect/tighten .............. 5-69
5.8.8.4 Cab door hinge and front window slide rail - inspect/add grease ....... 5-70
5.8.8.5 Windshield wiper arm nut - Inspect/tighten ......................................... 5-71
5.8.8.6 Engine exhaust pipe clamps - check .................................................. 5-71
5.8.8.7 Fan belt tension - check/replace ......................................................... 5-71
5.8.8.8 Nitrogen pressure in accumulator (breaker) - check ........................... 5-71
5.8.8.9 Fan belt tension - check/replace ......................................................... 5-72
5.8.8.10 Nitrogen pressure in accumulator (breaker) - check ......................... 5-72
5.8.8.11 Swing mechanism grease - check and add ...................................... 5-72
5.8.9 Every 2000 service hours ............................................................................ 5-73
5.8.9.1 Final drive oil - change ........................................................................ 5-73
5.8.9.2 Hydraulic tank filter strainer - clean..................................................... 5-75
5.8.9.3 Nitrogen pressure in accumulator (control oil circuit) - check ............. 5-76
5.8.9.4 Hydraulic tank oil - change.................................................................. 5-80
5.8.9.5 Cooling system interior - clean............................................................ 5-82
5.8.9.6 Alternator - inspect .............................................................................. 5-84
5.8.9.7 Engine valve clearance - check/adjust................................................ 5-84
5.8.10 Every 4000 service hours .......................................................................... 5-85
5.8.10.1 Water pump - inspect ........................................................................ 5-85
5.8.10.2 Start motor - check............................................................................ 5-85
5.8.10.3 Accumulator - replace ....................................................................... 5-86
5.8.10.4 High-pressure tube clamps and rubber - check ................................ 5-87
5.8.10.5 Compressor working condition - inspect ........................................... 5-88
5.8.11 Every 8000 service hours........................................................................... 5-88
5.8.11.1 High-pressure tube clamps - replace ................................................ 5-88
5.8.12 Every 10000 service hours ........................................................................ 5-88
6 Troubleshooting
6.1 Troubleshooting Preparation.................................................................................... 6-3
6.1.1 Checks before troubleshooting ...................................................................... 6-3
6.1.2 Troubleshooting precautions .......................................................................... 6-4
6.1.3 Electrical circuits troubleshooting precautions ............................................... 6-6
6.1.4 Hydraulic components handling precautions ................................................. 6-7
6.2 Measures Taken When Failure Occurs.................................................................... 6-9
6.2.1 Failure-like phenomena ................................................................................. 6-9
Safety, Operation & Maintenance Manual - October 2013 IX

6.2.2 Towing the machine ..................................................................................... 6-10

6.2.3 Towing hook for light loads........................................................................... 6-12
6.3 Engine Failures ...................................................................................................... 6-13
6.3.1 Engine troubleshooting table ....................................................................... 6-13
6.3.2 Coolant temperature high ............................................................................ 6-18
6.3.3 Engine oil pressure low ................................................................................ 6-20
6.3.4 When fuel runs out ....................................................................................... 6-21
6.3.5 When engine rotates reversely .................................................................... 6-24
6.4 Failures of the Electrical System ........................................................................... 6-25
6.4.1 Electrical system troubleshooting table........................................................ 6-25
6.4.2 Failure codes ............................................................................................... 6-29
6.5 Battery ................................................................................................................... 6-31
6.5.1 Battery removal and installation ................................................................... 6-31
6.5.2 Battery charging ........................................................................................... 6-32
6.5.3 Starting engine with jumper cable ................................................................ 6-33
6.5.3.1 Connecting jumper cables .................................................................. 6-34
6.5.3.2 Starting engine .................................................................................... 6-35
6.5.3.3 Disconnecting jumper cables ............................................................. 6-35
6.6 Failures of the Hydraulic System ........................................................................... 6-36
6.7 Other Common Failures ........................................................................................ 6-40
7 Specifications
7.1 Machine Dimensions ............................................................................................... 7-3
7.2 Working Ranges ...................................................................................................... 7-4
7.3 Operating Parameters ............................................................................................. 7-5
8 Optional Equipment
8.1 Safety Information.................................................................................................... 8-3
8.1.1 Optional equipment selection......................................................................... 8-3
8.1.2 Read equipment instruction ........................................................................... 8-3
8.1.3 Optional equipment removal and installation precautions ............................ 8-3
8.1.4 Optional equipment operation precautions .................................................... 8-4
8.2 Hydraulic Control Elements and Oil Circuit ............................................................. 8-5
8.2.1 Component locations ..................................................................................... 8-5
8.2.1.1 Stop valve ............................................................................................. 8-6
8.2.1.2 Selector valve ....................................................................................... 8-6
8.2.1.3 Attachment control pedal ...................................................................... 8-7
8.2.2 Hydraulic circuit.............................................................................................. 8-8
X Safety, Operation & Maintenance Manual - October 2013

8.2.2.1 Hydraulic circuit switching ..................................................................... 8-8

8.2.2.2 Switching between breaker and general attachment ............................ 8-8
8.2.2.3 Connecting hydraulic oil circuit ............................................................ 8-9
8.2.2.4 Hydraulic oil path ................................................................................ 8-10
8.2.3 Attachment removal and installation .............................................................8-11
8.2.3.1 Removal ...............................................................................................8-11
8.2.3.2 Installation .......................................................................................... 8-13
8.2.4 Hydraulic oil and filter - change/replace ....................................................... 8-15
8.2.5 Long-term storage........................................................................................ 8-16
8.3 Work equipment combination ................................................................................ 8-17
8.4 Recommended Operation...................................................................................... 8-19
8.4.1 Hydraulic breaker ......................................................................................... 8-19
8.4.2 Hydraulic breaker operation ......................................................................... 8-20
8.4.3 Restricted operations ................................................................................... 8-22
8.4.4 Hydraulic breaker greasing .......................................................................... 8-25
8.5 Quick Coupler ........................................................................................................ 8-26
8.5.1 Quick coupler control ................................................................................... 8-26
8.5.2 Precautions for quick coupler safe operation .............................................. 8-28
8.6 Fueling System ...................................................................................................... 8-30
8.6.1 Introduction .................................................................................................. 8-30
8.6.2 Fueling system makeup ............................................................................... 8-30
8.7 Central Lubrication System.................................................................................... 8-32
8.7.1 Lubrication scheme and system makeup..................................................... 8-32
8.7.2 Working principle ......................................................................................... 8-34
8.7.3 Lubrication time setup .................................................................................. 8-35
8.7.4 Technical description.................................................................................... 8-37
8.7.5 Grease filling ................................................................................................ 8-38
Safety, Operation & Maintenance Manual - October 2013 XI

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XII Safety, Operation & Maintenance Manual - October 2013

SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator Introduction
Introduction
1 Introduction
1.1 Overview .................................................................................................................. 1-3
1.2 Your Documentation Package ................................................................................. 1-4
1.2.1 CD system requirements ............................................................................... 1-4
1.2.2 Recommendations on using the documentation ............................................ 1-4
1.2.3 Documentation storage .................................................................................. 1-5
1.2.4 Manual organization....................................................................................... 1-5
1.2.4.1 Introduction ........................................................................................... 1-5
1.2.4.2 Safety .................................................................................................... 1-5
1.2.4.3 System functions................................................................................... 1-5
1.2.4.4 Operation .............................................................................................. 1-5
1.2.4.5 Maintenance ......................................................................................... 1-5
1.2.4.6 Troubleshooting .................................................................................... 1-6
1.2.4.7 Specifications ........................................................................................ 1-6
1.2.4.8 Optional Equipment .............................................................................. 1-6
1.3 Your Sany Machine .................................................................................................. 1-7
1.3.1 Machine applications ..................................................................................... 1-7
1.3.2 Machine directions ......................................................................................... 1-7
1.3.3 Breaking in a new machine ............................................................................ 1-8
1.3.4 Machine information....................................................................................... 1-8
1.3.4.1 Product identification plate .................................................................... 1-9
1.3.4.2 Engine identification plate ..................................................................... 1-9
1.3.4.3 Drive motors identification plate .......................................................... 1-12
1.3.4.4 Swing motor identification plate .......................................................... 1-12
1.3.4.5 Hydraulic pump identification plate ..................................................... 1-12
1.3.4.6 Chassis serial number ........................................................................ 1-13
1.3.5 Table for serial number and distributor information ...................................... 1-14
Safety, Operation & Maintenance Manual - October 2013 1-1

Introduction SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator
1.4 Correction Request Form - Technical Publications ................................................ 1-15

1.5 Contact Information ............................................................................................... 1-16
WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.
1-2 Safety, Operation & Maintenance Manual - October 2013

1 INTRODUCTION
1.1 Overview
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. CZ335-1102004
Fig. 1-1
● 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

model can lead to changes in details which
may not be covered in this manual. Always
consult your Sany dealer for the latest avail-
able information on your machine or if you
have questions regarding information in this
manual.

1.2 Your Documentation Package
The documentation for this machine includes the following items:
● Safety, Operation & Maintenance Manual (SOMM) — This manual is in the operator cab seat
pocket.
● Parts Book — This publication consists of parts lists and matching drawings for ordering spare
parts as-needed. If it was not already shipped with your machine, the parts book for your ma-
chine is available directly from Sany.
● CD — Along with this machine you will receive a CD that contains video instructions on safety,
operation and maintenance of this machine.
1.2.1 CD system requirements
In order to use the Sany CD, be sure of the following:
Hardware:
● Intel® Pentium II® running at 500 MHz or above
● At least 128 MB RAM
● CD-ROM drive
● Minimum screen resolution of 800 x 600 pixels, high-color depth
Software:
● Windows 2000, XP, Vista or Windows 7 operating systems
● Internet Explorer 6.0 or later version (pop-up blocker disabled)
● Acrobat Reader 7.0 or later version
1.2.2 Recommendations on using the documentation
● This documentation applies only to this machine and should not be used with any other ma-
chines.
● Ensure that the documentation is always complete and up to date:
● Keep all pages inside its binder (if shipped loose leaf).
● Insert Sany replacement pages immediately into the appropriate book; destroy old versions of
those pages.
● Replace outdated CDs with new ones; destroy the old ones to prevent any confusion in the
future.

1.2.3 Documentation storage
Always keep the operation manual and load charts with the machine in the operator cab.
The parts book is best left either shelved in the workshop area or office. It should always be avail-
able to the maintenance and service personnel as required.
1.2.4 Manual organization
The operator’s manual is designed for use and maintenance of this machine. Each section of this
manual provides information you should be familiar with before operating this machine.
Keep this manual with the machine for your reference at all times. Replace it immediately if it
is damaged or lost. Due to improvement and updating of products, some information may differ
from your machine. If you have any questions on the machine, contact your Sany dealer before
operating or repairing the machine.
1.2.4.1 Introduction
This chapter provides an overview of what is covered in the rest of this manual, including ma-
chine label information and Sany contact information.
1.2.4.2 Safety
This chapter covers basic safety information relating to this equipment. Make sure you fully un-
derstand all the precautions described in this manual and the safety labels on the machine before
operating or maintaining this machine. Failure to do so may result in serious injury or death.
1.2.4.3 System functions
This chapter provides an overview of all the controls, alerts and operating systems on the ma-
chine. It is important to study and become familiar with all systems before proceeding with any
operations.
1.2.4.4 Operation
This chapter provides some basic operating procedures for this machine. Study and become fa-
miliar with all operating procedures before performing any job functions with the machine.
1.2.4.5 Maintenance
This chapter provides all general maintenance and repair procedures. (Detailed rebuild/replace-
ment/repair information are covered in a separate shop manual.) Study and become familiar with
all repair and maintenance procedures before performing any repair or maintenance operations.

1.2.4.6 Troubleshooting
This chapter includes common malfunctions and fault diagnostics procedures for this crawler
hydraulic excavator operating system. Basic mechanical, hydraulic and electrical system trouble-
shooting is included.
1.2.4.7 Specifications
This chapter provides general required machine information for this crawler hydraulic excavator.
Some information may vary due to design changes.
1.2.4.8 Optional Equipment
This section provides information regarding optional equipment for the excavator as authorized
by Sany. If you will be using any optional equipment, it is important to read the instruction manual
for the optional equipment and the general information related to optional equipment in this man-
ual.

1.3 Your Sany Machine
1.3.1 Machine applications
Sany hydraulic excavators are designed for the following operations:
● Excavating
● Leveling
● Digging
● Loading
● Demolishing
1.3.2 Machine directions
C D
B
CZ335-1101001
Fig. 1-2
(A) Front In this manual, the front, rear, left or right di-
rection indicates, when the cab faces the front
(B) Rear and the final drive is behind of the machine,
(C) Left the moving direction that you could see from
the cab.
(D) Right
(E) Operator’s seat
(F) Sprocket

1.3.3 Breaking in a new machine
Your machine has been thoroughly adjusted

and tested before shipment. However, initial
operation of the machine under severe condi-
tions can adversely affect the performance
of the machine or shorten the machine life.
Therefore, Sany recommends that you allow
a break-in period of 100 operating hours for a
new machine.
During the break-in period:
● Let the machine preheat prior to any op-

eration.
● Avoid operating with severe loads or at

high speeds.
● Avoid sudden starts, fast movements or

stops.
● Always let the system cool down at the end

of the working day.
1.3.4 Machine information
The serial numbers and model numbers on

the components are the only numbers that
your Sany dealer will need when ordering re-
placement parts or requiring assistance for
your equipment. It is a good idea to record this
information in this manual for future use. Be-
low are the locations of the data plates

1.3.4.1 Product identification plate
On the right side of the operator’s cab on the bottom.
履带式液压挖掘机 Hydraulic Excavator

产品型号 MODEL
出厂编号 NUMBER
整机重量 WEIGHT
发动机功率 RATED POWER
三一重机有限公司 SANY HEAVY MACHINERY LIMITED.
CQ13031501-2
Fig. 1-3
1.3.4.2 Engine identification plate
SY195C9
昆山三一动力有限公司
KUNSHAN SANY POWER CO., LTD
柴油机
产品名称
Product Name DIESEL
出厂编号 DL
Serial No.
产品型号
Product Type
D06S2 额定功率/转速
Rated Power/speed
114 / 2050 kW/rpm
用途及排放
非道路II阶段
型式核准号
Approved Type No.
CN FC G2 OE76 00 001
Usage & Emission
产品净重订货代号
Product Net Wt.
520 kg Order No.
生产日期生产许可证号
Date Of Production Licence No.
公司地址：江苏省昆山开发区澄湖路9999号
Address:9999,Chenghu Rd.,Kunshan Economic Development Zone,Jiangsu
中国制造 MADE IN CHINA
CQ13101401
Fig. 1-4

SY205/215/225C9
MITSUBISHI FUSO
TRUCK & BUS CORPORATION
机系族名称 G20277L0586D3A
发动机的型号 6D34-TLC1B
型号核准号 CN FC G2 0277 03 0004
发动机的功率参数 114kW-2050 r/min
本发动机符合中华人民共和国国家标准GB20891-2007
Ⅱ阶段 72kW≤功率＜130kW
生产日期：年月 M386
0-13001-1
Fig. 1-5
SY235C9
型式核准达到国家第Ⅱ阶段
非道路移动机械用柴油机排放标准
系族名称：G20097L0649FXA
发动机的型号：6BG1-XABEC-03-C2
发动机功率：128.5 kW/ 2100 r/min
制造厂名称：五十铃汽车公司
生产日期：
功率段：75 ≤ kW ＜ 130
型式核准号：CN FC G2 0097 07 0001
发动机编号：
0-13001-2
Fig. 1-6

SY265C9
6FRC TAA
TOTAL CYL.VOL.6.373l(389cuin)
ENGINE NO. G D C 6 0 9 5 3
OUTPUT 1 3 8 K W
ENGINE SPEED 2 1 0 0 m i n- 1
MITSUBISHI
HEAVY INDUSTRIES,LTD.
TOKYO JAPAN
0-13001-3
Fig. 1-7

1.3.4.3 Drive motors identification plate
On each drive motor.
Model:_______________________________
ID No.: ______________________________
CZ235-3100801
Fig. 1-8
1.3.4.4 Swing motor identification plate
On top of swing motor.
Model:_______________________________
ID No.: ______________________________
CZ235-3100802
Fig. 1-9
1.3.4.5 Hydraulic pump identification plate
On bottom of pump.
Model:_______________________________
ID No.: _______________________________
CZ235-3100803
Fig. 1-10

1.3.4.6 Chassis serial number
An additional serial number is stamped on the

front part of the travel carriage frame.
SYJ263038018060480
CZ235-3100804
Fig. 1-11

1.3.5 Table for serial number and distributor information
This location is for you to record information relating to your machine. It is advised that you
keep this manual with your machine at all times for reference.
Machine Serial No.
Engine Serial No.
Distributor Name:
Address:
Phone Numbers:

1.4 Correction Request Form - Technical Publications
If you find a problem with this manual, please make a copy of this page, fill out the information
and send it to us attention Technical Publications. See Contact Information on the next page.
Date of this request

Your Name
Company Name
Your Department
Street Address
City, State & ZIP
Phone
E-mail
Machine Model & Serial No.
Description of Problem (Wrong information, unclear or erroneous procedure, etc.)
Corrective Action by You (if any)

1.5 Contact Information

Thank you for purchasing a Sany machine. In the event that you should contact us for any rea-
son, you can reach us as follows:
Shanghai Sany Heavy Machinery Limited
318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P.R. of China
201413
Tel: 0086-10-60738666
Fax: 0086-10-60738831

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SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator Safety
Safety
2 Safety
2.1 Foreword.................................................................................................................. 2-5
2.2 Safety Messages ..................................................................................................... 2-7
2.2.1 Hazard alert wording ...................................................................................... 2-8
2.2.2 Other alert wording ........................................................................................ 2-9
2.2.3 Safety decals ............................................................................................... 2-10
2.2.3.1 Textual safety decals........................................................................... 2-10
2.2.3.2 Graphical safety decals....................................................................... 2-10
2.2.4 Safety decal locations ...................................................................................2-11
2.3 General Precautions .............................................................................................. 2-21
2.3.1 Safety rules .................................................................................................. 2-21
2.3.2 Abnormal cases ........................................................................................... 2-21
2.3.3 Personal protective equipment .................................................................... 2-22
2.3.4 Fire extinguisher and first aid kit .................................................................. 2-23
2.3.5 Safety equipment ......................................................................................... 2-24
2.3.6 Machine cleaning ........................................................................................ 2-25
2.3.7 Keeping cab clean ....................................................................................... 2-25
2.3.8 Lock the hydraulic controls before leaving the cab ...................................... 2-26
2.3.9 Handholds and steps .................................................................................. 2-27
2.3.10 Elevated work ............................................................................................ 2-28
2.3.11 No sitting on attachment ........................................................................... 2-28
2.3.12 Articulated parts ......................................................................................... 2-28
2.3.13 Prevention of burns and scalds.................................................................. 2-29
2.3.13.1 Hot coolant ........................................................................................ 2-29
2.3.13.2 Hot oil ................................................................................................ 2-29
2.3.14 Fire and explosion hazard.......................................................................... 2-30
2.3.14.1 Fire caused by fuel or oils ................................................................. 2-30

Safety SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator
2.3.14.2 Fire caused by flammable materials ................................................. 2-31

2.3.14.3 Fire caused by electric lines.............................................................. 2-31
2.3.14.4 Fire caused by hydraulic lines .......................................................... 2-31
2.3.14.5 Fire caused by illumination equipment.............................................. 2-32
2.3.14.6 Fire caused by heat shield ................................................................ 2-32
2.3.15 In the event of fire ...................................................................................... 2-32
2.3.16 Windshield cleaning detergent ................................................................... 2-33
2.3.17 Ejecting parts ............................................................................................ 2-33
2.3.18 Falling object protection ........................................................................... 2-34
2.3.19 Attachment installation ............................................................................... 2-34
2.3.20 Attachment combination ............................................................................ 2-35
2.3.21 Cab windows glasses ................................................................................ 2-35
2.3.22 Unauthorized modification ......................................................................... 2-35
2.3.23 Worksite investigation ................................................................................ 2-36
2.3.24 Operation on loose ground ........................................................................ 2-37
2.3.25 Overhead power cables ............................................................................. 2-38
2.3.26 Visibility ...................................................................................................... 2-39
2.3.27 Ventilation .................................................................................................. 2-39
2.3.28 Asbestos .................................................................................................... 2-40
2.3.29 Alternate exit .............................................................................................. 2-41
2.4 Safe Operation Precautions................................................................................... 2-42
2.4.1 Safe starting ................................................................................................ 2-42
2.4.1.1 Safe mounting ..................................................................................... 2-42
2.4.1.2 Operator seat ...................................................................................... 2-42
2.4.1.3 Seat belt .............................................................................................. 2-43
2.4.1.4 Before starting the engine ................................................................... 2-43
2.4.1.5 Engine starting rules ........................................................................... 2-44
2.4.1.6 Machine starting.................................................................................. 2-44
2.4.1.7 Starting engine in cold season ............................................................ 2-45
2.4.1.8 Engine starting aid .............................................................................. 2-45
2.4.1.9 After starting the engine ...................................................................... 2-46
2.4.2 Operation ..................................................................................................... 2-47
2.4.2.1 Inspection before operation ................................................................ 2-47
2.4.2.2 Prior-operation precautions ................................................................ 2-48
2.4.2.3 Travel direction confirmation ............................................................... 2-49
2.4.2.4 Safety rules for turning ........................................................................ 2-50
2.4.2.5 Safety rules for traveling ..................................................................... 2-52
2.4.2.6 Safe traveling ..................................................................................... 2-53

2.4.2.7 Machine operation on slope ................................................................ 2-54

2.4.2.8 Operation in snowy weather ............................................................... 2-55
2.4.2.9 Restricted operation ............................................................................ 2-56
2.4.3 Parking the machine .................................................................................... 2-58
2.4.3.1 Select a parking place......................................................................... 2-58
2.4.3.2 Machine shutdown .............................................................................. 2-59
2.4.4 Transportation .............................................................................................. 2-60
2.4.4.1 Loading and unloading........................................................................ 2-60
2.4.4.2 Transportation ..................................................................................... 2-61
2.4.5 Battery.......................................................................................................... 2-62
2.4.6 Towing .......................................................................................................... 2-64
2.4.7 Lifting objects with the machine ................................................................... 2-65
2.5 Precautions for Maintenance ................................................................................. 2-66
2.5.1 Pre-maintenance precautions ...................................................................... 2-66
2.5.2 Select a working area .................................................................................. 2-66
2.5.3 Prepare the machine ................................................................................... 2-67
2.5.4 Prepare yourself........................................................................................... 2-68
2.5.6 Use proper tools........................................................................................... 2-69
2.5.7 Maintenance with engine running ................................................................ 2-70
2.5.8 Work under the machine .............................................................................. 2-71
2.5.9 Track maintenance....................................................................................... 2-72
2.5.10 Track tension adjustment ........................................................................... 2-73
2.5.11 Recoil spring .............................................................................................. 2-73
2.5.12 Welding operation ...................................................................................... 2-74
2.5.13 High-pressure hoses .................................................................................. 2-74
2.5.14 Pressurized fluid ........................................................................................ 2-75
2.5.15 Hot cooling system..................................................................................... 2-76
2.5.16 Air-conditioning system maintenance ........................................................ 2-76
2.5.17 High voltage precautions ........................................................................... 2-77
2.5.18 Accumulator ............................................................................................... 2-77
2.5.19 Fire and explosion prevention .................................................................... 2-78
2.5.20 Regular replacement of safety-related parts .............................................. 2-79
2.5.21 Maintenance operation ............................................................................. 2-79
2.5.22 Proper disposal of wastes .......................................................................... 2-80

WARNING
jury or death.

2 SAFETY
2.1 Foreword
This Operation and Maintenance Manual is a guide for you to operate your machine properly. It
contains technical and safety information necessary for operation of your machine. Please read
and understand each section of the manual.
Only eligible and experienced operators with an official license (according to local laws) are al-
lowed to operate the machine.
Always operate your machine according to national and/or local laws and regulations. The opera-
tion safety information and description in this manual are just suggestive and attentive.
Sany cannot anticipate every possible circumstance that might involve a potential hazard during
operation and maintenance. The Safety messages in this manual and on the product are, there-
fore, not all inclusive. If a procedure, work method or operating technique that is not specifically
recommended in this manual is used, you must be sure that it is safe for you and for others. You
should also ensure that the product will not be damaged or made unsafe by the operation, lubri-
cation, maintenance or repair procedures that you choose.
Modifying or abusing the machine according to your own will might impair the machine's perfor-
mance, or result in more serious potential hazard. For instance, the specific volume of fuel oil
exceeds set limit or the machine is overloaded. Please drive and operate the machine carefully.
Improper operation or application may cause personal injury or damage. Sany assumes no re-
sponsibility for such losses.
Machines covered by this manual are used for various operations under normal conditions. Do
not use the machine in flammable or explosive environment, or in areas containing asbestos
dust.
Please select a Sany excavator with a configuration suitable for high-plateau operation
when operating in areas 2,000 m above sea level.
This machine has gone through electromagnetic capacity test according to EN 13309-200C. All
unapproved electronic attachments (such as communication devices) are therefore to be tested
before installation and application. Make sure that the electromagetic attachments will not cause
electromagnetic interference.
The information, specifications, and illustrations in this publication are on the basis of information
that was available at the time that the publication was written. Sany reserves the right to change
these information at any time without prior notice. Please consult your Sany dealer to obtain the
latest information or if you have any question on the information provided in this manual.

Before starting operation and maintenance, operator and maintainer shall observe the following
items:
● Read and understand the whole manual.
● Read and understand the safety notices contained in this manual and the safety messages on
the machine.
● Do not apply or operate your machine under any circumstances in a manner that is prohibited
in this manual.
● If the amount of fuel added, content of particulates ,or latitude is beyond the specification of
this type of machine, damage could occur and the warranty of your machine would become
invalid.
The manual should be kept in the cab all the time for operator to refer to at any time.
Please contact your Sany dealer to obtain a new manual if the original one is missing or cannot
be read.
This manual should be regarded as a permanent component of your machine. If the machine is
sold to a third party, please give this manual to the new owner.
The machine provided by Sany to its buyer is in line with all specifications and standards of
buyer's country. If the machine is purchased from another country or someone of a third country,
it might be lacking of some safety devices or technical requirements necessary for using the ma-
chine in your country. In case you question whether the machine is in accordance with the stan-
dards and specifications of your country, please contact your Sany dealer before operating the
machine.

2.2 Safety Messages

Safety precautions are given in this manual
and warning decals, both textual and graphi-
cal, are adhered to various parts on the ma-
chine to provide information of hazardous
situations and the method to avoid such situa-
tions.
Before conducting operation and maintenance

on the machine, the operator and after-sale
service personnel must understand all warn-
ing signs or symbols on the machine decals,
strictly follow the safety rules and precautions
in this manual, and take positive actions so as
to reduce the risk of personal injury and death,
the damage of machine caused by improper
service, and the risk of unsafe factors, to the
minimum.

2.2.1 Hazard alert wording
Hazard alert words are used in this manual

and on some of the machine decals to inform
the operator of imminent or potential hazard
that lead to death, personal injury or property
damage.
Different alert words are used to indicate the

degree of hazard.
DANGER It indicates an imminently

hazardous situation which,
if not avoided, will result in
death or serious injury.
WARNING It indicates a potentially

if not avoided, could result
in death or serious injury.
CAUTION It indicates a potentially

if not avoided, may result
in minor or moderate in-
jury. It can also be used to
alert unsafe operation as
which may cause property
loss.
NOTICE It indicates a situation

which can cause damage
to the machine, personal
property and/or the en-
vironment, or cause the
equipment to operate im-
properly.
This hazard alert symbol appears with

most DANGER, WARNING and CAU-
TION hazard alerts. It means attention,
become alert, your safety is involved!
Please read and abide by the message
that follows the hazard alert symbol.

An example alert wording and alert text
WARNING
● The lockout lever must be placed in the
locked position before leaving the op-
erator compartment.
● A free control lever can cause serious

injury or death if touched by mistake.
2.2.2 Other alert wording
In addition to the safety-related alert words

above, the following words are used in this
manual to provide additional information to
which extra attention shall be paid.
Note:
It is followed by information on how to avoid

reduction of machine service life.
Remark:
It is followed by very useful information.

2.2.3 Safety decals
Safety decals are fixed to the machine to alert

the operator or maintenance workers that po-
tential danger might be involved when operat-
ing or servicing the machine.
The machine uses textual and graphical (or

combined) decals to indicate hazardous situa-
tion and safety measures.
2.2.3.1 Textual safety decals
Textual safety decals use brief text to indicate

hazardous situation and safety measures.
警告 WARNING
Fig. 2-1 is an example of textual safety decals.
卸压时只允许拧松一圈。如果
将阀拧得太松，阀内的高压脂
会使阀喷出。
To release pressure, loosen
only one turn. If the valve is
loosened too much, grease
under high pressure may
squirt out.
A820601990968
Fig. 2-1
2.2.3.2 Graphical safety decals
Graphical safety decals use images or sym-

bols to indicate a hazardous situation and how
to avoid it.
Fig. 2-2 is an example of graphical safety de-

cals.
The upper triangle indicates the type of haz-

ardous situation while the lower circle indi-
cates the way to avoid it.
A820601990973
Fig. 2-2

2.2.4 Safety decal locations
4 6
5
A-A
A
B
B-B
A B
1 2 3
CA13102101
Fig. 2-3
1) Read the operation manual 4) Operating mode

2) Overhead power cable 5) Lock the front window
3) Power OFF 6) Emergency exit

7 9 10 12
8 11
危险 DANGER 注意 CAUTION
STOP
注意　CAUTION
It is forbidden that stepping the prim-

ing pump to bleed the air.Pleae tighten
the priming pump when it has been used.
严禁脚踏手油泵排气，使用手
13
油泵后请旋紧。
危险DANGER
14
15
警告 WARNING
卸压时只允许拧松一圈。如果
会使阀喷出。
squirt out.
16 17 18 19
CA13102102
Fig. 2-4
7) Falling hazard 12) High pressure fluid 16) Side crushing hazard
8) Rotating fan 13) No stepping on priming 17) Track tension adjustment
9) Moving belt pump 18) Anchoring point
10) Do not step 14) Hot surface 19) Hook point
11) No seating 15) Overhead crushing hazard

(1) Read the manual first
● Read the Operation and Maintenance

Manual prior to operation, maintenance,
disassembly, assembly and transportation
of the machine.
A820601990971
Fig. 2-5
(2) High voltage
● Electrocution hazard.
● Keep the machine a safe distance away

from overhead power lines.
A820601990974
Fig. 2-6
(3) Power off
Before leaving the machine, lower the work

equipment to the ground, secure the lockout
lever in the LOCKED position and remove the
ignition key.
A820699001020
Fig. 2-7

(4) Control pattern
● To avoid bodily injury or death caused by

misunderstanding, the running condition
and indicated mode of machine shall be
confirmed during operation.
● When the running condition has been con-

firmed, pay attention to the surrounding
and operate slowly.
A820601990961
Fig. 2-8
(5) Lock the front window
● Personal injury may occur if the front win-

dow is not latched in the overhead posi-
tion.
● When the front window is raised, be sure

to secure it with the lock pin.
A820699001019
Fig. 2-9
(6) Emergency exit
A820601990969
Fig. 2-10

(7) Falling hazard
● Stay away from the edge of the machine.
A820601990926
Fig. 2-13
(8) Rotating fan

危险 DANGER
● A rotating fan may cause injury.
● Stop the fan before maintenance.
A820600000002
Fig. 2-11
(9) Moving belt
● A rotating belt is dangerous.
● Stop the belt before maintenance.
STOP
A820699001017
Fig. 2-12

(10) Falling hazard
● Falling hazard.
● Do not step here.
A820601990973
Fig. 2-16
(11) No seating
注意 CAUTION
A820699001023
Fig. 2-14
(12) High pressure fluid
● Read the instruction before removing the

cover or cap of any vessel. To prevent
squirting, relieve internal pressure first and
open the cover or cap slowly.
A820699000948
Fig. 2-15

(13) Do not step the priming pump
● Do NOT bleed the air in the fuel system by

注意　CAUTION
stepping on the priming pump.
严禁脚踏手油泵排气，使用手
油泵后请旋紧。
It is forbidden that stepping the prim-
ing pump to bleed the air.Pleae tighten
the priming pump when it has been used.
12728493
Fig. 2-17
(14) Hot parts/hot surfaces
危险DANGER
● Do NOT touch hot parts or hot surfaces to
avoid burns.
10123433
Fig. 2-18
(15) Moving work equipment
● Moving work equipment may cause per-

sonal injury.
● Stay away from an operating machine.
A820601990963
Fig. 2-19

(16) Crushing hazard
● The counterweight of a swinging machine

may knock you down.
● Do NOT enter the swing radius of the ma-

chine.
A820699001016
Fig. 2-20
(17) Track tension adjustment
● Do NOT loosen the grease fitting for more 警告 WARNING

than one turn when reducing track tension;
otherwise, the adjustment valve under high 卸压时只允许拧松一圈。如果
pressure may shoot out and cause injury. 会使阀喷出。
squirt out.
A820601990968
Fig. 2-21
(18) Wire rope anchoring point
A820601990934
Fig. 2-22

(19) Hooking point
A820101990552
Fig. 2-23

WARNING
● Be sure to recognize the correct posi-
tion and content of the decals.
● To ensure that the decals can be read

and understood easily, they have to
be attached to the right locations and
always kept clean. The use of organic
solution or gasoline to clean the decals
is not allowed.
● There are also other decals besides

those for warning and safety. These
messages should be treated in the
same way.
● A new decal should be used for replace-

ment if the old one is broken or miss-
ing, or cannot be read. See the manual
or the message for part number of the
decal. You may order a new one from
your Sany dealer.

2.3 General Precautions
2.3.1 Safety rules
● Only trained personnel are allowed to op-

erate and service the machine.
● All safety rules, precautions and instruc-

tions must be followed when operating and
servicing the machine.
● Taking alcohol or drug could seriously im-

pair one's ability in operating or repairing
the machine, and it is hazardous for you
and other persons.
● When working with another operator or

worksite traffic signalman, be sure to make
all people understand all hand signals to
be used.
2.3.2 Abnormal cases
In case of any abnormalities found during

operation and maintenance, such as noise, vi-
bration, odor, incorrect gauge display, smoke,
or oil leakage, notify your Sany dealer and
take necessary measures. Do not operate the
machine before the fault is corrected.

2.3.3 Personal protective equipment
Wear proper work clothes and personal pro-

tective equipment (PPE) suitable for the envi-
ronment of the worksite. You may need:
● Hard hat
● Safety shoes
● Safety glasses, goggles or face shield
● Protective gloves
● Hearing protection
● Reflective clothing CZ335-1102002
● Wet weather gear Fig. 2-24
● Respirator or filter mask
Wear whatever is needed, and other safety

equipment that the employer, public service
manage department (or government), rules
and regulations request. Do not take chances.
WARNING
● Do not wear loose fitting clothes and
decorative ornaments, which can easily
catch on control lever or other protrud-
ing parts.
● Long hair outside safety hat may be

caught by machine. In this case, long
hair should be made into a bun to avoid
being entangled by machine.
● Always wear safety hat and safety

shoes. In operation or maintenance
of machine, if the job requests, wear
safety glasses, face shield, gloves, ear
protection and seat belt.
● Check all protective devices for proper

functioning prior to operation.
● Do not listen to the radio or wear music

earphones when operating the machine.

2.3.4 Fire extinguisher and first aid kit
To prevent injury or fire, observe the following

precautions:
● First aid kit and fire extinguisher should be

available nearby.
● Read and understand the instruction at-

tached to fire extinguisher. Use fire extin-
guisher properly.
● Regular inspection and maintenance shall

be done to ensure proper functioning of fire
CZ335-1102003
extinguisher at any time.
Fig. 2-25
● Check the first aid kit regularly and replen-
ish it when necessary.
● Make emergency scheme to deal with fire

and accidents.

2.3.5 Safety equipment
To protect you and others around you, your

machine may be equipped with the following
safety equipment. Make sure that they are se-
curely in place and in good condition.
● Falling object protective structures (FOPS)

● Front guard
● Lamps
● Safety signs
● Horn CZ335-1102004
● Guards Fig. 2-26

● Travel alarm
● Mirrors
● Fire extinguisher
● First aid kit
● Windshield wipers
WARNING
● Make sure all guards and covers are in
correct position. Repair any damaged
parts immediately once observed.
● Understand the operating methods of

safety equipment and use them correct-
ly.
● Never remove the front guard of cab ex-

cept for service.

2.3.6 Machine cleaning
● Clean the windshields, mirrors and lights.

Make sure that the operating area, steps
and handholds are free from oil, grass,
snow, ice or mud, which can cause you to
slip and fall. Clean the mud on your soles
before getting on the machine.
● If the machine is checked or serviced with

presence of mud or oil dirt, it may cause
you to slip or fall, or dirt may get into your
eyes. Keep the machine clean all the time.
● If water has penetrated into the electri-

cal system, do not rush to power on your
machine and start the engine, which can
cause machine failure or cause damage
to the electrical system. Do not flush the
electrical system (including sensors, con-
nectors, etc.) with water or steam. CZ335-1102005
Fig. 2-27
2.3.7 Keeping cab clean
● Clean the mud and oil on your soles when

getting into the cab. Mud or oil under your
shoes can cause your foot to slip on the
pedal during operation, and serious acci-
dent could result.
● Remove all loose personal items or other

objects from the operator's area. Secure
these items in the tool box or remove them
from the machine.
● Do not use cellular phone when operating

or driving the machine.
● Do not bring hazardous articles, such as

flammable or explosive products, into the
cab.

2.3.8 Lock the hydraulic controls before leaving the cab
● Before you rise from the operator seat (e.g.

to open or close the front window or to ad-
just the seat), lower the work equipment
to the ground, move the hydraulic lockout
control lever [1] from F (free) to L (locked)
position, and then stop the engine. If the
hydraulic control is not locked, accidental
touching of control levers can cause sud-
den machine movement and serious injury
or machine damage.
CC13031805
Fig. 2-28
● Before leaving your machine, always lower

the work equipment to the ground, place
the hydraulic lockout control lever [1] to the
L (locked) position, and then shut down the
engine. Lock all lockable components and
remove the key.
CZ335-1102074
Fig. 2-29

2.3.9 Handholds and steps
To avoid personal injuries due to slipping or

falling off the machine, follow the instructions
below:
● Before mounting or dismounting the ma-

chine, check the handholds and steps (in-
cluding track shoe). If oil, grease or mud is
observed on handholds or steps (including
track shoe), remove it immediately. Keep
these components clean. Repair them in
case of any damage. Tighten loosen bolts.
● Use handholds and steps when mounting

or dismounting the machine.
● Face the machine and maintain a three- CZ335-1102008

point contact (two feet and one hand or two
Fig. 2-30
hands and one foot) with the handholds or
step (including track shoe).
● Do not use any controls as handholds

when you mount or dismount the machine.
● Do not try to mount or dismount the ma-

chine when you carry tools or supplies.
● Do not mount the engine hood or cover

without a non-slip mat.
CAUTION
● Face the machine whenever you mount
or dismount the machine.
● Never jump on/off the machine. Do not

mount a moving machine. Do not jump
onto the machine and try to stop it.
● The cab must be aligned with the under-

carriage center line before you enter or
exit the cab.

2.3.10 Elevated work
When working in a high place, use ladders or

other supporting devices to ensure safe opera-
tion.
2.3.11 No sitting on attachment
To avoid falling hazard, no one is allowed to sit

on work equipment or other machine attach-
ments.
2.3.12 Articulated parts
The space around work equipment changes

with the movement of the linkage. Serious
personal injury will result if one is stuck in be-
tween. Nobody is allowed to approach the ro-
tating or retracting/extending components.

2.3.13 Prevention of burns and scalds
2.3.13.1 Hot coolant
● To prevent scalds caused by hot coolant or

steam when checking or discharging the
coolant, always wait for the engine coolant
to cool down before you proceed.
● Do not open the cap of radiator before the

engine cools down. Loosen the cap of the
radiator slowly before removing it. Internal
pressure of radiator must be relieved to
avoid serious scalds.
CZ335-1102011
Fig. 2-31
2.3.13.2 Hot oil
To prevent scalds caused by hot oil when

checking or discharging the oil, always wait
for the engine oil to cool down before you pro-
ceed.
When the engine has cooled down, loosen the

cover or screw plug slowly to relieve internal
pressure.
CZ335-1102012
Fig. 2-32
CZ335-1102013
Fig. 2-33

2.3.14 Fire and explosion hazard
2.3.14.1 Fire caused by fuel or oils
● Machine oil or fuel oil must be stored in

designated place, where unauthorized per-
sons cannot enter.
● Do not smoke or use fire near fuel or ma-

chine oil.
● Tighten, repair or replace any missing,

loose or damaged pipe clips, pipelines,
hoses, oil coolers or other flange bolts.
● Refuel or store oils in a place with good

ventilation. CZ335-1102014
Fig. 2-34
● Shut down the engine before refueling.
● Do not leave the machine when refilling the

fuel or machine oil.
● Do not let fuel overflow onto overheated

surface or electrical components.
● Remove overflowed fuel or machine oil af-

ter refilling.
● Store oily rags and flammable materials

properly to keep the jobsite safe.
● Screw on the caps of fuel tank and oil tank

tightly.
CZ335-1102015
● When oil is used to clean the parts, use
non-flammable oil. Do not use diesel oil or Fig. 2-35
gasoline as they can easily catch on fire.
● All flammable materials should be moved

to a safe place before carrying out grinding
or welding operation on the chassis.
● Do not weld or flame cut the lines contain-

ing flammable fluid.

2.3.14.2 Fire caused by flammable materials
● Remove at any time dry leaves, wood

chips, paper pieces, dirt and other flamma-
ble materials built up or stuck on engine,
exhaust manifold, battery or interior of en-
gine hood to prevent fire.
2.3.14.3 Fire caused by electric lines
Short circuit of electrical system can cause

fire.
● Keep electric terminals clean and fastened.
● Check power cables and electric lines for

looseness, entanglement, hardening or
break each day after operating for 8-10
hours. Check the presence or damage of
wiring terminal cover.
● In case of slack or entangled power cables

or electric wires, tighten the connections
or wire clips, and repair or replace broken
wires.
2.3.14.4 Fire caused by hydraulic lines
● Check the clips, guards and gaskets of all

hoses and pipes to see whether they are
tightened in position.
● In case of loosening, their vibration in op-

eration may lead to friction against other
components, resulting damage of hose,
ejection of high-pressure oil, disastrous fire
or serious injury.

2.3.14.5 Fire caused by illumination equip-

ment
● Anti-blast illumination equipment shall be

used to avoid explosion when checking
fuel, oil, electrolyte, window cleaning deter-
gent or cooling fluid.
● Instructions in this manual must be fol-

lowed when power outlet on the machine
is used for illumination.
2.3.14.6 Fire caused by heat shield
● Damage or missing of heat shield may

lead to fire.
● In case of any abnormality, heat shield

must be repaired or replaced prior to op-
eration of machine.
2.3.15 In the event of fire
When a fire breaks out, leave the machine im-

mediately by the following steps.
● Turn the start switch to the OFF position

and shut down the engine.
● Leave the machine with the help of hand-

holds and step.

