SANY Excavator SY335 (Part Number: 11282013). Safety, Operation & Maintenance Manual

SY335 Excavator

2,000 Hours of Service

8. .Clean the filter (h) of all dirt by flushing it with mineral

spirits. Replace if damaged.

NOTE: See “Fluids & Lubricants” on page 5-11 for the

correct type of mineral spirits.

Fig. 5-158

Place a suitably sized pan under the drain plug (k).

Remove the drain plug to drain the oil. Check the O-

ring on the drain plug and replace if broken.

10. Replace and tighten the plug (k) after draining.

NOTE: Tightening torque:

683.5

76.0lb ft

(927±103N·m)

11.

Add hydraulic oil through the filer cover (f).

12. Check and confirm that there is enough fluid in the tank

through the sight glass on the side of the hydraulic tank

(see page 5-25).

13. Replace the filter cover, spring and filter when

complete (f).

14. Start the engine, unlock the hydraulic lockout lever (d)

and run the engine for 10 minutes. Shut the engine

down and check for leaks.

15. Tighten connections if leaks found; if no leaks replace

the hydraulic tank cover plate (a) and dispose of the

used hydraulic oil.

Fig. 5-159

NOTICE

Dispose of contaminated oil properly. Failure to do so will violate environmental laws and

ordinances.

5-101

2,000 Hours of Service

SY335 Excavator

Engine Coolant

CAUTION

Do not remove the filler cap while the engine is hot. Engine coolant is under pressure when

hot and will spurt out. Always wait for the engine to cool to outdoor ambient temperatures

before removing the filler cap. Failure to follow this warning could result in minor or major

injury.

NOTE: See “Fluids & Lubricants” on page 5-11.

1. Swing the upper structure in order to position the drain

valve beneath the radiator for better access.

2. Unscrew the bolts of the radiator tank cover plate (a)

and remove the cover plate to access the bottom of the

hydraulic tank.

Fig. 5-160

3. Shut down the engine. Go the engine compartment and

open both doors (b).

Fig. 5-161

5-102

2,000 Hours of Service

SY335 Excavator

6. Place a suitable catch container (12.5 gal/48 L) under

the radiator drain hose (e).

NOTE: See “Fluids & Lubricants” on page 5-11 for

additional information on capacity.

Fig. 5-164

Open the radiator drain valve (f) and allow the coolant

to completely drain into the catch container.

Reinstall and tighten the drain valve (f) after the cooling

system is empty.

Add new coolant directly into the expansion tank filler

neck (d) until the coolant level reaches the bottom of the

filler neck inspection hole.

NOTE: See “Fluids & Lubricants” on page 5-11 for the

type of coolant to be used.

Fig. 5-165

10. Start the engine and run it at idle speed for about 5

minutes and allow the coolant level to drop.

11.

Shut down the engine, check the fluid level and add fresh coolant directly into the expansion tank filler neck

until the coolant level again reaches the bottom of the filler neck inspection hole. (See “Engine Coolant Level”

on page 5-21.)

12. Reinstall the expansion tank filler cap.

13. Replace the radiator tank cover plate and dispose of the used coolant.

5-104

SY335 Excavator

2,000 Hours of Service

NOTICE

Dispose of contaminated coolant properly. Failure to do so will violate environmental laws and

ordinances.

Final Drive Oil

CAUTION

When the engine is just shut off, the oil and final drive components are still hot and can

burn. Wait until the oil ad the final drive has cooled before servicing.

Residual pressure in the final drive can cause oil to squirt out or the screw plug to fly out.

Slowly loosen the screw plug in order to release the pressure. Personal injury could result if

you stand in front of the plug as you loosen it.

1. Drive the machine on to a flat surface placing the final

drive cover such that the plugs line up as shown (a).

Fig. 5-166

5-105

2,000 Hours of Service

SY335 Excavator

Adjust the position of the final drive cover by driving

forward/backward so the filler cap plug (b) is at the top

of the cover such that if a line was drawn through the

drain screw plug (c) it would be perpendicular to the

ground.

