Content      ..     9      10      11     

SANY Crawler Hydraulic Excavator SY115C9, SY135C8, SY135C9, SY155H. Safety, Operation and Manitenance Manual - page 11

Optional Equipment

8.2.1.2 Selector valve

Selector valve changes flowing direction of hy-

draulic oil.

The change of direction is made according to

the working mode selected. The working mode

must be applicable to the installed optional

equipment. For changing the working mode,

see“Hydraulic circuit” on page 8-8.

CZ335-1105003

Fig.

8-3

8.2.1.3 Control pedal

WARNING

Do not operate when placing your foot on

the pedal. If the pedal is pushed mistaken-

ly, the optional equipment will move sud-

denly and cause severe accidents.

Control pedal is used to control the optional

equipment.

A

When the front, center, or rear of the pedal is

N

pushed down, the optional equipment will op-

erate as the following.

B

Hydraulic breaker

Front (A): Operate

CZ335-1105004

Center (N): Stop

Fig. 8-4

Rear (B): Stop

For other optional equipment, consult its man-

ufacturer for installation in order to confirm the

operation of pedal and optional equipment be-

fore operating your machine.

8-7

Optional Equipment

8.2.2 Hydraulic circuit

Note:

● When the breaker is mounted, the oil return line must be connected directly to the return filter.

Therefore, do not use the return line except for mode B.

● In the stand-by valve, the safety valve's standard pressure was set at the factory before the

machine was delivered. When mode B is selected, the pressure is set to 20.6MPa (210kgf/

cm², 2980PSI); when the mode of hydraulic shear is chosen, the pressure is set to 27.4MPa

(280 kgf/cm², 3980PSI). Readjustment may be necessary according to the type of optional

equipment. In this case, please contact Sany distributor for adjustment.

8.2.2.1 Hydraulic circuit switching

● Set the working mode on the monitor according to the following standards according to the

type of optional equipment.

● The pressures set for the safety valve in the stand-by valve and for the switch of hydraulic line

are determined by the working mode selected.

Optional equipment

Mode

Hydraulic line

Safety Valve Pressure Setting

Hydraulic path forms

automatically at the

When delivered from factory:

One-way hydraulic optional

B

control valve where the

equipment, such as breaker

return oil does not pass

20.6Mpa (210kgf/ cm² 2980PSI)

through.

Hydraulic path forms

Dual-action hydraulic optional

automatically at the

When delivered from factory:

equipment, such as hydraulic

S

control valve where

shear

the return oil passes

27.4MPa (280kgf/cm², 3980PSI)

through.

8.2.2.2 Shifting to breaker / general optional equipment

● When installing an optional equipment with working mode B

(a) Breaker hydraulic path (one-way hydraulic path) has been formed.

(b) The overflow valve is set to low pressure.

When delivered from the factory: 20.6MPa (210kgf/cm², 2980PSI)

● When installing an optional equipment with working mode S

8-8

Optional Equipment

(a) Shear hydraulic path (dual-action hy-

draulic path) has been formed.

(b) The overflow valve is set to high pres-

sure.

When delivered from the factory:

27.4MPa 280kgf/cm2, 3980PSI

8.2.2.3 Connecting hydraulic oil circuit

Connect the hydraulic lines to the optional

equipment according to the following steps.

1. Check the stop valve, which should be in

1

the locked position (b).

a

(a) unlocked: allows flow of the hydrau-

b

lic oil (the arrow-indicated direction is

CZ135B-1105002

parallel to the longitudinal direction of

arm).

Fig.

8-5

(b) locked: stops flow of the hydraulic oil

(the arrow-indicated direction is per-

pendicular to the longitudinal direction

of arm).

2. Remove the screw plug (3) from the end of

3

the stop valve line.

Note:

CZ335-1105005

The disassembled parts should not be lost or

Fig.

8-6

damaged.

3. The optional equipment manufacturer is

responsible to connect the line (4) of the

optional equipment after the screw plug (3)

4

has been removed.