2.3.16 Windshield cleaning detergent
Use alcohol based detergent. Do not use

methanol based detergent as it irritates eyes.
2.3.17 Ejecting parts
The grease in track tensioner is under high

pressure. Improper handling may result in se-
rious injury, blindness or death. Observe the
following instructions.
● Do not disassemble grease nozzle or valve

components. These parts may eject. Keep
your body and face away from the valve.
● Travel reducer is under pressure.
● Gear oil is hot liquid. Wait for it to cool

CZ335-1102016
down before loosening the vent plug to re-
lease pressure. Keep your body and face Fig. 2-36
away from the plug to avoid injury.

2.3.18 Falling object protection
● When the machine is operating in places

where the cab is likely to be hit or invaded
by falling objects, scattered materials and
foreign bodies, protective covers shall be
used to protect the operator.
● In demolishing or breaking operation, a

front guard is necessary. In addition, a
transparent glass film shall be applied onto
the front window.
● In a coal mine or a quarry where falling ob- CZ335-1102017
jects are present, install falling object pro- Fig. 2-37

tection structures (FOPS) and front guard,
and apply a transparent glass film onto the
front window. The operator shall wear a
hard hat and goggles.
● Keep the front window shut in such condi-

tions and make sure other people are kept
a safe distance away from the operating
area.
● Other guards may be necessary according

to different working conditions. In this case,
contact your Sany dealer in advance.
2.3.19 Attachment installation
● Installation of optional parts or attachments

may involve safety issues or be limited by
the law. In this case, please contact your
Sany dealer in advance.
● Sany has no responsibility for the use

of unauthorized attachments and parts,
hence the injury, accidents and product
failure.
● Before installing and using machine attach-

ments, read related instructions regarding
the attachment and general precautions on
attachment in this manual.

2.3.20 Attachment combination
Different or combined work equipment may

collide with the cab or interfere with other
machine components. Before operating work
equipment you are not familiar with, check the
clearance between it and the machine and op-
erate carefully.
2.3.21 Cab windows glasses
● Broken cab windows at the side of the

work equipment may expose the operator
in direct contact with the work equipment.
In this case, stop operation immediately
and replace the glasses.
● Broken or damaged window provides no

protection to the operator. When the roof
window is damaged, replace it immediately
with a new one.
2.3.22 Unauthorized modification
Any modification unauthorized by Sany may

lead to safety problems, personal injury or
death. Improper modification can affect ma-
chine's strength and operator's view. Please
contact your Sany dealer before making any
modification. Sany assumes no responsibility
for any accidents, failure or damage caused
by unauthorized modification.

2.3.23 Worksite investigation
● Machine operation near flammable materials

(e.g. dry tree leaves) poses a fire hazard. Be
careful during operation.
● Check the terrain and ground condition and

use the safest operating method. Do not
operate in areas with the risk of landslide or
falling stones.
● Solidify the ground when operating beside

a ditch or on road shoulders. Keep machine
a safe distance away from the ditch or road
shoulder. Assign a signal man, when neces-
sary, to avoid accidental injury.
● When underground water mains, gas lines,

CZ335-1102018
cables or high-voltage electric wires are
available on the work site, inform related utili- Fig. 2-38
ties providers and mark the area. Be careful
not to cut or damage any lines.
● Prevent any unauthorized personnel from

entering the work site. Assign a signal man
and fence the work site when operating on a
highway.
● Be especially alert when operating on frozen

ground. Increase of ambient temperature
may result in soft and slippery ground.
● When traveling or operating in shallow water

or soft ground, check the type and condition CZ335-1102019
of rock bed as well as the depth and water Fig. 2-39

flow prior to operation.

2.3.24 Operation on loose ground
● Avoid traveling or operating the machine

near cliffs, road shoulders or trenches.
The soft ground in these areas plus the
machine weight and vibration may cause
the machine to sink or tumble down. The
ground may become even softer after
heavy rain, an explosion or an earthquake.
● When operating on a dam or near an exca-

vated ditch, vibration and machine weight
may trigger a landslide. Prior to operation,
take protective measures to prevent ma-
chine from tumbling down or falling over.

2.3.25 Overhead power cables
Do not travel or operate your machine near

power cables, which may bring electrocution
hazard and cause machine damage, personal
injury or death. The following steps are to be
followed while working at where power cables
could be nearby.
● Prior to operation in the vicinity of power

cables, inform local power company of the
coming operation and ask them to take
necessary measures. CZ335-1102020
● If the machine is too close to power cable, Fig. 2-40

electric shock is most likely to occur and
cause burns or death. A safe distance must
be kept between machine and the cable
(See the right table). Prior to operation, Cable Voltage Min. Safe Distance
communicate with local power company
100V-200V 2 m ( 7 ft)
regarding safety measures.
6,600V 2 m ( 7 ft)
● A signalman is to be assigned to send
22,000V 3 m ( 10 ft)
signals if the machine is too close to the
66,000V 4 m ( 14 ft)
cable.
154,000V 5 m ( 17 ft)
● Nobody is allowed to approach the ma-
187,000V 6 m ( 20 ft)
chine when operating near high-voltage
275,000V 7 m ( 23 ft)
cables.
500,000V 12 m ( 36 ft)
● If the machine is too close to the cable
Table 2-1
or touches the cable, to prevent electric
shock, operator shall not leave the cab
until power is surely cut off. In addition, no-
body is allowed to approach the machine.
● To prevent accidents, wear rubber shoes

and rubber gloves during operation. Cover
the operator’s seat with rubber sheet and
pay attention to exposed part of body that
should not touch the lower part of the ma-
chine.

2.3.26 Visibility
The machine is equipped with rearview mir-

rors to improve the visibility of the operator.
However, some areas cannot be seen from
the driver’s seat.
When driving or operating the machine in plac-

es with poor visibility, uncertainty of worksite
condition may cause machine damage and
personal injury. Observe the following instruc-
tions when operating or driving the machine in
a place without a clear view.
● Check rear view mirrors on each workday.

Remove debris and adjust the view to en-
sure good visibility.
● Working in a darkened area requires turn-

ing on work lights and headlights of the
machine. Set up auxiliary illumination in
the worksite if necessary.
● If a clear view cannot be guaranteed in

days with fog, snow, rain or sand storm for
example, stop operation.
● Road shoulder or soft ground should be

marked. In case of bad vision, a signalman
should be available if necessary. Operator
shall especially pay attention to the marks
and follow the instruction of the signalman.
● Only one signalman is allowed to give sig-

nals.
● Prior to operation, make sure all the work-

ers understand the signals and gestures.
2.3.27 Ventilation
Engine exhaust gas can be fatal. If the engine

must be started, or if fuel, cleaning oil or paint
must be handled in an enclosed area, to pre-
vent gas poisoning, doors and windows shall
be kept open to ensure sufficient ventilation.

2.3.28 Asbestos
Inhalation of asbestos dust can cause lung

cancer. There is the danger of inhaling asbes-
tos dust when engaging in tear-down opera-
tion or handling of industrial wastes at work-
site. The following rules must be followed.
● Water, instead of compressed air, shall be

used to clean the dust.
● If the air contains asbestos dust, operate

the machine following the wind. All persons
shall wear acceptable filter mask. CZ335-1102022
● Nobody is allowed to approach the ma- Fig. 2-41

chine during operation.
● The regulations, rules and environment cri-

terion at worksite shall be observed.
No asbestos is used in this machine. But after-

market parts could contain asbestos. There-
fore, use only the parts and components sup-
plied by Sany.
WARNING
● Exposure to hazardous chemicals or
dusts poses a serious danger if re-
leased or mishandled.
● Performing demolition work or handling

hazardous materials often release sub-
stances that could pose a hazard.
● Serious injury or death may result un-

less proper precautions are observed
while working with these materials.
● All workers involved in demolition or

handling of hazardous materials should
use approved personal protective
equipment and follow all environmental
safety regulations.

2.3.29 Alternate exit
● If the cab door fails to open in an emergen-

cy, use the escape hammer to break the
window.
● Remove the pieces of glass from the win-

dow frame before escaping. Be careful
with the broken glass to avoid being cut.
Pay attention to the debris on the ground,
which may cause you to slip and fall.
A820601990969
Fig. 2-42

2.4 Safe Operation Precautions
2.4.1 Safe starting
2.4.1.1 Safe mounting
When you mount or dismount the machine:
● Always face the machine and maintain a

three-point contact (one hand and two feet
or two hands and one foot).
● Never jump on/off the machine. Do not

mount a moving machine.
● Do not use any control lever as handhold.
● Remove the mud, oil dirt and water from

pedal, handholds and your soles at any
time.
CA13031506
● The cab must be aligned with the under- Fig. 2-43
carriage centerline before you enter or exit
the cab.
2.4.1.2 Operator seat
● Uncomfortable seat position can eas-

ily lead to operator fatigue and operating
mistakes. The seat position should be ad-
justed upon change of operator.
● The operator seat shall be properly adjust-

ed so that the operator can have easy ac-
cess to all the control levers and pedals in
a comfortably seated position. Otherwise,
the seat should be readjusted.
Fore more information, see "Operator seat CZ335-1102026
adjustment" on page 4-17. Fig. 2-44

2.4.1.3 Seat belt
● The operator may get seriously injured or

killed when the machine tips over. Before
operating the machine, examine your seat
belt, the buckles and the anchor point. Re-
place the seat belt if damage or excessive
wear is observed. When the machine is
operating, keep your seat belt buckled up.
For more information, see "Seat belt" on

page 4-21.
● The seat belt shall be replaced every three CZ335-1102027

years regardless of its condition.
Fig. 2-45
2.4.1.4 Before starting the engine
Before starting your daily work, the following

items shall be observed prior to start of the en-
gine.
● Clean the front window and the mirrors to

ensure good visibility.
● Clean the work lamps, and check if they

work.
● Check coolant level, fuel level and engine

oil level.
CZ335-1102028
● Check for blocked air filter and damaged Fig. 2-46
electrical wires.
● Adjust the seat to a position easy for op-

eration; check seat belt and buckles for
damage and wear.
● Check if the control levers are all in neu-

tral position. Check if the hydraulic lockout
control lever is in the LOCKED position.
● Adjust the rear view mirrors so as to see

clearly from the driver’s seat what is hap-
pening behind the machine.

2.4.1.5 Engine starting rules
● Before starting the machine, make sure

nobody is on, under or around the ma-
chine. Sound the horn to warn people
around.
● Always start and operate the machine from

the operator seat.
● No one is allowed to stay on the machine

except the operator.
● Do not start the engine by shorting the

start motor circuit, which is dangerous and
may cause machine damage.
2.4.1.6 Machine starting
WARNING
● Ample ventilation must be provided if
you have to start the engine or operate
the machine in a confined space.
● Excessive inhalation of exhaust gas can

be fatal.
● If you do not know how to stop the ma-

chine, do not start it.
CZ335-1102029
● Adjust the position of the operator seat so
Fig. 2-47
that you can easily access all controls in a
seated position.
● Make sure you are familiar with all the

warning devices, gauges and operation
controls.
● Place all controls to neutral/ or OFF posi-

tion.
● Make sure nobody is present in the sur-

rounding area of the machine.

2.4.1.7 Starting engine in cold season
● Sufficient warm-up operation is necessary.

Incomplete warming up may result in slow
reaction and accidents.
● Before starting, check the battery electro-

lyte. In case of frozen electrolyte, do not
charge the battery or use alternative power
source to start the engine; instead, melt the
electrolyte first. Otherwise, fire may break
out on the battery.
2.4.1.8 Engine starting aid
Improper handling may cause battery explo-

sion or loss of machine control, resulting in
personal injury and death. Never use jumper
cables to start the engine unless necessary.
Contact your Sany dealer before such an at-
tempt.
● Using jumper cables to start the engine

needs two persons working together with
one seated in the operator seat and the
other handling the battery.
● Wear goggles and rubber gloves before

starting the engine with jumper cables.
● When connecting a normal machine with a

faulty machine with jumper cables, battery
voltage of the two machines shall be the
same. Be careful not to allow the two ma-
chines to contact with each other.
● Turn both start switches to the OFF posi-

tion when connecting the two machines.
Otherwise, the machines may move and
cause danger when power is on.
● Start with the positive terminal when con-

necting the jumper cable. Start with the
ground or negative terminal when discon-
necting the jumper cables.

● When disconnecting the jumper cable, take

care not to allow the clips of jumper cable
to contact with each other or with the ma-
chine.
● Ether is a liquid used for cold start, which is

extremely flammable and explosive. Read
the instructions on the ether container be-
fore application.
● Do not use ether if the engine is equipped

with a spark-plug preheater or other forms
of preheater.
2.4.1.9 After starting the engine
Run the engine at low idle for 3 to 5 minutes

after engine startup, and check the running
parameters and make sure they are normal
and all readings are within normal working
range.

2.4.2 Operation
2.4.2.1 Inspection before operation
● When conducting inspection, move the

machine to a spacious area without barri-
ers and operate slowly. Any other person is
not allowed to approach the machine.
● Be sure to fasten the seat belt.
● Check the gauges and machine operation

for abnormality; check the bucket, arm,
boom, travel system, swivel system and
steering system for abnormal operation.
● Check for abnormal noise, vibration, heat-

ing, odor or gauge reading; check oil or
fuel for leakage.
● When the travel control levers are in neu-

tral position, test the engine's speed con-
trol device; operate each control lever and
confirm they work properly. Understand the
control mode of work equipment.
● In case of any abnormality, stop operation

and take corrective measures immediately.
CAUTION
● Observe the machine and listen careful-
ly for abnormal noise. In case of fault or
abnormality, shut down the machine im-
mediately. Do not operate the machine
until corrective measures are taken.

2.4.2.2 Prior-operation precautions
To prevent serious injury or death, follow the

items below before moving the machine.
● Sound the horn to warn people around.
● Working range of the machine is 12 m to

the slewing center. It is dangerous to stay
in the working range during machine op-
eration.
● Nobody is allowed to stay on or near the

machine, or within the swivel range. 12
m
● To improve the visibility in the travel direc-

tion, you may turn the cab if necessary.
CZ215S-1102003
● Assign a signalman where visibility is poor.
Fig. 2-48
CZ335-1102033
Fig. 2-49

2.4.2.3 Travel direction confirmation
WARNING
● Improper operation of travel control le-
vers/pedals can cause serious injury or
death.
● Always check the position of the travel mo-

tor and the idler in relation to the operator
cab before you operate the travel control
levers or pedals.
● A direction mark is attached onto the inner

side of track frame. It shows the forward
direction when the idlers are before the op-
erator cab.
● When the idlers are before the opera-

tor cab, push the travel control levers (or CZ335-1102031
press the upper part of the pedal) to move Fig. 2-50

the machine forward.
● When the travel motors are before the

operator cab, pull the travel control levers
(or press the lower part of the pedals) to FRONT
move machine forward. Operator Seat
Idler
NOTE: LEFT RIGHT
In this manual, the front, rear, left or right di-

rections are the directions seen from the cab Sprocket
when the cab is straight forward and the driv- REAR
ing wheels are in the rear. CZ335-1102032
Fig. 2-51

2.4.2.4 Safety rules for turning
● Always drive and operate the machine in a

seated position.
● Nobody is allowed in the cab except the

operator.
● Check if the travel alarm works.
● Always secure the cab door or windows,

either open or closed. At worksite where
flying objects may get into the cab, check if
the doors and windows are properly shut.
CZ335-1102033
Fig. 2-52
● Assign a signalman if a blind area exists

at the rear of the machine. In turning or
swivel operation, be alert not to hit other
machines or personnel.
● Sound the horn to warn personnel in the

area before traveling.
● Check for the presence of personnel and/

or obstacles again in the machine sur-
roundings before traveling.
CZ335-1102034
Fig. 2-53
● Before traveling, position the machine so

that the sprockets are behind the operator
cab. If the sprockets are in front of the cab,
the machine will move in a direction oppo-
site to the move direction of control levers.
Special attention must be paid to opera-
tions under such circumstances.
CZ335-1102035
Fig. 2-54

● If your vision is limited during reverse trav-

el, assign a signalman and keep him within
the range of your vision.
● When a signalman is necessary on some

occasions, use hand signals specified in
local regulations.
● The machine can only be moved when

both the signalman and the operator un-
derstand the signals.
● Understand all vocal, graphic and flag

signals used in work and decide who is to
give signals.
● Keep the windows, rear view mirrors and CZ335-1102045
work lights clean and intact. Fig. 2-55

● Dust, heavy rain and fog may reduce vis-
ibility. Drive slowly and use proper lights in
case of low visibility.
WARNING
● During reverse or swivel operation,
people around the machine may get hit
by the counterweight or work equip-
ment, resulting in serious injury or even
death.

2.4.2.5 Safety rules for traveling
● To prevent machine breakdown and avoid

damage of work equipment, do not operate
the machine beyond its maximum load or
rated capacity.
● When driving or operating the machine,

keep the machine a safe distance away
from people, building or other machine so
as to avoid collision.
● When traveling on a highway, contact re-

lated departments in advance and follow
their instructions.
● When traveling on flat ground, the work

equipment should be retracted and kept
20-30cm (8-12in) off the ground.
● When traveling on rough ground, the ma- 20~30cm

chine shall move at a low speed and avoid (8~12i n)
sudden change of direction, or the machine
may tumble down. If the work equipment CZ335-1102036
hits the ground, the machine will lose bal- Fig. 2-56
ance and get damaged.
● When traveling on rough ground or on a

steep slope, the auto-deceleration switch
(if equipped) shall be switched off. If auto-
idle is activated, engine speed and travel
speed may drop suddenly.
● Avoid traveling over a barrier if possible. If

you have to do that, lower the work equip-
ment close to the ground and drive slowly.
Never let the machine travel on a barrier
that would make it tilt sharply.
CZ335-1102037
● Check first the structural strength of a Fig. 2-57

bridge or a building before driving the ma-
chine on it.
● Operate slowly when working in a tunnel,

under a bridge or power cables. Take care
not to damage anything with work equip-
ment.

2.4.2.6 Safe traveling
WARNING
● Driving the machine on a slope may
cause it to slip or tumble down, result-
ing in serious injury or death.
● Check the travel direction of the machine

before driving it. Make sure you know how
to operate the control levers and pedals.
● Press the upper part of the control pedal or

push the control lever forward to move the
machine in the direction of the idlers.
● Work equipment should be kept 20-30cm

20~30cm
(8-12 in) off the ground when moving on a (8~12i n)
slope. In case of an emergency, the work
equipment could be lowered to ground im- CZ335-1102038
mediately to help stop the machine. Fig. 2-58
● When driving the machine up a slope, face

the cab to the uphill direction; when driving
down a slope, face the cab to the downhill
direction.
● Before traveling, always check the hard-

ness of ground before your machine.
CZ335-1102040
Fig. 2-59
● When driving the machine up a slope, ex-
tend the work equipment to keep balance.
Keep the work equipment 20-30cm (8-
12in) off the ground and drive the machine
slowly.
● When driving down a slope, lower the en-

gine speed, keep the travel control levers
close to "neutral" position and drive slowly.
CZ335-1102039
Fig. 2-60

● Drive straight up and down a steep slope.

It is very dangerous to turn on or drive
across a slope.
● To adjust the position of the machine on a

slope, drive it onto a flat surface, reposi-
tion it and driving the machine to the slope
again.
● Drive at low speed on meadow, fallen

leaves or wet steel plate because even a
CZ335-1102041
small grade could cause the machine to
slip. Fig. 2-61
● If your engine stalls out when traveling on

a slope, place the control levers to "neu-
tral" position immediately and restart the
engine.
2.4.2.7 Machine operation on slope
CZ335-1102042
WARNING
Fig. 2-62
● Swinging the upper structure or operat-
ing the work equipment on a slope may
cause the machine to lose balance and
tumble down, resulting in serious injury
or machine damage.
● Do not operate the machine on a slope un-

less a flat platform is provided. Extra care
shall be taken when operating the machine
under this condition.
● When the bucket is fully-loaded, do not

turn the work equipment from the higher
part to the lower part of the slope, which is
dangerous and may cause the machine to
tumble down.
● If you have to operate your machine on a CZ335-1102046
slope, build an earth platform that could Fig. 2-63

keep the machine as horizontal as pos-
sible.

2.4.2.8 Operation in snowy weather
● Snow-covered or frozen surfaces are slip-

pery. Do not manipulate the control lever
suddenly when driving or operating the
machine. Extra attention should be paid to
operation on a slope because even small
inclination could cause the machine to slip.
● The machine may tip over on frozen sur-

face which may become soft upon increase
of ambient temperature.
● Avoid deep snow, which may cause your

machine to tip over or to be buried in
snow. Be noted that you shall never be
away from road shoulder and avoid being
trapped in snow.
● When cleaning the snow, it is hard to see

the snow-covered road shoulder and ob-
jects near the road. There is danger for
your machine to tip over or hit the covered
objects. Therefore, please operate with ex-
treme caution.

2.4.2.9 Restricted operation
● Never dig under an overhang, which may

lead to falling stones, collapse of overhang,
and accidents.
CZ335-1102047
Fig. 2-64
● Never dig too much under the machine,

which may cause the ground to collapse
due to cave-in, hence the accidents.
CZ335-1102048
Fig. 2-65
● Never tear down under your machine,

which may cause your machine to lose bal-
ance and roll over.
● When operating on building or other

structures, strength of structure must be
checked to avoid collapse of building, thus
resulting injury or death.
CZ335-1102050
Fig. 2-66

● Never tear down any structure over your

machine. The falling of broken objects or
collapse of building could damage your
machine and cause personal injury or
death.
CZ335-1102051
Fig. 2-67
● Never break anything with the impact force

of work equipment as broken pieces could
lead to personal injury, the work equipment
could be damaged, and the counter-action
of impact force could roll over your ma-
chine.
● Generally speaking, it is easier to tip over

with the work equipment at one side than it
is positioned in the front or rear.
CZ335-1102052
Fig. 2-68
● Lifting, moving or swinging the bucket shall

never pass over anybody or a truck's cab.
The falling of substances from the bucket
or collision of buckets could result in per-
sonal injury or machine damage.
● The use of crusher or other heavy working

unit could cause your machine to lose bal-
ance and tip over. When operating on a flat
surface or slope:
CZ335-1102053
Never lower, swing or stop the working unit
suddenly. Fig. 2-69
Never extend or retract the boom cylinder

suddenly as which may cause your ma-
chine to tip over due to impact.

2.4.3 Parking the machine
2.4.3.1 Select a parking place
● Park your machine on a solid and flat sur-

face.
● Park the machine in an area free of such

hazards as falling stones or landslide. If the
terrain is low, park it in a relatively higher
place.
● If you have to park the machine on a slope,

observe the following instructions:
● Position the bucket in the downhill di-

CZ335-1102054
rection and cut the bucket tips into the
earth. Fig. 2-70
● Chock the tracks to prevent unexpected

movement.
● Do not park your machine on a road under-

going construction. If you have to park your
machine in such a place, flags are to be
120°
used on daytime and signal lamps at night
to warn other people or vehicles according
to local regulations.
CZ335-1102055
Fig. 2-71

2.4.3.2 Machine shutdown
Follow the procedures below to shut down the

machine. For detailed information, see "En-
gine Shutdown" on page 4-29.
● Stop the machine.
● Position the machine properly.
● Lower the work equipment to the ground or

place it in a fixed position.
● Slow down the engine and keep it running

at low idle for 5 minutes. CZ335-1102074
● Turn the start switch to OFF position to Fig. 2-72

stop the engine.
● Move the lockout lever to the LOCKED po-

sition.
● Remove the key.
● Close the windows and the cab door.
● Lock all access doors, boxes and cham-

bers.
When leaving your machine, face the machine

and maintain a three-point contact with it. Do
not jump off the machine.
Be careful with slippery track, step and hand-

holds when dismounting the machine. CZ335-1102028
Fig. 2-73

2.4.4 Transportation
2.4.4.1 Loading and unloading
Improper loading and unloading of the ma-

chine may cause it to fall or tip over. Follow
the procedures below:
● Load or unload the machine only on a solid

and flat surface. Keep it a safe distance
away from road sides or a cliff.
● Keep on-lookers away.
● Use an access ramp with enough strength.

Make sure that the width, length and thick-
ness of the access ramp is capable of pro-
viding a safe loading/unloading operation
(at an angle ≤15°).
● Make sure the access ramp is free from

grease, oil, water and debris. Clean the
track if necessary. Be extremely careful Max.15° Chocks
when loading or unloading the machine in
rainy or snowy weather.
● Never load or unload the machine using CZ335-1102058
the force of work equipment, which may Fig. 2-74

cause the machine to fall or tip over.
● Run the engine at low speed and drive

slowly.
● Place the work equipment straight forward.
● Do not operate any control levers other

than the travel control lever when the ma-
chine is driving up the ramp.
● Do not reposition the machine on the ac-

cess ramp. If necessary, drive it off the CZ335-1102059
ramp, reposition, and get on the ramp
again. Fig. 2-75
● Gravity center of the machine may alter

when it passes the jointing area between
the ramp and the trailer. The machine may
tilt at this moment. Travel slowly when the
machine is on the joint area.

● When loading or unloading the machine on

a platform, make sure the platform has ad-
equate width, strength and a proper grade.
● The trailer may become less stable with

the machine on it. Retract the work equip-
ment and swing the upper structure slowly.
● Once the machine is loaded, lock the cab

door. Otherwise, it may swing open during
transportation.
CZ335-1102060
● Secure the machine with chains and
Fig. 2-76
chocks.
● Secure all work equipment, lower the buck-

et, the arm and the boom, and place them
in position for transport.
2.4.4.2 Transportation
Observe the following items when transporting

the machine:
● Note the dimension of the trailer and the

machine, especially the height. Watch out
for barriers overhead and in narrow pas-
sages.
● Check the structure and strength of a

bridge before crossing it. Obey local traf-
fic regulations and traffic police directions
when transporting the machine on high-
ways.

2.4.5 Battery
WARNING
● Electrolyte is a strong acid. If electrolyte
contacts your clothing or skin, flush im-
mediately with plenty of water.
● Electrolyte may cause blindness. Flush

immediately with plenty of clean water
when electrolyte gets into your eyes
and seek medical attention.
CZ335-1102061
Electrolyte contains sulfuric acid, which gives Fig. 2-77

off flammable and explosive gases. Improper
handling may cause personal injury or fire.
Observe the instructions below when handling
battery:
● Never smoke or use fire near a battery.
● Turn the engine ignition key to the OFF po-

sition before working on the battery.
● Wear safety glasses and rubber gloves

when handling battery.
CZ335-1102062
Fig. 2-78

● Never allow tools and other metal parts to

contact with battery terminals. Keep tools
or metal parts away from batteries.
● Stop the engine and wait for one minute

before you proceed. Always disconnect the
grounding terminal (negative(-) ) first. To
connect battery cables, always begin with
the positive (+) terminal, and then connect
the negative (-) terminal. Ensure all termi-
nals are securely connected.
● Battery temperature rises when it is be-

ing charged. When battery temperature
exceeds 45°C, stop charging and wait till
it is at ambient temperature. Reduce the
charging current by half and continue the
charging process.
● A battery being charged may give off flam-

mable gases. Before charging a battery,
remove it from the undercarriage, put it in
well-ventilated area and remove the cap.
● If acid squirts out of battery vent during

charging, stop charging immediately.
● Never smoke and keep flames or sparks

out when charging.
● When the battery has been fully charged, a

green indicator will be on. Stop the charg-
ing process at this time.
● Restore the battery cover after charging.
● Put the battery back to its original position.

2.4.6 Towing
When towing a damaged machine, improper

operation or use of unacceptable wire cable
could lead to serious accident:
A
● Do not tow the machine on a slope.
B
● Wear protective gloves and a hard hat
when using wire ropes.
C
● Check the strength of wire cable and make
sure it could bear the weight of machine.
● Do not use ropes with broken wires (A), re- CZ335-1102063
duced diameter (B) and twisting (C). Such Fig. 2-79

ropes may break when towing.
● Do not stand between the towing machine

and the towed machine during towing op-
eration.
● Operate the machine slowly. Do not add

load to the wire cable suddenly.

2.4.7 Lifting objects with the machine
WARNING
● Overload is dangerous and can cause
serious injury and death.
● Make sure the load is within the loading

range and working radius of the ma-
chine.
● Nobody is allowed to enter the working

area. CZ335-1102064
● Confirm all signals to be used and assign a Fig. 2-80

signalman prior to operation.
● Lift a load on a flat surface to prevent the

machine from tilting or tipping over.
● Never use chains, wire ropes, shackles

and slings that are damaged.
● Anchor wire ropes or slings onto the desig-

nated lifting lug. Never attach the shackle
or sling onto the bucket tips. Loosened
bucket tips could cause the load to fall.
● Never leave the operator seat when lifting

is in progress. CZ335-1102065
● To prevent the load from hitting any person Fig. 2-81

or building, inspect carefully the machine
surroundings before swinging or operating
the work equipment.
● Never swing or operate the work equip-

ment suddenly. This may cause the load
to drift and the machine to tip over. Use a
drag rope if necessary.
● Never use the work equipment or the

swing force to drag the load in any direc-
tion. The work equipment will jerk if the
shackle breaks and the load comes free,
resulting in serious personal injury.
CZ335-1102066
Fig. 2-82

2.5 Precautions for Maintenance
2.5.1 Pre-maintenance precautions
To prevent accidents:
● Understand maintenance procedure prior

to operation.
● Keep a clean and dry working area.
● Do not spray water or steam in the cab.
● Never add lubricant and carry out other

maintenance work when your machine is
moving.
● Keep your hands, feet and clothing away

from rotating parts.
2.5.2 Select a working area
● For maintenance work, select a clean and

flat area with plenty of space, ample sun-
light and good ventilation.
● Clean the working area by removing fuel,

lubricant and water, and covering slippery
ground with sand or other absorptive mate-
rials.
● Do not leave your hammer or other tools at

the working area.
● If a clean and tidy working area cannot be

guaranteed, there would be danger of tip-
ping, thus resulting in personal injury.

2.5.3 Prepare the machine
Before maintaining the machine:
● Park the machine on solid and flat ground.
● Lower the bucket to the ground.
● Place blocks under the tracks to prevent

movement of the machine.
● Turn the fuel control dial to first gear. Run

the engine at low speed for 5 minutes.
● Turn the start switch to OFF position and CZ335-1102054

stop the engine.
Fig. 2-83
● Turn the start switch to ON position. Oper-
ate the control levers 2 or 3 times in all di-
rections to relieve internal pressure of the
hydraulic system.
● Remove the key from the switch.
● Place the hydraulic lockout control to the

LOCKED position.
CZ335-1102074
Fig. 2-84

2.5.4 Prepare yourself
Only approved personnel can maintain or

repair the machine. An observer may be as-
signed if necessary.
● Wear protective clothing and shoes neces-

sary for the job.
● Wear rubber apron and rubber gloves

when handling corrosive materials. Wear
heavy gloves when handling wooden ma-
terials, wire ropes or sharp-edged metals.
CZ335-1102069
● Wear a face shield when removing spring
or elastic parts, or adding acid to battery. Fig. 2-85
Wear a hard hat and goggles when you
weld or cut with a torch.
● Do not carry out grinding, flame cutting or

welding without an aspirator and ventilation
equipment.
● Loud noise may impair your hearing per-

manently or temporarily. When maintaining
the engine, wear ear covers or ear plugs if
you have to work in loud noise for a long
time.
● When using a hammer to strike hard metal

parts such as pin, bucket teeth, cutting
edge or shaft, the flying of parts and metal
pieces may cause bodily injury. Therefore,
wear goggles and gloves and ensure the
CZ335-1102071
surrounding area is clear of any other peo-
ple. Fig. 2-86
● When compressed air is used for cleaning,

flying particles may cause personal injury.
In this case, wear goggles, dust-preventive
mask, gloves and other protective gear.

2.5.5 Lockout and tag-out measures
● When maintenance is underway, starting

the engine or moving the control levers or
pedals could lead to serious accident.
● Prior to maintenance, attach a DO NOT

OPERATE tag or similar sign to the ma-
chine's start switch or control levers to
warn others that this machine is under
maintenance.
● Attach other warning tags around the ma-

chine if necessary. CZ335-1102067
Fig. 2-87
CZ335-1102068
Fig. 2-88
2.5.6 Use proper tools
Use proper tools and use them correctly. Us-

ing damaged, inferior, defective, temporary
tools or using the tools incorrectly could lead
to serious accidents.
CZ335-1102072
Fig. 2-89

2.5.7 Maintenance with engine running
To prevent injury, no maintenance shall be car-

ried out when the engine is running. However,
if maintenance has to be done on a running
engine, at least two workers are needed to
carry out the maintenance.
● One of the workers shall stay in the opera-

tor seat ready to shut down the engine at
any time. All the workers involved shall
keep in touch.
● Place the hydraulic lockout control lever

to the LOCKED position to prevent move-
ment of work equipment.
CZ335-1102028
Fig. 2-90
● Pay special attention to rotating parts like

fans and fan belts.
● Do not leave or insert any tool or other ob-

jects in the fan or the fan belt, which may
cause the parts to break or fly.
● Do not touch any control lever. If one of the

control levers must be used, give signals
to other workers and warn them to move
quickly to a safe area.
CZ335-1102077
Fig. 2-91

2.5.8 Work under the machine
● Never carry out maintenance before the

machine is well supported.
● Lower the work equipment to the ground

before maintaining the machine.
● If the machine or work equipment has to

be lifted for maintenance, blocks or sup-
ports that are strong enough to support
the machine or work equipment should be
used. Never use loose bricks, empty tires
or stands to support the machine. These CZ335-1102078
things may collapse under continuing load.
Never use a single jack to support the ma- Fig. 2-92
chine.
● If the track shoes are lifted and the ma-

chine is solely supported by the work
equipment, it is very dangerous to work
under the machine. In case of failure of hy-
draulic pipe or accidental touch of control
lever, the work equipment or machine may
fall suddenly, causing injury or death. Nev-
er work under the machine if it is not firmly
supported with blocks or supports.

2.5.9 Track maintenance
WARNING
● Do not strike the recoil springs of the
track. Recoil springs are under im-
mense pressure and spring rupture may
cause bodily injury. Do not remove any
spring when it is compressed.
● Dry rubbing of pin against bushing may

produces extreme heat. Wear protective
gloves to avoid burns.
● Maintain proper track tension. When work-

ing on mud- or snow-covered ground, mud
or snow may attach to track components
and causes over tension. Adjust track ten-
sion properly. For more information on
track tension adjustment, see "Track ten-
sion - inspect/adjust" on page 5-22.
● Check for loosened or broken track shoes.

Check the pins and bushings for wear or
damages. Check the track rollers and car-
rier rollers.

2.5.10 Track tension adjustment
WARNING
● Grease is injected into track tension ad-
justment system under high pressure.
● Failure to observe specified main-

tenance procedures may cause the
grease discharge plug to eject and
cause serious injury and damage.
CZ335-1102080
● When loosening the grease discharge plug
to reduce track tension, the plug shall be Fig. 2-93
unscrewed slowly for no more than one
turn.
● Keep your face, hand, foot or any other

body part away from the grease discharge
plug.
2.5.11 Recoil spring
The recoil springs are used to reduce the im-

pact of tension rollers. It includes a high pres-
sure spring, which may fly out and cause seri-
ous injury or death if removed improperly.
If it has to be removed, contact your Sany

dealer.
CZ335-1102081
Fig. 2-94

2.5.12 Welding operation
Welding operation may lead to fire or electric

shock. Only qualified welders are allowed to
conduct welding operation using proper equip-
ment.
2.5.13 High-pressure hoses
If oil leaks from high-pressure hose, fault or

even fire may occur. If any bolt on the hoses
is loose, stop operation and tighten it to speci-
fied torque. In case of hose damage, stop
operation immediately and contact your Sany
dealer.
Replace the hose immediately in case of the

following problems:
● Damage or leak of hydraulic hose fitting
● Damage or break of outer cover, or ex-

posed steel wires of reinforcement layer
● Ballooning outer cover in some places
● Distortion or crushing of movable parts
● Impurities in outer cover

2.5.14 Pressurized fluid
The hydraulic system is always under pres-

sure. Make sure pressure in hydraulic circuits
has been relieved before checking or replac-
ing the lines. Residual pressure in the circuit
may cause serious accidents.
● Release system pressure before maintain-

ing the hydraulic system.
Fore more information, see "How to

release pressure in the hydraulic circuit" on
page 5-36.
● Open fire is not allowed around the hydrau-

lic system. Remove splashed hydraulic oil
as quickly as possible.
● Diesel oil or pressurized hydraulic oil can

penetrate skin or eyes, causing serious
injury, blindness or death. It is hard to find
the leaking of hydraulic oil with naked eyes.
A cardboard or wooden board is necessary
for checking for leaks. Do not touch leaking
liquid with bare hand. Wear face shield or
safety goggles to protect your eyes. If any
CZ335-1102082
liquid penetrates your skin, flush with clean
water immediately and get medical atten- Fig. 2-95
tion as soon as possible.
● The fuel lines are under high pressure

when the engine is running. When check-
ing or servicing the fuel system, shut down
the engine and wait for 30 seconds till in-
ternal pressure drops prior to operation.

2.5.15 Hot cooling system
WARNING
● Touching hot high-pressure coolant
may cause serious injury.
When engine temperature rises, pressure of

the cooling system increases. Before remov-
ing the radiator cover, stop the engine and
let the system cool down. The radiator cover
could only be removed after the coolant in it
CZ215L-1102001
has cooled down.
Fig. 2-96
2.5.16 Air-conditioning system maintenance
WARNING
● Refrigerant R134 a is a harmless gas
under room temperature. It will change
into highly toxic gas when burning.
● Refrigerant getting into eyes may cause

blindness. It may cause frostbite if
splashed on your skin.
● Keep fire source away when servicing air-

conditioning system.
● In maintenance of air-conditioning system,

observe the instruction on the refrigerant
cylinder and use it correctly. The type of
refrigerant is R134a. Use of other refriger-
ants may damage the air-conditioning sys-
tem.
● Obey local material disposal regulations.

Never discharge refrigerant directly into the CZ335-1102083
air. Fig. 2-97

2.5.17 High voltage precautions
When the engine is running or has just been

shut down, high voltage can occur in fuel in-
jector terminal and engine controller. Since
there is danger of electric shock, do not touch
fuel injector or interior of engine controller.
Please contact your Sany dealer if you have to

access fuel injector terminal or interior of en-
gine controller.
CZ335-1102084
2.5.18 Accumulator Fig. 2-98
The accumulator contains highly pressurized

nitrogen. Improper operation of the accumula-
tor can cause explosion and serious accidents.
Therefore, the following precautions must be
observed:
● Do not disassemble the accumulator.
● Do not let the accumulator be near a fire

source or exposed in flame.
● Do not punch, weld or flame-cut on accu-

mulator. CZ335-1102085
Fig. 2-99
● Do not strike or roll the accumulator, or let
it bear any impact.
● The gas must be released when dispos-

ing of the accumulator. Contact your Sany
dealer for this disposal.

2.5.19 Fire and explosion prevention
WARNING
● Never smoke when handling the fuel or
maintaining the fuel system. The gases
in empty fuel tank can cause explosion
easily.
● Never carry out flame-cutting or weld-

ing operation on fuel pipe, fuel tank or
fuel vessels, which can lead to fire, ex-
plosion, injury or death.
● Then engine must be shut down and elec-

trical equipment must be switched off when
refueling the tank. Be extremely care-
ful when adding fuel to a hot engine. No
sparks shall occur around the grounding
nozzle.
● Handle all solvents and dry chemicals in a

place with good ventilation according to the
instructions provided on vessel.
● Clean the machine of all dust and residu-

als. Do not place greasy rag or other flam-
mable materials on the machine.
● When cleaning the parts and components,

use nonflammable solvents instead of gas-
oline, diesel oil or other flammable fluids.
● Store flammable liquids and materials in

suitable vessels as required by safety laws
and regulations.
● Check fire extinguishers, fire-fighting sys-

tem and fire detectors (if equipment) and
make sure they are ready for use.

2.5.20 Regular replacement of safety-related parts
● Safety-related parts such as hoses and

seat belt must be replaced regularly for
the consideration of operating the machine
safely in a long term.
● Materials of some parts may deteriorate

naturally when exceeding specific time
limit. Repeated use may lead to deteriora-
tion, wear and damage, hence the acci-
dents and serious injury. Through merely
visual inspection or feel it is hard to find out
how long the parts could serve. Therefore,
regular replacement is necessary.
● Repair or replace any safety parts once

found defective regardless of its service
time.
2.5.21 Maintenance operation
● Check all parts and replace the worn, bro-

ken and damaged parts during repairing
work. Over-worn and over-damaged parts
may fail in operation and cause injury and
death. Replace damaged or illegible signs
and marks.
● Tighten all fasteners and connectors to

specified torques.
● Install all guards, covers and hoods after

repair and service. Replace or repair dam-
aged guards. Only the type of hydraulic oil
approved or recommended by Sany should
be used to refill the hydraulic system.
● Start the engine and check for any leaks

(check the hydraulic system), and operate
all control devices to be sure of their prop-
er functioning. Make road test if necessary.
Shut down the engine and check the work
you have done (see if there are missing
pins, gaskets and nuts). Check hydraulic
oil level once again prior to operation.

