Oper. Mtto - SY305C LC

Quality Changes the World
Crawler Hydraulic
Excavator
SY305C LC
Operation and Maintenance Manual

SY305C LC (Stage Ⅴ)Hydraulic Excavator
SY305C LC (Stage Ⅴ)
Hydraulic Excavator
Safety, Operation and Maintenance Manual
WARNING
Read and follow the safety precautions and instructions in this manual and on the machine
decals. Failure to do can cause serious injury, death or property damage. Keep this manual with
the machine for reading and future reference.
Operation & Maintenance Manual-May-2020 1

2 Operation & Maintenance Manual-May-2020

Sany Group
Shanghai Sany Heavy Machinery (LTD)
Sany Industrial Park, Xinyang Road,
No.1831, Fengxian District, Shanghai, China
Zip code: 201413
Service hotline: 4008 28 2318

Inquiring and Complaint Number: 4008 87 9318
http://www.sanygroup.com
© 2013 by Sany Group. All right reserved. No part of this publication may be
reproduced, used, distributed or disclosed except during normal operation of the
machine as 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 information, please contact Sany Group.


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 con-
struction, bridge building, city construction, as well as airport, sea port and water conservation
construction. It can also perform the function of bull dozer, loader and crane. Application other than
the specified range are excluded from the scope. Sany assumes no responsibility for any conse-
quence 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 op-
erator 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 repair
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 Main-
tenance 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
required.

• 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 haz-
ards 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, Operation
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 quality,
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.

SY305C LC (Stage Ⅴ)Hydraulic Excavator Table of Contents
Table of Contents
1 Introduction........................................................................................................................1-1
1.1 Overview.................................................................................................................................1-5
1.2 Your Documentation Package.............................................................................................1-6
1.2.1 foreword .........................................................................................................................1-6
1.2.2 CD system requirements.............................................................................................1-6
1.2.3 Recommendations on using the documentation .....................................................1-6
1.2.4 Documentation storage ...............................................................................................1-7
1.2.5 Manual organization.....................................................................................................1-7
1.2.5.1 foreword..................................................................................................................1-7
1.2.5.2 Introduction ............................................................................................................1-7
1.2.5.3 Safety......................................................................................................................1-7
1.2.5.4 System functions...................................................................................................1-7
1.2.5.5 Operation................................................................................................................1-7
1.2.5.6 Maintenance ..........................................................................................................1-7
1.2.5.7 Troubleshooting.....................................................................................................1-8
1.2.5.8 Specifications.........................................................................................................1-8
1.2.5.9 Optional Equipment ..............................................................................................1-8
1.3 Your Sany Machine...............................................................................................................1-8
1.3.1 Machine applications ...................................................................................................1-8
1.3.2 Machine directions .......................................................................................................1-9
1.3.3 Breaking in a new machine .........................................................................................1-9
1.3.4 Machine information.................................................................................................. 1-10
1.3.4.1 foreword............................................................................................................... 1-10
1.3.4.2 Product identification and authorized representative plates........................ 1-10
1.3.4.3 Engine identification plate..................................................................................1-11
1.3.4.4 Drive motors identification plate........................................................................1-11
1.3.4.5 Swing motor identification plate ....................................................................... 1-12
1.3.4.6 Hydraulic pump identification plate.................................................................. 1-12
1.3.4.7 Chassis serial number....................................................................................... 1-13
1.3.4.8 Regulatory Compliance..................................................................................... 1-13
1.3.5 Table for serial number and distributor information .............................................. 1-19
1.4 Contact Information ........................................................................................................... 1-19
2 Safety.....................................................................................................................................2-1
2.1 Foreword ................................................................................................................................2-5
2.2 Safety Messages...................................................................................................................2-6
Operation & Maintenance Manual-May-2020 I

Table of Contents SY305C LC (Stage Ⅴ)Hydraulic Excavator
2.2.1 foreword .........................................................................................................................2-6

2.2.2 Hazard alert wording....................................................................................................2-6
2.2.3 Other alert wording.......................................................................................................2-8
2.2.4 Safety decals.................................................................................................................2-8
2.2.4.1 foreword..................................................................................................................2-8
2.2.4.2 Textual safety decals ............................................................................................2-9
2.2.4.3 Graphic safety decals ...........................................................................................2-9
2.2.4.4 Safety decal locations...........................................................................................2-9
2.3 General Precautions.......................................................................................................... 2-22
2.3.1 Safety rules................................................................................................................. 2-22
2.3.2 Abnormal cases ......................................................................................................... 2-23
2.3.3 Personal protective equipment................................................................................ 2-23
2.3.4 Fire extinguisher and first aid kit.............................................................................. 2-24
2.3.5 Safety equipment....................................................................................................... 2-25
2.3.6 Machine cleaning....................................................................................................... 2-25
2.3.7 Keeping cab clean..................................................................................................... 2-26
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 ............................................................. 2-30
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 ......................................................... 2-31
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 .............................................................................. 2-32
2.3.17 Ejecting parts ........................................................................................................... 2-32
2.3.18 Falling object protection ......................................................................................... 2-33
2.3.19 Attachment installation ........................................................................................... 2-33
2.3.20 Attachment combination......................................................................................... 2-34
2.3.21 Cab windows glasses ............................................................................................. 2-34
2.3.22 Unauthorized modification ..................................................................................... 2-34
2.3.23 Worksite investigation............................................................................................. 2-35
II Operation & Maintenance Manual-May-2020

2.3.24 Operation on loose ground .................................................................................... 2-35

2.3.25 Overhead power cables ......................................................................................... 2-36
2.3.26 Visibility ..................................................................................................................... 2-37
2.3.27 Ventilation................................................................................................................. 2-37
2.3.28 Asbestos................................................................................................................... 2-38
2.3.29 Alternate exit ............................................................................................................ 2-39
2.4 Safe Operation Precautions ............................................................................................. 2-39
2.4.1 Safe starting ............................................................................................................... 2-39
2.4.1.1 Safe mounting..................................................................................................... 2-39
2.4.1.2 Operator seat...................................................................................................... 2-40
2.4.1.3 Seat belt............................................................................................................... 2-40
2.4.1.4 Before starting the engine................................................................................. 2-41
2.4.1.5 Engine starting rules .......................................................................................... 2-41
2.4.1.6 Machine starting ................................................................................................. 2-42
2.4.1.7 Starting engine in cold season ......................................................................... 2-42
2.4.1.8 Engine starting aid ............................................................................................. 2-42
2.4.1.9 After starting the engine .................................................................................... 2-43
2.4.2 Operation .................................................................................................................... 2-44
2.4.2.1 Inspection before operation .............................................................................. 2-44
2.4.2.2 Prior-operation precautions .............................................................................. 2-45
2.4.2.3 Travel direction confirmation ............................................................................ 2-45
2.4.2.4 Safety rules for turning ...................................................................................... 2-46
2.4.2.5 Safety rules for traveling ................................................................................... 2-47
2.4.2.6 Safe traveling...................................................................................................... 2-48
2.4.2.7 Machine operation on slope ............................................................................. 2-50
2.4.2.8 Operation in snowy weather ............................................................................. 2-51
2.4.2.9 Restricted operation........................................................................................... 2-52
2.4.3 Parking the machine ................................................................................................. 2-54
2.4.3.1 Select a parking place ....................................................................................... 2-54
2.4.3.2 Machine shutdown ............................................................................................. 2-55
2.4.4 Transportation............................................................................................................ 2-56
2.4.4.1 Loading and unloading ...................................................................................... 2-56
2.4.4.2 Transportation..................................................................................................... 2-57
2.4.5 Battery......................................................................................................................... 2-57
2.4.6 Towing ......................................................................................................................... 2-59
2.4.7 Lifting objects with the machine .............................................................................. 2-60
2.5 Precautions for Maintenance............................................................................................ 2-61
2.5.1 Pre-maintenance precautions ................................................................................. 2-61
2.5.2 Select a working area ............................................................................................... 2-61
Operation & Maintenance Manual-May-2020 III

2.5.3 Prepare the machine................................................................................................. 2-62

2.5.4 Prepare yourself ........................................................................................................ 2-63
2.5.5 Lockout and tag-out measures................................................................................ 2-64
2.5.6 Use proper tools ........................................................................................................ 2-64
2.5.7 Maintenance with engine running ........................................................................... 2-65
2.5.8 Work under the machine .......................................................................................... 2-65
2.5.9 Track maintenance.................................................................................................... 2-66
2.5.10 Track tension adjustment ....................................................................................... 2-67
2.5.11 Recoil spring............................................................................................................. 2-67
2.5.12 Welding operation ................................................................................................... 2-67
2.5.13 High-pressure hoses............................................................................................... 2-68
2.5.14 Pressurized fluid...................................................................................................... 2-68
2.5.15 Hot cooling system.................................................................................................. 2-69
2.5.16 Air-conditioning system maintenance .................................................................. 2-69
2.5.17 High voltage precautions........................................................................................ 2-70
2.5.18 Accumulator ............................................................................................................. 2-70
2.5.19 Fire and explosion prevention ............................................................................... 2-71
2.5.20 Regular replacement of safety-related parts....................................................... 2-71
2.5.21 Maintenance operation........................................................................................... 2-72
2.5.22 Proper disposal of wastes...................................................................................... 2-73
3 System Functions...........................................................................................................3-1
3.1 Machine general drawing.....................................................................................................3-5
3.2 Monitoring System ................................................................................................................3-6
3.2.1 Monitor functions ..........................................................................................................3-6
3.2.2 Monitor operation..........................................................................................................3-9
3.3 Switches .............................................................................................................................. 3-34
3.3.1 foreword ...................................................................................................................... 3-34
3.3.2 Start switch ................................................................................................................. 3-35
3.3.3 Fuel control dial.......................................................................................................... 3-36
3.3.4 Work lamp switch ...................................................................................................... 3-37
3.3.5 Head lamp switch ...................................................................................................... 3-38
3.3.6 Windshield wiper switch ........................................................................................... 3-40
3.3.7 Washer switch............................................................................................................ 3-41
3.3.8 Horn switch................................................................................................................. 3-42
3.3.9 AEC switch ................................................................................................................. 3-43
3.3.10 Cab lamp switch ...................................................................................................... 3-43
3.3.11 12V Socket................................................................................................................ 3-44
3.3.12 24V cigarette lighter ................................................................................................ 3-44
3.3.13 Preheat indicator ..................................................................................................... 3-45
3.3.14 Charging indicator ................................................................................................... 3-45
IV Operation & Maintenance Manual-May-2020

3.4 Control Levers and Pedals ............................................................................................... 3-46

3.4.1 foreword ...................................................................................................................... 3-46
3.4.2 Hydraulic lockout control .......................................................................................... 3-46
3.4.3 Travel control levers.................................................................................................. 3-47
3.4.4 Joysticks ..................................................................................................................... 3-48
3.5 Cab Windows and Cab Door ............................................................................................ 3-50
3.5.1 Ceiling window ........................................................................................................... 3-50
3.5.2 Front window.............................................................................................................. 3-51
3.5.3 Cab door window....................................................................................................... 3-58
3.6 Cup Holder .......................................................................................................................... 3-59
3.7 Ash Tray .............................................................................................................................. 3-59
3.8 Manual Pocket.................................................................................................................... 3-60
3.9 Drink Box ............................................................................................................................. 3-60
3.10 Alternate exit..................................................................................................................... 3-61
3.11 Fire Extinguisher .............................................................................................................. 3-61
3.12 Electronic Control Module .............................................................................................. 3-62
3.13 Fusible Link....................................................................................................................... 3-62
3.14 Air Conditioning System.................................................................................................. 3-63
3.14.1 Control panel............................................................................................................ 3-63
3.14.2 Operation method ................................................................................................... 3-68
3.14.3 Air conditioner operation precautions................................................................... 3-70
3.15 Radio.................................................................................................................................. 3-72
3.15.1 Control panel............................................................................................................ 3-72
3.15.2 Operation.................................................................................................................. 3-74
3.16 Cab door catch ................................................................................................................. 3-77
3.17 Lockable Caps and Covers ............................................................................................ 3-78
3.17.1 foreword.................................................................................................................... 3-78
3.17.2 Lockable caps.......................................................................................................... 3-78
3.17.3 Lockable covers....................................................................................................... 3-79
4 Operation.............................................................................................................................4-1
4.1 Before Starting the Engine...................................................................................................4-5
4.1.1 Walk-around inspection ...............................................................................................4-5
4.1.2 Inspection before starting............................................................................................4-6
4.1.2.1 foreword..................................................................................................................4-6
4.1.2.2 Water and sediment in fuel tank - drain .............................................................4-6
4.1.2.3 Water and sediment in water separator - check/drain .....................................4-7
4.1.2.4 Hydraulic oil level - check/refill ............................................................................4-8
4.1.2.5 Coolant level - check/refill ................................................................................. 4-10
4.1.2.6 Oil level in oil pan - check/add...........................................................................4-11
Operation & Maintenance Manual-May-2020 V

4.1.2.7 Electric wires - check ..........................................................................................4-11

4.1.2.8 Fuel level - Check and add ............................................................................... 4-12
4.1.2.9 Work lamp switches - check ............................................................................. 4-14
4.1.2.10 Horn - check...................................................................................................... 4-14
4.1.3 Adjustment before operation.................................................................................... 4-15
4.1.3.1 Operator seat adjustment ................................................................................. 4-15
4.1.3.2 Rear view mirrors ............................................................................................... 4-17
4.1.3.3 Seat belt............................................................................................................... 4-18
4.1.4 Operation before engine startup ............................................................................. 4-19
4.2 Engine Startup.................................................................................................................... 4-21
4.2.1 foreword ...................................................................................................................... 4-21
4.2.2 Engine Preheating..................................................................................................... 4-23
4.2.3 Warm-up operation.................................................................................................... 4-24
4.3 Engine Shutdown ............................................................................................................... 4-25
4.4 Machine Operation............................................................................................................. 4-26
4.4.1 Machine Operation.................................................................................................... 4-26
4.4.2 Before moving the machine ..................................................................................... 4-26
4.4.3 Move the machine ..................................................................................................... 4-27
4.4.4 Stopping the machine ............................................................................................... 4-28
4.5 Machine Turning................................................................................................................. 4-29
4.5.1 foreword ...................................................................................................................... 4-29
4.5.2 Direction change when the machine is stopped ................................................... 4-29
4.5.3 Pivot turning ............................................................................................................... 4-30
4.6 Work Equipment Control ................................................................................................... 4-31
4.7 Restricted Operations........................................................................................................ 4-33
4.7.1 foreword ...................................................................................................................... 4-33
4.7.2 Operation with swinging force ................................................................................. 4-33
4.7.3 Operation with traveling force.................................................................................. 4-34
4.7.4 Operation when hydraulic cylinder reaches its stroke end.................................. 4-34
4.7.5 Operation with bucket landing force ....................................................................... 4-35
4.7.6 Hard rocky ground..................................................................................................... 4-35
4.7.7 Operation with machine weight ............................................................................... 4-36
4.7.8 Sudden shift of control levers or pedals ................................................................. 4-36
4.8 Permissible depth of water ............................................................................................... 4-37
4.9 Traveling on a Slope .......................................................................................................... 4-38
4.9.1 foreword ...................................................................................................................... 4-38
4.9.2 Traveling downhill...................................................................................................... 4-39
4.9.3 When engine stalls on a slope................................................................................. 4-39
4.9.4 Cab door on a slope .................................................................................................. 4-39
4.10 Escaping from Mud.......................................................................................................... 4-40
VI Operation & Maintenance Manual-May-2020

4.10.1 foreword.................................................................................................................... 4-40

4.10.2 When one track is trapped ..................................................................................... 4-40
4.10.3 When both tracks are trapped ............................................................................... 4-40
4.11 Recommended Application............................................................................................. 4-41
4.11.1 foreword .................................................................................................................... 4-41
4.11.2 Backhoe operation .................................................................................................. 4-41
4.11.3 Trenching work......................................................................................................... 4-42
4.11.4 Loading operation.................................................................................................... 4-42
4.12 Parking .............................................................................................................................. 4-43
4.13 Post-operation Inspection............................................................................................... 4-45
4.14 Locking .............................................................................................................................. 4-46
4.15 Operation in Cold Weather ............................................................................................. 4-46
4.15.1 foreword.................................................................................................................... 4-46
4.15.2 Fuel and lubricant.................................................................................................... 4-46
4.15.3 Coolant...................................................................................................................... 4-47
4.15.4 Battery....................................................................................................................... 4-47
4.15.5 After operation in cold weather.............................................................................. 4-47
4.15.6 After cold season..................................................................................................... 4-48
4.16 Long-Term Storage.......................................................................................................... 4-48
4.16.1 Before storage ......................................................................................................... 4-48
4.16.2 During storage ......................................................................................................... 4-49
4.16.3 After storage............................................................................................................. 4-49
4.16.4 Engine startup after long-term storage ................................................................ 4-50
4.17 Transportation Information ............................................................................................. 4-50
4.17.1 Transport methods .................................................................................................. 4-50
4.17.2 Loading and unloading ........................................................................................... 4-51
4.17.2.1 foreword ............................................................................................................ 4-51
4.17.2.2 Loading.............................................................................................................. 4-52
4.17.2.3 Securing the machine...................................................................................... 4-54
4.17.2.4 Unloading .......................................................................................................... 4-57
4.17.2.5 Lifting the machine........................................................................................... 4-59
5 Maintenance.......................................................................................................................5-1
5.1 Maintenance Information .....................................................................................................5-5
5.2 Oil, fuel and coolant ..............................................................................................................5-7
5.2.1 Oil....................................................................................................................................5-7
5.2.2 Fuel.................................................................................................................................5-8
5.2.3 Coolant...........................................................................................................................5-9
5.2.4 Grease ...........................................................................................................................5-9
5.2.5 Oil and fuel storage ................................................................................................... 5-10
Operation & Maintenance Manual-May-2020 VII

5.2.5.1 foreword............................................................................................................... 5-10

5.2.5.2 Filter element ...................................................................................................... 5-10
5.2.6 Electrical system........................................................................................................ 5-10
5.3 Wear Parts .......................................................................................................................... 5-10
5.4 Recommended Fuel, Coolant and Lubricant ..................................................................5-11
5.4.1 foreword .......................................................................................................................5-11
5.4.2 Table of recommended fuel, oil and coolant .......................................................... 5-14
5.4.3 Table of capacities..................................................................................................... 5-16
5.5 Tightening Torque Table.................................................................................................... 5-16
5.6 Safety Critical Parts ........................................................................................................... 5-18
5.7 Maintenance Schedule...................................................................................................... 5-19
5.8 Maintenance Procedures.................................................................................................. 5-22
5.8.1 Lockout and tag-out measures................................................................................ 5-22
5.8.2 Initial 50 hours of operation...................................................................................... 5-22
5.8.3 Initial 500 hours of operation.................................................................................... 5-23
5.8.3.1 Swing drive oil - change .................................................................................... 5-23
5.8.3.2 Final drive oil - change ...................................................................................... 5-24
5.8.4 When Required.......................................................................................................... 5-25
5.8.4.1 Track shoe bolts - inspect/tighten .................................................................... 5-25
5.8.4.2 Track tension - inspect/adjust........................................................................... 5-25
5.8.4.3 Bucket - replace.................................................................................................. 5-29
5.8.4.4 Bucket tips - replace .......................................................................................... 5-31
5.8.4.5 Window washer fluid level - check/fill.............................................................. 5-33
5.8.4.6 Refrigerant level - check ................................................................................... 5-34
5.8.4.7 Ceiling window gas spring - inspect ................................................................ 5-36
5.8.5 Inspection Prior to Startup........................................................................................ 5-38
5.8.6 Every 100 service hours ........................................................................................... 5-39
5.8.6.1 Lubrication........................................................................................................... 5-39
5.8.7.1 Air filter element - inspect/clean/replace......................................................... 5-41
5.8.7.2 Fan belt tension - inspect/adjust ...................................................................... 5-44
5.8.7.3 Compressor belt tension - inspect/adjust ....................................................... 5-45
5.8.7.4 Oil return check valve - check .......................................................................... 5-46
5.8.7.5 Pipe clamps of hydraulic system - check........................................................ 5-47
5.8.8.1 foreword............................................................................................................... 5-47
5.8.8.2 Swing bearing - lubricate................................................................................... 5-47
5.8.8.3 Engine pan oil and filter element - change/replace ....................................... 5-48
5.8.8.4 Swing pinion gear grease level - inspect/fill ................................................... 5-50
VIII Operation & Maintenance Manual-May-2020

5.8.8.5 Primary fuel filter element - replace................................................................. 5-51

5.8.8.6 Secondary fuel filter element - replace ........................................................... 5-53
5.8.8.7 Radiator and oil cooler fins - inspect/clean..................................................... 5-56
5.8.8.8 Air conditioner fresh air/recirculation filter - clean ......................................... 5-58
5.8.8.9 Swing drive oil level - check/fill......................................................................... 5-60
5.8.8.10 Final drive oil level - check/fill......................................................................... 5-61
5.8.9 Every 1000 service hours......................................................................................... 5-62
5.8.9.1 foreword............................................................................................................... 5-62
5.8.9.2 Hydraulic oil return filter element - replace..................................................... 5-62
5.8.9.3 Swing drive oil - change .................................................................................... 5-63
5.8.9.4 Cab door lock and front window lock catch - inspect/tighten ....................... 5-65
5.8.9.5 Cab door hinge and front window slide rail - inspect/add grease ............... 5-66
5.8.9.6 Windshield wiper arm nut - Inspect/tighten .................................................... 5-67
5.8.9.7 Engine exhaust pipe clamps - check............................................................... 5-67
5.8.9.8 Fan belt tension - check/replace ...................................................................... 5-67
5.8.9.9 Nitrogen pressure in accumulator (breaker) - check..................................... 5-67
5.8.9.10 Swing mechanism grease - check and add ................................................. 5-68
5.8.9.11 Hydraulic tank breather valve filter element - replace................................. 5-68
5.8.10 Every 2000 service hours....................................................................................... 5-69
5.8.10.1 foreword ............................................................................................................ 5-69
5.8.10.2 Final drive oil - change .................................................................................... 5-70
5.8.10.3 Hydraulic oil suction filter element – clean/replace..................................... 5-71
5.8.10.4 Nitrogen pressure in accumulator (control oil circuit) - check.................... 5-72
5.8.10.5 Cooling system interior - clean....................................................................... 5-75
5.8.10.6 Alternator - inspect........................................................................................... 5-77
5.8.10.7 Engine valve clearance - check/adjust ......................................................... 5-78
5.8.11.1 foreword............................................................................................................. 5-78
5.8.11.2 Water pump - inspect....................................................................................... 5-78
5.8.11.3 Start motor - check........................................................................................... 5-78
5.8.11.4 Hydraulic tank oil - change.............................................................................. 5-79
5.8.11.5 Accumulator - replace...................................................................................... 5-80
5.8.11.6 High-pressure tube clamps and rubber - check........................................... 5-81
5.8.11.7 Compressor working condition - inspect....................................................... 5-81
5.8.12.1 Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter - Change............. 5-82
5.8.12.2 Aftertreatment Diesel Particulate Filter - Check .......................................... 5-86
5.8.12.3 Aftertreatment Diesel Exhaust Fluid Tank Filter - Inspect and
reuse................................................................................................................... 5-87
Operation & Maintenance Manual-May-2020 IX


5.8.13.1 foreword ............................................................................................................ 5-91
5.8.13.2 High-pressure tube clamps - replace ............................................................ 5-91
5.8.14 Every 10000 service hours .................................................................................... 5-91
6 Troubleshooting ..............................................................................................................6-1
6.1 foreword..................................................................................................................................6-5
6.2 Troubleshooting Preparation ...............................................................................................6-6
6.2.1 Checks before troubleshooting...................................................................................6-6
6.2.2 Troubleshooting precautions ......................................................................................6-6
6.2.3 Electrical circuits troubleshooting precautions.........................................................6-8
6.2.4 Hydraulic components handling precautions ...........................................................6-9
6.3 Measures Taken When Failure Occurs............................................................................6-11
6.3.1 Failure-like phenomena.............................................................................................6-11
6.3.2 Towing the machine .................................................................................................. 6-12
6.4 Engine Failures................................................................................................................... 6-13
6.4.1 Engine troubleshooting table ................................................................................... 6-13
6.4.2 Coolant temperature high......................................................................................... 6-17
6.4.3 Engine oil pressure low............................................................................................. 6-18
6.4.4 When fuel runs out .................................................................................................... 6-19
6.4.5 When engine rotates reversely................................................................................ 6-22
6.5 Failures of the Electrical System...................................................................................... 6-22
6.5.1 Electrical system troubleshooting table.................................................................. 6-22
6.5.2 Failure codes.............................................................................................................. 6-25
6.6 Battery.................................................................................................................................. 6-28
6.6.1 foreword ...................................................................................................................... 6-28
6.6.2 Battery removal and installation .............................................................................. 6-28
6.6.3 Battery charging......................................................................................................... 6-28
6.6.4 Starting engine with jumper cable........................................................................... 6-29
6.6.4.1 foreword............................................................................................................... 6-29
6.6.4.2 Connecting jumper cables ................................................................................ 6-30
6.6.4.3 Starting engine ................................................................................................... 6-31
6.6.4.4 Disconnecting jumper cables ........................................................................... 6-31
6.7 Failures of the Hydraulic System ..................................................................................... 6-32
6.8 Other Common Failures.................................................................................................... 6-37
7 Specifications ...................................................................................................................7-1
7.1 Machine Dimensions ............................................................................................................7-3
7.2 Working Ranges....................................................................................................................7-4
7.3 Operating Parameters ..........................................................................................................7-5
X Operation & Maintenance Manual-May-2020

8 Optional Equipment.......................................................................................................8-1
8.1 Safety Information.................................................................................................................8-5
8.1.1 foreword .........................................................................................................................8-5
8.1.2 Optional equipment selection .....................................................................................8-5
8.1.3 Read equipment instruction ........................................................................................8-5
8.1.4 Optional equipment removal and installation precautions .....................................8-5
8.1.5 Optional equipment operation precautions...............................................................8-6
8.2 Work Tool Control..................................................................................................................8-7
8.2.1 Stop valves ....................................................................................................................8-7
8.2.2 One-Way Flow ..............................................................................................................8-7
8.2.2.1 One-Way flow mode selection.............................................................................8-7
8.2.2.2 Joystick ...................................................................................................................8-7
8.2.3 Two-Way Flow...............................................................................................................8-8
8.2.3.1 Two-Way flow mode selection.............................................................................8-8
8.2.3.2 Joystick ...................................................................................................................8-8
8.3 Attachment removal and installation ..................................................................................8-9
8.3.1 Removal.........................................................................................................................8-9
8.3.2 Installation ...................................................................................................................8-11
8.4 Hydraulic shears operation............................................................................................... 8-13
8.5 Hydraulic Hammer Operation........................................................................................... 8-14
8.5.1 Recommended Operation........................................................................................ 8-14
8.5.2 Hydraulic breaker ...................................................................................................... 8-15
8.5.3 Hydraulic breaker operation..................................................................................... 8-15
8.5.4 Restricted operations................................................................................................ 8-17
8.5.5 Hydraulic breaker greasing ...................................................................................... 8-20
8.6 Hydraulic oil and filter - change/replace.......................................................................... 8-21
8.7 Long-term storage.............................................................................................................. 8-21
8.8 Quick Coupler ..................................................................................................................... 8-22
8.8.1 Coupling the Work Tool............................................................................................. 8-22
8.8.2 Uncoupling the work tool .......................................................................................... 8-28
8.8.3 Precautions for quick coupler safe operation ........................................................ 8-32
8.9 Fueling System................................................................................................................... 8-33
8.9.1 Introduction................................................................................................................. 8-33
8.9.2 Fueling system makeup............................................................................................ 8-33
8.10 Work equipment combination ........................................................................................ 8-34
Operation & Maintenance Manual-May-2020 XI

XII Operation & Maintenance Manual-May-2020

SY305C LC (Stage Ⅴ)Hydraulic Excavator Introduction
Introduction
1 Introduction........................................................................................................................1-1
1.1 Overview.................................................................................................................................1-5
1.2 Your Documentation Package.............................................................................................1-6
1.2.1 foreword........................................................................................................................1-6
1.2.2 CD system requirements ...........................................................................................1-6
1.2.3 Recommendations on using the documentation ....................................................1-6
1.2.4 Documentation storage ..............................................................................................1-7
1.2.5 Manual organization ...................................................................................................1-7
1.2.5.1 foreword ................................................................................................................1-7
1.2.5.2 Introduction ...........................................................................................................1-7
1.2.5.3 Safety.....................................................................................................................1-7
1.2.5.4 System functions..................................................................................................1-7
1.2.5.5 Operation ..............................................................................................................1-7
1.2.5.6 Maintenance .........................................................................................................1-7
1.2.5.7 Troubleshooting ...................................................................................................1-8
1.2.5.8 Specifications .......................................................................................................1-8
1.2.5.9 Optional Equipment.............................................................................................1-8
1.3 Your Sany Machine...............................................................................................................1-8
1.3.1 Machine applications ..................................................................................................1-8
1.3.2 Machine directions ......................................................................................................1-9
1.3.3 Breaking in a new machine........................................................................................1-9
1.3.4 Machine information ................................................................................................ 1-10
1.3.4.1 foreword ............................................................................................................. 1-10
1.3.4.2 Product identification and authorized representative plates ...................... 1-10
1.3.4.3 Engine identification plate.................................................................................1-11
1.3.4.4 Drive motors identification plate ......................................................................1-11
1.3.4.5 Swing motor identification plate...................................................................... 1-12
1.3.4.6 Hydraulic pump identification plate ................................................................ 1-12
1.3.4.7 Chassis serial number...................................................................................... 1-13
Operation & Maintenance Manual-May-2020 1-1

Introduction SY305C LC (Stage Ⅴ)Hydraulic Excavator
1.3.4.8 Regulatory Compliance ................................................................................... 1-13

1.3.5 Table for serial number and distributor information............................................. 1-19
1.4 Contact Information ........................................................................................................... 1-19
1-2 Operation & Maintenance Manual-May-2020


WARNING
Read and understand all safety precautions and instructions in this manual before reading any
other manuals provided with this machine and before operation or maintaining it.Failure to do
this could result in death or serious injury.

1.Introduction
1.1 Overview
This operator’s manual provides safety, oper-
ation, maintenance, troubleshooting and tech-
nical specifications. In order to properly use
your equipment, it is important to read this
manual carefully before beginning any
operations
This operator’s manual provides safety, oper-

ation, maintenance, troubleshooting and tech-
nical 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.
Fig.1-1
● Reduce improper operation and point out
possible hazardous situations.
● Increase equipment efficiency during

operation.
● 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 distributor for the latest
available information on your machine or if
you have questions regarding information in
this manual.

1.2 Your Documentation Package

1.2.1 foreword
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 machine
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
1.2.2 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
1.2.3 Recommendations on using the documentation
● This documentation applies only to this machine and should not be used with any other
machines.
● To 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.

1.2.4 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.
1.2.5 Manual organization
1.2.5.1 foreword
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 distributor before op-
erating or repairing the machine.
1.2.5.2 Introduction
This chapter provides an overview of what is covered in the rest of this manual, including machine
label information and Sany contact information.
1.2.5.3 Safety
This chapter covers basic safety information relating to this equipment. Make sure you fully under-
stand all the precautions described in this manual and the safety labels on the machine before op-
erating or maintaining this machine. Failure to do so may result in serious injury or death.
1.2.5.4 System functions
This chapter provides an overview of all the controls, alerts and operating systems on the machine.
It is important to study and become familiar with all systems before proceeding with any
operations.
1.2.5.5 Operation
This chapter provides some basic operating procedures for this machine. Study and become famil-
iar with all operating procedures before performing any job functions with the machine.
1.2.5.6 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.