Use a flat tip screwdriver to eliminate dirt from the

hexagonal socket of plugs (b-c-d) in order to avoid

damage to the bolts.

Place a suitable sized container (1 gal/4 L) under drain

plug (c) to catch the oil. and remove the drain plug

slowly taking care not to stand in front of the drain plug.

Fig. 5-167

Check the O-ring on screw plug (c), replace the O-ring

if broken.

Replace and tighten drain plug (c) and remove plugs (b)

and (d).

Add new oil through the filler cap plug (b).

NOTE: See “Fluids & Lubricants” on page 5-11 for

additional information.

When the oil is seen coming out of the final drive oil

check plug (d), reinstall both plugs (b) and (d), tighten

the plugs to 50 ft•lb (68 N•m).

Repeat this process for the other final drive, dispose of

Fig. 5-168

all used oil.

NOTICE

Dispose of contaminated oil properly. Failure to do so will violate environmental laws and

ordinances.

Check

Hydraulic Hoses

See “Hydraulic Hoses” on page 5-85.

Accumulator Gas Pressure

See “Accumulator Nitrogen Pressure (Breaker only)” on page 5-92 and perform this procedure every 1,000 service

hours or once each year, which ever occurs first.

5-106

SY335 Excavator

Machine Storage

MACHINE STORAGE

Follow these procedures when placing the machine in storage. Store the machine in a secure area free of public

access. If your storage area is near the ocean or other salt water environment, it is important to be aware of salt

damage. Contact your Sany1 distributor for additional storage procedures if this is case.

Short-Term Storage (Less than 30 days)

•

Clean the machine, keep it dry and fully lubricated.

•

Cover the machine to protect from dust.

Long-Term Storage (Longer than 30 days)

•

Clean the machine and travel system.

•

Keep the machine in a dry well ventilated area.

•

Lubricate oil all corrosive parts.

•

Carefully lubricate the slewing bearing teeth.

•

Change out the engine and hydraulic oils.

•

Replace all the filter elements.

•

Remove the batteries in accordance with the procedures shown in “Batteries” on page 5-45.

•

Drain the cooling system and post a sign “No Coolant in Machine System” on the crane.

•

Cover the engine with film to prevent moisture and dust.

•

Inventory and properly store all required tools.

Run the engine at low speed with no load every month. During the period, pay attention to the engine cylinder

temperature

5-107

SY335 Excavator

Troubleshooting

Before Troubleshooting

6-2

Troubleshooting Precautions

6-3

Precautions Troubleshooting Electrical Circuits

6-4

Precautions Handling Hydraulic Components

6-5

Towing the Machine

6-6

Towing Light Loads

6-7

Severe Operating Conditions

6-7

Jump-Starting the Engine

6-7

General Information

6-7

Battery Access

6-8

Connecting the Jumper Cables

6-8

Starting the Engine

6-9

Disconnecting the Jumper Cables

6-9

Fuses

6-10

Engine Failures

6-11

Failure Codes

6-20

Hydraulic System

6-22

Other Common Failures

6-25

WARNING

Read and understand all safety precautions and

instructions in this manual before reading any

other manuals provided with this equipment and

before operating or servicing it. Failure to do this

can cause property damage, personal injury or

death.

6-1

SY335 Excavator

Troubleshooting Precautions

TROUBLESHOOTING PRECAUTIONS

WARNING

Observe the following before performing any troubleshooting operations. Failure do so can

cause machine damage, personal injury or death.

Park the machine on a hard, level ground. Make sure that the safety pins and blocks are

effective.

•

Co-workers must use the same signal system. Keep irrelevant people a safe distance

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 metal parts or be caught by any rotating parts.

•

Before disconnecting any electrical wiring, always disconnect the batteries.

•

Before removing the plug or cap from any vessel that contains pressurized oil. water, or

air, release the internal pressure. When installing a measuring device, 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

occurrence of the failure. A short cut to effective troubleshooting is to ask the operator questions to form some idea

of possible causes of the failure that would produce the reported symptoms.

