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SANY Crawler Hydraulic Excavator SY115C9, SY135C8, SY135C9, SY155H. Safety, Operation and Manitenance Manual - page 10

Troubleshooting

4.

Change hydraulic oil when the temperature

is high.

When hydraulic oil or other oil is warm, it

flows easily. In addition, the sludge can

also be drained out easily from the circuit

together with the oil, so it is best to change

the oil when it is still warm. When changing

the oil, as much as possible of the old hy-

draulic oil must be drained out. (Drain the

oil from the hydraulic tank; also drain the

oil from the filter and from the drain plug in

the circuit.) If any old oil is left, the contam-

inants 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

Flushing oil

the equipment, or changing the oil, use

flushing oil to remove the contaminants,

sludge, and old oil from the hydraulic cir-

cuit. Normally, flushing is carried out twice:

primary flushing is carried out with flushing

oil, and secondary flushing is carried out

with the specified hydraulic oil.

ZX215-1000026

Fig. 6-3

6.

Cleaning operations

After repairing the hydraulic equipment

(pump, control valve, etc.) or when run-

ning the machine, carry out oil cleaning to

remove the sludge or contaminants in the

hydraulic oil circuit. The oil cleaning equip-

ment is used to remove the ultra fine (about

3μ) particles that the filter built into the hy-

draulic equipment cannot remove, so it is

an extremely effective device.

ZX215-1000027

Fig. 6-4

6-11

Troubleshooting

6.2 Pseudo Failures

Note that the following failures are pseudo

ones:

● The arm speed may drop suddenly when

retracting the arm with the work equipment

lowering unloaded and the arm in a nearly

vertical position.

CZ335-1103213

Fig. 6-5

● When the bucket tips are nearly parallel

to the ground, the bucket speed may drop

suddenly.

CZ335-1103214

Fig. 6-6

● The brake valve produces noise when

starting or stopping swinging operation.

● The travel motor produces noise when the

machine travels downhill at low speed.

6-12

Troubleshooting

6.3 Towing the Machine

WARNING

Towing the machine improperly or using

wire cables beyond the specification could

lead to serious injury or death.

● Make sure that the wire cables used for

A

towing the machine are strong enough,

which may otherwise result in acci-

B

dents.

● While towing the machine, do not use

wire cables with broken wires (A), re-

C

duced diameter (B) or knot (C) in order

to prevent rupture of the wire cables.

CZ335-1103215

● Always wear protective gloves when

handling wire cables.

Fig.

6-7

● Never tow the machine on a slope.

● Never stand between the towing ma-

chine and the towed machine when

performing towing operation.

● Operate the machine slowly and avoid

imposing sudden load on wire cable.

Note:

The towing operation must be performed with-

in the maximum towing capacity.

6-13

Troubleshooting

Ɣ

If the machine is trapped in mud and can-

not move out of the mud with its own force,

or the towing force of excavator is occu-

pied by heavy object, wire cables can be

used as shown in the right illustration.

Ɣ

Place wood blocks or other protective

materials between where the wire cable

contacts the machine in order to prevent

CZ335-1103216

friction between the wire cable and the ma-

Fig. 6-8

chine.

●

Keep the wire cable parallel to the ground

and align its direction with that of the track

frame.

●

Move at a speed of 1Km/h when towing

the machine. Tow the machine to a place

suitable for repair. Never tow the machine

over a long distance.

●

Towing of the machine is only allowed in

case of emergency.

CZ335-1103217

Fig. 6-9

6-14

Troubleshooting

6.4 Towing Hook for Light Loads

WARNING

● Towing the machine improperly could

cause severe accidents. The following

items must be observed when towing

the machine.

● Shackle must be used.

● Keep the wire cable parallel to the

ground and align its direction with that

of the track frame.

● Move the machine slowly and avoid im-

posing sudden load on wire cable.

The track frame has an eye, which can be

hooked when towing a light object.

CZ335-1103218

Fig. 6-10

6.5 Severe Operating Conditions

● When performing excavation in water, if the

installation pins of work tool go below wa-

ter surface, it is necessary to add grease

to the pins before each operation.

● For heavy-loaded operation and deep ex-

cavation, it is necessary to add grease to

the installation pins of the work tool before

each operation. Cycle the operation of the

boom, stick and bucket for several times

before refilling the grease.

6-15

Troubleshooting

6.6 Engine Failures

6.6.1 Engine troubleshooting table

Check the engine according to the following table if any failure occurs to it. Contact your Sany

distributor to repair the engine.

Failure

Causes

Remedy

●

Recharge/replace the bat-

●

Battery low

tery.