1.2.5.7 Troubleshooting
This chapter includes common malfunctions and fault diagnostics procedures for this crawler hy-
draulic excavator operating system. Basic mechanical, hydraulic and electrical system trouble-
shooting is included.
1.2.5.8 Specifications
This chapter provides general required machine information for this crawler hydraulic excavator.
Some information may vary due to design changes.
1.2.5.9 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 manual.
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
Fig.1-2 2
(A) Front In this manual, the front, rear, left or right

(B) Rear direction indicates, when the cab faces the
front and the final drive is behind of the
(C) Left machine, the moving direction that you could
(D) Right see from the cab.
(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 conditions 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 op-
erating hours for a new machine.
During the break-in period:
● Let the machine preheat prior to any operation.
● 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
1.3.4.1 foreword
The serial numbers and model numbers on the components are the only numbers that your Sany
distributor will need when ordering replacement parts or requiring assistance for your equipment. It
is a good idea to record this information in this manual for future use. Below are the locations of
the data plates.
1.3.4.2 Product identification and authorized representative plates
On the right side of the operator’s cab on the bottom.
Fig.1-3

1.3.4.3 Engine identification plate
Fig.1-4
1.3.4.4 Drive motors identification plate
1. On each drive motor. Fig.1-5 5
On each drive motor.
Model:______________________________
ID No.: ______________________________

1.3.4.5 Swing motor identification plate
1. On top of swing motor. Fig.1-6 6
Model:______________________________
ID No.: ______________________________
1.3.4.6 Hydraulic pump identification

plate
1. On the left side of pump. Fig.1-7 7
Model:_____________________________
ID No.: _____________________________

1.3.4.7 Chassis serial number
An additional serial number is stamped on the Fig.1-8 8

front part of the travel carriage frame.
1.3.4.8 Regulatory Compliance
1. Certificate of Conformity EC Council Directive 2006/42/EC Machinery

Fig.1-9
2. Certificate of Conformity EC Council Directive 2014/30/EU Electromagnetic Compatibility

Fig.1-10
3. Certificate for EC-Type Examination EC Directive 2000/14/EC

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 Contact Information

Thank you for purchasing a Sany machine. In the event that you should contact us for any reason,
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: 0086-21-57008518
Service hotline: 0086-4006 098 318

E-mail: crd@sany.com.cn

SY305C LC (Stage Ⅴ)Hydraulic Excavator Safety
Safety
2 Safety.....................................................................................................................................2-1
2.1 Foreword ................................................................................................................................2-5
2.2 Safety Messages...................................................................................................................2-6
2.2.1 foreword........................................................................................................................2-6
2.2.2 Hazard alert wording...................................................................................................2-6
2.2.3 Other alert wording .....................................................................................................2-8
2.2.4 Safety decals ...............................................................................................................2-8
2.2.4.1 foreword ................................................................................................................2-8
2.2.4.2 Textual safety decals ...........................................................................................2-9
2.2.4.3 Graphic safety decals..........................................................................................2-9
2.2.4.4 Safety decal locations .........................................................................................2-9
2.3 General Precautions.......................................................................................................... 2-22
2.3.1 Safety rules ............................................................................................................... 2-22
2.3.2 Abnormal cases........................................................................................................ 2-23
2.3.3 Personal protective equipment .............................................................................. 2-23
2.3.4 Fire extinguisher and first aid kit ............................................................................ 2-24
2.3.5 Safety equipment ..................................................................................................... 2-25
2.3.6 Machine cleaning ..................................................................................................... 2-25
2.3.7 Keeping cab clean.................................................................................................... 2-26
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 SY305C LC (Stage Ⅴ)Hydraulic Excavator
2.3.14.2 Fire caused by flammable materials ............................................................ 2-30

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 ........................................................ 2-31
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............................................................................. 2-32
2.3.17 Ejecting parts.......................................................................................................... 2-32
2.3.18 Falling object protection ........................................................................................ 2-33
2.3.19 Attachment installation.......................................................................................... 2-33
2.3.20 Attachment combination ....................................................................................... 2-34
2.3.21 Cab windows glasses............................................................................................ 2-34
2.3.22 Unauthorized modification.................................................................................... 2-34
2.3.23 Worksite investigation ........................................................................................... 2-35
2.3.24 Operation on loose ground ................................................................................... 2-35
2.3.25 Overhead power cables ........................................................................................ 2-36
2.3.26 Visibility.................................................................................................................... 2-37
2.3.27 Ventilation................................................................................................................ 2-37
2.3.28 Asbestos.................................................................................................................. 2-38
2.3.29 Alternate exit........................................................................................................... 2-39
2.4 Safe Operation Precautions ............................................................................................. 2-39
2.4.1 Safe starting.............................................................................................................. 2-39
2.4.1.1 Safe mounting ................................................................................................... 2-39
2.4.1.2 Operator seat..................................................................................................... 2-40
2.4.1.3 Seat belt ............................................................................................................. 2-40
2.4.1.4 Before starting the engine ............................................................................... 2-41
2.4.1.5 Engine starting rules......................................................................................... 2-41
2.4.1.6 Machine starting................................................................................................ 2-42
2.4.1.7 Starting engine in cold season........................................................................ 2-42
2.4.1.8 Engine starting aid ............................................................................................ 2-42
2.4.1.9 After starting the engine................................................................................... 2-43
2.4.2 Operation................................................................................................................... 2-44
2.4.2.1 Inspection before operation............................................................................. 2-44
2.4.2.2 Prior-operation precautions............................................................................. 2-45
2.4.2.3 Travel direction confirmation ........................................................................... 2-45
2.4.2.4 Safety rules for turning ..................................................................................... 2-46
2.4.2.5 Safety rules for traveling .................................................................................. 2-47
2.4.2.6 Safe traveling..................................................................................................... 2-48
2.4.2.7 Machine operation on slope ............................................................................ 2-50
2.4.2.8 Operation in snowy weather............................................................................ 2-51
2.4.2.9 Restricted operation ......................................................................................... 2-52
2.4.3 Parking the machine ................................................................................................ 2-54

2.4.3.1 Select a parking place...................................................................................... 2-54
2.4.3.2 Machine shutdown............................................................................................ 2-55
2.4.4 Transportation........................................................................................................... 2-56
2.4.4.1 Loading and unloading..................................................................................... 2-56
2.4.4.2 Transportation ................................................................................................... 2-57
2.4.5 Battery........................................................................................................................ 2-57
2.4.6 Towing........................................................................................................................ 2-59
2.4.7 Lifting objects with the machine ............................................................................. 2-60
2.5 Precautions for Maintenance............................................................................................ 2-61
2.5.1 Pre-maintenance precautions ................................................................................ 2-61
2.5.2 Select a working area .............................................................................................. 2-61
2.5.3 Prepare the machine ............................................................................................... 2-62
2.5.4 Prepare yourself ....................................................................................................... 2-63
2.5.5 Lockout and tag-out measures............................................................................... 2-64
2.5.6 Use proper tools ....................................................................................................... 2-64
2.5.7 Maintenance with engine running.......................................................................... 2-65
2.5.8 Work under the machine ......................................................................................... 2-65
2.5.9 Track maintenance .................................................................................................. 2-66
2.5.10 Track tension adjustment...................................................................................... 2-67
2.5.11 Recoil spring ........................................................................................................... 2-67
2.5.12 Welding operation.................................................................................................. 2-67
2.5.13 High-pressure hoses ............................................................................................. 2-68
2.5.14 Pressurized fluid..................................................................................................... 2-68
2.5.15 Hot cooling system ................................................................................................ 2-69
2.5.16 Air-conditioning system maintenance................................................................. 2-69
2.5.17 High voltage precautions ...................................................................................... 2-70
2.5.18 Accumulator............................................................................................................ 2-70
2.5.19 Fire and explosion prevention.............................................................................. 2-71
2.5.20 Regular replacement of safety-related parts...................................................... 2-71
2.5.21 Maintenance operation ......................................................................................... 2-72
2.5.22 Proper disposal of wastes..................................................................................... 2-73

WARNING

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, lubrica-
tion, maintenance or repair procedures that you choose.
Modifying or abusing the machine according to your own will might impair the machine's perform-
ance, or result in more serious potential hazard. For instance, the specific volume of fuel oil ex-
ceeds 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 machine in
your country. In case you question whether the machine is in accordance with the standards and
specifications of your country, please contact your Sany dealer before operating the machine.
2.2 Safety Messages

2.2.1 foreword
Safety precautions are given in this manual and warning decals, both textual and graphical, are ad-
hered to various parts on the machine to provide information of hazardous situations and the meth-
od to avoid such situations.
Before conducting operation and maintenance on the machine, the operator and after-sale service
personnel must understand all warning 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 un-
safe factors, to the minimum.
2.2.2 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 hazardous situation
which, if not avoided, could result in death or
serious injury.
CAUTION
It indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury. It can also be used to alert
unsafe operation as which may cause
property loss.
CAUTION
It indicates a situation which can cause
damage to the machine, personal property
and/or the environment, or cause the
equipment to operate improperly.
WARNING
This hazard alert symbol appears with most
DANGER, WARNING and CAUTION 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 operator
compartment.
• A free control lever can cause serious in-
jury or death if touched by mistake.

2.2.3 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.
2.2.4 Safety decals
2.2.4.1 foreword
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.

2.2.4.2 Textual safety decals
Textual safety decals use brief text to indicate

hazardous situation and safety measures.
Fig. 2-1 is an example of textual safety

decals.
Fig.2-1
2.2.4.3 Graphic 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

decals.
The left part indicates the type of hazardous

situation while the right part shows the way to
avoid it.
Fig.2-2
2.2.4.4 Safety decal locations
Sany cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this manual and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Sany is used, you
must be sure that it is safe for you and for others.
Application or operation not specified in this manual shall not be performed at any time.
The following safety decals are used on the machine.

• Be sure to recognize the correct locations and information on 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 replacement if the old one is broken or missing, 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 distributor.
Fig.2-3

(1) Bucket strike hazard (23) Alternate exit

(2) Seat belt (24) Fire prevention
(3) Read the manual (25) Engine hood hazard
(4) High voltage hazard (26) Accumulator
(5) Lifting capacity chart (27) Counterweight hazard
(6) Button illustration (28) Water separator draining instruction
(7) Control pattern information (29) Drain water from the fuel tank
(8) Pattern change card (30) Power source
(9) Grease fitting squirting hazard (31) Power supply switch
(10) Tie-down point for shipment (32) Fuel tank
(11) Lifting point (33) Hydraulic oil tank
(12) Lubrication chart (34) Hot surface
(13) Unlock the door (35) Track tensioning warning
(14) Pattern change warning (36) Fan cutting hazard
(15) No seating (37) Belt running hazard
(16) Falling hazard (38) Squirting hazard
(17) Seat adjusting instruction (39) Battery warning
(18) Emergency stop (40) Oil level
(19) Arm hazard (41) Tie-down point distribution
(20) Secure the front window (42) Swing bearing warning
(21) Travel direction (43) Delay disconnecting the battery switch
(22) Tree-way ball valve flow directions
1. Bucket strike hazard
Fig.2-4

2. Seat belt
• Fasten your seat belt before operating the

machine.
Fig.2-5
3. Read the manual
• Read the Manual before operation, mainte-

nance, disassembly, reassembly and trans-
portation of your machine.
Fig.2-6
4. High voltage hazard
• This decal indicates that electrocution could

happen if your machine is close to power
transmission cable.
Fig.2-7

5. Lifting capacity chart
Fig.2-8
6. Button illustration
Fig.2-9
7. Control pattern information
• To prevent bodily injury, death or accident,

be sure of the running condition and the in-
dicated mode of your machine before oper-
ation. Observe your surrounding
circumstances and operate the machine
slowly.
Fig.2-10
8. Pattern change card
Fig.2-11

9. Grease fitting squirting hazard
• To loosen the track, never loosen the regu-

lator valve more than one turn. The regula-
tor valve may otherwise eject due to high
pressure and cause personal injury.
Fig.2-12
10.Tie-down point for shipment
Fig.2-13
11.Lifting point
Fig.2-14
12.Lubrication chart
Fig.2-15

13.Unlock the door
Fig.2-16
14.Pattern change warning
Fig.2-17
15.No seating
Fig.2-18
16.Falling hazard
• Possible to fall.
• Never stand close on the edge of machine.
Fig.2-19

17.Seat adjusting instruction
Fig.2-20
18.Emergency stop
Fig.2-21
19.Arm hazard
• Possible to be hit by work equipment.

• Keep a safe distance from a working
machine.
Fig.2-22
20.Secure the front window
• The front window may fall down.

• The front window must be secured with pin
when it is lifted.
Fig.2-23

21.Travel direction
Fig.2-24
22.Three-way ball valve flow directions
Fig.2-25
23.Alternate exit
Fig.2-26
24.Fire prevention
Fig.2-27

25.Engine hood hazard
• Do not step here!
Fig.2-28
26.Accumulator
Fig.2-29
27.Counterweight hazard
• This decal indicates the possibility of being

hit by machine. Do not enter the swinging
range.
• Keep a safe distance from a working
machine.
Fig.2-30
28.Water separator draining instruction
Fig.2-31

29.Drain water from the fuel tank
Fig.2-32
30.Power source
Fig.2-33
31.Power supply switch
Fig.2-34
32.Fuel tank
Fig.2-35

33.Hydraulic oil tank
Fig.2-36
34.Hot surface
• To prevent burns, do not touch hot surface.
Fig.2-37
35.Track tensioning warning
Fig.2-38
36.Fan cutting hazard
• Keep a safe distance from rotating parts as

which can cause injury.
• Stop rotating prior to maintenance.
Fig.2-39

37.Belt running hazard
• This decal indicates the potential hazard of

a running belt.
• Stop running the belt prior to maintenance.
Fig.2-40
38.Squirting hazard
• Read the instruction before opening a ves-

sel such as oil tank. Release the pressure
and open it slowly in order to prevent
squirting.
Fig.2-41
39.Battery warning
Fig.2-42
40.Oil level
Fig.2-43

41.Tie-down point distribution
Fig.2-44
42.Swing bearing warning
Fig.2-45
43.Delay disconnecting the battery switch
Fig.2-46
2.3 General Precautions

2.3.1 Safety rules
• Only trained personnel are allowed to oper-

ate 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 op-

eration 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
• Wet weather gear CZ335-1102002
• Respirator or filter masker Fig.2-47
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 deco-
rative ornaments, which can easily catch
on control lever or other protruding 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 en-
tangled 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.
• Check the first aid kit regularly and replen- Fig.2-48
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
• Guards CZ335-1102004
• Travel alarm Fig.2-49

• 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 correctly.
• 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
CZ335-1102005
eyes. Keep the machine clean all the time.
• If water has penetrated into the electrical Fig.2-50
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 elec-
trical system (including sensors, connec-
tors, etc.) with water or steam.
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 be-

fore 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 con-
trol lever [1] from F (free) to L (locked) posi-
tion, and then stop the engine. If the
hydraulic control is not locked, accidental
touching of control levers can cause sudden
machine movement and serious injury or
CC13031805
machine damage.
Fig.2-51

• 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.2-52
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
CZ335-1102008
case of any damage. Tighten loosen bolts.
• Use handholds and steps when mounting Fig.2-53
or dismounting the machine.
• Face the machine and maintain a three-
point contact (two feet and one hand or two
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 on-
to 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
operation.
2.3.11 No sitting on attachment
To avoid falling hazard, no one is allowed to

sit on work equipment or other machine
attachments.
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.
• 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.2-54
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
proceed.
When the engine has cooled down, loosen

the cover or screw plug slowly to relieve inter-
nal pressure.
CZ335-1102012
Fig.2-55
CZ335-1102013
Fig.2-56

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 des-

ignated place, where unauthorized persons
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, ho-
ses, oil coolers or other flange bolts.
• Refuel or store oils in a place with good
CZ335-1102014
ventilation.
• Shut down the engine before refueling. Fig.2-57
• 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 after
refilling.
• Store oily rags and flammable materials
properly to keep the job-site safe.
• Screw on the caps of fuel tank and oil tank
CZ335-1102015
tightly.
• When oil is used to clean the parts, use Fig.2-58
non-flammable oil. Do not use diesel oil or
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, ex-
haust manifold, battery or interior of engine
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 ho-

ses and pipes to see whether they are tight-
ened in position.
• 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 oper-
ation may lead to friction against other com-
ponents, resulting damage of hose, ejection
of high-pressure oil, disastrous fire or seri-
ous injury.
2.3.14.5 Fire caused by illumination

equipment
• Anti-blast illumination equipment shall be

used to avoid explosion when checking fuel,
oil, electrolyte, window cleaning detergent
or cooling fluid.
• Instructions in this manual must be followed
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 f re.
• In case of any abnormality, heat shield must
be repaired or replaced prior to operation 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
serious 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 down
CZ335-1102016
before loosening the vent plug to release
pressure. Keep your body and face away Fig.2-59
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.
CZ335-1102017
• In a coal mine or a quarry where falling ob-
jects are present, install falling object pro- Fig.2-60
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 un-
authorized 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 ma-
chine 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 di-
rect contact with the work equipment. In this
case, stop operation immediately and re-
place 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 materi-

als (e. g. dry tree leaves) poses a fire haz-
ard. Be careful during operation.
• Check the terrain and ground condition and
use the safest operating method. Do not op-
erate in areas with the risk of landslide or
falling stones.
• Solidify the ground when operating beside
a ditch or on road shoulders. Keep machine
CZ335-1102018
a safe distance away from the ditch or road
shoulder. Assign a signal man, when nec- Fig.2-61
essary, to avoid accidental injury.
• When underground water mains, gas lines,
cables or high-voltage electric wires are
available on the work site, inform related
utilities 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
CZ335-1102019
a highway.
• Be especially alert when operating on fro- Fig.2-62
zen ground. Increase of ambient tempera-
ture may result in soft and slippery ground.
• When traveling or operating in shallow
water or soft ground, check the type and
condition of rock bed as well as the depth
and water 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 ma-
chine 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 ca-
bles, inform local power company of the
coming operation and ask them to take nec-
CZ335-1102020
essary measures.
• If the machine is too close to power cable, Fig.2-63
electric shock is most likely to occur and
cause burns or death. A safe distance must Cable Voltage Min. Safe Distance
be kept between machine and the cable 100V-200V 2 m ( 7 ft)
(See the right table). Prior to operation, 6,600V 2 m ( 7 ft)
communicate with local power company re-
22,000V 3 m ( 10 ft)
garding safety measures.
66,000V 4 m ( 14 ft)
• A signalman is to be assigned to send sig-
nals if the machine is too close to the cable. 154,000V 5 m ( 17 ft)
• Nobody is allowed to approach the machine 187,000V 6 m ( 20 ft)
when operating near high-voltage cables. 275,000V 7 m ( 23 ft)
• If the machine is too close to the cable or
500,000V 12 m ( 36 ft)
touches the cable, to prevent electric shock,
operator shall not leave the cab until power
is surely cut off. In addition, nobody is al-
lowed 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
machine.

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 pla-

ces 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 turning
on work lights and headlights of the ma-
chine. 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 exam-
ple, 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
signals.
• 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
worksite. 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
CZ335-1102022
the machine following the wind. All persons
shall wear acceptable filter mask. Fig.2-64
• Nobody is allowed to approach the machine
during operation.
• The regulations, rules and environment cri-
terion at worksite shall be observed.
No asbestos is used in this machine. But

aftermarket parts could contain asbestos.
Therefore, use only the parts and components
supplied by Sany.
WARNING
• Exposure to hazardous chemicals or dusts
poses a serious danger if released or
mishandled.
• Performing demolition work or handling
hazardous materials often release sub-
stances that could pose a hazard.
• Serious injury or death may result unless
proper precautions are observed while
working with these materials.
• All workers involved in demolition or han-
dling 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 emer-

gency, 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 at-
tention to the debris on the ground, which
may cause you to slip and fall.
A820601990969
Fig.2-65
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 hand-hold.
• Remove the mud, oil dirt and water from
pedal, handholds and your soles at any
CA13031506
time.
• The cab must be aligned with the undercar- Fig.2-66
riage center-line before you enter or exit the
cab.

2.4.1.2 Operator seat
• Uncomfortable seat position can easily lead

to operator fatigue and operating mistakes.
The seat position should be adjusted upon
change of operator.
• The operator seat shall be properly ad-
justed so that the operator can have easy
access to all the control levers and pedals
in a comfortably seated position. Otherwise,
the seat should be readjusted.
CZ335-1102026
Fore more information, see "Operator seat ad-

Fig.2-67
justment" on page 4-17.
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 op-
erating, keep your seat belt buckled up.
For more information, see "Seat belt" on page

4-21. CZ335-1102027
• The seat belt shall be replaced every three Fig.2-68

years regardless of its condition.

2.4.1.4 Before starting the engine
Before starting your daily work, the following

items shall be observed prior to start of the
engine.
• 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.
• Check for blocked air filter and damaged CZ335-1102028
electrical wires. Fig.2-69

• Adjust the seat to a position easy for opera-
tion; check seat belt and buckles for dam-
age and wear.
• Check if the control levers are all in neutral
position. Check if the hydraulic lockout con-
trol 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 no-

body is on, under or around the machine.
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 ma-
chine 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.
• Adjust the position of the operator seat so

CZ335-1102029
that you can easily access all controls in a
seated position. Fig.2-70
• Make sure you are familiar with all the warn-
ing devices, gauges and operation controls.
• Place all controls to neutral/ or OFF
position.
• 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
attempt.

• Using jumper cables to start the engine

needs two persons working together with
one seated in the operator seat and the oth-
er 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 position
when connecting the two machines. Other-
wise, 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
machine.
• 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 pre-heater or other forms
of pre-heater.
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 ma-

chine to a spacious area without barriers
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 neutral
position, test the engine's speed control de-
vice; operate each control lever and confi
rm they work properly. Understand the con-
trol mode of work equipment.
• In case of any abnormality, stop operation
and take corrective measures immediately.
CAUTION
• Observe the machine and listen carefully
for abnormal noise. In case of fault or ab-
normality, shut down the machine immedi-
ately. 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 12
m
operation.
• Nobody is allowed to stay on or near the
machine, or within the swivel range.
CZ215S-1102003
• To improve the visibility in the travel direc-
tion, you may turn the cab if necessary. Fig.2-71
• Assign a signalman where visibility is poor.
2.4.2.3 Travel direction confirmation
WARNING
• Improper operation of travel control levers/
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
CZ335-1102031
side of track frame. It shows the forward di-
rection when the idlers are before the oper- Fig.2-72
ator cab.
• When the idlers are before the operator
cab, push the travel control levers (or press
the upper part of the pedal) to move the ma-
chine forward.
• When the travel motors are before the oper-
ator cab, pull the travel control levers (or
press the lower part of the pedals) to move
machine forward.
NOTE:
Fig.2-73
In this manual, the front, rear, left or right di-
rections are the directions seen from the cab

when the cab is straight forward and the driv-

ing wheels are in the rear.
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, ei-
ther open or closed. At worksite where fly-
ing objects may get into the cab, check if
the doors and windows are properly shut.
CZ335-1102033
Fig.2-74
• 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 surround-
ings before traveling.
CZ335-1102034
Fig.2-75
• 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 operations
under such circumstances.
CZ335-1102035
Fig.2-76

• If your vision is limited during reverse travel,

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 lo-
cal regulations.
• The machine can only be moved when both
the signalman and the operator understand
the signals. CZ335-1102045
• Understand all vocal, graphic and flag sig-
Fig.2-77
nals used in work and decide who is to give
signals.
• Keep the windows, rear view mirrors and
work lights clean and intact.
• Dust, heavy rain and fog may reduce visibil-
ity. 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 equipment, 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
20~30cm
as to avoid collision. (8~12i n)
• When traveling on a highway, contact re-

CZ335-1102036
lated departments in advance and follow
their instructions. Fig.2-78
• 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-

chine shall move at a low speed and avoid
sudden change of direction, or the machine
may tumble down. If the work equipment
hits the ground, the machine will lose bal-
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 autoidle
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
CZ335-1102037
that would make it tilt sharply.
• Check first the structural strength of a Fig.2-79
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
equipment.
2.4.2.6 Safe traveling
WARNING
• Driving the machine on a slope may cause
it to slip or tumble down, resulting in seri-
ous 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 CZ335-1102038
equipment could be lowered to ground im-

Fig.2-80
mediately to help stop the machine.
• 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.2-81
• 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.2-82

• Drive straight up and down a steep slope. It

is very dangerous to turn on or drive across
a slope.
CZ335-1102041
Fig.2-83
• To adjust the position of the machine on a

slope, drive it onto a flat surface, reposition
it and driving the machine to the slope
again.
• Drive at low speed on meadow, fallen
leaves or wet steel plate because even a
small grade could cause the machine to
slip.
• If your engine stalls out when traveling on a CZ335-1102042
slope, place the control levers to "neutral"

position immediately and restart the engine. Fig.2-84
2.4.2.7 Machine operation on slope
WARNING
• Swinging the upper structure or operating
the work equipment on a slope may cause
the machine to lose balance and tumble
down, resulting in serious injury or ma-
chine 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 danger-
ous and may cause the machine to tumble
down. CZ335-1102046
• If you have to operate your machine on a

Fig.2-85
slope, build an earth platform that could
keep the machine as horizontal as possible.
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 ma-
chine. Extra attention should be paid to op-
eration on a slope because even small
inclination could cause the machine to slip.
• The machine may tip over on frozen surface
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 ob-
jects. 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.2-86
• Never dig too much under the machine,

which may cause the ground to collapse
due to cave-in, hence the accidents.
CZ335-1102048
Fig.2-87
• Never tear down under your machine,

which may cause your machine to lose bal-
ance and roll over.
• When operating on building or other struc-
tures, strength of structure must be checked
to avoid collapse of building, thus resulting
injury or death.
CZ335-1102050
Fig.2-88

• Never tear down any structure over your

machine. The falling of broken objects or
collapse of building could damage your ma-
chine and cause personal injury or death.
CZ335-1102051
Fig.2-89
• 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
machine.
• 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.2-90
• 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 personal
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.2-91
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

surface.
• 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 direc- CZ335-1102054
tion and cut the bucket tips into the Fig.2-92

earth.
– Chock the tracks to prevent unexpected

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

120°
going construction. If you have to park your
machine in such a place, flags are to be
used on daytime and signal lamps at night
to warn other people or vehicles according
to local regulations. CZ335-1102055
Fig.2-93

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 stop
the engine. Fig.2-94
• Move the lockout lever to the LOCKED
position.
• Remove the key.
• Close the windows and the cab door.
• Lock all access doors, boxes and
chambers.
NOTE：
When leaving your machine, face the machine
and maintain a three-point contact with it. Do CZ335-1102028
not jump off the machine.
Fig.2-95
Be careful with slippery track, step and hand-
holds when dismounting the machine.

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-
CZ335-1102059
ness of the access ramp is capable of pro-
viding a safe loading/unloading operation Fig.2-96
(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
when loading or unloading the machine in
rainy or snowy weather.
• Never load or unload the machine using the
force of work equipment, which may cause
the machine to fall or tip over.
• Run the engine at low speed and drive CZ335-1102060
slowly. Fig.2-97
• Place the work equipment straight forward.
• Do not operate any control levers other than
the travel control lever when the machine is
driving up the ramp.
• Do not reposition the machine on the ac-
cess ramp. If necessary, drive it off the
ramp, reposition, and get on the ramp
again.
• 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 equipment
and swing the upper structure slowly.
• Once the machine is loaded, lock the cab
door. Otherwise, it may swing open during
transportation.
• Secure the machine with chains and
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 transport-

ing the machine:
• Note the dimension of the trailer and the

machine, especially the height. Watch out
for barriers overhead and in narrow
passages.
• Check the structure and strength of a bridge
before crossing it. Obey local traffic regula-
tions and traffic police directions when
transporting the machine on highways.
2.4.5 Battery
WARNING
• Electrolyte is a strong acid. If electrolyte
contacts your clothing or skin, flush imme-
diately with plenty of water.
• Electrolyte may cause blindness. Flush im-
mediately with plenty of clean water when
electrolyte gets into your eyes and seek
medical attention.
CZ335-1102061
Electrolyte contains sulfuric acid, which gives
off flammable and explosive gases. Improper Fig.2-98
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.
• Never allow tools and other metal parts to
contact with battery terminals. Keep tools or
metal parts away from batteries.
• 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 be-
fore 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-
CZ335-1102062
nals are securely connected.
• Battery temperature rises when it is being Fig.2-99
charged. When battery temperature ex-
ceeds 45°C, stop charging and wait till it is
at ambient temperature. Reduce the charg-
ing current by half and continue the charg-
ing process.
• A battery being charged may give off flam-
mable gases. Before charging a battery, re-
move 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 charging
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.
• Wear protective gloves and a hard hat B
when using wire ropes.
• Check the strength of wire cable and make C
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
ropes may break when towing. Fig.2-100
• Do not stand between the towing machine
and the towed machine during towing
operation.
• 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 seri-
ous injury and death.
• Make sure the load is within the loading
range and working radius of the machine.
• Nobody is allowed to enter the working

area.
• Confirm all signals to be used and assign a CZ335-1102064
signalman prior to operation.

Fig.2-101
• 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
CZ335-1102065
in progress.
• To prevent the load from hitting any person
Fig.2-102
or building, inspect carefully the machine
surroundings before swinging or operating
the work equipment.
• Never swing or operate the work equipment
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 direction. The
work equipment will jerk if the shackle CZ335-1102066
breaks and the load comes free, resulting in

Fig.2-103
serious personal injury.

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 fl

at area with plenty of space, ample sunlight
and good ventilation.
• Clean the working area by removing fuel,
lubricant and water, and covering slippery
ground with sand or other absorptive
materials.
• 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
stop the engine.
CZ335-1102054
• Turn the start switch to ON position. Oper-
ate the control levers 2 or 3 times in all di- Fig.2-104
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.2-105

2.5.4 Prepare yourself
Only approved personnel can maintain or re-

pair 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 materials,
wire ropes or sharp-edged metals.
• Wear a face shield when removing spring CZ335-1102069
or elastic parts, or adding acid to battery. Fig.2-106

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 perma-
nently 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 CZ335-1102071
parts such as pin, bucket teeth, cutting Fig.2-107

edge or shaft, the flying of parts and metal
pieces may cause bodily injury. Therefore,
wear goggles and gloves and ensure the
surrounding area is clear of any other
people.
• 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-
CZ335-1102067
chine if necessary.
Fig.2-108
CZ335-1102068
Fig.2-109
2.5.6 Use proper tools
• Use proper tools and use them correctly.

Using damaged, inferior, defective, tempo-
rary tools or using the tools incorrectly could
lead to serious accidents.
CZ335-1102072
Fig.2-110

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

carried out when the engine is running. How-
ever, if maintenance has to be done on a run-
ning 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 CZ335-1102028
the LOCKED position to prevent movement Fig.2-111

of work equipment.
• 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.2-112
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 supports
that are strong enough to support the ma-
chine or work equipment should be used.
Never use loose bricks, empty tires or
CZ335-1102078
stands to support the machine. These
things may collapse under continuing load. Fig.2-113

Never use a single jack to support the

machine.
• If the track shoes are lifted and the machine
is solely supported by the work equipment,
it is very dangerous to work under the ma-
chine. In case of failure of hydraulic pipe or
accidental touch of control lever, the work
equipment or machine may fall suddenly,
causing injury or death. Never 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 immense pres-
sure and spring rupture may cause bodily
injury. Do not remove any spring when it is
compressed.
• Dry rubbing of pin against bushing may pro-

duces 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 tension - in-
spect/adjust" on page 5-24.
• 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 adjust-
ment system under high pressure.
• Failure to observe specified maintenance
procedures may cause the grease dis-
charge plug to eject and cause serious in-
jury and damage.
• When loosening the grease discharge plug

CZ335-1102080
to reduce track tension, the plug shall be
unscrewed slowly for no more than one Fig.2-114
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 fl y out and cause
serious injury or death if removed improperly.
If it has to be removed, contact your Sany

dealer.
CZ335-1102081
Fig.2-115
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
equipment.

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 op-
eration 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-
38.
• Open fire is not allowed around the hydraul-
ic system. Remove splashed hydraulic oil
as quickly as possible.
• Diesel oil or pressurized hydraulic oil can
penetrate skin or eyes, causing serious in-
jury, blindness or death. It is hard to fi nd
the leaking of hydraulic oil with naked eyes.
A cardboard or wooden board is necessary
for checking for leaks. Do not touch leaking
CZ335-1102082
liquid with bare hand. Wear face shield or
safety goggles to protect your eyes. If any Fig.2-116
liquid penetrates your skin, flush with clean

water immediately and get medical atten-

tion as soon as possible.
• The fuel lines are under high pressure when
the engine is running. When checking or
servicing the fuel system, shut down the en-
gine and wait for 30 seconds till internal
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
has cooled down. CZ215L-1102001
Fig.2-117
2.5.16 Air-conditioning system

maintenance
WARNING
• Refrigerant R134a 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-

CZ335-1102083
conditioning system.
• In maintenance of air-conditioning system, Fig.2-118
observe the instruction on the refrigerant
cylinder and use it correctly. The type of re-
frigerant is R134a. Use of other refrigerants
may damage the air-conditioning system.

• Obey local material disposal regulations.