Connection sizes and additional accumula-

tor may vary according to different optional

equipment manufacturers. Please consult

CZ335-1105006

Sany distributor in this regard.

Fig.

8-7

8-9

Optional Equipment

8.2.2.4 Hydraulic oil passage

The operating directions of the pedal and hydraulic path are shown below.

CZ335-1105007

Fig. 8-8

By pushing the front of the pedal, the hydraulic oil flows to the left of the work equipment; by

pushing the rear, the hydraulic oil flows to the right. (Only the front part of the pedal can be oper-

ated upon the installation of breaker.)

8-10

Optional Equipment

8.2.3 Optional equipment removal and installation

8.2.3.1 Removal

A

1.

Lower the work equipment to the ground

B

and shut down the engine.

2.

Turn the start switch to ON position (B),

C

and place the lockout control to FREE

position (F).

CZ215-1105002

Fig.

8-9

3.

After finishing step 2, fully cycle each

control level and control pedal for 2-3 times

within 15 seconds in order to release the

internal pressure remained in the hydraulic

F

lines.

L

CZ335-1105009

Fig.

8-10

4.

Place the lockout control to LOCK position

(L).

F

L

CZ335-1105010

Fig. 8-11

8-11

Optional Equipment

5.

The breather valve (F) on top of the

F

hydraulic tank can be used to release the

internal 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 re-

lease the pressure.

CZ335-1105011

Fig. 8-12

6.

Check the temperature of hydraulic oil,

which should be cooled to a safe tempera-

ture, and then turn the rotor of the stop

valve (mounted to the inlet and outlet lines

to the side of the arm) to locked position (b).

1

a

(a) unlocked: allows flow of the hydraulic

oil

(the arrow-indicated direction is

parallel to the longitudinal direction of

b

arm).

CZ135B-1105002

(b) locked: stops flow of the hydraulic oil

Fig. 8-13

(the arrow-indicated direction is per-

pendicular to the longitudinal direction

of arm).

7.

Disconnect the hose at the side of the

optional equipment. Install the screw plugs

to the two outlets.

The screw plugs are used to prevent that

the invasion of foreign materials could lead

to the malfunction of the optional equip-

ment. Put the optional equipment in stor-

age after the screw plugs have been in-

CZ335-1105013

stalled properly.

Fig. 8-14

8.

Remove the two installation pins, disas-

semble the optional equipment, and install

the bucket.

For more information on the bucket instal-

lation procedures see“Bucket Replace-

ment” on page 5-47.

8-12

Optional Equipment

9. Check the oil level in the hydraulic tank af-

ter the bucket has been installed properly.

8.2.3.2 Optional equipment installation

1. Remove the bucket.

2. Place the optional equipment to a flat

A

surface. Install the optional equipment to

the arm with the pin (A) followed by the pin

(B).

B

CZ335-1105014

Fig. 8-15

3. Lower the equipment to the ground and

A

shut down the engine.

B

4. Turn the start switch to ON position (B),

and place the lockout control to FREE

C

position (F).

5. After finishing step 2, fully cycle each

CZ215-1105002

control level and optional equipment con-

trol pedal for 2-3 times within 15 seconds

Fig. 8-16

in order to release the internal pressure

remained in the hydraulic lines.

F

L

CZ335-1105009

Fig. 8-17

8-13

Optional Equipment

6.

Place the lockout control to LOCK position

(L).

7.

The breather valve (F) on top of the

F

hydraulic tank can be used to release the

internal pressure of the hydraulic lines.

L

To release the pressure completely, turn

and open the butterfly nut on the breather

valve (F) and press the relief button to re-

CZ335-1105010

lease the pressure.

Fig. 8-18

8.

Check the temperature of the hydraulic

F

oil, which should be cooled down to a safe

temperature. Remove the two screw plugs

from the inlet and outlet. Be careful not to

contaminate the hose connections with any

dirt or soil.

If the O-ring is broken, replace it with a

new one.

CZ335-1105011

9.

Connect the hose to the side of the op-

Fig. 8-19

tional equipment.