2.5.22 Proper disposal of wastes
Improper disposal of wastes harms the en-

vironment. Consult local environmental pro-
tection department or your Sany dealers for
methods of recycling and waste disposal.
● Potential harmful substances used in Sany

products include hydraulic oil, fuel, engine
coolant, refrigerant, filter and batteries etc..
● Use leak-proof vessels to hold discharged

fluids. Do not use food or beverage con-
tainers. CZ335-1102086
● Do not drain waste fluids directly to the Fig. 2-100

ground, sewage or water source.
● Leaking of refrigerant from air conditioner

can spoil the atmosphere of the earth.
Related laws and regulations must be fol-
lowed to recover or recycle the refrigerant.
CZ335-1102087
Fig. 2-101

E
G
PA
K
AN
BL

E
G
PA
K
AN
BL

SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator System Functions
System Functions
3 System Functions
3.1 Machine general drawing......................................................................................... 3-3
3.2 Monitoring System ................................................................................................... 3-4
3.2.1 Monitor functions............................................................................................ 3-4
3.2.2 Monitor operation ........................................................................................... 3-7
3.3 Switches ................................................................................................................ 3-24
3.3.1 Start switch .................................................................................................. 3-25
3.3.2 Fuel control dial............................................................................................ 3-26
3.3.3 Work lamp switch ......................................................................................... 3-26
3.3.4 Head lamp switch......................................................................................... 3-28
3.3.5 Windshield wiper switch ............................................................................... 3-29
3.3.6 Washer switch .............................................................................................. 3-30
3.3.7 Horn switch .................................................................................................. 3-30
3.3.8 Cab lamp switch........................................................................................... 3-30
3.3.9 Cigarette lighter............................................................................................ 3-31
3.3.10 Preheat switch (If equipped) ...................................................................... 3-31
3.3.11 Preheat indicator ........................................................................................ 3-32
3.3.12 Charging indicator ...................................................................................... 3-32
3.4 Control Levers and Pedals .................................................................................... 3-33
3.4.1 Hydraulic lockout control .............................................................................. 3-34
3.4.2 Travel control levers ..................................................................................... 3-35
3.4.3 Joysticks ...................................................................................................... 3-36
3.5 Cab Windows and Cab Door ................................................................................ 3-38
3.5.1 Ceiling window ............................................................................................. 3-38
3.5.2 Front window................................................................................................ 3-39
3.5.3 Cab door window ......................................................................................... 3-45
3.6 Cup Holder............................................................................................................. 3-46

System Functions SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator
3.7 Ash Tray ................................................................................................................. 3-46

3.8 Manual Pocket ....................................................................................................... 3-46
3.9 Drink Box ............................................................................................................... 3-47
3.10 Alternate exit ........................................................................................................ 3-47
3.11 Fire Extinguisher .................................................................................................. 3-47
3.12 Electronic Control Module.................................................................................... 3-48
3.13 Fusible Link.......................................................................................................... 3-48
3.14 Air Conditioning System....................................................................................... 3-49
3.14.1 Control panel.............................................................................................. 3-49
3.14.2 Operation method ...................................................................................... 3-55
3.14.3 Air conditioner operation precautions ........................................................ 3-58
3.15 Radio ................................................................................................................... 3-59
3.15.1 Control panel.............................................................................................. 3-59
3.15.2 Operation ................................................................................................... 3-61
3.16 Cab door catch .................................................................................................... 3-65
3.17 Lockable Caps and Covers.................................................................................. 3-65
3.17.1 Lockable caps ............................................................................................ 3-66
3.17.2 Lockable covers ......................................................................................... 3-67
3.18 Toolbox ................................................................................................................ 3-68
3.19 Grease Pump Frame ........................................................................................... 3-68
WARNING
jury or death.

3 SYSTEM FUNCTIONS
3.1 Machine general drawing
4 5 6
9
10
CC13051001-1
Fig. 3-1
1) Bucket 6) Boom cylinder

2) Bucket cylinder 7) Sprocket
3) Arm 8) Track frame
4) Arm cylinder 9) Track shoe
5) Boom 10) Track idler

3.2 Monitoring System
3.2.1 Monitor functions
The front side of the machine monitor is made

up of three sections:
A. Warning and signal indicators A

A B
B. Display screen
C. Key pad
F1 F2 F3 F4 F5
C Esc Enter
XP13031506
Fig. 3-2
Warning and signal indicators
● When a machine fault occurs, the warning

indicator lights up, reminding the user to
check and address the fault.
A B
XP13031505
Fig. 3-3

Screen display
The LCD display is where monitor items are

shown. This display is also the interface where
most monitor operations are performed. Items
on a normal operation display include:
1. Working mode indicator

2. Coolant temperature gage
Sany Hydraulic Excavator
3. Fuel level gage
1 S 1 10
4. Failure code
5. Total service hours 2
C H
6. Function icons
7. System time (Hr: Min: Sec) 3
8. Date (YY:MM:DD) E F
4 9
9. GPS signal 11/11/01 8
5 0032h25m E101 09:32:24 7
10. Engine speed level (1 to 11)
6 S AUTO
n/min
XP13032601
Fig. 3-4
Key pad
The key pad is composed of 5 function keys

and six navigation keys.
1 F1 F2 F3 F4 F5
Esc Enter
2
XP13031502
Fig. 3-5

1. Function keys
Functions of the five keys ( F1 , F2 , F3 , F4 , F5 ) are indicated by the function icons above them
on the screen.
Function keys and icons
Function key Icon Function Operation interface
S , H
Working mode selection Home page
L , B
Select the next item; Information Menu page
Go to the next page; Engine and Throttle Signal page, etc.
F1
Increase password value Password Entry page
Save System Time Calibration page, etc.
Lower monitor brightness Brightness Adjustment page

Switch between Auto idle and Non
AUTO
or Home page
auto idle
n/min n/min
Move the cursor to the right Password Entry page

F2
Enter a selected entry Information Menu page, etc.
Increase monitor brightness Brightness Adjustment page

Switch between High and Low
or Home page
travel speed
Password validation Password Entry page
F3
Confirm the validity of a password Password Entry page
and, if it’s correct, enter the de-
sired page.
Save monitor brightness Brightness Adjustment page
Go to “Fault Information” page Home page
Enter/Confirm Same as Enter
F4 Go to Brightness Adjustment page Password Entry page
Go to System Setup page Information Menu page
Go to Information Menu Home page

F5
Return to Home page, Information
Password Entry page, etc.
Menu or System Setup page
Machine Configuration Calibration
Save
page
Go to System Unlock page Lockout Information page
Table 3-1
NOTE: When no icon is displayed above a function key, this key is disabled.

2. Navigation keys
Navigation keys Function
Enter Enter/Confirm
ESC Return
Select the item above (returns to the bottom item after the top item); or increase the
value where the cursor blinks.
Select the item below (returns to the top item after the bottom item); or decrease the
value where the cursor blinks.
Move the cursor to the left (returns to the right end digit after the left end digit).
Move the cursor to the right (returns to the left end digit after the right end digit).
Table 3-2
3.2.2 Monitor operation
1. Home page
The Home page is the normal operation display of the monitor. Items on this page include:
truck load counter, working mode, speed level, coolant temperature, fuel level, service hours,
clock, fault code, etc..
Operation
Working mode selection (1)

Sany Hydraulic Excavator
● Press F1 switch between S, H. L and B
S 1
mode.
NOTE: S mode is the default working

C H
mode.
Auto-idle and Non auto-idle mode (2)
● Press F2 to switch between auto-idle and E F
Non auto-idle mode. 11/11/01

0032h25m E101 09:32:24
Auto-idle mode is indicated by AUTO
n/min
.
S AUTO
n/min
Non auto-idle mode is indicated by n/min .

XP13032602
NOTE: Auto-idle mode is the default mode.
Fig. 3-6

When neither of the joysticks are operated

for 5 seconds, the engine enters the idling
state automatically in order to save fuel
and reduce noise.
High and low travel speed (3)
● Press F3 to switch between high and low

travel speed.
High travel speed is indicated by .
Low travel speed is indicated by .
NOTE: Default travel speed is Low.
Fault Information (4)
● Press F4 to go to “Fault Information” when

a fault occurs.
NOTE: When the ECU detects an error in

the machine, a fault code will appear on
the monitor display. The tick icon on the
bottom will turn red.
Information Menu (5)
● Press F5 to go to the Password Entry

page before accessing the “Information
Menu” page.

2. Information Menu password entry
A 5-digit password is required to access the

“Information Menu”. You can ask your local
dealer to obtain this password.
Operation
1. Press F1 to change the number where the

cursor blinks in an ascending order. You
can also use or to increase or de-
Information Menu
crease the number.
2. Press F2 to move the cursor to the right.

You can also use or to move the Please enter the password
cursor to the left or to the right. ＊　＊　＊　＊　＊
NOTE: The cursor moves back to the left

end side after the right end side.
3. When all the five digits of the password

have been entered, press F3 or Enter . If the
password is correct, the display moves to
the “Information Menu” page; if not, please
try again.
XP13031501
4. Press F5 or ESC to return to the Home Fig. 3-7

page.
5. Press F4 on this page to go to Brightness

Adjustment page.

3. Information Menu
The information menu is a list of system func-

tions. On this page, you can select and access
any of the items on the list. Information Menu
Operation
Running parameter
● Press F1 to select the item below the high-
Fault information
lighted one. The highlighter returns to the
Throttle installation
top after the bottom item. You can also use
System language
and to move the highlighter up and
System time setup
down.
GPS monitoring
● Press F2 or Enter to access the selected en-
try. Engine, pump and valve parameters
● Press F5 or ESC to return to the Home

page.
XP1251203007
Fig. 3-8
● Press F4 on this page to go to the Pass-
word Entry page before accessing the Sys-
tem Setup page.
NOTE: Once an entry on the list is highlighted,

an introductory hint will appear on the bottom
of the display giving a short description of the
selected entry. These hints include:
● Running parameters of the engine, main

pup and main valve
● Fault code and description
● Throttle installation assistance
● System language selection
● System time setup
● GPS monitoring information

4. Engine & Throttle Signal
Select “Running Parameter” on the Informa-

tion Menu page and press F2 or Enter , and the
display moves to Engine & Throttle Signal Engine & Throttle Signal
page. This page is a real-time display of the
running parameter of the engine and throttle. Coolant temp °C:
Fuel level %:
Oil press kPa:
Operation
Throttle gear:
● Press F1 to go to “Pilot Pressure Signal” Eng speed rpm:
page.
Gear position V:
● Press F5 or ESC to return to the “Information Throt position V:
Menu”.
XP1251203008
Fig. 3-9
5. Pilot Pressure Signal
This page is a real-time display of the pilot

pressure signal of the hydraulic system.
Operation Pilot Pressure Signal
● Press F1 to go to “Main Pump and Main Boom UP kg:

Valve Signal” page. Boom DOWN kg:
Arm IN kg:
● Press F5 or ESC to return to the “Information Arm OUT kg:
Menu”. Bucket DIG kg:
Bucket DUMP kg:
Swing kg:
Travel L kg:
Travel R kg:
XP2051203009
Fig. 3-10

6. Main Pump & Main Valve Signal
This page is a real-time display of the main

pump and main valve signals of the hydraulic
system. Main Pump & Main Valve Signal
Operation
Pump1 press kg:
● Press F1 to go to “Engine & Throttle Sig- Pump2 press kg:
nal” page. Prop valve1 current mA:
Prop valve2 current mA:
● Press F5 or ESC to return to the “Information
Bucket confluence valve ○
Menu”.
Swing priority valve ○
Boom priority valve ○
Hi/Lo speed switch ○
XP2051203010
Fig. 3-11
7. Fault Information
Select “Fault Information” on the Information

Menu page and press F2 or Enter , and the dis-
play moves to Fault Information page. This Fault Information
page lists important machine fault information.
Current fault code:XXX
XXX:
XXX:
Operation
XXX:
XXX:
XXX:
XXX:
● Press F1 to go to the next page. XXX:
XXX:
XXX:
● Press F5 or to return to the “Information

XXX:
ESC
XXX:
Menu”.
XXX:
XXX:
XXX:
XXX:
XXX:
XXX:
XP13041501
Fig. 3-12

8. Throttle Installation
Select “Throttle Installation” on the Information

play moves to Throttle Installation page. This Throttle Installation
page displays throttle installation assistance
function.
Current gear N:
Operation Eng speed rpm: 1200 ?
● Press F2 to switch between auto-idle and Gear position V:

full speed.
Throttle position V:
● Press F3 to select high or low travel
speed.
● For machines equipped with SYFCS con- AUTO

rpm
trollers, press F4 to switch between rpm n/min
(blue) and rpm (red).

XP2051203013
● Press F5 or ESC to return to the “Information Fig. 3-13

Menu”.
NOTE: For machines equipped with SYFCS

controllers, when engine speed calibration is
not successful, a question mark will appear.
9. System Language
Select “System Language” on the Information System Language

play moves to this page.
Operation 中文系统
English Systems
● Press F2 to select 中文.
● Press F3 to select English.
● You can also use or to select a sys-

tem language on the list.
● Press F5 or ESC to return to the “Information 中文 Eng
Menu”.
XP2051203014
Fig. 3-14

10. System Time Setup
Select “System Time Setup” on the Informa-

tion Menu page and press F2 or Enter , and the
display moves to this page. You can set sys- System Time Setup
tem time on this page.
Operation Current time and time zone:
1234·12·12 12:12:12 W
● Use and to change the number
where the cursor blinks.
Setup time and time zone:
1234·12·12 12:12:12 W
● Use and to move the cursor.
● Press F1 or Enter to save adjusted time.
● Press F5 or ESC to return to the “Information Use [ ↑] [↓] [←] [→] t o adj ust syst em t i m e!
Menu”.
NOTE: When F1 or Enter is pressed, the screen

XP2051203015
displays “Setup Finished” on the bottom. If
system time has been adjusted, it cannot be Fig. 3-15
adjusted again until the system is re-ener-
gized.
11. GPS Monitoring
Select “GPS Monitoring” on the Information

Menu and press F2 or Enter to view this page.
GPS Monitoring
Longitude ° ：
Operation
Latitude °：
● Press F5 or ESC to return to the “Information Elevation m:
Speed Km/h:
Menu”.
Satellite No.:
Comm index：
Remark: S/N ratio 1： dB
S/N ratio 2： dB
● Longitude: “E” stands for “East”, while “W” S/N ratio 3： dB
for “West”. S/N ratio 4： dB
● Latitude: “N” stands for “North”, while “S”

for “South”.
XP130426011
● Altitude: “P” means “Above Sea Level”,
Fig. 3-16
while “N” means “Below Sea Level”.

● The blue-white bars show signal-to-Noise

ratio ranges from 0 to 99.
● When the altitude is nonzero and the longi-

tude and latitude is zero, it means that the
system is receiving GPS data, yet still in
the process of precise positioning.
● GPS is normal when the signal indicator

shows 1023, otherwise it is abnormal when
the signal indicator shows 615.
● When the signal indication changes to 0

from 7, a connection failure occurs either
in the SIM card or in the antenna.
● When the signal indication changes to

0 from 15, it is either because the GPS
service is not available, or the SIM card
charge is overdue, or the GPS network is
abnormal.
● When the signal indication changes to 0

from 31, it is because the monitoring cen-
ter suspends.
12. Brightness Adjustment
Press F4 on the Information Menu Password

Entry page to go to Bright Adjustment page.
This page is used to adjust monitor screen Brightness Adjustment
brightness.
Brightness: 20%
Operation
● Press F1 to decrease brightness level.

The progress bar moves to the left side.
Minimum brightness is 10%.
● Press F2 to increase brightness level. The

progress bar moves to the right side. Maxi-
mum brightness is 100%. Tips: Use F3 to save brightness value.
● Press F3 to save brightness adjustment.
● Press F5 to return to the “Information XP2051203029

Menu”. Fig. 3-17

13. System Setup password entry
Press F4 on the Information Menu page to en-

ter the Password Entry page before accessing
the System Setup page. System Setup
Operation
Please enter the password
1. For password entry method, see Informa-
tion Menu Password Entry page.

the “System Setup” page; if not, please try
again.
3. Press F5 or ESC to return to the Home

page. XP130426012
Fig. 3-18
NOTE: Contact your local dealer to obtain this

password.
14. System Setup
This page is used to set up machine configu-

ration.
Operation System Setup
● Press F1 to select the item below the high- Machine configuration

lighted one. The highlighter returns to the Service hour setup
top after the bottom item. You can also use
Machine configuration setup
and to move the highlighter up and
Hydraulic oil temperature
down.
● Press F2 or Enter to access the selected en-

try.
● Press F5 or ESC to return to the Home

page.
XP2051203016
Fig. 3-19

15. Machine Configuration password entry
Select Machine Configuration on the System

Setup list and press F2 or Enter , and the display
moves to the Password entry page before ac- System Setup
cessing the Machine Configuration page.
Please enter the password

Operation


the “Machine Configuration” page; if not,
please try again.
3. Press F5 or ESC to return to the “System XP13060801
Setup” page. Fig. 3-20
16. Machine Configuration
You can view machine configuration informa-

tion on this page.
Machine Configuraiton
Operation
● Press F5 or ESC to return to the “System Machine model：

Setup” page.
Machine No.:
Engine model:
Hydr system model:
Controller model:
XP13041502
Fig. 3-21

17. Service Hour Setup password entry
Select “Service Hour Setup” on the System

Setup list and press F2 or Enter , and the display
moves to the Password entry page before ac- System Setup
cessing the Service Hour Setup page.
Operation Please enter the password


password is correct, the display moves
to the “Service Hour Setup” page; if not,
please try again.
3. Press F5 or ESC to return to the “System

XP13060802
Setup” page.
Fig. 3-22
18. Service Hour Setup
This page is used to set up machine service

hours.
Service Hour Setup
Operation
Current service hour
● Use and to change the number
where the cursor blinks. 100 h 50 m
● Use and to move the cursor. Setup service hour
● Press F1 or Enter to save adjusted time. 100 h 50 m
● Press F5 or ESC to return to the “System

Setup” page.
Use [↑][↓][←][→] to adjust service hour!
NOTE: When F1 or ENTER is pressed, the

screen displays “Setup Finished” on the bot-
tom. If system time has been adjusted, it can- XP2051203021
not be adjusted again until the system is re-
Fig. 3-23
energized.

19. Machine Configuration Setup password

entry
Select “Machine Configuration Setup” on the

System Setup list and press F2 or Enter , and the
display moves to this Password entry page. 系统设置
Operation 请输入机器配置设定密码：


the “Machine Configuration Setup” page; if
not, please try again.
3. Press F5 or ESC to return to the “System XP13060803

Setup” page.
Fig. 3-24

20. Machine Configuration Setup
This page is used to set up machine configu-

ration after installation of the monitor.
Operation Machine Config Setup
● Press F1 to change machine model. Machine model:
● Press F2 to change engine model. Engine model:
● Press F3 to change hydraulic system Hydraulic model:

model.
Control model:
● Press F4 to change controller model.
Machine No.:
● Press F5 to save machine configura- Use[↑][↓][←][→] to set up machine number!
tion. The screen displays “Setup finished.
Mach Eng Hydr Cont
Please re-energize the system.”
● Press Enter to move the cursor between dif- XP13041503
ferent parts in the machine number. Fig. 3-25

● Use and to increase and decrease
the selected machine number by 100 each
time.
● Use and to increase and decrease

the selected machine number. One quick
pressing increase or decrease the number
by 1. Long pressing increase or decrease
the number in a quicker pace.
● Press ESC to return to the “System Setup”

page.

Remark:
The machine serial number is composed of

4 parts: 1) Production year, 2) Product code,
3) Tonnage code, 4) Alteration code, 5) Serial
number, and 6) Tail number “8”.
1) Press Enter to move the cursor to different

part (Production year, Product code and
Serial number) in the machine number.
2) When the cursor moves to Production year

and Alteration code, press and to
increase or decrease Production year and
Alteration code by 1 each time.
3) When the cursor moves to Tonnage code,

press and to increase or decrease
tonnage code by 1 each time; or press
and to increase or decrease tonnage
code by 100 each time.
4) When the cursor moves to Serial number,

press and to increase or decrease
this number by 1 each time. Long press-
ing to change the number in a quick pace.
Press and to increase or decrease
this number by 100 each time.
5) The machine number has 4 adjustable dig-

its. Use and to switch between the
four digits, and use and to change
the value on a digit. The value of the first
digit from the left could be any numbers
from 0 to 9 and any letters from A to Z; the
value of the rest three digits could only be
any number from 0 to 9. When the number
exceed 9999, capital letter from A to Z will
have to be used. A, B, C, D, E ... means
respectively 10000, 11000, 12000, 13000,
14000, 15000 .... For example: 10000 will
be written as A000; 11020 as B020, 12999
as C999.

21. Hydraulic Oil Temperature
Select “Hydraulic Oil Temperature” on the Sys-

tem Setup list and press F2 or Enter , and the
display moves to this page. Hydraulic Oil Temp
Operation
Hydraulic Oil Temp:
● Press or
F5 ESC to return to the “System
Setup” page.
XP2051203028
Fig. 3-26

22. Lockout Information (Level 1)
This display indicates that the machine has

entered lockout state (level 1).
Lockout Information
Operation
● Press F5 to enter “System Unlock” page.

Macine model:
Machine No.:
Machine state: Lockout (1)
NOTE: Contact your local dealer to unlock the Current time:
machine when the system is locked.
System locked
Contact manufacturer to unlock system
XP13041504
Fig. 3-27
30. Lockout Information (Level 2)
This display indicates that the machine has

entered lockout state (level 2).
Lockout Information
Operation
● Press F5 to enter “System Unlock” page. Macine model:

Machine No.:
Machine state: Lockout (2)
NOTE: Contact your local dealer to unlock the Current time:
machine when the system is locked.
System locked
Contact manufacturer to unlock system
XP13041505
Fig. 3-28

3.3 Switches
1 9
2 F1 F2 F3 F4 F5
12 11
Esc Enter
24V
3
4
5
6
10
CC13040207-1
Fig. 3-29
1) Start switch 7) Horn switch

2) Fuel control dial 8) Cab lamp switch
3) Work lamp switch 9) Cigarette lighter
4) Wiper switch 10) Preheat switch*
5) Washer switch 11) Charging indicator (Red)
6) Head lamp switch 12) Preheat indicator (Yellow)
*NOTE: Preheat switch is available on machines equipped with MITSUBISHI 6D34-TL and SANY
D06S2 engines.

3.3.1 Start switch
Start switch is used to start and shut down the

engine.
OFF position
This is the position for the insertion and re-

moval of the ignition key. When the key slot
points to OFF position, all devices in the elec-
trical system are power off. To stop the engine, OFF ON
EAT
turn the ignition key from ON position to OFF H
START
position.
ON position
When the ignition key is turned to ON position,

the electrical system is energized.
CC13031503
START position
Fig. 3-30
This is engine start position. To start the en-
gine, turn the ignition key to this position. Re-
lease the key once the engine is started, and it
returns to ON position automatically.
HEAT position
This is engine preheating position. Insert the

ignition key, turn and keep it at the HEAT posi-
tion to preheat the engine. It returns to OFF
position automatically once released, and pre-
heating process ends.

3.3.2 Fuel control dial
The fuel control dial is located below the start

switch. It is used to adjust engine speed and
output power. MA
X
Turn the knob clockwise to increase engine
speed, and counterclockwise to decrease en-
MIN
gine speed.
● MIN position: Low idle speed
● MAX position: Full speed

CC13031401
Fig. 3-31
3.3.3 Work lamp switch
Work lamp switch is used to turn on or turn off

the work lamp(s).
CC13040203
Fig. 3-32

Work lamp locations
Two work lamps on the boom
CZ335-1103040
Fig. 3-33
One work lamp on the right platform.
CZ335-1103041
Fig. 3-34

3.3.4 Head lamp switch
Head lamp switch is used to switch on or

switch off the lamps on top of the cab.
CC13040204
Fig. 3-35
Head lamps on top of the operator cab
CZ335-1103047
Fig. 3-36

3.3.5 Windshield wiper switch
NOTICE
● When using the wiper, press the washer
switch to spray detergent on the wind-
shield to reduce friction between the
wiper blade and the windshield.
When it is raining or when the front window is

dirty, you can press the switch to activate the
windshield wiper.
CC13040205
Fig. 3-37
Operating range
CZ335-1103044
Fig. 3-38

3.3.6 Washer switch
NOTICE
● Before pushing the button, make sure
that the front window of the cab is
closed.
Press this switch to spray cleaning detergent

onto the windshield.
It returns to its original position automatically

once released, and spray of detergent stops.
CC13040206
Fig. 3-39
3.3.7 Horn switch
The horn switch is located on top of the right

joystick. Press the button to sound the horn.
With the button depressed, the horn keeps

hooting.
CC13040209
Fig. 3-40
3.3.8 Cab lamp switch
The cab lamp is installed inside the cab. Move

the toggle-switch up and down to turn on and
off the cab lamp.
Position [a] - ON
a
Position [b] - OFF
NOTE: The cab lamp can be turned on when

b
the start switch is in the OFF position.
CC13041501-1
Fig. 3-41

3.3.9 Cigarette lighter
A cigarette lighter is installed in the cab for op-

erators who smoke.
To light a cigarette, push the lighter inward

first. Take it out of the socket when it springs
back after a few seconds and light a cigarette.
When the lighter removed, its socket can 24V

serve as a 240W (24V×10A) power source.
NOTE: The cigarette lighter is 24V. Do not use

it to power 12V devices.
CC13041502
Fig. 3-42
3.3.10 Preheat switch (If equipped)
Preheat switch is designed on machines

equipped with MITSUBISHI 6D34-TL and
SANY D06S2 engines.
This switch is used in combination with the en-

gine start switch.
● Press the preheat switch and turn the start

switch to the HEAT position to start pre-
heating process.
● Preheating continues when the start key is CC13040208

hold at the HEAT position.
Fig. 3-43
● Release the start key, and it will return to
the OFF position and engine preheating
stops.
● Turn off the preheat switch.
NOTE: Time needed for preheating may vary

according to ambient temperature. Do not heat
the engine for more than 30 seconds.
Fore more information, see "Engine Preheat-

ing" on page 4-27.

3.3.11 Preheat indicator
Preheating indicator [1] lights up when ambi-

ent temperature is low and engine preheating
is in progress. It goes out when preheating
process is over. START
X
MA
T OFF ON
HEA
MIN
3.3.12 Charging indicator
The battery charging indicator [2] lights up 1 2

when the ignition key is turned to ON position. CC13040211-1
It goes out when the engine is started and the Fig. 3-44
alternator is working. Check the alternator if
the indicator is on all the time.

3.4 Control Levers and Pedals
2
4
CC13040210-1
Fig. 3-45
1) Hydraulic lockout control 3) Left joystick

2) Travel control 4) Right joystick

3.4.1 Hydraulic lockout control
WARNING
● When leaving the operator cab, always
place the hydraulic lockout control to
the LOCKED position.
● If the hydraulic lockout control lever is

not placed in the LOCKED position, in-
advertent touching of any of the control
levers may cause serious injury or even
death.
● When moving the hydraulic lockout

control lever, be careful not to touch the
joysticks.
The hydraulic lockout control is used to lock

the work equipment controls, swing and travel
systems and the attachment (if equipped).
● LOCKED position ( ): Push the lever

downward to apply the lock. With the lock-
out lever in the LOCKED position, the ma-
chine will not move when the joysticks are
operated.
● FREE position ( ): When the lockout lever

CC13031504
is at FREE position, the machine will move
as you operate the joysticks. Fig. 3-46
When all control levers are neutralized and the

lockout lever is placed in the FREE position,
any movement of any part of your machine is
indicative of an error on the machine. In this
case, place the lockout lever to the LOCKED
position immediately, and stop the engine.
CC13030402
Fig. 3-47

3.4.2 Travel control levers
WARNING
● Accidental touching of the travel control
pedals during machine operation may
cause the machine to move suddenly,
resulting in serious accidents.
● Keep your feet off the pedal unless you

are moving the machine.
The travel control levers and pedals are used

a
to control the movement of the undercarriage
and the travel direction of the machine. N
a
a. Forward travel:
Push the control lever forward. b
N
(The pedal tilts forward)
b. Backward travel: b a
a
Pull the control lever backward.
b
(The pedal tilts backward)
b
N - (Neutral Position): The machine stops.
NOTE: When the idler wheel is behind the op-

erator cab, the travel direction is reversed as CZ335-1103054
you operate the travel control levers. Fig. 3-48

3.4.3 Joysticks
WARNING
● Accidental touching of the joysticks
will cause the machine to swing or work
equipment movement, resulting in seri-
ous accidents.
● Move the joysticks carefully before op-

eration, and check if work equipment
movement is consistent with that on the
operation mode decal.
The left and right joysticks are used to control

work equipment operation.
3
1
The joysticks will return to the neutral position
once released and work equipment movement 2
4
stops. Combined machine operation can be
performed when the joysticks are moved to-
gether or when a joystick is moved diagonally.
Left Joystick Control

CC13031505
1 Forward Arm out
2 Backward Arm in Fig. 3-49
3 Left Swing to left

4 Right Swing to right
Table 3-3
3 4
CZ335-1103056
Fig. 3-50

Right Joystick Control

5 Forward Boom down 8
5
6 Backward Boom up
7 Left Bucket in 6
7
8 Right Bucket out
Table 3-4
NOTE:
CC13031506
● When the travel controls and the joysticks Fig. 3-51
are neutralized, engine speed drops to a
moderate level even if the fuel control dial
is set at a higher speed. Engine speed
rises to previous level set by the fuel con-
trol dial when any of the control levers is
moved.
5
● If all the control levers are placed in neutral
position, the engine speed will decrease by 7 8
about 100 rpm. After about 4 seconds, the
engine will fall to the speed (about 1,400 6
rpm) set by auto-deceleration.
CZ335-1103058
Fig. 3-52

3.5 Cab Windows and Cab Door
3.5.1 Ceiling window
WARNING
● Place the hydraulic lockout control to
the LOCKED position before standing
up from the operator seat.
● Serious accidents may result if the joy-

sticks are operated by mistake when
the hydraulic lockout control is FREE.
Open
1. Secure the hydraulic lockout control to the

locked position.
CC13031403
Fig. 3-53
2. Push upward the locks [B] at both sides of

grip [A]. Hold the grip [A] and push upward
the ceiling window. B B
Close
1. Hold grip [A] and pull downward the ceiling

window. The locks [B] will be engaged au-
tomatically. CZ335-1103060
2. If the locks are not engaged properly, open Fig. 3-54

the ceiling window and try again.

3.5.2 Front window
WARNING
● Move the hydraulic lockout lever to
the LOCKED position when opening or
closing the front window.
● Serious accidents may result if the joy-

sticks are operated by mistake when
the hydraulic lockout control is FREE.
● Do not raise or lower the front window

when the machine is on a slope.
Raising the front window
1. Park your machine on a level ground, low-

er the work equipment to the ground, and
stop the engine.

locked position.
CC13031403
Fig. 3-55
3. Check that the wiper blade is stored in the

right bracket.
CZ335-1103062
Fig. 3-56

4. Hold the left and right hand grips [A] and

pull the two levers [B] to release the locks
on top of the front window.
A A
CZ335-1103063
Fig. 3-57
B
A
CZ335-1103064
Fig. 3-58
5. Hold the lower hand hold [C] with your left

hand and the upper hand hold [D] with
your right hand, and push the window up-
ward. Continue to push the window toward
D
the latch [E] in the rear of the cab till it is
locked securely.
CZ335-1103065
Fig. 3-59

CZ335-1103067
Fig. 3-60
CZ335-1103066
Fig. 3-61
6. Check the lever [B], which shall be secured

in the LOCKED position.
● Check the arrow on the catch [F], which F

shall be aligned with the arrow on lever
[B]. The lock is engaged.
● If the arrow on the catch [F] is not

aligned with the arrow on lever [B], the B
lock is not engaged. Repeat step 5 to
engage the lock.
CZ335-1103068
Fig. 3-62

Lowering the front window
CAUTION
● Close the front window slowly and do
not get your hand caught by the win-
dow.
● When closing the front window, hold

the hand grips and allow the windshield
to drop under its own weight.
1. Park your machine on a level ground, low-

er the work equipment to the ground, and
stop the engine.

LOCKED position.
CC13031403
Fig. 3-63
3. Hold the left and right hand grips [A] and

pull the lever [B] downward to release the
lock.
CZ335-1103069
Fig. 3-64

4. Hold the lower hand hold [C] with your left

hand and upper hand hold [D] with your
right hand, push the window forward and
lower the window slowly.
C
CZ335-1103070
Fig. 3-65
CZ135B-1103009
Fig. 3-66
5. When the bottom of the windshield meets

the top of bottom window, push the top of
G
the front window to engage both the left
and right latches [G] of the locks.
CZ335-1103072
Fig. 3-67

6. Check the lever [B], which shall be secured

in the LOCKED position.
● Check the arrow on the catch [F], which F

shall be aligned with the arrow on lever
[B]. The lock is engaged.
● If the arrow on the catch [F] is not

aligned with the arrow on lever [B], the B
lock is not engaged. Repeat step 5 to
engage the lock.
CZ335-1103068
Fig. 3-68
Removing bottom front window
1. Raise the front window.
2. Hold the hand grips and pull to remove the

bottom glass of the front window.
CZ335-1103077
Fig. 3-69
● Removal of the bottom glass may be diffi-

cult if sand or dust if built up at the bottom.
The sand or dust may be brought into the
cab along with the glass when storing the
glass. To avoid this, the area [A] shall be
cleaned before removing the bottom glass.
CZ335-1103078
Fig. 3-70

3.5.3 Cab door window
1. Release the lock catch before opening the

cab door window.
2. Slide the window glass back and forth to

open and close the window.
3. Make sure the lock catch is engaged after

closing the window.
CZ335-1103079
Fig. 3-71

3.6 Cup Holder
A cup holder is designed and installed below

the machine monitor.
24V
0-13004
Fig. 3-72
3.7 Ash Tray
● This tray is located above the cigarette
lighter.
● Make sure that the cigarette has been F1 F2 F3 F4 F5
extinguished before closing the ash tray

Esc
Enter
cover. 24V
0-13007
Fig. 3-73
3.8 Manual Pocket
● The pocket is on the back of the operator
seat.
● The operation manual of the machine can

be stored in this pocket for reference when
necessary.
CZ335-1103090
Fig. 3-74

3.9 Drink Box

● The box is located to the rear right of op-
erator seat. It is used to keep your drink
warm in winter and cool in summer.
● Cool or warm air is blown into the box as

per the setting of air conditioner.
0-13005
Fig. 3-75
3.10 Alternate exit
If the cab door fails to open in an emergency,

you can break the rear window with the es-
cape hammer and take it as an alternate exit.
Note:
Use the escape hammer to break the rear

window ONLY in an emergency.
CZ215-1103029
3.11 Fire Extinguisher
Fig. 3-76
NOTICE
● Read the instruction label on the extin-
guisher and understand how to use it in
case of emergency.
● Inspect the fire extinguisher periodically

and make sure it is in good condition.
● Replace the fire extinguisher if it has

expired.
A fire extinguisher is installed at the rear of the

operator cab.
CZ215-1103044
Fig. 3-77

3.12 Electronic Control Module

This machine is equipped with an Electronic
Control Module (ECM).
Note:
Be careful not to get the ECM contaminated

by water, mud or juice, which can cause fail-
ure.
Do not disassemble the ECM in case of any

failure. Contact your Sany dealer for repair.
CB13041001-1
Fig. 3-78
3.13 Fusible Link

If the start motor fails to start when the start
switch is turned to the ON position, there may
be a broken circuit in the fusible links. Open
the fuse box behind the operator seat and
check the fusible links.
NOTE:
● Fuses protect electrical equipment and

electrical wires from burning. CC13032901
● The fuse should be replaced if it is eroded, Fig. 3-79

produces white powder or becomes loose
in the fuse panel.
● Replace a blown fuse with one of the same

capacity.
● Turn the start switch to the OFF position

when replacing a fusible link.

3.14 Air Conditioning System
3.14.1 Control panel
1 2 3 4 5
6 7 8
CZ205-1203020G
Fig. 3-80
1) OFF switch 5) AUTO switch

2) Fan control switch 6) Air circulation mode switch
3) TEMP switch 7) LCD panel
4) MODE switch 8) A/C switch
1. OFF switch
This switch is used to stop the fan and the air-

conditioner.
When the OFF switch is pressed, the tempera-

ture and air flow displayed on the LCD panel
disappear, and the indicators above the AUTO
switch and the A/C switch go out, and the op-
eration stops.
OFF
CZ335-1103094
Fig. 3-81

2. Fan control switch
This switch is used to regulate the volume of

air flow, which can be set to any of six levels.
The amount of air flow is displayed on the

LCD panel.
● Press to increase the air flow.

● Press to decrease the air flow.
● The air flow changes automatically in the
automatic control mode. CZ335-1103095
LCD panel and air flow volume Fig. 3-82
LCD display Air flow volume

Low flow
Moderate flow -1
Moderate flow - 2
Moderate flow - 3
Moderate flow - 4
High flow
Table 3-5
3. TEMP switch
This switch is used to set the temperature in-

side the operator cab.
The temperature can be set between 18°C

(64.4°F) and 32°C (89.6°F).
● Press to increase temperature.
● Press to decrease temperature.
● The temperature is generally set at 25°C

(77°F). CZ335-1103096
Fig. 3-83
LCD display and function
LCD display Set Temperature

18.0 (°C) Maximum cooling
Adjust temperature inside opera-
18.5~31.5 (°C)
tor cab to selected temperature
32.0 (°C) Maximum heating
Table 3-6

4. MODE switch
This switch is used to select air outlet mode.
● When this switch is pressed, the LCD pan-

el will display the selected air outlet mode
and air will blow out from the selected
outlet(s).
MODE
● Air outlet is regulated automatically in au-
tomatic control mode.
CZ335-1103225
Fig. 3-84
Air outlet mode
Air Outlet
LCD Display Air Outlet Mode Remark
A B C D
Front ○ Disabled in auto mode
Front-Rear ○ ○
Front-Rear-Bottom ○ ○ ○
Bottom ○
Defrost-Bottom ○ ○ Disabled in auto mode
Defrost ○ Disabled in auto mode
Table 3-7
NOTE: Air comes out of the outlet identified with ○.

Air outlet location
[A]: Rear air outlets.
They are located generally behind the A

operator seat.
0-13010-2
Fig. 3-85
[B]: Front air outlet
[C]: Defrosting air outlet
0-13011-3
Fig. 3-86
[D]: Bottom air outlet
NOTE:
● The number and design of the air outlet(s)

may vary depending on machine models.
● The grill of the front, rear and defrosting D

outlet is adjustable; whereas, the bottom
air outlet is not adjustable.
CZ335-1103100
Fig. 3-87

5. AUTO switch
This switch is used to set air flow, outlets and

fresh air or circulation automatically according
to the preset temperature.
● Press the AUTO switch and the indicator

above it will light up.
● Press the AUTO switch and press the

AUTO
TEMP switch to set a suitable temperature,
and the air conditioner will run automati-
cally. CZ335-1103101
● When manual control mode, instead of Fig. 3-88

auto mode, is selected, air flow, air outlet
mode and circulation mode will have to be
set manually with the switches. The indica-
tor above the AUTO switch goes out.
NOTE:
Under automatic control mode, the air flow

may remain at HIGH if the temperature is set
at 18 °C (64.4°F) or 32 °C (89.6°F). This is not
a fault.
6. Air circulation mode switch
This switch is used to switch between fresh air

intake and air recirculation mode.
● After the switch is pressed, the indicator

above the switch lights up to indicate that
fresh air is being taken in.
● Fresh air intake and recirculation modes

toggle automatically in automatic control.
CZ335-1103102
Fig. 3-89
Mode Air recirculation Fresh air intake

Fresh air inlet is closed and air recircu-
Function Take fresh air into the cab.
lates inside the cab.
Quick heating/Quick cooling Take in clean air
Application
When external air is not clean Defrosting
Table 3-8

7. LCD display
LCD display shows preset temperature [a], air

flow [b] and air outlet mode [c] during opera- c
tion.
● When the OFF switch is pressed, the LCD

display goes off and the A/C operation
stops. a
CZ335-1103103
Fig. 3-90
8. A/C switch
This switch is used to activate and deactivate

air conditioner operation (heating, defrosting
and cooling).
● When the fan is working (LCD displays

[b]), press the A/C switch to activate the air
conditioner. The indicator above it will light A/C
up. Press this switch again to deactivate
the air conditioner. The indicator goes out.
● The air conditioner is disabled when the CZ335-1103104
fan is switched off (air flow symbol on the Fig. 3-91

LCD disappears).

3.14.2 Operation method
Automatic control
1. Press the AUTO switch.
● When the AUTO switch is pressed, the LCD

panel displays the temperature [a] and c
air flow [b]. The indicators above the AUTO
switch and the A/C switch [8] will light up.
a
2. Use the TEMP
switch to set a desired temper-
ature.
b
● Under automatic control mode, the air con-
ditioner adjusts air flow volume, air outlet
CZ335-1103103
mode and air circulation mode automati-
cally according to the preset temperature. Fig. 3-92
NOTE:
When air outlet is in Front-Rear-Bottom mode

[d] or Bottom mode [e], and engine coolant
temperature is low, the air flow will be restrict- d e
ed to prevent cool air from blowing out.
CZ335-1103107
Fig. 3-93
Stop AUTO operation
● Press the OFF switch to stop automatic op-

eration.

Manual control
1. Press the switch to adjust air flow.

Check the temperature [a] and air flow [b] c
displayed on the LCD display.
2. Press the A/C switch.
3. Press the switch to set the internal tem-

TEMP
a
perature of the operator cab.
b
4. Press the MODE switch to select an air outlet
mode. The selected mode is displayed at [c]
on the LCD panel. CZ335-1103103
Fig. 3-94
5. Press the or switch to select the
recirculation or fresh air intake mode.
Stop manual operation
Press the OFF switch to stop the manual op-

eration.
Bi-Level mode
In order to direct cooling air to your face and

warm air to your feet, observe the following
procedures:
1. Press the switch to adjust the air flow.

Check the temperature and air flow dis-
played on the LCD display.
2. Press the MODE switch and select the Front-

Rear-Bottom outlet mode.
3. Press the A/C switch. CZ335-1103226
4. Press the switch, the switch and the

TEMP
Fig. 3-95
or switch to set these features as
desired.

Defrosting operation
1. Press the switch to set air flow volume.

Check the temperature [a] and air flow [b] c
displayed on the LCD panel.
CZ335-1103103
Fig. 3-96
2. Press the MODE switch and select the Defrost

mode [f] or Defrost-Bottom mode [g].
f g
CZ335-1103109
Fig. 3-97
3. Press the switch and select fresh air
intake.
4. Press the switch and set the tempera-

TEMP
ture on the LCD panel to maximum (32°C).

3.14.3 Air conditioner operation precautions
● When running the air conditioning system, always start with the engine running at a low
speed. Avoid starting the air conditioner when the engine is running at a high speed, or pos-
sible damage to the air conditioner may result .
● If water should get on control panel or sunlight sensor, an unexpected failure may result. Al-
ways keep these components clear and free from water. In addition, keep these components
away from naked flame.
● For the auto function of the air conditioner to work properly, always keep the sunlight sensor
clean and free from debris, or it will influence the function of sunlight sensor.
Ventilation
● When the air conditioner has been operating for hours, the "fresh air/recirculation mode" shall
be switched to "fresh air mode" every hour for ventilation.
● If you smoke when air conditioner is running, the smoke may hurt your eyes. In this case, the
"fresh air/recirculation mode" shall be switched to "fresh air mode" in order to eliminate the
smoke through continuous cooling.
Temperature control
● When the compressor is working, set the temperature (5 or 6°C (9 or 10.8°F) above outdoor
temperature) that just makes you feel cool after entering the cab. This temperature difference
is considered as the most healthy temperature. Therefore, the temperature shall be adjusted
properly.
Inspection and maintenance of air conditioned machine
● When checking and maintaining the air conditioned machine, follow the instructions in the
Maintenance section.
● When the air conditioner has not been used for a long time, it is necessary to often run the
engine at low speed and conduct cooling, dehumidifying and heating operations for several
minutes in order to prevent loss of oil film on each component.
● The air conditioner will not work if the internal temperature of cab is low. You can circulate
fresh air into the cab so as to increase the temperature. Switch on the air conditioner again to
make it work.