1. When performing troubleshooting, do not hurry to disassemble the components. If components are

disassembled immediately it is possible that have no connection to the failure may be disassembled. It may

become impossible to determine the root cause of the failure. It may also cause a waste of man-hours, parts, or

fluids and may loose the confidence of the user or operator. For these reasons it is necessary to carry out a

through investigation and carry out troubleshooting in accordance with the established procedure.

2. Questions to ask the user or operator:

•

Have any other problems occurred apart from the problem reported?

•

Was there anything strange about the machine before the failure occurred?

•

Did the failure occur suddenly, or were there problems th the machine condition before this?

•

Under what conditions did the failure occur?

•

Had any repairs been carried out before the failure, if so, what and when?

•

Has the same kind of failure occurred before?

6-3

Troubleshooting Precautions

SY335 Excavator

Check before troubleshooting

•

Check the oil level

•

Check for any external leakage of oil from the piping or hydraulic equipment.

•

Check the travel of the control levers

•

Other maintenance items can be checked externally, so check any item that is considered necessary

Confirming failure

•

Confirm the extent of the failure yourself, and judge whether to handle it as a real failure of as a problem

with the method of operation, etc.

•

When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation

or measurement that will make the problem worse.

Troubleshooting

•

Use the results of the investigation and inspection in items 2, 3 and 4 to narrow down the causes of the

failure, then use the troubleshooting as follows:

• Start from the simple points

• Start from the most likely points

• Investigate other related parts or information

Measure 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 rood cause.

Precautions Troubleshooting Electrical Circuits

1. Always turn off the power before disconnecting of connecting connectors.

2. Check that all related connectors are connected before any troubleshooting.

•

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 disconnected, unnecessary abnormality displays will be

generated.

4. When carrying out troubleshooting of circuits (measuring voltage, resistance, continuity, or current) move the

related wiring several times and check that there is no change in the reading on the tester.

•

If there is any change, there is probably a short in that circuit.

6-4

SY335 Excavator

Troubleshooting Precautions

Precautions Handling Hydraulic Components

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt

(foreign material) in the hydraulic circuit. When adding hydraulic fluid, or when disassembling hydraulic

equipment, it is necessary to be particularly careful.

Be careful of the operating environment.

•

Avoid adding hydraulic fluid, replacing filters, or repairing the machine in rain or high winds, or places

where there is lots of dust.

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 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 performance should be confirmed with special test equipment.

Be careful not to let any dirt or dust get in when refilling hydraulic fluid. Always keep the oil filler and the area

around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to

filter out the dirt that has collected during storage, so this is an even more effective method.

When changing the fluid, as much as possible of the old hydraulic fluid must be drained out. (Drain the fluid

from the hydraulic tank, also drain the fluid from the filter and from the drain plug in the circuit.) If any old

fluid that is left, the contaminates and sludge in it will mix with the new fluid and will shorten the lift of the

hydraulic fluid.

After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out

fluid cleaning to remove the sludge or contaminates in the hydraulic fluid circuit. The fluid 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.

6-5

Towing the Machine

SY335 Excavator

TOWING THE MACHINE

WARNING

Towing the machine improperly or using wire rope beyond specified limits could lead to

serious injury or death.

•

Make sure that the wire ropes used for towing the machine are strong enough.

•

While towing the machine, do not use wire rope with broken wires, reduced diameter, or

knots to prevent rupture of the wire ropes.

•

Always wear protective gloves when handling wire ropes.

•

Never tow the machine on a slope.

•

Never stand between the towing machine and the towed machine when performing

towing operations.

•

Operate the machine slowly and avoid imposing any sudden load on the wire rope.

NOTE: The acceptable towing force is 9,921 ft/lb (4,500 kgf).

If the machine is trapped in mud and cannot move out of the

mud with its own force, or the towing force of excavator is

occupied by heavy object, wire cables can be used as shown

in the right illustration.

Place wood blocks or other protective materials between

where the wire cable contacts the machine in order to

prevent friction between the wire cable and the machine.

