Quality Changes the World

Excavator

(SY215C9M3KS)

Safety, Operation & Maintenance Manual

SY215 Excavator

SY215 Excavator

(SY215C9M3KS)

Safety, Operation & Maintenance Manual

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

Safety, Operation & Maintenance Manual - January 8 2016

 SY215 Excavator

This manual and its contents prepared by Sany group Technical Publications while
deemed to be accurate, is based upon technical information
provided, and for equipment designed, manufactured and tested by:
Sany heavy machinery CO., LTD
Sany Industry Town, Lianggang Road,No.318,Fengxian,Shanghai,
China201413
www.sanygroup.com
It is the responsibility of the owner, user, properly trained operator and lessor to be
knowledgeable of, and comply with, all industry standards, government regulations, workplace
rules and other directives that may govern and/or apply to this equipment as well as
its environment/conditions of use.

Sany heavy machinery CO., LTD

Sany Industry Town, Lianggang Road,No.318,Fengxian,Shanghai,
China201413
www.sanygroup.com
Phone: 4008 28 2318
Fax: 021-57001222

© 2015 by Sany group, Inc. All rights reserved. No part of this publication may be
reproduced, used, distributed or disclosed except for normal operation and maintenance 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. For more information, contact Sany
group, Inc.

Safety, Operation & Maintenance Manual - January 8 2016

SY215 Excavator Table of Contents

CONTENTS
TABLEOF
INTRODUCTION
Table of Contents

SAFETY
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

FUNCTION
Your Documentation Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

SYSTEM
Safety, Operation & Maintenance
Parts Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

OPERATION
Organization of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

MAINTENACE
System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

SPECIFICATIONS TROUBLRSHOOTING
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Record of Serial Number and Dealer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Correction Request Form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
EQUIPMENT
OPTIONAL

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Table of Contents SY215 Excavator

SAFETY
Safety - General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hazard Alerts in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Diesel Engine Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Battery Posts, Terminals and Related Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Operator Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Operator is Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operator Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Machine Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Keep the Operator Cab Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Mount and Dismount the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Unauthorized Machine Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Job Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Job Site Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Surface and Underground Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
High Voltage Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Start-Up Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Fluid Fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Electrical Fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
In Case of Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Dust and Chemical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Dust Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Safety Data Sheets (SDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Clean the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Use the Correct Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Jack Up the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Rotating Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

i-II Safety, Operation & Maintenance Manual - January 8 2016

SY215 Excavator Table of Contents

CONTENTS
TABLEOF
Remove Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Weld, Drill, Cut or Grind on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Fluid Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

INTRODUCTION
Add Fluids to the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Refuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
High-Pressure Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

SAFETY
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Battery Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Disconnect the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Jump-Start Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

FUNCTION
SYSTEM
Environmental Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Product-Specific Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Lockout/Tagout Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

OPERATION
Lock Out of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Return to Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Machine Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Type, Location and Meaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

MAINTENACE
Authorized Use of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Unauthorized Use of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Job Site Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

SPECIFICATIONS TROUBLRSHOOTING
Surface and Underground Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Job Site Working Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Travel Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Traveling on Sloped Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Snow or Frozen Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Accumulation of Flammable Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Escape Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Crush or Pinch-Point Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Tow or Lift the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
EQUIPMENT
OPTIONAL

Operation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Operation on a Sloped Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

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Table of Contents SY215 Excavator

System Functions
Exterior Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cab Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Seat and Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Hydraulic Lockout Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Left Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Radio Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Right Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Indicator Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Throttle Control Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
12V Power Supply Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Work Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Windshield Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Head Lamp Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
SAE/BHL Joystick Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
SAE Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Travel Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Auto Deceleration Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Combined Instruments Display/Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Screen Displays - Configuration 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Main Operator Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
System Information (Password) Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Main Menu Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Running Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Failure Codes Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Throttle Help Info Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

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SY215 Excavator Table of Contents

CONTENTS
TABLEOF
Language Selection Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Sys Clock Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Units Display Setting Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

INTRODUCTION
Screen Displays - Configuration 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Main Operator Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
System Information (Password) Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Main Menu Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

SAFETY
Running Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Failure Codes Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Throttle Help Info Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Language Selection Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

FUNCTION
SYSTEM
Sys Clock Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

OPERATION
Operation
Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
General Job Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

MAINTENACE
Job Site Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Work Crew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Supervisor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Owner and Other Authorized Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