●

Engine start switch internal failure

●

Replace

●

Pilot switch failure

●

Repair/replace

●

Start motor failure

●

Repair/replace

Unable to start the en-

●

Open circuit of wire harness

●

Check/repair

gine

●

Fuse failure (F1)

●

Replace

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Alternator internal failure

●

Repair/replace

●

Start relay failure

●

Replace

●

Brake failure

●

Repair/replace

●

Open circuit of wire harness

●

Check/repair

●

Sensor internal failure

●

Replace

Rough engine speed

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Sensor internal failure

●

Replace

Unable to power off the

●

Battery relay failure

●

Replace

machine

●

Breakdown of surge diode

●

Replace

●

Boom-up signal failure

●

Check/repair

●

Boom-down signal failure

●

Check/repair

●

Arm-in signal failure

●

Check/repair

●

Arm-out signal failure

●

Check/repair

●

Bucket-dig signal failure

●

Check/repair

Auto idle fails.

●

Bucket-dump signal failure

●

Check/repair

●

Swing signal failure

●

Check/repair

●

Travel signal failure

●

Check/repair

●

Attachment signal failure

●

Check/repair

●

Controller failure

●

Replace

●

Preheat fuse failure

●

Replace

●

Preheat relay failure

●

Replace

Preheating function fails.

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Preheat controller failure

●

Replace

●

Hydraulic lockout control failure

●

Repair/replace

All devices fail.

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Failure of internal coil of pilot lockout valve

●

Replace

●

Sensor failure

●

Replace

●

Short circuit of harness (grounding failure)

●

Check/repair

Boom slow and weak

●

Open circuit of harness

●

Check/repair

●

Controller failure

●

Replace

6-16

Troubleshooting

Failure

Causes

Remedy

●

Sensor failure

●

Replace

●

Short circuit of harness (grounding failure)

●

Check/repair

Arm slow and weak

●

Open circuit of harness

●

Check/repair

●

Controller failure

●

Replace

●

Sensor failure

●

Replace

●

Short circuit of harness (grounding failure)

●

Check/repair

Bucket slow and weak

●

Open circuit of harness

●

Check/repair

●

Bucket confluence solenoid valve failure

●

Replace

●

Controller failure

●

Replace

●

Sensor failure

●

Replace

●

Short circuit of harness (grounding failure)

●

Check/repair

Travel slow and weak

●

Open circuit of harness

●

Check/repair

●

Controller failure

●

Replace

●

Fuse failure

●

Replace

●

Open circuit of wire

●

Check/repair

Monitor black-out

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Monitor failure

●

Replace

●

Resistor failure

●

Replace

●

Open circuit of wire

●

Check/repair

Monitor displays nothing.

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Monitor or controller failure

●

Replace

●

Dual travel speed solenoid valve failure

●

Replace

Dual-travel speed failure

●

Open circuit of wire

●

Check/repair

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Coolant temperature sensor failure

●

Replace

Engine coolant tempera-

●

Open circuit of wire

●

Check/repair

ture reading incorrect

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Wire short-circuited with 24V

●

Check/repair

●

Fuel level sensor failure

●

Replace

Fuel level reading incor-

●

Open circuit of wire

●

Check/repair

rect

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Wire short-circuited with 24V

●

Check/repair

●

Wiper motor internal failure

●

Repair/replace

Wiper failure

●

Open circuit of wire

●

Check/repair

●

Short circuit of wire (grounding failure)

●

Check/repair

●

5V power supply failure

●

Repair/replace

Arm-in pilot pressure

●

Open circuit of signal line

●

Check/repair

reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

●

5V power supply failure

●

Repair/replace

Arm-out pilot pressure

●

Open circuit of signal line

●

Check/repair

reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

6-17

Troubleshooting

Failure

Causes

Remedy

●

5V power supply failure

●

Repair/replace

Boom-up pilot pressure

●

Open circuit of signal line

●

Check/repair

reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

●

5V power supply failure

●

Repair/replace

Boom-down pilot pres-

●

Open circuit of signal line

●

Check/repair

sure reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

●

5V power supply failure

●

Repair/replace

Bucket-dig pilot pressure

●

Open circuit of signal line

●

Check/repair

reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

●

5V power supply failure

●

Repair/replace

Bucket-dump pilot pres-

●

Open circuit of signal line

●

Check/repair

sure reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

●

5V power supply failure

●

Repair/replace

Swing pilot pressure

●

Open circuit of signal line

●

Check/repair

reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

●

5V power supply failure

●

Repair/replace

Travel pilot pressure

●

Open circuit of signal line

●

Check/repair

reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

Table 6-2

6-18

Troubleshooting

Always prepare your machine as required and

lock out/tag out your machine before proceed-

ing. See “Preparing the machine” on page

1

2-58 and “Lock-out and tag-out” on page

2-60.

1. Check radiator hoses for coolant leak.

2. Check V-belt for rupture. Check the belt

tension.

CZ215-1105003

3. Check coolant level. Refill coolant if neces-

sary.

Fig. 6-11

● Remove the radiator cap (1) and refill

coolant to the opening. Tighten the cap

properly.

● Open the reservoir (2) and refill coolant

to the FULL mark. Tighten the cap prop-

erly.

FULL

4. Check the front of radiator for any contami-

LOW

nants.

2

5. If your machine has coolant leak or often

CZ135B-1103022

encounters higher coolant temperature, the

cooling system has a problem.