Never discharge refrigerant directly into the
air.
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
engine controller.
CZ335-1102084
Fig.2-119
2.5.18 Accumulator
The accumulator contains highly pressurized

nitrogen. Improper operation of the accumula-
tor can cause explosion and serious acci-
dents. 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
CZ335-1102085
accumulator.
• Do not strike or roll the accumulator, or let it Fig.2-120
bear any impact.
• The gas must be released when disposing
of the accumulator. Contact your Sany deal-
er 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 welding
operation on fuel pipe, fuel tank or fuel ves-
sels, which can lead to fire, explosion, in-
jury or death.
• Then engine must be shut down and electri-

cal equipment must be switched off when
refueling the tank. Be extremely careful
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 residuals.
Do not place greasy rag or other flammable
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 con-
sideration 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 deterioration,
wear and damage, hence the accidents and
serious injury. Through merely visual in-
spection or feel it is hard to find out how
long the parts could serve. Therefore, regu-
lar 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 re-
pair 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 proper
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 envi-

ronment. Consult local environmental protec-
tion 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
containers. CZ335-1102086
• Do not drain waste fluids directly to the Fig.2-121

ground, sewage or water source.
• Leaking of refrigerant from air conditioner
can spoil the atmosphere of the earth. Re-
lated laws and regulations must be followed
to recover or recycle the refrigerant.
CZ335-1102087
Fig.2-122


SY305C LC (Stage Ⅴ)Hydraulic Excavator System Functions
System Functions
3 System Functions...........................................................................................................3-1
3.1 Machine general drawing.....................................................................................................3-5
3.2 Monitoring System ................................................................................................................3-6
3.2.1 Monitor functions.........................................................................................................3-6
3.2.2 Monitor operation ........................................................................................................3-9
3.3 Switches .............................................................................................................................. 3-34
3.3.1 foreword..................................................................................................................... 3-34
3.3.2 Start switch................................................................................................................ 3-35
3.3.3 Fuel control dial ........................................................................................................ 3-36
3.3.4 Work lamp switch ..................................................................................................... 3-37
3.3.5 Head lamp switch..................................................................................................... 3-38
3.3.6 Windshield wiper switch .......................................................................................... 3-40
3.3.7 Washer switch .......................................................................................................... 3-41
3.3.8 Horn switch ............................................................................................................... 3-42
3.3.9 AEC switch................................................................................................................ 3-43
3.3.10 Cab lamp switch..................................................................................................... 3-43
3.3.11 12V Socket .............................................................................................................. 3-44
3.3.12 24V cigarette lighter............................................................................................... 3-44
3.3.13 Preheat indicator.................................................................................................... 3-45
3.3.14 Charging indicator.................................................................................................. 3-45
3.4 Control Levers and Pedals ............................................................................................... 3-46
3.4.1 foreword..................................................................................................................... 3-46
3.4.2 Hydraulic lockout control......................................................................................... 3-46
3.4.3 Travel control levers................................................................................................. 3-47
3.4.4 Joysticks .................................................................................................................... 3-48
3.5 Cab Windows and Cab Door ............................................................................................ 3-50
3.5.1 Ceiling window.......................................................................................................... 3-50
3.5.2 Front window............................................................................................................. 3-51
3.5.3 Cab door window...................................................................................................... 3-58
System Functions SY305C LC (Stage Ⅴ)Hydraulic Excavator
3.6 Cup Holder .......................................................................................................................... 3-59

3.7 Ash Tray .............................................................................................................................. 3-59
3.8 Manual Pocket.................................................................................................................... 3-60
3.9 Drink Box ............................................................................................................................. 3-60
3.10 Alternate exit..................................................................................................................... 3-61
3.11 Fire Extinguisher .............................................................................................................. 3-61
3.12 Electronic Control Module .............................................................................................. 3-62
3.13 Fusible Link....................................................................................................................... 3-62
3.14 Air Conditioning System.................................................................................................. 3-63
3.14.1 Control panel .......................................................................................................... 3-63
3.14.2 Operation method .................................................................................................. 3-68
3.14.3 Air conditioner operation precautions ................................................................. 3-70
3.15 Radio.................................................................................................................................. 3-72
3.15.1 Control panel .......................................................................................................... 3-72
3.15.2 Operation ................................................................................................................ 3-74
3.16 Cab door catch ................................................................................................................. 3-77
3.17 Lockable Caps and Covers ............................................................................................ 3-78
3.17.1 foreword .................................................................................................................. 3-78
3.17.2 Lockable caps......................................................................................................... 3-78
3.17.3 Lockable covers ..................................................................................................... 3-79


WARNING

3.System Functions
3.1 Machine general drawing
3
4
10 9 8 7
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
When the working status of the HomePage is

displayed in full screen, it is shown in the right
figure. In the full screen display state, the de-
scriptions of each part of the information are
as follows:
Area 1: Time and Date.
Area 2: Fault Alarm Icon; It is to quickly enter

the "Fault Code Query" by clicking this icon.
Area 3: Maintenance Icon; when the display

triggers the maintenance mechanism, the icon
will pop up to remind the customer that the ex-
cavator needs to be maintained.
Area 4: Mode and Gear; it displays the mode

and gear information when the SANY Excava-
tor works.
Area 5: Implement Icon; it shows the imple-

ment used by the SANY Excavator when it
works. Fig.3-2
Area 6: Engine Emergency Stop Warning

Icon.
Area 7: Engine Maintenance Warning Icon.
Area 8: Engine Shutdown Warning Icon.
Area 9:Aftertreatment Warning Icon.
Area 10:DPF Warning Icon.
Area 11: Inhibit Regeneration Warning Icon.

Area 12: Low Oil Pressure Warning Icon.
Area 13: Engine Coolant Temperature above

Normal Warning Icon.
Area 14: Exhaust Gas Temperature above

Area 15: Excavator camera screen area, click

this area to switch and adjust the screen.
Area 16: Fuel Level below Normal Warning

Icon.
Area 17: This area is a multiplexing area,

which contains two alarm icons: Engine Ab-
normal Warning Icon and Diesel Exhaust Flu-
id below Normal Warning Icon.
Area 18: Engine Air Filter Blockage Warning

Icon.
Area 19: Fuel Filter Blockage Warning Icon.
Area 20: Water Separator Full Warning Icon.
Area 21: Battery Voltage below Normal Warn-

ing Icon.
Area 22: Hydraulic Oil Temperature above

Area 23: Pre-High Engine Temperature Warn-

ing Icon.
Area 24: Hoisting Warning Icon.
Area 25: Fuel Level Dial.
Area 26: Total Working Time Displaying-Area.
Area 27: Instantaneous Fuel Consumption In-

formation Displaying-Area.
Area 28: The Button of Mode; it displays the

working mode of the SANY Excavator; to click
this button to switch the working mode of the
SANY Excavator, including S mode (Econom-
ic mode), H mode (Heavy load mode) and L
mode (Light load mode).

Area 29: Gear area, which shows the working

gear of the SANY Excavator; the working gear
can be adjusted through the throttle knob
switch.
Area 30:Engine Coolant Temperature Dial.
Area 31: Diesel Exhaust Fluid Dial.
Area 32: Working Time Displaying-Area.
Area 33: Excavator Speed Displaying-Area.
Area 34: Hydraulic Oil Temperature Dial.
Area 35:Information Tips Area.
Area 36: Shortcut Button; To click this button

to enter the shortcut menu; after enabling the
shortcut menu, to click other areas in the
Homepage to close the shortcut menu.
Area 37: Idle / Auto Idle Button; to click this

button to enter idle / auto idle status.
Area 38: High /Low Speed Button; to click this

Button to enter high / low speed status.
Area 39:KeyPad Button; to click this button to

start the keypad menu; after enabling the key-
pad menu, to click other areas in the Home-
page to close the keypad menu.
Area 40: User Menu Button; to click this but-

ton to enter the user menu.

3.2.2 Monitor operation
1. KeyPad Menu
Area 1: KeyPad Button; to click this button to

start the keypad menu; after enabling the key-
pad menu, to click other areas in the Home-
page to close the keypad menu.
Area 2: Platform Lighting Button in KeyPad

Menu; to click this button to turn on platform
light of excavator.
Area 3: Cab Dome Light Button in KeyPad

Menu; to click this button to turn on cab dome
light of excavator.
Area 4: Water Spray Button in KeyPad Menu;

to click this button to open the wiper-water
spray of excavator.
Area 5: Wiper Button in KeyPad Menu; to

click the button to open the wiper of
excavator.
Fig.3-3
Area 6: Light Alarm Button in KeyPad Menu;
to click this button to turn off light alarm light of
excavator.
Area 7: Walking Alarm Button in KeyPad

Menu; to click this button to turn off the walk-
ing alarm horn of the excavator.
Area 8: Inhibit Regeneration Button in Key-

Pad Menu; to click this button to Inhibit
regeneration.
Area 9: Manual Regeneration Button in Key-

Pad Menu; to click this button to manually re-
generate the excavator.

2. Shortcut Menu
Area 1: Shortcut Button; to click this button to

enter the shortcut menu; after enabling the
shortcut menu, to click other areas in the
Homepage to close the shortcut menu.
Area 2: Fault Code Query Button; to click this

button to enter the "Fault Code Query" page.
Area 3: Maintenance Button; to click this but-

ton to enter the "Maintenance Information"
page.
Area 4: Backlight Button; to click this button

to adjust the backlight of display-screen.
Area 5: Implement Button; to click this button

to enter the "Tool select" page.
Fig.3-4
3. User Menu
This page displays user menu information, in-

cluding system language function, alarm set-
ting function, date and time function, local
information query function, parameter setting
function and service assistant function.
Area 1: System Language Button; to click this

button to enter the "Language Selection"
page.
Area 2: Alarm Setting Button; to click this but-

ton to enter the "Alarm Content Setting" page.
Area 3: System Date Time Button; to click this

button to enter the "Sys Clock Calibration"
page.
Area 4: Machine Info Button; to click this but-

ton to enter the "Base Information" page.
Area 5: Parameter Setting Button; to click this

Fig.3-5
button to enter the "Parameter Settings" page.

Area 6: Service Assistant Button; to click this

button to enter the "Service Assistant" page
for service engineer by passwords.
Area 7: Homepage Button; to click this button

to quickly return to the "HomePage" page.
Area 8: Pre-page Button; to click this button

to return to the previous page.
4. System Language Selection
This page displays the language types being

able to be configured in the system; at
present, it supports Chinese and English only,
and other languages are gradually designed..
Area 1: Chinese Button; to select this button

and click the confirm button (area 10) to set
the system language to Chinese.
Area 2: English Button; to select this button

the system language to English.
Area 3: Pусский Button; to select this button

the system language to Russian.
Area 4: Português Button; to select this but-

ton and click the confirm button (area 10) to
set the system language to Portuguese.
Fig.3-6
Area 5: Français Button; to select this button
the system language to French.
Area 6: Türkçe Button; to select this button

the system language to Turkish.
Area 7: Español Button; to select this button

the system language to Spanish.
Area 8: Tips Area; after clicking the confirm

button (area 10), this area will pop up the
message of "Saved Successfully".


Area 10: Confirm Button; it is used to confirm

the selected language.

5. Alarm Content Setting
This page is used to set the voice and light

alarm functions of travel, swing and load.
Area 1: Travel-Voice Button; to select this but-

start the travel-voice alarm function.
Area 2: Swing-Voice Button; to select this but-

start the swing-voice alarm function.
Area 3: Load-Voice Button; to select this but-

start the load-voice alarm function.
Area 4: Travel-Light Button; to select this but-

start the travel-light alarm function.
Area 5: Swing-Light Button; to select this but-

Fig.3-7
start the swing-light alarm function.
Area 6: Load-Light Button; to select this but-

start the load-light alarm function.

button (area 9), this area will pop up the mes-
sage of "Saved Successfully".


various configurations.


6. System Clock Calibration
This page is used to set the system clock

information.
Area 1: Clock Button; to click this button to

set the clock standard: 24-hour or 12-hour.
Area 2: Time Zone Setting Button; this button

is used to set the time zone based on UTC.
Area 3: Time Setting Area; this area is used

to calibrate year, month, day, hour, minute
and second.



various configurations. Fig.3-8


7. Base Information
This page is used to show the base informa-

tion of SANY excavator.
Area 1: Base Information Zone; it shows the

information of device-ID, total service hours
and working hours.


Fig.3-9
8. Parameter Settings
This page is used to set the functions of intelli-

gent-lighting-system and GPS.
Area 1: Intelligent-Lighting-System Button; to

click this button to set the time of lighting sys-
tem when the SANY excavator stalls.
Area 2: GPS Button; to click this button to turn

on or off the GPS function of the display-
screen, only operated by service engineers or
administrators;



Fig.3-10


9. Service Assistant – Login
Area 1: Passwords Input Area; it needs ad-

ministrator passwords to enter "Service Assis-
tant" page, and this function is operated by
service engineers or administrators only.


Fig.3-11

10. Service Assistant Menu
This page shows the information of service

assistant menu.
Area 1: Running Info Button; to click this but-

ton to enter the "Running Information" page.
Area 2: Machine Config Button; to click this

button to enter the "Machine Configuration"
page.
Area 3: Machine Setup Button; to click this

button to enter the "Machine Configuration
Setup" page.
Area 4: Camera Config Button; to click this

button to enter the "Camera Configuration
Calibration" page.
Area 5: Upgrade Button; to click this button to

enter the "SoftWare Update" page.
Fig.3-12
Area 6: Failure History Button; to click this
button to enter the "Fault history Information"
page.
Area 7: Maintain History Button; to click this

button to enter the "Maintenance history infor-
mation" page.
Area 8: Running correct Button; to click this

button to enter the "Running Correct" page.
Area 9: Work-time Calibration Button; to click

this button to enter the "Service Hour Calibra-
tion" page.
Area 10: Homepage Button; to click this but-

ton to quickly return to the "HomePage" page.


11. Running Information Menu
This page shows the relevant parameters of

SANY excavator running information.
Area 1: Engine Running Information Button;

to click this button to enter the "Engine Infor-
mation" page.
Area 2: Hydraulic System Signal Button; to

click this button to enter the "Hydraulic Sys-
tem Signal" page.
Area 3: Main Controller Signal Button; to click

this button to enter the "Main Controller Sig-
nal" page.
Area 4: Total Work Time Button; to click this

button to enter the "Total Work Time" page.

Fig.3-13
12. Engine Information

engine running information.
Area 1: Zone of engine running information.

Area 3: Page Number – Pre-page Button; to

click this button to switch to the previous page
of engine information.
Area 4: Zone of Page Number information;

this area shows total page numbers and the
index of the current page in all pages.
Area 5: Page Number – Next-page Button; to

of engine information.

to return to the previous page. Fig.3-14

13. Hydraulic System Signal
Area 1: Zone of hydraulic system signal.


of hydraulic system signal.


of hydraulic system signal.

Fig.3-15
14. Main Controller Signal

main controller signal.
Area 1: Zone of main controller signal.


of main controller signal.


of main controller signal.

to return to the previous page. Fig.3-16

15. Total Work Time

total work time.
Area 1: Zone of different work time.


Fig.3-17
16. Machine Configuration Query

machine configuration.
Area 1: Zone of machine configuration

information.


of machine configuration.


of machine configuration
Area 6: Pre-page Button; to click this button Fig.3-18


17. Machine Configuration Setup
This page is used to set different system con-

figuration information.
Area 1: Calibration Area of Device-ID; to click

this area to calibrate device-ID.
Area 2: Calibration Area of Engine Brand; to

click this area to calibrate Engine Brand.
Area 3: Calibration Area of Engine Emissions;

to click this area to calibrate Engine
Emissions.
Area 4: Calibration Area of Hydraulic Pump

Model; to click this area to calibrate hydraulic
pump model.
Area 5: Calibration Area of Hydraulic Valve

Model; to click this area to calibrate hydraulic
valve model.
Fig.3-19
Area 6: Calibration Area of Control System; to
click this area to calibrate control system.

sage of "Calibration successfully".




18. Camera Configuration Calibration
This page is used to set camera configuration

information. These parameters will be effec-
tive after restarting display-screen.
Area 1: Camera Switch Button; to click this

button to turn on or off cameras function.
Area 2: Calibration Area of Camera Type; to

click this area to calibrate camera type.
Area 3: Calibration Area of Camera 1; to click

this area to calibrate camera 1.



Fig.3-20



19. SoftWare Update
This page is used to upgrade display-screen

software program.
Area 1: USB Upgrade Button; insert the de-

vice into USB port of the display-screen, and
to click this button to upgrade the display-
screen software program, but this is operated
by the service assistant and administrator.
Area 2: Zone of Upgrading Progress Tips; this

area shows the upgrading progress of the cur-
rent application.


Fig.3-21
20. Fault History Information
This page shows the diachronic fault informa-

Area 1: Zone of fault history information; this

area shows the data of fault.

Area 3: Refresh Button; to click this button to

refresh the data of fault.

Fig.3-22

21. Maintenance History Information
This page shows the diachronic maintenance

information of SANY excavator.
Area 1: Zone of maintenance history informa-

tion; this area shows the data of maintenance.


refresh the data of maintenance.

Fig.3-23
22. Running Correct
This page is used to adjust walking deviation.

The default value is 10.
Area 1: Travel Left Adjust Offset Decreases

Button; to click this button, the value of travel-
left-offset -1.
Area 2: Display the real-time adjustment off-

set of left-walking.
Area 3: Travel Left Adjust Offset Increases

left-offset +1.

Area 5: Display the real-time adjustment off-

set of right-walking.
Fig.3-24

Area 6: Travel Right Adjust Offset Increases

right-offset +1.




23. Service Hour Calibration
his page is mainly used to calibrate work time.

This function is only used by service engi-
neers, system administrators and factory
registration, and it is only one calibration
opportunity.
Area 1: Display the current working time of

SANY excavator.
Area 2: Zone of calibrating the work time; to

click this area to calibrate the work time.
Area 3: Display the remaining times of

calibration.


Area 6:Pre-page Button; to click this button to Fig.3-25

return to the previous page.

24. Fault Code Query
This page shows the real-time fault informa-

Area 1: Zone of real-time fault information;

this area shows the data of fault.


refresh the data of fault.

Fig.3-26
25. Maintenance Information
This page is used to show maintenance

information.
Area 1: Zone of maintenance information; this

area shows the data of maintenance
operations.
Area 2: Zone of maintenance information

Tips; this area shows the current maintenance
cycle and the next maintenance time.
Area 3:Homepage Button; to click this button

Area 4:Confirm Button; to click this button to

enter "Maintenance Confirmation" page.
Area 5:Pre-page Button; to click this button to

return to the previous page.
Fig.3-27

26. Maintenance Confirmation
This page is used for maintenance

confirmation.
Area 1: Passwords Input Area; you can gen-

erate passwords according to maintenance in-
formation, and input the passwords into this
area.
Area 2: Maintenance information area, which

is used to generate maintenance password.
Area 3: Zone of maintenance information

Tips; this area shows the current maintenance
cycle and the next maintenance time.

Area 5: Confirm Button; to click this button to

eliminate the maintenance alarm.
Fig.3-28

27. Backlight Brightness Adjustment
This page is mainly used to adjust the back-

light brightness of the displaying-screen.
Area 1: Brightness-Decrease Button; to click

this button, the backlight value subtracts 10.
Area 2: Zone of Backlight Brightness Bar; this

area displays the current backlight brightness
value.
Area 3: Brightness-Increase Button; to click

this button, the backlight value pluses 10.
Fig.3-29
28. Tool Selection Menu
This page is mainly used to select particular

work tools for SANY excavator.
Area 1: Bucket Button; when the excavator

uses bucket equipment, click the button, and
the area-2 shows the current excavator's
working tool is bucket.
Area 2: Zone of Excavator Work Tool Tips;

this area shows the current working tool of the
SANY excavator.
Area 3: Hammer Button; when the excavator

uses hammer equipment, click the button to
enter "Hammer" page, and the area-2 shows
the current excavator's working tool is
hammer.
Area 4: Hydraulic Shear Button; when the ex-

cavator uses hydraulic shear equipment, click
the button to enter "Hydraulic Shear" page, Fig.3-30

and the area-2 shows the current excavator's

working tool is hydraulic shear.
Area 5: Hoist Button; when the excavator

uses hoist equipment, click the button to enter
"Hoist" page, and the area-2 shows the cur-
rent excavator's working tool is hoist.
Area 6: Quick Coupler Button; when the exca-

vator uses quick coupler function, click the
button to enter "Quick Coupler" page, and the
area-2 shows the current excavator's working
tool is quick coupler.

Area 8: Counterweight Unloading Button,

click this button to unload the machine
counterweight.

29. Hammer
This page is used to calibrate the relevant pa-

rameters of hammer.
Area 1: Hammer Button; when the excavator

uses hammer equipment, click the button to
enter "Hammer" page, and the area-2 shows
the current excavator's working tool is
hammer.

SANY excavator.
Area 3: Area of Hammer Parameters Group

to Nominate; to click this area to nominate the
current configured hammer parameters
group.
Area 4: Area of Breaker to Calibrate; to click

this area to calibrate the breaker information.
Area 5: Area of Breaker Information Showing; Fig.3-31

this area displays breaker information.
Area 6: Area of Relief Pressure (Hammer) to

Calibrate; to click this area to calibrate the
hammer relief pressure information.
Area 7: Parameter-Group – Pre-group Button;

to click this button to switch to the previous
group of hammer calibration.
Area 8: Zone of Group Number Information;

this area shows total group numbers and the
index of the current group in all group.
Area 9: Parameter-Group – Next-group But-

ton; to click this button to switch to the next
group of hammer calibration.
Area 10: Confirm Button. After the current

hammer parameters are calibrated, click this
button to confirm the calibration operation;



counterweight.


30. Hydraulic Shears

rameters of hydraulic shear.
Area 1: Hydraulic Shear Button; when the ex-

cavator uses hydraulic shear equipment, click
the button to enter "Hydraulic Shear" page,
and the area-2 shows the current excavator's
working tool is hydraulic shear.

SANY excavator.
Area 3: Area of Hydraulic Shear Parameters

Group to Nominate; to click this area to nomi-
nate the current configured hydraulic shear
parameters group.
Area 4: Area of Shear Rotate Flow to Cali-

brate; to click this area to calibrate the shear
rotate flow information. Fig.3-32
Area 5: Area of Shear Rotate Flow Informa-

tion Showing; this area displays shear rotate
flow information.
Area 6: Area of Shear O/C Flow to Calibrate;

to click this area to calibrate the shear O/C
flow information.
Area 7: Area of Shear O/C Flow Information

Showing; this area displays shear O/C flow
information.
Area 8: Area of Relief Pressure (Close) to

Calibrate; to click this area to calibrate the re-
lief pressure (close) information.
Area 9: Area of Relief Pressure (Open) to

Calibrate; to click this area to calibrate the re-
lief pressure (open) information.
Area 10: Parameter-Group – Pre-group But-

ton; to click this button to switch to the pre-
vious group of hydraulic shear calibration.

Area 11: Zone of Group Number Information;

this area shows total group numbers and the
index of the current group in all group.
Area 12: Parameter-Group – Next-group But-

ton; to click this button to switch to the next
group of hydraulic shear calibration.
Area 13: Confirm Button. After the current hy-

draulic shear parameters are calibrated, click
this button to confirm the calibration
operation.



counterweight.


31. Hoist

rameters of hoist.
Area 1: Hoist Button; when the excavator

uses hoist equipment, click the button to enter
"Hoist" page, and the area-2 shows the cur-
rent excavator's working tool is hoist.

SANY excavator.
Area 3: Area of Pressure Alarm to Calibrate;

to click this area to calibrate the pressure
alarm information.
Area 4: Area of Pressure Alarm Information

Showing; this area displays pressure alarm
information
Area 5: Area of Boom Big Antrum Press Infor-

Fig.3-33
mation Showing; this area displays boom big
antrum press information.

operation;



counterweight.


32. Quick Coupler

rameters of quick coupler.
Area 1: Quick Button; when the excavator

uses quick function, click the button to enter
"Quick" page, and the area-2 shows the cur-
rent excavator's working tool is quick.

SANY excavator.
Area 3: Area of Front Pump Pressure Infor-

mation Showing; this area displays front pump
pressure information.
Area 4: Area of Rear Pump Pressure Informa-

tion Showing; this area displays rear pump
pressure information.
Area 5: Area of Quick Pressure to Calibrate;

Fig.3-34
to click this area to calibrate the quick pres-
sure information.
Area 6: Quick-Enable Button; to click this but-

ton to enable quick coupler function.
Area 7: Quick Pressure Unlock Button; when

the quick-enable button (area 6) is pressed,
the quick pressure unlock button is able to be
used. At this moment, to click this button to
unlock the quick pressure.

operation.

Area 10: Tips Area of Quick; this area is used

to prompt whether quick function is enabled.



counterweight.

3.3 Switches
3.3.1 foreword
Fig.3-35

Fig.3-36
1)Horn switch 6) Radio

2) Fuel control dial 7) Storage box
3) Start switch 8) 12 V Socket
4) Mobile Phone case 9) Air conditioning
5) Indicator light 10) Cab lamp switch
11) 24 V Cigarette lighter
*NOTE: Preheat switch is available on machines equipped with MITSUBISHI engines.
3.3.2 Start switch
Start switch is used to start and shut down the

engine.

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

F
moval of the ignition key. When the key slot AT OF ON
H E
points to OFF position, all devices in the elec-
START
trical system are power off. To stop the en-
gine, turn the ignition key from ON position to
OFF position.
ON position
CC13031503
When the ignition key is turned to ON position,
the electrical system is energized. Fig.3-37
START position
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.
NOTE: Preheating process varies depending

on the engine. For more information, see "En-
gine Preheating" on page 3-27.
3.3.3 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
MIN
speed, and counterclockwise to decrease en-

gine speed.
• MIN position: Low idle speed

• MAX position: Full speed
CC13031401
Fig.3-38

3.3.4 Work lamp switch
Work lamp switch : click icon 2 to turn on or

turn off the work lamp(s).
Fig.3-39
Work lamp locations
Two work lamps on the boom
CZ335-1103040
Fig.3-40

One work lamp on the right platform.
CZ335-1103041
Fig.3-41
3.3.5 Head lamp switch
Head lamp switch : click icon 3 to turn on or

turn off the lamps on top of the cab.
Fig.3-42

Head lamps on top of the operator cab
CZ335-1103047
Fig.3-43

3.3.6 Windshield wiper switch
switch : click icon 5 to turn on or turn off the

wiper .
CAUTION
• When using the wiper, press the washer
switch to spray detergent on the windshield
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.
Fig.3-44
Fig.3-45

3.3.7 Washer switch
Washer switch :click icon 4 to turn on or turn

off .
CAUTION
• 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.
Fig.3-46

3.3.8 Horn switch
The horn switch is located on top of the left

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

hooting.
Fig.3-47

3.3.9 AEC switch
1. AEC Switch – Press the AEC switch on the

right joystick in order to activate low engine
speed. Press the switch again in order to acti-
vate high engine speed.
Fig.3-48
3.3.10 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.3-49

3.3.11 12V Socket
12V Socket
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
24V
back after a few seconds and light a cigarette.
When the lighter removed, its socket can

serve as a 120W (12V×10A) power source. CC13041502
NOTE: The cigarette lighter is 12V. Do not

Fig.3-50
use it to power 24V devices.
3.3.12 24V cigarette lighter
24V 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.
24V
When the lighter removed, its socket can

serve as a 240W (24V×10A) power source.
CC13041502
NOTE: The cigarette lighter is 24V. Do not

Fig.3-51
use it to power 12V devices.

3.3.13 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.
Fig.3-52
3.3.14 Charging indicator
The battery charging indicator [2] lights up

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

3.4 Control Levers and Pedals

3.4.1 foreword
2
4
CC13040210-1
Fig.3-53
1) Hydraulic lockout control 3) Left joystick

2) Travel control 4) Right joystick
3.4.2 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, inadver-
tent 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 down-
ward to apply the lock. With the lockout lev-
er in the LOCKED position, the machine will
not move when the joysticks are operated.
• FREE position : When the lockout lever is
at FREE position, the machine will move as
CC13031504
you operate the joysticks.
Fig.3-54
When all control levers are neutralized and
the lockout lever is place in the FREE posi-
tion, any movement of any part of your ma-
chine 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.3-55
3.4.3 Travel control levers
WARNING
• Accidental touching of the travel control
pedals during machine operation may
cause the machine to move suddenly, re-
sulting 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:
N b
Push the control lever forward. (The pedal tilts
forward)
b a
b. Backward travel: a
b
Pull the control lever backward. (The pedal
b
tilts backward)
N - (Neutral Position): The machine stops.
NOTE: When the idler wheel is behind the op- CZ335-1103054
erator cab, the travel direction is reversed as

Fig.3-56
you operate the travel control levers.
3.4.4 Joysticks
WARNING
• Accidental touching of the joysticks will
cause the machine to swing or work equip-
ment movement, resulting in serious
accidents.
• Move the joysticks carefully before opera-
tion, and check if work equipment move-
ment 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 move- 2
4
ment stops. Combined machine operation can
be performed when the joysticks are moved
together or when a joystick is moved
diagonally.
CC13031505
Left Joystick Control
Fig.3-57
1 Forward Arm out
2 Backward Arm in
3 Left Swing to left
Swing to
4 Right 1
right
3 4
CZ335-1103056
Fig.3-58
Right Joystick Control

5 Forward Boom down 8
5
6 Backward Boom up
6
7 Left Bucket in 7
8 Right Bucket out
CC13031506
Fig.3-59

NOTE：
• When the travel controls and the joysticks
are neutralized, engine speed drops to a
moderate level even if the fuel control dial is 5
set at a higher speed. Engine speed rises to

7 8
previous level set by the fuel control dial
when any of the control levers is moved. 6
• If all the control levers are placed in neutral
position, the engine speed will decrease by
about 100 rpm. After about 4 seconds, the CZ335-1103058
engine will fall to the speed (about 1,400
Fig.3-60
rpm) set by auto-deceleration.
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.3-61

2. Push upward the locks [B] at both sides of

grip [A]. Hold the grip [A] and push upward the
B B
ceiling window.
CZ335-1103060
Fig.3-62
Close
1. Hold grip [A] and pull downward the ceiling

window. The locks [B] will be engaged
automatically.
2. If the locks are not engaged properly, open

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, lower

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

locked position.
CC13031403
Fig.3-63
3. Check that the wiper blade is stored in the

right bracket.。
CZ335-1103062
Fig.3-64

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.3-65
B
A
CZ335-1103064
Fig.3-66

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 upward.
Continue to push the window toward the latch D
[E] in the rear of the cab till it is locked
securely.
C
CZ335-1103065
Fig.3-67
CZ335-1103067
Fig.3-68
CZ335-1103066
Fig.3-69

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 lock is not B
engaged. Repeat step 5 to engage the lock.
CZ335-1103068
Fig.3-70
Lowering the front window
CAUTION
• Close the front window slowly and do not
get your hand caught by the window.
• 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, lower

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

LOCKED position.
CC13031403
Fig.3-71

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

pull the lever [B] downward to release the
lock.
CZ335-1103069
Fig.3-72
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.
CZ335-1102050
Fig.3-73
CZ135B-1103009
Fig.3-74

5. When the bottom of the windshield meets

the top of bottom window, push the top of the
G
front window to engage both the left and right
latches [G] of the locks.
CZ335-1103072
Fig.3-75
6. Check the lever [B], which shall be secured

in the LOCKED position.
• Check the arrow on the catch [F], which
shall be aligned with the arrow on lever [B]. F
The lock is engaged.