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 FREE position (a).

(a) unlocked: allows flow of the hydraulic oil

(the arrow-indicated direction is parallel

a

to the longitudinal direction of arm).

(b) locked: stops flow of the hydraulic oil (the

arrow-indicated direction is perpendicu-

b

CZ335-1105012

lar to the longitudinal direction of arm).

Fig. 8-20

11. Check the oil level in hydraulic tank after

installation of the optional equipment.

8-14

Optional Equipment

8.2.4 Hydraulic oil and hydraulic tank filter - change/replace

The operation of hydraulic breaker could contaminate the hydraulic system and deteriorate the

hydraulic oil. In this case, the hydraulic oil and hydraulic tank filter should be changed more of-

ten, as compared with the machine installed with bucket. Otherwise, damage could occur in the

hydraulic breaker, hydraulic pump and other hydraulic components. The recommended replace-

ment intervals are shown below. (For information about how to change oil and replace a filter, see

related items in the Maintenance Section.)

Table 8-1 Change interval (hours)

Machine with Hydraulic Breaker

Machine with Common Bucket

Hydraulic oil

600

1500 or 2500 or 4000

Filter cartridge

100

1000

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 illustration.

The filter cartridge must be replaced after the breaker has been operated for 100 hours.

100

When microglass filter is used

When paper filter is used

Hydraulic oil change

80

interval after 1500

service hours

60

Hydraulic oil change

interval after 2500

service hours

40

Hydraulic oil change

interval after 4000

service hours

20

0

0

500

1000

1500

2000

2500

3000

3500

4000

Service Hours

CZ335-1105015

Fig. 8-21

8-15

Optional Equipment

Note:

● In excavation, the boom may intervene with the undercarriage when the boom is fully low-

ered. 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.

● It is recommended using high-strength and high-antiwearing rockwork bucket when you dig or

load hard soil or soft soil containing stone pieces.

Capacity

Outer Width

Weight

Stand Arm（◇）

Bucket Type

m³

mm

Kg

m

Remark

（cu.yd）

（ft in）

（lb）

（ft in）

Rockwork

0.48

882

405

2.36

Standard

（SY115C9）

（0.64）

（2ft 10in）

（893）

（7 ft 9 in）

Rockwork

0.53

880

480

2.5

Standard

Earthwork

（0.71）

（2ft 10in）

（1058）

（8 ft 2 in）

（SY135C8）

0.53

946

478

2.5

Rockwork

（0.71）

（3 ft 1 in）

（1052）

（8 ft 2 in）

0.54

860

484

2.5

Standard

Earthwork

（0.71）

（2ft 10in）

（1058）

（8 ft 2 in）

（SY135C9）

0.6

950

960

2.5

Optional

（0.71）

（3 ft 1 in）

（1052）

（8 ft 2 in）

0.53

946

479.6

2.5

Rockwork

Earthwork

（0.71）

（3 ft 1in）

（1057）

（8 ft 2 in）

（SY155H）

0.6

986

489

2.5

Standard

（0.80）

（3 ft 3 in）

（1078）

（8 ft 2 in）

Table 8-2

◇―Digging or loading materials of specific gravity ” 1.8 t/m³

8-18

Optional Equipment

8.3.2 Bucket tips selection

Bucket tips may break off the adapter due to the working condition. In this case, suitable bucket

tips must be determined. Currently, we offer bucket tips with a lateral pin. So the following types

of bucket tips are recommended according to different working conditions.

8.3.2.1 Rockwork bucket tips

● Would be used at where the bucket tips service life could be impaired, such as loading hard

rocks.

● Would be used at where the bucket tips will not penetrate into the soils, such as handling

gravels after blasting or loosening the soils.

● Would be used at where heavy load operation is carried out, such as tapping or pulling the

rock with bucket tips.

8.3.2.2 Earthwork bucket tips

● Would be used at where the bucket tips will penetrate into the soils, such as excavating and

loading sand or clay.