3.15 Radio
3.15.1 Control panel
6 5 4 3 2 1
PRESET STATION SANY
1 2 3 4 5 6 AS/PS AM/FM TIME SEL
TUNING TIME ADJ VOL

ST
AM
FM
H M ADJ - +
7 8 9 10
CZ335-1103111
Fig. 3-98
1) Power switch 6) Preset buttons

2) Sound effect selector (SEL) 7) LCD display
3) TIME button 8) Tuning buttons
4) FM/AM selector 9) Time adjustment buttons
5) AS/PS button 10) Volume control
Power switch [1]
● Press to turn on the radio. The frequency is shown on the LCD display [7]. Press this
switch again to turn off the radio.
SEL (sound effect selector) [2]
● Press the button to select a sound effect from VOL (volume), BAS (bass), TRE (treble)
SEL
and BAL (balance). Sound effect is displayed on the LCD panel.
● The LCD returns to frequency display when no operation is done within 5 seconds.
TIME button [3]
● When the radio is on, the LCD displays system time once the TIME
button is pressed. The LCD
returns to frequency display after 5 seconds.
● Keep the TIME

button pressed for more than 5 seconds to display the region code. (ASA and
EU)

FM/AM selector [4]
Press the FM/AM

button to switch between FM and AM.
AS/PS button [5]
The button is used for automatic scanning of saved radio stations and automatic search-
AS/PS
ing of radio stations.
● Automatic scanning:
Turn on the radio and press the button. The radio starts automatic scanning of the previ-
AS/PS
ously saved radio stations. Each of the preset stations is tuned in for 10 seconds, with the
number of the radio station displayed on the LCD.
To tune in one of the save stations, press the AS/PS

button.
● Automatic searching of radio stations:
Turn on the radio and press the button for 2 seconds. The radio starts an automatic
AS/PS
searching of radio stations within the present wave band. The first 6 radio stations with good
reception are saved in the radio memory.
Preset stations [6]
● Press any of the 6 preset station buttons to tune in one of the preset station.
● This function is available only when there are saved radio stations in the radio memory.
LCD display [7]
Wave band, radio frequency, preset numbers and time are displayed on the LCD display.
TUNING buttons [8]
Press and to decrease and increase radio frequency on the LCD display.
TIME ADJ (time adjustment) buttons
Radio time is reset using the time adjustment buttons: H , M and ADJ .
H : Hour adjustment
M : Minute adjustment
ADJ : Set to zero.
VOL (volume control)
● VOL buttons [10] are used to control radio volume.
● Press to raise radio volume up to 40.
● Press to lower radio volume up to 0.
● The LCD returns to frequency display when no operation is done within 5 seconds.

3.15.2 Operation
Presetting radio station
1. Press to turn on the radio. Radio fre-

quency is displayed on the LCD [7].
6 2 1
2. Press or to locate the desired fre-
quency. There are two tuning ways: manu- PRESET STATION SANY
al and automatic. 1 2 3 4 5 6 AS/PS AM/FM TIME SEL
TUNING TIME ADJ VOL

ST
3. When desired frequency is shown on the AM
FM
H M ADJ - +
display [7], depress one of the preset but-
tons for at least 1.5 seconds. The voice will 7 8
disappear. But the voice will come back
when the presetting operation (storing to CZ335-1103112
the memory) is completed. The preset but-

Fig. 3-99
ton number and the frequency will be dis-
played, indicating the completion of preset-
ting operation. After presetting the stations,
press one of the preset buttons (6) for at
least 1.5 seconds in order to tune in the
preset station.
NOTE: The button can be used to preset

AS/PS
the stations automatically.
Searching radio station
1. Press to turn on the radio. Radio fre-

quency is displayed the LCD [7].
2. Press or to locate the desired fre-

quency. There are two tuning ways: manual
and automatic.
Manual tuning
Press the tuning buttons [8] till the frequency

appears on the display [7].
: Decrease radio frequency

: Increase radio frequency
When the frequency reaches its maximum or

minimum limit, it will cycle in the order of max-
min or min -max.

Automatic tuning
Depress one of the tuning buttons [8] will ac-

tivate automatic scanning of radio stations.
When any station is found, the tuning stops.
To scan next station, depress one of the tuning
buttons [8] again.
: Decrease radio frequency

: Increase radio frequency
If this button is pressed during automatic tun-

ing, automatic tuning will be cancelled. The
setting returns to the previous frequency be-
fore the button is pressed.
Sound effect adjustment
● BAS: Press the button and select BAS.

SEL
Within 5 seconds, press or to adjust

BAS value between +7 and -7.
● TRE: Press the button and select TRE.

SEL

TRE value between +7 and -7.
● BAL: Press the button and select BAL.

SEL

BAL value between L9 and R9. BAL.0
means that the left and right sound track
are balanced.
NOTE:
Sound effect mode returns to show previous

setting if no operation is done within 5 sec-
onds.

Radio time adjustment
1. Press the button [3] to display radio

TIME
time on the LCD. The display will return to

radio frequency after 5 seconds. 3
2. When radio time is displayed on the LCD, PRESET STATION SANY
press H or M to select Hour or Minute. 1 2 3 4 5 6 AS/PS AM/FM TIME SEL
TUNING TIME ADJ VOL

ST
AM
H : Hour adjustment FM
H M ADJ - +
(Hour goes up by 1 with each press) 9
M : Minute adjustment
CZ335-1103113
(Minute goes up by 1 with each press)
Fig. 3-100
Keep orH Mpressed, Hour or Minute will
keep going till the button is released.
ADJ is used for precision adjustment:
● Press ADJ when Minute reading is be-

tween 00 and 05 to decrease Minute to
zero. (Hour reading does not change)
● Press ADJ when Minute reading is be-

tween 55 and 59 to increase Minute to
zero. (Hour reading increases by 1)
● When Minute reading is between 06

and 54, neither Hour nor Minute read-
ing changes when ADJ is pressed.
Example:
10:05→10:00
10:59→11:00
10:26→10:26

Antenna
A fully extended radio antenna may collide

with other overhead objects. To prevent an-
tenna damage, retract it before moving the
machine into or out of a building.
1. Loosen the mounting bolt [1] and retract 1

the antenna to position [A].
A
2. Fasten the bolt [1] after retracting the an-
tenna.
CZ335-1103114
Radio operation precautions
Fig. 3-101
● Keep radio volume at a proper level so that
you can hear the outside sound during op-
eration.
● Water penetration may cause dysfunction

of the loud speaker and the radio. Be care-
ful not to splash water on the radio.
● Do not use benzol, diluent or other solvent

to clean the control panel and the buttons.
Soft dry cloth shall be used for cleaning. If
the device is too dirty, wipe it with alcohol-
soaked cloth.
● Preset stations and radio time setup will be

cleared when the battery is disconnected.
Radio setting need to be done once again.

3.16 Cab door catch
CAUTION
● Park the machine on a level ground be-
fore releasing the cab door catch.
● Do not release the door catch when the

machine is on a slope. The door may
shut suddenly and cause injury.
● Do not expose your body or hand out

of the cab or put your hand on the door
frame before releasing the door catch.
The door may shut suddenly and cause
injury.
Fasten the door to the door catch after open-

ing it.
1. Move the cab door toward catch [1] until it

engages with the catch.
2. When closing the door, press lever [2] to

the left of the operator seat to release the 1
catch [1].
2
CZ335-1103082
Fig. 3-102
3.17 Lockable Caps and Covers
The filler caps of the fuel tank, the cab door,

the engine hood and the access covers of the
machine are all lockable. Use the engine igni-
tion key to lock and unlock these places.
● Always insert the key to its shoulder [A].
● The key may break if it is turned before

fully inserted.
A
CZ335-1103083
Fig. 3-103

3.17.1 Lockable caps
NOTICE
● Make sure the key slot is covered after
removing the key. Otherwise, invasion
of foreign objects may block or even
disable the lock.
● Lock the filler cap after is has been fully

screwed on; otherwise, the lock may be
damaged.
● Always keep the sealing in the filler cap

clean. Metal chips or sands on the seal-
ing may cause fuel leakage.
Unlocking
1. Slide off cover [1] to expose the key slot.

1
2. Insert the ignition key into the slot. 2
3. Turn the key clockwise to mark A on the

cap to unlock the cap [2].
B
Position [A]: Unlock
A
Position [B]: Lock
CZ215-1103001
Fig. 3-104
Locking
1. Screw on the cover [2] tightly and insert 1

the ignition key into the key slot.
2. Turn the key to LOCK position [B], and

then remove the key.
3. Slide cover [1] onto the key slot. B
CZ215-1103002
Fig. 3-105

3.17.2 Lockable covers
Unlocking
1. Insert the ignition key into the key slot.
2. Turn the key counterclockwise to unlock A

the cover and open it by the handle.
Position [A]: Unlock

Position [B]: Lock
Locking
1. Shut the cover properly and insert the key. B
2. Turn the key clockwise to position (B) and CZ335-1103085
remove the key. Fig. 3-106

3.18 Toolbox
Store tools in this box.
CZ205-1203022G
Fig. 3-107
3.19 Grease Pump Frame

The grease pump frame is inside the access
door at the left rear part of the machine. When
the grease pump is not in service, place it on
the frame.
CZ335S-1103048
Fig. 3-108

E
G
PA
K
AN
BL

E
G
PA
K
AN
BL

SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator Operation
Operation
4 Operation
4.1 Before Starting the Engine....................................................................................... 4-5
4.1.1 Walk-around inspection ................................................................................. 4-5
4.1.2 Inspection before starting............................................................................... 4-7
4.1.2.1 Water and sediment in fuel tank - drain ................................................ 4-7
4.1.2.2 Water and sediment in water separator - check/drain .......................... 4-8
4.1.2.3 Hydraulic oil level - check/refill ............................................................ 4-9
4.1.2.4 Coolant level - check/refill ................................................................... 4-10
4.1.2.5 Oil level in oil pan - check/add .............................................................4-11
4.1.2.6 Electric wires - check .......................................................................... 4-13
4.1.2.7 Fuel level - Check and add ................................................................. 4-14
4.1.2.8 Work lamp switches - check ............................................................... 4-16
4.1.2.9 Horn - check........................................................................................ 4-16
4.1.3 Adjustment before operation ........................................................................ 4-17
4.1.3.1 Operator seat adjustment ................................................................... 4-17
4.1.3.2 Rear view mirrors ................................................................................ 4-19
4.1.3.3 Seat belt .............................................................................................. 4-21
4.1.4 Operation before engine startup .................................................................. 4-22
4.2 Engine Startup ....................................................................................................... 4-24
4.2.1 Engine Preheating ...................................................................................... 4-27
4.2.2 Warm-up operation ...................................................................................... 4-28
4.3 Engine Shutdown................................................................................................... 4-29
4.4 Machine Operation ................................................................................................ 4-30
4.4.1 Before moving the machine ......................................................................... 4-31
4.4.2 Move the machine........................................................................................ 4-32
4.4.3 Stopping the machine .................................................................................. 4-33
4.5 Machine Turning .................................................................................................... 4-34

Operation SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator
4.5.1 Direction change when the machine is stopped ......................................... 4-34

4.5.2 Pivot turning ................................................................................................. 4-36
4.6 Work Equipment Control........................................................................................ 4-37
4.7 Restricted Operations ............................................................................................ 4-39
4.7.1 Operation with swinging force ...................................................................... 4-39
4.7.2 Operation with traveling force ...................................................................... 4-39
4.7.3 Operation when hydraulic cylinder reaches its stroke end ......................... 4-40
4.7.4 Operation with bucket landing force............................................................. 4-40
4.7.5 Hard rocky ground ...................................................................................... 4-40
4.7.6 Operation with machine weight .................................................................... 4-41
4.7.7 Sudden shift of control levers/ pedals ......................................................... 4-41
4.8 Permissible depth of water .................................................................................... 4-42
4.9 Traveling on a Slope .............................................................................................. 4-43
4.9.1 Traveling downhill ....................................................................................... 4-44
4.9.2 When engine stalls on a slope ..................................................................... 4-44
4.9.3 Cab door on a slope..................................................................................... 4-44
4.10 Escaping from Mud .............................................................................................. 4-45
4.10.1 When one track is trapped ......................................................................... 4-45
4.10.2 When both tracks are trapped.................................................................... 4-45
4.11 Recommended Application .................................................................................. 4-46
4.11.1 Backhoe operation ..................................................................................... 4-46
4.11.2 Trenching work ........................................................................................... 4-47
4.11.3 Loading operation ...................................................................................... 4-47
4.12 Parking................................................................................................................. 4-48
4.13 Post-operation Inspection .................................................................................... 4-51
4.14 Locking ................................................................................................................ 4-52
4.15 Operation in Cold Weather .................................................................................. 4-53
4.15.1 Fuel and lubricant ...................................................................................... 4-53
4.15.2 Coolant....................................................................................................... 4-53
4.15.3 Battery........................................................................................................ 4-53
4.15.4 After operation in cold weather .................................................................. 4-54
4.15.5 After cold season ....................................................................................... 4-55
4.16 Long-Term Storage .............................................................................................. 4-55
4.16.1 Before storage ........................................................................................... 4-55
4.16.2 During storage ........................................................................................... 4-56
4.16.3 After storage............................................................................................... 4-56
4.16.4 Engine startup after long-term storage ...................................................... 4-56
4.17 Transportation Information ................................................................................... 4-57

4.17.1 Transport methods ..................................................................................... 4-57

4.17.2 Loading and unloading .............................................................................. 4-57
4.17.2.1 Loading ............................................................................................. 4-58
4.17.2.2 Securing the machine ....................................................................... 4-61
4.17.2.3 Unloading .......................................................................................... 4-63
4.17.2.4 Lifting the machine ............................................................................ 4-65

WARNING
jury or death.

4 OPERATION
4.1 Before Starting the Engine
4.1.1 Walk-around inspection
WARNING
● Remove flammable materials on the battery, engine, muffler, turbocharger and other
components that heat up during machine operation.
● The leak of oil or fuel may cause the machine to catch on fire.
Check and clean the following items each day before starting the engine:
1. Check the work equipment, cylinders, arms and hoses for cracks, excessive wear or loosen-
ing. Repair it in case of any problem.
2. Remove the dirt and debris around the engine, battery and radiator.
Check the surrounding of engine and radiator for buildup of dirt. Check the surrounding of
muffler, turbo charger or other hot components for flammable materials like dry leaves and
thin branches. Remove them if any dirt or flammable materials are found.
For method of removing dirt from radiator, see "Radiator and oil cooler fins - inspect/clean" on
page 5-59.
Check for any leaks of coolant or oil around the engine.
Check the engine for leak of oil. Check the cooling system for leak of coolant. Repair it in case
of any problem.
3. Check the hydraulic unit, hydraulic tank, hoses and joints for any leaks of oil.
Check for oil leaks. Repair the leaks if any.
4. Check the undercarriage (track, sprockets, tension rollers and guards) for damage, wear,
loose bolts or roller leakage.
Correct the problem if any.
5. Check the handholds and step for any problem like loose bolts.
Repair it in case of any problem. Tighten the loose bolts.
6. Check the gauges and monitor.
Check the gauges and monitor in operator compartment. Change the parts or components in
case of any problem. Clean their surfaces.

7. Clean and check rear mirrors
Clean and check the rear mirrors for any damage. Repair it in case of any damage. Clean the
mirrors and adjust their positions so that the area behind the machine could be seen clearly
from operator’s seat.
8. Check the safety belt and holds for damage or wear. Replace it with a new one in case of any
damage.
9. Check the bucket with hook (if equipped) for any damage.
10. Check the hoisting hook, guide plate and hook seat for any damage. Contact your Sany deal-
er for repair in case of any problem.

4.1.2 Inspection before starting
The items in this section must be checked ev-

ery day before starting the engine.
4.1.2.1 Water and sediment in fuel tank -

drain
1. Open the right access door of the machine.
2. Place a suitable container under the drain

hose [1].
3. Open the drain valve [2] to drain the sedi-

ment, water and fuel from fuel tank.
2
4. When clean fuel is seen, turn off the drain
valve [2].
1
5. Shut the access door.
CZ215-1203001X
Fig. 4-1

4.1.2.2 Water and sediment in water sepa-

rator - check/drain
1. Open the access cover on the right side of

the machine.
2. Check water level and volume of sediment

through the transparent cover [1]. If water
or sediment is built up at the bottom, place 1
a container under drain hose [3] to receive
drainage.
3. Open drain valve [2] to discharge water. 2

3
4. Close drain valve [2] once fuel is seen
coming out of drain hose [3]. CC13040701
Fig. 4-2
NOTE:
● If cover [2] is dirty and opaque, clean it

when replacing fuel filter element [1].
● When the drain valve [3] has been re-

moved during cleaning, its O-ring [4] must
be greased and the valve must be tight-
ened till it contacts the bottom.
CC13040702
Fig. 4-3

4.1.2.3 Hydraulic oil level - check/refill
CAUTION
● Engine oil and components are still hot
and may cause burns after the engine
has been just shut down. Wait for them
to cool down before working on them.
● Before removing the filler cap, turn it

slowly to release internal pressure.
1. Adjust the work equipment to the position

shown in the right illustration. Stop the en-
gine. CC13041001-1
Fig. 4-4
2. Operate the joysticks and travel control
levers in all directions 15 seconds after en-
gine shutdown to release internal pressure.
3. Open the access door on the right side to

F
check the oil level gauge (G).
● Cold state: (Oil temperature: 10~30°C or

50~86°F) G
L+12.5~L+32.5
P
● Hot state: (Oil temperature: 55~80°C or
131~176°F)
Higher than the mid-mark. CZ335-1103126
4. If oil level is below the L mark, add oil Fig. 4-5

through the filler opening (F) on top of the
hydraulic tank.
Recommended oil: Caltex anti-wear

hydraulic oil HDZ46 (B420106000036)
Hydraulic tank capacity: 380L H
Note:
Do not add oil to a level above the H mark. If

the oil level is above the H mark, stop the en-
L
gine and wait for the oil to cool down. Place
a container under the drain plug (P) beneath
the hydraulic tank and discharge excessive oil CZ335-1103127-1
from the tank via the drain plug. Fig. 4-6

4.1.2.4 Coolant level - check/refill
CAUTION
● The coolant is hot and the radiator is
under high pressure upon shutdown of
the engine. Removing the radiator cap
1
(1) at the moment may cause burns.
● Do not remove the cap until coolant

temperature has dropped.
● Turn the filler cap slowly to release in-

ternal pressure.
0-13013
The coolant level must remain between the Fig. 4-7

upper and lower limits marked on the reserve
tank (2) when the engine is running. If coolant
level is below the lower limit, add coolant to
the radiator as well as to the reserve tank.
1. Open the rear door on the left side of ma-

2
chine and check the level of coolant in the FULL
reserve tank [2]. If coolant level is low, add LOW
coolant to FULL position through the filler
opening of the reserve tank [2].
2. Tighten the cap after refilling the tank.
3. An empty reserve tank [2] might be caused

by coolant leakage. Correct the fault im-
0-13014
mediately after inspection. If no problem
has been found, check coolant level in the Fig. 4-8
radiator. Add coolant to reserve tank [2] if
its level is low.
4. If reserve tank [2] is dirty inside and the

level cannot be seen clearly, clean the
tank. For more information, see "Cooling
system interior - clean" on page 5-82.

4.1.2.5 Oil level in oil pan - check/add
CAUTION
● Engine oil and components are still hot
and may cause burns after the engine
has been just shut down. Wait for them
to cool down before working on them.
G
1. Open the engine hood.
2. Take out oil dipstick (G) and wipe the oil off
the dipstick with cloth.
3. Insert the dipstick (G) to bottom and then

pull it out.
0-13015
Fig. 4-9
4. Oil level should be between the H and

L marks on dipstick (G). Add oil through
opening (F) if oil level is below the L mark.
Recommended oil: Caltex CH-4 15W-40
L H
CZ335-1103131
Fig. 4-10
0-13016
Fig. 4-11

5. If oil level is above H mark, the drain

valve (P) on the bottom of oil pan is to be
opened to discharge extra oil. Check oil
level again.
6. Tighten the filler opening cap and properly

close the engine hood if oil level is normal.
NOTE:
● If you need to check oil level after opera-

P
tion of the engine, shut off the engine and
wait at least for 15 minutes before check- CZ335S-1103057
ing.
Fig. 4-12
● If the machine is on a slope, move it to a
level ground prior to inspection.

4.1.2.6 Electric wires - check
NOTICE
● If fuses blow frequently or any short
circuits are detected in the system, in-
vestigate the cause and make repairs,
or contact your Sany dealer.
● Keep battery surface clean and check

the vent on battery cover. Flush the
cover to clean the vent if the vent is
blocked by dirt or dust.
Check whether the fuse is damaged; whether

the fuse with proper capacity is used; whether
any wire connection is off; whether wire sheath
is broken.
Check for loose terminals. Fix it if any.
Moreover, pay special attention to electric

wires when checking battery, engine, start
motor and alternator. Make sure to check for
flammable materials around battery. Immedi-
ately remove them if any.

4.1.2.7 Fuel level - Check and add
WARNING
● Be careful not to splash fuel on the tank
when filling the fuel tank to reduce fire
risk.
● Clean splashed fuel completely if any.

Remove contaminated earth or sand if
fuel flows onto the ground.
● Fuel is flammable and dangerous. No

open fire is allowed in the vicinity of
fuel.
1. Turn the engine start switch to the ON

position and check the fuel level on the
monitor screen. Turn the switch to the OFF
position after checking.
E F
CZ215-1303002
Fig. 4-13
2. When fuel level is low, remove the fuel tank

cap (F) and fill the tank till the float meter F
(G) reaches the highest point.
● Fuel tank capacity: 340L
● When the fuel tank is full, top (a) of the

float level meter (G) is positioned at about
50mm.
● When fuel level is below 10%, alarm on the

monitor will sound. CZ335-1103134
Fig. 4-14

3. Press down the float meter (G) with the

fuel tank cap (F). Make sure that the float F
meter is not stuck on the cover plate of
filler cap. Screw on the filler cap. a
CZ335-1103135
NOTE: Fig. 4-15

● Pressure in the fuel tank may drop if the
vent hole on the cap is blocked, which
may hinder the flow of fuel. Clean the vent
whenever necessary.
● Lock the filler cap after is has been fully

screwed on; otherwise, the lock may be
damaged.
● Always keep the sealing in the filler cap

clean. Metal chips or sands on the sealing
may cause fuel leakage.
CZ335-1103136
Fig. 4-16

4.1.2.8 Work lamp switches - check
Check the work lamps for normal functioning.
Check for any dirt or damage.
If any lamp does not work, the bulb may be

burned or broken circuit may be present. Con-
tact your Sany dealer for repair.
1. Turn the start switch to the ON position.
2. Switch on the work lamp switch and check

CC13040203
if the lamps light up.
Fig. 4-17
4.1.2.9 Horn - check
2. The horn sounds immediately when the

horn button is pressed. Make sure that the
horn sounds normally. In case of dead horn
or abnormal sound, contact your Sany
dealer for repair.
CC13040209
Fig. 4-18

4.1.3 Adjustment before operation
4.1.3.1 Operator seat adjustment
It is necessary to adjust seat position before D

operating or after changing operator.
Adjust the seat so as to enable the operator

to easily manipulate the control levers, pedals
and switches from the seat.
(A) Forward and backward adjustment
Pull the lever [1] upward, slide the seat to E

desired position, and release the lever.
Adjusting length: 200mm (10mm per step) A
C
(B) Adjust the seat forward and backward
as a whole
Pull the lever (2), slide the seat to desired

position, and release the lever. In this case,
the operator seat moves along with both 1
armrest boxes and pilot lockout lever.
3 2 4
B CZ335-1103139
(C) Suspension adjustment (if equipped)
Fig. 4-19
Turning the lever (3) counterclockwise will
bring you a hard suspension which is suit-
able for heavy operator; turning the lever (3)
clockwise will bring you a soft suspension
which is suitable for light operator.
NOTE:
To achieve the best adjustment, adjust the

reading (kg) on dial (4) to weight of operator.

(D) Backrest adjustment
Lift lever (5), move the backrest to an

optimum position at where operation can
be easily conducted, and release the lever.
Do not allow the backrest to interfere with

the cover plate of air conditioner behind it.
Be careful with the control levers, which 5
shall not be touched by armrest.
CZ335-1103140
Fig. 4-20
(E) Armrest angle adjustment
Turning the plate (7) beneath armrest (6) 6

can adjust the angle of armrest to desired
position.
The armrest can be placed vertically so

that the operator can leave the seat easily. 7
Adjustable angle: 40°
CC13031516
Fig. 4-21

4.1.3.2 Rear view mirrors
CAUTION
Adjust the rear view mirrors before opera-
B A
tion. Failure to do so may cause poor vis-
ibility, resulting in personal injury.
Rear mirror (A)
Adjust installation of rear mirror (A) so that

people to rear left of machine can be seen
clearly.
CZ335-1103142
● Install rear mirror (A) to the position as Fig. 4-22
shown in the right illustration.
● Turn the fixing rod [1] around the handrail

to a suitable position and fix rod [1].
● If the mirror cannot move smoothly, you

2
may loosen bolt [2] and bolt [3] to release
the mirror.
Torque of bolt (2): 4.0~5.4 N·m {0.41~0.55

kgf·m}
1
CZ335-1203005G
Fig. 4-23
● Adjustment of rear mirror is accomplished

when side of machine can be seen in the
mirror, as shown in the right illustration.
CZ335-1203006G
Fig. 4-24

Rear mirror (B)
Adjust installation of rear mirror (B) so that

people to rear right of machine can be seen
clearly.
● Install rear mirror (B) to the position as

● When adjusting mirror angle, if the mirror 4

cannot move smoothly, you may loosen
bolt [4] and bolt [5] to release the mirror.
5
Torque of bolt (5):
4.0~5.4 N·m {0.41~0.55 kgf·m} CZ335-1203008G
● Adjustment of rear mirror is accomplished Fig. 4-25

when side of machine can be seen in the
mirror, as shown in the right illustration.
CZ335-1203009G
Fig. 4-26

4.1.3.3 Seat belt
WARNING
● Check the condition of the seat belt and
the buckle before you fasten it. Replace
the belt if excessive wear or damage is
observed.
● Replace the seat belt every 3 years re-

gardless of its condition.
● Be sure to fasten your seat belt during

machine operation.
● Do not twist the seat belt.
Buckle up and release
The seal belt has a coiler, and belt length

needs no adjustment.
1. Buckle up
4 3 2 1
Hold clip [2] and pull the belt out of coiler [1].
Check that there is no twist on the belt and
insert catch [3] into buckle [4].
SS
PRE
Check if the belt has been fastened by

pulling it slightly.
CZ335-1103147
Fig. 4-27
2. Release
Press button on buckle [4] to release catch

[3]. The belt will retract into the coiler
automatically.
Hold clip [2] so that the belt retract slowly

into the coiler.

4.1.4 Operation before engine startup
WARNING
● Before starting the engine, check if the
hydraulic lockout control is secured in
● If the hydraulic lockout control is not in

the LOCKED position, accidental touch-
ing of control lever or pedal when start-
ing the engine may lead to unexpected
movement of machine, which may
cause serious accidents.
● When rising from the operator seat,

make sure the hydraulic lockout lever
is in the LOCKED position, whether the
engine is running or not.
1. Check if the hydraulic lockout lever is in

2. Check if all control levers and pedals are

neutralized. They shall remain in NEU-
TRAL position if not operated.
CC13031403
Fig. 4-28
ON
OFF
STA
T
HEA
RT
CC13031804
Fig. 4-29

4. Check the condition of the machine

through the gauges on the monitor display..
NOTE:
● When a fault arises, the alarm indicator will

light up.
● If a fault code is displayed on the monitor,

check the fault immediately.
● If no fault code appears, the alarm indica-

tor may light up because:
coolant temperature is too high; or
engine oil pressure is too high or too low.

4.2 Engine Startup
WARNING
● Only start the engine from the operator
seat.
● Never start the engine by shorting the

starter circuit, which may cause serious
injury or fire.
● Sound the horn and start the engine

after confirming that the machine sur-
roundings are clear of personnel or ob-
stacles.
● Never use any aerosol starting aid,

which may cause an explosion.
● Exhaust gas is poisonous. Provide ad-

equate ventilation when starting the en-
gine in a confined space.
● Before starting the engine, check if the fuel

control dial is in MIN position for low idling
speed. If it is in MAX position, starting the START X
engine can lead to sudden acceleration MA
ON
and machine damage.
OFF
AT
HE
MIN
CC13031502
Fig. 4-30
1. Check that the hydraulic lockout lever is in
the LOCKED position. If it is in the FREE
position, do not start the engine.
CC13031403
Fig. 4-31

2. Turn the fuel control dial to the MIN posi-

tion.
MA
X
MIN
CC13031401
Fig. 4-32
NOTE:
ON
OFF
When ambient temperature is below 10°C,
STA
T
heat the engine before startup. HEA
RT
CC13031804
Fig. 4-33

4. Turn the start switch to the START position

and start the engine.
ON
OFF
STA
T
HEA
RT
CC13031801
Fig. 4-34
5. Release the switch when the engine is

started. It returns to ON position automati-
cally.
ON
Note: OFF
STA
T
HEA
RT
● When ambient temperature is low, the en-
gine may fail to start after the start switch
is kept at START position for more than 10
seconds. In this case, wait at least for 1
minute before restarting the engine.
CC13031802
Fig. 4-35
6. When the engine is started, do not operate

any control lever or pedal until oil pressure
is within normal operating range.
Note:
● If oil pressure remains abnormal after four

or five minutes, shut down the engine and
check oil level. Take necessary actions in
case of oil leakage.

4.2.1 Engine Preheating
When ambient temperature is below 10°C,

heat the engine before startup.
Preheating procedures are different depending

on the engine equipped on the machine.
Machines equipped with MITSUBISHI 6D34-

TL and SANY D06S2 engines
● Turn the fuel control dial to MIN position,
and turn on the preheat switch [1]. Turn the
engine start switch to the HEAT position.
When preheating indicator [2] lights up, en- START
X
MA
gine preheating begins.
N
T OFF O
HEA
Preheating takes from 10 to 30 seconds
MIN
depending on ambient temperature:
Temperature (°C) 0~10 -10~0 <-10

2 1
Preheating time 10s 20s 30s
CC13040301
● Do not preheat the engine for more than Fig. 4-36

30 seconds. Try starting the engine when
preheating process is over. Switch off the
preheat switch when the engine is started.
Machines equipped with ISUZU engines
● No preheat switch is designed on ma-

chines that are equipped with ISUZU en-
gines.
● Turn the fuel control dial to MIN position,
and turn the engine start switch to the ON
position. When preheating indicator lights
up, engine preheating begins.
● When heating process is over, turn the

start switch to the START position in order
to start the engine.
● If the engine fails to start, wait for one min-

ute at minimum and repeat the preheating
and startup procedure.

4.2.2 Warm-up operation
WARNING
● Insufficient warm-up of the machine may cause slow response or abrupt movement
during operation, resulting in serious accidents. Warm-up is especially necessary in
cold areas.
● Do not accelerate the machine suddenly before warm-up process is finished.
● Do not continuously run the engine at low or high speed for more than 20 minutes,
which may cause leaks in the oil supply pipe of the turbocharger.
● If the engine has to be run at idle speed, add load to it or run it at a moderate speed.
● In case of emergency, abnormal running of engine, or other faults, turn the start switch key to
OFF position and shut off the engine.
● Do not operate any control lever or pedal suddenly when hydraulic oil remains at low tem-
perature. Make sure to warm up the machine till temperature of hydraulic oil rises to a suitable
point.
Do not start machine operation immediately after engine start. Check the following items:
1. Adjust the fuel control dial to run the engine at a low speed (about 1,100 rpm) for about five
minutes.
2. Adjust the fuel control dial to run the engine at a moderate speed (about 1,400 rpm), and then
slowly operate the bucket for five minutes.
3. Adjust the fuel control dial to run the engine at a high speed, and operate the boom, arm and
bucket for 5-10 minutes.
4. Cycle each action of excavator for several times before ending the preheat operation.
5. Check all gauges for normal display after preheating the machine.
Continue to warm up the machine if coolant temperature (see monitor display) and hydraulic
oil temperature (50~80°C) fail to reach normal values.
6. Check exhaust color, noise or vibration for abnormality. Repair it if any.

4.3 Engine Shutdown
CAUTION
● Sudden shutdown of the engine may
considerably reduce service life of its
components.
● Never shut down the engine abruptly

except for emergency.
● Never shut down the engine if it is

too hot. Run the engine at a moderate
speed and stop it after it has cooled.
1. Run the engine at idle speed for about five

minutes to cool it down gradually.
2. Turn the start switch to the OFF position to ON

shut off the engine.
OFF
STA
T
HEA
RT
3. Remove the ignition key.
CC13031803
Fig. 4-37

4.4 Machine Operation
WARNING
● Check the area around the machine and
sound the horn before moving the ma-
chine. Nobody is allowed to enter the
area around the machine.
● Remove any barriers from the travel

route.
● There is a blind area behind the ma-

chine. Take extra care when reversing
the machine.
NOTE:
Before operating the travel control levers or

pedals, make sure the idlers (A) are in the
front and sprockets (B) are at the rear (C) of
the machine. C
A B
CC13031518
Fig. 4-38

4.4.1 Before moving the machine
1. Adjust the fuel control dial to a desired po-

sition to increase engine speed. MA
X
MIN
CC13031507
Fig. 4-39
2. Place the hydraulic lockout control to the

FREE position and retract the work equip-
ment. Keep the bucket 40~50cm off the
ground.
NOTE:
Raise the boom a little if necessary to provide

good visibility to the right side of the operator
cab.
CC13031404
Fig. 4-40
40~50cm
CC13050601
Fig. 4-41

4.4.2 Move the machine
Forward moving
Push both of the travel control levers or

press the upper part of the control pedals
at the same time with equal force to move
the machine forward.
CC13031508
Fig. 4-42
Backward moving
Pull both of the travel control levers or

press the lower part of the control pedals
at the same time with equal force to move
the machine backward.
NOTE:
● If the sprockets are in the front of the ma-

chine, the moving direction of the machine
is opposite when the travel control levers
(pedals) are operated.
CC13031509
● To ensure straight travel, operate the travel Fig. 4-43

control levers or pedals at the same with
equal force.
● When ambient temperature is low, travel

speed may become abnormal. In this case,
warm up the machine completely before
operation.

4.4.3 Stopping the machine
CAUTION
● Do not stop the machine suddenly.
● Before stopping the machine, leave

yourself enough space so that you can
leave the machine easily.
● Release the left and right travel control le-

vers (or pedals) at the same time to stop
the machine. N
● The control levers or pedals will return to

neutral position (N) once they are released.
N
CZ335-1103169
Fig. 4-44

4.5 Machine Turning
● Check the direction of the track frame

before operating the travel control. If the
sprockets are in front of the cab, when
the travel controls are operated, machine
movement is opposite to that when ma-
chine direction is normal.
● Avoid sudden change of direction. Stop the

machine before turning, especially for a
pivot turn.
4.5.1 Direction change when the ma-

chine is stopped
Left turn
● Push the right travel control lever, or press

the upper part of the right control pedal.
The machine turns left as the right side
track moves forward;
CC13031510
Fig. 4-45
or,
● Pull the left travel control, or press the

lower part of the left control pedal. The ma-
chine turns left as the left side track moves
backward.
CC13031511
Fig. 4-46

Right turn
● Push the left travel control lever, or press

the upper part of the left control pedal. The
machine turns right as the left side track
moves forward;
CC13031512
Fig. 4-47
or,
● Pull the right travel control, or press the

lower part of the right control pedal. The
machine turns right as the right side track
moves backward.
CC13031513
Fig. 4-48

4.5.2 Pivot turning
Left turn
● Push the right travel control lever and pull

the left control lever at the same time; or
● Press the upper part of the right travel con-

trol pedal and the lower part of the left con-
trol pedal at the same time.
CC13031514
Fig. 4-49
Right turn
● Push the left travel control lever and pull

the right control lever at the same time; or
● Press the upper part of the left travel con-

trol pedal and the lower part of the right
control pedal at the same time.
CC13031515
Fig. 4-50

4.6 Work Equipment Control
CAUTION
● Operating the control levers while the
engine is idling may cause engine
speed to rise abruptly. Be careful with
the operation of control levers.
● Work equipment is controlled with the left

and right joysticks.
● The joysticks will return to the neutral posi-

tion once released, and the work equip-
ment will hold at the same time.
Arm control
Move the LEFT joystick forward and backward

to control the movement of the arm.
CZ335-1103175
Fig. 4-51
Swing control
Move the LEFT joystick to the left and right to

control the swing of upper structure.
CZ335-1103176
Fig. 4-52

Boom control
Move the RIGHT joystick forward and back-

ward to control the movement of the boom.
CZ335-1103177
Fig. 4-53
Bucket control
Move the RIGHT joystick to the left and right

to control the movement of the bucket.
NOTE:
● An accumulator is installed in the con-

trol circuit of the machine. It enables the
operator to lower the work equipment to
the ground even if the engine has been
stopped. Turn the start switch to the ON
position and place the lockout lever to the CZ335-1103178
FREE position within 15 seconds after en- Fig. 4-54
gine shutdown, move the joysticks to lower
the work equipment to ground.
● This method can also be used to release

the residual pressure of hydraulic system,
or to lower the boom after the machine has
been loaded onto a trailer.

4.7 Restricted Operations
CAUTION
● Do not operate the joysticks while the
machine is traveling. Stop the machine
first before operating the joysticks.
● Operation of the control levers while

the engine is idling may cause engine
speed to increase abruptly.
4.7.1 Operation with swinging force
Do not use the swinging force to compact the

ground or break objects. Doing this is danger-
ous. In addition, the service life of machine
would be reduced considerably.
CZ335-1103181
4.7.2 Operation with traveling force Fig. 4-55
Do not cut your bucket into ground and use

the traveling force to excavate, which could
damage the machine or work equipment.
CZ335-1103182
Fig. 4-56

4.7.3 Operation when hydraulic cylin-

der reaches its stroke end
If the cylinder's piston reaches its end of

stroke, using the work equipment under ex-
ternal impact could damage hydraulic cylinder
and cause personal injury. Avoid operating the
machine when its hydraulic cylinder is fully re-
tracted or extended.
CZ335-1103183
4.7.4 Operation with bucket landing Fig. 4-57

force
Do not use the bucket's landing force for exca-

vating, digging, breaking or pile-driving opera-
tion, which may otherwise reduce the service
life of the machine considerably.
To avoid damage of hydraulic cylinders, do not

use the bucket to strike or compact the ground
while its cylinder is fully extended or retracted.
4.7.5 Hard rocky ground
Do not try to directly excavate hard rocky

ground. Perform excavation after breaking the
rocks through other means. By doing so, dam-
age to the machine could be minimized, in ad-
dition to cost reduction.
CZ335-1103184
Fig. 4-58

4.7.6 Operation with machine weight
Do not use the weight of machine to excavate.
CZ335-1103185
4.7.7 Sudden shift of control levers/ Fig. 4-59

pedals
1. Do not maneuver any control lever or pedal

abruptly to change the action of machine.
2. Do not suddenly change the position of

control lever or pedal from forward (A) to
A 3
reverse (B), or vice versa.
2
1
3. Do not stop the machine by suddenly re-
leasing the control lever or pedal while B
traveling at high speed.
CZ335-1103186
Fig. 4-60

4.8 Permissible depth of water

When driving the machine out of water, an in-
clination of slope exceeding 15° will have the
rear of the upper structure immersed in water,
thus the fan could be damaged due to water.
Be extremely careful when driving the machine

out of water.
CZ335-1103189
Fig. 4-61
● Do not drive the machine into water where

water level could reach the center of car-
rier roller [1].
● Add grease to parts that have been soaked

long in water, till old grease is completely
squeezed out of the bearing (especially the
area around the pin of bucket).
● Do not operate the machine in water un-

less the foundation of worksite is strong 1
enough so that the level of water could not CZ335-1103190
reach the center of carrier roller. Fig. 4-62
● If the swing bearing, swing gear and cen-

tral swing joint are soaked in water, the
drain plug should be opened to remove
mud and water. Clean the swinging area
and reinstall the plug. Lubricate the mesh
gear and swing bearing inside the swing
unit.

4.9 Traveling on a Slope
WARNING
● Never drive or turn the machine or op-
erate the work equipment on a slope as
that may cause it to loose balance.
● Swinging the upper structure toward

the downhill direction with the bucket
loaded is very dangerous. If such oper-
ation is necessary, provide a solid plat-
form on the slope so that the machine
can be kept on a level ground.
CZ335-1102046
● Never use the force of the bucket to
help the machine climb up a slope when Fig. 4-63
the track shoes slide.
1. Drive the machine very slowly when the

machine travels down a steep slope. Use
the fuel control dial to adjust travel speed.
When driving the machine down a slope

with a grade larger than 15°, adjust the
work equipment to an attitude as shown
the right illustration and drive slowly.
CZ335-1103192
Fig. 4-64
CZ335-1102039
Fig. 4-65

2. When driving the machine up a steep

slope, move the work equipment to the for-
ward direction. Keep the work equipment
about 20-30cm above the ground and trav-
el at a low speed.
CZ335-1102040
Fig. 4-66
4.9.1 Traveling downhill
Place the travel control levers to the neutral

position, which can make the brake function
automatically.
4.9.2 When engine stalls on a slope
If the engine stops while traveling on a slope,

place the travel control lever to its neutral po-
sition, lower the bucket to the ground and park
the machine before restarting the engine.
4.9.3 Cab door on a slope
● If the engine stalls out on a slope, do not

perform swinging operation with the left
joystick. The upper turntable will swing
naturally under its weight.
● When the machine is on a slope, do not

open or close your cab door because it
would cause sudden change of force ap-
plied on the machine. Always secure the
cab door in either open or closed position.

4.10 Escaping from Mud

Operate the machine carefully on muddy
ground and avoid being trapped in mud. If the
machine is trapped in mud, drive it out as per
the following instruction.
4.10.1 When one track is trapped
When one side of the tracks is trapped in mud,

swing the boom to the side of the trapped
track and use the bucket to lift the track. Place
wood planks or logs under the track and then
drive the machine out of the mud.
Note:
When the boom and arm are used to lift the

machine, use the bottom of the bucket to con-
tact the ground.
Put wood planks under the bucket bottom if CZ335-1103195

necessary.
Fig. 4-67
The boom and arm shall form an angle be-
tween 90 and 110°.
4.10.2 When both tracks are trapped
When both tracks are trapped in mud, insert

wood planks under the tracks using the meth-
od as described above and cut your bucket
into the ground in front of the machine.
Retract the arm as you do in normal excava-

tion and drive the machine out of mud.
CZ335-1103196
Fig. 4-68

4.11 Recommended Application

Besides the following applications, the scope
of application could be expanded by using
various additional attachments.
4.11.1 Backhoe operation
Backhoe operation is suitable for digging an

area which is lower than the machine.
When the machine is in a state shown in the

right illustration, maximum digging force can 90°
be obtained through the thrusting force of
each hydraulic cylinder. 90°
Make use of this angle effectively to help you

achieve the maximum working efficiency.
CZ335-1103197
Fig. 4-69
The digging range of arm is from 30 to 45°, as

45° 30°
relative to the machine.
The angle may vary according to digging

depth, but it is better to keep it within the
above range if possible. Do not operate the
hydraulic cylinders to their full stokes.
CZ335-1103198
Fig. 4-70

4.11.2 Trenching work
You can dig a trench efficiently by installing

a bucket suitable for this job and adjust your
tracks to parallel the to-be-dug trench line.
When digging a wider trench, excavate first

both sides of the trench and then remove the
middle part.
CZ335-1103199
Fig. 4-71
● In excavating operation, the track should

be adjusted vertical to road shoulder or
cliff, with sprockets behind the cab, so that
the machine can retreat easily in case of
an emergency.
CZ335-1102049
Fig. 4-72
4.11.3 Loading operation
In a place where the swinging angle is small,

working efficiency can be improved by parking
the dump truck at where the operator could
see easily.
It is more convenient to load more material if

the truck is loaded from rear rather than from
its sides.
CZ335-1103200
Fig. 4-73

4.12 Parking
WARNING
● Inadvertent of the control levers may
cause the machine to move suddenly
and result in serious accidents.
● Make sure the hydraulic lockout control

is placed in the LOCKED position be-
fore leaving the cab.
Always park the machine on a hard, level and

safe ground.
If you have to park the machine on a slope,

chock the tracks with blocks. You can also
thrust the bucket tips into the ground as addi- 120°
tional safety measures.
CZ335-1102055
Fig. 4-74
1. Place the travel control levers to neutral

position to stop the machine.
N
CZ335-1103169
Fig. 4-75

2. Turn the fuel control dial to MIN position for

low idle to reduce engine speed.
MA
X
MIN
CC13031401
Fig. 4-76
3. Lower the bucket horizontally till its bottom

touches the ground.
CZ335-1103207
Fig. 4-77
4. Place the hydraulic lockout lever to the

LOCKED position.
CC13031403
Fig. 4-78

5. Use the monitor to check the engine cool-

ant temperature and oil pressure.
● If fault indicator blinks and oil pressure is

abnormal, shut down the engine immedi-
ately.
● If the coolant temperature gauge stays in

the red range, wait until the indicator enters C H
the yellow range before engine shutdown.
CC13050802-1
Fig. 4-79
6. Turn the start switch from the ON position

to the OFF position and shut off the en-
gine.