SPECIFICATIONS TROUBLRSHOOTING
Operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Mount and Dismount the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Seat Belt Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
New Machine Run-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Safety, Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Daily Maintenance Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
EQUIPMENT
OPTIONAL

Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
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Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Lamps and Warning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Escape Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Front Window Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Combined Instruments Display/Monitor Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
First-Time Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Access the Main Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Language Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
System Clock Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Units Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Engine Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Cold-Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Engine Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Idle the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Engine Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Machine Warm-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Travel Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Before Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Track Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Right Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Left Turn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Straight Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Left Zero-Degree Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Right Zero-Degree Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Operations in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Release Machine from Mud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
One Track Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Two Tracks Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Control Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
SAE Control Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

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CONTENTS
TABLEOF
Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

INTRODUCTION
BHL Control Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

SAFETY
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Backhoe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Digging a Trench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

FUNCTION
SYSTEM
Loading Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Bucket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
End-of-Workday Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

OPERATION
Park and Store the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Overnight Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Short-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

MAINTENACE
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
During Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

SPECIFICATIONS TROUBLRSHOOTING
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Lift the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Load the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Unload the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53 EQUIPMENT
OPTIONAL

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Maintenance
Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Checks Before Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Checks After Maintenance or Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Hour Meter Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Genuine Sany Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Sany-Approved Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Weld, Drill, Cut or Grind on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Clean Parts or the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Covers and Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Hydraulic Fluid Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Inspection and Maintenance in Adverse Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Mud, Rain or Snow Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Near Ocean (Salt Air) Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Dusty Environments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Rocky Ground Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Cold Environments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Other Weather Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Specific Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
General Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Fluids & Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Location, Capacity and Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Engine Oil Viscosity/Temperature Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Lubricating Grease/Temperature Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Industrial Gear Oil/Temperature Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Hydraulic Fluid/Ambient Temperature Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Supplemental Coolant Additive (SCA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

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CONTENTS
TABLEOF
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Windshield Washer Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

INTRODUCTION
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Secure the Machine for Maintenance (Power Off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Safety, Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

SAFETY
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Escape Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

FUNCTION
SYSTEM
Engine Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Engine Serpentine Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

OPERATION
Pump Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Hydraulic Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Idler Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Sheet Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

MAINTENACE
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Primary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

SPECIFICATIONS TROUBLRSHOOTING
Secure the Machine for Maintenance (Power On). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Operating Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Engine Coolant Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Hydraulic Fluid Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
EQUIPMENT
OPTIONAL

50-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

Secure the Machine for Maintenance (Power Off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

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Engine Air Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

Muffler and Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Track Shoe Connecting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Track Support Roller Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Final Drive Motor Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Secure the Machine for Maintenance (Power On). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Engine Oil and Filter (Initial). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Final Drive Gearbox Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Track Tension (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-64
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
250-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Secure the Machine for Maintenance (Power Off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
Hydraulic Pilot Line Filter Element (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
Hydraulic Fluid - Breaker-Equipped (400 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Air Conditioner Compressor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Windshield Washer and Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
Track Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
Supplemental Coolant Additive (SCA) Levels (if used) . . . . . . . . . . . . . . . . . . . . . . . 5-72
Grab Handles and Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Cab Door, Access Panels and Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Secure the Machine for Maintenance (Power On). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74

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CONTENTS
TABLEOF
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Hydraulic Tank Return Filter (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77

INTRODUCTION
Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
500-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78

SAFETY
Secure the Machine for Maintenance (Power Off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
Hydraulic System Breather Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80

FUNCTION
SYSTEM
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
Radiator, Oil Cooler, and A/C Condenser Fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
Air Conditioning Fresh Air & Recirculation Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82

OPERATION
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
Swing Gearbox Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
Upperworks and Lowerworks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86

MAINTENACE
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
Swing Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
Swing Gearbox Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88

SPECIFICATIONS TROUBLRSHOOTING
Secure the Machine for Maintenance (Power On). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
Swing Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
Primary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
EQUIPMENT
OPTIONAL

1,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96

Secure the Machine for Maintenance (Power Off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97

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Hydraulic Pilot Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97

Hydraulic Tank Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
Engine Exhaust Pipe Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
Fuel Tank Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
Secure the Machine for Maintenance (Power On). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
Accumulator Function Check (Breaker-Equipped only) . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
2,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
Secure the Machine for Maintenance (Power Off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
Final Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
Secure the Machine for Maintenance (Power On). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Accumulator Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Swing Bearing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
Short-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115

i-XII Safety, Operation & Maintenance Manual - January 8 2016

SY215 Excavator Table of Contents

CONTENTS
TABLEOF
Troubleshooting
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