Applicable Worksite

Rocks

Gravel

Sandstone

Clay and loose sand

Excavation during

pile-driving

Scraping the earth

Rockwork Tips

Earthwork Tips

General Excavation

Loading

Table 8-3

8-19

Optional Equipment

8.4 Recommended Operations

The following instruction must be followed

when operating an excavator with optional

equipment.

Note:

Select the optimum model of optional equip-

ment for your hydraulic excavator.

● The type of optional equipment to be in-

stalled and the model of special optional

equipment may vary according to the mod-

el of your hydraulic cylinder. In this case,

for selecting the optimum optional equip-

ment, please consult Sany distributor.

8.4.1 Hydraulic breaker

Major applications:

● Crushing rocks

● Demolition

● Road Engineering

This optional equipment can be used widely

for, such as demolishing buildings, breaking

road surface or slag, tunneling, crushing rocks,

and breaking operation at quarry.

CZ335-1105016

Fig. 8-22

8-20

Optional Equipment

8.4.2 Hydraulic breaker operation

1. Press the breaker chisel vertically and

firmly onto the object to be broken during

breaking operation.

2. Press the breaker chisel tightly onto the

90°

working surface when striking and slightly

raise the front of the undercarriage about 5

90°

mm (0.2 in) from the ground, as shown in

the right illustration. This clearance above

CZ335-1105017

ground shall not exceed 5 mm (0.2 in).

Fig. 8-23

Note:

The excavator shall not be raised too much.

CZ335-1105018

Fig. 8-24

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. 8-25

8-21

Optional Equipment

4. The chisel's penetrating direction will devi-

ate gradually to the working direction of

R

breaking hammer. It is important to align

them by readjusting the bucket cylinder.

CZ335-1105020

Fig. 8-26

5. Always press the chisel properly on the

working surface in order to prevent striking

without resistance.

CZ335-1105021

Fig. 8-27

8.5 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. 8-28

8-22

Optional Equipment

2. Breaking with swinging force.

CZ335-1105023

Fig. 8-29

3. Moving the chisel during striking operation.

CZ335-1105024

Fig. 8-30

4. Keep the chisel level or upward during

striking operation.

CZ335-1105025

Fig. 8-31

8-23

Optional Equipment

5. Swing the chisel when the rock has been

penetrated.

CZ335-1105026

Fig. 8-32

6. Pecking operation.

CZ335-1105027

Fig. 8-33

7. Raise your machine above ground by fully

extending the bucket cylinder and by the

pushing force.

CZ335-1105028

Fig. 8-34

8-24

Optional Equipment

8.6 Hydraulic Breaker Lubrication

Grease the breaker at the correct point.

CZ335-1105029

Fig. 8-35

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. 8-36

CZ335-1105031

Fig. 8-37

8-25

Optional Equipment

8.7 Quick Coupler and Control System

8.7.1 Quick coupler installation

1. Remove the safety pin of quick coupler, as

shown in the right illustration.

Safety pin

Jaw

CZ335-1105032

Fig. 8-38

2. Depress the quick coupler operation button

1

(1) (auto reset) on the left joystick in order

to slowly reduce the opening of the flexible

jaws and the fixed jaws of quick coupler.

CZ335-1105033

Fig. 8-39

3. Make the quick coupler's fixed jaws to

slowly grip the bucket's support pin (2), as

shown in the right illustration.

2

3

CZ335-1105034

Fig. 8-40

8-26

Optional Equipment

4. Extend the bucket cylinder to slowly move

the flexible jaws of quick coupler toward

the bucket's support pin (3).

2

3

CZ335-1105034

Fig. 8-41

5. Make sure that the jaws of quick coupler

grip completely the support pin (3) of the

bucket.

2

3

CZ335-1105035

Fig. 8-42

8-27

Optional Equipment

6. Release the operation button of quick

coupler in order to enable the quick cou-

pler to grip the bucket's support pin before

conducting other operations.

7. Insert the safety pin after installation.

CZ335-1105036

Fig. 8-43

8.7.2 Operating precautions

1. After installation of the quick coupler, the

bucket and other optional equipment will

make the swing diameter longer during the

operation. In this case, they could possibly

impact the cab or boom of your excavator.