• If the arrow on the catch [F] is not aligned
with the arrow on lever [B], the lock is not
B
engaged. Repeat step 5 to engage the lock.
CZ335-1103068
Fig.3-76
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.3-77

● Removal of the bottom glass may be difficult

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 be-
fore removing the bottom glass.
CZ335-1103078
Fig.3-78
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.3-79

3.6 Cup Holder

A cup holder is designed and installed below
the machine monitor.
0-13004
Fig.3-80
3.7 Ash Tray
• This tray is located above the cigarette

lighter.
• Make sure that the cigarette has been extin-
guished before closing the ash tray cover.
0-13007
Fig.3-81

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.3-82
3.9 Drink Box
• The box is located to the rear right of opera-

tor 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.3-83

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
Fig.3-84
3.11 Fire Extinguisher
CAUTION
• 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

CZ215-1103044
the operator cab.
Fig.3-85

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
failure.
Do not disassemble the ECM in case of any

failure. Please contact Sany dealer for repair.
CB13041001-2
Fig.3-86
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:
NOTE：
• Fuses protect electrical equipment and elec-
CC13032901
trical wires from burning.
• The fuse should be replaced if it is eroded, Fig.3-87
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.3-88
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 temper-

ature and air flow displayed on the LCD panel OFF
disappear, and the indicators above the AUTO
switch and the A/C switch go out, and the op-
eration stops. CZ335-1103094
Fig.3-89

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
CZ335-1103095
automatic control mode. Fig.3-90

LCD panel and air flow volume
LCD display Air flow volume
Low flow
Moderate flow -1
Moderate flow -2
Moderate flow -3
Moderate flow -4
High flow
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 CZ335-1103096
(77°F). Fig.3-91
LCD display and function
LCD display Set Temperature
18.0°C Maximum cooling
Adjust temperature inside
18.5~31.5°C operator cab to selected
temperature
32.0°C Maximum heating

4. MODE switch
This switch is used to select air outlet mode.

• When this switch is pressed, the LCD panel
will display the selected air outlet mode and
air will blow out from the selected outlet(s). MODE
• Air outlet is regulated automatically in auto-
matic control mode.
CZ335-1103225
Fig.3-92
Air outlet mode

LCD Air Outlet
Air Outlet Mode Remark
Display 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
NOTE: Air comes out of the outlet identified

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

tor seat. A A
0-13010-1
Fig.3-93

[B]: Front air outlet
[C]: Defrosting air outlet

F1 F2 F3 F4 F5
Esc
Enter
24V
C B
0-13011-1
Fig.3-94
[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 out-
let is adjustable; whereas, the bottom air out- D
let is not adjustable.
CZ335-1103100
Fig.3-95
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.
AUTO
• Press the AUTO switch and press the
TEMP switch to set a suitable temperature,
CZ335-1103101
and the air conditioner will run
automatically. Fig.3-96
• When manual control mode, instead of auto
mode, is selected, air flow, air outlet mode
and circulation mode will have to be set
manually with the switches. The indicator
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.3-97
Mode Air recirculation Fresh air intake

Function Fresh air inlet is closed and air Take fresh air into the cab.
recirculates inside the cab.
Application Quick heating/Quick cooling When Take in clean air Defrosting
external air is not clean
7. LCD display
c
LCD display shows preset temperature [a], air
flow [b] and air outlet mode [c] during
operation.
• When the OFF switch is pressed, the LCD a
display goes off and the A/C operation
stops. b
CZ335-1103103
Fig.3-98

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]), A/C
press the A/C switch to activate the air con-
ditioner. The indicator above it will light up.
Press this switch again to deactivate the air CZ335-1103104
conditioner. The indicator goes out.
Fig.3-99
• The air conditioner is disabled when the fan
is switched off (air flow symbol on the LCD
disappears).
3.14.2 Operation method
Automatic control
c
1. Press the AUTO
switch.
• When the AUTO
switch is pressed, the LCD
panel displays the temperature [a] and air
flow [b]. The indicators above the AUTO
switch a
and the A/C
switch [8] will light up.
b
2. Use the TEMP
switch to set a desired

temperature. CZ335-1103103
• Under automatic control mode, the air con-

Fig.3-100
ditioner adjusts air flow volume, air outlet
mode and air circulation mode automati-
cally according to the preset temperature.
NOTE：
When air outlet is in Front-Rear-Bottom mode
[d] or Bottom mode [e], and engine coolant d e
temperature is low, the air flow will be re-

stricted to prevent cool air from blowing out.
CZ335-1103107
Fig.3-101

Stop AUTO operation
• Press the OFF

switch to stop automatic
operation.
Manual control
c
1. Press the switch to adjust air flow. Check
the temperature [a] and air fl ow [b] displayed
on the LCD display.
a
2. Press the A/C
switch.
b
3. Press the TEMP
switch to set the internal tem-

perature of the operator cab. CZ335-1103103
4. Press the MODE

switch to select an air outlet Fig.3-102
mode. The selected mode is displayed at [c]
on the LCD panel.
5. Press the or switch to select the recir-

culation or fresh air intake mode.
Stop manual operation
Press the OFF

switch to stop the manual
operation.
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 displayed
on the LCD display.
2. Press the MODE

switch and select the Front- CZ335-1103226
Rear-Bottom outlet mode.

Fig.3-103
3. Press the A/C
switch.
4. Press the switch, the TEMP
switch and the

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] dis- c
played on the LCD panel.
2. Press the MODE

switch and select the Defrost
a
mode [f] or Defrost-Bottom mode [g].
b
3. Press the switch and select fresh air
intake.
CZ335-1103103
4. Press the TEMP
switch and set the temperature Fig.3-104

on the LCD panel to maximum (32°C).
f g
CZ335-1103109
Fig.3-105
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 possible dam-
age to the air conditioner may result .
• If water should get on control panel or sunlight sensor, an unexpected failure may result. Always
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.
•
1. Ventilation
• When the air conditioner has been operat-

ing 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 run-
ning, 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.
2. 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 tem-
perature difference is considered as the
most healthy temperature. Therefore, the
temperature shall be adjusted properly.
3. Inspection and maintenance of air con-

ditioned machine
• When checking and maintaining the air con-

ditioned 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 cool-
ing, dehumidifying and heating operations
for several minutes in order to prevent loss
of oil fi lm on each component.
• The air conditioner will not work if the inter-
nal temperature of cab is low. You can cir-
culate 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
AS/ PS AM/FM TIME SEL
TUNING TIME ADJ VOL

ST
AM
FM
7 8 9 10
CZ335-1103111
Fig.3-106
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 the 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) and
SEL
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 button is pressed. The LCD re-
TIME
turns to frequency display after 5 seconds.
Keep the button pressed for more than 5 seconds to display the region code. (ASA and EU)
TIME

FM/AM selector [4]
Press the button to switch between FM and AM.

FM/AM
AS/PS button [5]
The button is used for automatic scanning of saved radio stations and automatic searching of
AS/PS
radio stations.
• Automatic scanning:
Turn on the radio and press the button. The radio starts automatic scanning of the previously
AS/PS
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 button.
AS/PS
• Automatic searching of radio stations:

Turn on the radio and press the button for 2 seconds. The radio starts an automatic search-
AS/PS
ing 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 [1] to turn on the radio. Radio fre- 6 2 1

quency is displayed on the LCD [7].
PRESET STATION SANY
AS/PS AM/FM TIME SEL
2. Press [8] to locate the desired frequency. ST TUNING TIME ADJ VOL
AM
There are two tuning ways: manual and FM
automatic. 7 8
3. When desired frequency is shown on the CZ335-1103112
display [7], depress one of the preset buttons

Fig.3-107
for at least 1.5 seconds. The voice will disap-
pear. But the voice will come back when the
presetting operation (storing to the memory) is
completed. The preset button number and the
frequency will be displayed, indicating the
completion of presetting operation. After pre-
setting 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 the sta-
AS/PS
tions automatically.
Searching radio station
1. Press [1] to turn on the radio. Radio fre-

quency is displayed the LCD [7].
2. Press [8] to locate the desired frequency.

There are two tuning ways: manual and
automatic.
• Manual tuning
Press the tuning buttons [8] till the fre-
quency appears on the display [7].

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
activate automatic scanning of radio sta-
tions. When any station is found, the tuning
stops. To scan next station, depress one of
the tuning buttons [8] again.
If this button is pressed during automatic
tuning, automatic tuning will be cancelled.
The setting returns to the previous fre-
quency before the button is pressed.
Sound effect adjustment
• BAS: Press the

SEL
button and select BAS.
Within 5 seconds, press or to adjust
BAS value between +7 and -7.
• TRE: Press the
SEL
TRE value between +7 and -7.
• BAL: Press the
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
seconds.
Radio time adjustment
1. Press the button [3] to display radio time on 3
the LCD. The display will return to radio fre- PRESET STATION SANY
quency after 5 seconds. AS/PS AM/FM TIME SEL
TUNING TIME ADJ VOL

ST
AM
FM
2. When radio time is displayed on the LCD,

press or to select Hour or Minute.
H M 9
H
: Hour adjustment
(Hour goes up by 1 with each press) CZ335-1103113
M
: Minute adjustment
Fig.3-108
(Minute goes up by 1 with each press)

Keep or pressed, Hour or Minute will keep
H M
going till the button is released.

is used for precision adjustment:
ADJ
• Press ADJ
when Minute reading is between
00 and 05 to decrease Minute to zero.
(Hour reading does not change)
• Press ADJ
when Minute reading is between
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 reading
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
1
machine into or out of a building.
A
1. Loosen the mounting bolt [1] and retract the
antenna to position [A].
2. Fasten the bolt [1] after retracting the

CZ335-1103114
antenna.
Radio operation precautions Fig.3-109

• Keep radio volume at a proper level so that
you can hear the outside sound during
operation.
• 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 before
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.
• Move the cab door toward catch [1] until it

engages with the catch.
• When closing the door, press lever [2] to
the left of the operator seat to release the 1
catch [1].
2
CZ335-1103082
Fig.3-110

3.17 Lockable Caps and Covers

3.17.1 foreword
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.3-111
3.17.2 Lockable caps
CAUTION
• Make sure the key slot is covered after re-
moving the key. Otherwise, invasion of for-
eign 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 sealing
may cause fuel leakage.

Unlocking
1. Slide off cover [1] to expose the key slot.

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

B
cap to unlock the cap [2].
Position [A]: Unlock A
Position [B]: Lock
CZ215-1103001
Fig.3-112
Locking
1. Screw on the cover [2] tightly and insert the

1
ignition key into the key slot.
2. Turn the key to LOCK position [B], and then

remove the key.
B
3. Slide cover [1] onto the key slot.
A
CZ215-1103002
Fig.3-113
3.17.3 Lockable covers
Unlocking
1. Insert the ignition key into the key slot.

A
2. Turn the key counterclockwise to unlock the

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

B
Locking
CZ335-1103085
1. Shut the cover properly and insert the key. Fig.3-114

2. Turn the key clockwise to position (B) and

remove the key.

SY305C LC (Stage Ⅴ)Hydraulic Excavator Operation
Operation
4 Operation.............................................................................................................................4-1
4.1 Before Starting the Engine...................................................................................................4-5
4.1.1 Walk-around inspection..............................................................................................4-5
4.1.2 Inspection before starting...........................................................................................4-6
4.1.2.1 foreword ................................................................................................................4-6
4.1.2.2 Water and sediment in fuel tank - drain ............................................................4-6
4.1.2.3 Water and sediment in water separator - check/drain....................................4-7
4.1.2.4 Hydraulic oil level - check/refill...........................................................................4-8
4.1.2.5 Coolant level - check/refill................................................................................ 4-10
4.1.2.6 Oil level in oil pan - check/add .........................................................................4-11
4.1.2.7 Electric wires - check.........................................................................................4-11
4.1.2.8 Fuel level - Check and add.............................................................................. 4-12
4.1.2.9 Work lamp switches - check............................................................................ 4-14
4.1.2.10 Horn - check .................................................................................................... 4-14
4.1.3 Adjustment before operation .................................................................................. 4-15
4.1.3.1 Operator seat adjustment ................................................................................ 4-15
4.1.3.2 Rear view mirrors.............................................................................................. 4-17
4.1.3.3 Seat belt ............................................................................................................. 4-18
4.1.4 Operation before engine startup ............................................................................ 4-19
4.2 Engine Startup.................................................................................................................... 4-21
4.2.1 foreword..................................................................................................................... 4-21
4.2.2 Engine Preheating ................................................................................................... 4-23
4.2.3 Warm-up operation .................................................................................................. 4-24
4.3 Engine Shutdown ............................................................................................................... 4-25
4.4 Machine Operation............................................................................................................. 4-26
4.4.1 Machine Operation................................................................................................... 4-26
4.4.2 Before moving the machine.................................................................................... 4-26
4.4.3 Move the machine.................................................................................................... 4-27
4.4.4 Stopping the machine.............................................................................................. 4-28
Operation SY305C LC (Stage Ⅴ)Hydraulic Excavator
4.5 Machine Turning................................................................................................................. 4-29

4.5.1 foreword..................................................................................................................... 4-29
4.5.2 Direction change when the machine is stopped .................................................. 4-29
4.5.3 Pivot turning .............................................................................................................. 4-30
4.6 Work Equipment Control ................................................................................................... 4-31
4.7 Restricted Operations........................................................................................................ 4-33
4.7.1 foreword..................................................................................................................... 4-33
4.7.2 Operation with swinging force ................................................................................ 4-33
4.7.3 Operation with traveling force................................................................................. 4-34
4.7.4 Operation when hydraulic cylinder reaches its stroke end ................................ 4-34
4.7.5 Operation with bucket landing force ...................................................................... 4-35
4.7.6 Hard rocky ground.................................................................................................... 4-35
4.7.7 Operation with machine weight.............................................................................. 4-36
4.7.8 Sudden shift of control levers or pedals................................................................ 4-36
4.8 Permissible depth of water ............................................................................................... 4-37
4.9 Traveling on a Slope .......................................................................................................... 4-38
4.9.1 foreword..................................................................................................................... 4-38
4.9.2 Traveling downhill .................................................................................................... 4-39
4.9.3 When engine stalls on a slope ............................................................................... 4-39
4.9.4 Cab door on a slope................................................................................................. 4-39
4.10 Escaping from Mud.......................................................................................................... 4-40
4.10.1 foreword .................................................................................................................. 4-40
4.10.2 When one track is trapped.................................................................................... 4-40
4.10.3 When both tracks are trapped.............................................................................. 4-40
4.11 Recommended Application............................................................................................. 4-41
4.11.1 foreword................................................................................................................... 4-41
4.11.2 Backhoe operation ................................................................................................. 4-41
4.11.3 Trenching work ....................................................................................................... 4-42
4.11.4 Loading operation .................................................................................................. 4-42
4.12 Parking .............................................................................................................................. 4-43
4.13 Post-operation Inspection............................................................................................... 4-45
4.14 Locking .............................................................................................................................. 4-46
4.15 Operation in Cold Weather ............................................................................................. 4-46
4.15.1 foreword .................................................................................................................. 4-46
4.15.2 Fuel and lubricant .................................................................................................. 4-46
4.15.3 Coolant .................................................................................................................... 4-47
4.15.4 Battery ..................................................................................................................... 4-47
4.15.5 After operation in cold weather ............................................................................ 4-47
4.15.6 After cold season ................................................................................................... 4-48
4.16 Long-Term Storage.......................................................................................................... 4-48
4.16.1 Before storage........................................................................................................ 4-48
4.16.2 During storage........................................................................................................ 4-49

4.16.3 After storage ........................................................................................................... 4-49
4.16.4 Engine startup after long-term storage ............................................................... 4-50
4.17 Transportation Information ............................................................................................. 4-50
4.17.1 Transport methods................................................................................................. 4-50
4.17.2 Loading and unloading.......................................................................................... 4-51
4.17.2.1 foreword ........................................................................................................... 4-51
4.17.2.2 Loading ............................................................................................................ 4-52
4.17.2.3 Securing the machine .................................................................................... 4-54
4.17.2.4 Unloading......................................................................................................... 4-57
4.17.2.5 Lifting the machine ......................................................................................... 4-59

WARNING

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 compo-
nents 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 loosening.
Check the O-ring between the bucket and the arm for damage. Repair or replace 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 mir-
rors and adjust their positions so that the area behind the machine could be seen clearly from op-
erator’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 Sany dealer for
repair in case of any problem.
4.1.2 Inspection before starting
4.1.2.1 foreword
The items in this section must be checked

every day before starting the engine.
4.1.2.2 Water and sediment in fuel tank

- drain
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].
2
3. Open the drain valve [2] to drain the sedi-
ment, water and fuel from fuel tank. 1
4. When clean fuel is seen, turn off the drain

CZ215-1203001X
valve [2].
Fig.4-1
5. Shut the access door.

4.1.2.3 Water and sediment in water

separator - 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 a 1
container under drain hose [3] to receive 2
drainage. 3
3. Open drain valve [2] to discharge water. 2015083105
4. Close drain valve [2] once fuel is seen com- Fig.4-2

ing out of drain hose [3].
2
3
2015083106
Fig.4-3
NOTE：
• If cover [2] is dirty and opaque, clean it when replacing fuel filter element [1].
• When the drain valve [3] has been removed during cleaning, its O-ring [4] must be greased and
the valve must be tightened till it contacts the bottom.

4.1.2.4 Hydraulic oil level - check/refill
WARNING
Hot oil and hot components can cause
personal injury. Do not allow hot oil or hot
components to contact skin.
Never remove the fill/vent plug from the hy-

draulic tank if the oil is hot.
Air can enter the system and cause pump
damage.
The hydraulic oil tank is on the right side of

the machine.
1. Park the machine on level ground. Lower

the bucket to the ground with the stick in a
vertical position, as shown.
2. Open the access door on the right side of

the machine. Check the oil level gauge (G).
3. For a cold machine, maintain the hydraulic

oil level in the low temperature range (L). For Fig.4-4
a machine that is at normal operating temper-
ature, maintain the hydraulic oil level in the
high temperature range (H).
F
4. Close the access door.
CZ335-1103126
Fig.4-5

CC13052101
Fig.4-6
Perform Step 5 through Step 8 if the oil level is low.
WARNING
Pressurized system!
The hydraulic tank contains hot oil under pressure. To prevent burns from the sudden release of
hot oil, Remove the butterfly nut on the breather valve of the hydraulic tank and press the air vent
to relieve the internal pressure.
5. Remove the butterfly nut on the breather

valve of the hydraulic tank and press the air
vent to relieve the internal pressure. Remove
the cap (F) of the oil filler.
6. Add oil if necessary.
7. Check the O-ring seal of the filler cap. Re-

place the O-ring seal if the O-ring seal is
damaged.
8. Clean the filler cap. Tighten the filler cap (F)

on the hydraulic tank.
Do not add oil to a level above the H mark. If the oil level is above the H mark, stop the engine and
wait for the oil to cool down. Place a container under the drain plug (P) beneath the hydraulic tank
and discharge excessive oil from the tank via the drain plug.

4.1.2.5 Coolant level - check/refill
CAUTION
• The coolant is hot and the radiator is under
high pressure upon shutdown of the en- 1
gine. Removing the radiator cap (1) at the

moment may cause burns.
• Do not remove the cap until coolant tem-
perature has dropped.
• Turn the filler cap slowly to release internal
pressure.
0-13013
The coolant level must remain between the
upper and lower limits marked on the reserve Fig.4-7
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.
2
FULL
1. Open the rear door on the left side of ma- LOW
chine and check the level of coolant in the re-
serve tank [2]. If coolant level is low, add
coolant to FULL position through the filler
opening of the reserve tank [2].
2. Tighten the cap after refilling the tank. 0-13014
3. An empty reserve tank [2] might be caused Fig.4-8

by coolant leakage. Correct the fault immedi-
ately after inspection. If no problem has been
found, check coolant level in the radiator. Add
coolant to reserve tank [2] if its level is low.
4. If reserve tank [2] is dirty inside and the lev-

el cannot be seen clearly, clean the tank. For
more information, see "Cooling system interior
- clean" on page 5-79.

4.1.2.6 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
F
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. 0-13015
Fig.4-9
3. Insert the dipstick (G) to bottom and then
pull it out.
4. Oil level should be between the H and L

marks on dipstick (G). Add oil through open-
ing (F) if oil level is below the L mark.
Recommended oil: Caltex CH-4 15W-40 L H
5. If oil level is above H mark, the drain valve

CZ335-1103131
(P) on the bottom of oil pan is to be opened to
discharge extra oil. Check oil level again. Fig.4-10
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 operation
of the engine, shut off the engine and wait at
least for 15 minutes before checking.
• If your machine is on a slope, move it to a
P
level ground prior to inspection.
CZ335S-1103057
Fig.4-11
4.1.2.7 Electric wires - check

CAUTION
• If fuses blow frequently or any short circuits
are detected in the system, investigate 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.
4.1.2.8 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. Re-
move 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 posi-

tion and check the fuel level on the monitor
screen. Turn the switch to the OFF position
after checking.
E F
CZ215-1303002
Fig.4-12
2. When fuel level is low, remove the fuel tank

cap (F) and fill the tank till the float meter (G)
F
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.4-13
3. Press down the float meter (G) with the fuel

tank cap (F). Make sure that the fl oat meter is F
not stuck on the cover plate of filler cap.
Screw on the filler cap. a
CZ335-1103135
Fig.4-14

NOTE：
• 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 CZ335-1103136
clean. Metal chips or sands on the sealing

may cause fuel leakage. Fig.4-15
4.1.2.9 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.
Please contact Sany dealer for repair.
1. Turn the start switch to the ON position.
2. Switch on the work lamp switch and check if

CC13040203
the lamps light up.
Fig.4-16
4.1.2.10 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, please contact Sany dealer
for repair.
CC13040209
Fig.4-17

4.1.3 Adjustment before operation
4.1.3.1 Operator seat adjustment
It is necessary to adjust seat position before

operating or after changing operator. D
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

E
Pull the lever [1] upward, slide the seat to de-
sired position, and release the lever.
A
Adjusting length: 200mm (10mm per step)
C
(B) Adjust the seat forward and backward
as a whole
Pull the lever (2), slide the seat to desired po-

sition, and release the lever. In this case, the
1
operator seat moves along with both armrest
boxes and pilot lockout lever.
3 2 4
(C) Suspension adjustment (if equipped) B CZ335-1103139
Turning the lever (3) counterclockwise will Fig.4-18

bring you a hard suspension which is suitable
for heavy operator; turning the lever (3) clock-
wise 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 opti-

mum 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
5
careful with the control levers, which shall not
be touched by armrest.
CZ335-1103140
Fig.4-19
(E) Armrest angle adjustment
Turning the plate (7) beneath armrest (6) can

6
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.4-20

4.1.3.2 Rear view mirrors
CAUTION
Adjust the rear view mirrors before operation.
Failure to do so may cause poor visibility, B A
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.
• Install rear mirror (A) to the position as
CZ335-1103142
shown in the right illustration.
• Turn the fixing rod [1] around the handrail to Fig.4-21
a suitable position and fix rod [1].
• If the mirror cannot move smoothly, you
may loosen bolt [2] and bolt [3] to release 2
the mirror.
Torque of bolt (2): 4.0~5.4 N·m {0.41~0.55
kgf·m}
1
CZ335-1203005G
Fig.4-22
• 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.4-23

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
4
• When adjusting mirror angle, if the mirror
cannot move smoothly, you may loosen bolt 5
[4] and bolt [5] to release the mirror.

Torque of bolt (5): CZ335-1203008G
4.0~5.4 N·m {0.41~0.55 kgf·m}

Fig.4-24
• Adjustment of rear mirror is accomplished
when side of machine can be seen in the
mirror, as shown in the right illustration.
CZ335-1203009G
Fig.4-25
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 regard-
less of its condition.
• Be sure to fasten your seat belt during ma-
chine operation.
• Do not twist the seat belt.

1. Buckle up and release
The seal belt has a coiler, and belt length

needs no adjustment.
4 3 2 1
1) Buckle up
Hold clip [2] and pull the belt out of coiler
SS
PRE
[1]. Check that there is no twist on the belt
and insert catch [3] into buckle [4].
Check if the belt has been fastened by pull-
CZ335-1103147
ing it slightly.
Fig.4-26
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 in-
to the coiler.
4.1.4 Operation before engine startup
WARNING
• Before starting the engine, check if the hy-
draulic lockout control is secured in the
LOCKED position.
• If the hydraulic lockout control is not in the
LOCKED position, accidental touching of
control lever or pedal when starting the en-
gine 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 the Fig.4-27

LOCKED position.
2. Check if all control levers and pedals are

neutralized. They shall remain in NEUTRAL
position if not operated.
CC13031403
4. Check the condition of the machine through

the gauges on the monitor display.. ON
OFF
STA
T
HEA
RT
CC13031804
Fig.4-28
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 indicator may light up because:
coolant temperature is too high; or engine oil pressure is too high or too low.

4.2 Engine Startup

4.2.1 foreword
WARNING
• Only start the engine from the operator
seat.
• Never start the engine by shorting the
starter circuit, which may cause serious in-
jury or fire.
• Sound the horn and start the engine after
confirming that the machine surroundings
are clear of personnel or obstacles.
• Never use any aerosol starting aid, which
may cause an explosion.
• Exhaust gas is poisonous. Provide ad-
equate ventilation when starting the engine
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 and MA
ON
machine damage.
OFF
AT
HE
NIM
CC13031502
Fig.4-29
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.4-30

2. Turn the fuel control dial to the MIN

position.
MA
X
MIN
CC13031401
Fig.4-31
NOTE：
When ambient temperature is below 10° C, ON
OFF
heat the engine before startup.
STA
T
HEA
RT
CC13031804
Fig.4-32
4. Turn the start switch to the START position

and start the engine.
ON
OFF
STA
T
HEA
RT
CC13031801
Fig.4-33

5. Release the switch when the engine is

started. It returns to ON position
automatically.
ON
OFF
STA
NOTE：
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 sec-
onds. In this case, wait at least for 1 minute
CC13031802
before restarting the engine.
Fig.4-34
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.
4.2.2 Engine Preheating
When ambient temperature is below 10° C,

heat the engine before startup.
Preheating procedures are different depend-

ing on the engine equipped on the machine.
Machines equipped with MITSUBISHI

engines
• Turn the fuel control dial to MIN position,

X
START
MA
and turn on the preheat switch [1]. Turn the

N
T OFF O
engine start switch to the HEAT position.

HEA
NIM
When preheating indicator [2] lights up, en-

gine preheating begins.
Preheating takes from 10 to 30 seconds de-
2 1
pending on ambient temperature: CC13040301
Fig.4-35

Tempera
0~10 -10~0 <-10
ture (°C)
Preheat
10 s 20 s 30 s
ing time
• Do not preheat the engine for more than 30

seconds. Try starting the engine when pre-
heating process is over. Switch off the pre-
heat switch when the engine is started.
Machines equipped with ISUZU engines

• No preheat switch is designed on machines
that are equipped with ISUZU engines.
• 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 mi-
nute at minimum and repeat the preheating
and startup procedure.
4.2.3 Warm-up operation
WARNING
• Insufficient warm-up of the machine may cause slow response or abrupt movement during op-
eration, 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 tempera-
ture. 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 con-
siderably reduce service life of its
components.
• Never shut down the engine abruptly ex-
cept 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.
ON
2. Turn the start switch to the OFF position to OFF
STA
T
HEA
shut off the engine.

RT
3. Remove the ignition key.
CC13031803
Fig.4-36

4.4 Machine Operation

4.4.1 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
C
around the machine.
• Remove any barriers from the travel route.
• There is a blind area behind the machine.
Take extra care when reversing the
A B
machine.
CC13031518
Fig.4-37
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.
4.4.2 Before moving the machine
1. Adjust the fuel control dial to a desired posi-

tion to increase engine speed.
MA
X
MIN
CC13031507
Fig.4-38

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.4-39
40~50cm
CC13050601
Fig.4-40
4.4.3 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.4-41

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 ma-
chine backward.
CC13031509
Fig.4-42
NOTE：
• If the sprockets are in the front of the machine, the moving direction of the machine is opposite
when the travel control levers (pedals) are operated.
• To ensure straight travel, operate the travel 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.
4.4.4 Stopping the machine
CAUTION
• Do not stop the machine suddenly.
• Before stopping the machine, leave your-
self enough space so that you can leave
the machine easily.
• Release the left and right travel control lev-

ers (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.4-43

4.5 Machine Turning

4.5.1 foreword
• Check the direction of the track frame be-

fore 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 machine
direction is normal.
• Avoid sudden change of direction. Stop the
machine before turning, especially for a piv-
ot turn.
4.5.2 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.4-44
• Pull the left travel control, or press the lower

part of the left control pedal. The machine
turns left as the left side track moves
backward.
CC13031511
Fig.4-45

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.4-46
• Pull the right travel control, or press the low-

er part of the right control pedal. The ma-
chine turns right as the right side track
moves backward.
CC13031513
Fig.4-47
4.5.3 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.4-48

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 control
pedal and the lower part of the right control
pedal at the same time.
CC13031515
Fig.4-49
4.6 Work Equipment Control
CAUTION
• Operating the control levers while the en-
gine 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 equipment
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.4-50

Swing control
Move the LEFT joystick to the left and right to

control the swing of upper structure.
CZ335-1103176
Fig.4-51
Boom control
Move the RIGHT joystick forward and back-

ward to control the movement of the boom.
CZ335-1103177
Fig.4-52
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 control cir-
cuit 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 lock- CZ335-1103178
out lever to the FREE position within 15 sec- Fig.4-53

onds after engine 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

4.7.1 foreword
CAUTION
• Do not operate the joysticks while the ma-
chine 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.
4.7.2 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
Fig.4-54

4.7.3 Operation with traveling force
Do not cut your bucket into ground and use

the traveling force to excavate, which could
damage your machine or work equipment.
CZ335-1103182
Fig.4-55
4.7.4 Operation when hydraulic cylin-

der reaches its stroke end
If the cylinder's piston reaches its end of

stroke, using the work equipment under exter-
nal impact could damage hydraulic cylinder
and cause personal injury. Avoid operating
the machine when its hydraulic cylinder is fully
retracted or extended.
CZ335-1103183
Fig.4-56

4.7.5 Operation with bucket landing

force
Do not use the bucket's landing force for ex-

cavating, digging, breaking or pile-driving op-
eration, 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.
CZ335-1103184
Fig.4-57
4.7.6 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 your machine could be minimized, in
addition to cost reduction.

4.7.7 Operation with machine weight
Do not use the weight of machine to

excavate.
CZ335-1103185
Fig.4-58
4.7.8 Sudden shift of control levers or

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 con- A 3

trol lever or pedal from forward (A) to reverse 2
1
(B), or vice versa. B
3. Do not stop the machine by suddenly re-

leasing the control lever or pedal while travel-
ing at high speed. CZ335-1103186
Fig.4-59

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 ma-

chine out of water.
CZ335-1103189
Fig.4-60
• Do not drive your machine into water where

water level could reach the center of carrier
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 your machine in water un-
less the foundation of worksite is strong 1
CZ335-1103190
enough so that the level of water could not
reach the center of carrier roller. Fig.4-61
• If the swing bearing, swing gear and central
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

4.9.1 foreword
WARNING
• Never drive or turn the machine or operate
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 operation is neces-
sary, provide a solid platform on the slope
so that the machine can be kept on a level CZ335-1102046
ground.
Fig.4-62
• Never use the force of the bucket to help
the machine climb up a slope when 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 equip-
ment to an attitude as shown the right illustra-
tion and drive slowly.
CZ335-1103192
Fig.4-63
CZ335-1102039
Fig.4-64

2. When driving the machine up a steep slope,

move the work equipment to the forward di-
rection. Keep the work equipment about 20-
30cm above the ground and travel at a low
speed.
CZ335-1102040
Fig.4-65
4.9.2 Traveling downhill
Place the travel control levers to the neutral

position, which can make the brake function
automatically.
4.9.3 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.
4.9.4 Cab door on a slope
• If the engine stalls out on a slope, do not

perform swinging operation with the left joy-
stick. The upper turntable will swing natu-
rally under its weight.
• When your 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

4.10.1 foreword
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.
4.10.2 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 your 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. CZ335-1103195
Put wood planks under the bucket bottom if

Fig.4-66
necessary.
The boom and arm shall form an angle be-

tween 90 and 110°.
4.10.3 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 in-
to the ground in front of your machine.
Retract the arm as you do in normal excava-

tion and drive your machine out of mud.
CZ335-1103196
Fig.4-67

4.11 Recommended Application

4.11.1 foreword
Besides the following applications, the scope

of application could be expanded by using
various additional attachments.
4.11.2 Backhoe operation
Backhoe operation is suitable for digging an

area which is lower than your machine.
When your machine is in a state shown in the

right illustration, maximum digging force can 90°
be obtained through the thrusting force of
90°
each hydraulic cylinder.
Make use of this angle effectively to help you

achieve the maximum working efficiency.
CZ335-1103197
Fig.4-68
The digging range of arm is from 30 to 45°, as

relative to the machine. 45° 30°
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.4-69

4.11.3 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.4-70
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.4-71
4.11.4 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.4-72

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 before
leaving the cab.
Always park the machine on a hard, level and

safe ground.
If you have to park your 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.4-73
1. Place the travel control levers to neutral po-

sition to stop your machine.
CZ335-1103169
Fig.4-74

2. Turn the fuel control dial to MIN position for

low idle to reduce engine speed.
MA
X
MIN
CC13031401
Fig.4-75
3. Lower the bucket horizontally till its bottom

touches the ground.
CZ335-1103207
Fig.4-76
4. Place the hydraulic lockout lever to the

LOCKED position.
CC13031403
Fig.4-77

5. Use the monitor to check the engine coolant

temperature and oil pressure.
• If fault indicator blinks and oil pressure is
abnormal, shut down the engine
immediately.
• If the coolant temperature gauge stays in
the red range, wait until the indicator enters C H
the yellow range before engine shutdown.
6. Turn the start switch from the ON position CC13050802-1
to the OFF position and shut off the engine.