INTRODUCTION
Light Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Purge the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Jump-Start the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

SAFETY
Failure Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Specifications

FUNCTION
SYSTEM
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Operating Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Lift Chart - Long Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

OPERATION
Lift Chart - Super Long Reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Optional Equipment

MAINTENACE
Optional Equipment Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Optional Equipment Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Read Equipment Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Removal and Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

SPECIFICATIONS TROUBLRSHOOTING
Optional Equipment Operation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Optional Equipment System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Component Location and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Stop Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Combined Instrument Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Optional Equipment Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Attach Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
EQUIPMENT
OPTIONAL

Optional Equipment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Breaker Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Shear Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Disconnect Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Safety, Operation & Maintenance Manual - January 8 2016 i-XIII
Table of Contents SY215 Excavator

Super Long Reach Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Combined Instrument Display - Super Long Reach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Attach the Bucket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Disconnect the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

i-XIV Safety, Operation & Maintenance Manual - January 8 2016

SY215 Excavator Introduction

CONTENTS
TABLEOF
INTRODUCTION
Introduction

SAFETY
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

FUNCTION
SYSTEM
Your Documentation Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety, Operation & Maintenance
Parts Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

OPERATION
Organization of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

MAINTENACE
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

SPECIFICATIONS TROUBLRSHOOTING
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Record of Serial Number and Dealer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Correction Request Form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
EQUIPMENT
OPTIONAL

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Introduction SY215 Excavator

WARNING
To prevent death or serious injury:
• Avoid unsafe operation and maintenance.
• This machine must be operated and maintained by trained and
experienced personnel. Sany is not responsible for qualifying
these personnel.
• Do not operate or work on this machine without first reading
and understanding this Safety, Operation & Maintenance manual
supplied with the machine.
• Store the Safety, Operation & Maintenance manual in the opera-
tor cab.
If the Safety, Operation & Maintenance manual is missing or dam-
aged, do not use the machine until a replacement has been ob-
tained from your Sany dealer. Failure to have and to refer to an
available copy of the manual can result in damage to the machine
or improper operation.

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

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SY215 Excavator Introduction

CONTENTS
TABLEOF
ABOUT THIS MANUAL
This manual provides safety, operation, maintenance
and technical specification information. A copy must be

INTRODUCTION
kept in the cab (a) at all times. If you sell the machine, a
copy of this manual must be provided to the new owner.
It is important to read this manual carefully before
beginning any operation or maintenance. All
personnel involved with this machine must read this
manualperiodically to remain knowledgeable about its

SAFETY
operation and maintenance.
Fig. 1-1
a

FUNCTION
SYSTEM
Items addressed in this manual are designed to help you:
• Understand the different systems and performance of your machine.
• Reduce improper operation.
• Point out possible hazardous situations when operating and maintaining the machine.

OPERATION
• Increase machine efficiency during operation.
• Prolong the service life of your machine.
• Reduce maintenance costs.

MAINTENACE
Continuing improvements in the design of this machine can lead to changes in detail which may not be
covered in this manual. Always consult your Sany dealer for the latest available information on your ma-
chine or if you have questions regarding information in this manual.

CONTACT INFORMATION

SPECIFICATIONS TROUBLRSHOOTING
Thank you for purchasing a Sany machine. If you need to contact us for any reason, you can reach us as
follows:
Sany Group
Sany Industry Town, Changsha Economic &
Technical Development Zone
Hunan, China 410100
www.sanygroup.com
Phone: 0086-0731-84031711
Fax: 0086-0731-84031999-654
EQUIPMENT
OPTIONAL

Fig. 1-2

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Introduction SY215 Excavator

YOUR DOCUMENTATION
PACKAGE
This documentation applies only to this machine
and should not be used with any other machine. The
documentation for this machine includes the following
items:
a
Safety, Operation & Maintenance
Manual
A copy of this Safety, Operation & Maintenance
manual must always remain in the operator cab (a) at
all times. See “Organization of This Manual” on page
1-5 for complete details.
A copy of this manual should be made available
to maintenance personnel when maintaining the
machine.