4.13 Post-operation Inspection

1. Inspect the machine and check the work
equipment, the exterior of machine, and
the undercarriage. Check for leaks of oil or
coolant. Repair it in case of any problem.
2. Refill the fuel tank to maximum level.
3. Check the engine compartment for any pa-

per or other debris. Remove them, if any,
in order to prevent fire.
4. Clean the mud on the undercarriage if any.
5. If the ambient temperature is below -35°C,

discharge the coolant in the radiator and
engine (Sany Heavy Machine uses the
type of anti-freeze liquid that freezes at
-35°C).

4.14 Locking
Make sure the following parts are locked prop-
erly when the machine is not used. The igni-
tion key is used to lock and unlock all the lock-
able components on the machine.
3
1) Cab door
4
2) Filler cap of fuel tank
5
3) Engine hood 7
4) Battery chamber 1
5) Left access door CZ335-1103208
6) Right access door Fig. 4-80
7) A/C fresh air cleaner cover
6
CZ335-1103209
Fig. 4-81

4.15 Operation in Cold Weather

The engine may fails to start and the coolant may freeze under low temperature. In this case, the
following instructions must be followed.
4.15.1 Fuel and lubricant
Select fuel and lubricant with low viscosity for all components when ambient temperature is low.
For more information on viscosity, see "Recommended Fuel, Coolant and Lubricant" on page 5-12.
4.15.2 Coolant
WARNING
● Antifreeze is flammable. Keep it away from fire. Do not smoke when handling anti-
freeze.
● Antifreeze is toxic. Wash with plenty of water and seek medical treatment immediately
if antifreeze gets into your eyes or on your skin.
● Never drain antifreeze directly into the sewer or onto the ground.
Please use Sany genuine, efficient TEEC-L35 antifreeze as the coolant. Choosing any other type
of coolant is not recommended.
4.15.3 Battery
Battery capacity decreases as the ambient temperature drops. Keep battery capacity at 100%
level. Do not let the battery stay long under low temperature so as to avoid the difficulty in starting
the machine.
Cover the battery or remove it from the machine when ambient temperature is low. Store the bat-
tery in a warm place and reinstall it before operating the machine.

4.15.4 After operation in cold weather
When temperature is very low, mud and wa-

ter on the undercarriage may freeze at night,
which may make the machine hard to move
the next day. Observe the following instruc-
tions:
● Remove all mud and water from the ma-

chine. Clean especially the piston rods of
hydraulic cylinders in order to prevent mud,
dirt or water from penetrating the cylinders
and spoiling the seals.
● Park the machine on a hard, level ground.

Park it on wood planks if possible, which
can prevent the machine from being fro-
zen unto the ground.
● Open the drain valve to discharge accu-

mulated water of the fuel system so as to
prevent it from freezing.
● Refill the fuel tank to tis maximum level to

reduce condensation in the tank when am-
bient temperature drops.
To remove the mud and water on the track:
1. Run the engine at idle speed and swing

the upper structure 90º so that the work
equipment is at the track side.
2. Lift one side of the tracks just above the

ground and move the travel control lever to
rotate the track.
3. Repeat the steps above and remove the

mud on the other track.
CAUTION
CZ335-1103210
● It is dangerous to run the track freely.
Fig. 4-82
● Keep people a safe distance away from
the track when running it freely.

4.15.5 After cold season
When the season changes and the weather

gets warm, replace fuel and lubricant with that
of specified viscosity.
For more information see "Recommended

Fuel, Coolant and Lubricant" on page 5-12.
4.16 Long-Term Storage
4.16.1 Before storage
When storing the machine for more than one

month, adjust the machine to the attitude as
shown in the right illustration in order to pro-
tect cylinder piston rod against rusting.
● Clean all parts of the machine and then

store the machine indoors. If you have to
store the machine outdoors, choose a level
ground and cover the machine with can-
vas.
● Refill your fuel tank to its maximum level in

CZ335-1103211
order to avoid accumulation of water.
Fig. 4-83
● Lubricate the machine and change its oil
before storing it.
● Apply grease to the exposed part of the

piston rod of hydraulic cylinder.
● Disconnect the negative terminal of the

battery and reinstall its cover, or remove
the battery from the machine and store it in
a separate place.
● For machines equipped with optional

equipment, the control pedal of optional
equipment shall be placed to locked posi-
tion.
● To prevent rusting, please use Sany’s gen-

uine TEEC-L35 anti-freeze.

4.16.2 During storage
CAUTION
● When anti-rusting greasing operation is performed indoors, proper ventilation shall be
provided to avoid gas poisoning.
● During storage, operate the machine and drive it for a short distance once a month. This can
help apply a new oil film on parts and components. Meanwhile, charge the battery of the ma-
chine.
● Before operating the work equipment, wipe off all the grease from the piston rod of hydraulic
cylinder.
● If the machine is equipped with air conditioner, switch on the air conditioner for 3-5 minutes
once a month, which can lubricate all parts of its compressor. The engine shall run at low idle
speed when air conditioner is working. In addition, check its refrigerant twice a year.
4.16.3 After storage
If the machine has been stored for a long period but no rusting prevention had been made each
month, contact your Sany dealer before operating the machine again.
Before operating the machine again after a long-term storage, observe the following instructions:
● Wipe off the grease from the piston rod of hydraulic cylinder.
● Apply lubricant or grease to all necessary locations.
● Water in the air can mix with oils of the machine when it has been stored for a long time.
Check the oils before and after starting the engine. Replace the oil if necessary.
4.16.4 Engine startup after long-term storage
Before starting the engine of the machine that has been stored for a long period of time, it is im-
portant to fully preheat the machine.
For more information see "Warm-up operation" on page 4-28.

4.17 Transportation Information
4.17.1 Transport methods
● Choose a method that is suitable for the

weight and dimensions provided in "Speci-
fication" section.
● The weight and dimensions provided in the

Specifications section may vary due to dif-
ferent type of track shoe, arm or other ad-
ditional equipment.
● For transport of machines installed with

cab protection structures, contact your
Sany dealer for more information.
● Observe local laws and regulations when

transporting the machine.
4.17.2 Loading and unloading
The following instructions must be followed

when loading/unloading the machine to/from a
trailer.
● Use an access ramp with enough width,

length, thickness and strength. The maxi-
mum loading and unloading angle of the
ramp must not exceed 15 degrees.
● When piling the earth to build a platform,

CZ335-1103227
the platform must be fully compacted to
prevent landslide. Fig. 4-84
● To prevent the machine from skidding on

the ramp, clean its track shoes and the
ramp before loading and unloading.
● The machine is likely to skid when the ac-

cess ramp is contaminated with water,
snow, grease or ice.
CZ335-1103228
Fig. 4-85

4.17.2.1 Loading
1. Choose a hard and level surface to load

the machine. Keep the machine a safe dis-
tance away from roadside.
2. Brake the trailer and put blocks [1] under

its wheels.
Place access ramps [2] the left and right 2

sides respectively. The two ramps shall
parallel to each other and have equal 1
distance to the centerline [3] of the trailer. 4
3
Mounting angle [4] shall not exceed 15º. If
the ramps bend too much under the weight CZ335-1103229
of machine, supports must be placed under Fig. 4-86

the ramps to prevent them from bending.
3. Set the travel speed to LOW speed.
4. Set engine speed to MIN with the fuel con-

trol dial.
WARNING
MA
X
● Deactivate auto-idle function when load-
MIN
ing or unloading the machine. If auto-

idle mode is active, engine speed may
change abruptly.
● Keep travel speed at low level. Do not

switch travel speed when loading or un- CC13031401
loading the machine.
Fig. 4-87

5. If work equipment is installed on the ma-

chine, placed it in front of the machine.
Move the machine straight forward up the
ramps. If no work equipment is installed,
reverse the machine up the ramps.
Lower the bucket onto the trailer to support 90°-110°
the machine immediately after getting

aboard.
Follow the instructions and signals from a

commander, especially in reverse travel.
CZ335-1103231
Fig. 4-88
WARNING
● Do not reposition the machine on the
access ramps. If necessary, reposition
the machine on a level ground or on the
trailer.
● Do not maneuver any control levers

except the travel control on the access
ramps.
CZ335-1103232
Fig. 4-89
6. Align the machine with the ramps before

driving up the ramp. The centerline of ma-
chine shall match the centerline of trailer.
Align the machine with the ramp and travel

slowly.
Lower the work equipment as low as pos-

sible.
Once the machine is on the ramps, only

the travel control can be maneuvered. Do
not operate any other control levers.

7. Drive the machine slowly forward till all

tracks are on the trailer and have full con-
tact with trailer floor.
8. When the machine passes the rear wheels

of the trailer, the machine could lean for-
ward. So drive the machine slowly and
carefully in order to avoid impact with the
trailer.
9. Slightly raise the bucket, retract the arm

and maintain it in lower position, and slow-
ly swing the upper structure by 180º. CZ335-1103233
Fig. 4-90
10. Fully extend the bucket cylinder and arm
cylinder, and slowly lower the boom.
11. Place a wood block under the end of the

bucket cylinder in order to prevent it from
touching the trailer floor, which could result
in damage to the cylinder.
CZ335-1102060
Fig. 4-91

4.17.2.2 Securing the machine
● Place a wood block under the end of the

bucket linkage to prevent the bucket cylin-
der from touching the trailer floor.
● Locked the engine hood. Unlocked engine

hood may swing open during transit.
Secure the machine to the trailer according to

the following steps:
1. Fully extend the bucket cylinder and arm

cylinder, and slowly lower the boom.
CZ335-1104086
Fig. 4-92
2. Place the hydraulic lockout control to the

LOCKED position.
3. Stop the engine and remove the key from

the start switch.
4. Close all doors, windows and covers prop-

erly. Lock the covers, caps and doors.
CC13031403
Fig. 4-93

5. Chock the tracks on both ends in order

to prevent the machine from moving dur-
ing transportation. Tie down the machine
with chains or wire ropes with sufficient
strength.
Care must be taken to keep the machine

in a proper position to ensure that the
machine will not slip sideways.
CZ335-1103237
Fig. 4-94
Rear view mirror
The rear view mirror is located in the position

When the rear view mirrors have to be re- B A

moved and installed afterwards for transporta-
tion purpose, follow the instructions below:
Removal
1. Loosen bolt [2] and remove the rear view

mirror [1] from the bar [3].
CZ335-1103142
2. Loosen bolt [4] and remove the bar [3] and
the clamp [5]. Fig. 4-95
Installation
1. Install the bar [3] and the clamp [5] to the

handhold, and tighten bolt [4]. 4
1
2. Install the rear view mirror [1] to the bar [3],
5
and tighten the bolt [2].
2
Note:
3
The rear view mirror must be readjusted after
installation. For more information see "Rear
view mirrors" on page 4-19.
CB13041002-2
Fig. 4-96

4.17.2.3 Unloading
1. Choose a hard and level surface to load

the machine. Keep the machine a safe dis-
tance away from roadside.
2. Brake the trailer and put blocks [1] under

its wheels.
● Place access ramps [2] the left and right 2

sides respectively. The two ramps shall
parallel to each other and have equal dis- 1
tance to the centerline [3] of the trailer. 4
3
Mounting angle [4] shall not exceed 15º. If
the ramps bend too much under the weight CZ335-1103229
of machine, supports must be placed under Fig. 4-97

the ramps to prevent them from bending.
3. Remove the chains and wire ropes fasten-

ing the machine.
4. Start the engine and warm it up fully.
5. Place the hydraulic lockout control to

FREE position.
6. Set the travel speed to LOW speed.
WARNING
CC13031404
● Deactivate auto-idle function when load-
ing or unloading the machine. If auto- Fig. 4-98
idle mode is active, engine speed may
change abruptly.
● Keep travel speed at low level. Do not

switch travel speed when loading or un- MA
X
loading the machine.
MIN
7. Set engine speed to MIN with the fuel con-

trol dial.
CC13031401
Fig. 4-99

8. Raise the work equipment, retract the arm

below the boom, and drive the machine
slowly.
9. Stop the machine when it comes to the

rear wheels of the trailer and is positioned
horizontally.
CZ335-1103242
NOTE: Fig. 4-100
● Keep an angle of 90 - 110° between the

arm and the boom when unloading the ma-
chine.
● The machine could be damaged if it is un-

loaded with retracted arm.
90°-110°
● When the machine runs on the access
ramp, do not penetrate the bucket into
ground, which could damage the hydraulic
cylinder.
CZ335-1103243
Fig. 4-101
10. While the machine is on the ramps, keep

an angle of 90 - 110º between the arm and
the boom. Lower the bucket to the ground
and move the machine slowly.
11. When the machine is going down the

ramps, slowly operate the boom and arm,
and carefully drive the machine off the
ramps.
CZ335-1103244
Fig. 4-102

4.17.2.4 Lifting the machine
WARNING
● Only eligible, experienced operator with official license (as per local laws) is allowed to
operate a crane.
● Do not lift the machine when someone is riding on it.
● Nobody shall be allowed to enter the area below or around the lifted machine.
● Make sure that the wire ropes used for lifting are strong enough to bear the weight of
machine. Never use damaged or aged wire cable or sling.
● Do not lift the machine when its upper structure is sideways.
● Do not lift the machine at a fast speed, which may otherwise overload the wire cables
or slings and result in rupture.
Lifting instructions
Refer to the following table to choose and use proper wire ropes.
Wire ropes
Use proper wire ropes according to the weight of the load
Wire Ropes
(Z or S laid wire cable, ungalvanized)

Diameter Allowable Load
mm kN t
10 9.8 1.0
11.5 13.7 1.4
12.5 15.7 1.6
14 21.6 2.2
16 27.5 2.8
18 35.5 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
Table 4-1
Allowable load is 1/6 or 1/7 of the breaking strength of the wire rope.

When lifting the machine, operate on a level

ground according to the following steps.
1. Start the engine and swing the upper struc-

ture to position the work equipment at the
side of the sprockets [1].
2. Fully extend the bucket cylinder and the

arm cylinder, and lower the work equip-
ment to the ground, as shown in the right
illustration.
CZ335-1103245
Fig. 4-103
3. Move the hydraulic lockout control to

LOCKED position.
4. Shut off the engine. Check the surround-

ing of the cab before leaving the machine.
Close the cab door and windows properly.
CC13031403
Fig. 4-104
5. Run a wire rope between the first two track

A
rollers and between the last two track
rollers. For machines installed with roller
guard, the cable shall go through under the
tracks.
6. Adjust the wire rope lifting angle [A] to 30 -

40º, and lift the machine slowly.
7. When the machine is above the ground,

make sure that the hook condition and the
lifting condition are normal, and lift the ma-
chine slowly. CZ335-1103246
Fig. 4-105

E
G
PA
K
AN
BL

E
G
PA
K
AN
BL

SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator Maintenance
Maintenance
5 Maintenance
5.1 Maintenance Information ......................................................................................... 5-3
5.2 Oil, fuel and coolant ................................................................................................. 5-6
5.2.1 Oil................................................................................................................... 5-6
5.2.2 Fuel ................................................................................................................ 5-6
5.2.3 Coolant .......................................................................................................... 5-7
5.2.4 Grease ........................................................................................................... 5-8
5.2.5 Oil and fuel storage ........................................................................................ 5-8
5.2.5.1 Filter element ........................................................................................ 5-9
5.2.6 Electrical system ........................................................................................... 5-9
5.3 Wear Parts ............................................................................................................. 5-10
5.4 Recommended Fuel, Coolant and Lubricant ......................................................... 5-12
5.4.1 Table of recommended fuel, oil and coolant ................................................ 5-13
5.4.2 Table of capacities ...................................................................................... 5-14
5.5 Tightening Torque Table......................................................................................... 5-15
5.6 Safety Critical Parts ............................................................................................... 5-17
5.7 Maintenance Schedule .......................................................................................... 5-18
5.8 Maintenance Procedures ....................................................................................... 5-20

Maintenance SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator
WARNING
jury or death.

5 MAINTENANCE
5.1 Maintenance Information

Never conduct any inspection and maintenance work other than the scope specified in this man-
ual.
Service hour meter reading
Check the service hour meter reading on a daily basis and determine whether the machine re-
quires the specified maintenance.
Genuine Sany parts
Always use genuine Sany replacement parts listed in the Parts Manual.
Genuine Sany lubricants
Always use genuine Sany oil and grease. Select oil and grease of suitable viscosity according to
ambient temperature.
Window washer fluid
Use automotive windshield washer fluids only. Make sure it is not contaminated by foreign sub-
stances.
Using clean lubricants
Always use clean oil and grease and keep the container clean. Keep oil and grease free of any
impurities.
Checking the drained oil and used filter elements
After oil change and filter element replacement, check the used oil and filter element for signs of
metal particles and foreign material. If large amount of metal particles and/or impurities are ob-
served in the used oil and filter element, take immediate action or inform your boss in time.
Fuel strainer
If a fuel strainer is equipped in the fuel tank filler opening, do not remove it when filling the tank.
Welding instruction
● Disconnect the negative (-) post of the battery one(1) minute after turning off the start switch.
● Connect grounding cable in a place where is more than 1 meter from the welding location.
The meters and gauges will fail if the grounding cable is connected to the instrument, connec-
tors or other attachments.
● If any sealing part or bearing is present between the welding location and the grounding point,
change the grounding point to avoid such parts.
● Never use a grounding point in the vicinity of the work equipment pin or hydraulic cylinder.

● Never apply more than 200V continuously.
Preventing things from falling into machine
● When opening the access window or tank filler for inspection, make sure that the nuts, bolts
or tools are not left inside the machine. Failure to do so may result in unexpected failure or
damage to the machine, or accidents. In case that any materials fall into the machine, remove
it immediately.
● Do not carry unnecessary items in your pockets except those necessary for inspection.
Dusty work site
Observe the following items before working in a dusty place.
● When inspecting the machine or changing the oil, park the machine in a dust-free place in or-
der to prevent dust from getting into the oil.
● Clean the air filter cartridge immediately if the filter's alarm indicates clogging.
● Clean the fins and other heat exchanger parts frequently to avoid them being clogged.
● Clean and replace the fuel filter frequently.
● Clean the electrical components, especially the start motor and the alternator, to prevent dust
from building up on them.
Lubricants of different brands
Never mix lubricants of different brands and/or grades together. If you need to use the lubricant of
another brand or grade, drain the old lubricant completely and replace with the new brand.
Securing access cover
When servicing the machine with the access covers open, use a locking lever to secure the cover
to certain position. Otherwise, the cover can be swung close by wind and cause bodily injury.
Purging air from hydraulic system
When any hydraulic units have been repaired or replaced or any hydraulic lines have been re-
moved or installed, always bleed the air from the system.
Connecting hydraulic hoses
● In removal of parts with O-rings or gaskets, clean the installation surfaces and replace with
new parts. Remember to install the O-rings or gaskets.
● Do not twist or bend the hydraulic hoses when assembling. Failure to do so could cause dam-
age to the hoses and considerably reduce their service life.
After inspection and maintenance
If no checks have been made after inspection and maintenance, unexpected failure may occur,
causing severe injury or damage. The following items must be observed:

● Checks when machine is running
● For more information, see "Maintenance with engine running" on page 2-70.
● Whether the checked or maintained parts work normally.
● Whether oil leakage occurs when the engine speed increases and the oil is under pres-
sure.
● Checks after the operation (when the engine has been shut down)
● Whether you have missed the items to be checked or maintained.
● Whether all the checks and maintenance have been performed correctly.
● Whether any tools and parts are left in the machine. It is very dangerous to have a foreign
object blocked in the linkage.
● Whether leakage of water or oil occurs; whether all the bolts have been screwed tightly.
Closing engine hood properly
When the engine hood is closed after inspection and maintenance, hold the lever and lift the en-
gine hood slightly in order to check whether the lock is securely engaged. An unlocked hood may
be opened and cause accidents.

5.2 Oil, fuel and coolant
5.2.1 Oil
● The oils in engine and hydraulic units keep deteriorating when operating the machine under
extreme conditions, such as high pressure and high temperature.
● Always use recommended type of oil which shall also be applicable under extreme ambient
temperatures.
● Within the specified oil change interval, the oil must be changed even if it is not dirty.
● Lubricant shall be handled carefully in order to prevent impurities such as water, metal par-
ticles and dust.
● Most troubles of the machine are caused by impurities. Pay special attention to the prevention
of any impurities when storing or filling the oil.
● Fill the amount of oil as specified. Failure to do so could result in abnormality.
● Do not mix oils of different grades or brands together.
● Contact your Sany dealer when the oil in your work equipment has been contaminated by wa-
ter or air.
● To know the condition of the machine, regular oil quality analysis is recommended. Contact
your Sany dealer if you need such service.
● Related filter elements must be replaced when changing the oil. In replacement of machine oil
filter element, acceptable clean oil shall be filled into the new filter element prior to installation.
● Please use the oils approved by Sany.
● Do not use the hydraulic oil that has not been approved by Sany, which can block filter car-
tridge.
● Remove the remaining oil as much as possible from the lines and cylinders when changing
the hydraulic oil. A small amount of different residual is acceptable.
5.2.2 Fuel
● To prevent the moisture in air from condensing in the fuel tank, the tank must be fully refueled
after each workday.
● The fuel injection pump is a precise component, which may not work normally if the fuel con-
tains water or other foreign substances.
● The sediment and water in the fuel tank must be drained before starting the engine or after 10
minutes since injection of oil.
● Flush the fuel tank and the fuel system in case of any impurities found in the fuel tank.

● The air in fuel path must be eliminated in case that the engine runs out of fuel or the filter car-
tridge has been replaced.
● Always use the type of fuel specified in the "Maintenance" section.
● The fuel can freeze below the specified temperature (especially lower than -15°C (5°F)).
● When the fuel is used above the specified temperature, its viscosity and output power will de-
crease .
● Pay special attention to prevention of impurities when storing or refilling the fuel.
Note:
● Always use diesel oil as the fuel.
● To ensure favorable consumption and exhaust of the fuel, the engine installed to the machine
uses high-pressure oil injection unit with mechanical control. The unit contains high-precision
components that require high-quality lubrication. Therefore, the use of low-viscosity fuel with
low lubricating capability will considerably reduce the service life of the unit.
● When the sulfur content of fuel is less than 0.5%, change the fuel according to the required
maintenance interval given in this manual. If the sulfur content is more than 0.5%, change the
fuel according to the following table:
Sulfur Content in Fuel Oil-Change Interval - Engine Oil Pan

0.5~1.0% 1/2 of standard interval
More than 1.0% 1/4 of standard interval
Table 5-1
5.2.3 Coolant
● The coolant is an important fluid against corrosion and freezing.
Anti-freezing coolant is also necessary in regions where freezing prevention is unnecessary.
● Sany recommends TEEC-L35 antifreeze. This antifreeze has a concentration of 50% and
needs no dilution. TEEC-L35 antifreeze has excellent performance in anticorrosion, anti-
freezing and cooling, and can last for one year or 2000 hours.
Sany does not recommend you using coolants other than TEEC-L35 antifreeze. The use of
other coolants is possible to cause serious problems, such as corrosion of the light metal
parts of the engine and cooling system.
● If you buy antifreeze from the market, make sure that the antifreeze's concentration is within
the range 30-68% in order to ensure its performance against corrosion.
● The ratio of mixing antifreeze with water is determined by the minimum ambient temperature,
as shown in the following table.

Water-antifreeze mixing ratio
°C -10 -15 -20 -25 -30 -35 -40

Min. temperature
°F 14 5 -4 -13 -22 -31 -40
Mixing ratio (%) 30 36 41 46 50 54 58
Table 5-2
NOTE:
● Use distilled water or tap water (softened water) to dilute anti-freezing coolant.
● Natural water, such as river water and well water (hard water), contains large amount of min-
erals (calcium, magnesium, etc.), which can easily scale in the engine and radiator. The scale
is hardly removed once formed in the engine and radiator. Overheat can occur due to unfa-
vorable heat exchange.
5.2.4 Grease
● Grease is used to prevent distortion and noise of joints.
● It is necessary to add grease to any component that appears inflexible or noisy after operation
for a long period.
● Always use the recommended greases. Select the grease according to change interval and
ambient temperature recommended in this manual.
● Wipe off the used grease that has been squeezed out when greasing. Make sure to wipe off
the used grease that has been contaminated by sand or debris, which can otherwise lead to
wear of rotating components.
5.2.5 Oil and fuel storage
● Store the oils and fuel indoors in order to keep them free from water, dust and other foreign
substances.
● To store the barrel of oil or fuel for a long period, it is necessary to place the barrel with its
opening facing the side in order to prevent intake of moisture. If you have to place the barrels
outdoors, cover them properly with waterproof canvas or take other protective measures.
● To prevent deterioration of oil or fuel during long-term storage, use the oil or fuel that has
been stored earlier than others.

5.2.5.1 Filter element
● Filter element is extremely important for safety. It can prevent failures by keeping important
devices free from impurities coming from oil path or air path. All filter elements must be re-
placed regularly. For more information see related sections in this manual.
● When operating in severe conditions, the filter elements shall be replaced more frequently ac-
cording to the sulfur content in lubricant and fuel.
● Do not use an element that has been cleaned. Replace it with a new one.
● In replacement of filter element, check the element for attached metal particles. Contact your
Sany dealer if metal particles are found.
● Do not open the package of a spare element when it is in storage.
● Use genuine Sany elements.
5.2.6 Electrical system
● Humid electrical devices or damaged wire can cause short circuit and machine failure. Do not
flush the interior of your cab with water. When flushing the machine, be careful with water,
which shall not penetrate into the electrical components.
● Electrical system maintenance correlates to checking the tension, damage or wear of fan belt.
● Do not install any other electrical components except those specified by Sany.
● External electromagnetic interference can cause failure of system controller. Contact your
Sany dealer before installing radio receiver or other wireless devices.
● Operating on beach requires cleaning the electrical system thoroughly in order to prevent cor-
rosion.
● When installing an electrical device, connect it to dedicated power source. Do not connect
other power sources to the fuse, start switch or battery relay.

5.3 Wear Parts
● Wear parts, such as filter element, bucket tips, etc. are to be replaced at the time of periodic
maintenance or before their abrasion limits.
● The wear parts shall be changed correctly in order to use the machine economically.
● For part change, Sany genuine parts of excellent quality shall be used.
● When ordering parts, please check the part number in the parts book.
Component Part Number Part Qty Interval

Primary fuel filter 60201220 Filter element 1 Every 250 Hrs
60201217 (SY195/205/215C9)
Filter element 1
Secondary fuel filter 60201218 (SY225/235C9) Every 500 Hrs
60176475 (SY265C9) Filter element 2
B222100000551 (SY195/205/215C9)
Machine oil filter B222100000494 (SY225/235C9) Filter element 1 Every 500 Hrs
60176476 (SY265C9)
Hydraulic oil filter 60200364 Element - Intake 1
Every 1000 Hrs
(SY195/205/215/225/235C9) 60101256 Element - Return 1
Hydraulic oil filter 60200363 Element - Intake 1
Every 1000 Hrs
(SY265C9) 60200365 Element - Return 1
Pilot filter B229900000063 Element 1 Every 500 Hrs
A/C air filter B222100000660 Filter - fresh air 1 Every 6 Mons
Filter - recircula-
A/C air filter B222100000711 1 Every 6 Mons
tion air
60207264 (SY195/205/215/225/265C9)
Air cleaner Element 1 ─
B222100000646 (SY235C9)
60207265 (SY195/205/215/225/265C9)
Main air cleaner Element 1 ─
B222100000647 (SY235C9)
Breather valve filter ele-
60174894 Element 1 Every 1500 Hrs
ment
Lateral pin bucket
11912709 (SY195/205/215/225C9) 5
tips
60116436 (SY235C9) 5
Bucket tips
Earth work bucket (11902152) (5)
(Pin)
(SY195/205/215/225C9) ─
11182515 Left cutter 1
11182516 Right cutter 1
(A210110000427) (Bolt) (8)
(A210334000013) (Nut) (8)

Lateral pin bucket

11902148 5
tips ─
(11902152) (5)
Rockwork bucket (Pin)
(SY225C9) 11280631 Side cutter 2
(A210110000427) (Bolt) (6) ─
(A210334000013) (Nut) (6)
Lateral pin bucket
60116437 5
tips ─
(60116440) (5)
Rockwork bucket (Lateral pin)
(SY235/265C9) 11280631 Side cutter 2
(A210111000321) (Bolt) (6) ─
(A210334000013) (Nut) (6)
Table 5-3

5.4 Recommended Fuel, Coolant and Lubricant
● Unless specified otherwise, the machine contains the following oils and coolants when deliv-
ered from the factory.
Item Type
Engine Oil Pan Caltex CH-4 15W-30
Swing Drive
Gear oil 85W/140
Final Drive
Hydraulic System Caltex HDZ46
Radiator TEEC-L35 antifreeze
Table 5-4
● To keep the machine at the maximum state for a long period of time, it is necessary follow the
oil instructions described in this manual. Failure to do so can cause overwear and service life
reduction of the engine, power train, cooling system and other components.
● The additives available in market could benefit the machine, but they could impair the ma-
chine as well. We do not recommend any lubricant additives.
● The specific capacity refers to the overall oil volume in tanks and lines. Supplementary vol-
ume refers to the amount of oil used to make up the system in inspection and maintenance.
● The use of multigrade oils is strongly recommended when starting the engine at temperatures
below 0°C (32°F), even if the daytime temperatures rises above 0°C (32°F).
● Use the recommended oils according the ambient temperatures given in the following table.

5.4.1 Table of recommended fuel, oil and coolant
Ambient Temperature
Recommended
Liquids -22 -4 14 32 50 68 86 104 122 °F liquids
-30 -20 -10 0 10 20 30 40 50°C
5W-30
5W-40
10W-30
Engine oil
15W-40
(Note 1)
40
HDZ32
(ISO VG32)
Hydraulic
oil
HDZ46
(ISO VG46)
-30# diesel fuel
Diesel fuel -10# light diesel
0# light diesel
TEEC-L35
Coolant
Antifreeze
Table 5-5
Note: The HTHS (high-temperature high-shear viscosity at 150°C) required by ASTM D4741
must be equal to or more than 3.5 mPa-S. Sany recommends use of Caltex15W-40 engine oil.

Recommended oils:
1. Engine oil
Select the oil of proper viscosity according to the temperature range given in the oil change
schedule.
Machine oil grade: Above API CF-4
Recommended engine oil brand and type: Caltex CG-4 15W-40
2. Engine fuel
Light diesel oil (GB252.81)
3. Hydraulic oil
The hydraulic system uses Caltex HDZ46 hydraulic oil (code B420106000036).
NOTICE
● In most cases, the use of fuel ASTH2 and the diesel oil (minimum cetane number is 40)
can achieve the best economic result and operating performance. At where the eleva-
tion is high or the ambient temperature is too low, it is necessary to use the fuel whose
cetane number is more than 40 in order to prevent flameout and too much smoke.
● When the fuel of low sulfur content is used, its cloud point shall be at least 10ºC lower
than the expected minimum fuel temperature. Cloud point is the temperature at which
the waxy crystals begin to form.
● The universal diesel fuel of commercial brands shall contain sulfur that is less than
0.5%.
● Clean fuel free from water and/or impurities shall be ensured before refueling.
5.4.2 Table of capacities
Engine Swing drive Final drive Hydraulic Cooling

Model Fuel tank
oil pan casing casing system system
SY195C9 L 22 4.0 5.5 239 22.5 340
Specified
SY205C9
capacity US gal 5.83 1.06 1.45 63.14 5.94 89.8
SY215C9
SY225C9 Specified L 24.5 4.0 5.5 239 20 340
SY235C9 capacity US gal 6.49 1.06 1.45 63.14 5.28 89.8
Specified L 29 5.3 4.0 239 20 500

SY265C9
capacity US gal 7.69 1.4 1.05 63.14 5.28 132
Table 5-6

5.5 Tightening Torque Table
NOTICE
● Nuts, bolts or other parts not tightened to specific torque values may lead to loose or
damaged parts, resulting in machine failure and operating troubles.
● Special attention shall be paid when tightening parts.
Unless specified otherwise, the metric nuts

and bolts shall be tightened to the values giv-
en in the following table.
The tightening of torque is determined by the

width of screw cap or nut. b
In replacement of the bolts or nuts, use Sany

genuine parts of equivalent size.
a
CZ335-1104001
Fig. 5-1
Thread Square Tightening Torques

Diameter Size b Target Values Torque Limits
a (mm) (mm) N·m kgf·m lbft N·m kgf·m lbft
6 10 13.2 1.35 9.8 11.8~14.7 1.2~1.5 8.7~10.8
8 13 31 3.2 23.1 27~34 2.8~3.5 20.3~25.3
10 17 66 6.7 48.5 59~74 6.0~7.5 43.4~54.2
12 19 113 11.5 83.2 98~123 10.0~12.5 72.3~90.4
14 22 177 18 130.2 157~196 16.0~20.0 115.7~144.7
16 24 279 28.5 206.1 245~309 25.0~31.5 180.8~227.8
18 27 382 39 282.1 343~425 35.0~43.5 253.2~314.6
20 30 549 56 405 490~608 50.0~62.0 361.7~448.4
22 32 745 76 549.7 662~829 67.5~84.5 488.2~611.2
24 36 927 94.5 683.5 824~1030 84.0~105.0 607.6~759.5
27 41 1320 135 976.5 1180~1470 120.0~150.0 868.0~1085.0
30 46 1720 175 1265.8 1520~1910 155.0~195.0 1121.1~1410.4
33 50 2210 225 1627.4 1960~2450 200.0~250.0 1446.6~1808.3
36 55 2750 280 2025.2 2450~3040 250.0~310.0 1808.3~2242.2
39 60 3280 335 2423.1 2890~3630 295.0~370.0 2133.7~2676.2
42 65 4700 480 3478 4250~5150 434.0~525.0 3145~3811
Table 5-7

● Hydraulic hoses are tightened according to

the torques given in the following table.
b a
CZ335-1104002
Fig. 5-2
Tightening Torques
Nominal Thread Square Size
Target Values Permissible Range
Number (a) (b) (mm)
N·m kgf·m lbft N·m kgf·m lbft
9/16-18UNF 19 44 4.5 32.5 35~63 3.5~6.5 25.3~47
11/16-16UN 22 74 7.5 54.2 54~93 5.5~9.5 39.8~68.7
13/16-16UN 27 103 10.5 75.9 84~132 8.5~13.5 61.5~97.6
1-14UNS 32 157 16.0 115.7 128~186 13.0~19.0 94~137.4
13/16-12UN 36 216 22.0 159.1 177~245 18.0~25.0 130.2~180.8
*1 -7/16 - 12UN
41 215 22.0 159.1 176~234 18.0~24.0 130.2~180.8
- 2B
Note: The item marked with * is used for tightening the hose on top of the swivel joint.
Table 5-8

5.6 Safety Critical Parts
● To ensure safety when operating or driving ● If these parts show signs of abnormality
the machine, the user of the machine shall before its scheduled replacement, they
carry out regular maintenance. In addition, must be repaired or replaced immediately.
the user shall also replace the parts listed
● If the hose clamps show any deterioration,
in the table in order to further improve
such as deforming or cracking, replace the
safety condition. These parts are closely
clamps at the same time as the hoses.
related to safety and fire prevention.
● O-rings, gaskets and other such parts shall
● Safety critical parts may easily wear or
also be replaced when replacing hoses.
deteriorate due to material change as time
passes and it is hard to judge their condi- ● Consult your Sany dealer to replace the
tions through regular maintenance. These safety critical parts.
parts shall be replaced as scheduled re-
gardless of their conditions, which can ef-
fectively guarantee the functions of these
parts.
No. Safety critical parts for periodic replacement Quantity Frequency

1 Fuel hose (fuel tank - water separator) 1
2 Fuel hose (water separator - primary filter) 1
3 Fuel return hose (engine - fuel tank) 1
4 Fuel hose (primary filter - engine) 1
5 Pump outlet hose (pump - control valve) 2
6 Work equipment hose (boom cylinder oil inlet) 4
7 Work equipment hose (Bucket cylinder line - boom root) 2 Every 2 years
8 Work equipment hose (bucket cylinder oil inlet) 2 or 4000 hours,
9 Work equipment hose (arm cylinder line - boom root) 2 whichever occurs
10 Work equipment hose (arm cylinder oil inlet) 2 first.
11 Swing drive hose (swing motor oil inlet) 2

12 Main oil suction hose 1
13 Travel control hose (control valve - swivel joint) 4
14 Travel control hose (swivel joint - travel motor) 4
15 Pump pressure hose 1
16 Accumulator (control oil) 1
17 High-pressure tube clamps 1
Every 8000 hours
18 Cover - fuel squirt prevention 1
19 Seat belt 1 Every 3 years
Table 5-9

5.7 Maintenance Schedule

If the machine is equipped with hydraulic breaker, the maintenance schedule for some parts may
vary. For more information and proper maintenance, see "Hydraulic oil and filter - change/re-
place" on page 8-15.
Maintenance schedule list
Initial 50 hours of operation ................................................................................................... 5-20
When Required ........................................................................................................................ 5-21

Track shoe bolts - inspect/tighten .............................................................................................. 5-21
Track tension - inspect/adjust .................................................................................................... 5-22
Bucket - replace......................................................................................................................... 5-25
Bucket tips - replace .................................................................................................................. 5-28
Bucket clearance - adjust .......................................................................................................... 5-30
Window washer fluid level - check/fill ........................................................................................ 5-32
Refrigerant level - check ............................................................................................................ 5-33
Ceiling window gas spring - inspect .......................................................................................... 5-35
Inspection Prior to Startup ..................................................................................................... 5-37
Every 100 service hours ......................................................................................................... 5-38

Lubrication ................................................................................................................................. 5-38

Air filter element - inspect/clean/replace.................................................................................... 5-41
Engine pan oil and filter element - change/replace ................................................................... 5-44
Fan belt tension - inspect/adjust ................................................................................................ 5-46
Compressor belt tension - inspect/adjust .................................................................................. 5-47
Oil return check valve - check ................................................................................................... 5-48
Pipe clamps of hydraulic system - check................................................................................... 5-49

Swing bearing - lubricate ........................................................................................................... 5-50
Swing pinion gear grease level - inspect/fill............................................................................... 5-51
Primary fuel filter element - replace ........................................................................................... 5-52
Secondary fuel filter element - replace ...................................................................................... 5-55
Prmiming pump strainer - Clean ................................................................................................ 5-58
Radiator and oil cooler fins - inspect/clean ................................................................................ 5-59
Air conditioner fresh air/recirculation filter - clean...................................................................... 5-61
Swing drive oil level - check/fill .................................................................................................. 5-63
Final drive oil level - check/fill .................................................................................................... 5-64
Breather valve - service ............................................................................................................. 5-65

Every 1000 service hours ....................................................................................................... 5-66

Hydraulic oil filter element - replace .......................................................................................... 5-66
Swing drive oil - change ............................................................................................................ 5-68
Cab door lock and front window lock catch - inspect/tighten ..................................................... 5-69
Cab door hinge and front window slide rail - inspect/add grease .............................................. 5-70
Windshield wiper arm nut - Inspect/tighten................................................................................ 5-71
Engine exhaust pipe clamps - check ......................................................................................... 5-71
Fan belt tension - check/replace................................................................................................ 5-71
Nitrogen pressure in accumulator (breaker) - check ................................................................. 5-71
Fan belt tension - check/replace................................................................................................ 5-72
Nitrogen pressure in accumulator (breaker) - check ................................................................. 5-72
Swing mechanism grease - check and add ............................................................................... 5-72

Final drive oil - change .............................................................................................................. 5-73
Hydraulic tank filter strainer - clean ........................................................................................... 5-75
Nitrogen pressure in accumulator (control oil circuit) - check .................................................... 5-76
Hydraulic tank oil - change ........................................................................................................ 5-80
Cooling system interior - clean .................................................................................................. 5-82
Alternator - inspect .................................................................................................................... 5-84
Engine valve clearance - check/adjust ...................................................................................... 5-84

Water pump - inspect ................................................................................................................ 5-85
Start motor - check .................................................................................................................... 5-85
Accumulator - replace................................................................................................................ 5-86
High-pressure tube clamps and rubber - check......................................................................... 5-87
Compressor working condition - inspect.................................................................................... 5-88

High-pressure tube clamps - replace......................................................................................... 5-88
Every 10000 service hours ..................................................................................................... 5-88

5.8 Maintenance Procedures
5.8.1 Lockout and tag-out measures
● When maintenance is underway, starting

the engine or moving the control levers or
pedals could lead to serious accident.
● Prior to maintenance, attach a DO NOT

OPERATE tag or similar sign to the ma-
chine's start switch or control levers to
warn others that this machine is under
maintenance.
CZ335-1102067
● Attach other warning tags around the ma- Fig. 5-3

chine if necessary.
CZ335-1102068
Fig. 5-4
5.8.2 Initial 50 hours of operation
The following maintenance is to be conducted

after the initial 50 hours of operation on a new
machine.
● Machine oil and machine oil filter element

- Replace. For detailed information, see
"Every 250 service hours".
● Fuel filter - Replace. For detailed informa-

tion, see "Every 500 service hours."