Fig.4-78
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 cool-
ant. 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 en-
gine (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
lockable components on the machine. 3
1. Cab door
4
2. Filler cap of fuel tank 5

7
3. Engine hood 1
4. Battery chamber CZ335-1103208
5. Left access door Fig.4-79
6. Right access door
7. A/C fresh air cleaner cover

2
6
CZ335-1103209
Fig.4-80
4.15 Operation in Cold Weather

4.15.1 foreword
The engine may fails to start and the coolant may freeze under low temperature. In this case, the
following instructions must be followed.
4.15.2 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 5-11.

4.15.3 Coolant
WARNING
• Antifreeze is flammable. Keep it away from fire. Do not smoke when handling antifreeze.
• Antifreeze is toxic. Wash with plenty of water and seek medical treatment immediately if anti-
freeze 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.
4.15.4 Battery
Battery capacity decreases as the ambient temperature drops. Keep battery capacity at 100% lev-
el. Do not let the battery stay long under low temperature so as to avoid the difficulty in starting
your machine.
Cover the battery or remove it from your machine when ambient temperature is low. Store the bat-
tery in a warm place and reinstall it before operating the machine.
4.15.5 After operation in cold weather
When temperature is very low, mud and water

on the undercarriage may freeze at night,
which may make the machine hard to move
the next day. Observe the following
instructions:：
• Remove all mud and water from your 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 your machine on a hard, level ground.
Park it on wood planks if possible, which
can prevent your machine from being fro-
zen unto the ground.
• Open the drain valve to discharge accumu-
lated water of the fuel system so as to pre-
vent 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 equip-
ment is at the track side.
2. Lift one side of the tracks just above the

ground and move the travel control lever to ro-
tate the track.
3. Repeat the steps above and remove the CZ335-1103210
mud on the other track.

Fig.4-81
CAUTION
• It is dangerous to run the track freely.
• Keep people a safe distance away from
the track when running it freely.
4.15.6 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 5-11.
4.16 Long-Term Storage

4.16.1 Before storage
When storing your machine for more than one

month, adjust your machine to the attitude as
shown in the right illustration in order to pro-
tect cylinder piston rod against rusting.
• Clean all parts of your machine and then
store your machine indoors. If you have to
store your machine outdoors, choose a lev-
el ground and cover your machine with
canvas.
• Refill your fuel tank to its maximum level in
CZ335-1103211
order to avoid accumulation of water.
Fig.4-82

• Lubricate your machine and change its oil

before storing it.
• Apply grease to the exposed part of the pis-
ton rod of hydraulic cylinder.
• Disconnect the negative terminal of the bat-
tery and reinstall its cover, or remove the
battery from your machine and store it in a
separate place.
• For machines equipped with optional equip-
ment, the control pedal of optional equip-
ment shall be placed to locked position.
• To prevent rusting, please use Sany’s genu-
ine 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 your 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 your
machine.
• Before operating the work equipment, wipe off all the grease from the piston rod of hydraulic
cylinder.
• If your 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 your machine has been stored for a long period but no rusting prevention had been made each
month, contact authorized Sany dealers 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 your machine that has been stored for a long period of time, it is im-
portant to fully preheat your 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 "Specifi-
cation" section.
• The weight and dimensions provided in the
Specifications section may vary due to dif-
ferent type of track shoe, arm or other addi-
tional 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
4.17.2.1 foreword
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,
the platform must be fully compacted to pre-
vent landslide.
CZ335-1103227
• To prevent the machine from skidding on
the ramp, clean its track shoes and the Fig.4-83
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.4-84

4.17.2.2 Loading
1. Choose a hard and level surface to load the

machine. Keep the machine a safe distance
away from roadside.
2. Brake the trailer and put blocks [1] under its

wheels.
2
Place access ramps [2] the left and right sides
respectively. The two ramps shall parallel to
each other and have equal distance to the 1
4
3
center-line [3] of the trailer. Mounting angle [4]
shall not exceed 15º. If the ramps bend too CZ335-1103229
much under the weight of machine, supports

Fig.4-85
must be placed under 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. MA
X
WARNING
MIN
• Deactivate auto-idle function when loading

or unloading the machine. If auto-idle
mode is active, engine speed may change
abruptly.
CC13031401
• Keep travel speed at low level. Do not
switch travel speed when loading or un- Fig.4-86
loading the machine.

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.
90°-11 0°
Lower the bucket onto the trailer to support
the machine immediately after getting aboard.
Follow the instructions and signals from a

commander, especially in reverse travel.
CZ335-1103231
WARNING Fig.4-87
• Do not reposition the machine on the ac-
cess ramps. If necessary, reposition your
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.4-88
6. Align your machine with the ramps before

driving up the ramp. The center-line of ma-
chine shall match the center-line of trailer.
Align your machine with the ramp and travel

slowly.
Lower the work equipment as low as possible.
Once the machine is on the ramps, only the

travel control can be maneuvered. Do not op-
erate any other control levers.

7. Drive the machine slowly forward till all

tracks are on the trailer and have full contact
with trailer floor.
8. When the machine passes the rear wheels

of the trailer, the machine could lean forward.
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 slowly
CZ335-1103233
swing the upper structure by 180º.
Fig.4-89
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.4-90
4.17.2.3 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.4-91
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.4-92
5. Chock the tracks on both ends in order to

prevent the machine from moving during
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.4-93

Rear view mirror
The rear view mirror is located in the position

B A
When the rear view mirrors have to be re-

moved and installed afterwards for transporta-
tion purpose, follow the instructions below:
CZ335-1103142
Fig.4-94
Removal
1. Loosen bolt [2] and remove the rear view

4
mirror [1] from the bar [3].
1
5
2. Loosen bolt [4] and remove the bar [3] and
2
the clamp [5].
3
Installation
1. Install the bar [3] and the clamp [5] to the

CB13041002-2
hand-hold, and tighten bolt [4].
Fig.4-95
2. Install the rear view mirror [1] to the bar [3],
and tighten the bolt [2].
NOTE：
The rear view mirror must be readjusted after
installation. For more information see "Rear
view mirrors" on page 4-19.

4.17.2.4 Unloading
1. Choose a hard and level surface to load the

machine. Keep the machine a safe distance
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 par-
allel to each other and have equal distance 1
4
to the center-line [3] of the trailer. Mounting 3
angle [4] shall not exceed 15º. If the ramps CZ335-1103229

bend too much under the weight of ma-
Fig.4-96
chine, supports must be placed under 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.

CC13031404
WARNING Fig.4-97
• Deactivate auto-idle function when loading
or unloading the machine. If auto-idle
mode is active, engine speed may change MA
abruptly. X
• Keep travel speed at low level. Do not
MIN
switch travel speed when loading or un-

loading the machine.
7. Set engine speed to MIN with the fuel con-

trol dial. CC13031401
Fig.4-98

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
Fig.4-99
NOTE：
• Keep an angle of 90 - 110° between the arm
and the boom when unloading the machine.
• The machine could be damaged if it is un-
loaded with retracted arm.
• When the machine runs on the access ramp, 90°-110°
do not penetrate the bucket into ground,

which could damage the hydraulic cylinder.
CZ335-1103243
Fig.4-100
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.4-101

4.17.2.5 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
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
40 176.5 18
50 274.6 28
60 392.2 40
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.

Start the engine and swing the upper structure

to position the work equipment at the side of
the sprockets [1].
Fully extend the bucket cylinder and the arm

cylinder, and lower the work equipment to the
ground, as shown in the right illustration.
CZ335-1103245
Fig.4-102
1. Move the hydraulic lockout control to

LOCKED position.
2. Shut off the engine. Check the surrounding

of the cab before leaving the machine. Close
the cab door and windows properly.
CC13031403
Fig.4-103
3. Run a wire rope between the first two track

rollers and between the last two track rollers. A
For machines installed with roller guard, the

cable shall go through under the tracks.
4. Adjust the wire rope lifting angle [A] to 30 -

40º, and lift the machine slowly.
5. When the machine is above the ground,

make sure that the hook condition and the lift-
ing condition are normal, and lift the machine
slowly. CZ335-1103246
Fig.4-104

SY305C LC (Stage Ⅴ)Hydraulic Excavator Maintenance
Maintenance
5 Maintenance.......................................................................................................................5-1
5.1 Maintenance Information .....................................................................................................5-5
5.2 Oil, fuel and coolant ..............................................................................................................5-7
5.2.1 Oil ..................................................................................................................................5-7
5.2.2 Fuel ...............................................................................................................................5-8
5.2.3 Coolant .........................................................................................................................5-9
5.2.4 Grease ..........................................................................................................................5-9
5.2.5 Oil and fuel storage.................................................................................................. 5-10
5.2.5.1 foreword ............................................................................................................. 5-10
5.2.5.2 Filter element..................................................................................................... 5-10
5.2.6 Electrical system ...................................................................................................... 5-10
5.3 Wear Parts .......................................................................................................................... 5-10
5.4 Recommended Fuel, Coolant and Lubricant ..................................................................5-11
5.4.1 foreword......................................................................................................................5-11
5.4.2 Table of recommended fuel, oil and coolant......................................................... 5-14
5.4.3 Table of capacities ................................................................................................... 5-16
5.5 Tightening Torque Table.................................................................................................... 5-16
5.6 Safety Critical Parts ........................................................................................................... 5-18
5.7 Maintenance Schedule...................................................................................................... 5-19
5.8 Maintenance Procedures.................................................................................................. 5-22
5.8.1 Lockout and tag-out measures............................................................................... 5-22
5.8.2 Initial 50 hours of operation .................................................................................... 5-22
5.8.3 Initial 500 hours of operation .................................................................................. 5-23
5.8.3.1 Swing drive oil - change................................................................................... 5-23
5.8.3.2 Final drive oil - change ..................................................................................... 5-24
5.8.4 When Required......................................................................................................... 5-25
5.8.4.1 Track shoe bolts - inspect/tighten................................................................... 5-25
5.8.4.2 Track tension - inspect/adjust ......................................................................... 5-25
5.8.4.3 Bucket - replace ................................................................................................ 5-29

Maintenance SY305C LC (Stage Ⅴ)Hydraulic Excavator
5.8.4.4 Bucket tips - replace ......................................................................................... 5-31

5.8.4.5 Window washer fluid level - check/fill............................................................. 5-33
5.8.4.6 Refrigerant level - check .................................................................................. 5-34
5.8.4.7 Ceiling window gas spring - inspect ............................................................... 5-36
5.8.5 Inspection Prior to Startup ...................................................................................... 5-38
5.8.6 Every 100 service hours.......................................................................................... 5-39
5.8.6.1 Lubrication ......................................................................................................... 5-39
5.8.7.1 Air filter element - inspect/clean/replace ....................................................... 5-41
5.8.7.2 Fan belt tension - inspect/adjust..................................................................... 5-44
5.8.7.3 Compressor belt tension - inspect/adjust ...................................................... 5-45
5.8.7.4 Oil return check valve - check ......................................................................... 5-46
5.8.7.5 Pipe clamps of hydraulic system - check ...................................................... 5-47
5.8.8.1 foreword ............................................................................................................. 5-47
5.8.8.2 Swing bearing - lubricate ................................................................................. 5-47
5.8.8.3 Engine pan oil and filter element - change/replace...................................... 5-48
5.8.8.4 Swing pinion gear grease level - inspect/fill .................................................. 5-50
5.8.8.5 Primary fuel filter element - replace ............................................................... 5-51
5.8.8.6 Secondary fuel filter element - replace .......................................................... 5-53
5.8.8.7 Radiator and oil cooler fins - inspect/clean ................................................... 5-56
5.8.8.8 Air conditioner fresh air/recirculation filter - clean ........................................ 5-58
5.8.8.9 Swing drive oil level - check/fill ....................................................................... 5-60
5.8.8.10 Final drive oil level - check/fill ....................................................................... 5-61
5.8.9 Every 1000 service hours ....................................................................................... 5-62
5.8.9.1 foreword ............................................................................................................. 5-62
5.8.9.2 Hydraulic oil return filter element - replace.................................................... 5-62
5.8.9.3 Swing drive oil - change................................................................................... 5-63
5.8.9.4 Cab door lock and front window lock catch - inspect/tighten...................... 5-65
5.8.9.5 Cab door hinge and front window slide rail - inspect/add grease .............. 5-66
5.8.9.6 Windshield wiper arm nut - Inspect/tighten ................................................... 5-67
5.8.9.7 Engine exhaust pipe clamps - check ............................................................. 5-67
5.8.9.8 Fan belt tension - check/replace..................................................................... 5-67
5.8.9.9 Nitrogen pressure in accumulator (breaker) - check ................................... 5-67
5.8.9.10 Swing mechanism grease - check and add ................................................ 5-68
5.8.9.11 Hydraulic tank breather valve filter element - replace ............................... 5-68
5.8.10 Every 2000 service hours ..................................................................................... 5-69
5.8.10.1 foreword ........................................................................................................... 5-69
5.8.10.2 Final drive oil - change................................................................................... 5-70
5.8.10.3 Hydraulic oil suction filter element – clean/replace ................................... 5-71
5.8.10.4 Nitrogen pressure in accumulator (control oil circuit) - check .................. 5-72
5.8.10.5 Cooling system interior - clean ..................................................................... 5-75

5.8.10.6 Alternator - inspect ......................................................................................... 5-77
5.8.10.7 Engine valve clearance - check/adjust ........................................................ 5-78
5.8.11.1 foreword ........................................................................................................... 5-78
5.8.11.2 Water pump - inspect ..................................................................................... 5-78
5.8.11.3 Start motor - check ......................................................................................... 5-78
5.8.11.4 Hydraulic tank oil - change ............................................................................ 5-79
5.8.11.5 Accumulator - replace .................................................................................... 5-80
5.8.11.6 High-pressure tube clamps and rubber - check ......................................... 5-81
5.8.11.7 Compressor working condition - inspect ..................................................... 5-81
5.8.12.1 Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter - Change ........... 5-82
5.8.12.2 Aftertreatment Diesel Particulate Filter - Check......................................... 5-86
5.8.12.3 Aftertreatment Diesel Exhaust Fluid Tank Filter - Inspect and
reuse........................................................................................................... 5-87
5.8.13.1 foreword ........................................................................................................... 5-91
5.8.13.2 High-pressure tube clamps - replace........................................................... 5-91
5.8.14 Every 10000 service hours ................................................................................... 5-91

WARNING

5.Maintenance
5.1 Maintenance Information
Never conduct any inspection and maintenance work other than the scope specified in this
manual.
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
substances.
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, connectors 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 your machine or changing the oil, park your 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 damage
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".
– Whether the checked or maintained parts work normally.
– Whether oil leakage occurs when the engine speed increases and the oil is under pressure.
• 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 ob-
ject 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 your machine under ex-
treme 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 particles
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 Sany dealer when the oil in your work equipment has been contaminated by water or
air.
• To know the condition of your machine, regular oil quality analysis is recommended. Contact
Sany dealer if you need such service.
• In replacement of engine 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 cartridge.
• 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 contains
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 .
• When the fuel is used above the specified temperature, its viscosity and output power will de-
crease .
NOTE：
• Always use diesel oil as the fuel.
• To ensure favorable consumption and exhaust of the fuel, the engine installed to your 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.
• Sulfur content in fuel generates sulfur oxide in combustion, which reacts with water and produces
dilute sulphuric acid that will impair the engine. To prevent such fault, always use a fuel whose
sulfur content is lower than 0.2%.

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 oth-
er 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

Min. ℃ -10 -15 -20 -25 -30 -35 -40
temperature ℉ 14 5 -4 -13 -22 -31 –40
Mixing ratio (%) 30 36 41 46 50 54 58
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 minerals
(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 unfavorable 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 am-
bient 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
5.2.5.1 foreword
• 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 open-
ing facing the side in order to prevent intake of moisture. If you have to place the barrels out-
doors, 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.
5.2.5.2 Filter element
• Filter element is extremely important for safety. It can prevent failures by keeping important devi-
ces free from impurities coming from oil path or air path. All filter elements must be replaced reg-
ularly. 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.
• In replacement of filter element, check the element for attached metal particles. Contact 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 your 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 Sany deal-
er before installing radio receiver or other wireless devices.
• Operating on beach requires cleaning the electrical system thoroughly in order to prevent
corrosion.
• 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 Qt. Interval

Primary fuel filter Filter element 1 Every 500 hours or Clogging
Secondary fuel filter Filter element 1 Every 500 hours or Clogging
Engine oil filter Cartridge 1 Every 500 hours
Element - suction 1 Every 2000 hours
Hydraulic oil filter
Element - return 1 Every 1000 hours
Pilot filter Filter element 1 Every 500 hours
A/C air filter Fresh air filter 1 Every 6 months
A/C air filter Recirculated air filter 1 Every 6 months
Cleaned 6 times or every 12
Main filter element 1
months
Air cleaner
Cleaned 6 times or every 12
Safety filter element c
months
Breather valve Filter element 1 Every 1500 hours
Lateral pin bucket tips 5
(Pin) （5）
Side cutter 2 ─
Rock-work Bucket
(Bolt) （6）
(Nut) （6）
(Washer) （6）
NOTE：
Parts in the brackets shall also be replaced.
5.4 Recommended Fuel, Coolant and Lubricant

5.4.1 foreword
• Unless specified otherwise, your machine contains the following oils and coolants when deliv-
ered from the factory.
Item Type
Engine Oil Pan Caltex CI-4 15W-30
Swing Drive
Gear oil 85W/140
Final Drive
Hydraulic System Caltex HDZ46
Radiator TEEC-L35 antifreeze

• To keep your 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 over-wear and service life
reduction of the engine, power train, cooling system and other components.
• The additives available in market could benefit your machine, but they could impair your 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 volume
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.


5.4.2 Table of recommended fuel, oil and coolant
Ambient Temperature
Recom
Liquids 12 mended
-22 -4 -14 32 50 68 86 104
2℉ liquids
-30 -20 -10 0 10 20 30 40 50℃
5W-30
5W-40
Engine oil 10W-30
NOTE(1) 15W-40
40
HDZ32-Ⅱ
(ISO VG32)
Hydraulic
oil
HDZ46-Ⅱ
(ISO VG46)
-30# diesel
fuel
-10# light
Diesel fuel
diesel
0# light
diesel
TEEC-L35
Coolant
Antifreeze
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.
Engine oil grade: Above API CI-4
Recommended engine oil brand and type: Caltex CI-4 15W-40
2. Engine fuel
Light diesel oil (GB252.81)
3. Hydraulic oil
The hydraulic system uses Caltex HDZ46 hydraulic oil (code B420106000036).
CAUTION
• 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 elevation 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 0.2%. If it is
more than 0.2%, Please shorten the change interval. Be sure to conduct according to the fol-
lowing table:
sulfur containing change interval

0.2 ～ 0.5% 1/2 standard interval
0.5 ～ 1.0% 1/4 standard interval
• Clean fuel free from water and/or impurities shall be ensured before refueling.
• The diesel fuel that contains more water and/or impurities can cause clogging, Please change
the filter when it is clogged.

5.4.3 Table of capacities
Swing Final
Engine oil Hydraulic Cooling
Specified capacity drive drive Fuel tank
pan system system
casing casing
SY285C- L 35 10.5 2×4.0 380 11 540
9
SY305C-
9H US gal 9.3 2.8 2×1 100 3 143
SY335C-
9H
5.5 Tightening Torque Table
CAUTION
• Nuts, bolts or other parts not tightened to
specific torque values may lead to loose or
damaged parts, resulting in machine fail-
ure and operating troubles.
• Special attention shall be paid when tight-
ening 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 Tightening Torques

Square
Diame- Target Values Torque Limits
Size b
ter a
(mm) N·m kgf·m lbft N·m kgf·m lbft
(mm)
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
115.7～
14 22 177 18 130.2 157～196 16.0～20.0
144.7
180.8～
16 24 279 28.5 206.1 245～309 25.0～31.5
227.8
253.2～
18 27 382 39 282.1 343～425 35.0～43.5
314.6
361.7～
20 30 549 56 405 490～608 50.0～62.0
448.4
488.2～
22 32 745 76 549.7 662～829 67.5～84.5
611.2
607.6～
24 36 927 94.5 683.5 824～1030 84.0～105.0
759.5
120.0～ 868.0～
27 41 1320 135 976.5 1180～1470
150.0 1085.0
155.0～ 1121.1～
30 46 1720 175 1265.8 1520～1910
195.0 1410.4
200.0～ 1446.6～
33 50 2210 225 1627.4 1960～2450
250.0 1808.3
250.0～ 1808.3～
36 55 2750 280 2025.2 2450～3040
310.0 2242.2
295.0～ 2133.7～
39 60 3280 335 2423.1 2890～3630
370.0 2676.2
42 65 4700 480 3478 4250~5150 434.0~525.0 3145~3811

• Hydraulic hoses are tightened according to

the torques given in the following table.
b a
CZ335-1104002
Fig.5-2
Square Tightening Torques

Nominal Thread
Size (b) Target Values Permissible Range
Number (a)
(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
130.2 ～
13/16-12UN 36 216 22.0 159.1 177～245 18.0～25.0
180.8
☆1 -7/16 - 12UN - 130.2～
41 215 22.0 159.1 176～234 18.0～24.0
2B 180.8
NOTE：
The item marked with * is used for tightening
the hose on top of the swivel joint.
5.6 Safety Critical Parts
• To ensure safety when operating or driving the machine, the user of the machine shall carry out
regular maintenance. In addition, the user shall also replace the parts listed in the table in order
to further improve safety condition. These parts are closely related to safety and fire prevention.
• Safety critical parts may easily wear or deteriorate due to material change as time passes and it
is hard to judge their conditions through regular maintenance. These parts shall be replaced as
scheduled regardless of their conditions, which can effectively guarantee the functions of these
parts.
• If these parts show signs of abnormality before its scheduled replacement, they must be re-
paired or replaced immediately.
• If the hose clamps show any deterioration, such as deforming or cracking, replace the clamps at
the same time as the hoses.

• O-rings, gaskets and other such parts shall also be replaced when replacing hoses.
• Consult Sany dealer to replace the safety critical parts.
Safety critical parts for periodic Quan-

No. Frequency
replacement tity
1 Fuel hose (fuel tank - primary filter) 1
2 Fuel return hose (engine - fuel tank) 1
3 Fuel hose (primary filter - engine) 1
4 Pump outlet hose (pump - control 1
valve)
5 Work equipment hose (boom 1
cylinder oil inlet)
6 Work equipment hose (Bucket 1
cylinder line - boom root)
7 Work equipment hose (bucket 2
cylinder oil inlet)
8 Work equipment hose (arm cylinder 4 Every 2 years or 4000 hours,
line - boom root) whichever occurs first.
9 Work equipment hose (arm cylinder 2
oil inlet)
10 Swing drive hose (swing motor oil 2
inlet)
11 Main oil suction hose 2
12 Travel control hose (control valve - 2
swivel joint)
13 Travel control hose (swivel joint - 2
travel motor)
14 Pump pressure hose 1
15 Accumulator (control oil) 4
19 High-pressure tube clamps 1
Every 8000 hours
20 Cover - fuel squirt prevention 1
21 Seat belt 1 Every 3 years
5.7 Maintenance Schedule

If your 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/ replace"
on page 8-15.

Maintenance schedule list

Initial 50 hours of operation .............................................................................................. 5-22
Initial 500 hours of operation ............................................................................................ 5-23
Swing drive oil - change ....................................................................................................... 5-23
Final drive oil - change ......................................................................................................... 5-24
When Required ................................................................................................................... 5-25
Track shoe bolts - inspect/tighten ......................................................................................... 5-25
Track tension - inspect/adjust ............................................................................................... 5-25
Bucket - replace.................................................................................................................... 5-31
Bucket tips - replace ............................................................................................................ 5-31
Window washer fluid level - check/fill ................................................................................... 5-33
Refrigerant level - check ....................................................................................................... 5-34
Ceiling window gas spring - inspect ..................................................................................... 5-36
Inspection Prior to Startup ................................................................................................ 5-38
Every 100 service hours .................................................................................................... 5-39
Lubrication ............................................................................................................................ 5-39
Air filter element - inspect/clean/replace............................................................................... 5-41
Fan belt tension - inspect/adjust ........................................................................................... 5-44
Compressor belt tension - inspect/adjust ............................................................................. 5-45
Pipe clamps of hydraulic system - check.............................................................................. 5-47
Swing bearing - lubricate ...................................................................................................... 5-47
Engine pan oil and filter element - change/replace .............................................................. 5-48
Swing pinion gear grease level - inspect/fill.......................................................................... 5-50
Primary fuel filter element - replace ...................................................................................... 5-51
Secondary fuel filter element - replace ................................................................................. 5-53
Radiator and oil cooler fins - inspect/clean ........................................................................... 5-56
Air conditioner fresh air/recirculation filter - clean................................................................. 5-58
Swing drive oil level - check/fill ............................................................................................. 5-60
Final drive oil level - check/fill ............................................................................................... 5-61
Every 1000 service hours .................................................................................................. 5-62
Hydraulic oil return filter element - replace ........................................................................... 5-62
Swing drive oil - change ....................................................................................................... 5-63
Cab door lock and front window lock catch - inspect/tighten ................................................ 5-65
Cab door hinge and front window slide rail - inspect/add grease ......................................... 5-66
Windshield wiper arm nut - Inspect/tighten........................................................................... 5-67
Engine exhaust pipe clamps - check .................................................................................... 5-67
Fan belt tension - check/replace........................................................................................... 5-67
Nitrogen pressure in accumulator (breaker) - check ............................................................ 5-67
Swing mechanism grease - check and add .......................................................................... 5-68
Hydraulic tank breather valve filter element - replace .......................................................... 5-68
Final drive oil - change ......................................................................................................... 5-70
Hydraulic oil suction filter element – clean/replace............................................................... 5-71
Nitrogen pressure in accumulator (control oil circuit) - check ............................................... 5-72
Cooling system interior - clean ............................................................................................. 5-75
Alternator - inspect ............................................................................................................... 5-77
Engine valve clearance - check/adjust ................................................................................. 5-78
Water pump - inspect ........................................................................................................... 5-78
Start motor - check ............................................................................................................... 5-78
Hydraulic tank oil - change ................................................................................................... 5-79
Accumulator - replace........................................................................................................... 5-80
High-pressure tube clamps and rubber - check.................................................................... 5-81
Compressor working condition - inspect............................................................................... 5-81
Aftertreatment diesel exhaust fluid dosing unit filter - change ........................................ 5-82
Aftertreatment Diesel Particulate Filter - Check .................................................................... 5-86
Aftertreatment Diesel Exhaust Fluid Tank Filter - Inspect and reuse ............................... 5-87
High-pressure tube clamps - replace.................................................................................... 5-91
Every 10000 service hours ................................................................................................ 5-91

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.
• Attach other warning tags around the ma-
chine if necessary.
Fig.5-3
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.
• Engine oil and engine oil filter element - Re-

place. For detailed information, see "Every
500 service hours".

5.8.3 Initial 500 hours of operation
5.8.3.1 Swing drive oil - change
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.
• Swing drive casing capacity: 10.6 L (2.8 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 completion of
the draining.
NOTE：
• If the gear oil flows out in a thin thread pat- CB13051401-1
tern, stop draining.

Fig.5-5
• 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 F
G
otherwise damage the swing unit.
3. Remove the filler cap (F) and add oil as re-

quired through the filler opening.
4. Check the oil level. For more information,

see "Swing drive oil level - check/fill" on page CB13050901-1
5-63.
Fig.5-6
5. Apply sealant onto the thread of the filler
opening and tighten the filler cap.
Tightening torque: 130±10N·m
NOTE：
Improper tightening of the filler cap may cause
the gear oil in the swing drive to leak.

5.8.3.2 Final drive oil - change
WARNING
• When the engine is shut down, the oil is
still hot. Wait until the oil is cool enough be-
fore 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 order to re-
lease the pressure.
• When the screw plug is being loosened, do
not stand in front of the screw plug.
• Refilling capacity: Refer to "Table of capaci-

ties" on page 5-14.
Adjust the position of the machine so that the

arrow mark on the drain port plug (D) points to F
the ground and the line between the fi ll port L
plug (F) and the drain port plug (D) is vertical D
to the ground.
1. Use a proper screwdriver to remove the dirt F

in the hexagonal socket of screw plug. FILL
L
LEVEL
2. Place a vessel under the drain port to col- D

DRAIN
lect the oil.

CB13041501-02
3. Use the spanner to remove the drain plug
(D) in order to drain the oil. Fig.5-7
4. Tighten the plug (D) and remove the plugs

(F) and (L).
5. Add oil through the fill port (F).
6. When the oil is seen coming out of level port

(L), reinstall the plug (F) and (L).
Tightening torques of the plugs (P), (L) and

(F): 108±9.8 N·m (10.0±1 kgf·m)

5.8.4 When Required
5.8.4.1 Track shoe bolts - inspect/

tighten
If your machine is operated with loose track

shoe bolts [1], the bolts can break. Tighten
any loose bolts immediately.
Tightening
Three-grouser track shoe
1. Tighten the bolts to torque values 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.
2. Inspect and further tighten the bolts by 120

± 10°.
CZ335-1104014
Fig.5-8
Tightening sequence
Tighten the bolts in the sequence shown in

the right illustration. After tightening, make
sure that the nuts and track shoe are in close
contact with the link mating surface.
1 3
4 2
CZ335-1104015
Fig.5-9
5.8.4.2 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 equivalent to 2
the length of the track on the ground. Then, a
stop the machine slowly.
2. Place a straight piece of wood bar on top of

the track grousers between the idler [1] and
the carrier roller [2]. 1
CZ335-1104016
3. Measure the gap [a] between the bottom
the wood bar and the top surface of the track Fig.5-10
grousers just below the bar.
Standard dimension of gap (a): 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 ob-
serve maintenance procedures as speci-
fied may cause the grease discharge plug
to eject and result in serious injury or CZ335-1102081
death.
Fig.5-11
• Do not have your face, hands, feet and
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. Failure
to follow this warning could result in seri-
ous injury or death.
To increase track tension, prepare a grease

CZ335-1102080
gun.
Fig.5-12
To increase track tension, prepare a grease

gun.
1
1. Inject grease through the grease fitting [2]
2
with the grease gun. (The grease fitting [2]
and the grease discharge plug [1] form an in-
tegral part.)
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. CZ335-1104020
3. Check the track tension again. Make further Fig.5-13

adjustment if track tension is still beyond the
standard range.
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 bushing are
over-worn. In this case, the pin rolls or bush-
ings must be swapped or replaced. Contact
S
Sany dealer for repair.
CZ335-1104019
Fig.5-14

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 ex-
cept the grease discharge plug.
CZ335-1102080
To reduce track tension, prepare a long socket
wrench. Fig.5-15
1. Slowly turn the grease discharge plug [1]

counterclockwise with the long socket wrench.
Grease will come out from the grease fitting
[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,

tighten the discharge plug [1].
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 further

adjustment if track tension is still beyond the
standard range.
NOTE：
• If the track tension can not be reduced through the above precedures , contact your Sany dealer
for repairs.

5.8.4.3 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
operation.
• 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 working at one side.
• Do not get your finger pinched while removing 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.5-16
2. Remove the nuts on the bolts of the retain-

ing plate of arm pin (A) and link pin (B). Re-
move the bolts and take out arm pin (A) and
link pin (B), and then remove the bucket.
NOTE：
• Make sure the pin is free from mud or sand
after removal.
• Both ends of the bushing are installed with
seals against dust. Be careful not to damage
them.
Fig.5-17

3. Align the arm with the pin hole (1) of the re-
placement bucket as well as the link rod with 1
the hole (2). Insert the greased pins (A) and
2
(B) into hole (1) and hole (2) respectively.
CZ335-1103202
Fig.5-18
4. When mounting the bucket, place the O-

ring (3) of bucket to the position, as shown in
the right illustration. After the pin is inserted,
align it to the standard notch.
3 3
CB13031501
Fig.5-19

5. Reinstall the nuts and bolts onto the pins.

Add grease.
NOTE：
• Inject sufficient amount of grease till the
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.
Fig.5-20
5.8.4.4 Bucket tips - replace
Replace the bucket tip before the tip adapter

is worn.
CAUTION
• Operating the work equipment by mistake
is very dangerous when replacing bucket
tips.
• The pin may fly out can cause personal in-
jury if too much force is applied onto it.
Make sure that nobody is in the surround-
ing area.
• Wear safety goggles, gloves and other per-
sonal protective gears.