Fig. 6-12

6.6.3 Engine oil pressure low

NOTICE

When oil pressure low alert indicator is on,

shut down the engine immediately. Dam-

age could occur to the engine if leave it

running.

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 gauge shows a val-

ue lower than the one given in the following ta-

6-20

Troubleshooting

ble, the low oil pressure alert indicator and oil

filter alert indicator will be on at the same time,

altering that oil pressure is abnormal. Stop

operating your machine, shut down the engine

immediately, and proceed as the following.

Always prepare your machine as required and

lock out/tag out your machine before proceed-

ing. See “Preparing the machine” on page

2-58 and “Lock-out and tag-out” on page

2-60.

1. Check for oil leak.

1

2. Check engine oil level. Refill oil when

required.

● Remove the dipstick (1). Wipe off the oil

on dipstick(1) with cloth.

● Fully insert the dipstick into oil and then

slowly pull it out.

● If oil level between the marks L and H,

CZ215-1105004

the amount of oil is good.

Fig. 6-13

● If oil level is low, refill it immediately. If

engine oil is contaminated, change the

oil immediately.

● Replace the dipstick(1) after checking.

L H

3. If engine oil level is normal but abnormal

pressure of engine oil is altered, contact

your Sany distributor in time to solve the

problem.

CZ335-1104059

Fig. 6-14

6-21

Troubleshooting

6.6.4 When fuel exhausts

When fuel exhausts, it is necessary to refuel

the engine and purge air from the fuel system

before restarting it.

WARNING

● Never use a lighter, smoke, or use other

fire sources when purging the air. A fire

source can cause fire.

● Completely remove engine oil or fuel

splashed onto the exhaust pipe and

other places. These oil and fuel can

cause fire or slipping accident.

● The space for air-purging operation is

limited. Take care not to be cut by the

edges.

1. Turn counterclockwise the handle (1) of

manual pump to release it.

1

CZ215-1105005

Fig. 6-15

2. Loosen air vent plug (2) on fuel filter and

2

cover it with cloth.

CZ215-1105006

Fig. 6-16

6-22

Troubleshooting

3. Repeatedly push the pump to transfer fuel

until no foam is seen at the vent.

CZ215-1105007

Fig. 6-17

4. Retighten plug (2) when you are sure no

foam is seen.

2

Plug tightening torque：

9.8±2.0N·m {1±0.2 kgf·m}

CZ215-1105009

Fig. 6-18

5. Continue to operate the manual pump until

heavy resistance is felt.

Resistance of pump operation may not rise

when fuel temperature is low. It is neces-

sary to operate the pump continuously and

repeatedly.

CZ215-1105008

Fig. 6-19

6. After purging the air, completely remove

WARNING

splashed fuel before starting the engine.

Make sure no fuel leaks from filter and its

7. Make sure no fuel leaks.

housing. Fuel leak could cause fire.

6-23

Troubleshooting

6.7 Failures of the Electrical System

6.7.1 Electrical system troubleshooting table

Trouble-shoot the electrical system according to the following tables. Contact your Sany distribu-

tor solve the problem.

Failure

Causes

Remedy

●

Recharge/replace the bat-

●

Battery low

tery.

●

Engine start switch internal failure

●

Replace

●

Pilot switch failure

●

Repair/replace

●

Start motor failure

●

Repair/replace

Unable to start the en-

●

Open circuit of wire harness

●

Check/repair

gine

●

Fuse failure (F1)

●

Replace

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Alternator internal failure

●

Repair/replace

●

Start relay failure

●

Replace

●

Brake failure

●

Repair/replace

●

Open circuit of wire harness

●

Check/repair

●

Sensor internal failure

●

Replace

Rough engine speed

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Sensor internal failure

●

Replace

Unable to power off the

●

Battery relay failure

●

Replace

machine

●

Breakdown of surge diode

●

Replace

●

Boom-up signal failure

●

Check/repair

●

Boom-down signal failure

●

Check/repair

●

Arm-in signal failure

●

Check/repair

●

Arm-out signal failure

●

Check/repair

●

Bucket-dig signal failure

●

Check/repair

Auto idle fails.

●

Bucket-dump signal failure

●

Check/repair

●

Swing signal failure

●

Check/repair

●

Travel signal failure

●

Check/repair

●

Attachment signal failure

●

Check/repair

●

Controller failure

●

Replace

●

Preheat fuse failure

●

Replace

●

Preheat relay failure

●

Replace

Preheating function fails.

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Preheat controller failure

●

Replace

●

Hydraulic lockout control failure

●

Repair/replace

All devices fail.