So be careful with the operation. After the

quick coupler has been installed, retract

the bucket to its position (the bucket

cylinder is fully extended) before retracting

CZ335-1105037

the arm when carrying out retracting the

operation. To avoid damaging the boom,

Fig. 8-44

never retract the arm to its position (the

arm cylinder is fully extended) before

operating the bucket.

2. Overloaded preparation may impair your

machine and its optional equipment, thus

reducing their service life.

CZ335-1105038

Fig. 8-45

8-28

Optional Equipment

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 optional equipment.

CZ335-1105039

Fig. 8-46

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

CZ335-1105040

you are using an optional equipment that has

been approved by Sany. Sany assumes no re-

Fig. 8-47

sponsibility for any failure and accident result-

ed from installation of any optional equipment

that has not been approved by Sany.

8.8 Refueling System

8.8.1 Introduction

Sany excavators are equipped with a fueling

system, which uses a refueling pump assem-

bly. The refueling pump assembly is intended

specially for large mobile off-the-road machin-

ery, vehicles and vessels. It uses on-board

battery as the power source and is not limited

by terrain and power supply, which makes it

very suitable for construction side and field.

For information regarding refueling amount,

see“Fluid capacities” on page 5-19.

8-29

Optional Equipment

8.8.2 Components

1

2

● The fueling system of Sany excavators in-

cludes mainly: a refueling pump assembly

(including relevant piping and valves), a

control switch and a fuel level control relay.

● Open the battery cover (1) and you can

see the control switch and the refueling

pump (2).

CZ135B-1105003

Fig.

8-48

●

The main structure of the refueling pump 2)

is shown in the right illustration.

●

Technical specifications of the refueling

pump:

Pump flow rate: 46L/min

Rated voltage: 24V

Rate speed: 2800 rpm

CZ135B-1105004

Coupling thread: 3/4’G

Fig.

8-49

Weight: 3.5kg

Packing dimension: 215×120×160mm

●

The fuel level control relay (3) is shown in

the right illustration.

This relay is installed in front of the fuel

tank filler opening and is connected with

the refueling pump control switch and re-

lay. Its signaling position is 100mm from

the tank top surface.

3

CZ135B-1105005

Fig. 8-50

8-30

Optional Equipment

8.9 Central Lubrication System

8.9.1 Scheme and components

1. Models SY115C9, SY135C8/9 and SY155H adopt a 18-point lubrication scheme.

A sketch on distribution of excavator lubricating points is shown below:

12

11

10

9

7a8

13、14、15

16

3a4

1、2

17

5a6

18

CZ135B-1105006

Fig. 8-51

2. System components

● Electric grease pumping section

1

It is composed of the pump-mounting

base, the electric pump, the pumping unit,

the safety valve and the filter.

CZ135B-1105007

Fig. 8-52

8-31

Optional Equipment

● Distributor section

Boom

System distributor is mainly composed of:

B

A

Main distributor (1)

MX-F3/3

Secondary distributors (3)

MX-F510

MX-F3/5

MX-F3/4

CZ335-1105043

Fig. 8-53

The main distributor (A) and the secondary

distributor (B) installed to the boom root

are shown in the right illustration.

Arm

C

Secondary distributor (C) mounted to the

arm.

CZ335-1105044

Fig. 8-54

Secondary distributor (D) mounted to the

inside of the linking rod.

● Major lines configuration

Linkage

The system's major lines include high-

pressure hoses, straight connectors, el-

bows, straight expansion core, bent expan-

sion core, steel wire protection sleeves,

hose protection sleeves, bucket distributor

protection plates, etc.

D

CZ335-1105045

Fig. 8-55

8-32

Optional Equipment

8.9.2 System working principle

As Sany SY series excavators have a relatively central distribution of lubricating points that are

close to each other, we choose to use a progressive central lubrication system which is shown in

the illustration below.