1. Place a block beneath the bucket and keep

the bucket bottom level.
CZ335-1104023
Fig.5-21
2. Make sure the work equipment is stable

and the hydraulic lockout control lever is in
the LOCKED position.
CC13031403
Fig.5-22
3. Place a metal stick against one end of the

pin (1) and hammer the metal stick in order to
drive the pin (1) out and remove the bucket tip
2
(2).
1
NOTE：
• The metal stick shall have a smaller diameter
than the pin.
• If the tip cannot be removed safely in this
way, consult Sany dealer for replacement.
CZ335-1104025
Fig.5-23

4. Remove the tip and check the retainer for

any damage. Replace it if necessary. The re-
tainers and tips worn short must be replaced
with new ones. 2
5. Clean the installation surface. Insert the re-

tainer 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 order to lock 1
the bucket tip onto its adapter. CZ335-1104026
Fig.5-24
5.8.4.5 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 right access door of the ma-

chine and check the solvent level in the wash-
er reservoir.
2. Open the cap on the reservoir and fill it with

washer solvent. Cover the reservoir.
3. Press the washer switch and check the

function of the windshield washer.
NOTE：
Be careful not to allow dirt or dust get into the
reservoir when adding washer solvent. Fig.5-25
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
- 10°C
General 1:2
(14°F)
Cold regions - 20°C (-
1:1
in winter 4°F)
Extremely
Pure washer - 30°C (-
cold regions
solvent 22°F)
in winter
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 accord-
ing to the operating region.
5.8.4.6 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 leaking 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 refriger-

ation when the engine is running at a high
speed.
Observe through the glass on the condenser

reservoir in order to inspect the condition of
refrigerant gas flowing to the tube. CZ335-1104036
Fig.5-26

• Refrigerant flows without foam: OK

• Refrigerant flow contains foam that pass
continuously: Insufficient
• Colorless and transparent: None
NOTE：
The existence of foams indicates low refriger-
ant level. Please consult your Sany dealer to
add refrigerant.
Fig.5-27
Inspection during idle period
When the air conditioner will not be used for a

long period of time, the air conditioner shall be
operated 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 (spring and
Refilling
autumn)
Refrigerant (gas)
Tube connections and internal
Daily
leakage of parts and components
Condenser Radiator fins plugged Every 500 hours
Compressor Function Every 4000 hours
Loose and bent Every 250 hours
Deterioration, wear, scratch and
V - belt Every 250 hours
cracking
Noise, odd smell or abnormal heat When necessary
Fan motor and fan Function (check for abnormal noise) When necessary
Air conditioner air flow Air flow control switch and switching
Daily
switch function
Function (make sure the function is
Control unit When necessary
normal)
Loose connections and loose or
Joining bolts Every 6 months
detached nuts and bolts
Installation condition, loose
Connection tubes connections, air leakage or any When necessary
damage
Reservoir dryer Temperature difference indicates a
Every year
temperature difference blocked dryer.
5.8.4.7 Ceiling window gas spring -

inspect
WARNING
• The gas spring contains highly-pressurized
nitrogen. Wrong operation can cause ex-
plosion 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 expose it
under any impact.

The gas springs are located on top of the cab

(at both the left and right sides).
Contact Sany dealer for inspection, repair and

replacement :
• When the ceiling window cannot be
opened easily;
• Or when oil or gas leaks from the gas
spring.
CZ335-1104036
Fig.5-28
How to release pressure in the hydraulic

circuit
WARNING
• The hydraulic circuit is always under pres-
sure. Relieve the pressure in hydraulic cir-
cuit when checking or replacing the hoses
or fittings.
• When the engine is stopped, oil and engine
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 your machine on a hard, level ground.
CZ335-1103207
Fig.5-29

2. Turn the start switch to ON position within

15 seconds after engine shutdown and move
the hydraulic control lever to FREE position.
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 breather

valve of the hydraulic tank and press the air
vent to relieve the internal pressure.
Fig.5-30
5.8.5 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)
5.8.6 Every 100 service hours
5.8.6.1 Lubrication
CAUTION
• 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.
• Adjust the machine to a to-be-greased position, lower the work equipment to the ground and
shut down the engine.
• Use a grease gun to inject grease at the greasing points shown in the following illustration.
• 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.5-31
1. Boom cylinder root pin (2 points)
1
1
CZ335-1104047
Fig.5-32

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.5-33
5. Boom-arm joining pin (2 points)
CZ335-1104049
Fig.5-34
6. Arm cylinder piston rod end (1 point)

6
7. Bucket cylinder root pin (1 point)
7
CZ335-1104051
Fig.5-35

8. Bucket-rod joining pin (1 point)
9. Arm-Bucket joining pin (1 point) 8
CZ265-1204001
Fig.5-36
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.5-37
5.8.7.1 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 12 months 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] before
removing the cover [2]. P
2
T O
×××××××××××××××××××××××××××××
×××××××××××××××××××××××××××
××××××××××××××××××××××××××
×××××××××××××××××××××××××
××××××××××××××××××××××
××××××××××××××××××
0-13017
Fig.5-38
2. Hold the outer filter element [3], shake it

slightly and turn it in both directions in order 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
3
case of displacement or tilting.
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

CZ335-1104006
the housing.
Fig.5-39
6. Blow the outer filter element with com-

pressed air (less than 0.2MPa) along the in-
side and outside pleats.
NOTE：
• Do not tap the air filter element with any ob-
ject when cleaning it.
• Do not use air filter elements with damaged
pleats, gaskets or seals.
• Using a filter element that has been used for CZ335-1104008
more than a year or an O-ring that has been

Fig.5-40
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 material.
CZ335-1104107
Fig.5-41
Replacement of the inner filter element
1. Remove the outer filter element [3] and then

the inner filter element [4].
4
2. Cover both ends of the elements with a
piece of clean cloth to prevent dust form en- 3
tering the filter element.
3. Clean the inside of the air cleaner body and

then remove the covering cloth.
4. Place the new inner filter element [4] onto CZ215-1304005
the connecting side.

Fig.5-42
5. Install the outer filter element [3].
Push the filter element straight forward into

the air cleaner housing. You can hold and
shake it slightly to make the task easier.
2
6. Install the cover [2]. Make sure the arrow
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 1
excessive.
CZ215-1304006
Fig.5-43

NOTE：
• Never use the inner filter element after clean-
ing it. Replace the inner filter element when
the outer one is replaced.
• 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 preci-
sion in the sealing area. Therefore, fake
parts shall not be used under any
circumstances.
5.8.7.2 Fan belt tension - inspect/adjust
CAUTION
• Stop the engine before inspecting or ad-
justing 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-

tween the fan belt pulley and the alternator
belt pulley with a force of about 98N {10kgf}
with your finger.
2. Measure the deflection (A). Standard value

of size A shall be 7~10mm {0.28~0.30in}.
Fig.5-44

Adjustment
Loosen the mounting bolt [1] and adjusting

nut [2].
1. Loosen the mounting bolt [1] and adjusting

nut [2].
2. Loosen the adjusting bolt [3] and adjust the

belt tension of the alternator as specified.
Then, tighten the mounting bolt [1] and the ad-
justing nut [2].
Fig.5-45
3. Start and run the engine at low idle for
about 5 minutes. Stop the engine and check
belt tension once again.
The second check if especially necessary
when a new belt is installed. Belt tension may
change when a new belt seats into the belt
pulley.
5.8.7.3 Compressor belt tension - in-

spect/adjust
Inspection
1. Press the middle of the belt between the

drive pulley and the compressor pulley with
your finger (about 58.8N {6kgf}).
2. Measure the deflection (A). Standard value

of size A shall be 5-8mm {0.20-0.31in.}.
Fig.5-46

Adjustment
1. Loosen the bolts [1] and [2].
2. Move the compressor [3] and its bracket [4]

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

adjustment.
Fig.5-47
NOTE：
• Check for damaged pulleys and worn V
groove and V - belt. In addition, make sure
that the V - belt must not rub against the bot-
tom of the V - groove.
• Consult Sany dealer to replace the belt
timely in case of the following conditions.
– 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.
5.8.7.4 Oil return check valve - check
CAUTION
before you proceed.

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 or on
the screen if any.
• If the valve or the screen is damaged, re-
place then with new ones.
3. Install the oil return check valve [3], return

hose [1] and hose [2] and tighten the pipe clip.
Fig.5-48
5.8.7.5 Pipe clamps of hydraulic sys-

tem - check
• Check the hydraulic system for missing, de-

formed pipe clamps and loose bolts. Re-
place 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 specifi ed torques
if necessary.
5.8.8.1 foreword
The 100 hours and 250 hours services shall

be carried out in the meantime.
5.8.8.2 Swing bearing - lubricate
CAUTION
• Applying grease to the swing bearing is
dangerous. Do not swing the upper struc-
ture when grease is being applied.

1. Lower the work equipment to the ground

and then shut down the engine. Place the hy-
draulic 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
CZ335-1104065
bucket 20-30 mm above the ground. Swing
the upper structure by 90°. Fig.5-49
4. Repeat steps 1 through 3 and add grease.
NOTE：
• The grease is used to prevent distortion and
noise of joints.
• It is necessary to add grease to any compo-
nent that appears inflexible or noisy after op-
eration 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 dif-
ferent locations. Using a grease that has
been contaminated by sand or debris can
lead to wear of rotating components.
5.8.8.3 Engine pan oil and filter element

- change/replace
CAUTION
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].
Hold a piece of cloth between the valve and
Fig.5-50
the vessel. Open the drain valve slowly and
discharge oil
Fig.5-51
5. Open the right access door of the machine

and turn the filter element [1] leftward with fil-
ter element spanner in order to disassemble
the filter element. 1
6. Clean the filter element seat [2]. Fill the new

filter element with clean engine oil. Apply en-
2
gine oil (or a film of grease) to the filter sealing
surface and the threads before installing the
filter element to its seat.
Remark: 2015090101
Check the filter element seat [2] for presence Fig.5-52

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 seal-

ing surface with that of the filter element 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 oil
level is between the H and L marks on the L H
dipstick.
9. Run the engine idly for a short time and CZ335-1103131
then turn off the engine. Check again the oil

Fig.5-53
level, which shall be between the H and L
marks of the dipstick. For more information,
see "Oil level in oil pan - check/add".
10.Reinstall the bottom cover.
CAUTION
• Be sure to use SANY genuine Engine- Oil
and Oil-Filter.
5.8.8.4 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.5-54

2. Put the dipstick [3] into the grease through

the inspection hole. Check the grease level
(S). A 3
Height of S: 7 mm {0.3 in} at minimum
3. Check if the grease turns milk-white. Milk- S

white grease indicates that the grease has
been contaminated. Consult Sany dealer in
order to change the grease.
CZ335-1104069
Fig.5-55
4. Use the bolts [1] to reinstall the cover [2].
CZ335-1104070
Fig.5-56
5.8.8.5 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 sys-
tem when the engine is running.
• Wait at least 30 seconds after engine shut-
down 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 special
filter of effective filtration. The filter element
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 CB13040702
parts contaminated by dust, flush them clean
Fig.5-57
with engine oil.
• Prepare a container to store the fuel drained.
• Prepare a filter spanner.
1. Open the right access cover of the

machine.
2. Place a container under the primary fuel fil-

ter 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].
4. Turn the transparent cover [4] counterclock-

2015090102
wise with a filter spanner to remove it. This
cover can be used repeatedly. Fig.5-58
5. Remove the old filter element. Clean the fil-

ter seat and replace the old filter element with
a new one.
6. Replace the gasket [3] and install the trans-

parent cover [4] onto the filter seat [1].
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 clear-
ance of O-ring. To avoid such problems, the
transparent cover must be tightened to specif-
ic torque.
8. Bleed the air after replacement of the filter

element [2].
For the method of air bleeding, see "Secon-

dary fuel filter element - replace" on page 5-
56.
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. Re-

move the filter element and replace it with a
new filter element if any damage or foreign
object is found on the sealing surface.
5.8.8.6 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.
• High pressure is generated in the fuel sys-
tem when the engine is running.
• Wait at least 30 seconds after engine shut-
down and replace the filter when internal
pressure drops to a safe level.

• Sany genuine fuel filter element is a special

filter of effective filtration. The filter element
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 engine oil.
• Prepare a container to hold the fuel
drained.
• Prepare a filter element spanner.
1. Open the engine hood.
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 cartridge be-
fore mounting it to the filter element seat.
Fig.5-59
NOTICE
• Do not fill the new filter cartridge with fuel.
• Remove the cover [B] and install the
cartridge.
Fig.5-60

5. Replace the internal seal [2] with a new

one.
6. During installation, tighten the filter car-

tridge until its sealing surface contacts that of
the filter seat. Then, tighten it further by 3/4
turn.
If the filter cartridge is over-tightened, the

seals may be broken and oil leakage could re-
sult. If the cartridge is too loose, fuel will leak
from the sealing location. Therefore, the filter
element must be tightened to a suitable Fig.5-61
torque.
7. Bleed the air after filter element

replacement.
Air bleeding procedure:
8. Fill the fuel tank till the float reaches its

maximum level.
9. Loosen the plug [3] of the fuel filter.
Fig.5-62
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, tight-
en the plug.
Tightening torque : 9.8 ± 2.0 N·m {1.0

±0.2kgf·m}
13.Stroke the priming pump five to six times

and tighten the handle [4]. Fig.5-63

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.
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 it. Fig.5-64
5.8.8.7 Radiator and oil cooler fins - in-

spect/clean
WARNING
• Wear goggles, dust-proof mask or other
personal protective gears when handling
compressed air, water or steam.
CAUTION
• When compressed air is used for cleaning,
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.
1. Open the engine hood (1).
2015083103
Fig.5-65
2. Loosen the bolts (3) and (8) and pull out the
screen (2) and (9).
5
3. Clean the screens.
3
4. Inspect the radiator (4), the inter-cooler (5), 6

the air conditioner condenser fins (6) and the
hydraulic oil cooler (7).
2
If mud, dust or leaves are found on these
components, clean them with compressed air
or water in the opposite direction of air flow. CZ335-1104073
NOTE： Fig.5-66
When high pressure water is used for flush-
ing, lower the pressure of the spray gun and
keep the gun about 30cm away from the radi-
ator fins. When the spry gun is too close to
the radiator, the fins may deform, resulting in
premature plugging and cracking of the
4
radiator. 9
8
CAUTION 7
• Do not try to pick dirt out of the fins using

hard tools; otherwise, the radiator fins may CZ335-1204004
become damaged. Fig.5-67
5. Check the radiator fins for deformation,

holes or cracking after cleaning. Make repairs
or replacement if necessary. Inspect the ho-
ses. Replace the hoses in case of cracking or
aging. Check for loose hose clamps.
6. Remove the bottom cover (10). Remove the

dirt, debris and tree leaves that have been
10
swept to the external edge.
7. Restore screens (2) and (9) that have been

cleaned and secure them with wing bolts (3) CZ335-1104074
and (8). Fig.5-68

8. Install bottom cover (10) and lock the en-
gine hood.

5.8.8.8 Air conditioner fresh air/recircu-

lation filter - clean
CAUTION
• Wear goggles, dust-proof mask or other
personal protective gears when handling
compressed air, water or steam.
NOTE：
The filter shall be cleaned every 500 hours,
but operating your machine in a dusty place
requires 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
1. Remove the screw [1] from the access cov-
er in the rear of the cab, loosen the 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
CZ335-1104075
before reuse. This filter shall be replaced
Fig.5-69
every year with a new one. If a plugged air fil-
ter cannot be cleaned with compressed air or
flushing water, replace it immediately.
CZ335-1104076
Fig.5-70

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 CZ335-1104077
before reuse. This filter shall be replaced

Fig.5-71
every year with a new one. If a plugged air fil-
ter cannot be cleaned with compressed air or
flushing water, replace it immediately.
3. After cleaning, restore the filter [6], tighten

the nut [5] and lock the cover. 5
4
CZ335-1104078
Fig.5-72
NOTE：
The fresh air filter must be installed correctly.
To install the filter, the long end (L) of the filter S
[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.5-73

5.8.8.9 Swing drive oil level - check/fill
CAUTION
serious burns. Wait for them to cool down F
G
before you proceed.
1. Remove the dipstick (G) and wipe off the oil

on it.
2. Insert the dipstick (G) back into the tube.

CB13050901-1
Fig.5-74
3. Take out the dipstick (G) and check whether

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.5-75
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 Sany deal-
P
er for inspection.
• Place a container under the drain valve be-
fore draining engine 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.5-76

5.8.8.10 Final drive oil level - check/fill
WARNING
fore operation.
lease the pressure.
1. Adjust the position of the machine so that

the arrow mark on the drain port plug (D) F
points to the ground and the line between fill L
port plug (F) and the drain port plug (D) is ver- D
tical to the ground.
L
LEVEL
3. Use a spanner to remove the screw plug DRAIN

D
(F). When oil level is 10 mm {0.4''} lower than
the bottom line of port (L), the amount of oil CB13041501-02
added is just perfect. Fig.5-77

4. If the oil level is too low, reinstall the screw
plug (F), operate the travel level and slowly
travel your machine forward or backward in
order to run the sprocket one turn. Repeat
step 3 and check again.
5. If the oil level is low, add oil through the fill

port (F) till the oil overflows through the level
port (L).
6. When the oil level is too high, consult your

Sany dealer for inspection.
7. Restore the screw plugs (F) and (L) after

check. Tighten the screw plugs to the follow-
ing torques:
108±9.8 N·m {10.0±1 kgf·m}

5.8.9.1 foreword
The 100-, 250- and 500- hours services shall

5.8.9.2 Hydraulic oil return filter ele-

ment - replace
CAUTION
before you proceed.
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 your machine on a hard and level

ground. Adjust the work equipment to an atti-
tude ready for service. Lower the work equip-
ment to ground and stop the engine.
CZ335-1104086
Fig.5-78
2. Remove the butterfly nut [1] of the breather

valve on top of the hydraulic tank. Press the
vent valve to release internal pressure.
Fig.5-79

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 this 2
case, hold down the cap when removing the 3

bolts. 4
4. Remove the spring [3], valve [4] and 5
strainer [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.5-80
5. Clean the disassembled parts with cleaning
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.
5.8.9.3 Swing drive oil - change
WARNING
before you proceed.

• Swing drive casing capacity: 10.6 L (2.8 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 completion of
the draining.
NOTE：
• If the gear oil flows out in a thin thread pat- CB13051401-1
tern, stop draining. Fig.5-81

• 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-

quired through the filler opening.
4. Check the oil level. For more information,

see "Swing drive oil level - check/fill" on page
F
5-63. G
5. Apply sealant onto the thread of the filler

opening and tighten the filler cap.
Tightening torque: 130±10N·m
CB13050901-1
NOTE：
Improper tightening of the filler cap may cause Fig.5-82
the gear oil in the swing drive to leak.

5.8.9.4 Cab door lock and front window

lock catch - inspect/tighten
1. Check the body of the cab door lock.
Fig.5-83
2. Check the lock catch of the cab door lock.
Fig.5-84
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
properly.
Fig.5-85

5.8.9.5 Cab door hinge and front win-

dow 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.
Fig.5-86
Apply grease onto the slide rails at both sides

of the cab door ceiling.
Fig.5-87

5.8.9.6 Windshield wiper arm nut - In-

spect/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.
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
Fig.5-88
5.8.9.7 Engine exhaust pipe clamps -

check
Consult Sany dealer to check the fastening

conditions of the air cleaner - turbocharger -
post cooler - engine clamps.
5.8.9.8 Fan belt tension - check/replace
Check the tension of fan belt. Replace the fan

belt in case of cracks or damage. Contact
Sany dealer if you have any troubles.
5.8.9.9 Nitrogen pressure in accumula-

tor (breaker) - check
(If equipped)
Special tools will be used in order to check the

accumulator and inject nitrogen.
Please consult Sany dealer, if possible, to

conduct related inspection and inflating
operation.

5.8.9.10 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.5-89
5.8.9.11 Hydraulic tank breather valve

filter element - replace
CAUTION
• Stop the engine before replacing the
breather valve.
before you proceed.

1. Clean the top of the hydraulic tank and re-

move the contaminants around the breather
valve.
Disassemble the valve in a place that is free

from fire sources and dust.
2. Remove the butterfly nut [1] on the breather

valve and press the vent valve to release in-
ternal pressure.
3. Remove lock nut [2], cover [3] and take off CZ335-1104080
the filter element [4].

Fig.5-90
4. Clean the cover [3] with a brush if excessive
dirt is found inside. Replace a new filter ele-
ment if it is broken.
1
5. Install the cover [3] and tighten lock nut [2].

3
2
NOTE： 4
• When assembling the lock nut [2], tighten it

to the specific torque (10-14 N·m).
CC13031501
Fig.5-91
5.8.10.1 foreword
The 100 -, 500 - and 1000 - hours services will


5.8.10.2 Final drive oil - change
WARNING
fore operation.
lease the pressure.
1. Adjust the position of the machine so that

the arrow mark on the drain port plug (D) F
points to the ground and the line between the L
fill port plug (F) and the drain port plug (D) is D
vertical to the ground.
L
LEVEL
3. Place a vessel under the drain port to col- DRAIN

D
lect the oil.
CB13041501-02
4. Use the spanner to remove the drain plug
(D) in order to drain the oil. Fig.5-92
5. Tighten the plug (D) and remove the plugs

(F) and (L).
6. Add oil through the fill port (F).


Tightening torques of the plugs (P), (L) and

(F): 108±9.8 N·m (10.0±1 kgf·m)

5.8.10.3 Hydraulic oil suction filter ele-

ment – clean/replace
CAUTION
before you proceed.
1. Remove the butterfly nut [1] of the breather

valve on the hydraulic tank and press the vent
valve to relieve internal pressure.
2. Loosen the four bolts and remove the cap

[2]. When the cap is being removed, it may fly
out due to the action of the spring [3]. In this
case, hold down the cap when removing the
bolts.
3. Hold the top end of the rod [4] and pull it up-
ward to remove the spring [3] and the suction
filter element [5].
4. Clean the suction filter element [5]. Flush it

with cleaning oil. Replace the suction filter ele-
ment if it is damaged.
5. During installation, fix the suction filter ele-

ment [5] to the projected part [6] of the oil tank
before assembling.
Fig.5-93
6. When assembling, use the bulged part of
the cap [2] to hold the spring [3] before tight- 2
ening the bolts.
3
CZ335-1104093
Fig.5-94

5.8.10.4 Nitrogen pressure in accumu-

lator (control oil circuit) - check
WARNING
• The accumulator contains pressurized ni-
trogen, which may explode due to improp-
er 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 Sany’s authorized
dealer to do this job.
NOTE：
In continuous operation with low nitrogen
pressure in the accumulator, the remaining
pressure in hydraulic circuit will not be re-
leased once failure occurs to your 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
released. CB13041502-1
The installation location of the accumulator is Fig.5-95

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:
1. Park the machine on a hard and flat

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 1.5m
retracted).
The step 3 through step 5 shall be conducted CZ335-1104095

within 15 seconds.
Fig.5-96
The accumulator’s pressure drops gradually
after engine shutdown. Check the accumula-
tor immediately after the engine is shut down.
3. Keep the work equipment at its maximum

operating radius, turn the start switch to OFF
position and stop the engine.

FREE position. Operate the joysticks and low-
er the work equipment. Check if the work
equipment touches the ground.
CC13031404
Fig.5-97

6. If the work equipment fall under its own

weight to the ground, this shows the accumu-
lator functions normally.
If the work equipment fails to fall to the

ground, this shows pressure in the accumula-
tor has dropped.
Consult Sany dealer for such inspection.

LOCKED position and turn the start switch to CZ335-1104099
the OFF position.

Fig.5-98
How to release pressure in hydraulic

circuit
1. Low the work equipment to the ground.
2. Place the lockout lever to the LOCKED

position.
The steps 4 through step 6 shall be carried

out within 15 seconds.
Pressure of the accumulator will drop gradu-

ally after the engine is stopped. Therefore, the
pressure can only be released when the en-
CC13031403
gine has just be turned off.
Fig.5-99
3. Turn off the engine.
ON
OFF
STA
T
HEA
RT
CC13031804
Fig.5-100

5. Place the lockout lever to the FREE position

and then cycle the control levers in all direc-
tions to release the pressure in control circuit.
6. Place the lockout lever to the LOCKED po-

sition and then turn the start switch to the OFF
position.
CC13031404
Fig.5-101
5.8.10.5 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 coolant
has cooled down to relieve internal pres-
sure before removing it.
• When the engine is started for cleaning
purpose, place the hydraulic lockout con-
trol in the LOCKED position to prevent un-
expected machine movement.
• Antifreeze is flammable. Keep it away from
fire.
• Antifreeze is toxic. Never allow it to contact
your eyes and/or your skin. Wash with
plenty of water and seek medical treatment
immediately if antifreeze contacts 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 your machine on a level ground and

then shut off the engine.
1
2. Remove slowly the radiator cap [1] to re-
lieve pressure only when the coolant is cool
enough for you to touch the radiator cap with
your bare hand.
0-13018
Fig.5-102
3. Remove the bottom cover under the radia-

tor and place a container to collect the coolant
under the drain valve [2]. Open the drain valve 2
[2] to drain the coolant.
4. Close the drain valve [2] after draining the

coolant. Add tap water and cleaning agent in-
to 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. Continue to run
the engine for about 10 minutes.
CZ335-1104012
5. Stop the engine and open the drain valve

Fig.5-103
[2] to discharge water. Flush the cooling sys-
tem 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

slowly into the radiator till it overflows from the
filler opening.
7. Run the engine at low speed for about 5 mi-

nutes and then at high speed for another 3 mi-
nutes 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

draining the coolant inside. Add water till the 3
FULL
coolant level reaches a level between the high
LOW
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- CB13040901-2
fore adding water through the filler opening.

Fig.5-104
Screw on the radiator cap tightly.
11.Install the bottom cover.
1. Clean the inside of hydraulic oil cooler
2. Remove the hydraulic oil cooler before

cleaning. Cleaning shall be performed on
a clean washing table.
3. 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 cool-
er with cotton, linen or synthetic fibers.
4. Recommended cleaning agent: Hydraulic

oil of the same grade, plane kerosene,
petrol, diesel fuel.
5.8.10.6 Alternator - inspect
Contact Sany dealer to inspect the alternator.
Check the engine every 1000 service hours if

the engine is started frequently.

5.8.10.7 Engine valve clearance -

check/adjust
Special tools are necessary for inspection and

maintenance. Consult Sany dealer to do this
job.
5.8.11.1 foreword
The 100-, 250-, 500-, 1000- and 2000- hours

services shall be carried out in the meantime.
5.8.11.2 Water pump - inspect
Check the water pump for water leakage or oil

leakage. In case of any problem, contact Sany
dealer for disassembly, repair or replacement.
CZ335-1104104
Fig.5-105
5.8.11.3 Start motor - check
Consult Sany dealer to check the start motor.

Check it every 1000 service hours if the en-
gine is started frequently.

5.8.11.4 Hydraulic tank oil - change
CAUTION
before you proceed.
• Press the breather valve venting button to
release the internal pressure before re-
moving 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.
• 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.
4. Place the lockout lever to the LOCKED po-

sition and turn off the engine.
Fig.5-106

5. Remove the cap of the oil filler (F).
6. Place a container under the drain plug. Re-

move 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).
Add hydraulic oil as required through the filler

Fig.5-107
(F). Check the oil level, which shall be be-
tween the H and L marks of dipstick.
7. Add hydraulic oil as required through the fill-

er (F). Check the oil level, which shall be be-
tween the H and L marks of dipstick.
5.8.11.5 Accumulator - replace
Replace the accumulator every two years or

4000 service hours, whichever occurs first.
WARNING
• The accumulator contains pressurized ni-
trogen, which may explode due to improp-
er 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 Sany’s authorized
dealer to do this job.

If your machine is kept operating when the

performance of accumulator decreases, the
pressure in the hydraulic system will not be re-
leased. Consult Sany dealer to replace the
accumulator.
The accumulator's installation location is

CB13041502-1
Fig.5-108
5.8.11.6 High-pressure tube clamps and rubber - check
Fig.5-109
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 Sany dealer to replace the
parts in trouble.
5.8.11.7 Compressor working condition

- inspect
The following two items are to be inspected:

• Whether the compressor and the magnetic

clutch are switched on/off when switching
on/off the air conditioner.
• Whether the clutch or compressor produces
abnormal noise.
In case of any problem, contact Sany dealer
for disassembly, repair or replacement of
the parts.
5.8.12.1 Aftertreatment Diesel Exhaust

Fluid Dosing Unit Filter - Change
1 General Information
The aftertreatment diesel exhaust fluid (DEF)

dosing unit filter is designed to prevent foreign
objects, that may be suspended in the DEF,
from entering the dosing system.
Debris can cause permanent damage and

premature malfunction to either the aftertreat-
ment DEF dosing unit or the aftertreatment
DEF dosing valve. The aftertreatment DEF
dosing unit filter is a maintenance item.
Fig.5-110
For handling incorrect or contaminated DEF,
contact a SANY Authorized Repair Location.
The aftertreatment DEF dosing unit consists

of the following components:
1. Aftertreatment DEF dosing unit
2. Aftertreatment DEF dosing unit element
3. Aftertreatment DEF dosing unit frost protec-

tion membrane
4. Aftertreatment DEF dosing unit filter o-ring
5. Aftertreatment DEF dosing unit filter

housing. Fig.5-111
2 Preparatory Steps

WARNING: Diesel exhaust fluid (DEF) contains urea. Do not get the substance in your eyes. In
case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes.
Do not swallow. In the event the DEF is ingested, contact a physician immediately.
WARNING: The diesel exhaust fluid (DEF) line connecting the aftertreatment diesel exhaust fluid
dosing unit to the aftertreatment diesel exhaust fluid dosing valve is under low pressure and should
not be disconnected while the engine is running or before the system has completed the purge
process after engine shutdown. Disconnecting the DEF line while under low pressure could cause
DEF to spray.
Use a clean damp cloth to remove any contamination, to reduce the risk of contaminants entering
the DEF dosing unit.
3 Remove
CAUTION: A small amount of dirt and debris

can be very harmful to the DEF dosing sys-
tem. Dirt or other foreign objects must not get
into the DEF dosing unit.
NOTE: There may be residual DEF in the filter

housing. A collection container placed below
the DEF filter housing is recommended.
1. Use a 46 mm socket to remove the DEF fil-

ter housing. Fig.5-112
2. Remove and discard the o-ring.
NOTE: In the next step, the frost protection

membrane will be removed. A small amount
of DEF could leak.
3. Remove the frost protection membrane and

inspect. A small amount of DEF could leak out
of it.
4. Remove the filter element from the unit by

twisting, while pulling. Absorb the dripping
DEF with a dry clean lint-free cloth and dry the
unit.
5. Discard the o-ring, frost protection mem-

brane, and filter element.