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Failure of internal coil of pilot lockout valve

●

Replace

●

Sensor failure

●

Replace

●

Short circuit of harness (grounding failure)

●

Check/repair

Boom slow and weak

●

Open circuit of harness

●

Check/repair

●

Controller failure

●

Replace

6-25

Troubleshooting

Failure

Causes

Remedy

●

Sensor failure

●

Replace

●

Short circuit of harness (grounding failure)

●

Check/repair

Arm slow and weak

●

Open circuit of harness

●

Check/repair

●

Controller failure

●

Replace

●

Sensor failure

●

Replace

●

Short circuit of harness (grounding failure)

●

Check/repair

Bucket slow and weak

●

Open circuit of harness

●

Check/repair

●

Bucket confluence solenoid valve failure

●

Replace

●

Controller failure

●

Replace

●

Sensor failure

●

Replace

●

Short circuit of harness (grounding failure)

●

Check/repair

Travel slow and weak

●

Open circuit of harness

●

Check/repair

●

Controller failure

●

Replace

●

Fuse failure

●

Replace

●

Open circuit of wire

●

Check/repair

Monitor black-out

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Monitor failure

●

Replace

●

Resistor failure

●

Replace

●

Open circuit of wire

●

Check/repair

Monitor displays nothing.

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Monitor or controller failure

●

Replace

●

Dual travel speed solenoid valve failure

●

Replace

Dual-travel speed failure

●

Open circuit of wire

●

Check/repair

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Coolant temperature sensor failure

●

Replace

Engine coolant tempera-

●

Open circuit of wire

●

Check/repair

ture reading incorrect

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Wire short-circuited with 24V

●

Check/repair

●

Fuel level sensor failure

●

Replace

Fuel level reading incor-

●

Open circuit of wire

●

Check/repair

rect

●

Short circuit of wire (grounding failure)

●

Check/repair

●

Wire short-circuited with 24V

●

Check/repair

●

Wiper motor internal failure

●

Repair/replace

Wiper failure

●

Open circuit of wire

●

Check/repair

●

Short circuit of wire (grounding failure)

●

Check/repair

●

5V power supply failure

●

Repair/replace

Arm-in pilot pressure

●

Open circuit of signal line

●

Check/repair

reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

●

5V power supply failure

●

Repair/replace

Arm-out pilot pressure

●

Open circuit of signal line

●

Check/repair

reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

6-26

Troubleshooting

Failure

Causes

Remedy

●

5V power supply failure

●

Repair/replace

Boom-up pilot pressure

●

Open circuit of signal line

●

Check/repair

reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

●

5V power supply failure

●

Repair/replace

Boom-down pilot pres-

●

Open circuit of signal line

●

Check/repair

sure reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

●

5V power supply failure

●

Repair/replace

Bucket-dig pilot pressure

●

Open circuit of signal line

●

Check/repair

reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

●

5V power supply failure

●

Repair/replace

Bucket-dump pilot pres-

●

Open circuit of signal line

●

Check/repair

sure reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

●

5V power supply failure

●

Repair/replace

Swing pilot pressure

●

Open circuit of signal line

●

Check/repair

reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

●

5V power supply failure

●

Repair/replace

Travel pilot pressure

●

Open circuit of signal line

●

Check/repair

reading incorrect

●

Short circuit of signal line

●

Check/repair

●

Sensor failure

●

Replace

Table 6-3

6-27

Troubleshooting

6.7.2 Failure codes

The failure code(1) displayed on the monitor

can be used to make failure analysis.