5.8.3 When Required
5.8.3.1 Track shoe bolts - inspect/tighten
If the machine is operated with loose track

shoe bolts [1], the bolts can break. Tighten any
loose bolts immediately.
Tightening
Three-grouser track shoe
1. Ti g h t e n t h e b o l t s t o t o r q u e v a l u e s
of 600~680N·m (61.2~69.4kgf or
441~500Ibft). Make sure that the nuts and
track shoe are in close contact with the link
mating surface.
1
2. Inspect and further tighten the bolts by 120
± 10°.
CZ335-1104014
Tightening sequence
Fig. 5-5
Tighten the bolts in the sequence shown in the
right illustration. After tightening, make sure
that the nuts and track shoe are in close con-
tact with the link mating surface.
1 3
4 2
CZ335-1104015
Fig. 5-6

5.8.3.2 Track tension - inspect/adjust
Wear of the undercarriage pins and bushings

may vary with operating conditions and soil
type. Therefore, the tracks shall be inspected
often so as to maintain a proper track tension.
Park the machine on a hard and level ground

before checking and adjusting track tension.
Track Tension Inspection
1. Run the engine at low idle speed. Travel

the machine forward for a distance equiv-
alent to the length of the track on the
ground. Then, stop the machine slowly. 2
a
2. Place a straight piece of wood bar on top
of the track grousers between the idler [1]
and the carrier roller [2].
3. Measure the gap [a] between the bottom

the wood bar and the top surface of the
track grousers just below the bar. 1
CZ335-1104016
Standard dimension of gap (a):
Fig. 5-7
10~30mm (0.4~1.2in)
Adjustment
If track tension is beyond the standard range,

adjust it as per the following procedures.
WARNING
● When adjusting track tension, failure
to observe maintenance procedures
as specified may cause the grease dis-
charge plug to eject and result in seri-
ous injury or death.
CZ335-1102081
● Do not have your face, hands, feet and
Fig. 5-8
other body parts directly facing the
grease discharge plug when adjusting
track tension.

Increasing track tension
WARNING
● Never loosen the grease discharge plug
when increasing the track tension. Fail-
ure to follow this warning could result
in serious injury or death.
To increase track tension, prepare a grease

gun.
CZ335-1102080
Fig. 5-9
1. Inject grease through the grease fitting [2]

with the grease gun. (The grease fitting [2]
1
and the grease discharge plug [1] form an
integral part.) 2
2. Slowly travel the machine forward (7~8 m

{23 ft~26 ft 3 in}) in order to check whether
the track tension is suitable.
3. Check the track tension again. Make fur-

ther adjustment if track tension is still be-
yond the standard range.
CZ335-1104020
Fig. 5-10
4. Continue to add grease till the distance (S)

becomes null (0). If the track is still loose, it
is probably because the pin roll and bush-
ing are overworn. In this case, the pin rolls
or bushings must be swapped or replaced.
Contact Sany dealer for repair.
S
CZ335-1104019
Fig. 5-11

Reducing track tension
WARNING
● The grease discharge plug may shoot
out under high pressure. Never loosen
the plug more than one turn.
● Do not loosen any other components

except the grease discharge plug.
To reduce track tension, prepare a long socket CZ335-1102080

wrench.
Fig. 5-12
1. Slowly turn the grease discharge plug

[1] counterclockwise with the long socket
1
wrench. Grease will come out from the
grease fitting [2]. 2
Do not loosen the plug [1] more than one

turn.
2. If the grease does not come out smoothly,

travel the machine back and forth for a
short distance.
3. When suitable track tension is obtained, CZ335-1104020

tighten the discharge plug [1].
Fig. 5-13
To check whether proper track tension is
achieved, run the engine at low idle speed,
travel the machine forward (for a distance
that is equivalent to the length of the track
on the ground), and then stop the machine.
4. Check the track tension again. Make fur-

ther adjustment if track tension is still be-
yond the standard range.
NOTE:
● If the track tension can not be reduced

through the above procedures, contact
your Sany dealer for repairs.

5.8.3.3 Bucket - replace
WARNING
● Driving a pin shaft with a hammer can
cause flying metal pieces that could
lead to severe injury. Wear goggles,
safety hat, protective gloves and other
protective gears during such an opera-
tion.
● If the pin shaft is hit with strong force, it

could fly out and cause personal injury.
Make sure that the surrounding area is
clear of people before doing the job.
● Do not stand behind the bucket when

removing the pin shaft. Do not place
your foot under the bucket when work-
ing at one side.
● Do not get your finger pinched while re-

moving or installing the pin shaft.
Replacement
1. Park the machine on a hard and level

ground and lower the bucket onto the
ground.
CZ335-1103207
Fig. 5-14

2. Remove the nuts on the bolts of the retain-

ing plate of arm pin (A) and link pin (B).
Remove the bolts and take out arm pin
(A) and link pin (B), and then remove the Arm
Link pin
bucket.
NOTE: A
● Make sure the pin roll is free from mud or

sand after removal.
● Both ends of the bushing are installed with B

seals against dust. Be careful not to dam-
CZ335-1103201
age them.
Fig. 5-15
3. Align the arm with the pin hole (1) of the

replacement bucket as well as the link rod 1
with the hole (2). Insert the greased pin
rolls (A) and (B) into hole (1) and hole (2) 2
respectively.
CZ335-1103202
Fig. 5-16

NOTE:
When mounting the bucket, place the O-ring

(3) of bucket to the position, as shown in the
right illustration. After the pin roll is inserted,
align it to the standard notch.
4. Reinstall the nuts and bolts onto the plate

retaining the pin rolls. Add grease to the
pin rolls.
3 3
NOTE: CB13031501
● Inject sufficient amount of grease till the Fig. 5-17

grease is squeezed out of the end face.
● Replace any broken seals when replacing

a bucket. The use of broken seals could
allow sand or dust to penetrate through to
the pin roll and cause its abnormal wear.

5.8.3.4 Bucket tips - replace
Replace the bucket tip before the tip adapter

is worn.
CAUTION
● Operating the work equipment by mis-
take is very dangerous when replacing
bucket tips.
● The pin may fly out can cause personal

injury if too much force is applied onto
it. Make sure that nobody is in the sur-
rounding area.
● Wear safety goggles, gloves and other

personal protective gears.
1. Place a block beneath the bucket and keep

the bucket bottom level.
CZ335-1104023
Fig. 5-18
2. Make sure the work equipment is stable

and the hydraulic lockout control lever is in
CC13031403
Fig. 5-19

3. Place a metal stick against one end of the

pin (1) and hammer the metal stick in or-
der to drive the pin (1) out and remove the
2
bucket tip (2).
1
NOTE:
● The metal stick shall have a smaller diam-

eter than the pin.
● If the tip cannot be removed safely in this

way, consult your Sany dealer for replace-
ment. CZ335-1104025
Fig. 5-20
4. Remove the tip and check the retainer for

any damage. Replace it if necessary. The
retainers and tips worn short must be re-
placed with new ones. 2
5. Clean the installation surface. Insert the

retainer spring into the mounting hole of
the adapter. Mount the new bucket tip (2)
to the adapter. Push part of the pin (1) into
the tip and hammer it in completely in or- 1
der to lock the bucket tip onto its adapter.
CZ335-1104026
Fig. 5-21

5.8.3.5 Bucket clearance - adjust
CAUTION
● Operating the work equipment by mis-
take is dangerous when adjusting buck-
et clearance.
● Position the work equipment securely.

Shut down the engine and place the hy-
draulic lockout control to the LOCKED
position.
The bucket clearance must be readjusted after

the machine has been operated for a period of
time. When the clearance is excessively large
or small, it is necessary to install or remove
the shims.
1. Park the machine on a level ground. Lower

the bucket to the ground, in an attitude
2. Run the engine at low speed. Fix the buck-

et on the ground. Slowly turn the upper
structure counterclockwise till the inside of
the left side of the bucket contacts closely
with the left end surface of the arm.
3. Shut off the engine. Place the lockout con-

trol lever to the LOCKED position.
CZ335-1103207
Fig. 5-22

4. Move the O-ring [1] and measure the clear-

ance (a). It is easy to obtain accurate result
with a feeler gauge.
a 4 3
5. Loosen the four plate-mounting bolts [2]
in order to detach the plate [3]. Each shim
has an opening, so it is unnecessary to re-
move the bolt when making adjustment.
6. Remove the spacer equivalent to the mea-

sured clearance (a).
1 2
CB13031502-1
EXAMPLE: Fig. 5-23

If the clearance is 3 mm {0.118 in}, remove
two 1.0 mm {0.039 in} spacers and one
0.5 mm {0.02 in} spacer, or one 2.0 mm
{0.078 in} spacer and one 0.5 mm {0.02
in} spacer. The clearance is reduced to
0.5 mm {0.02 in}. The spacers [4] include
three types, 2.0 mm {0.078 in}, 1.0 mm
{0.039 in} and 0.5 mm {0.02 in}. When the
clearance (a) is less than one spacer, no
adjustment shall be made.
7. Tighten the four bolts [2].

5.8.3.6 Window washer fluid level - check/fill
When the solvent level in the washer reservoir

is low, air or foam will be sprayed onto the
front window. Refill the washer reservoir when
solvent level is low.
1. Open the left access door of the machine

and check the solvent level in the washer
reservoir.
2. Open the cap on the reservoir and fill it

with washer solvent. Cover the reservoir.
CZ335-1104030
3. Press the washer switch and check the
Fig. 5-24
function of the windshield washer.
NOTE: Be careful not to allow dirt or dust get

into the reservoir when adding washer solvent.
Mixing ratio of pure washer solvent and

water
Select different mixture ratio according to am-

bient temperature. Mix pure washer solvent
and water according the ratios listed below.
Operating Mixture
Temperature
Regions Ratio
General 1:2 - 10°C (14°F)
Cold regions in
1:1 - 20°C (- 4°F)
winter
Extremely cold Pure wash-

- 30°C (- 22°F)
regions in winter er solvent
Table 5-10
There are two types of detergent: one for

-10°C {4°F} (common) and one for -30°C
{-22°F} (frigid regions), which can be selected
according to the operating region.

5.8.3.7 Refrigerant level - check
WARNING
● Refrigerant getting into eyes may cause
blindness. It may cause frostbite if
splashed on your skin.
● Keep any naked fire away from the leak-

ing position of refrigerant gas.
Insufficient refrigerant (R134a) will severely

impair the cooling performance. Running the
air conditioner when refrigerant level is low
may cause damage to the compressor.
Operate the air conditioner for strong refrig-

eration when the engine is running at a high
speed. 1
Observe through the glass [2] on the condens-

er reservoir [1] in order to inspect the condition
of refrigerant gas flowing to the tube.
CZ215-1304001
Fig. 5-25
● Refrigerant flows without foam: OK
● Refrigerant flow contains foam that pass

continuously: Insufficient 2
OK
● Colorless and transparent: None
Insufficient
NOTE: The existence of foams indicates low
refrigerant level. Please consult your Sany 1 None
dealer to add refrigerant.
CZ215-1104007
Fig. 5-26

Inspection during idle period
When the air conditioner will not be used for a long period of time, the air conditioner shall be op-
erated for 3-4 minutes each month in order to lubricate the compressor components.
Air conditioner components inspection and maintenance schedule
Components Description Service Interval
Twice a year
Refilling
(spring and autumn)
Refrigerant (gas)
Tube connections and internal leakage of
Daily
parts and components
Condenser Radiator fins plugged Every 500 hours
Compressor Function Every 4000 hours
Loose and bent Every 250 hours
V-belt Deterioration, wear, scratch and cracking Every 250 hours
Noise, odd smell or abnormal heat When necessary
Fan motor and fan Function (check for abnormal noise) When necessary
Air conditioner air flow switch Air flow control switch and switching function Daily
Control unit Function (make sure the function is normal) When necessary
Loose connections and loose or detached

Joining bolts Every 6 months
nuts and bolts
Installation condition, loose connections, air

Connection tubes When necessary
leakage or any damage
Reservoir dryer temperature Temperature difference indicates a blocked

Every year
difference dryer.
Table 5-11

5.8.3.8 Ceiling window gas spring - inspect
WARNING
● The gas spring contains highly-pres-
surized nitrogen. Wrong operation can
cause explosion and result in machine
damage and personal injury or death.
● Keep the gas spring away from naked

fire.
● Do not drill or weld on the gas spring.
● Do not hammer the gas spring or ex-

pose it under any impact.
The gas springs are located on top of the cab

(at both the left and right sides).
Contact your Sany dealer for inspection, repair

and replacement when
● The ceiling window cannot be opened eas-

ily; or when
● Oil or gas leaks from the gas spring.
CZ335-1104036
Fig. 5-27

How to release pressure in the hydraulic circuit
WARNING
● The hydraulic circuit is always under
pressure. Relieve the pressure in hy-
draulic circuit when checking or replac-
ing the hoses or fittings.
● When the engine is stopped, oil and en-

gine components are still hot and can
cause serious burns. Wait until they
have cooled down before operating.
● Oil may squirt out when removing the

oil filler cap. Therefore, slowly remove
the cap in order to release the internal
pressure.
1. Park the machine on a hard, level ground.
CZ335-1103207
Fig. 5-28
2. Turn the start switch to ON position within

1
15 seconds after engine shutdown and
move the hydraulic control lever to FREE
position. Press
3. Move the joysticks and the travel control

levers in all directions to relieve the internal
pressure.
4. Remove the butterfly nut (1) on the breath-

er valve of the hydraulic tank and press the
air vent to relieve the internal pressure.
CZ215-1304004
Fig. 5-29

5.8.4 Inspection Prior to Startup
For more information about the following

items, see "Inspection before starting" on page
4-7.
● Drain the water and sediment from the fuel

tank.
● Check the water separator for water and

sediment. Drain the water.
● Check the oil level in the hydraulic tank.

Add oil.
● Check the coolant level. Add coolant.
● Check the oil level in the engine oil pan.

Add oil.
● Check the wires.
● Check the fuel level. Add fuel.
● Check the work lamp switch.
● Check the function of the horn.

● Air vent pipe under the engine. (This item
shall be checked all the time when the ma-
chine is operating in muddy places)

5.8.5 Every 100 service hours
5.8.5.1 Lubrication
NOTICE
● If the lubricated components produce abnormal noise, additional lubrication is required
besides regular maintenance.
● After operating in water, the machine's wet pin rolls are to be greased.
1. Adjust the machine to a to-be-greased position, lower the work equipment to the ground and
shut down the engine.
2. Use a grease gun to inject grease at the greasing points shown in the following illustration.
3. Finally, wipe off the old grease that has been squeezed out.
2,3,4 1
6 5
7 8 9 10,11 12
CZ335-1104046
Fig. 5-30

(1) Boom cylinder root pin (2 points)
1
1
CZ335-1104047
Fig. 5-31
(2) Boom root pin (2 points)
(3) Boom cylinder piston rod end (2 points)
(4) Arm cylinder root pin (1 point)
4 3
3
2
2
CZ335-1104048
Fig. 5-32
(5) Boom-arm joining pin (2 points)
CZ335-1104049
Fig. 5-33

(6) Arm cylinder piston rod end (1 point) 6
(7) Bucket cylinder root pin (1 point)
7
CZ335-1104051
Fig. 5-34
(8) Bucket-rod joining pin (1 point)
(9) Arm-Bucket joining pin (1 point)

8
CZ265-1204001
Fig. 5-35
(10) Rod joining pin (2)
(11) Bucket cylinder piston rod end (1)

10
(12) Bucket-rod joining pin (1)
11
10
12 CZ335-1104053
Fig. 5-36

5.8.6.1 Air filter element - inspect/clean/replace
CAUTION
● Dust may enter the engine when the
filter element is checked or replaced
with the engine running. To protect the
engine, shut it down before conducting
this job.
● The sealing rubber of the end cap must

be held tightly against the filter.
Outer filter element - Clean and replace
● Clean: Every 250 service hours or when

the air cleaner clogging alarm appears.
● Replace
Every 1000 service hours or when it has

been cleaned for six times, whichever oc-
curs first.
1. Open the rear-left access cover of the ma-

chine and loosen the clip or clasp [1] be-
2
fore removing the cover [2]. T O P
×××××××××××××××××××××××××××××
×××××××××××××××××××××××××××
××××××××××××××××××××××××××
×××××××××××××××××××××××××
××××××××××××××××××××××
××××××××××××××××××
0-13017
Fig. 5-37

2. Hold the outer filter element [3], shake it

slightly and turn it in both directions in or-
der to pull it out.
4
3. Check the inner filter element [4] to see if it
displaces or tilts. Push it back to position in
case of displacement or tilting. 3
5
4. Cover the inner element [4] with a piece of
clean cloth to avoid entering of dirt.
5. Clean the cover and clear the dust inside

the housing [5]. CZ335-1104006
Fig. 5-38
6. Blow the outer filter element with com-

pressed air (less than 0.2MPa) along the
inside and outside pleats.
Note:
● Do not tap the air filter element with any

object when cleaning it.
● Do not use air filter elements with dam-

aged pleats, gaskets or seals.
CZ335-1104008
● Using a filter element that has been used
for more than a year or an O-ring that has Fig. 5-39
been cleaned could result failure. Never
use them again.
7. Use a light to illuminate the filter element.

Replace the filter element in case of holes
or reduced thickness found in the filter ma-
terial.
CZ335-1104107
Fig. 5-40

Replacement of the inner filter element
1. Remove the outer filter element [3] and

then the inner filter element [4].
2. Cover both ends of the elements with a 4

piece of clean cloth to prevent dust form
entering the filter element.
3
3. Clean the inside of the air cleaner body
and then remove the covering cloth.
4. Place the new inner filter element [4] onto

the connecting side.
CZ215-1304005
5. Install the outer filter element [3].
Fig. 5-41
Push the filter element straight forward into
the air cleaner housing. You can hold and
shake it slightly to make the task easier.
6. Install the cover [2]. Make sure the ar-

row mark points upward. Lock the clip (or
clasp) [1]. Check the gap between the
housing and the cover. Reinstall the cover
if the gap is excessive. 2
Note:
1
● Never use the inner filter element after
cleaning it. Replace the inner filter element
CZ215-1304006
when the outer one is replaced.
Fig. 5-42
● When the outer filter element and the cover
have been installed, improper installation
of the inner filter element could damage
the outer element.
● Fake parts will allow dirt to pass through

and damage the engine due to insufficient
precision in the sealing area. Therefore,
fake parts shall not be used under any cir-
cumstances.

5.8.6.2 Engine pan oil and filter element - change/replace
CAUTION
● When the engine has just been stopped,
the parts and oil are still hot and can
cause serious burns. Wait for them to
cool down before you proceed.
1. Park the machine on solid and level ground

and lower the work equipment onto the
ground.
2. Start and run the engine at low idle for 5

minutes.
3. Stop the machine and place the hydraulic

lockout control to the LOCKED position.
4. Remove the bottom cover of the machine.

Place a container under the drain valve [P]. P
Hold a piece of cloth between the valve
CZ335S-1103057
and the vessel. Open the drain valve slow-
ly and discharge oil Fig. 5-43
Oil pan
clean cloth
Container
CZ335-1104057
Fig. 5-44

5. Open the right access door of the machine

and turn the filter element [1] leftward with
filter element spanner in order to disas-
semble the filter element.
6. Clean the filter element seat [2]. Fill the

new filter element with clean engine oil. 2
Apply engine oil (or a film of grease) to the
filter sealing surface and the threads be- 1
fore installing the filter element to its seat.
Remark: CB13040903-1
Check the filter element seat [2] for presence Fig. 5-45
of used seal. The presence of used seal in the
filter element seat [2] can cause oil leakage.
7. The installation requires contact of the

sealing surface with that of the filter ele-
ment seat [2]. Turn the filter element 3/4-1
turn.
8. Open the engine hood and add engine oil

through the filler. After 15 minutes, check if
L H
oil level is between the H and L marks on
the dipstick.
CZ335-1103131
9. Run the engine idly for a short time and Fig. 5-46
then turn off the engine. Check again the
oil level, which shall be between the H and
L marks of the dipstick. For more informa-
tion, see "Oil level in oil pan - check/add"
on page 4-11.
10. Reinstall the bottom cover.

5.8.6.3 Fan belt tension - inspect/adjust
CAUTION
● Stop the engine before inspecting or
adjusting fan belt tension.
● Over-tightened fan belt may cause dam-

age to the belt itself or to the bearings.
Inspection
1. Press the middle section of the belt be- Alternator

tween the fan belt pulley and the alternator
belt pulley with a force of about 98N {10kgf}
Fan belt pulley
with your finger. A
2. Measure the deflection (A). Standard value

of size A shall be 7~10mm {0.28~0.30in}.
Crankshaft pulley
WX235-1306002
Fig. 5-47
Adjustment 2
1. Loosen the mounting bolt [1] and adjusting

3
nut [2].
2. Loosen the adjusting bolt [3] and adjust the

belt tension of the alternator as specified.
1
Then, tighten the mounting bolt [1] and the
adjusting nut [2].
3. Start and run the engine at low idle for

about 5 minutes. Stop the engine and
check belt tension once again. WX235-1306003
The second check if especially necessary Fig. 5-48

when a new belt is installed. Belt tension
may change when a new belt seats into
the belt pulley.

5.8.6.4 Compressor belt tension - inspect/adjust
Inspection
1. Press the middle of the belt between the

drive pulley and the compressor pulley with Compressor pulley
your finger (about 58.8N {6kgf}).
2. Measure the deflection (A). Standard value A

of size A shall be 5-8mm {0.20-0.31in.}.
Drive pulley
CZ335-1104054
Fig. 5-49
Adjustment
1. Loosen the bolts [1] and [2].

4
2. Move the compressor [3] and its bracket [4] 1
in order to adjust belt tension.
3. Tighten the bolt [1] and [2] after positioning

the compressor [3].
4. Check again the belt tension after adjust-

ment. 2
3
Note:
CZ215-1104019
● Check for damaged pulleys and worn V-
Fig. 5-50
groove and V-belt. In addition, make sure
that the V-belt must not rub against the
bottom of the V-groove.
● Consult your Sany dealer to replace the

belt timely in case of the following condi-
tions.
● The fan belt has been stretched and

little margin is left for adjustment.
● Cuts or cracks are found in the belt.
● The belt skids or squeaks.
● A newly installed V-belt shall be readjusted

after one hour of operation.

5.8.6.5 Oil return check valve - check
CAUTION
1. Remove the oil return hose [1] and hose [2].
2. Remove the oil return check valve [3] and

check it.
● Remove the dirt built up in the valve

3
or on the screen if any.
● If the valve or the screen is damaged, 2 1

replace then with new ones.
3. Install the oil return check valve [3], return

hose [1] and hose [2] and tighten the pipe
CZ215-1104021
clip.
Fig. 5-51

5.8.6.6 Pipe clamps of hydraulic system - check
● Check the hydraulic system for missing,

deformed pipe clamps and loose bolts.
Replace missing or deformed pipe clamps
if any. Tighten loosened bolts to specified
torques.
● Check if the hoops of the return oil hose

and the T-clamp of the main pump suction
hose are loose. Replace these hoops and
clamps or tighten them to specified torques
if necessary.

The 100- hour and 250-hour services shall be

carried out in the meantime.
5.8.7.1 Swing bearing - lubricate
CAUTION
● Applying grease to the swing bearing
is dangerous. Do not swing the upper
structure when grease is being applied.
1. Lower the work equipment to the ground

and then shut down the engine. Place
the hydraulic lockout control lever to the
LOCKED position.
2. Add grease through the two grease fittings

while the upper structure is kept still.
3. Start the engine, move the lockout control

lever to the FREE position, and raise the
bucket 20-30 mm above the ground. Swing
the upper structure by 90°.
4. Repeat steps 1 through 3 and add grease.
CZ335-1104065
Fig. 5-52
Note:
● The grease is used to prevent distortion

and noise of joints.
● It is necessary to add grease to any com-

ponent that appears inflexible or noisy after
operation for a long period.
● Wipe off the used grease that has been

squeezed out when greasing.
● Make sure to wipe off all used grease in

different locations. Using a grease that has
been contaminated by sand or debris can
lead to wear of rotating components.

5.8.7.2 Swing pinion gear grease level - inspect/fill
● Prepare a dipstick.
1. Remove the two bolts [1] from the swing

frame. Remove the cover [2].
CZ335-1104068
Fig. 5-53
2. Put the dipstick [3] into the grease through

the inspection hole. Check the grease level
(S). A 3
Height of S: 14 mm {0.6 in} at minimum
3. Check if the grease turns milk-white. Milk-

white grease indicates that the grease has S
been contaminated. Consult your Sany

dealer in order to change the grease.
Grease capacity: 15L (3.97 US gal)
CZ335-1104069
Fig. 5-54
4. Use the bolts [1] to reinstall the cover [2].
CZ335-1104070
Fig. 5-55

5.8.7.3 Primary fuel filter element - replace
CAUTION
● Do not replace the filter immediately
after the engine is shut off, as all parts
are still hot. Wait for the parts to cool
down before you proceed.
● High pressure is generated in the fuel

system when the engine is running.
● Wait at least 30 seconds after engine

shutdown and replace the filter when
internal pressure drops to a safe level.
● Be away from fire sources.
Note:
● Sany genuine fuel filter element is a spe-

cial filter of effective filtration. The filter ele-
ment must be replaced with a genuine one.
● The use of other parts may allow dirt or de-

bris to pass through and cause the spray
system failure. Therefore, avoid using any
substitutes.
● Prevent dirt from entering the fuel system

during inspection and service. In case of
any parts contaminated by dust, flush them
clean with machine oil. CB13040702
Fig. 5-56
● Prepare a container to store the fuel

drained.
● Prepare a filter spanner.

1. Open the right access cover of the ma-

chine.
2. Place a container under the primary fuel

filter to collect the fuel drained.
3. Loosen the drain valve [5], drain all water

and sediment from the transparent cover
[4], and remove the fuel accumulated in
the filter element [3].
1
4. Turn the transparent cover [4] counter-
clockwise with a filter spanner to remove it. 2
This cover can be used repeatedly.
3
5. Remove the old filter element. Clean the
filter seat and replace the old filter element 4
with a new one. 5
CB13040701
6. Replace the gasket [3] and install the
transparent cover [4] onto the filter seat [1]. Fig. 5-57
7. The sealing surface is to be oiled for instal-

lation. The sealing surface shall be in close
contact with that of the filter element before
further tightening it by 1/4-1/2 turn.
NOTE:
Overtightened transparent cover will

damage the O-ring and cause oil leakage.
Insufficient tightening will allow oil to leak
from the clearance of O-ring. To avoid such
problems, the transparent cover must be
tightened to specific torque.

8. Bleed the air after replacement of the filter

element [2].
For the method of air bleeding, see

"Secondary fuel filter element - replace" on
page 5-55.
9. After replacing the filter element, start and

run the engine at low idle for 10 minutes.
Check the filter-sealing surfaces and the

transparent cover for fuel leakage. Check
the tightening degree of the filter element
when fuel leaks.
If the fuel still leaks, repeat the steps 1-7.

Remove the filter element and replace it
with a new filter element if any damage or
foreign object is found on the sealing sur-
face.

5.8.7.4 Secondary fuel filter element - replace
CAUTION
● Do not replace the filter immediately
after the engine is shut off, as all parts
are still hot. Wait for the parts to cool
down before you proceed.

system when the engine is running.
● Wait at least 30 seconds after engine

shutdown and replace the filter when
internal pressure drops to a safe level.
Note:
● Sany genuine fuel filter element is a spe-

cial filter of effective filtration. The filter ele-
ment must be replaced with a genuine one.
● The use of other parts may allow dirt or de-

bris to pass through and cause the spray
system failure. Therefore, avoid using any
substitutes.
● Prevent dirt from entering the fuel system

during inspection and service. In case of
any parts contaminated by dust, flush them
clean with machine oil.
● Prepare a container to hold the fuel

drained.
● Prepare a filter element spanner.

2. Place a container under the filter element.
3. Turn counterclockwise the filter cartridge [1]

with the filter element spanner to remove
it.
4. Clean the filter element seat. Apply a film

of oil to the surface of the new filter car-
1
tridge before mounting it to the filter ele-
ment seat.
0-13021
Fig. 5-58
Note:
● Do not fill the new filter cartridge with fuel.
● Remove the cover [B] and install the car-

A B
tridge.
5. Replace the internal seal [2] with a new

one.
6. During installation, tighten the filter car-

CZ335-1104091
tridge until its sealing surface contacts that
of the filter seat. Then, tighten it further by Fig. 5-59
3/4 turn.
If the filter cartridge is over-tightened, the

seals may be broken and oil leakage could
result. If the cartridge is too loose, fuel will
leak from the sealing location. Therefore,
the filter element must be tightened to a
suitable torque.
7. Bleed the air after filter element replace-
ment.
CZ335-1104090
Fig. 5-60

Air bleeding procedure:
8. Fill the fuel tank till the float reaches its

maximum level.
3
9. Loosen the plug [3] of the fuel filter.
CZ215-1104016
Fig. 5-61
10. Pull out the handle [4] of the priming pump.
11. Stroke the handle [4] of the priming pump

to feed fuel.
12. When no foams are observed in the fuel

leaking from the plug [3] of the fuel filter, 4
tighten the plug.
Tightening torque: 9.8±2.0N·m

{1.0±0.2kgf·m}
Priming pump
13. Stroke the priming pump five to six times
CZ215-1104017
and tighten the handle [4].
Fig. 5-62
14. When air has been purged, clean the

spilled fuel. Start and run the engine at low
idle for 10 minutes.
Check for fuel leakage on the sealing

surface of the filter cartridge. If fuel leaks,
check if the cartridge is well tightened. 4
If fuel leakage does not stop, repeat steps

1 through 3 to remove the filter cartridge. If
damage or foreign objects are found on the
sealing surface, the cartridge with a new
one and follow steps 4 through 13 to install Priming pump
it. CZ215-1104018
Fig. 5-63

5.8.7.5 Prmiming pump strainer - Clean
NOTE: This schedule only applies to SY-

265C9M2K machines that are equipped with
MITSUBISHI D06FRC engines.
CAUTION
● Do not work on the egine immediately
after the engine is shut offt. Wait for it
to cool down before you proceed.

system when the engine is running. Do
not work on the engine until internal
pressure drops to a safe level.

Fig. 5-64
2. Remove the bolt (2) on the priming pump

(1).
3. Remove the pump strainer (3) in the bolt (2)

with a screw driver.
4. Soak the stainer (3) in diesel fuel and clean

it with a brush.
CAUTION
● Be careful not to allow dirt to enter the Fig. 5-65
fule line when cleaning the strainer.
● Rinse with clean machine oil when dust

is found on the parts.
5. Check the strainer for damages. Replace

the strainer with a new one if necessary.
6. Install the strainer (3) into the bolt (2) with

a screw driver after cleanining.
7. Install the bolt (2) onto the priming pump.
8. Bleed the air in the fuel filters.
See “Secondary fuel filter element - Clean”

5.8.7.6 Radiator and oil cooler fins - inspect/clean
CAUTION
● Wear goggles, dust-proof mask or other
personal protective gears when han-
dling compressed air, water or steam.
NOTICE
● When compressed air is used for clean-
ing, use the air at certain distance to
avoid damaging the radiator fins.
● The fins shall be inspected on a daily

basis despite of the service schedule
when the machine is working on a dusty
place.
2. Open the left access door of the machine.
3. Loosen the wing bolts [1] and pull out the

screen [2]. 1
2
4. Clean the screens with compressed air
(0.2MPa) or water.
CZ215-1304002
Fig. 5-66
CZ215-1304003
Fig. 5-67

5. Inspect the radiator [3], the hydraulic oil

cooler fins [4], the inter-cooler [5], the air 4
conditioner condenser fins [6] and the fuel 3
cooler (if equipped).
If mud, dust or leaves are found on these

components, clean them with compressed 5
air or water in the opposite direction of air 6
flow.
NOTE: When high pressure water is used for

flushing, lower the pressure of the spray gun
and keep the gun about 30cm away from the 0-13022
radiator fins. When the spry gun is too close to Fig. 5-68
the radiator, the fins may deform, resulting in
premature plugging and cracking of the radia-
tor.
NOTICE
● Do not try to pick dirt out of the fins us-
ing hard tools; otherwise, the radiator
fins may become damaged.
6. Check the radiator fins for deformation,

holes or cracking after cleaning. Make re-
pairs or replacement if necessary. Inspect
the hoses. Replace the hoses in case of
cracking or aging. Check for loose hose
clamps.
7. Remove the bottom cover [7]. Remove the

dirt, debris and tree leaves that have been
swept to the external edge.
8. Restore screen [2] that has been cleaned

and secure them with wing bolt [1]. 7
9. Install bottom cover [7] and lock the engine

hood and the left access door.
CZ335S-1104018
Fig. 5-69

5.8.7.7 Air conditioner fresh air/recirculation filter - clean
CAUTION
● Wear goggles, dust-proof mask or other
personal protective gears when han-
dling compressed air, water or steam.
Note:
The filter shall be cleaned every 500 hours,

but operating the machine in a dusty place re-
quires cleaning the filter more frequently.
A dust-clogged air filter reduces air flow and

causes the A/C unit to produce noise.
Internal air filter - clean
1. Remove the screw [1] from the access

cover in the rear of the cab, loosen the 1
locking nut [2] and remove the internal air
filter [3].
2. Use compressed air to clean the filter. If

the filter bears oil or too much dirt, clean it
with moderate detergent. After the filter has
been flushed with water, it must be dried
completely before reuse. This filter shall
be replaced every year with a new one. If
a plugged air filter cannot be cleaned with
compressed air or flushing water, replace it CZ335-1104075
immediately. Fig. 5-70
CZ335-1104076
Fig. 5-71

Fresh air filter - clean
1. Unlock and open the cover [4] on the left

side of the cab. Remove the locking nut [5]
and take out the fresh air filter [6].
4
2. Use compressed air to clean the filter. If
the filter bears oil or too much dirt, clean it
with moderate detergent. After the filter has
been flushed with water, it must be dried
completely before reuse. This filter shall
be replaced every year with a new one. If
a plugged air filter cannot be cleaned with CZ335-1104077
compressed air or flushing water, replace it Fig. 5-72
immediately.
3. After cleaning, restore the filter [6], tighten

the nut [5] and lock the cover.
4 5
CZ335-1104078
Fig. 5-73
NOTE:
The fresh air filter must be installed correctly.

S
To install the filter, the long end (L) of the filter
[6] must be inserted first into the filter box. By L
inserting the short end (S), the cover [4] will

not be closed.
6
4
CZ335-1104079
Fig. 5-74

5.8.7.8 Swing drive oil level - check/fill
CAUTION
1. Remove the dipstick (G) and wipe off the F

G
oil on it.
2. Insert the dipstick (G) back into the tube.
CB13050901-1
Fig. 5-75
3. Take out the dipstick (G) and check wheth-

er the oil level is between the H and L
marks.
4. If the oil level is lower than the L mark on

the dipstick (G), remove the filler cap (F)
and add oil. H
L
CZ335-1204006
Fig. 5-76
5. If the oil level goes beyond the H mark on

the dipstick (G), loosen the drain valve (P)
and to drain the excessive oil.
● If the oil level is too high, consult your

P
Sany dealer for inspection.
● Place a container under the drain valve

before draining machine oil.
6. After checking the oil level or refilling the

oil, insert the dipstick (G) into the tube and
restore the filler cap (F). CB13051401-1
Fig. 5-77

5.8.7.9 Final drive oil level - check/fill
WARNING
● When the engine is shut down, the oil is
still hot. Wait until the oil is cool enough
before operation.
● Residual pressure in the tank can cause

oil to squirt out or the screw plug to fly
out. Slowly loosen the screw plug in or-
der to release the pressure.
● When the screw plug is being loosened,

do not stand in front of the screw plug.
1. Park the machine on a hard and flat

ground and adjust position so that the drain
F
plug (D) is closest to the ground. Stop the
L
engine and place the lockout lever to the
LOCKED position. D
2. Use a proper screwdriver to remove the Oil level

dirt in the hexagonal socket of screw plug.
3. Remove the screw plug (L) with a spanner.

When oil level is 10 mm {0.4 in} lower than
the bottom line of the port (L), the amount
of oil added is just perfect. CZ235-1104017
Fig. 5-78
4. If the oil level is low, add specified gear oil
through the fill port.
5. Restore the screw plugs (F) and (L) after

check. Tighten the screw plugs to specified
torques.
6. Check the other final drive using the same

method.

5.8.7.10 Breather valve - service
CAUTION
1. Clean the top of the hydraulic tank and re-

move the contaminants around the breath-
er valve.
Disassemble the valve in a place that is

free from fire sources and dust.
2. Remove the butterfly nut [1] on the breath-

er valve and press the vent valve to re-
lease internal pressure.
3. Remove lock nut [2], cover [3] and take off

the filter element [4]. CZ335-1104080
4. Clean the filter element with a brush if ex- Fig. 5-79

cessive dirt is found around the filter ele-
ment. Then flush the element using Tonson
detergent.
5. Dry the filter element after it is cleaned. 1
6. Install the filter element. 3

2
NOTE: 4
● When assembling the hexagonal nut [2],

tighten it to the specific torque (10-14 N·m).
● Replace the breather valve filter element

if it has serviced for 1500 hours or if it has
been cleaned for more than 6 times. CC13031501
Fig. 5-80
● Replace the breather valve when the filter
element is worn out.

The 100-, 250- and 500-hour services shall be

carried out in the meantime.
5.8.8.1 Hydraulic oil filter element - replace
CAUTION
Note:
For machines equipped with a hydraulic

breaker, the hydraulic oil deteriorates faster
than that of machines operating with a bucket.
For more information, see "Hydraulic oil and
filter - change/replace" on page 8-15.
1. Park the machine on a hard and level

ground. Adjust the work equipment to an
attitude ready for service. Lower the work
equipment to ground and stop the engine.
CZ335-1104086
Fig. 5-81
2. Remove the butterfly nut [1] of the breather

1
valve on top of the hydraulic tank. Press
the vent valve to release internal pressure.
按压
CZ215-1304004
Fig. 5-82

3. Loosen the four bolts and remove the cap

[2]. When the cap is being removed, it may
eject due to the action of the spring [3]. In 2
this case, hold down the cap when remov-
3
ing the bolts.
4
4. Remove the spring [3], valve [4] and strain- 5
er [5] before disassembling the filter ele- 6
ment [6].
● Check the bottom of the filter box and re-

move the dirt if any. Keep the hydraulic oil
CZ335-1104088
free from any dirt.
Fig. 5-83
5. Clean the disassembled parts with clean-
ing oil.
6. Install a new filter element.
7. Restore the valve [4], strainer [5] and

spring [3].
8. Install the cap [2] to its position. Hold down

the cap and tighten the bolts.
9. In order to bleed internal air, start and run

the engine at low idle for 10 minutes.
10. Stop the engine.

5.8.8.2 Swing drive oil - change
CAUTION
● Swing drive casing capacity: 4.0 L (1.06

US gal)
1. Place a container under the drain valve (P)

to collect the gear oil drained.
P
2. Loosen the drain valve (P) to drain the
gear oil. Tighten the drain valve upon com-
pletion of the draining.
NOTE:
● If the gear oil flows out in a thin thread pat- CB13051401-1

tern, stop draining.
Fig. 5-84
● When ambient temperature is low, you can
swing the work equipment to slightly in-
crease the oil temperature before draining
the oil. However, the work equipment shall
not be swung during draining, which may
otherwise damage the swing unit.
3. Remove the filler cap (F) and add oil as re- F

G
quired through the filler opening.
4. Check the oil level. For more information,

see "Swing drive oil level - check/fill" on
page 5-63.
5. Apply sealant onto the thread of the filler

CB13050901-1
opening and tighten the filler cap.
Fig. 5-85
Tightening torque: 2.7N·m
NOTE:
Improper tightening of the filler cap may cause

the gear oil in the swing drive to leak.

5.8.8.3 Cab door lock and front window lock catch - inspect/tighten
1. Check the body of the cab door lock.
Cab door lock
C13082201
Fig. 5-86
2. Check the lock catch of the cab door lock.
Lock catch
C13082202
Fig. 5-87
3. Check the windshield lock catch inside the

cab. (One at each side)
When the items listed above are found loose,

tighten them immediately so that the cab door
and windows can be opened and shut prop-
erly.
Windshield lock catch
C13082203
Fig. 5-88

5.8.8.4 Cab door hinge and front window slide rail - inspect/add grease
Inject grease through the grease fitting on top

of the cab door hinge till grease is seen spill-
ing out. Grease fitting
C13082204
Fig. 5-89
Apply grease onto the slide rails at both sides

of the cab door ceiling.
Slide rail
C13082205
Fig. 5-90

5.8.8.5 Windshield wiper arm nut - Inspect/tighten
Check the nut of the windshield wiper arm.

Tighten the nut immediately when it is found
loose so that the wiper can function properly.
Cap
1. Raise the nut cap at the end of the wiper
arm and check if the nut comes loose.
2. Tighten it with a torque wrench or an ordi-

nary wrench if the nut is loose.
Tightening torque: 35~45N·m

Nut
C13082206
Fig. 5-91
5.8.8.6 Engine exhaust pipe clamps - check
Consult your Sany dealer to check the fasten-

ing conditions of the air cleaner - turbocharger
- post cooler - engine clamps.
5.8.8.7 Fan belt tension - check/replace
Check the tension of fan belt. Replace the fan

belt in case of cracks or damage. Contact your
Sany dealer if you have any troubles.
5.8.8.8 Nitrogen pressure in accumulator (breaker) - check
(If equipped)
Special tools will be used in order to check the

accumulator and inject nitrogen.
Please consult your Sany dealer, if possible, to

conduct related inspection and inflating opera-
tion.

5.8.8.9 Fan belt tension - check/replace
Check the tension of fan belt. Replace the fan

belt in case of cracks or damage. Contact your
Sany dealer if you have any troubles.
5.8.8.10 Nitrogen pressure in accumulator (breaker) - check
(If equipped)
Special tools will be used in order to check the

accumulator and inject nitrogen.
Please consult your Sany dealer, if possible, to

conduct related inspection and inflating opera-
tion.
5.8.8.11 Swing mechanism grease - check and add
Add grease through injection port [1] until

grease seeps out from overflow port [2].
● Use EP grease (SHELL: Albanian EP2,

etc.)
● Lube oil: Change and add lube oil after

1,000 hours of motor running.
2 1
CZ215-1104013
Fig. 5-92

The 100-, 250-, 500- and 1000-hour services

will be carried out in the meantime.
5.8.9.1 Final drive oil - change
WARNING
● When the engine is shut down, the oil is
still hot. Wait until the oil is cool enough
before operation.
● Residual pressure in the tank can cause

oil to squirt out or the screw plug to fly
out. Slowly loosen the screw plug in or-
der to release the pressure.
● When the screw plug is being loosened,

do not stand in front of the screw plug.
● Refilling capacity: Refer to "Table of capac-

ities" on page 5-14.

ground and adjust position so that the drain
plug (D) is closest to the ground. Stop the
engine and place the lockout lever to the F
LOCKED position. L
D
2. Use a proper screwdriver to remove the
dirt in the hexagonal socket of screw plug.
Oil level
3. Place a container under the drain port (D)
to collect the oil. Loosen the level port plug
(L) and the drain port plug to discharge oil.
4. When the oil in the final drive is drained,

CZ235-1104017
clean the drain port plug with clear diesel
fuel and install the plug. Fig. 5-93
5. Remove the fill port plug (F) and add spec-

ified gear oil through the filler opening until
oil flows out from the level port.
6. Clean the plug with clear diesel fuel and

re-install the plug.