Operating principle: The pressurized grease from the electric plunger pump goes through the

pumping unit, safety valve and filter to the main distributor, where the grease is sent through the

tubes to three secondary distributors and then supplied in turn to each lubricating point according

to a certain proportion.

Electric grease pump

Safety valve

Pump unit

Filter

Secondary distributor

Secondary distributor

Main distributor

Secondary distributor

CZ335-1105046

Fig. 8-56

8-33

Optional Equipment

8.9.3 Setting the lubrication time of electric grease pump

The electronic controller built in the electric grease pump can realize related control over the

time or cycle of the central lubrication system. When the time programming control is applied,

the cab's central lubrication system indicator flashes after the excavator is powered on; the yel-

low LED indicator of the electronic controller will be illuminated for 25 seconds, indicating that the

system is ready for lubrication.

By pressing the start button on the motor's shell or instrument panel, the lubrication cycle begins.

Upon completion of the lubrication cycle, the motor of lubricating pump stops and the shutdown

cycle begins. Subsequent lubrication will start according to the predetermine time schedule. If the

engine is shut off during shutdown period or lubrication cycle, the cycle will be terminated and the

time period will be recorded. When the engine is started again, the lubrication cycle will continue

counting the time from when the previous cycle is terminated. For the suspended lubrication cy-

cle, pressing the forcible start button allows you to activate the lubricant pump. Once the control

unit is energized, a lubrication cycle will be activated. The following illustration shows the panel of

electronic controller of the grease pump.

EA/PA Controller Type S-EP 4

Schmierzeit(min.)

Forcible start key for

Pausenzeit(h)

Control

intermittent lubrication

4

2

2

6

1

3

LED

1

0.5

16

8

8

4

14

10

7

5

12

6

Yellow LED for

Dial switch for

Dial switch for

function display

interval setup

lubrication time setup

CZ335-1105047

Fig. 8-57

8-34

Optional Equipment

● Setting the parameters

The interval can be set to 0.5 - 8 hours; the lubrication cycle can be set to 1 - 16 minutes, as

shown in the illustration below. If you need to adjust the time, use a flat-headed screw driver

to disassemble the red edge frame, loosen the four cross-headed screws, and remove the

transparent covers in turn. If any of the covers is not shut properly, water could penetrate into

the control unit and damage may result in.

2

4

1

3

2

6

1

16 segments for time intervals, with

0.5

16 segments for lubrication intervals, with

each segment standing for 0.5 hour

8

4

16

8

each segment standing for one(1) minute

7

5

14

10

6

12

CZ335-1105048

Fig. 8-58

8.9.4 Technical description

1. The system will lubricate for 10 minutes every half an hour, which was set at the factory

before delivery.

2. After operating for 100 hours, you can adjust (increase or decrease) the lubricating time ac-

cording to actual condition. The lubricating interval, however, shall not be changed.

3. Clean lithium base grease NLG12# is recommended for the lubrication.

4. Electric lubricant pump (24V/DC, 19 kg) with built-in electronic controller is used.

8-35

Optional Equipment

8.9.5 Adding grease with electric pump

The electric grease pump of the central lubrication system lubricates your machine in the follow-

ing three ways.

1. Standard Method:

Manual or pneumatic grease gun is used to add grease through the ball-type nozzle (1), as

shown in the following illustration.

1

CZ335-1105049

Fig. 8-59

2. Add grease through the connector, as shown in the illustration below.

Remove grease fitting and

connect the quick coupler.

Gasket

CZ335-1105050

Fig. 8-60

8-36

Optional Equipment

Coupler

Gasket

CZ335-1105051

Fig. 8-61

3. Add grease through the grease gun, as shown in the illustration below.

Grease gun

Coupler

CZ335-1105052

Fig. 8-62

Note:

Please consult Sany distributor if you need to install the central lubrication system. Make sure

that you are using accessories specified by Sany. Sany assumes no responsibility for failures and

accidents caused by the installation of any accessories that have not been approved by Sany.

8-37

Content      ..     9      10      11