Sany Hydraulic Excavator

S

5

C

H

E

F

1

2010/07/27

36 h 25 m

12

15:32:48

S

Lo

CZ215-1103058

Fig. 6-20

Failure

Symptom

Alarm Trigger Condition

Code

Oil pressure lower than 200 and engine speed higher than

3

Engine oil pressure low

800 for 15s

4

Fuel level low

Fuel level lower than 10% for 10s

Coolant temperature higher than 105°C or coolant tempera-

5

Coolant temperature high

ture over-high pressure switch off

6

Air cleaner plugged

Air cleaner plugging pressure switch off

Engine speed lower than 800 rpm but higher than 400 rpm

7

Engine speed low

for 3s

8

Engine speed high

Engine speed higher than 2500 rpm

10

Hydraulic oil temperature high

Hydraulic oil temperature higher than 90°C for 10s

Motor feedback voltage lower than 0.25V or higher than 4.75V

12

Motor working range irregular

for 3s

Front pump pressure sensor

Front pump pressure collecting volt lower than 0.25V or

20

abnormal

higher than 4.75V for 3s

Rear pump pressure sensor

Rear pump pressure collecting volt lower than 0.25V or high-

21

abnormal

er than 4.75V for 3s

Bucket-dig pilot pressure sen-

Bucket-dig pilot pressure collecting volt lower than 0.25V or

22

sor abnormal

higher than 4.75V for 3s

Bucket-dump pilot pressure

Bucket-dig pilot pressure collecting volt lower than 0.25V or

23

sensor abnormal

higher than 4.75V for 3s

Arm-in pilot pressure sensor

Arm-in pilot pressure collecting volt lower than 0.25 and

24

abnormal

higher than 4.75 for 3s

Arm-out pilot pressure sensor

Arm-out pilot pressure collecting volt lower than 0.25 and

25

abnormal

higher than 4.75 for 3s

6-28

Troubleshooting

Failure

Symptom

Alarm Trigger Condition

Code

Boom-up pilot pressure sensor

Boom-up pilot pressure collecting volt lower than 0.25 and

26

abnormal

higher than 4.75 for 3s

Boom-down pilot pressure sen-

Boom-down pilot pressure collecting volt lower than 0.25 and

27

sor abnormal

higher than 4.75 for 3s

Left travel pilot pressure sensor

Left travel pilot pressure collecting volt lower than 0.25 and

28

abnormal

higher than 4.75 for 3s

Right travel pilot pressure sen-

Right travel pilot pressure collecting volt lower than 0.25 and

29

sor abnormal

higher than 4.75 for 3s

Swing pilot pressure sensor

Swing pilot pressure collecting volt lower than 0.25 and high-

30

abnormal

er than 4.75 for 3s

Front pump proportional valve

Front pump proportional valve current higher than 1300mA

34

overcurrent

for 3s

Rear pump proportional valve

Rear pump proportional valve current higher than 1300mA for

35

overcurrent

3s

Front pump proportional valve

Front pump proportional valve current lower than 200mA for

36

undercurrent

3s and controller PWM output higher than 10V

Rear pump proportional valve

Rear pump proportional valve current lower than 200mA for

37

undercurrent

3s and controller PWM output higher than 10V

Front pump proportional valve feedback current lower than

38

Front pump proportional valve

150mA or higher than 1350mA for 3s and controller PWM

duty output higher than 10V

Rear pump proportional valve feedback current lower than

39

Rear pump proportional valve

150mA or higher than 1350mA for 3s and controller PWM

duty output higher than 10V

Hydraulic oil temperature sen-

Hydraulic oil temperature collecting volt lower than 0.25V or

40

sor abnormal

higher than 4.75V for 3s

Coolant temperature collecting resistance lower than 10ȍ or

41

Coolant sensor abnormal

higher than 120 ȍ for 3s after 30 minutes since engine start-

ing

Fuel level collecting resistance lower than 10ȍ or higher than

42

Fuel level sensor abnormal

120 ȍ for 3s

43

Speed sensor abnormal

Speed collecting frequency lower than 100 for 3s under load

Fuel control dial collecting volt lower than 0.25V or higher

44

Fuel control dial abnormal

than 4.75V for 3s

CAN communication monitoring component overtime or reset

45

CAN bus abnormal

characters changed for 3s

Table 6-4

6-29

Troubleshooting

6.8 Battery

WARNING

●

It is dangerous to charge a battery

while it is installed on the machine. Re-

move the battery before charging it.

2

1

●

Stop the engine and turn the start

switch key to OFF position before

checking or handling the battery.

●

Wear goggles and rubber gloves when

handling the battery.

●

Disconnect first the grounding cable

(negative terminal (-)) before removing

the battery. Connect first the positive

1

terminal (+) while installing the bat-

2

tery. Be especially careful with your

tools, which may produce sparks when

touching the positive terminals and the

chassis.

CZ335-1103219

●

A loose terminal can result in improper

contact, which may cause sparks and

Fig. 6-21

explosion.

●

Check that which terminal is positive

(+) and which one is negative (-) when

removing or installing the terminals.

6.8.1 Battery removal and installation

● Disconnect the grounding cable (generally

the one in connection with the negative ter-

minal (-)) before removing the battery.

● Sparks can occur if your tool touches the

positive terminal and the chassis.

● Secure the battery with clamping plates

when changing the battery.

6-30

Troubleshooting

6.8.3 Jump-starting the engine

WARNING

●

Never let the positive terminal (+) con-

tact with the negative terminal (-) when

connecting the cable.

●

Keep a normal machine away from

the faulty machine in order to prevent

sparks around the battery from burning

the hydrogen released from the battery.

●

Avoid mistakes in connection of the

CZ335-1103221

jumper cable. Its final connection with

Fig. 6-23

upper structure of the machine can

produce sparks. In this case, the bat-

tery shall be connected to a location

that is far enough from the battery. (But

the work tool shall be excluded as the

work tool is not a good conductor.)

●

When removing the jumper cables, pay

extra attention to the cables, whose

clips shall not contact with each other

or with the chassis.

Note:

● The start system of the machine is sup-

plied with a 24V power source. Two 12V

batteries are connected serially to supply

power to a normally-operating machine.

● The sizes of jumper cables and clips shall

match the size of battery.

● Generally, the batteries of the machine

shall have the same capacity with the en-

gine to be started.

● Check the cables and clips for damage or

corrosion.

● Make sure that the cables and clips are

connected securely.

● Check both machines whether their lock-

out controls and brake levers are in the

6-32

Troubleshooting

"LOCKED" position.

● Check the control levers whether they are

in the neutral position.

6.8.3.1 Connecting the jumper cables

Turn the start switches of the normal machine

and the faulty machine to the 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 machine.

2. Connect the clip on the other end of jumper

A

cable (A) to the positive terminal (+) of bat-

2

1

tery (D) of the normal machine.

3

3. Connect the clip of jumper cable (B) to the

negative terminal of battery (D) of the nor-

D

C

mal machine.