NOTE:
Check the O-ring on screw plug and replace

the O-ring if it is damaged.

5.8.9.2 Hydraulic tank filter strainer - clean
CAUTION
1. Remove the butterfly nut [1] of the breather

valve on the hydraulic tank and press the 1
vent valve to relieve internal pressure.
Press
CZ215-1304004
Fig. 5-94
2. Loosen the four bolts and remove the cap

[2]. When the cap is being removed, it may 2
fly out due to the action of the spring [3]. In
this case, hold down the cap when remov- 3
ing the bolts.
4
3. Hold the top end of the rod [4] and pull it
upward to remove the spring [3] and the 5
strainer [5].
6
4. Clean the strainer [5]. Flush it with cleaning
oil. Replace the strainer if it is damaged.
CZ335-1104093
5. During installation, fix the strainer [5] to the
Fig. 5-95
projected part [6] of the oil tank before as-
sembling.
6. When assembling, use the bulged part of

the cap [2] to hold the spring [3] before
tightening the bolts.

5.8.9.3 Nitrogen pressure in accumulator (control oil circuit) - check
WARNING
● The accumulator contains pressurized
nitrogen, which may explode due to im-
proper operation and result in machine
damage and personal injury.
● Do not bump or roll the accumulator.

Keep it free from any impacts.
● Vent the air completely when handling

the accumulator. Consult your Sany
dealer to do this job.
Note:
In continuous operation with low nitrogen pres-

sure in the accumulator, the remaining pres-
sure in hydraulic circuit will not be released
once failure occurs to the machine.
Functions of the accumulator
The accumulator stores the pressure of the

control circuit. Even if the engine is turned off,
the control oil circuit allows you to achieve the
following operations:
● Operate the control lever to lower the work

equipment. The work equipment will fall
due to gravity.
● The pressure in hydraulic circuit can be re-

leased.
The installation location of the accumulator is CB13041502-1

Fig. 5-96

Checking the functions of accumulator
CAUTION
● During inspection, make sure the sur-
rounding area is clear of personnel or
any barriers.
Check nitrogen pressure in the accumulator

through the following steps:

ground.
2. Keep the work equipment 1.5m (4'11'')

above the ground at maximum reach (with
the arm cylinder and the bucket cylinder
fully retracted). 1.5m
The step 3 through step 5 shall be con-

ducted within 15 seconds.
CZ335-1104095
The accumulator’s pressure drops gradu- Fig. 5-97
ally after engine shutdown. Check the
accumulator immediately after the engine
is shut down.
3. Keep the work equipment at its maximum

operating radius, turn the start switch to
the OFF position and stop the engine.


FREE position. Operate the joysticks and
lower the work equipment. Check if the
work equipment touches the ground.
CC13031404
Fig. 5-98
6. If the work equipment fall under its own

weight to the ground, this shows the accu-
mulator functions normally.
If the work equipment fails to fall to the

ground, this shows pressure in the ac-
cumulator has dropped.
Consult your Sany dealer for such an

inspection.

LOCKED position and turn the start switch CZ335-1104099
to the OFF position.
Fig. 5-99

How to release pressure in hydraulic circuit
1. Low the work equipment to the ground.
2. Place the lockout lever to the LOCKED po-

sition.
The steps 4 through step 6 shall be carried

out within 15 seconds.
Pressure of the accumulator will drop

gradually after the engine is stopped.
Therefore, the pressure can only be re-
leased when the engine has just be turned CC13031403
off.
Fig. 5-100
3. Turn off the engine.
ON
OFF
STA
T
HEA
RT
CC13031804
Fig. 5-101
5. Place the lockout lever to the FREE posi-

tion and then cycle the control levers in all
directions to release the pressure in control
circuit.

sition and then turn the start switch to the
OFF position.
CC13031404
Fig. 5-102

5.8.9.4 Hydraulic tank oil - change
CAUTION
● Press the breather valve venting button

to release the internal pressure before
removing the oil filler cap.
NOTE:
For machines equipped with a hydraulic

breaker, the hydraulic oil deteriorates faster
than that of machines operating with a bucket.
For more information, see "Hydraulic oil and
filter - change/replace" on page 8-15.
● Refilling capacity: Refer to "Table of capac-

ities" on page 5-14.
● Prepare a lever (used for 36 mm socket

wrenches)
1. Unscrew the bolts of the bottom cover

plate and remove the cover plate.
2. Swing the upper structure in order to posi-

tion the drain plug beneath the hydraulic
tank between the tracks.
3. Retract the arm and bucket cylinders and

lower the boom in order to enable the
bucket tips to touch the ground.

sition and turn off the engine. CZ335-1104102
Fig. 5-103

5. Remove the cap of the oil filler (F).

F
6. Place a container under the drain plug.
Remove the drain plug (P) with the lever to
drain the oil. Check the O-ring on the drain
plug (P) and replace it timely if broken.
Tighten the plug (P) after draining.
NOTE:
Do not get oil on your body when removing the

drain plug (P).
P
7. Add hydraulic oil as required through the CZ335-1104103-1
filler (F). Check the oil level, which shall be Fig. 5-104
between the H and L marks of dipstick.
● For more information on applicable hy-

draulic oil, see "Recommended Fuel,
Coolant and Lubricant" on page 5-12.
● For more information on oil level in-

spection, see "Hydraulic oil level -
check/refill" on page 4-9.

5.8.9.5 Cooling system interior - clean
WARNING
● Coolant in the radiator is still hot and
under high pressure when the engine is
shut down. Removing the radiator cap
at this time may cause severs burns.
● Loosen the cover slowly when the cool-

ant has cooled down to relieve internal
pressure before removing it.
● When the engine is started for cleaning

purpose, place the hydraulic lockout
control in the LOCKED position to pre-
vent unexpected machine movement.
● Antifreeze is flammable. Keep it away

from fire.
● Antifreeze is toxic. Never allow it to con-

tact your eyes and/or your skin. Wash
with plenty of water and seek medical
treatment immediately if antifreeze con-
tacts your eyes or skin.
● Never drain antifreeze directly into the

sewer or onto the ground.
Clean the inside of radiator fins and re-

place coolant
1. Park the machine on a level ground and

then shut off the engine.
2. Remove slowly the radiator cap [1] to re-

lieve pressure only when the coolant is
cool enough for you to touch the radiator 1
cap with your bare hand.
0-13018
Fig. 5-105

3. Remove the bottom cover under the ra-

diator and place a container to collect the
coolant under the drain valve [2]. Open the 2
drain valve [2] to drain the coolant.
4. Close the drain valve [2] after draining the

coolant. Add tap water and cleaning agent
into the radiator. When the radiator is full,
start the engine at a low speed in order to
heat up to 90°C (194°F) at minimum. Con-
tinue to run the engine for about 10 min-
utes.
CZ335-1104012
5. Stop the engine and open the drain valve Fig. 5-106
[2] to discharge water. Flush the cooling
system with clean water till discharged
water is clear so as to remove the rust and
sediment inside the radiator.
6. Close the drain valve [2]. Add coolant slow-

ly into the radiator till it overflows from the
filler opening.
7. Run the engine at low speed for about 5

minutes and then at high speed for another
3 minutes to bleed the air from the coolant.
(The radiator cap [1] shall be left open at
the moment.)
8. Check coolant level once again. Add more

if necessary.
9. Clean the reserve tank [3] after completely 3

draining the coolant inside. Add water till FULL
the coolant level reaches a level between LOW

the high and the low marks.
Replace the reserve tank with a new one if

the old one is hardly cleaned.
10. Stop the engine. Wait about 3 minutes be-

fore adding water through the filler open-
CB13040901-1
ing. Screw on the radiator cap tightly.
Fig. 5-107
11. Install the bottom cover.

Clean the inside of hydraulic oil cooler
1. Remove the hydraulic oil cooler before

cleaning. Cleaning shall be performed on a
clean washing table.
2. Rinse the cooler with hydraulic oil of the

same grade, plane kerosene, petrol or die-
sel fuel. Blow the inside of the cooler with
an air pump.
NOTE: Keep the inside of the hydraulic oil

cooler clean during the cleaning process. Do
not wipe the cooler with cotton, linen or syn-
thetic fibers.
Recommended cleaning agent: Hydraulic oil of

the same grade, plane kerosene, petrol, diesel
fuel.
5.8.9.6 Alternator - inspect
Contact your Sany dealer to inspect the alter-

nator.
Check the engine every 1000 service hours if

the engine is started frequently.
5.8.9.7 Engine valve clearance - check/adjust
Special tools are necessary for inspection and

maintenance. Consult your Sany dealer to do
this job.

The 100-, 250-, 500-, 1000- and 2000-hour

services shall be carried out in the meantime.
5.8.10.1 Water pump - inspect
Check the water pump for water leakage or oil

leakage. In case of any problem, contact your
Sany dealer for disassembly, repair or replace-
ment.
CZ335-1104104
Fig. 5-108
5.8.10.2 Start motor - check
Consult your Sany dealer to check the start

motor. Check it every 1000 service hours if the
engine is started frequently.

5.8.10.3 Accumulator - replace
Replace the accumulator every two years or

4000 service hours, whichever occurs first.
WARNING
● The accumulator contains pressurized
nitrogen, which may explode due to im-
proper operation and result in machine
damage and personal injury.
● Do not bump or roll the accumulator.

Keep it free from any impacts.
● Vent the air completely when handling

the accumulator. Consult your Sany
dealer to do this job.
If the machine is kept operating when the

performance of accumulator decreases, the
pressure in the hydraulic system will not be
released. Consult your Sany dealer to replace
the accumulator.
The accumulator's installation location is

CB13041502-1
Fig. 5-109

5.8.10.4 High-pressure tube clamps and rubber - check
CZ335-1104106
Fig. 5-110
Check, through visual inspection and feel, for any loose bolts on the five mounting clamps of
high-pressure pipe between the supply pump and the spray nozzle. Contact your Sany dealer to
replace the parts in trouble.

5.8.10.5 Compressor working condition - inspect
The following two items are to be inspected:
1. Whether the compressor and the magnetic

clutch are switched on/off when switching
on/off the air conditioner.
2. Whether the clutch or compressor produc-

es abnormal noise.
In case of any problem, contact your Sany

dealer for disassembly, repair or replace-
ment of the parts.
The 100-, 250-, 500-, 1000-, 2000- and 4000-

hour services shall be carried out in the mean-
time.
5.8.11.1 High-pressure tube clamps - replace
Contact your Sany dealer to replace the high-

pressure tube clamps of the engine.
Contact your Sany dealer if service hours of

the machine reaches 10, 000 hours or overall
maintenance.

E
G
PA
K
AN
BL

E
G
PA
K
AN
BL

SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator Troubleshooting
Troubleshooting
6 Troubleshooting
6.1 Troubleshooting Preparation.................................................................................... 6-3
6.1.1 Checks before troubleshooting ...................................................................... 6-3
6.1.2 Troubleshooting precautions .......................................................................... 6-4
6.1.3 Electrical circuits troubleshooting precautions ............................................... 6-6
6.1.4 Hydraulic components handling precautions ................................................. 6-7
6.2 Measures Taken When Failure Occurs.................................................................... 6-9
6.2.1 Failure-like phenomena ................................................................................. 6-9
6.2.2 Towing the machine ..................................................................................... 6-10
6.2.3 Towing hook for light loads........................................................................... 6-12
6.3 Engine Failures ...................................................................................................... 6-13
6.3.1 Engine troubleshooting table ....................................................................... 6-13
6.3.2 Coolant temperature high ............................................................................ 6-18
6.3.3 Engine oil pressure low ................................................................................ 6-20
6.3.4 When fuel runs out ....................................................................................... 6-21
6.3.5 When engine rotates reversely .................................................................... 6-24
6.4 Failures of the Electrical System ........................................................................... 6-25
6.4.1 Electrical system troubleshooting table........................................................ 6-25
6.4.2 Failure codes ............................................................................................... 6-29
6.5 Battery ................................................................................................................... 6-31
6.5.1 Battery removal and installation ................................................................... 6-31
6.5.2 Battery charging ........................................................................................... 6-32
6.5.3 Starting engine with jumper cable ................................................................ 6-33
6.5.3.1 Connecting jumper cables .................................................................. 6-34
6.5.3.2 Starting engine .................................................................................... 6-35
6.5.3.3 Disconnecting jumper cables ............................................................. 6-35
6.6 Failures of the Hydraulic System ........................................................................... 6-36

Troubleshooting SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator
6.7 Other Common Failures ........................................................................................ 6-40
WARNING
jury or death.

6 TROUBLESHOOTING
6.1 Troubleshooting Preparation
6.1.1 Checks before troubleshooting
Item Judgement value Remedy
1. Check fuel level and type of fuel — Add fuel

2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
4. Check hydraulic oil strainer — Clean, drain
Lubricating
5. Check swing drive oil level — Add oil
oil, coolant
6. Check engine oil level (in oil pan) — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
1. Check for looseness and corrosion of battery termi-

— Tighten or replace
nal and wiring
E l e c t r i c a l 2. Check for looseness and corrosion of alternator ter-
equipment minal and wiring
3. Check for looseness and corrosion of start motor
terminal and wiring
H y d r a u l i c , 1. Check for abnormal noise and smell — Repair

mechanical 2. Check for oil leakage — Repair
equipment 3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20~30V Replace

2. Check battery electrolyte level — Add or replace
3. Check for discolored, burnt, exposed wiring — Replace
4. Check for missing wiring clamps and hanging wiring — Repair
5. Check for water leaking on wiring (be particularly —
Electrics, Disconnect con-
careful attention to water leaking on connectors or
electrical nector and dry
terminals)
equipment —
6. Check for blown or corroded fuses
Replace
7. Check alternator voltage (engine running at 1/2 After running for
Replace
throttle or above) several minutes:
8. Check operating sound of battery relay 27.5~29.5V
— Replace
(when switch is turned ON/OFF)
Table 6-1

6.1.2 Troubleshooting precautions
● Park the machine on a hard, level ground. Make sure safety pins, blocks and machine brake
are functional.
● Workers in the same team must use the same signal system. Keep other personnel a safe
distance away from the machine.
● If the radiator cap is removed when the engine is hot. Hot coolant may squirt out and cause
burns, wait for the engine to cool down before troubleshooting.
● Take care not to touch any hot parts or be caught by any rotating parts.
● Before disconnecting any electrical wiring, always disconnect the negative (–) post of battery.
● Before removing the plug or cap from any vessel that contains pressurized oil, water or air,
release the internal pressure. When installing a measuring equipment, be sure to connect it
properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly,
and to prevent reoccurrence of the failure.
When carrying out troubleshooting, it is important to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form
some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately any failure occurs:
● Parts that have no connection with the failure or other unnecessary parts will be disas-
sembled.
● It will become impossible to find the cause of the failure.
It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also
lose the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fixed procedure.
2. Points to ask user or operator:
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?

5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Check the oil level.
2) Check for any external leakage of oil from the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
5) Other maintenance items can be checked externally, so check any item that is considered to
be necessary.
4. Confirming failure
● Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or
as a problem with the method of operation, etc.
● When operating the machine to reenact the troubleshooting symptoms, do not carry out
any investigation or measurement that may make the problem worse.
5. Troubleshooting
● Use the results of the investigation and inspection in Items 2 – 4 to narrow down the
causes of failure, then use the troubleshooting flowchart to locate the position of the failure
exactly.
● The basic procedure for troubleshooting is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure
● Even if the failure is repaired, if the root cause of the failure is not repaired, the same fail-
ure will occur again. To prevent this, always investigate why the problem occurred. Then,
remove the root cause.

6.1.3 Electrical circuits troubleshooting precautions
1. Always turn the power off before disconnecting or connect connectors.
2. Before carrying out troubleshooting, check that all the related connectors are properly insert-
ed.
● Disconnect and connect the related connectors several times to check.
3. Always connect any disconnected connectors before going on to the next step.
● If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity,
or current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
● If there is any change, there is probably defective contact in that circuit.

6.1.4 Hydraulic components handling precautions
With the increase in pressure and precision

of hydraulic equipment, the most common
cause of failure is dirt (foreign material) in the
hydraulic circuit. When adding hydraulic oil, or
when disassembling or assembling hydraulic
equipment, it is necessary to be particularly
careful.
1. Be careful of the operating environment
Avoid adding hydraulic oil, replacing filters,

or repairing the machine in rain or high
winds, or places where there is a lot of
dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is

carried out on hydraulic equipment in the
field, there is danger of dust entering the
equipment. It is also difficult to confirm the ZX215-1000023
performance after repairs, so it is desir- Fig. 6-1
able to use unit exchange. Disassembly
and maintenance of hydraulic equipment
should be carried out in a specially
prepared dust-proof workshop, and the
performance should be confirmed with
special test equipment.
3. Do not let any dirt or dust get in during re-

filling operations.
Be careful not to let any dirt or dust get

in when refilling with hydraulic oil. Always
keep the oil filler and the area around it
clean, and also use clean pumps and oil
containers. If an oil cleaning device is
used, it is possible to filter out the dirt that
has collected during storage, so this is an
even more effective method.
ZX215-1000025
Fig. 6-2

4. Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it

flows easily. In addition, the sludge can
also be drained out easily from the circuit
together with the oil, so it is best to change
the oil when it is still warm. When changing
the oil, as much as possible of the old
hydraulic oil must be drained out. (Drain
the oil from the hydraulic tank; also drain
the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
5. Flushing operations
After disassembling and assembling

the equipment, or changing the oil, use
flushing oil to remove the contaminants,
sludge, and old oil from the hydraulic cir-
Flushing oil
cuit. Normally, flushing is carried out twice:
primary flushing is carried out with flushing
oil, and secondary flushing is carried out
with the specified hydraulic oil.
ZX215-1000026
Fig. 6-3
6. Cleaning operations
After repairing the hydraulic equipment

(pump, control valve, etc.) or when run-
ning the machine, carry out oil cleaning
to remove the sludge or contaminants in
the hydraulic oil circuit. The oil cleaning
equipment is used to remove the ultra fine
(about 3μ) particles that the filter built into
the hydraulic equipment cannot remove, so
it is an extremely effective device.
ZX215-1000027
Fig. 6-4

6.2 Measures Taken When Failure Occurs
6.2.1 Failure-like phenomena
Note that the following phenomena are not

machine failures:
● The arm speed may drop suddenly when

retracting the arm with the work equipment
lowering unloaded and the arm in a nearly
vertical position.
CZ335-1103213
Fig. 6-5
● When the bucket tips are nearly parallel

to the ground, the bucket speed may drop
suddenly.
● The brake valve produces noise when

starting or stopping swinging operation.
● The travel motor produces noise when the

machine travels downhill at low speed.
CZ335-1103214
Fig. 6-6

6.2.2 Towing the machine
WARNING
● Make sure that the wire cables used for
towing the machine are strong enough,
which may otherwise result in acci-
dents.
● While towing the machine, do not use

wire cables with broken wires (A), re-
duced diameter (B) or knot (C) in order
to prevent rupture of the wire cables. A
● Always wear protective gloves when B

handling wire cables.
● Never tow the machine on a slope. C
● Never stand between the towing ma-

chine and faulty machine when perform-
CZ335-1102063
ing towing operation.
Fig. 6-7
● Operate the machine slowly and avoid
imposing sudden load on wire cable.
Note:
The acceptable towing force of the machine is:
SY195C9, SY205C9, SY215C9:
146,000 N (14,900kgf)
SY225C9, SY235C9, SY265C9:
195,000 N (19,900kgf)
The towing operation must be performed with-

in the maximum towing capacity.

● If the machine is trapped in mud and can-

not move out of the mud with its own force,
or the towing force of excavator is occu-
pied by heavy object, wire cables can be
used as shown in the right illustration.
● Place wood blocks or other protective

materials between where the wire cable
contacts the machine in order to prevent
friction between the wire cable and the ma-
chine.
● Keep the wire cable parallel to the ground CZ335-1103216
and align its direction with that of the track Fig. 6-8
frame.
● Move at a speed of 1Km/h when towing

the machine. Tow the machine to a place
suitable for repair. Never tow the machine
over a long distance.
● Towing of the machine is only allowed in

case of emergency.
CZ335-1103217
Fig. 6-9

6.2.3 Towing hook for light loads
WARNING
● Shackle must be used.
● Keep the wire cable parallel to the

ground and align its direction with that
of the track frame.
● Move the machine slowly and avoid im-

posing sudden load on wire cable.
Two front towing eyes are designed on front of

the lower frame. These two eyes are used to
secure the machine during shipment or trans-
portation.
Two rear towing eyes are designed on the rear

of the lower frame. These two eyes are used
to tow light loads or to secure the machine
during shipment or transportation.
CZ215-1305219
Fig. 6-10
Max. permissible towing force:
SY195C9, SY205C9, SY215C9:
58,800 N (6,000kgf)
SY225C9, SY235C9, SY265C9:
79,600 N (8,100kgf)
CZ215-1305220
Fig. 6-11

6.3 Engine Failures
6.3.1 Engine troubleshooting table
Check the engine according to the following table if any failure occurs to it. Contact your Sany
dealer to repair the engine.
Failure Causes Remedy
● Battery dead ● Recharge/replace the battery.

● Battery that has disconnected or loose ● Remove the corroded part.
cable, or is corroded.
Starter failure ● Fuse breaks. ● Replace the fuse.
or reluctant
● Failure of start switch or start relay. ● Replace the start switch or relay.
rotation.
● Failure of start motor. ● Repair/replace the start motor.
● Engine oil viscosity high. ● Use engine oil with suitable viscos-
When the engine fails to start
ity.
● Fuel exhausted. ● Refill the fuel and purge the air.

● Fuel injector opening pressure low. ● Adjust/replace the fuel injector.
● Failure of fuel delivery valve of injection ● Replace the fuel delivery valve.
pump
● Failure of control rack of injection pump ● Repair or replace the control rack.
● Worn or stuck plunger of injection pump ● Replace the plunger assembly.
Starter is OK. ● Improper starting operation ● Start the engine in regular steps.
● Air trapped in the fuel system ● Purge air from the fuel system.
● Fuel filter plugged ● Replace filter element or cartridge.
● Air cleaner plugged ● Clean/replace air cleaner element.
● Clutch sideslip ● Battery dead
● Turbocharger intake hose clamp loose ● Replace filter element or catridge.
● Turbocharger intake hose crack ● Clean or place air cleaner element.
● Idle speed low. ● Battery dead

Engine shuts ● Fuel filter plugged ● Replace fuel filter element or car-
down immediately
tridge.
after starting.

● Failure of low idle controller ● Repair/replace the low idle control

system.
● Fuel system leaks or is blocked. ● Repair the fuel system.
● Air trapped in the fuel system ● Pure the air from fuel system.
● Fuel system contains water. ● Change the fuel.
● Fuel filter element plugged ● Replace fuel filter element or car-
Low idle speed
tridge.
instable
● Failure of injection pump ● Repair/replace related parts of fuel
injection pump.
● Bad adjustment of air valve clearance ● Readjust air valve clearance.
● Broken cylinder gasket, worn cylinder liner, ● Replace relevant parts.
stuck or ruptured piston ring, or defective
contact between air valve and its seat
● Fuel filter plugged ● Replace fuel filter element or car-
tridge.
● Fuel contaminated by water ● Change the fuel.
● Failure of fuel delivery pump ● Repair/replace fuel delivery pump
● Fuel injector activating pressure low; injec- ● Readjust/replace fuel injector.
tion effect not good
● Failure of injection pump ● Repair/replace related parts of the
fuel injection pump.
Power insufficient
● Exhaust gas leaks. ● Replace relevant parts.
Air leaks.
● Turbocharger assembly damaged ● Replace turbocharge assembly.
● Exhaust valve blocked ● Clean the exhaust pipe.
● Bad adjustment of air valve clearance ● Adjust valve clearance.
● Soft or broken spring of air valve ● Replace gas spring.

● Insufficiency of coolant ● Refill coolant.

● Fan belt skids due to looseness or crack- ● Replace fan belt.
ing.
● Radiator cap damaged or radiator core ● Replace radiator cap or clean radia-
plugged tor core.
Engine overheat- ● Coolant pump damaged ● Repair/replace coolant pump.
ed ● Coolant leaks due to broken cylinder head ● Replace seal cap.
or cylinder block seal cap
● Thermostat damaged ● Replace thermostat.
● Cooling system blocked by foreign object ● Remove foreign object from the
● Improper adjustment of fuel injection tim- cooling system.
ing ● Readjust fuel injection timing.
● Fuel contaminated by water ● Change the fuel.
● Sluggish fuel injection timing ● Readjust fuel injection timing.
White exhaust
● Failure of turbocharger ● Repair/replace.
gas
● Defective valve oil seal or worn valve stem ● Replace valve oil seal, valve and
and valve guide tube valve guide tube.
● Wear, rupture or incorrect setup of piston ● Replace the piston or reset it cor-
ring rectly.
● Scratch or wear of cylinder liner ● Replace cylinder liner.
● Fuel injector activating pressure low or bad ● Readjust/replace fuel injector.
injection effect
● Improper adjustment of fuel injection tim- ● Readjust fuel injection timing.
Black exhaust gas
ing
● Fuel drips after injection due to damage of ● Replace fuel delivery valve.
fuel injection pump delivery valve
● Excessive injection of the injection pump ● Readjust fuel injection amount.

● Fuel leaks. ● Repair/replace related parts of the

fuel system.
● Low idle improper ● Readjust low idle.
● Fuel injector activating pressure low, or ● Adjust/replace fuel injector.
bad injection effect
● Fuel injection timing incorrect ● Readjust fuel injection timing.
● Fuel drips after injection due to damage of ● Replace fuel delivery valve.
Excessive con-
fuel injection pump delivery valve.
sumption of fuel
● Air leaks from the intake side of turbo-
charger. ● Repair the intake side of turbo-
● Turbocharger assembly damaged charger.
● Bad valve clearance ● Replace turbocharger assembly.
● Soft or broken valve spring ● Readjust valve clearance.
● Broken cylinder gasket, worn cylinder liner, ● Replace valve spring.
stuck or ruptured piston ring, or defective ● Replace relevant parts.
● Bad oil ● Use suitable oil.

● Excessive oil ● Drain excessive oil.
● Oil leaks through oil seal and/or gasket. ● Replace oil seal and/or gasket.
● No preheating operation
Excessive con- ● Defective valve oil seal, or wear of valve ● Follow the procedure specified
sumption of oil stem and valve guide tube ● Replace related parts.
● Wear, rupture or improper setup of piston
ring ● Replace piston ring or reset it prop-
● Scratch or wear of cylinder liner erly.
● Replace cylinder liner.
● Oil insufficient ● Refill oil.
● Bad oil viscosity ● Use lubricant with proper viscosity.
● Oil leaks through oil seal and/or gasket. ● Replace oil seal and/or gasket.
● Oil filter element plugged
● Replace oil filter element or car-
Oil pressure low
● Stuck safety valve and/or soft bypass tridge.
valve spring ● Replace spring of safety valve and/
● Oil pump screen plugged or bypass valve.
● Wear of oil pump related parts ● Clean the screen of oil pump.
● Replace related parts of oil pump.

● Exhaust pipe connector loose or exhaust ● Tighten exhaust pipe connector or

pipe broken replace exhaust pipe.
● Fuel injector loose ● Replace gasket and tighten fuel in-
Strange engine noise
Gas leaking jector .

noise
● Exhaust manifold connector loose ● Tighten the connector of exhaust
manifold.
● Cylinder gasket broken ● Replace cylinder gasket.
● Fan belt loose ● Readjust belt tension.
C o n t i n u o u s ● Cooling fan loose ● Tighten the cooling fan.
noise ● Worn or damaged coolant pump bearing ● Replace coolant pump bearing.
● Bad valve clearance ● Readjust valve clearance.
Table 6-2

6.3.2 Coolant temperature high
CAUTION
● Never remove the radiator cap when the
coolant is still hot. Hot water or steam
may squirt and cause burns.
● Wait the coolant to cool down before re-

moving the radiator cap.
NOTICE
● Do not stop the engine immediately.
Sudden rise of coolant temperature can
cause engine parts to burn.
● Refill the coolant slowly in several

times. Quick filling of low-temperature
coolant can cause engine cracks.
When the coolant temperature gauge shows

a temperature higher than 100°C, the coolant
temperature alert indicator will be on. Stop op-
erating the machine and keep engine running
at a speed a little higher than idle in order to
reduce temperature. When the pointer of cool-
ant temperature gauge returns to the middle
position, the alert indicator is off. Now, stop the
engine and perform the following steps.

1. Check radiator hoses for coolant leak.
2. Check V-belt for rupture. Check the belt

tension. 1
3. Check coolant level. Refill coolant if neces-

sary.
● Remove the radiator cap (1) and refill

coolant to the opening. Tighten the cap
properly.
CZ215-1105003
Fig. 6-12
● Open the reservoir (2) and refill cool-

ant to the FULL mark. Tighten the cap
properly.
2
FULL
LOW
4. Check the front of radiator for any contami-
nants.
5. If the machine has coolant leak or often

encounters higher coolant temperature, the
cooling system has a problem.
0-13014
Fig. 6-13

6.3.3 Engine oil pressure low
● When the engine is just started, the oil

pressure gauge indicates high pressure
before the engine is preheated. Check oil
pressure after the engine is fully preheat-
ed.
● When engine oil pressure is abnormal,

which is shown on the monitor, stop oper-
ating the machine, shut down the engine
immediately, and proceed as the following.
NOTICE
● Shut down the engine immediately.
Keep running the engine can cause
damage to the engine.
1. Check for oil leak.

1
2. Check engine oil level. Refill oil if neces-
sary.
● Remove the dipstick [1]. Wipe off the oil

on it with cloth.
● Fully insert the dipstick [1] into oil and

then slowly pull it out.
● If oil level between the marks L and H,

the amount of oil is good.
CZ215-1105004
● If oil level is low, add oil immediately. If Fig. 6-14
engine oil is contaminated, change the
oil immediately.
● Replace the dipstick (1) after checking.
3. If engine oil level is normal but the oil pres-

sure gauge reads wrong, the low oil pres-
sure alert indicator and oil filter indicator
will be on. Contact your Sany dealer to
solve the problem. L H
CZ335-1103131
Fig. 6-15

6.3.4 When fuel runs out
Engine shuts down when fuel exhausts or air

enters the fuel system due to replacement of
fuel filter. If you are unable to start the engine
after refilling the fuel, purge the air through the
following steps.
WARNING
● Never use a lighter, smoke, or use other
fire sources when purging the air. A fire
source can cause fire.
● Completely remove engine oil or fuel

splashed onto the exhaust pipe and
other places. These oil and fuel can
cause fire or slipping accident.
● The space for air-purging operation is

limited. Take care not to be cut by the
edges
1. Turn the handle (1) of hand pump counter-

clockwise to unlock it.
CZ215-1105005
Fig. 6-16

2. Loosen the fuel filter vent plug (2) and cov-

er the vent with cloth.
2
CZ215-1105006
Fig. 6-17
3. Operate the hand pump to deliver fuel until

no foam is seen in the vent.
CZ215-1105007
Fig. 6-18
4. Screw on the vent plug (2) when no foam

is observed.
2
CZ215-1105009
Fig. 6-19

5. Keep pumping the fuel until high resistance

is felt.
With the fuel temperature is low, the

pressure of hand pump may not grow. It is
important to operate the hand pump many
a time continuously .
6. After eliminating the air, completely remove

the splashed fuel before starting the en-
gine.
7. Make sure that no fuel leaks any more. CZ215-1105008
Fig. 6-20
WARNING
● Check the fuel filter and its shell for
fuel leak. The leak of fuel is possible to
cause fire.

6.3.5 When engine rotates reversely
WARNING
● Reverse rotation of engine can burn the
engine within several minutes or cause
severe injury. Shut down the engine
immediately once reverse rotation is
found. The exhaust gas from air cleaner
is possible to cause fire.
The following symptoms can be used to iden-

tify reverse rotation of engine.
● High colliding sound produced after start-

ing
● Heavy smoke coming out air cleaner
● Tachometer and oil pressure gauge giving

no response
● Low oil pressure alert indicator on
Check and clean the air cleaner and intake

hoses after shutting down the engine. Replace
any defective air cleaner or hose immediately.

6.4 Failures of the Electrical System
6.4.1 Electrical system troubleshooting table
Trouble-shoot the electrical system according to the following tables. Contact your Sany distribu-
tor solve the problem.
● Recharge/replace the bat-

● Battery low
tery.
● Engine start switch internal failure
● Replace
● Pilot switch failure
● Repair/replace
● Start motor failure
● Repair/replace
● Open circuit of wire harness
Engine fails to start ● Check/repair
● Fuse failure (F1)
● Replace
● Short circuit of wire (grounding failure)
● Check/repair
● Alternator internal failure
● Repair/replace
● Start relay failure
● Replace
● Brake failure
● Repair/replace
● Open circuit of wire harness ● Check/repair
● Sensor internal failure ● Replace
Rough engine speed
● Short circuit of wire (grounding failure) ● Check/repair
● Sensor internal failure ● Replace
Unable to power off the ● Battery relay failure ● Replace
machine ● Breakdown of surge diode ● Replace
● Boom-up signal failure ● Check/repair
● Boom-down signal failure ● Check/repair
● Arm-in signal failure ● Check/repair
● Arm-out signal failure ● Check/repair
● Bucket-dig signal failure ● Check/repair
Auto idle fails.
● Bucket-dump signal failure ● Check/repair
● Swing signal failure ● Check/repair
● Travel signal failure ● Check/repair
● Attachment signal failure ● Check/repair
● Controller failure ● Replace
● Preheat fuse failure ● Replace
● Preheat relay failure ● Replace
Preheating function fails.
● Preheat controller failure ● Replace

● Hydraulic lockout control failure ● Repair/replace

All devices fail. ● Short circuit of wire (grounding failure) ● Check/repair
● Failure of internal coil of pilot lockout valve ● Replace
● Sensor failure ● Replace
● Short circuit of harness (grounding failure) ● Check/repair
Boom slow and weak
● Open circuit of harness ● Check/repair
Arm slow and weak
Bucket slow and weak ● Open circuit of harness ● Check/repair
● Bucket confluence solenoid valve failure ● Replace
Travel slow and weak
● Fuse failure ● Replace
● Open circuit of wire ● Check/repair
Monitor black-out
● Monitor failure ● Replace
● Resistor failure ● Replace
● Open circuit of wire ● Check/repair
Monitor displays nothing.
● Monitor or controller failure ● Replace
● Dual travel speed solenoid valve failure ● Replace
Dual-travel speed failure ● Open circuit of wire ● Check/repair
● Coolant temperature sensor failure ● Replace
Engine coolant tempera- ● Open circuit of wire ● Check/repair
ture reading incorrect ● Short circuit of wire (grounding failure) ● Check/repair
● Wire short-circuited with 24V ● Check/repair

● Fuel level sensor failure ● Replace

Fuel level reading incor- ● Open circuit of wire ● Check/repair
rect ● Short circuit of wire (grounding failure) ● Check/repair
● Wire short-circuited with 24V ● Check/repair
● Wiper motor internal failure ● Repair/replace
Wiper failure ● Open circuit of wire ● Check/repair
● 5V power supply failure ● Repair/replace
Arm-in pilot pressure ● Open circuit of signal line ● Check/repair
reading incorrect ● Short circuit of signal line ● Check/repair
Arm-out pilot pressure ● Open circuit of signal line ● Check/repair
Boom-up pilot pressure ● Open circuit of signal line ● Check/repair
Boom-down pilot pres- ● Open circuit of signal line ● Check/repair
sure reading incorrect ● Short circuit of signal line ● Check/repair
Bucket-dig pilot pressure ● Open circuit of signal line ● Check/repair
Bucket-dump pilot pres- ● Open circuit of signal line ● Check/repair
sure reading incorrect ● Short circuit of signal line ● Check/repair
Swing pilot pressure ● Open circuit of signal line ● Check/repair



Travel pilot pressure ● Open circuit of signal line ● Check/repair
Table 6-3

6.4.2 Failure codes
The failure code displayed on the monitor can be used to make failure analysis.
Failure
Symptom Alarm condition
Code
- CPU error Ambient temperature or noise above specified value.
Lights up Memory error (RAM) Error detected when system is energized using FROM
11 Memory error (FROM) and RAM verification.
Motor current abnormal (above 1.8A) Abnormal motor load circuit detected. Current below
0.1A or above 1.8A lasts for two seconds. Current out-
Motor current abnormal (below 0.1A) put stopped via protection circuit action. Open circuit
12
and ground short circuit. Motor rotation limited.
Motor connection abnormal (short cir- Abnormal motor connection detected. Open circuit
cuit) and ground short circuit.
Motor stop detected. 30 seconds after energizing,
13 Motor operation stopped
bias above 5%.
Voltage at min stroke limit below 0.8V or voltage at
14 Motor error within operating range
max stroke limit above 4.2V last 100 msec.
15 Power supply abnormal Power supply above 36V
Temperature inside controller is above 80°C or below
16 Abnormal temperature inside controller
-30°C and lasts for 10 seconds.
Abnormal sensor power output detected. Short circuit
17 Abnormal sensor power
or over current.
Response signal (RS-422) from controller paused five
18 Abnormal controller communication
times in a row.
19 Backup batter voltage low Abnormal backup battery voltage detected.
20 From pump output voltage
21 Rear pump output voltage
22 Arm IN pilot valve pressure
23 Arm OUT pilot valve pressure
24 Boom UP pilot valve pressure
25 Boom DOWN pilot valve pressure Voltage beyond 0.25~4.75V lasts over 200 msec.
26 Bucket DIG pilot valve pressure
27 Bucket DUMP pilot valve pressure
28 Swing pilot valve pressure
29 Travel LEFT pilot valve pressure
30 Travel RIGHT pilot valve pressure

Failure
Symptom Alarm condition
Code
31 Potentiometer for motor setting Voltage beyond 0.25~4.75V lasts over 200 msec.
32 Built-in potentiometer of motor Voltage beyond 0.25~4.75V lasts over 50 msec.
33 Option pilot valve pressure Voltage beyond 0.25~4.75V lasts over 200 msec.
37 Oil temperature sensor Voltage beyond 0.25~4.75V lasts over 200 msec.
Low engine speed detected. Revolution speed below
41 Engine speed
100 rpm. Speed sensor broken wire or short circuit.
50 Front pump Load circuit of proportional solenoid coil abnormal
51 Rear pump (over current). Current above 1.8A lasts one second.
Bias current occurs on protection circuit. Broken wire
52 Swing priority
or short circuit.
53 Bucket confluence Load circuit of proportional solenoid coil abnormal
54 Boom priority (1) (under current). Current below 0.1A lasts one second.
Bias current occurs on protection circuit. Broken wire
55 Boom priority (2) or short circuit.
Abnormal ON/OFF solenoid valve coil detected. Bro-
60 Travel speed shift
ken wire or short circuit.
Table 6-4

6.5 Battery
WARNING
● Remove the battery from the machine
before charging it.
● Stop the engine and turn the key switch

to the OFF position when checking or
handling the battery.
● Wear goggles and rubber gloves when

handling the battery.
● A loose terminal can result in improper

contact, which may cause sparks and
explosion.
6.5.1 Battery removal and installation
● Disconnect the grounding cable (generally

the one in connection with the negative ter- 2
minal (-)) before removing the battery. 1
● Sparks can occur if your tool touches the

positive terminal and the chassis.
● Secure the battery with clamping plates

when changing the battery. 1
2
● Always disconnect the ground cable (nega-

tive terminal (-)) first when removing the
battery; always connect the positive termi- CZ335-1103219
nal (+) first when installing the battery.
Fig. 6-21

6.5.2 Battery charging
Improper handling can result in explosion

when charging the battery. Follow the instruc-
tions below:
● Regulate the charger to the voltage appli-

cable to the battery. Incorrect voltage can
over heat the charger and cause explo-
sion.
● Connect the charger's positive clip (+) to

the battery's positive terminal (+). Connect
the charger's negative clip (-) to the bat-
tery's negative terminal (-). The wire clips CZ335-1103220
must be fixed.
Fig. 6-22
● Regulate the charging current to 1/10 of
the rated capacity of battery. In case of
quick charging, regulate the charging cur-
rent to a level below the rated capacity of
battery. Larger charging current may cause
leakage or evaporation of electrolyte,
hence fire and explosion.
● If the battery electrolyte freezes, do not

charge the battery, or use an alternate
power supply to start the engine. Charging
a frozen battery may cause electrolyte to
catch on fire and the battery to explode.

6.5.3 Starting engine with jumper cable
WARNING
● Never let the positive pole (+) contact
with the negative pole (-) when connect-
ing the cables.
● Keep the normal machine away from the

faulty one to prevent sparks around the
battery which may ignite the hydrogen
released from the battery.
● Avoid mistakes in connection of the

jumper cable. Its final connection with
upper structure of the machine can pro-
duce sparks. In this case, the battery CZ335-1103221
shall be connected to a location that is Fig. 6-23
far enough from the battery.
● When removing the jumper cables,

take care not to allow the cables clips
to contact with each other or with the
chassis.
Note:
● The start system of the machine is sup-

plied with a 24V power source. Two 12V
batteries are connected serially to supply
power under normal operating conditions.
● The sizes of jumper cables and clips shall

match the battery.
● The battery of the starting machine shall

have the same capacity as the engine to
be started.
● Check the cables and clips for damage or

corrosion.
● Make sure that the cables and clips are

connected securely.
● Check if the hydraulic lockout levers of

both machines are in the LOCKED posi-
tion.
● Check if all control levers are neutralized.

6.5.3.1 Connecting jumper cables
Turn the start switches of the normal machine

and the faulty one to OFF position.
Connect the jumper cables in the numbered

sequence, as shown in the diagram.
1. Connect the clip of jumper cable (A) to the

positive terminal (+) of battery (C) of the
A
faulty machine.
2 1
2. Connect the clip on the other end of jump- 3
er cable (A) to the positive terminal (+) of
battery (D) of the normal machine.
3. Connect the clip of jumper cable (B) to the D C

negative terminal of battery (D) of the nor- 4
mal machine. B
E
4. Connect the clip on the other end of jump- CZ335-1103222
er cable (B) to the swivel frame (E) of the
Fig. 6-24
faulty machine.

6.5.3.2 Starting engine
WARNING
● Check the machine and make sure the
hydraulic lockout lever is placed in the
LOCKED position and the all the control
levers are neutralized.
1. Make sure the clips are securely connect-

ed with terminals of the battery.
2. Start the engine of the good machine and

run it at high idle.
3. Turn the start switch of the faulty machine

to "START" position and start the engine.
If the engine fails to start, wait for two

minutes before attempting to restart it.
6.5.3.3 Disconnecting jumper cables
After the engine is started, disconnect the

jumper cables in steps reversed to their con-
nection.
1. Disconnect the clip of the jumper cable (B)

from the swivel frame (E) of the faulty ma-
chine. A
2. Disconnect the clip of the jumper cable (B) 3 4

2
from the negative terminal (-) of battery (D)
of the normal machine.
3. Disconnect the clip of jumper cable (A) D C

from the positive terminal (+) of battery (D) 1
of the normal machine. B E
4. Disconnect the clip of jumper cable (A) CZ335-1103223

from the positive terminal (+) of battery (C)
Fig. 6-25
of the faulty machine.