Fig. 1-3
Parts Book
The Parts book consists of parts lists and matching
drawings used for ordering spare parts as needed. The
Parts book is best left in the workshop area or office.
It should always be available to the maintenance and
service personnel.

Maintenance Log
The Maintenance Log lists regularly scheduled maintenance to be performed by the operator or mainte-
nance personnel. All maintenance performed upon the machine must be recorded in the Maintenance Log.

Fig. 1-4

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SY215 Excavator Introduction

CONTENTS
TABLEOF
ORGANIZATION OF THIS MANUAL
Table of Contents

INTRODUCTION
List of the general topics that are contained in this manual along with the page number each starts on.
NOTE: There is also a table of contents at the start of each section in this manual.

Introduction
Overview of what is covered in the rest of this manual, including serial number information and Sany
contact information.

SAFETY
Safety
General and product-specific safety information relating to this machine. It describes what the hazard alerts
mean that are used throughout the manual. Decals used on the machine by location, type and meaning are

FUNCTION
SYSTEM
also addressed in this section.

System Functions
Overview of all controls and operating systems.

OPERATION
Operation
Detailed operator qualifications, pre-start checks, operating procedures and end-of-day checks and storage
information.

MAINTENACE
Maintenance
Routine maintenance procedures, fluid specifications, and torque values.

Troubleshooting

SPECIFICATIONS TROUBLRSHOOTING
Overview of common malfunctions for the operating systems, instructions on towing and jump-starting.

Specifications
Dimensions and weight of the machine, and systems/components performance information.

Optional Equipment
Information on the function and operation of optional equipment.
EQUIPMENT
OPTIONAL

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Introduction SY215 Excavator

SERIAL NUMBER LOCATION

The serial number (a) will be needed by your Sany
dealer when ordering replacement parts or provid-
ing assistance for your machine. Record this infor-
mation in this manual for future use.

Fig. 1-5 a

Record of Serial Number and Dealer Information

This location is for you to record information relating to your machine. It is required that you keep this
manual with your machine at all times for reference.

Machine Serial No.

Engine Serial No.

Right Final Drive Motor Serial No.

Left Final Drive Motor Serial No.

Swinging Gearbox Motor No.

Hydraulic Pump No.

Dealer Name:
Address:

Phone Numbers:

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SY215 Excavator Introduction

CONTENTS
TABLEOF
CORRECTION REQUEST FORM
If you find a problem with this manual, make a copy of this page, complete the form below and send it to
us, attention Technical Publications. You can also email us at [email protected].

INTRODUCTION
NOTE: See “Contact Information” on page 1-3.

Date of This Request

SAFETY
Your Name
Company Name
Your Department
Street Address
City, State & ZIP

FUNCTION
SYSTEM
Phone
E-mail

Machine Model & Serial No.

OPERATION
Description of Problem (wrong information, unclear or erroneous procedure, etc.)

MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
Corrective Action by You (if any)

EQUIPMENT
OPTIONAL

Safety, Operation & Maintenance Manual - January 8 2016 1-7

Introduction SY215 Excavator

This Page Intentionally Left Blank

1-8 Safety, Operation & Maintenance Manual - January 8 2016

SY215 Excavator Safety

CONTENTS
TABLEOF
INTRODUCTION
Safety

SAFETY
Safety - General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

FUNCTION
Hazard Alerts in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

SYSTEM
Diesel Engine Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Battery Posts, Terminals and Related Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Operator Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Operator is Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

OPERATION
Operator Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Machine Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Keep the Operator Cab Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Mount and Dismount the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

MAINTENACE
Unauthorized Machine Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Job Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Job Site Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Surface and Underground Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

SPECIFICATIONS TROUBLRSHOOTING
High Voltage Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Start-Up Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Fluid Fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Electrical Fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
In Case of Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Dust and Chemical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
EQUIPMENT
OPTIONAL

Dust Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Safety Data Sheets (SDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Clean the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Safety, Operation & Maintenance Manual - January 8 2016 2-1