4

B

E

CZ335-1103222

4. Connect the clip on the other end of jumper

cable (B) to the swivel frame (E) of the faulty

Fig.

6-24

machine.

6-33

Troubleshooting

6.8.3.2 Starting the engine

WARNING

Check the lockout control, which must

be in the "LOCKED" position regardless

of that the machine is operating normally

or has trouble. Check all control levers,

which shall be in the "retaining" or neutral

position.

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.

6.8.3.3 Disconnecting the jumper cables

After the engine is started, disconnect the

jumper cables in steps reversed to their con-

nection.

1. Disconnect the clip of the jumper cable (B)

A

from the swivel frame (E) of the faulty ma-

3

4

chine.

2

2. Disconnect the clip of the jumper cable (B)

from the negative terminal (-) of battery (D)

D

C

of the normal machine.

1

B

E

3. Disconnect the clip of jumper cable (A) from

CZ335-1103223

the positive terminal (+) of battery (D) of the

Fig. 6-25

normal machine.

4. Disconnect the clip of jumper cable (A) from

the positive terminal (+) of battery (C) of the

faulty machine.

6-34

Troubleshooting

6.9 Failures of the Hydraulic System

● Trouble-shoot the hydraulic system according to the following tables. Contact your Sany dis-

tributor solve the problem.

● Set the working mode to S and the fuel control dial to position 10 before troubleshooting

Failure

Causes

Remedy

●

Bad adjustment or failure of main relief valve

●

Replace

●

Pilot relief valve failure

●

Replace

Work equipment moving

●

Regulator failure

●

Repair/replace

slowly, or travel and swing

●

Plunger pump failure

●

Check/repair

speed slow

●

Failure of pilot proportional solenoid valve of

●

Repair/replace

right joystick

●

Pilot safety valve failure

●

Repair/replace

Work equipment, final drive

●

Pilot pump relief valve failure

●

Replace

or swing drive not function-

●

Hydraulic pump failure

●

Check/repair

ing

●

Coupling failure

●

Check/repair

●

Hydraulic oil level low

●

Refill hydraulic oil

●

Bad hydraulic oil

●

Use suitable hyd oil

Abnormal noise in hydraulic

●

Hydraulic tank cap vent plugged

●

Clean/replace

pump

●

Hydraulic tank filter screen plugged

●

Clean/replace

●

Plunger pump failure

●

Check/repair

●

Sensor failure

●

Replace

Auto idle not functioning

●

Pilot valve failure

●

Replace

●

Controller failure

●

Repair/replace

●

Right pilot valve (boom circuit) failure

●

Check/repair

●

Pressure sensor failure

●

Replace

●

Boom control valve (spool) failure

●

Repair/replace

Boom speed slow

●

Boom control valve (retaining valve) failure

●

Repair/replace

●

Boom control valve (Safety valve and feed

●

Repair/replace

valve) seal failure

●

●

Boom cylinder failure

●

Check/repair

●

Left pilot valve (arm circuit) failure

●

Check/repair

●

Pressure sensor failure

●

Replace

●

Arm control valve (spool) failure

●

Repair/replace

Arm speed slow

●

Arm control valve (regeneration valve) failure

●

Repair/replace

●

Arm control valve (Safety valve and feed valve)

●

Repair/replace

or seal failure

●

●

Arm cylinder failure

●

Check/repair

●

Check/repair

●

Right pilot valve (bucket circuit) failure

●

Replace

●

Pressure sensor failure

●

Repair/replace

●

Bucket control valve (spool) failure

●

Repair/replace

Bucket speed slow

●

Bucket control valve (regeneration valve) failure

●

●

Bucket control valve (Safety valve and feed

●

Repair/replace

valve) or seal failure

●

●

Bucket cylinder failure

●

Check/repair

6-35

Troubleshooting

Failure

Causes

Remedy

●

Pilot valve failure

●

Check/repair

One cylinder of work equip-

●

Pressure sensor failure

●

Replace

ment not working

●

Work equipment control valve (spool) failure

●

Repair/replace

●

Work equipment cylinder failure

●

Repair/replace

●

Retaining valve (of boom or arm) failure

●

Repair/replace

Work equipment cylinder

●

Work equipment control valve (safety valve and

●

Repair/replace

drifting excessively

feed valve) seal failure

●

●

Work equipment valve spool failure

●

Repair/replace

●

Arm regeneration valve failure

●

Repair/replace

Work equipment sluggish

●

Control valve (safety valve and feed valve) fail-

●

Repair/replace

ure

Other work equipment

moves when single cylinder

●

Control valve seal failure

●

Replace

is in relief.

Travel speed drops remark-

ably during swing or travel

●

Straight travel valve failure

●

Repair/replace

operation.