6.6 Failures of the Hydraulic System
● Trouble-shoot the hydraulic system according to the following tables. Contact your Sany deal-
er to solve the problem.
● Set the working mode to S and the fuel control dial to position 10 before troubleshooting
● Bad adjustment or main relief valve failure ● Replace

Work equipment moving
● Pilot relief valve failure ● Replace
slowly, or travel and swing
● Regulator failure ● Repair/replace
speed slow
● Plunger pump failure ● Check/repair
Work equipment, final drive ● Pilot pump relief valve failure ● Replace
or swing drive not function- ● Hydraulic pump failure ● Check/repair
ing ● Coupling failure ● Check/repair
● Hydraulic oil level low ● Refill hydraulic oil
● Bad hydraulic oil ● Use suitable hyd oil
Abnormal noise in hydraulic
● Hydraulic tank cap vent plugged ● Clean/replace
pump
● Hydraulic tank filter screen plugged ● Clean/replace
● Plunger pump failure ● Check/repair
Auto idle not functioning ● Pilot valve failure ● Replace
● Controller failure ● Repair/replace
● Right pilot valve (boom circuit) failure ● Check/repair
● Pressure sensor failure ● Replace
● Boom control valve (spool) failure ● Repair/replace
Boom speed slow ● Boom control valve (retaining valve) failure ● Repair/replace
● Boom control valve (Safety valve and feed ● Repair/replace
valve) seal failure
● Boom cylinder failure ● Check/repair
● Left pilot valve (arm circuit) failure ● Check/repair
● Arm control valve (spool) failure ● Repair/replace
Arm speed slow ● Arm control valve (regeneration valve) failure ● Repair/replace
● Arm control valve (Safety valve and feed valve) ● Repair/replace
or seal failure
● Arm cylinder failure ● Check/repair

● Check/repair
● Right pilot valve (bucket circuit) failure
● Replace
● Pressure sensor failure
● Repair/replace
● Bucket control valve (spool) failure
● Repair/replace
Bucket speed slow ● Bucket control valve (regeneration valve) failure
● Bucket control valve (Safety valve and feed
● Repair/replace
valve) or seal failure
● Bucket cylinder failure
● Check/repair
● Pilot valve failure ● Check/repair
One cylinder of work equip-
ment not working
● Work equipment control valve (spool) failure ● Repair/replace
● Work equipment cylinder failure ● Repair/replace
● Retaining valve (of boom or arm) failure ● Repair/replace
Work equipment cylinder
● Work equipment control valve (safety valve and ● Repair/replace
drifting excessively
feed valve) seal failure
● Work equipment valve spool failure ● Repair/replace
● Arm regeneration valve failure
● Repair/replace
Work equipment sluggish ● Control valve (safety valve and feed valve) fail-
● Repair/replace
ure
Other work equipment
moves when single cylinder ● Control valve seal failure ● Replace
is in relief.
Travel speed drops remark-
ably during swing or travel ● Straight travel valve failure ● Repair/replace
operation.
● Travel pilot valve failure ● Repair/replace
● Regulator failure ● Repair/replace
Machine runs out during ● Proportional solenoid valve sluggish ● Repair/replace
travel ● Travel valve spool sluggish ● Repair/replace
● Central swivel joint sluggish ● Repair/replace
● Travel motor failure ● Repair/replace
● Travel pilot pressure sensor failure ● Replace


Travel speed slow
● Travel control valve (spool) failure ● Repair/replace
● Travel control valve (feed valve) failure ● Repair/replace
● Travel motor failure ● Check/repair
● Travel pilot pressure sensor failure ● Replace
Machine steering difficult or ● Travel control valve (spool) failure ● Repair/replace
power insufficient ● Travel control valve (feed) failure ● Repair/replace
● Travel motor (safety valve) failure ● Repair/replace
● Travel motor (check valve) failure ● Repair/replace
● High/low travel speed shift valve failure ● Replace
Unable to shift travel speed
● Travel control pedal valve failure ● Repair/replace
● Travel motor safety valve failure ● Repair/replace
Travel fails (on one side) ● Travel motor balance valve failure ● Repair/replace
● Pilot pressure sensor failure ● Replace
● Swing motor (parking brake) failure ● Check/repair

● Misadjustment or failure of swing motor (safety ● Adjust/replace
Unable to swing
In both directions valve)

● Swing motor failure ● Check/repair
● Swing drive failure ● Check/repair
● Pilot valve failure ● Repair/replace

In one direction ● Swing control valve (spool) failure ● Repair/replace
● Swing motor (feed valve) seal failure ● Replace
● Swing motor (parking brake) failure ● Check/repair
Swing speed slow
● Misadjustment or failure of swing motor (safety ● Adjust/replace

valve)
Acceleration perfor-
mance bad
● Brake control line blocked ● Remove obstruction
or replace the pipe-
line.


Swing speed slow
● Swing motor (pressure compensation valve) fail- ● Repair/replace

Bad acceleration per-
ure
formance on one side
or swing speed slow
● Leak on one side the shuttle valve of swing pilot ● Repair/replace
pressure sensor
● Bad adjustment or failure of swing motor (safety ● Adjust/replace
Too much overrun in swing stoppage
In both directions valve)


In one direction ● Swing control valve (spool) failure ● Repair/replace
● Swing pilot valve failure ● Repair/replace

Too much jerk in swing stop-
● Swing anti-jerk valve failure ● Repair/replace
page
● Swing relief valve failure ● Repair/replace
● Back pressure valve failure ● Repair/replace
H i g h a b n o r m a l n o i s e i n ● Swing motor (safety valve) failure ● Repair/replace
swing stoppage ● Swing motor (feed valve) failure ● Repair/replace
● Swing system mechanical failure ● Check/repair
Excessive hydraulic drift of swing
When swing brake ● Swing brake control line failure ● Check/repair

engaged ● Swing motor (parking brake) failure ● Repair/replace
● Swing control valve (spool) failure ● Repair/replace

When swing brake
● Swing motor (relief valve) failure ● Repair/replace
disengaged
● Swing motor (feed valve) failure ● Repair/replace
Table 6-5

6.7 Other Common Failures
● Loose fastener ● Check and retighten.

Structure member
● Bigger clearance between arm and ● Reduce the clearance to a value
noise loud
bucket end faces due to wear that is smaller than 1mm.
● Spring deformed and weak due to re-
Bucket tip falls off dur-
peated use of bucket tip pin ● Replace bucket tip pin
ing operation.
● Bucket tip pin not matching the adaptor
● Loose track ● Tighten the track
Track kinks. ● Traveling at high speed on rough road ● Travel slowly on rough road in the
in the direction of sprocket direction of idler.
● Improper electrical connection or con-
nector contact
Fan not working ● Air flow control switch, relay or tem- ● Repair/replace.
perature control switch damaged
● Fuse exploded or battery voltage low
● Air intake side blocked
Fan running but pro- ● Evaporator or condenser fin plugged,
● Clean/replace.
ducing less air flow giving ineffective heat conduction
● Fan vane seized or damaged
● Compressor clutch not picking up due ● Repair
to wire break or defective contact of
Compressor not work- electrical circuit ● Adjust the tension of compressor
ing or working with ● Loose compressor belt belt
difficulty ● Wire break or failure of compressor ● Replace clutch coil
clutch coil ● Refill/drain the refrigerant to a suit-
● Insufficient or excessive refrigerant able level
● Eliminate the leaking point.
● Refrigerant leaks.
Refrigerant insufficient ● Refill suitable amount of refriger-
● Insufficient refilling
ant.
High/low pressure ● Ambient temperature: 30~50°C

reading in normal op- ● High pressure gauge: 1.47~1.67MPa (15~17kgf/cm²)
eration ● Low pressure gauge: 0.13~0.20MPa (1.4~2.11kgf/cm²)

● Expansion valve opening excessively. ● Replace expansion valve.

Low pressure gauge
● Defective contact of expansion valve ● Install thermo-bulb correctly.

Low pressure thermo-bulb ●
reads higher.
tube surface ● Excessive refrigerant in the system ● Drain refrigerant to the specified
frosted level.
Both high and

Low pressure gauge reads lower.
low pressure
gauge read- ● Refill refrigerant to the specified
● Refrigerant insufficient
ings lower level.
the standard
value.
Low pressure
● Low pressure hose blocked; expansion ● Repair the system. Replace reser-
gauge could
valve blocked by ice or contaminants. voir in case of ice blockage.
read negative.
Evaporator
● Thermostat failure ● Replace thermostat.
frozen
Expansion valve inlet
● Expansion valve blocked. ● Clean/replace expansion valve.
felt cool and frosted.
Expansion valve outlet
is not felt cool. Low ● Expansion valve thermo-tube or bulb
● Replace expansion valve.
pressure could be leaks.
negative.
Both high/ ● Air trapped in circulation system. ● Empty the system and vacuate to
low pressure refill refrigerant.
High pressure gauge reads higher.
gauges read ● Excessive refrigerant refilled. ● Drain refrigerant to the specified

higher than level.
standard
value.
● Condenser blocked by dust and debris ● Clean the condenser.
● Condenser fan damaged
Bad condens-
ing effect of ● Check/replace condenser fan.
condenser.

Both high and

low pressure
gauges read
lower.
High
pressure Low pres- ● Refrigerant insufficient ● Refill refrigerant as required.
gauge sure could be ● Low pressure line blocked/damaged ● Clean/replace faulty component.
reads negative. ● Compressor internal failure ● Replace compressor.
lower.
Condenser
and high
pressure tube
hot
Bad refrigerating effect ● Hot water valve damaged and left open Replace hot water valve.
due active heater
Table 6-6

E
G
PA
K
AN
BL

E
G
PA
K
AN
BL

SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator Specifications
Specifications
7 Specifications
7.1 Machine Dimensions ............................................................................................... 7-3
7.2 Working Ranges ...................................................................................................... 7-4
7.3 Operating Parameters ............................................................................................. 7-5

Specifications SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator
WARNING
jury or death.

7 SPECIFICATIONS
7.1 Machine Dimensions
D I
E C
L
H
G F J
B K
CJ13032601-1
Fig. 7-1
Unit: mm
Item SY195C9 SY205C9 SY215C9 SY225C9 SY235C9 SY265C9

A Overall Length (Transportation) 9560 9680 9680 9680 9920 10690
B Overall Width 2800 2800 2980 2980 2980 3190
C Overall Height (Transportation) 3250 3440 3440 3440 3550 3255
D Upper Width 2710 2710 2710 2710 2710 3045
E Overall Height (Top of Cab) 2990 2990 2990 2990 2990 3085
F Standard Track Width 600 600 600 600 600 600
G Track Gauge 2200 2200 2380 2380 2380 2590
*H Min Ground Clearance 440 440 440 440 440 440
I Tail Swing Radius 2890 2890 2890 2890 2890 3240
J Track Shoe Grounding Length 3260 3355 3445 3640 3640 3830
K Track Length 4060 4160 4250 4445 4445 4635
*L Counterweight Clearance 1130 1130 1130 1130 1130 1155
* Excluding track shoe lug
Table 7-1

7.2 Working Ranges
g
b
c d
CJ13032602-1
Fig. 7-2

Unit: mm
Item SY195C9 SY205C9 SY215C9 SY225C9 SY235C9 SY265C9

a Max. Cutting Height 9410 9570 9640 9560
b Max. Dumping Height 6490 6700 6725 6610
c Max. Digging Depth 6410 6600 6785 6400
d Max. Vertical Digging Depth 5790 5800 5845 6165
e Max. Horizontal Reach 9740 9950 10150 10160
f Min. Swing Radius 3755 3595 3800 3915
Max Height at Min Swing
g 7700 7665 7940 8010
Radius
Table 7-2
7.3 Operating Parameters
Item Unit SY195C9 SY205C9 SY215C9 SY225C9 SY235C9 SY265C9

Working Weight kg 21,000 21,200 21,800 22,600 24,200 26,500
Bucket Capacity m³ 0.8 0.8 0.9 1.0 1.1 1.3
SANY ISUZU MITUSIBISHI
Engine Model MITSUBISHI 6D34-TL
D06S2 6BG1 D06FRC
Engine Power kW/rpm 114 / 2050 128.5/2100 138/2100
Travel Speed
km/h 5.4/3.3 5.4/3.3 5.4/3.3 5.4/3.3 5.5/3.5 5.4/3.4
(High/Low)
Swing Speed rpm 11 11 11 11 11 10
Table 7-3

E
G
PA
K
AN
BL

SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator Optional Equipment
Optional Equipment
8 Optional Equipment
8.1 Safety Information.................................................................................................... 8-3
8.1.1 Optional equipment selection......................................................................... 8-3
8.1.2 Read equipment instruction ........................................................................... 8-3
8.1.3 Optional equipment removal and installation precautions ............................ 8-3
8.1.4 Optional equipment operation precautions .................................................... 8-4
8.2 Hydraulic Control Elements and Oil Circuit ............................................................. 8-5
8.2.1 Component locations ..................................................................................... 8-5
8.2.1.1 Stop valve ............................................................................................. 8-6
8.2.1.2 Selector valve ....................................................................................... 8-6
8.2.1.3 Attachment control pedal ...................................................................... 8-7
8.2.2 Hydraulic circuit.............................................................................................. 8-8
8.2.2.1 Hydraulic circuit switching ..................................................................... 8-8
8.2.2.2 Switching between breaker and general attachment ............................ 8-8
8.2.2.3 Connecting hydraulic oil circuit ............................................................ 8-9
8.2.2.4 Hydraulic oil path ................................................................................ 8-10
8.2.3 Attachment removal and installation .............................................................8-11
8.2.3.1 Removal ...............................................................................................8-11
8.2.3.2 Installation .......................................................................................... 8-13
8.2.4 Hydraulic oil and filter - change/replace ....................................................... 8-15
8.2.5 Long-term storage........................................................................................ 8-16
8.3 Work equipment combination ................................................................................ 8-17
8.4 Recommended Operation...................................................................................... 8-19
8.4.1 Hydraulic breaker ......................................................................................... 8-19
8.4.2 Hydraulic breaker operation ......................................................................... 8-20
8.4.3 Restricted operations ................................................................................... 8-22
8.4.4 Hydraulic breaker greasing .......................................................................... 8-25

Optional Equipment SY195/205/215/225/235/265C9 Crawler Hydraulic Excavator
8.5 Quick Coupler ........................................................................................................ 8-26

8.5.1 Quick coupler control ................................................................................... 8-26
8.5.2 Precautions for quick coupler safe operation .............................................. 8-28
8.6 Fueling System ...................................................................................................... 8-30
8.6.1 Introduction .................................................................................................. 8-30
8.6.2 Fueling system makeup ............................................................................... 8-30
8.7 Central Lubrication System.................................................................................... 8-32
8.7.1 Lubrication scheme and system makeup..................................................... 8-32
8.7.2 Working principle ......................................................................................... 8-34
8.7.3 Lubrication time setup .................................................................................. 8-35
8.7.4 Technical description.................................................................................... 8-37
8.7.5 Grease filling ................................................................................................ 8-38
WARNING
jury or death.

8 OPTIONAL EQUIPMENT
8.1 Safety Information
Observe the following precautions when selecting, installing and operating attachments or op-
tional equipment of the machine.
8.1.1 Optional equipment selection
● Please consult your Sany dealer before installing any optional equipment to the machine. You
may need to install front guard, top guard or other protective structures to the machine ac-
cording to the type of attachment or other optional equipment selected.
● You are only allowed to install Sany-approved optional equipment. Sany assumes no respon-
sibility to accidents, loss or failures caused by any optional equipment not approved by Sany.
8.1.2 Read equipment instruction
● Make sure you have read and understand the instruction manuals of the machine as well as
the optional equipment before installing and operating any optional equipment.
● If the instruction manual of the machine and/or the optional equipment is lost, please contact
the maker of the optional equipment or your Sany dealer to obtain a new one.
8.1.3 Optional equipment removal and installation precautions
The following items must be observed in order to ensure safety when removing or installing the
optional equipment.
● The removal or installation operation shall be performed on a hard, level ground.
● When the job is shared by two or more persons, a commander is to be assigned and his/her
instruction must be followed.
● Crane shall be used when handling heavy object above 25 kg. (Only eligible, experienced
personnel with official license are allowed to operate the crane.)
● Never stand under any lifted objects by the crane.
● Do not operate the machine when an object is being lifted with crane during removal or instal-
lation. Support can be used to prevent falling from the object when necessary.
● When a heavy part is to be removed, it is necessary to consider the impact to machine bal-
ance after removal. To prevent the machine from tipping over, support the machine, if neces-
sary, before removing the heavy component.
● Before or after the optional equipment has been installed or removed, make sure that it is
stable without the danger to tip.
● For more information about removal and installation please consult your Sany dealer.

8.1.4 Optional equipment operation precautions
Keep the following procedures in mind when installing a larger or heavy optional equipment. Prior
to the operation, move the machine to a safe ground for trial operation. Make sure that you know
very well the movement, center of gravity, and working range of the machine.
● If the machine stays inclined, swinging operation is not allowed in order to prevent tipping of
the machine.
● Keep a safe distance to surrounding barriers during operation.
● Pay attention to the following points when installing a heavy optional equipment.
● Heavy optional equipment probably requires a larger space for swinging operation. There
might be the danger of impacting other objects if the swinging range has not been calcu-
lated accurately. A larger space must be prepared before performing the swinging opera-
tion.
● When the lifting of heavy optional equipment is held, the distance moving downward is
relatively longer due to gravity. In this case, it should be lowered to the ground instead of
being held in air.
● Never swing, lower or stop the machine suddenly in order to prevent it from tipping over.
● Never extend or retract the boom cylinder suddenly in order to prevent impact that may
cause the machine to tip.

8.2 Hydraulic Control Elements and Oil Circuit
8.2.1 Component locations
CZ335-1105001-1
Fig. 8-1
1) Stop valve 3) Control pedal

2) Selector valve

8.2.1.1 Stop valve
The stop valve is used to stop the flow of hy-

draulic oil.
● FREE position (a) allows flow of the hy-

draulic oil.
● LOCK position (b) stops flow of the hydrau-

lic oil. A
Switch the valve to LOCK position when re-

moving or installing an attachment.
B
CZ335-1105002
Fig. 8-2
8.2.1.2 Selector valve
The selector valve is used to change the flow

direction of hydraulic oil.
The change of direction is made according to

the working mode selected. The working mode
must be applicable to the installed attachment.
For more information, see "Hydraulic circuit"
on page 8-8.
CZ335-1105003
Fig. 8-3

8.2.1.3 Attachment control pedal
This pedal is used to control the attachment.
By pressing the front, center, or rear part of

A
the pedal, different attachment operation can
be achieved.
N
When hydraulic breaker is installed
● Front part (A): Actuate B
● Center part (N): Stop
● Rear part (B): Stop

CZ335-1105004
NOTE:
Fig. 8-4
For control method of other attached tools,
consult the maker of the attachment before in-
stallation.

8.2.2 Hydraulic circuit
● When a breaker is installed on the machine, the return circuit must be connected directly to
the return filter. Therefore, do not use the return circuit except for mode B.
● Standard set pressure of the safety valve in the service valve was set at the factory before
delivery. When mode B is selected, this pressure is set at 20.6MPa {210kgf/cm², 2980PSI}.
When hydraulic shear mode is chosen, this pressure is set at 27.4MPa (280 kgf/cm²,
3980PSI).
● Further adjustment may be needed depending on the type of attachment. In this case, please
contact your Sany dealer for adjustment.
8.2.2.1 Hydraulic circuit switching
● Select a working mode on the monitor according to attachment type as per the following stan-
dards.
● The set pressures of the safety valve in the service valve and for the switch of hydraulic line
are determined by the working mode selected.
Attachment Mode Hydraulic line Safety valve set pressure

Hydraulic path forms automati-
One-way hydraulic attachment cally at the control valve where Before delivery:
B
(e.g. breaker) the return oil does not pass 20.6Mpa {210kgf/ cm² 2980PSI}
through.
Hydraulic path forms automati-
Dual-action hydraulic attach- Before delivery:
S cally at the control valve where
ment (e.g. hydraulic shear) 27.4MPa {280kgf/cm², 3980PSI}
the return oil passes through.
Table 8-1
8.2.2.2 Switching between breaker and general attachment
● When an attachment is installed and mode B is selected:
(1) Breaker hydraulic path (one-way hydraulic path) is formed.
(2) The overflow valve is set to low pressure.
When delivered from the factory: 20.6MPa {210kgf/cm2, 2980PSI}
● When an attachment is installed and mode S is selected.
(1) Shear hydraulic path (dual-action hydraulic path) is formed.
(2) The overflow valve is set to high pressure.
When delivered from the factory: 27.4MPa {280kgf/cm2, 3980PSI}

8.2.2.3 Connecting hydraulic oil circuit
Connect the hydraulic lines as per the follow-

ing steps when an attachment is installed.
1. Check the stop valve [1] and make sure it

is in the locked position (b).
● FREE position (a) allows flow of hy-

A
draulic oil. (The arrow is parallel to
arm).
● LOCK position (b) stops flow of hydrau-

lic oil. (The arrow is perpendicular to B
arm).
CZ335-1105002
Fig. 8-5
2. Remove the screw plug [1] from the end of

the stop valve line.
Note:
Do not damage or discard removed parts.

1
CZ335-1105005
Fig. 8-6
3. When plug [1] is removed, the attachment

maker is responsible for the connection of
attachment pipelines [2].
Coupler sizes and additional accumulator

2
may vary according to different attachment
makers. Please consult your Sany dealer
in this regard.
CZ335-1105006
Fig. 8-7

8.2.2.4 Hydraulic oil path
The operating directions of the pedal and hydraulic path are shown below.
CZ335-1105007
Fig. 8-8
● When the front part of the pedal is pressed, hydraulic oil flows to the pipelines on the left of
the work equipment.
● When the rear part is pressed, hydraulic oil flows to the pipelines on the right side.
● Only the front part of the pedal can be pressed if a hydraulic breaker is equipped.

8.2.3 Attachment removal and installation
8.2.3.1 Removal
1. Lower the work equipment to the ground

and shut down the engine.
2. Turn the start switch to ON position, and

move the hydraulic lockout lever to the
FREE position.
3. Move all control levers in all directions

and press the control pedal for 2-3 times
within 15 seconds after the lockout lever is
moved to the FREE position in order to re-
lieve the internal pressure in the hydraulic
lines.
CC13031404
Fig. 8-9

LOCKED position.
CC13031403
Fig. 8-10

5. The breather valve (F) on top of the hy-

draulic tank is used to release the internal
pressure of the hydraulic lines. F
To release the pressure completely, turn

and open the butterfly nut on the breather
valve (F) and press the relief button to
release the pressure.
CZ335-1105011
Fig. 8-11
6. When the hydraulic oil has cooled down,

turn the stop valve (mounted to the inlet
and outlet lines to the side of the arm) to
LOCK position (b).

draulic oil. (The arrow is parallel to arm A
length).

lic oil. (The arrow is perpendicular to
B
arm length).
CZ335-1105012
Fig. 8-12
7. Disconnect the hose at the side of the at-

tachment. Install the screw plugs to the two
outlets.
The screw plugs are used to avoid intrusion

of foreign objects. Store the disconnected
attachment properly when the screw plugs
are in place.
8. Remove the two retaining pins, remove

the attachment, and install the bucket. For
more information on bucket installation CZ335-1105013
procedures, see "Bucket - replace" on
Fig. 8-13
page 5-25.
9. Check the oil level in the hydraulic tank

when the bucket is installed properly.

8.2.3.2 Installation
1. Remove the bucket.
2. Place the attachment on a flat surface. In-

stall the attachment to the arm with the pin
(A) followed by the pin (B).
3. Lower the equipment to the ground and

shut down the engine. A
CZ335-1105014
Fig. 8-14
4. Turn the start switch to the ON position,

and place the hydraulic lockout lever to the
FREE position.
6. Move all control levers in all directions

and press the control pedal for 2-3 times
within 15 seconds after the lockout lever is
moved to the FREE position in order to re-
lieve the internal pressure in the hydraulic
lines. CC13031404
Fig. 8-15

LOCKED position.
CC13031403
Fig. 8-16

7. The breather valve (F) on top of the hy-

draulic tank can be used to release the in-
ternal pressure of the hydraulic lines. F
To release the pressure completely, turn

and open the butterfly nut on the breather
valve (F) and press the relief button to
release the pressure.
10. Check the temperature of the hydraulic

oil, which should be cooled down to a safe
temperature. Remove the two screw plugs CZ335-1105011
from the inlet and outlet. Be careful not to Fig. 8-17
contaminate the hose connections with any
dirt or soil.
If the O-ring is broken, replace it with a

new one.
11. Connect the hose to the side of the attach-

ment.
When connecting the hose, check the oil

flow direction and be careful not to make
any mistakes.
8. Turn the rotor of the stop valve (mounted

to the inlet and outlet lines to the side of
the arm) to FREE position (a).

draulic oil. (The arrow is parallel to arm
length). A

lic oil. (The arrow is perpendicular to
arm length).
B
9. Check the oil level in hydraulic tank after CZ335-1105012
installation of the attachment.
Fig. 8-18

8.2.4 Hydraulic oil and filter - change/replace
● Hydraulic breaker application causes faster contamination of the hydraulic system and dete-
rioration of hydraulic oil.
● As a result, the hydraulic oil and filter shall be replaced in shorter intervals, as compared with
machines installed with buckets. Otherwise, damage could occur in the hydraulic breaker, hy-
draulic pump and other hydraulic components.
● Recommended replacement intervals are listed below. For information on hydraulic oil and fil-
ter replacement, see related items in the Maintenance section.
Hydraulic oil Filter element

Machine with Hydraulic Breaker 600 hr 100 hr
Machine with Common Bucket 1500 or 2500 or 4000 hr 1000 hr
Table 8-2
NOTE:
● The figures in the above table are determined at 100 percent operation with hydraulic breaker.
As the operating hours of hydraulic breaker reduce, the change intervals could be prolonged
correspondingly as shown in the following chart.
● The filter cartridge must be replaced after the breaker has been operated for 100 hours.
100
Microglass Cartridge
Paper Cartridge
Change interval for
Hydraulic Breaker Operation Percentage%
80
hydraulic oil of 1,500
hour service life
60
Change interval for
hour service life
40
Change interval for
20 hour service life
0 500 1000 1500 2000 2500 3000 3500 4000

Hydraulic Excavator Operating Hours
CZ335-1105015
Table 8-3

8.2.5 Long-term storage
The following procedures shall be followed when the equipment is to be stored for a long period
of time.
● Turn the stop valve to LOCK position.
● Screw the plug on the valve.
● Place the latch pin to LOCK position.
Operating the pedal with no breaker or general attachment installed may cause overheating or
other problems.

8.3 Work equipment combination
WARNING
● Some work equipment may interfere with the operator cab or machine body due to the
type or combination of work equipment.
● Check the machine and the attachment for risks of interference before operating new
work equipment for the first time.
Note:
● An extended arm may interfere with the machine body when it is retracted toward the ma-
chine. Extra care shall be taken when operating a machine equipped with an extended arm.
● In excavation, the boom may intervene with the undercarriage when the boom is fully lowered.
Be careful with the operation of the boom.
● For excavating or loading hard soil or soft soil containing gravels, reinforced rock-digging
bucket with higher strength and abrasion resistance is recommended.
SY195C9, SY205C9, SY215C9
Bucket Capacity Outer width Weight Std. arm (1) Short arm Short arm
Type m³ (cu.yd) mm (ft in) Kg (lb) 2.7/2.9 m (8'10"/9'6") 2.5 m (8'2") 1.8 m (5'11")
0.48 600 574.7
(0.62) (2') (1267.3)
0.7 964 760.6
(0.83) (3'3") (1673.3)
0.8 1,000 783.6
Rockwork (2)
(1.04) (3'4") (1723.9)
0.9 1,154 846.1
(1.18) (3'10") (1692.2)
1.2 1,496 950.9
(1.56) (4'10") (2091.9)
0.8 1,084 680
(1.04) (3'7") (1496)
0.9 1,137 710.1
Common
(1.18) (3'9") (1562)
1.0 1,240 777.9
(1.3) (4'1") (1709.4)
1.1 1,370 837.1
Earthwork
(1.43) (4'7") (1841.6)
Table 8-4
Note: 1. SY195C9 standard arm length 2.7m; SY205C9 and SY215C9 standard arm length 2.9m.
2. Bucket with side cutters.

SY225C9, SY235C9, SY265C9

Capacity Outer width Weight Std. arm Short arm Short arm
Bucket Type
m³ (cu.yd) mm (ft in) Kg (lb) 3.2 m (10'6") 2.5 m (8'2") 2.1 m (6'11")
Earthwork 1.1 1,420 924.2
(SY225/235C9) (1.44) (4'8") (2038)
Rockwork 1.2 1,300 1,009
(SY235C9) (1.56) (4'3") (2224)
Rockwork 1.3 1,448 1,312
(SY265C9) (1.69) (4'9") (2859)
Table 8-5
- Loading materials of specific gravity ≤1.2 t/m³

- Digging or loading materials of specific gravity ≤1.2 t/m³
- Inapplicable

8.4 Recommended Operation
The following instructions must be followed

when operating an excavator with attachment.
Note:
Select attachment types that matches the ma-

chine best.
● The types and models of attachments to

be installed on the machine may vary ac-
cording to the model of the machine.
● Consult your Sany dealer for selection of

the most suitable attachment.
8.4.1 Hydraulic breaker
Major applications:
● Crushing rocks
● Demolition
● Road construction
CZ335-1105016
Fig. 8-19

8.4.2 Hydraulic breaker operation
1. Press the breaker chisel vertically and

firmly onto the object to be broken during
breaking operation.
90°
90°
CZ335-1105017
Fig. 8-20
2. Press the breaker chisel tightly onto the

working surface when striking and slightly
raise the front of the undercarriage about 5
mm (0.2 in) from the ground, as shown in
the right illustration.
Note:
The excavator shall not be raised too much.
CZ335-1105018
Fig. 8-21
3. If the same surface cannot be penetrated

or broken by the chisel within one min-
ute under continuous striking, change the
struck position and try to break it near the
edge.
CZ335-1105019
Fig. 8-22

4. The chisel's penetrating direction will mis-

align gradually to the working direction of
breaking hammer. It is important to align R
them by readjusting the bucket cylinder.
CZ335-1105020
Fig. 8-23
5. Always press the chisel properly on the

working surface in order to prevent striking
without resistance.
CZ335-1105021
Fig. 8-24

8.4.3 Restricted operations
Do not operate the machine in any of the fol-

lowing manners in order to ensure a longer
service life and safe operation.
● Do not operate any of the oil cylinders to

its full stroke. A distance of 5 cm (2 in) is to
be reserved for backup.
1. Accumulating rocks with the breaker.
CZ335-1105022
Fig. 8-25
2. Breaking with swinging force.
CZ335-1105023
Fig. 8-26

3. Moving the chisel during striking operation.
CZ335-1105024
Fig. 8-27
4. Keep the chisel level or upward during strik-

ing operation.
CZ335-1105025
Fig. 8-28
5. Swing the chisel when the rock has been

penetrated.
CZ335-1105026
Fig. 8-29

6. Pecking operation.
CZ335-1105027
Fig. 8-30
7. Raise the machine above ground by fully

extending the bucket cylinder and by the
pushing force.
CZ335-1105028
Fig. 8-31

8.4.4 Hydraulic breaker greasing
Grease the breaker at specified point correctly.
CZ335-1105029
Fig. 8-32
Note:
Greasing in an improper manner could add

grease more than desired. As a result, soil and
sand may enter the hydraulic system, which
can damage the hydraulic components when
using the breaker.
CZ335-1105030
Fig. 8-33
CZ335-1105031
Fig. 8-34

8.5 Quick Coupler
8.5.1 Quick coupler control
1. Remove the safety pin of the quick coupler.
Safety pin
Jaw
CZ335-1105032
Fig. 8-35
2. Depress the quick coupler button [1] (auto

reset) on the left joystick to reduce the 1
opening of the flexible jaw and the fixed
jaw slowly.
CZ335-1105033
Fig. 8-36
3. Allow the fixed jaw to slowly grip the sup-

port pin [2] of the bucket, as shown in the
right illustration.
2 3
CZ335-1105034
Fig. 8-37

4. Extend the bucket cylinder to slowly move

the flexible jaws toward the support pin [3]
of the bucket.
2
3
CZ335-1105035
Fig. 8-38
5. Make sure that the jaws of the quick cou-

pler grip completely the support pin [3] of
the bucket.
6. Release the operation button to enable the

quick coupler to grip the bucket's support
pin before conducting other operations.
7. Insert the safety pin after installation.
CZ335-1105036
Fig. 8-39

8.5.2 Precautions for quick coupler safe operation
1. Installation of the quick coupler may con-

tribute to longer swing radius when opera-
tion the bucket of other attachments. As a
result, the work equipment may interfere
with the cab or boom of the machine.
If a quick coupler has been installed,

retract the bucket fully (bucket cylinder
fully extended) before retracting the arm.
To avoid interference with the boom, never
retract the arm fully (arm cylinder fully
extended) before retracting the bucket.
CZ335-1105037
Fig. 8-40
2. Overloaded operation may impair the ma-

chine and the attachment, thus reducing
their service life.
CZ335-1105038
Fig. 8-41
3. Do not apply pressure when the quick cou-

pler touches the ground. Use the coupler
only when it is connected with the bucket
or other attachment.
CZ335-1105039
Fig. 8-42

4. It is very dangerous to move a heavy ob-

ject with the quick coupler. Meanwhile, the
service life of quick coupler could be re-
duced.
Note:
Consult your local Sany dealer if you need to

install a quick coupler. Make sure that you are
using an attachment that has been approved
by Sany. Sany assumes no responsibility for CZ335-1105040
any failure and accident resulted from installa-
Fig. 8-43
tion of any attachment unapproved by Sany.

8.6 Fueling System
8.6.1 Introduction
SANY excavators are equipped with a fueling

system, which uses a refueling pump assem-
bly. The refueling pump assembly is intended
specially for large mobile off-the-road machin-
ery, vehicles and vessels. It uses on-board
battery as the power source and is not limited
by terrain and power supply, which makes it
very suitable for construction side and field.
For information regarding refueling amount,
see "Table of capacities" on page 5-14.
8.6.2 Fueling system makeup
● The fueling system of SANY excavators in- 1 2

cludes mainly: a refueling pump assembly
(including relevant piping and valves), a
control switch and a fuel level control relay.
● Open the battery cover [1] and you can 3

see the control switch [2] and the refueling
pump [3].
CZ335S-1105001
Fig. 8-44

● The main structure of the refueling pump [3]

is shown in the right illustration.
Technical specifications:
Pump flow rate 46L/min
Rated voltage 24V
Rate speed 2800 rpm
Coupling thread 3/4’G
Weight 3.5kg CZ335S-1105002
Packing dimension 215×120×160mm
Fig. 8-45
● The fuel level control relay [4] is shown in

the right illustration.
This relay is installed in front of the fuel

tank filler opening and is connected with
the refueling pump control switch and
relay. Its signaling position is 100mm from
the tank top surface.
CZ335S-1105003
Fig. 8-46

8.7 Central Lubrication System
8.7.1 Lubrication scheme and system makeup
14 12、13 11 10
8、9
15、16、17
18
4、5
3
19
20、21 6、7
1、2
CF13051001-1
Fig. 8-47
System makeup
1
1. Electric grease pump
The electric grease pump [1] is installed

behind the operator cab.
The pump is composed of a mounting

base, an electric pump, a pumping unit, a
safety valve and a filter.
CZ335-1105042
Fig. 8-48

2. Distributors Boom
System distributors include a main distribu-

B
tor (MX-F3/3) and 3 secondary distributors A
(MX-F510, MX-F3/5, and MX-F3/4)
● The main distributor (A) and a secondary

distributor (B) installed on the boom root.
CZ335-1105043
Fig. 8-49
● Secondary distributor (C) mounted to the

arm.
Arm
C
CZ335-1105044
Fig. 8-50
● Secondary distributor (D) mounted to the

inside of the linkage.
3. Pipelines Linkage
Major pipelines of the system include

high pressure hoses, straight connectors,
elbows, straight expansion core, bent ex-
pansion core, steel wire protection sleeves,
hose protection sleeves, bucket distributor
protection plates, etc.. D
CZ335-1105045
Fig. 8-51

8.7.2 Working principle
● Sany excavators have a relatively central the electric grease pump is supplied to the
distribution of lubrication points that are main distributor via the pumping unit, the
close to each other. A progressive central safety valve and the filter. Grease in the
lubrication system is used. main distributor is fed through the pipelines
to the 3 secondary distributors and then
● Working principle: Pressurized grease from supplied in turn to the lubrication points.
Electric Grease Pump
Safety Valve
Pumping Unit
Filter
Secondary Distributor
Main Distributor
CZ335-1105046
Fig. 8-52

8.7.3 Lubrication time setup
● A built-in electronic controller controls the begins. Subsequent lubrication will start
lubrication time and interval of the sys- according to the preset time schedule. If
tem. When the machine is energized, the the engine is shut off during shutdown pe-
central lubrication indicator in the operator riod or lubrication cycle, the cycle will be
cab will blink and the LED indicator on the terminated and the time period will be re-
electric controller of the pump will light up. corded. When the engine is started again,
The system is actuated 25 seconds after the lubrication cycle will continue counting
the LED indicator lights up. the time from when the previous cycle is
terminated. For the suspended lubrication
● Lubrication interval starts when the start cycle, pressing the forced start button al-
key on the motor casing or on the instru- lows you to activate the lubricant pump.
ment panel is pressed. Upon completion of Once the control unit is energized, a lubri-
the lubrication cycle, the motor of lubricat- cation cycle will be activated.
ing pump stops and the shutdown cycle

EA/PA Controller Type S-EP 4

Schmierzeit(min.)
启动间断润滑作
Pausenzeit(h) Control 业的强制启动键
4 2
2 6 1 3 LED
1 0.5
16 8 8 4
14 10 7 5
12 6
用于功能
用于设定间隔
用于设定润滑时间的拨盘开关显示的黄色LED
时间的拨盘开关
CZ335-1105047
Fig. 8-53

● Setting the parameters
The interval can be set to 0.5 - 8 hours; the lubrication cycle can be set to 1 - 16 minutes, as
shown in the illustration below. If you need to adjust the time, use a flat-headed screw driver
to disassemble the red edge frame, loosen the four cross-headed screws, and remove the
transparent covers in turn. If any of the covers is not shut properly, water could penetrate into
the control unit and damage may result in.
2 4
1 3 2 6
0.5 1
8 4 16 8
7 5 14 10
6 12
Lubrication interval Lubrication time
(0.5~8 hr) (1~16 min)
CZ335-1105048
Fig. 8-54
8.7.4 Technical description
1. The system will lubricate for 10 minutes every half an hour, which was set at the factory be-
fore delivery.
2. After operating for 100 hours, you can adjust (increase or decrease) the lubricating time ac-
cording to actual condition. The lubricating interval, however, shall not be changed.
3. Clean lithium base grease NLG12# is recommended for the lubrication.
4. Electric lubricant pump (24V/DC, 19 kg) with built-in electronic controller is used.

8.7.5 Grease filling
Grease is fed into the electric grease pump in the following three ways.
1. Standard Method
Feed grease into the pump through the ball-type nozzle with a manual or pneumatic grease
gun.
Ball-type nozzle
CZ335-1105049
Fig. 8-55
2. Feed grease through an adapter
Remove the nozzle and

install the adapter.
Gasket
CZ335-1105050
Fig. 8-56

Adapter Gasket
CZ335-1105051
Fig. 8-57
3. Feed grease with a grease gun
Grease gun
Straight coupler
CZ335-1105052
Fig. 8-58
Note:
Consult your Sany dealer if you need to install the central lubrication system. Make sure that you
are using accessories specified by Sany. Sany assumes no responsibility for failures and acci-
dents caused by the installation of any accessories that have not been approved by Sany.

E
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www.sanyhi.

com Quality Changes the World

SANY HEAVY MACHINERY LIMITED SY265C-9

318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District,

Tel: (86) 21 5700 8518

Safety, Operation and Maintenance Manual

Shanghai Sany Heavy Machinery Limited

318A, Lianggang Avenue, Lingang Industrial Park,

Fengxian District, Shanghai, P.R. of China 201413

Sany assumes no responsibility for consequences caused by the following factors:

● Unauthorized restructuring or modification to the excavator;

● Use of non-genuine parts, or untested or unapproved parts or tools.

● Offer quality excavators along with correct information.

● Provide training for excavator operators and service persons as required.

Obligations of owners or authorized persons

● Regularly inspect the safety awareness of related persons at work.

Safety, Operation & Maintenance Manual - October 2013 3

● Ensure timely maintenance and repair of the hydraulic excavator.

● Make a detailed plan for proper use of the hydraulic excavator.

Obligations of all operating personnel

● All operators must know the operating items and procedures.

4 Safety, Operation & Maintenance Manual - October 2013

Safety, Operation & Maintenance Manual - October 2013 I

2.2.3 Safety decals ............................................................................................... 2-10

II Safety, Operation & Maintenance Manual - October 2013

2.3.26 Visibility ...................................................................................................... 2-39

Safety, Operation & Maintenance Manual - October 2013 III

2.5.4 Prepare yourself........................................................................................... 2-68

IV Safety, Operation & Maintenance Manual - October 2013

3.4 Control Levers and Pedals .................................................................................... 3-33

Safety, Operation & Maintenance Manual - October 2013 V

4.1.2.5 Oil level in oil pan - check/add .............................................................4-11

VI Safety, Operation & Maintenance Manual - October 2013

4.11 Recommended Application .................................................................................. 4-46

Safety, Operation & Maintenance Manual - October 2013 VII

5.4.1 Table of recommended fuel, oil and coolant ................................................ 5-13

VIII Safety, Operation & Maintenance Manual - October 2013

5.8.8 Every 1000 service hours ............................................................................ 5-66

Safety, Operation & Maintenance Manual - October 2013 IX

6.2.2 Towing the machine ..................................................................................... 6-10

X Safety, Operation & Maintenance Manual - October 2013

8.2.2.1 Hydraulic circuit switching ..................................................................... 8-8

Safety, Operation & Maintenance Manual - October 2013 XI

XII Safety, Operation & Maintenance Manual - October 2013

Safety, Operation & Maintenance Manual - October 2013 1-1

1.4 Correction Request Form - Technical Publications ................................................ 1-15

1-2 Safety, Operation & Maintenance Manual - October 2013

Items addressed in this manual are designed

● Understand the structure and performance

● Reduce improper operation and point out

● Increase equipment efficiency during op-

● Prolong the service life of equipment. CZ335-1102004

Always keep this manual nearby and have all

If you sell the machine, be sure to give this

Continuing improvements in the design of this

Safety, Operation & Maintenance Manual - October 2013 1-3

1.2 Your Documentation Package

The documentation for this machine includes the following items:

1.2.1 CD system requirements

In order to use the Sany CD, be sure of the following:

● Intel® Pentium II® running at 500 MHz or above

● At least 128 MB RAM

● Minimum screen resolution of 800 x 600 pixels, high-color depth