If there is the possibility that contaminated

DEF has gone through the DEF dosing sys-
tem, check the DEF filter prior to discarding it.
Check the diesel exhaust filter for evidence of

contaminated DEF. Use visual and aroma
characteristics of the filter to determine if con-
taminated fluid has passed through the dosing
system.
Inspect the DEF filter for debris. If debris is

evident, also check:
Fig.5-113
(1) DEF tank filter.
(2) The aftertreatment DEF dosing unit inlet

connector. Contact a SANY Authorized Repair
Location.
4 Clean and Inspect for Reuse
Inspect the aftertreatment DEF dosing unit

threads. This is especially important if the
aftertreatment DEF dosing unit cap was
damaged.
If the aftertreatment DEF dosing unit threads

are damaged, replace the entire aftertreat-
ment DEF dosing unit.
Be sure the frost protection membrane groove

is clean and free of debris. Clean using a Fig.5-114
clean damp cloth, warm water, and a mild
detergent.
NOTE: Never operate the vehicle with the

DEF filter or filter housing removed.
Clean the new aftertreatment DEF dosing unit

filter housing and threads on the dosing unit
with warm water and a clean cloth.
Fig.5-115

5 Install
Slide the filter element onto the DEF dosing

unit. Push up on the filter to make sure it is
fully seated.
Fig.5-116
Put the frost membrane over the filter

element.
NOTE: The sealing bead of the frost protec-

tion membrane must sit completely in the
groove of the pump housing.
Fig.5-117
NOTE: The provided lubricant must be used

when installing the filter housing.
Spray the threads on the pump housing and

sealing bead of the frost protection membrane
with Bio Lube. Put the o-ring into the groove
on the filter housing. The groove must be free
of dirt and foreign particle. Install and tighten
the filter housing with a socket. Torque Value:
80 n.m [59 ft-lb]
Fig.5-118

5.8.12.2 Aftertreatment Diesel Particu-

late Filter - Check
WARNING
During regeneration, exhaust gas temperature could reach 800°C [1500°F], and exhaust system
surface temperature could exceed 700°C [1300°F], which is hot enough to ignite or melt common
materials, and to burn the skin. The exhaust and exhaust components can remain hot after the
vehicle has stopped moving. To avoid the risk of fire, property damage, burns, or personal injury,
allow the exhaust system to cool before beginning this procedure or repair and make sure that no
combustible materials are located where they are likely to come in contact with hot exhaust or
exhaust components.
CAUTION
The aftertreatment diesel oxidation catalyst (DOC) elements contained in the aftertreatment sys-
tem are made of brittle material. Do not drop or strike the side of the aftertreatment system as dam-
age to the aftertreatment DOC element can result.
The aftertreatment system (DOC/DPF) is

composed of three sections. These sections
are:
1. Aftertreatment DOC
2. Aftertreatment Diesel Particulate Filter

(DPF)
3. Outlet.
Fig.5-119
Maintenance Check
If the aftertreatment DPF is being removed for

an ash cleaning or soot cleaning maintenance
interval, the aftertreatment DPF will need to
be removed and cleaned using a cleaning tool
approved by SANY. Refer to a SANY Author-
ized Repair Location for information regarding
parts and operation of SANY approved clean-
ing tools. Conventional cleaning can not be
Fig.5-120
used to clean aftertreatment DPFs.
While air cleaning is allowed, the SANY preferred method would be to exchange the DPF at the
recommended maintenance interval.
Because it can be difficult to determine if an aftertreatment DPF is plugged with ash or soot, it will
be necessary to clean the aftertreatment DPF before performing a stationary regeneration to

prevent any system damage from occurring. For information on how to perform a stationary regen-
eration, refer to a SANY Authorized Repair Location.
Performing the ash and/or soot cleaning procedure will:
(1) Remove excess soot to allow a stationary regeneration without damaging the aftertreatment
DPF.
(2) Allow the aftertreatment DPF to be reused after a 1981 and/or 1922 fault code occurs.
(3) Remove excess ash and improve regeneration frequency.
Performing a stationary regeneration after cleaning the aftertreatment DPF for ash and/or soot will:
(1) Remove any residual soot from the system that was not removed during the cleaning
procedure.
(2) Test the diesel oxidation catalyst efficiency.
(3) Test the aftertreatment system functionality.
5.8.12.3 Aftertreatment Diesel Exhaust

Fluid Tank Filter - Inspect and reuse
1 General Information
NOTE：
If the aftertreatment diesel exhaust fluid (DEF)
system components do not have a Cummins®
part number, see equipment manufacturer
service information.
The DEF dosing unit filter is a 40 micron filter

designed to prevent foreign objects sus- Fig.5-121
pended in the DEF from entering the dosing
system. Debris can cause permanent damage
and premature malfunctions to the aftertreat-
ment DEF dosing unit. The aftertreatment
DEF dosing unit filter is a maintenance item.

NOTE：
See equipment manufacturer service informa-
tion for the DEF tank filter service interval. For
Cummins® provided DEF tanks, filter replace-
ment is recommended every 2000 hours or
one year, whichever occurs first. For dusty en-
vironments inspect the filter every 1000 hours
and replace if dirty. For low dust environ-
ments, such as paved road or indoor equip-
ment, the recommended interval is 4500
hours or three years, whichever occurs first.
2 Preparatory Steps
WARNING
Diesel exhaust fluid (DEF) contains urea. Do
not get the substance in your eyes. In case of
contact, immediately flush eyes with large
amounts of water for a minimum of 15
minutes. Do not swallow. In the event the
DEF is ingested, contact a physician
immediately. Reference the materials safety
data sheet (MSDS) for additional information.
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment before
servicing the batteries. To reduce the
possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-)
battery cable last.
CAUTION
Do not pressure wash or steam clean this
unit. Pressure washing or steam can damage
the unit. Use compressed air to remove any
loose debris.
• Disconnect the batteries. See equipment

manufacturer service information.

• To access the DEF tank filter, remove the

DEF header tank assembly. See equipment
manufacturer service information.
3 Disassemble
NOTE：
The DEF tank filter must only be disas-
sembled if a symptom has been identified that
indicates further investigation is required or
during a maintenance interval.
Remove the clip from the inlet port of the DEF

tank filter. Fig.5-122
Remove the DEF tank filter.
NOTE：
If the DEF tank filter is removed as part of a
maintenance interval, discard the DEF tank fil-
ter and o-ring.
4 Clean and Inspect for Reuse
NOTE：
Inspect the filler neck filter for contamination
and debris. The filter is the first point of con-
tact with foreign elements.
If it is suspected that contaminated DEF has

gone through the DEF dosing system, check
the DEF tank filter prior to discarding the filter.
Inspect the DEF tank filter for evidence of con-

taminated DEF. Use visual and aroma charac- Fig.5-123
teristics of the filter to determine if
contaminated fluid has passed through the
dosing system.
Contact a Cummins® Authorized Repair Lo-

cation for further information on contaminated
DEF.
Inspect the DEF filter for debris. If debris is

evident, also inspect the aftertreatment DEF
dosing unit filter. Refer to Procedure 011-060
in Section 3. (https://quickserve. cummins.

com/qs3/pubsys2/xml/en/procedures/560/
560-011-060-om.html)
Inspect the DEF tank filter for cracks or other

damage.
If there is a crack, inspect the aftertreatment

DEF dosing unit filter.
NOTE：
Discard the DEF tank filter after inspection.
5 Assemble
Install the o-ring (1) on the DEF tank pickup

tube in its seated notch location.
Insert the DEF tank filter inlet port onto the

DEF tank pickup tube.
Install the clip over the notch on the DEF tank

filter inlet port.
Fig.5-124
6 Finishing Steps
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment before
servicing the batteries. To reduce the
possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-)
battery cable last.
• Install the DEF header tank assembly. See

Fig.5-125
equipment manufacturer service
information.
• Connect the batteries. See equipment man-
ufacturer service information.

5.8.13.1 foreword
The 100-, 250-, 500-, 1000-, 2000- and 4000-

hours services shall be carried out in the
meantime.
5.8.13.2 High-pressure tube clamps -

replace
Contact Sany dealer to replace the high-pres-

sure tube clamps of the engine.
Contact Sany’s authorized dealer if service

hours of the machine reaches 10, 000 hours
or overall maintenance.


SY305C LC (Stage Ⅴ)Hydraulic Excavator Troubleshooting
Troubleshooting
6 Troubleshooting ..............................................................................................................6-1
6.1 foreword..................................................................................................................................6-5
6.2 Troubleshooting Preparation ...............................................................................................6-6
6.2.1 Checks before troubleshooting .................................................................................6-6
6.2.2 Troubleshooting precautions .....................................................................................6-6
6.2.3 Electrical circuits troubleshooting precautions........................................................6-8
6.2.4 Hydraulic components handling precautions ..........................................................6-9
6.3 Measures Taken When Failure Occurs............................................................................6-11
6.3.1 Failure-like phenomena............................................................................................6-11
6.3.2 Towing the machine ................................................................................................. 6-12
6.4 Engine Failures................................................................................................................... 6-13
6.4.1 Engine troubleshooting table.................................................................................. 6-13
6.4.2 Coolant temperature high ....................................................................................... 6-17
6.4.3 Engine oil pressure low ........................................................................................... 6-18
6.4.4 When fuel runs out ................................................................................................... 6-19
6.4.5 When engine rotates reversely .............................................................................. 6-22
6.5 Failures of the Electrical System...................................................................................... 6-22
6.5.1 Electrical system troubleshooting table ................................................................ 6-22
6.5.2 Failure codes ............................................................................................................ 6-25
6.6 Battery.................................................................................................................................. 6-28
6.6.1 foreword..................................................................................................................... 6-28
6.6.2 Battery removal and installation............................................................................. 6-28
6.6.3 Battery charging ....................................................................................................... 6-28
6.6.4 Starting engine with jumper cable.......................................................................... 6-29
6.6.4.1 foreword ............................................................................................................. 6-29
6.6.4.2 Connecting jumper cables............................................................................... 6-30
6.6.4.3 Starting engine .................................................................................................. 6-31
6.6.4.4 Disconnecting jumper cables .......................................................................... 6-31
6.7 Failures of the Hydraulic System ..................................................................................... 6-32
Troubleshooting SY305C LC (Stage Ⅴ)Hydraulic Excavator
6.8 Other Common Failures.................................................................................................... 6-37


WARNING

6.Troubleshooting
6.1 foreword
WARNING
• Remove the battery from the machine be-
fore charging it.
• Stop the engine and turn the key switch to
the OFF position when checking or han-
dling 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.

6.2 Troubleshooting Preparation

6.2.1 Checks before troubleshooting
Judgement
Item Remedy
value
● Check fuel level and type of fuel — Add fuel
● Check for impurities in fuel — Clean, drain
● Check hydraulic oil level — Add oil
● Check hydraulic oil strainer — Clean, drain
Lubricating ● Check swing drive oil level — Add oil
oil, coolant ● Check engine oil level (in oil pan) — Add oil
● Check coolant level — Add water
● Check dust indicator for clogging — Clean or replace
● Check hydraulic filter — Replace
● Check final drive oil level — Add oil
● Check for looseness and corrosion of
battery terminal and wiring
—
Electrical ● Check for looseness and corrosion of Tighten or
—
equipment alternator terminal and wiring replace
—
● Check for looseness and corrosion of
start motor terminal and wiring
Hydraulic, ● Check for abnormal noise and smell — Repair
mechanical ● Check for oil leakage — Repair
equipment ● Carry out air bleeding — Bleed air
● Check battery voltage (engine stopped)
● Check battery electrolyte level
Replace
● Check for discolored, burnt, exposed 20~30 V
Add or replace
wiring —
Replace
● Check for missing wiring clamps and —
Repair
hanging wiring —
Electronics , Disconnect
● Check for water leaking on wiring (be —
Electrical connector and
particularly careful attention to water —
equipment dry
leaking on connectors or terminals) After running for
Replace
● Check for blown or corroded fuses several minutes:
Replace
● Check alternator voltage (engine 27.5~29.5V
running at 1/2 throttle or above) — Replace
● Check operating sound of battery relay
(when switch is turned ON/OFF)
6.2.2 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 dis-
tance 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, re-
lease 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 disassembled.
• 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 in-
vestigation 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 in-
vestigation 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 failure will
occur again. To prevent this, always investigate why the problem occurred. Then, remove the
root cause.
6.2.3 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 inserted.
• 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 dis-
plays 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.

6.2.4 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 hy-
draulic 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 performance after Fig.6-1
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dust-proof workshop, and the per-
formance should be confirmed with special
test equipment.
3. Do not let any dirt or dust get in during refill-

ing 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 fil-
ter out the dirt that has collected during stor-
age, so this is an even more effective method.
4. Change hydraulic oil when the temperature

Fig.6-2
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 hydraul-
ic 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 circuit. Normally,
flushing is carried out twice: primary flushing
is carried out with flushing oil, and secondary
flushing is carried out with the specified hy-
draulic oil.
Fig.6-3
6. Cleaning operations
After repairing the hydraulic equipment

(pump, control valve, etc.) or when running
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.
Fig.6-4

6.3 Measures Taken When Failure Occurs

6.3.1 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.
• When the bucket tips are nearly parallel to
the ground, the bucket speed may drop
suddenly.
• The brake valve produces noise when start-
ing or stopping swinging operation.
• The travel motor produces noise when the Fig.6-5
machine travels downhill at low speed.
Fig.6-6

6.3.2 Towing the machine
WARNING
• Make sure that the wire cables used for
towing the machine are strong enough, A
which may otherwise result in accidents.

B
• While towing the machine, do not use wire
cables with broken wires (A), reduced di-
C
ameter (B) or knot (C) in order to prevent
rupture of the wire cables.
• Always wear protective gloves when han- CZ335-1102063
dling wire cables.

Fig.6-7
• Never tow the machine on a slope.
• Never stand between the towing machine
and faulty machine when performing tow-
ing operation.
• Operate the machine slowly and avoid im-
posing sudden load on wire cable.
NOTE：
The towing operation must be performed with-
in the maximum towing capacity.
CZ335-1103216
• If the machine is trapped in mud and cannot
move out of the mud with its own force, or Fig.6-8
the towing force of excavator is occupied by
heavy object, wire cables can be used as
• Place wood blocks or other protective mate-
rials between where the wire cable contacts
the machine in order to prevent friction be-
tween the wire cable and the machine.
• Keep the wire cable parallel to the ground
and align its direction with that of the track
frame.
CZ335-1103217
• Move at a speed of 1 Km/h when towing the
machine. Tow the machine to a place suit- Fig.6-9
able for repair. Never tow the machine over
a long distance.

• Towing of the machine is only allowed in

case of emergency.
6.4 Engine Failures

6.4.1 Engine troubleshooting table
Check the engine according to the following table if any failure occurs to it. Contact your Sany dis-
tributor to repair the engine.

Failure Causes Remedy

● Battery dead
● Recharge/replace the battery
● Battery that has disconnected or
● Remove the corroded part
When the engine fails loose cable, or is corroded.
● Replace the fuse
to start ● Fuse breaks.
● Replace the start switch or relay
Starter failure or ● Failure of start switch or start
● Repair/replace the start motor
reluctant rotation. relay.
● Use engine oil with suitable
● Failure of start motor.
viscosity
● Engine oil viscosity high.
● Fuel exhausted. ● Refill the fuel and purge the air
● Fuel injector opening pressure ● Adjust/replace the fuel injector
low ● Replace the fuel delivery valve
● Failure of fuel delivery valve of ● Repair or replace the control
injection pump rack
● Failure of control rack of ● Replace the plunger assembly
injection pump ● Start the engine in regular steps
When the engine fails ● Worn or stuck plunger of ● Purge air from the fuel system
to start injection pump ● Replace filter element or
Starter is OK. ● Improper starting operation cartridge
● Air trapped in the fuel system ● Clean/replace air cleaner
● Fuel filter plugged element
● Air cleaner plugged ● Battery dead
● Clutch sideslip ● Replace filter element or
● Turbocharger intake hose clamp catridge
loose ● Clean or place air cleaner
● Turbocharger intake hose crack element
● Battery dead
Engine shuts down ● Idle speed low ● Replace fuel filter element or
immediately after ● Fuel filter plugged cartridge
starting. ● Air cleaner plugged ● Clean/replace air cleaner
element
● Failure of low idle controller
● Repair/replace the low idle
● Fuel system leaks or is blocked
control system
● Air trapped in the fuel system
● Repair the fuel system
● Fuel system contains water
● Pure the air from fuel system
● Fuel filter element plugged
● Change the fuel
Low idle speed ● Failure of injection pump
● Replace fuel filter element or
instable ● Bad adjustment of air valve
cartridge
clearance
● Repair/replace related parts of
● Broken cylinder gasket, worn
fuel injection pump
cylinder liner, stuck or ruptured
● Readjust air valve clearance
piston ring, or defective contact
● Replace relevant parts
between air valve and its seat
● Fuel filter plugged ● Replace fuel filter element or
Power insufficient
● Fuel contaminated by water cartridge


● Air cleaner plugged
● Failure of fuel delivery pump
● Change the fuel
● Fuel injector activating pressure
● Clean/replace air cleaner
low; injection effect not good
element
● Failure of injection pump
● Repair/replace fuel delivery
Air leaks.
pump
● Turbocharger assembly
● Readjust/replace fuel injector
damaged
● Exhaust valve blocked
the fuel injection pump
● Bad adjustment of air valve
● Replace turbocharge assembly
clearance
● Clean the exhaust pipe
● Soft or broken spring of air valve
● Adjust valve clearance
● Replace gas spring
● Insufficiency of coolant
● Fan belt skids due to looseness
or cracking ● Refill coolant
● Radiator cap damaged or ● Replace fan belt
radiator core plugged ● Replace radiator cap or clean
● Coolant pump damaged radiator core
● Coolant leaks due to broken ● Repair/replace coolant pump
Engine overheated
cylinder head or cylinder block ● Replace seal cap
seal cap ● Replace thermostat
● Thermostat damaged ● Remove foreign object from the
● Cooling system blocked by cooling system
foreign object ● Readjust fuel injection timing
● Improper adjustment of fuel
injection timing
● Fuel contaminated by water
● Sluggish fuel injection timing
● Change the fuel
● Readjust fuel injection timing
● Repair/replace
White exhaust gas ● Replace valve oil seal, valve and
● Failure of turbocharger
valve guide tube
● Defective valve oil seal or worn
● Replace the piston or reset it
valve stem and valve guide tube
correctly
● Wear, rupture or incorrect setup
● Replace cylinder liner
of piston ring
● Scratch or wear of cylinder liner
Black exhaust gas ● Air cleaner plugged
element


low or bad injection effect
● Improper adjustment of fuel
● Readjust/replace fuel injector
injection timing
● Readjust fuel injection timing
● Fuel drips after injection due to
● Replace fuel delivery valve
damage of fuel injection pump
● Readjust fuel injection amount
delivery valve
● Excessive injection of the
injection pump
● Fuel leaks
● Air cleaner plugged
● Low idle improper
the fuel system
low, or bad injection effect
● Fuel injection timing incorrect
element
● Fuel drips after injection due to
● Readjust low idle
damage of fuel injection pump
● Adjust/replace fuel injector
delivery valve
Excessive ● Readjust fuel injection timing
● Air leaks from the intake side of
consumption of fuel ● Replace fuel delivery valve
turbocharger
● Repair the intake side of
● Turbocharger assembly
turbocharger
damaged
● Replace turbocharger assembly
● Bad valve clearance
● Readjust valve clearance
● Soft or broken valve spring
● Replace valve spring
● Bad oil
● Excessive oil ● Use suitable oil
● Oil leaks through oil seal and/or ● Drain excessive oil
gasket ● Replace oil seal and/or gasket
Excessive ● No preheating operation ● Follow the procedure specified
consumption of oil ● Defective valve oil seal, or wear ● Replace related parts
of valve stem and valve guide tube ● Replace piston ring or reset it
● Wear, rupture or improper setup properly
of piston ring ● Replace cylinder liner
● Scratch or wear of cylinder liner
● Refill oil
● Oil insufficient
● Use lubricant with proper
● Bad oil viscosity
viscosity
Oil pressure low ● Oil leaks through oil seal and/or
● Replace oil seal and/or gasket
gasket
● Replace oil filter element or
● Oil filter element plugged
cartridge


● Replace spring of safety valve
● Stuck safety valve and/or soft
and/ or bypass valve
bypass valve spring
● Clean the screen of oil pump
● Oil pump screen plugged
● Replace related parts of oil
● Wear of oil pump related parts
pump
● Tighten exhaust pipe connector
● Exhaust pipe connector loose or
or replace exhaust pipe
exhaust pipe broken
● Replace gasket and tighten fuel
Strange engine noise ● Fuel injector loose
injector
Gas leaking noise ● Exhaust manifold connector
● Tighten the connector of
loose
exhaust manifold
● Cylinder gasket broken
● Replace cylinder gasket
● Fan belt loose
● Readjust belt tension
● Cooling fan loose
Strange engine noise ● Tighten the cooling fan
● Worn or damaged coolant pump
Continuous noise ● Replace coolant pump bearing
bearing
● Readjust valve clearance
● Bad valve clearance
6.4.2 Coolant temperature high
WARNING
• 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.
CAUTION
• Do not stop the engine immediately. Sud-
den 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 your machine and keep engine run-
ning at a speed a little higher than idle in order

to reduce temperature. When the pointer of

coolant temperature gauge returns to the mid-
dle position, the alert indicator is off. Now,
stop the engine and perform the following
steps.
Check radiator hoses for coolant leak.
Check V - belt for rupture. Check the belt

tension. 1
Check coolant level. Refill coolant if

necessary.
• Remove the radiator cap (1) and refill cool-

ant to the opening. Tighten the cap
properly.
• Open the reservoir (2) and refill coolant to CZ215-1105003
the FULL mark. Tighten the cap properly.

Fig.6-10
Check the front of radiator for any
contaminants.
If your machine has coolant leak or often en-

2
FULL
counters higher coolant temperature, the cool-
LOW
ing system has a problem.
0-13014
Fig.6-11
6.4.3 Engine oil pressure low
• When the engine is just started, the oil pres-

sure gauge indicates high pressure before
the engine is preheated. Check oil pressure
after the engine is fully preheated.
• When engine oil pressure is abnormal,
which is shown on the monitor, stop operat-
ing your machine, shut down the engine im-
mediately, and proceed as the following.

CAUTION
• 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
necessary.
• 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.
• If oil level is low, add oil immediately. If en- CZ215-1105004
gine oil is contaminated, change the oil

Fig.6-12
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 pressure
alert indicator and oil filter indicator will be on.
Contact your Sany distributor to solve the
problem. L H
CZ335-1103131
Fig.6-13
6.4.4 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 lim-
ited. Take care not to be cut by the edges
1. Turn the handle (1) of hand pump counter-

clockwise to unlock it.
Fig.6-14
2. Loosen the fuel filter vent plug (2) and cover

the vent with cloth.
Fig.6-15

3. Operate the hand pump to deliver fuel until

no foam is seen in the vent.
Fig.6-16
4. Screw on the vent plug (2) when no foam is Fig.6-17

observed.
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 continu-
ously .
6. After eliminating the air, completely remove

the splashed fuel before starting the engine.
7. Make sure that no fuel leaks any more.
WARNING Fig.6-18
• Check the fuel filter and its shell for fuel

leak. The leak of fuel is possible to cause
fire.

6.4.5 When engine rotates reversely
WARNING
• Reverse rotation of engine can burn the
engine within several minutes or cause se-
vere injury. Shut down the engine immedi-
ately 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
starting.
• 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. Re-
place any defective air cleaner or hose
immediately.
6.5 Failures of the Electrical System

6.5.1 Electrical system troubleshooting table
Trouble-shoot the electrical system according to the following tables. Contact your Sany distributor
to solve the problem.


● Battery low
● Recharge/replace the
● Engine start switch internal
battery.
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
● Check/repair
failure)
● Repair/replace
● Alternator internal failure
● Replace
● Start relay failure
● Repair/replace
● Brake failure
● Open circuit of wire harness
●Check/repair
● Sensor internal failure
● Replace
Rough engine speed ● Short circuit of wire (grounding
● Check/repair
failure)
● Replace
● Sensor internal failure
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. ● Short circuit of wire (grounding
● Check/repair
failure)
● Replace
● Preheat controller failure
● Hydraulic lockout control failure
● Short circuit of wire (grounding ● Repair/replace
All devices fail. failure) ● Check/repair
● Failure of internal coil of pilot ● Replace
lockout valve
● Sensor failure ● Replace
● Short circuit of harness ● Check/repair
Boom slow and weak
(grounding failure) ● Check/repair
● Open circuit of harness ● Replace


● Controller failure
● Sensor failure
● Replace
● Short circuit of harness
● Check/repair
Arm slow and weak (grounding failure)
● Check/repair
● Open circuit of harness
● Replace
● Sensor failure
● Short circuit of harness ● Replace
(grounding failure) ● Check/repair
Bucket slow and weak ● Open circuit of harness ● Check/repair
● Bucket confluence solenoid ● Replace
valve failure ● Replace
● Sensor failure
● Replace
● Short circuit of harness
● Check/repair
Travel slow and weak (grounding failure)
● Check/repair
● Open circuit of harness
● Replace
● Fuse failure
● Replace
● Open circuit of wire
● Check/repair
Monitor black-out ● Short circuit of wire (grounding
● Check/repair
failure)
● Replace
● Monitor failure
● Resistor failure
● Replace
● Check/repair
Monitor displays nothing. ● Short circuit of wire (grounding
● Check/repair
failure)
● Replace
● Monitor or controller failure
● Dual travel speed solenoid valve
failure ● Replace
Dual-travel speed failure ● Open circuit of wire ● Check/repair
● Short circuit of wire (grounding ● Check/repair
failure)
● Coolant temperature sensor
failure ● Replace
Engine coolant temperature ● Open circuit of wire ● Check/repair
reading incorrect ● Short circuit of wire (grounding ● Check/repair
failure) ● Check/repair
● Wire short-circuited with 24V
● Fuel level sensor failure ● Replace
● Open circuit of wire ● Check/repair
Fuel level reading incorrect
● Short circuit of wire (grounding ● Check/repair
failure) ● Check/repair


● Wire short-circuited with 24V
● Wiper motor internal failure
● Repair/replace
Wiper failure ● Check/repair
● Short circuit of wire (grounding
● Check/repair
failure)
● 5V power supply failure ● Repair/replace
Arm-in pilot pressure reading ● Open circuit of signal line ● Check/repair
incorrect ● Short circuit of signal line ● Check/repair
Arm-out pilot pressure reading ● Open circuit of signal line ● Check/repair
Boom-up pilot pressure ● Open circuit of signal line ● Check/repair
reading incorrect ● Short circuit of signal line ● Check/repair
Boom-down pilot pressure ● Open circuit of signal line ● Check/repair
Bucket-dig pilot pressure ● Open circuit of signal line ● Check/repair
Bucket-dump pilot pressure ● Open circuit of signal line ● Check/repair
Swing pilot pressure reading ● Open circuit of signal line ● Check/repair
Travel pilot pressure reading ● Open circuit of signal line ● Check/repair
6.5.2 Failure codes
The failure code displayed on the monitor can be used to make failure analysis.

Failure Code Symptom Alarm Trigger Condition

Engine oil pressure Oil pressure lower than 200 and engine speed higher
3
low than 800 for 15 s
4 Fuel level low Fuel level lower than 10% for 10 s
Coolant temperature Coolant temperature higher than 105 °C or coolant
5
high temperature over-high pressure switch off
6 Air cleaner plugged Air cleaner plugging pressure switch off
Engine speed lower than 800 rpm but higher than
7 Engine speed low
400 rpm for 3 s
8 Engine speed high Engine speed higher than 2500 rpm
10 Engine speed high Hydraulic oil temperature higher than 90°C for 10 s
Motor working range Motor feedback voltage lower than 0.25V or higher
12
irregular than 4.75V for 3 s
Front pump pressure Front pump pressure collecting volt lower than 0.25V
20
sensor abnormal or higher than 4.75V for 3 s
Rear pump pressure Rear pump pressure collecting volt lower than 0.25V
21
sensor abnormal or higher than 4.75V for 3 s
Bucket-dig pilot
Bucket-dig pilot pressure collecting volt lower than
22 pressure sensor
0.25V or higher than 4.75V for 3 s
abnormal
Bucket-dump pilot
Bucket-dig pilot pressure collecting volt lower than
23 pressure sensor
abnormal
Arm-in pilot pressure Arm-in pilot pressure collecting volt lower than 0.25
24
sensor abnormal and higher than 4.75 for 3 s
Arm-out pilot pressure Arm-out pilot pressure collecting volt lower than 0.25
25
Boom-up pilot
Boom-up pilot pressure collecting volt lower than
26 pressure sensor
0.25 and higher than 4.75 for 3 s
abnormal
Boom-down pilot
Boom-down pilot pressure collecting volt lower than
27 pressure sensor
abnormal
Left travel pilot
Left travel pilot pressure collecting volt lower than
28 pressure sensor
abnormal
Right travel pilot
Right travel pilot pressure collecting volt lower than
29 pressure sensor
abnormal

Failure Code Symptom Alarm Trigger Condition

Swing pilot pressure Swing pilot pressure collecting volt lower than 0.25
30
Front pump
Front pump proportional valve current higher than
34 proportional valve
1300 mA for 3 s
over-current
Rear pump
Rear pump proportional valve current higher than
35 proportional valve
1300 mA for 3 s
over-current
Front pump Front pump proportional valve current lower than 200
36 proportional valve mA for 3 s and controller PWM output higher than 10
undercurrent V
Rear pump Rear pump proportional valve current lower than 200
37 proportional valve mA for 3 s and controller PWM output higher than 10
undercurrent V
Front pump proportional valve feedback current
Front pump
38 lower than 150 mA or higher than 1350 mA for 3 s
proportional valve
and controller PWM duty output higher than 10 V
Rear pump proportional valve feedback current
Rear pump
39 lower than 150 mA or higher than 1350 mA for 3 s
proportional valve
and controller PWM duty output higher than 10 V
Hydraulic oil
Hydraulic oil temperature collecting volt lower than
40 temperature sensor
abnormal
Coolant temperature collecting resistance lower than
Coolant sensor
41 10Ω or higher than 120 Ω for 3 s after 30 minutes
abnormal
since engine starting
Fuel level sensor Fuel level collecting resistance lower than 10Ω or
42
abnormal higher than 120 Ω for 3 s
Speed sensor Speed collecting frequency lower than 100 for 3 s
43
abnormal under load
Fuel control dial Fuel control dial collecting volt lower than 0.25V or
44
abnormal higher than 4.75V for 3 s
CAN communication monitoring component overtime
45 CAN bus abnormal
or reset characters changed for 3 s

6.6 Battery
6.6.1 foreword
WARNING
• Remove the battery from the machine be-
fore charging it.
• Stop the engine and turn the key switch to
the OFF position when checking or han-
dling 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.
6.6.2 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
• Always disconnect the ground cable (nega-

2
tive terminal (-)) first when removing the

battery; always connect the positive termi-
CZ335-1103219
nal (+) first when installing the battery.
• Fig.6-19
6.6.3 Battery charging
Improper handling can result in explosion

when charging the battery. Follow the instruc-
tions below:

Improper handling can result in explosion

when charging the battery. Follow the instruc-
tions below:
• Regulate the charger to the voltage applica-
ble to the battery. Incorrect voltage can over
heat the charger and cause explosion.
• 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.6-20
• Regulate the charging current to 1/10 of the
rated capacity of battery. In case of quick
charging, regulate the charging current 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.
6.6.4 Starting engine with jumper cable
6.6.4.1 foreword
Fig.6-21

WARNING
• Never let the positive pole (+) contact with
the negative pole (-) when connecting the
cables.
• Keep the normal machine away from the
faulty one to prevent sparks around the
battery which may ignite the hydrogen re-
leased from the battery.
• Avoid mistakes in connection of the jumper
cable. Its final connection with upper struc-
ture of the machine can produce sparks. In
this case, the battery shall be connected to
a location that is 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 supplied
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 con-
nected securely.
• Check if the hydraulic lockout levers of both
machines are in the LOCKED position.
• Check if all control levers are neutralized.
6.6.4.2 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 faulty
A
machine.
2 1
3
2. Connect the clip on the other end of jumper
cable (A) to the positive terminal (+) of battery
(D) of the normal machine.
D C
4
3. Connect the clip of jumper cable (B) to the
B
negative terminal of battery (D) of the normal E
machine. CZ335-1103222
Fig.6-22
4. Connect the clip on the other end of jumper
cable (B) to the swivel frame (E) of the faulty
machine.
6.6.4.3 Starting engine
WARNING
• Check the machine and make sure the hy-
draulic lockout lever is placed in the
LOCKED position and the all the control
levers are neutralized.
1. Make sure the clips are securely connected

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.
6.6.4.4 Disconnecting jumper cables
After the engine is started, disconnect the

jumper cables in steps reversed to their
connection.