●

Travel pilot valve failure

●

Repair/replace

●

Pilot relief valve failure

●

Replace

●

Regulator failure

●

Repair/replace

Machine runs out during

●

Proportional solenoid valve sluggish

●

Repair/replace

travel

●

Travel valve spool sluggish

●

Repair/replace

●

Central swivel joint sluggish

●

Repair/replace

●

Travel motor failure

●

Repair/replace

●

Travel pilot pressure sensor failure

●

Replace

●

Travel pilot valve failure

●

Repair/replace

●

Pilot relief valve failure

●

Replace

●

Sensor failure

●

Replace

Travel speed slow

●

Travel control valve (spool) failure

●

Repair/replace

●

Travel control valve (feed valve) failure

●

Repair/replace

●

Travel motor failure

●

Check/repair

●

Travel pilot valve failure

●

Repair/replace

●

Travel pilot pressure sensor failure

●

Replace

Machine steering difficult or

●

Travel control valve (spool) failure

●

Repair/replace

power insufficient

●

Travel control valve (feed) failure

●

Repair/replace

●

Travel motor (safety valve) failure

●

Repair/replace

●

Travel motor (check valve) failure

●

Repair/replace

●

High/low travel speed shift valve failure

●

Repair/replace

Unable to shift travel speed

●

Travel motor failure

●

Check/repair

●

Travel control valve (feed valve) seat failure

●

Repair/replace

●

Travel motor (safety valve) seat failure

●

Repair/replace

Travel fails (on one side)

●

Travel motor (feed valve) seat failure

●

Repair/replace

●

Travel motor failure

●

Check/repair

●

Pilot pressure sensor failure

●

Replace

6-36

Troubleshooting

Failure

Causes

Remedy

●

Swing motor (parking brake) failure

●

Check/repair

●

Bad adjustment or failure of swing motor (safety

●

Adjust/replace

In both directions

valve)

●

●

Swing motor failure

●

Check/repair

●

Swing drive failure

●

Check/repair

●

Pilot valve failure

●

Repair/replace

In one direction

●

Swing control valve (spool) failure

●

Repair/replace

●

Swing motor (feed valve) seal failure

●

Replace

●

Swing motor (parking brake) failure

●

Check/repair

●

Bad adjustment or failure of swing motor (safety

●

Adjust/replace

valve)

●

Acceleration perfor-

●

Swing motor failure

●

Check/repair

mance bad

●

Brake control line blocked

●

Remove obstruction

or replace the pipe-

line.

●

Pilot valve failure

●

Repair/replace

Bad acceleration

●

Swing motor (pressure compensation valve) fail-

●

Repair/replace

performance on one

ure

●

side or swing speed

●

Swing motor (feed valve) seal failure

●

Replace

slow

●

Leak on one side the shuttle valve of swing pilot

●

Repair/replace

pressure sensor

●

Bad adjustment or failure of swing motor (safety

●

Adjust/replace

In both directions

valve)

●

●

Swing motor failure

●

Check/repair

● Pilot valve failure

● Repair/replace

In one direction

● Swing control valve (spool) failure

● Repair/replace

● Swing motor (feed valve) seal failure

● Replace

● Swing pilot valve failure

● Repair/replace

Too much jerk in swing

● Swing anti-jerk valve failure

● Repair/replace

stoppage

● Swing relief valve failure

● Repair/replace

● Back pressure valve failure

● Repair/replace

High abnormal noise in

● Swing motor (safety valve) failure

● Repair/replace

swing stoppage

● Swing motor (feed valve) failure

● Repair/replace

● Swing system mechanical failure

● Check/repair

6-37

Troubleshooting

Failure

Causes

Remedy

When swing brake

● Swing brake control line failure

● Check/repair

engaged

● Swing motor (parking brake) failure

● Repair/replace

● Swing control valve (spool) failure

● Repair/replace

When swing brake

● Swing motor (relief valve) failure

● Repair/replace

disengaged

● Swing motor (feed valve) failure

● Repair/replace

Table 6-5

6-38

Troubleshooting

6.10 Other Common Failures

Failure

Causes

Remedy

● Loose fastener

● Check and retighten.

Structure member

● Bigger clearance between arm and buck-

● Reduce the clearance to a value that

noise loud

et end faces due to wear

is smaller than 1mm.

● Spring deformed and weak due to re-

Bucket tip falls off dur-

peated use of bucket tip pin

● Replace bucket tip pin

ing operation.

● Bucket tip pin not matching the adaptor

● Loose track

● Tighten the track

Track kinks.

● Traveling at high speed on rough road in

● Travel slowly on rough road in the

the direction of sprocket

direction of idler.

● Improper electrical connection or con-

nector contact

Fan not working

● Air flow control switch, relay or tempera-

● Repair/replace.

ture control switch damaged

● Fuse exploded or battery voltage low

● Air intake side blocked

Fan running but pro-

● Evaporator or condenser fin plugged,

● Clean/replace.

ducing less air flow

giving ineffective heat conduction

● Fan vane seized or damaged

● Compressor clutch not picking up due to

● Repair

wire break or defective contact of electri-

cal circuit

● Loose compressor belt

Compressor not work-

● Adjust the tension of compressor

ing or working with diffi-

belt

culty

●Wire break or failure of compressor

● Replace clutch coil

clutch coil

● Insufficient or excessive refrigerant

● Refill/drain the refrigerant to a suit-

able level

● Refrigerant leaks.