Fig. 6-1

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

Fig. 6-2

6-6

SY335 Excavator

Towing Light Loads

TOWING LIGHT LOADS

WARNING

Towing objects with the machine improperly could cause severe injury or death. The following

items must be observed when towing with the machine:

A shackle must be used.

Keep the wire rope parallel to the ground and align its direction with that of the track frame.

Move the machine slowly and avoid imposing sudden loads on the wire rope.

The track frame has an eye which can be use when towing light objects.

NOTE: The maximum towing force is 3,968 ft/lb (1,800 kgf).

SEVERE OPERATING CONDITIONS

When excavating in water and the track support rollers go under water add grease to the support rollers before each

operating task.

For heavy-loaded operations and deep excavation, add grease to the installation pins of the work tool (bucket,

breaker, nibbler) prior to each operation. Cycle the operation of the boom, arm, and bucket several times prior to

refilling the grease.

JUMP-STARTING THE ENGINE

General Information

•

The starting system voltage and the battery voltage in the booster machine should be no more than 24

VDC.

•

The jumper cables and their clamps must be undamaged, have no corrosion and be suitable for the battery

amperage. All clamps must be securely attached to their jumper cable ends.

•

The battery capacity of both machines must be the same.

•

Place the hydraulic lock levers of both machines in the LOCK position.

•

Set all control levers to their neutral positions.

•

Use a jumper cable to connect ONLY the positive (+) terminals of BOTH the booster machine battery and

the drained machine battery. NEVER connect the positive (+) terminal to a negative (-) terminal.

Equipment damage or a possible explosion may result. Wear protective goggles and personal protective

equipment when jump-starting an engine.

6-7

Jump-Starting the Engine

SY335 Excavator

•

Use a jumper cable to connect the negative (-) terminal on the booster machine battery to the engine block

of the troubled machine and NOT the battery. A spark may result near the battery and cause an explosion.

•

Always check and then double-check the jumper cable connections to confirm that they are correct before

proceeding with engine startup.

•

Be careful when disconnecting jumper cables after both engines are running. Never allow the jumper cable

clamps to touch each other or to touch either machine.

Battery Access

Before proceeding with any battery jump-starting procedures, follow and remember these points:

•

Battery gases are explosive. Never smoke around batteries or expose them to sparks or open flames.

•

Wear personal protective equipment when working with batteries.

•

Work in a well-ventilated area.

•

If battery acid should get on your skin or in your eyes, flush the area immediately with fresh water and seek

medical attention.

CAUTION

Failure to observe and follow these points listed above may result in equipment damage or

possible injury.

Connecting the Jumper Cables

Ensure that the key switches of both machines are in the OFF position. See “Ignition Switch” on page 3-15 for key

switch location.

1. Clamp one end of jumper cable “A” to the positive

terminal (+) of the drained battery.

2. Clamp the other end of jumper cable “A” to the positive

terminal (+) of the charged battery.

3. Clamp one end of jumper cable “B” to the ground

Charged Battery

Drained battery

terminal (-) of the charged battery.

4. Clamp the other end of jumper cable “B” to the engine

cylinder block of the machine with the drained battery.

Fig. 6-3

6-8

SY335 Excavator

Jump-Starting the Engine

Starting the Engine

NOTICE

Ensure that all jumper cables are clamped to their connections securely. Failure to observe

and follow this notice may result in equipment damage or poor starting.

NOTE: See “Engine Start Procedure” on page 4-30

1. Start the engine of the good machine and run it at a medium speed.

2. Attempt to start the engine of the trouble machine using the key switch as normal. Retry every 3 minutes if the

engine will not start.

Disconnecting the Jumper Cables

Disconnect the jumper cables after the trouble engine has

started as described here:

1. Unclamp jumper cable “B” from the engine block of the

machine with the drained battery.

2. Unclamp the other end of jumper cable “B” from the

ground terminal (-) of the charged battery.

Charged battery

Drained battery

3. Unclamp jumper cable “A” from the positive terminal

(+) of the charged battery.