1. Disconnect the clip of the jumper cable (B)

from the swivel frame (E) of the faulty
A
machine.
3 4
2
2. Disconnect the clip of the jumper cable (B)
from the negative terminal (-) of battery (D) of
the normal machine. D C
1
B E
3. Disconnect the clip of jumper cable (A) from
the positive terminal (+) of battery (D) of the CZ335-1103223
normal machine.
Fig.6-23
4. Disconnect the clip of jumper cable (A) from
the positive terminal (+) of battery (C) of the
faulty machine.
6.7 Failures of the Hydraulic System
• Trouble-shoot the hydraulic system according to the following tables. Contact your Sany distrib-
utor solve the problem.
• Set the working mode to S and the fuel control dial to position 10 before troubleshooting


● Bad adjustment or main relief
Work equipment ● Replace
valve failure
moving slowly, or ● Replace
● Pilot relief valve failure
travel and swing ● Repair/replace
● Regulator failure
speed slow ● Check/repair
● Plunger pump failure
Work equipment,
● Pilot pump relief valve failure ● Replace
final drive or swing
● Hydraulic pump failure ● Check/repair
drive not
● Coupling failure ● Check/repair
functioning
● Hydraulic oil level low
● Refill hydraulic oil
● Bad hydraulic oil
● Use suitable hyd oil
Abnormal noise in ● Hydraulic tank cap vent plugged
● Clean/replace
hydraulic pump ● Hydraulic tank filter screen
● Clean/replace
plugged
● Check/repair
● Plunger pump failure
Auto idle not
● Pilot valve failure ● Replace
functioning
● 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
● Repair/replace
valve) failure
● Repair/replace
● Boom control valve (Safety valve
● Check/repair
and feed valve) seal failure
● Boom cylinder failure
● Left pilot valve (arm circuit) failure
● Pressure sensor failure ● Check/repair
● Arm control valve (spool) failure ● Replace
● Arm control valve (regeneration ● Repair/replace
Arm speed slow
valve) failure ● Repair/replace
● Arm control valve (Safety valve ● Repair/replace
and feed valve) or seal failure ● Check/repair
● Arm cylinder failure
● Right pilot valve (bucket circuit)
● Check/repair
failure
● Replace
● Repair/replace
Bucket speed slow ● Bucket control valve (spool)
● Repair/replace
failure
● Repair/replace
● Bucket control valve
● Check/repair
(regeneration valve) failure


● Bucket control valve (Safety valve
and feed valve) or seal failure
● Bucket cylinder failure
● Pilot valve failure
One cylinder of ● Check/repair
work equipment not ● Replace
● Work equipment control valve
working ● Repair/replace
(spool) failure
● Work equipment cylinder drifting
excessively
● Retaining valve (of boom or arm) ● Repair/replace
Work equipment failure ● Repair/replace
cylinder drifting ● Work equipment control valve ● Repair/replace
excessively (safety valve and feed valve) seal
failure ● Repair/replace
● Work equipment valve spool
failure
● Arm regeneration valve failure
Work equipment ● Repair/replace
● Control valve (safety valve and
sluggish ● Repair/replace
feed valve) failure
Other work
equipment moves
● Control valve seal failure ● Replace
when single
cylinder is in relief.
Travel speed drops
remarkably during
● Straight travel valve failure ● Repair/replace
swing or travel
operation.
● Travel pilot valve failure
● Pilot relief valve failure ● Repair/replace
● Regulator failure ● Replace
● Proportional solenoid valve ● Repair/replace
Machine runs out sluggish ● Repair/replace
during travel ● Travel valve spool sluggish ● Repair/replace
● Central swivel joint sluggish ● Repair/replace
● Travel motor failure ● Repair/replace
● Travel pilot pressure sensor ● Replace
failure
● Travel pilot valve failure ● Repair/replace
● Pilot relief valve failure ● Replace
Travel speed slow
● Travel control valve (spool) failure ● Repair/replace
● Travel control valve (feed valve) ● Repair/replace
failure ● Check/repair


● Travel motor failure
● Travel pilot valve failure
● Repair/replace
● Travel pilot pressure sensor
● Replace
Machine steering failure
● Repair/replace
difficult or power ● Travel control valve (spool) failure
● Repair/replace
insufficient ● Travel control valve (feed) failure
● Repair/replace
● Travel motor (safety valve) failure
● Repair/replace
● Travel motor (check valve) failure
● High/low travel speed shift valve
Unable to shift ● Replace
failure
travel speed ● Check/repair
● Travel motor failure
● Travel control pedal valve failure ● Repair/replace
● Travel motor safety valve failure ● Repair/replace
Travel fails (on one
● Travel motor balance valve failure ● Repair/replace
side)
● Travel motor failure ● Check/repair
● Pilot pressure sensor failure ● Replace
● Swing motor (parking brake)
failure ● Check/repair
Unable to swing in ● Mis-adjustment or failure of swing ● Adjust/replace
both directions motor (safety valve) ● Check/repair
● Swing motor failure ● Check/repair
● Swing drive failure
● Repair/replace
Unable to swing in ● Swing control valve (spool) failure
● Repair/replace
one direction ● Swing motor (feed valve) seal
● Replace
failure
● Check/repair
failure
Swing speed slow ● Adjust/replace
● Mis-adjustment or failure of swing
Acceleration ● Check/repair
motor (safety valve)
performance bad ● Remove obstruction or replace
● Swing motor failure
the pipeline.
● Brake control line blocked
Swing speed slow ● Swing motor (pressure
● Repair/replace
Bad acceleration compensation valve) failure
● Repair/replace
performance on ● Swing motor (feed valve) seal
● Replace
one side or swing failure
● Repair/replace
speed slow ● Leak on one side the shuttle valve
of swing pilot pressure sensor
Too much overrun ● Bad adjustment or failure of swing
● Adjust/replace
in swing stoppage motor (safety valve)
● Check/repair
in both directions ● Swing motor failure


Too much overrun ● Repair/replace
● Swing control valve (spool) failure
in swing stoppage ● Repair/replace
● Swing motor (feed valve) seal
in one direction ● Replace
failure
● Swing pilot valve failure ● Repair/replace
Too much jerk in
● Swing anti-jerk valve failure ● Repair/replace
swing stoppage
● Swing relief valve failure ● Repair/replace
● Back pressure valve failure ● Repair/replace
High abnormal
● Swing motor (safety valve) failure ● Repair/replace
noise in swing
● Swing motor (feed valve) failure ● Repair/replace
stoppage
● Swing system mechanical failure ● Check/repair
When swing brake
● Swing brake control line failure
engaged , ● Check/repair
excessive hydraulic ● Repair/replace
failure
drift of swing
When swing brake
● Swing control valve (spool) failure ● Repair/replace
disengaged,
● Swing motor (relief valve) failure ● Repair/replace
excessive hydraulic
● Swing motor (feed valve) failure ● Repair/replace
drift of swing

6.8 Other Common Failures

● Loose fastener ● Check and retighten.
Structure member
● Bigger clearance between arm ● Reduce the clearance to a value
noise loud
and bucket end faces due to wear that is smaller than 1 mm.
● Spring deformed and weak due to
Bucket tip falls off repeated use of bucket tip pin
● Replace bucket tip pin
during operation. ● Bucket tip pin not matching the
adaptor
● Loose track ● Tighten the track
Track kinks. ● Traveling at high speed on rough ● Travel slowly on rough road in the
road in the direction of sprocket direction of idler.
● Improper electrical connection or
connector contact
● Air flow control switch, relay or
Fan not working temperature control switch ● Repair/replace.
damaged
● Fuse exploded or battery voltage
low
● Air intake side blocked
Fan running but ● Evaporator or condenser fin
producing less air plugged, giving ineffective heat ● Clean/replace.
flow conduction
● Fan vane seized or damaged
● Compressor clutch not picking up
due to wire break or defective ● Repair
contact of electrical circuit ● Adjust the tension of compressor
Compressor not
● Loose compressor belt belt
working or working
● Wire break or failure of ● Replace clutch coil
with difficulty
compressor clutch coil ● Refill/drain the refrigerant to a
● Insufficient or excessive suitable level
refrigerant
● Eliminate the leaking point.
Refrigerant ● Refrigerant leaks.
● Refill suitable amount of
insufficient ● Insufficient refilling
refrigerant.
High/low pressure ● Ambient temperature: 30~50 °C
reading in normal ● High pressure gauge: 1.47~1.67 MPa (15~17kgf/cm²)
operation ● Low pressure gauge: 0.13~0.20 MPa (1.4~2.11kgf/cm²)
Low pressure
● Expansion valve opening ● Replace expansion valve.
gauge reads
excessively. ● Install thermobulb correctly.
higher.
● Defective contact of expansion ● Drain refrigerant to the specified
Low pressure tube
valve thermobulb level.
surface frosted


● Excessive refrigerant in the
system
Low pressure
gauge reads lower.
Both high and low ● Refill refrigerant to the specified
● Refrigerant insufficient
pressure gauge level.
readings lower the
standard value.
Low pressure
gauge reads lower. ● Low pressure hose blocked;
● Repair the system. Replace
Low pressure expansion valve blocked by ice or
reservoir in case of ice blockage.
gauge could read contaminants.
negative.
Low pressure
gauge reads lower. ● Thermostat failure ● Replace thermostat.
Evaporator frozen
Expansion valve
inlet felt cool and ● Expansion valve blocked. ● Clean/replace expansion valve.
frosted.
Expansion valve
● Expansion valve outlet is not felt
outlet is not felt
cool. Low pressure could be ● Replace expansion valve.
cool. Low pressure
negative.
could be negative.
High pressure
gauge reads
● Empty the system and vacuate to
higher.
● Air trapped in circulation system. refill refrigerant.
Both high/ low
● Excessive refrigerant refilled. ● Drain refrigerant to the specified
pressure gauges
level.
read higher than
standard value.
High pressure
gauge reads ● Condenser blocked by dust and
● Clean the condenser.
higher. debris
● Check/replace condenser fan.
Bad condensing ● Condenser fan damaged
effect of condenser.


Both high and low
pressure gauges
read lower. ● Refrigerant insufficient
● Refill refrigerant as required.
Low pressure could ● Low pressure line blocked/
● Clean/replace faulty component.
be negative. damaged
● Replace compressor.
Condenser and ● Compressor internal failure
high pressure tube
hot
Bad refrigerating
● Hot water valve damaged and left
effect due active ● Replace hot water valve.
open
heater


SY305C LC (Stage Ⅴ)Hydraulic Excavator Specifications
Specifications
7 Specifications ...................................................................................................................7-1
7.1 Machine Dimensions ............................................................................................................7-3
7.2 Working Ranges....................................................................................................................7-4
7.3 Operating Parameters ..........................................................................................................7-5

Specifications SY305C LC (Stage Ⅴ)Hydraulic Excavator
WARNING

7.Specifications
7.1 Machine Dimensions
D A
E C
L
H
F J
G
K
B
CJ13032601-2
Fig.7-1
Item SY305C LC
A Overall Length (Transportation) 10667
B Overall Width 3190
C Overall Height (Transportation) 3470
D Upper Width 2986
E Overall Height (Top of Cab) 3280
F Standard Track Width 600
G Track Gauge 2590
*H Min Ground Clearance 550
I Tail Swing Radius 3315
J Track Shoe Grounding Length 3916
K Track Length 4840
*L Counterweight Clearance 1250
* Excluding track shoe lug

7.2 Working Ranges
g
b
c d
CJ13032602-1
Fig.7-2
Item SY305C LC
a Max. Cutting Height 10497
b Max. Dumping Height 7359
c Max. Digging Depth 6815
d Max. Vertical Digging Depth 6170
e Max. Horizontal Reach 10870
f Min. Swing Radius 4000
g Max Height at Min Swing Radius 8405

7.3 Operating Parameters

Item Unit SY305C LC
Working Weight kg 32,265
Bucket Capacity m³ 1.57
Engine Model CUMMINS L 9
Engine Power kW/rpm 209/2100
Travel Speed (High/Low) km/h 5.2/3.4
Swing Speed rpm 9


SY305C LC (Stage Ⅴ)Hydraulic Excavator Optional Equipment
Optional Equipment
8 Optional Equipment.......................................................................................................8-1
8.1 Safety Information.................................................................................................................8-5
8.1.1 foreword........................................................................................................................8-5
8.1.2 Optional equipment selection....................................................................................8-5
8.1.3 Read equipment instruction.......................................................................................8-5
8.1.4 Optional equipment removal and installation precautions ....................................8-5
8.1.5 Optional equipment operation precautions .............................................................8-6
8.2 Work Tool Control..................................................................................................................8-7
8.2.1 Stop valves...................................................................................................................8-7
8.2.2 One-Way Flow .............................................................................................................8-7
8.2.2.1 One-Way flow mode selection ...........................................................................8-7
8.2.2.2 Joystick..................................................................................................................8-7
8.2.3 Two-Way Flow .............................................................................................................8-8
8.2.3.1 Two-Way flow mode selection ...........................................................................8-8
8.2.3.2 Joystick..................................................................................................................8-8
8.3 Attachment removal and installation ..................................................................................8-9
8.3.1 Removal .......................................................................................................................8-9
8.3.2 Installation ..................................................................................................................8-11
8.4 Hydraulic shears operation............................................................................................... 8-13
8.5 Hydraulic Hammer Operation........................................................................................... 8-14
8.5.1 Recommended Operation....................................................................................... 8-14
8.5.2 Hydraulic breaker ..................................................................................................... 8-15
8.5.3 Hydraulic breaker operation ................................................................................... 8-15
8.5.4 Restricted operations............................................................................................... 8-17
8.5.5 Hydraulic breaker greasing..................................................................................... 8-20
8.6 Hydraulic oil and filter - change/replace.......................................................................... 8-21
8.7 Long-term storage.............................................................................................................. 8-21
8.8 Quick Coupler ..................................................................................................................... 8-22
8.8.1 Coupling the Work Tool ........................................................................................... 8-22
Optional Equipment SY305C LC (Stage Ⅴ)Hydraulic Excavator
8.8.2 Uncoupling the work tool......................................................................................... 8-28

8.8.3 Precautions for quick coupler safe operation....................................................... 8-32
8.9 Fueling System................................................................................................................... 8-33
8.9.1 Introduction ............................................................................................................... 8-33
8.9.2 Fueling system makeup .......................................................................................... 8-33
8.10 Work equipment combination ........................................................................................ 8-34


WARNING

8.Optional Equipment
8.1 Safety Information

8.1.1 foreword
Observe the following precautions when selecting, installing and operating attachments or optional
equipment of the machine.
8.1.2 Optional equipment selection
• Please consult Sany dealer before installing any optional equipment to your machine. You may
need to install front guard, top guard or other protective structures to your machine according to
the type of attachment or other optional equipment selected.
• You are only allowed to install Sany-approved optional equipment. Sany assumes no responsi-
bility to accidents, loss or failures caused by any optional equipment not approved by Sany.
8.1.3 Read equipment instruction
• Make sure you have read and understand the instruction manuals of your 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 Sany dealer to obtain a new one.
8.1.4 Optional equipment removal and installation precautions
The following items must be observed in order to ensure safety when removing or installing the op-
tional 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 in-
struction must be followed.
• Crane shall be used when handling heavy object above 25 kg. (Only eligible, experienced per-
sonnel with official license are allowed to operate the crane.)
• Never stand under any lifted objects by the crane.
• Do not operate your machine when an object is being lifted with crane during removal or installa-
tion. 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 balance
after removal. To prevent the machine from tipping over, support your machine, if necessary, be-
fore 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 Sany dealer.

8.1.5 Optional equipment operation precautions
Keep the following procedures in mind when installing a larger or heavy optional equipment. Prior
to the operation, move your machine to a safe ground for trial operation. Make sure that you know
very well the movement, center of gravity, and working range of your 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 calculated
accurately. A larger space must be prepared before performing the swinging operation.
– When the lifting of heavy optional equipment is held, the distance moving downward is rela-
tively 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 your 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 Work Tool Control

8.2.1 Stop valves
The equipment controls include two stop

valves. The two stop valves are on each side
of the arm.
The stop valve is used to stop the flow of hy-

draulic oil.
• In the ON position , the stop valve is rotated
counterclockwise until it contacts the stop .
The ON position is shown. This allows hy-
draulic oil to flow to the equipment.
• In the OFF position, the stop valve is ro-
tated clockwise until it contacts the stop. Fig.8-1
This prevents hydraulic oil from flowing past
the stop valve.
Switch the valve to OFF position when remov-

ing or installing an attachment.
Fig.8-2
8.2.2 One-Way Flow
8.2.2.1 One-Way flow mode selection
Refer to “Monitor operation” “Hammer” for One-Way flow mode selection.
8.2.2.2 Joystick
The following information pertains to work tools that require hydraulic oil flow in one direction. Hy-
draulic hammers are an example of work tools that require hydraulic oil flow in one direction.
For information that pertains to work tools that require hydraulic oil flow in two directions, refer to
Operation and Maintenance Manual, “Work Tool Control (Two-Way Flow)”.

(1) Variable Speed – Move the thumb wheel

downward in order to activate the work tool.
Move the thumb wheel further in order to in-
crease the speed of the work tool.
(2) On/Off – Push this switch in order to acti-

vate the work tool at a constant rate. Push this
switch again in order to turn off the work tool.
Fig.8-3
8.2.3 Two-Way Flow
8.2.3.1 Two-Way flow mode selection
Refer to “Monitor operation” “Hydraulic Shears” for Two-Way flow mode selection.
8.2.3.2 Joystick
The following information pertains to work tools that require hydraulic oil flow in two directions.
These work tools can also be equipped with a rotate circuit. Hydraulic shears, pulverizers,
crushers, and grapples are examples of work tools that require hydraulic oil flow in two directions.
For information that pertains to hydraulic hammers, refer to Operation and Maintenance Manual,
“Work Tool Control (One-Way flow)”.

(1) ROTATE CLOCKWISE – Move the thumb

wheel upward in order to rotate the work tool
clockwise.
(2) ROTATE COUNTERCLOCKWISE – Move

the thumb wheel downward in order to rotate
the work tool counterclockwise.
(3) CLOSE – Move the thumb wheel upward

in order to close the work tool.
(4) OPEN – Move the thumb wheel downward

in order to open the work tool. Fig.8-4
8.3 Attachment removal and installation

8.3.1 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 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 move the
FREE position in order to relieve the internal CC13031404
pressure in the hydraulic lines.

Fig.8-5

LOCKED position.
CC13031403
Fig.8-6

5. The breather valve (F) on top of the hy-

draulic tank is used to release the internal
F
pressure of the hydraulic lines.
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.8-7
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 OFF
position.
tated clockwise until it contacts the stop.
Fig.8-8
This prevents hydraulic oil from flowing past
the stop valve.
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 at-
tachment 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 procedures. CZ335-1105013
9. Check the oil level in the hydraulic tank Fig.8-9

when the bucket is installed properly.

8.3.2 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 A

shut down the engine.
CZ335-1105014
Fig.8-10
4. Turn the start switch to the ON position, and

place the hydraulic lockout lever to the FREE
position.
5. Move all control levers in all directions and

press the control pedal for 2-3 times within 15
seconds after the lockout lever is move the
FREE position in order to relieve the internal
pressure in the hydraulic lines.
CC13031404
Fig.8-11
CC13031403
Fig.8-12

6. The breather valve (F) on top of the hy-

draulic tank can be used to release the inter-
F
nal pressure of the hydraulic lines.
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.
7. Check the oil level in hydraulic tank after in-

stallation of the attachment.
CZ335-1105011
8. Check the temperature of the hydraulic oil,

Fig.8-13
which should be cooled down to a safe tem-
perature. Remove the two screw plugs from
the inlet and outlet. Be careful not to contami-
nate the hose connections with any dirt or
soil.
If the O-ring is broken, replace it with a new

one.
9. Connect the hose to the side of the

attachment.
When connecting the hose, check the oil flow

direction and be careful not to make any
mistakes.
10.Turn the rotor of the stop valve (mounted

to the inlet and outlet lines to the side of the
arm) to ON position.
tated clockwise until it contacts the stop.
This prevents hydraulic oil from flowing past Fig.8-14
the stop valve.

8.4 Hydraulic shears operation

Fig.8-15
WARNING
Do not operate or work on this work tool unless you have read and understand the instructions
and warnings in the Operation And Maintenance Manual for both the work tool and the host
machine.
Failure to follow the instructions or heed the warnings could result in injury or death.
Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.
NOTICE
Selection of a hydraulic shear must be done with extra care.
Use of a hydraulic shear not recommended by SANY could result in structural damage to the host
machine.
Consult your SANY dealer for hydraulic shear information.

Be sure that no one is near the work tool in or-

der to prevent injury. Keep the work tool under
control at all times in order to prevent injury.
When a demolition tool is used, all personnel
should maintain a minimum distance of 10 m
(33 ft).
Close all windows. Make sure that all required

guards are in place. Wear all required protec-
tive equipment. Follow the instructions in the
Operation and Maintenance Manual for the
work tool.
WARNING
Serious injury or death could occur from the demolition of pipes, vessels, tanks or other
containers that may contain gas, flammable materials or hazardous chemicals.
Do not perform any demolition work on these items until all of their contents have been removed.
Follow all regulations for the removal and disposal of these materials.
NOTICE
Using the demolition tool to level the work site or push over standing structures may damage the
machine or the demolition tool. Use appropriate equipment to do site preparation or maintenance
operations.
NOTICE
To avoid structural damage to the machine, do not break road surfaces by placing the cutting
edge of the hydraulic shear on the ground and moving the machine.
8.5 Hydraulic Hammer Operation

8.5.1 Recommended Operation
The following instructions must be followed

when operating an excavator with attachment.
NOTE：
Select attachment types that matches your
machine best.
• The types and models of attachments to be
installed on the machine may vary accord-
ing to the model of your machine.
• Consult your Sany dealer for selection of
the most suitable attachment.

8.5.2 Hydraulic breaker
Major applications:
• Crushing rocks
• Demolition
• Road construction
CZ335-1105016
Fig.8-16
8.5.3 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.8-17

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.8-18
3. If the same surface cannot be penetrated or

broken by the chisel within one minute under
continuous striking, change the struck position
and try to break it near the edge.
CZ335-1105019
Fig.8-19
4. The chisel's penetrating direction will mis-

align gradually to the working direction of
breaking hammer. It is important to align them R
by readjusting the bucket cylinder.
CZ335-1105020
Fig.8-20

5. Always press the chisel properly on the

working surface in order to prevent striking
without resistance.
CZ335-1105021
Fig.8-21
8.5.4 Restricted operations
Do not operate your 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.8-22

2. Breaking with swinging force.
CZ335-1105023
Fig.8-23
3. Moving the chisel during striking operation.
CZ335-1105024
Fig.8-24
4. Keep the chisel level or upward during strik-

ing operation.
CZ335-1105025
Fig.8-25

5. Swing the chisel when the rock has been

penetrated.
CZ335-1105026
Fig.8-26
6. Pecking operation.
CZ335-1105027
Fig.8-27
7. Raise your machine above ground by fully

extending the bucket cylinder and by the
pushing force.
CZ335-1105028
Fig.8-28

8.5.5 Hydraulic breaker greasing
Grease the breaker at specified point

correctly.
CZ335-1105029
Fig.8-29
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.8-30
CZ335-1105031
Fig.8-31

8.6 Hydraulic oil and filter - change/replace
• Hydraulic breaker application causes faster contamination of the hydraulic system and deterio-
ration 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 filter
replacement, see related items in the Maintenance section.
Hydraulic oil Filter element

Machine with Hydraulic
600 hr 100 hr
Breaker
Machine with Common Bucket 1500 or 2500 or 4000 hr 1000 hr
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 corre-
spondingly as shown in the following chart.
• The filter cartridge must be replaced after the breaker has been operated for 100 hours.
Fig.8-32
8.7 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 oth-
er problems.
8.8 Quick Coupler

8.8.1 Coupling the Work Tool
WARNING
Place the work tool or bucket in a safe position before engaging the quick coupler. Ensure that the
work tool or bucket is not carrying a load.
Serious injury or death may result from engaging the work tool or bucket when it is in an unstable
position or carrying a load.
WARNING
Inspect the quick coupler engagement before operating the machine.
Serious injury or death may result from improperly engaged coupler.
WARNING
Crush injury. Could cause serious injury or death. Always confirm that the quick coupler is
engaged onto the pins. Read the Operator's Manual.
WARNING
The buzzer will not sound when the switch is in the lock position. The position of the switch does
not confirm the coupler pins are engaged. A physical test is required by dragging the attachment
on the ground to confirm the coupler pins are engaged.
With certain work tool combinations, including quick couplers, the work tool can hit the cab or the
front of the machine. Always check for interference when first operating a new work tool.
1. Position the bucket or the work tool on a

level surface.
2. Make sure that the pins are in the bucket or

the work tool. Make sure that the pin keepers
are installed correctly.

3. In order to prevent the blocking bar from

jamming, the quick coupler must be curled
past a vertical position. Extend the stick cylin-
der and extend the bucket cylinder until the
quick coupler is curled past a vertical position.
Fig.8-33

4. Select the quick coupler mode on the moni-

tor, then active quick coupler through pressing
the icon 6. A buzzer will sound. Press and
hold the right button on the left joystick.
Fig.8-34
Fig.8-35

5. Hold the control lever for the bucket cylinder

in the EXTEND position for 5 seconds after
the right button on the left joystick has been
pressed and held. The button must remain in
the HOLD position until the work tool is at-
tached in order to prevent the blocking bar
from jamming. The buzzer will continue to
sound until the quick coupler mode is inactive
through icon 6 on the monitor.
Fig.8-36
6. Align the quick coupler with the work tool.
Fig.8-37

7. Rotate the quick coupler in order to grab

the top pin.
Fig.8-38
8. Rotate the quick coupler downward in order

to grab the bottom pin.
Fig.8-39

9. Extend the stick cylinder and extend the

bucket cylinder until the work tool is curled
past a vertical position. This must be per-
formed before you release the right button on
the left joystick.
NOTICE
Hold the bucket cylinder control lever in the
EXTEND position while the right button on Fig.8-40
the left joystick is released. Failure to do so
may result in unwanted movement of the
work tool.
10.Release the right button on the left joystick.

Hold the control lever for the bucket cylinder
in the EXTEND position for 5 seconds in order
to lock the hook.
11.Disable the quick coupler mode through

icon 6 on the monitor and buzzer will not
sound.
WARNING Fig.8-41
Crush injury. Could cause serious injury or
death. Always confirm that the quick coupler
is engaged onto the pins. Read the
Operator's Manual.
WARNING
Inspect the quick coupler engagement before
operating the machine.
Verify that the quick coupler is engaged per
the procedure in the Operation and
Maintenance Manual. Verify prior to
operating the machine, after every engine
start, and after an extended time of inactivity.
Serious injury or death may result from
improperly engaged coupler.

12.Verify that the quick coupler and the work Fig.8-42

tool are locked together.
a. Retract the bucket cylinder and place the

work tool on the ground.
b. Apply pressure to the work tool against the

ground.
c. Drag the work tool backward.
NOTICE
Back drag the work tool on the ground to
ensure the quick coupler is properly locked.
Do Not strike the work tool on the ground to
ensure the quick coupler is properly locked.
Striking the work tool on the ground will result
in damage to the coupler cylinder.
8.8.2 Uncoupling the work tool
NOTICE
Place the work tool or bucket in a safe position before disengaging the coupler. Disengaging the
coupler will release the work tool or bucket from control of the operator.
Serious injury or death may result from disengaging the work tool or bucket when it is in an
unstable position or carrying a load.
WARNING
Auxiliary hoses for work tools must be disconnected before the quick coupler is disengaged.
Pulling the work tool with the auxiliary hoses could result in damage to the host machine or the
work tool.
1. Extend the stick cylinder and extend the

bucket cylinder until the work tool is curled
past a vertical position. This must be per-
formed before you move the switch from the
LOCK position to the UNLOCK position.
Fig.8-43

2. Select the quick coupler mode on the moni-

tor, then active quick coupler through pressing
the icon 6. A buzzer will sound. Press and
hold the right button on the left joystick.
Fig.8-44
Fig.8-45

3. Hold the control lever for the bucket cylinder

in the EXTEND position for 5 seconds in order
to unlock the hook. A buzzer will continue to
sound until the quick coupler mode is inactive
through icon 6 on the monitor.
Fig.8-46
4. Move the boom and the stick until the tool

or the bucket is in the storage position. Keep
the tool close to the ground.
Fig.8-47

5. Rotate the quick coupler upward in order to

release the bottom pin.
Fig.8-48
6. Continue to rotate the quick coupler upward

in order to release the top pin and completely
release the work tool from the quick coupler.
7. Move the stick to a position that is clear of

the work tool.
8. Release the right button on the left joystick.

Disable the quick coupler mode through icon
6 on the monitor and buzzer will not sound.
Fig.8-49

8.8.3 Precautions for quick coupler

safe operation
1. Installation of the quick coupler may contrib-

ute to longer swing radius when operation 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 ex-
tended) before retracting the arm. To avoid in-
terference with the boom, never retract the
arm fully (arm cylinder fully extended) before
CZ335-1105037
retracting the bucket.
Fig.8-50
2. Overloaded operation may impair your ma-

chine and the attachment, thus reducing their
service life.
CZ335-1105038
Fig.8-51
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.8-52

4. It is very dangerous to move a heavy object

with the quick coupler. Meanwhile, the service
life of quick coupler could be reduced.
NOTE：
Consult Sany local authorized 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 respon-
sibility for any failure and accident resulted
from installation of any attachment unap- CZ335-1105040
proved by Sany.
Fig.8-53
8.9 Fueling System

8.9.1 Introduction
SANY large excavators are equipped with a

fueling system, which uses a refueling pump
assembly. The refueling pump assembly is in-
tended specially for large mobile off - theroad
machinery, 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.
8.9.2 Fueling system makeup
1. The fueling system of SANY excavators in-

cludes mainly: a refueling pump assembly (in- 1 2
cluding relevant piping and valves), a control
switch and a fuel level control relay.
2. Open the battery cover [1] and you can see

3
the control switch [2] and the refueling pump
[3].
CZ335S-1105001
Fig.8-54

3. The main structure of the refueling pump [3]

is shown in the right illustration.
Technical specifications:
Pump flow rate 46 L/min
Rated voltage 24V
Rate speed 2800 rpm
Coupling thread 3/4’G
Weight 3.5kg
CZ335S-1105002
Packing dimension 215×120×160mm
Fig.8-55
8.10 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 machine.
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.
Capacity Outer width Weight Std. arm Short arm

Bucket Type
m³ (cu.yd) mm (ft in) Kg (lb) 3.2 m (10'6") 2.9 m (9'6")
Rockwork 1.7 1610 1384
◇ ◇
bucket (2.22) (4'10") (3051)
Earthwork 1.8 1688 1423
○ ◇
bucket (2.35) (5'1") (3137)
○ — Digging or loading materials of specific gravity ≤1.5 t/m³
◇ — Digging or loading materials of specific gravity ≤1.8 t/m³

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Quality Changes the World

Operation and Maintenance Manual

Safety, Operation and Maintenance Manual

Operation & Maintenance Manual-May-2020 1

2 Operation & Maintenance Manual-May-2020

Service hotline: 4008 28 2318

Operation & Maintenance Manual-May-2020 1

2 Operation & Maintenance Manual-May-2020

Sany assumes no responsibility for consequences caused by the following factors:

• Offer quality excavators along with correct information.

Obligations of owners or authorized persons

Operation & Maintenance Manual-May-2020 1

Obligations of all operating personnel

2 Operation & Maintenance Manual-May-2020

Operation & Maintenance Manual-May-2020 I

2.2.1 foreword .........................................................................................................................2-6

II Operation & Maintenance Manual-May-2020

2.3.24 Operation on loose ground .................................................................................... 2-35

Operation & Maintenance Manual-May-2020 III

2.5.3 Prepare the machine................................................................................................. 2-62

IV Operation & Maintenance Manual-May-2020

3.4 Control Levers and Pedals ............................................................................................... 3-46

Operation & Maintenance Manual-May-2020 V

4.1.2.7 Electric wires - check ..........................................................................................4-11

VI Operation & Maintenance Manual-May-2020

4.10.1 foreword.................................................................................................................... 4-40

Operation & Maintenance Manual-May-2020 VII

5.2.5.1 foreword............................................................................................................... 5-10

VIII Operation & Maintenance Manual-May-2020

5.8.8.5 Primary fuel filter element - replace................................................................. 5-51

Operation & Maintenance Manual-May-2020 IX

5.8.13 Every 8000 service hours....................................................................................... 5-91

X Operation & Maintenance Manual-May-2020

Operation & Maintenance Manual-May-2020 XI

XII Operation & Maintenance Manual-May-2020

Operation & Maintenance Manual-May-2020 1-1

1.3.4.8 Regulatory Compliance ................................................................................... 1-13

1-2 Operation & Maintenance Manual-May-2020

1-3 Operation & Maintenance Manual-May-2020

1-4 Operation & Maintenance Manual-May-2020

This operator’s manual provides safety, oper-

Items addressed in this manual are designed

● Understand the structure and performance

● Increase equipment efficiency during

● Reduce maintenance costs.

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

Operation & Maintenance Manual-May-2020 1-5

1.2 Your Documentation Package

The documentation for this machine includes the following items:

1.2.2 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 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

1.2.3 Recommendations on using the documentation

● To ensure that the documentation is always complete and up to date:

1-6 Operation & Maintenance Manual-May-2020

1.2.4 Documentation storage

1.2.5 Manual organization