● Eliminate the leaking point.

Refrigerant insufficient

● Insufficient refilling

● Refill suitable amount of refrigerant.

High/low pressure

Ambient temperature：30 ～ 50℃

reading in normal op-

High pressure gauge: 1.47 ～ 1.67MPa（15 ～ 17kgf/cm2）

eration

Low pressure gauge:

0.13 ～ 0.20MPa（1.4 ～ 2.11kgf/cm2）

● Expansion valve opening excessively.

● Replace expansion valve.

Low pressure

● Defective contact of expansion valve

● Install thermo-bulb correctly.

tube surface

thermo-bulb

frosted

● Excessive refrigerant in the system

● Drain refrigerant to the specified

level.

6-39

Troubleshooting

Failure

Causes

Remedy

Both high and

low pressure

gauge read-

● Refill refrigerant to the specified

● Refrigerant insufficient

ings lower

level.

the standard

value.

Low pressure

● Low pressure hose blocked; expansion

● Repair the system. Replace reser-

gauge could

valve blocked by ice or contaminants.

voir in case of ice blockage.

read negative.

Evaporator

● Thermostat failure

● Replace thermostat.

frozen

Expansion valve inlet

● Expansion valve blocked.

● Clean/replace expansion valve.

felt cool and frosted.

Expansion valve outlet

is not felt cool. Low

● Expansion valve thermo-tube or bulb

● Replace expansion valve.

pressure could be

leaks.

negative.

Both high/

● Air trapped in circulation system.

low pressure

● Empty the system and vacuate to

gauges read

refill refrigerant.

higher than

● Excessive refrigerant refilled.

● Drain refrigerant to the specified

standard

level.

value.

Bad condens-

● Condenser blocked by dust and debris

● Clean the condenser.

ing effect of

● Condenser fan damaged

● Check/replace condenser fan.

condenser.

Both high and

low pressure

● Refrigerant insufficient

● Refill refrigerant as required.

gauges read

lower.

High

pressure

Low pres-

gauge

sure could be

● Low pressure line blocked/damaged

● Clean/replace faulty component.

reads

negative.

lower.

Condenser

and high

pressure tube

● Compressor internal failure

● Replace compressor.

hot

Bad refrigerating effect

● Hot water valve damaged and left open

● Replace hot water valve.

due active heater

Table 6-6

6-40

Specifications

7 SPECIFICATIONS

7.1 Machine Dimensions

A

D

I

E

C

L

H

J

G

F

K

B

Fig. 7-1

Item

Unit

SY115C9

SY135C8/C9

SY135C8(M)

SY155H

Operating weight

kg

12400

13,500

14,100

Bucket capacity

m³

0.48

0.54

0.6

Engine model

4BG1-TABGC-03-C2

4D34-TLE2A

BB-4BG1TRP

Engine power

kW/rpm

72.7 / 2200

70 / 2050

72.7 / 2200

A

Shipping length

mm

7280

7700

7700

B

Total width

mm

2550

2550

2550

C

Shipping height

mm

2810

2815

2815

D

Top width

mm

2480

2490

2580

E

Total height to top of cab

mm

2810

2740

2740

Standard width of track

F

mm

500

500

500

shoe

G

Gauge

mm

1990

1990

1990

Min. ground clearance

H

mm

422

425

425

（Excluding grouser ）

I

Tail swing radius

mm

2325

2240

2240

J

Track grounding length

mm

2680

2930

2930

K

Track length

mm

3360

3665

3665

Ground clearance of upper

L

structure (excluding grous-

mm

915

870

870

er)

Travel speed (high/low)

km/h

3.5/5.5

3.5 / 5.5

3.5 / 5.5

Swing speed

rpm

12

12

12

Table 7-1

7-3

Specifications

7.2 Working Ranges

f

a

g

b

e

c

d

Fig. 7-2

7-4

Specifications

Item

Unit

SY115C9

SY135C8/C9

SY155H

a

Max cutting height

mm

7780

8645

8625

b

Max dumping height

mm

5530

6175

6120

c

Max digging depth

mm

5165

5500

5520

d

Max vertical digging depth

mm

4925

4890

5005

e

Max horizontal reach

mm

7605

8290

8330

f

Min. swing radius

mm

2600

2500

2315

Maximum height at minimum

g

mm

5995

6500

6495

swing radius

Table 7-2

7-5

Optional Equipment

8.2 Hydraulic Control Elements and Oil Circuit

8.2.1 Location of the components

2

1

3

CZ135B-1105001

Fig. 8-1

(1) Stop valve

(2) Selector valve

(3) Control pedal

8.2.1.1 Stop valve

Stop valve stops hydraulic oil flow.

(a) Unlocked position allows flow of the hy-

draulic oil.

1

a

(b) Locked position stops flow of the hydraulic

b

oil.

CZ135B-1105002

Switch the valve to locked position when re-

moving or installing an optional equipment.

Fig. 8-2

8-6

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