Fig. 6-4

4. Unclamp the other end of jumper cable “A” from the

positive terminal (+) of the drained battery.

6-9

Fuses

SY335 Excavator

FUSES

The fuse box is located in the cab behind the seat.

Open the fuse box door to access the fuses (1).

Fuse location, circuit & amperage

F2. Charging Lamp, 5A

F1. Starting Circuit, 30A

F4. Working Lamp, 15A

F3. KPM controller, 10A

F6. Travel Alarm, 2A

F5. Cab Lamp, 5A

F8. Radio, 10A

F7. 12V Converter, 20A

F10. Air Conditioner, 20A

F9. Diagnostic Terminal,

F12. Lighter, 20A

F11. Hydraulic Nibbler, 5A

F14. Pilot Control, 10A

F13. Fueling, 15A

Fig. 6-5

F16. Display, 5A

F15. Washer & Wiper,

10A

F18. Dome Lamp, 5A

F17. KPM Controller, 5A

F20. Ignition (ECM), 5A

F19. ECM Power, 20

6-10

Failure Codes

SY335 Excavator

FAILURE CODES

The failure codes (1) display in the cab on the machine

system monitor.

Fig.6-6

Code

Symptom

E101

Controller memory error

E102

Temperature inside controller error

E103

Sensor power source error

E401

CAN bus error

E501

Gear rotate error

H101

Front pump output pressure error

H102

Rear pump output pressure error

H103

Power valve over current

H105

Front pump over current

H108

Rear pump over current

H112

Backup pilot pressure abnormal

H201

Bucket-dig pilot pressure abnormal

H202

Bucket-dump pilot pressure abnormal

H203

Arm-in pilot pressure abnormal

H204

Arm-dump pilot pressure abnormal

H205

Boom-up pilot pressure abnormal

H206

Boom-down pilot pressure abnormal

H207

Left travel pilot pressure abnormal

H208

Right travel pilot pressure abnormal

H209

Swing pilot pressure abnormal

H210

Shear opening/closing pilot pressure

abnormal

6-20

SY335 Excavator

Failure Codes

Code

Symptom

H211

Shear rotating pilot pressure abnormal

H303

Swing priority current abnormal

H306

Bucket confluence current abnormal

H309

Boom priority-1 current abnormal

H312

Boom priority-2 current abnormal

H315

Travel speed shift abnormal

H401

Hyd oil temp sensor voltage abnormal

H402

Hydraulic oil temp too high

P103

Coolant level too low

P104

Engine oil pressure too low

P105

Boosting temperature too high

P302

Coolant temperature resistance abnormal

P303

Coolant temperature too high

P402

Fuel meter abnormal

P403

Fuel level low

P404

Fuel temperature too high

P501

Air filter clogged

P601

Primary fuel filter clogged

P602

Secondary fuel filter clogged

6-21

SY335 Excavator

Machine Dimensions & Specifications

Overall Dimensions

Weight (loaded - full fuel tank, operator and standard bucket)

82,371 lb (37,363 kg)

Transport Weight - bucket (15% fuel in tank, no operator)

81,361 lb (36,905 kg)

A. Transport Length

36’ 5” (11,100 mm)

B. Transport Width

11’ 2” (3,410 mm)

C. Transport Height

11’ 6” (3,505 mm)

D. Upper Width

9’ 10” (3,000 mm)

E. Cab Height

10’ 8” (3,262 mm)

F. Std. Track shoe Width

2’ 7” (800 mm)

G. Track Gauge

8’ 6” (2,590 mm)

H. Minimum Ground Clearance

1’ 8” (541 mm)

I. Tail Swing Radius

10’ 10” (3,300 mm)

J. Length Center Idler to Center Sprocket

13’ 7” (4,150 mm)

K. Track Length

16’ 7” (5,080 mm)

Boom Length

21’ (6,400 mm)

Std Arm Length

10’ 6” (3,187 mm)

Safety, Operation & Maintenance Manual —November 28, 2013

7-3

SANY Excavator SY335 (Part Number: 11282013). Safety, Operation & Maintenance Manual - page 8