Safety SY215 Excavator

Use the Correct Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Jack Up the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Rotating Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Remove Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Weld, Drill, Cut or Grind on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Fluid Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Add Fluids to the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Refuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
High-Pressure Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Battery Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Disconnect the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Jump-Start Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Environmental Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Product-Specific Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Lockout/Tagout Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Lock Out of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Return to Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Machine Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Type, Location and Meaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Authorized Use of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Unauthorized Use of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Job Site Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Surface and Underground Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Job Site Working Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Travel Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Traveling on Sloped Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Snow or Frozen Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Accumulation of Flammable Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Escape Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Crush or Pinch-Point Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Tow or Lift the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Operation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Operation on a Sloped Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

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

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CONTENTS
TABLEOF
SAFETY - GENERAL
WARNING
Make sure the precautions described in this manual and the safety decals on the machine

INTRODUCTION
are fully understood before operating or maintaining this machine. Read and follow all
safety precautions. Failure to do this could result in death or serious injury.

This section of the manual provides detailed information on basic safety precautions and preventative
measures to be followed during operation and maintenance of this machine.

SAFETY
Safe operation is very important. Prior to operation and maintenance, carefully read and understand all
content in this section of this manual. Only after completely understanding the content in this manual, can
the machine be safely and expertly operated. Following are some of the benefits of doing this:
• Avoid personal injury or machine damage caused by improper operation.

FUNCTION
SYSTEM
• Increase the reliability of the machine.
• Prolong the service life of the machine.
• Reduce repair cost and downtimes.
The safety information in this manual provides basic guidelines for safe operation for all authorized

OPERATION
personnel. Sany is unable to foresee all risks on work sites, so workers, operators and owners must consider
if there are other safety concerns that must be addressed for specific job situations.
Local governments or authorities may have stricter standards. If some stipulations in this manual disagree
with the local laws or regulations, the stricter ones prevail.

MAINTENACE
This manual must be kept on the machine for reference and periodically reviewed by all personnel involved
with operation or maintenance of this machine.
Some actions involved in the operation or maintenance of this machine could cause a serious accident if
they are not performed in the manner described in this manual.

SPECIFICATIONS TROUBLRSHOOTING
All procedures and precautions outlined in this manual apply only to intended use of this machine. If you
use your machine for any unintended use that is not specifically prohibited, you must be sure that it is
safe for you and others to do so. In no event should you or others engage in prohibited uses or actions as
described in this manual.
This machine complies with all applicable regulations and standards of the country to which the machine
has been shipped. If this machine was purchased in another country or purchased from someone in another
country, it may lack certain safety features and specifications that are necessary for use in your country. If
there is any question about whether your machine complies with the applicable standards and regulations
of your country, contact your Sany dealer before operating this machine.
EQUIPMENT
OPTIONAL

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Hazard Alerts in This Manual

Most accidents are usually caused by the failure to follow fundamental safety rules for the operation
and maintenance of the machine. To avoid accidents, it is important that all personnel involved with
the operation or maintenance of this machine must read this manual before operating or performing
maintenance on this machine.
Improper operation or maintenance of this machine could result in death or serious injury.
Carelessness or neglect by operators, job supervisors, maintenance staff, and job site workers can result in
their death or injury and costly damage to the machine and property.
To alert operators, job supervisors, maintenance staff, and job site workers to hazardous operating practices
and maintenance procedures, hazard alerts are used throughout this manual. Each hazard alert contains
a hazard alert symbol and a signal word to identify the hazard’s degree of consequence if the message is
ignored.
The following (ANSI/ISO) signal words are used to inform that there is a potentially hazardous situation
that may lead to damage, personal injury or even death. In this manual and on the machine decals, different
signal words or illustrations are used to express the potential level of hazard.

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

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

CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.

NOTICE
NOTICE indicates a situation which can cause damage to the machine, personal property
and/ or the environment, or cause the machine to operate improperly.

This symbol is used within a graphic to alert the user not to do something.

Sany cannot foresee every circumstance that might involve a potential hazard in operation or maintenance.
Therefore, some hazard alerts in this manual and on the machine may not include all possible safety
precautions.
If any procedure or action not specified, recommended or allowed in this manual is used, be sure that such
procedures and actions can be safely performed without damaging the machine or causing injury. When
unsure about the safety of some procedures, contact your Sany dealer.

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CONTENTS
TABLEOF
Diesel Engine Exhaust

WARNING

INTRODUCTION
CALIFORNIA PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.

Battery Posts, Terminals and Related Accessories

WARNING

SAFETY
CALIFORNIA PROPOSITION 65 WARNING
The battery posts, terminals, and related accessories contains chemical lead and lead
compounds, chemicals known to the State of California to cause cancer, birth defects or
other reproductive harm. Wash hands after handling.

FUNCTION
SYSTEM
Operator Safety Information
It is impossible to compile a list of safety precautions covering every situation. However, there are basic
principles that must be followed when operating this machine:
• Only qualified personnel who have been specially trained are permitted to operate and/or work on this

OPERATION
machine.
• Operator aids such as warning lights, horns, or buzzers, along with displays on the monitors are designed
to alert the operator to potential problems. Sole reliance on these operator aids, in place of good operating
practices, can lead to an accident. Inspect the operator aids of this machine daily and make sure each

MAINTENACE
operator aid is in normal working condition. Any faults found shall be reported to your Sany dealer. Stop
all work immediately if any operator aid is found to not be working properly.
• All accident prevention guidelines, operating instructions, etc., are based on authorized use of the
machine.

SPECIFICATIONS TROUBLRSHOOTING
• Read and understand this manual and any accompanying manuals before operating this machine.
• This manual must be readily available to the operator at all times and must remain in the cab while the
machine is in use.
• Ensure that all personnel in the working area around the machine are thoroughly familiar with safe
operating practices as stated in this manual.
• Review the local, state, and federal regulations and standards regarding this machine and its operation.
Work practice requirements may vary among government regulations, industry standards, and employer
policies. A thorough knowledge of all such relevant work rules is required before operating this machine or
performing maintenance on it.
• Inspect the maintenance log before the start of each workday shift. Ensure that routine maintenance has
EQUIPMENT

been performed as stated in this manual. Do not operate a damaged or poorly maintained machine.
OPTIONAL

• No one besides the operator is to be anywhere on the machine while it is in operation.

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Operator is Important
The operator’s responsibility is not lessened by the addition of operator aids. The operator must guard
against a false sense of security when using them. Operator aids and warning devices assist, but do not
direct, the operation. They are subject to failure or misuse and should not be relied upon in place of good
operating practices.
The operator’s first priority is to ensure his safety and the safety of those around him.
NOTE: See “Operation”on page 4-5 in this manual for additional information.
Report all accidents, malfunctions and machine damages to your Sany dealer immediately. Your Sany
dealer must be immediately advised of the incident and consulted on necessary inspections and repairs
following an accident or damage to machine.
If the dealer is not immediately available, contact Sany America directly. The machine must not be returned
to operation until it is thoroughly inspected following all accidents, malfunctions and machine damage. All
damaged parts must be repaired or replaced as authorized by your Sany dealer or Sany Group.
NOTE: See “Contact Information” on page 1-3.
Operator Qualifications
No one should operate this machine unless they comply with the following:
• They have been trained on this specific machine. Controls and design may vary among models; therefore,
it is important that they have specific training on the specific machine they will be operating. Training is
essential for proper machine operation and safety.
• They have read and understand this Safety section, the operating recommendations in the remainder of
this Safety, Operation & Maintenance manual, and any other manuals provided with this machine, the
employer’s work rules, and applicable industry standards and government regulations.
• They are sure the machine is operating properly and has been inspected and maintained in accordance
with this manual’s stated requirements.
• They are sure that all safety decals, guards, and other operating features are in place and in proper
condition.
• They are mentally and physically fit to operate this machine. They must never attempt to operate this
machine while under the influence of medication, narcotics, or alcohol. Any type of drug could impair
physical, visual and mental reactions, and capabilities.

Machine Safety
Do the following:
• Be sure all guards and covers are in place, especially after performing maintenance on the machine.
• If guards or covers are damaged, have them repaired or replaced immediately.
• Use all operator aids properly.

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CONTENTS
TABLEOF
• Never remove or modify operator aids. Always keep them in good condition.
• Always secure the machine in a safe location when job operations are done.

Keep the Operator Cab Clean

INTRODUCTION
Observe the following:
• When entering the operator cab (a), always
removeall mud, oils or any debris from the soles
of your shoes. If you operate the pedals with mud,
oils or any debris on your shoes, your foot may slip

SAFETY
and you could cause an accident.
• Always keep the operator cab clean. Never leave
tools or obstacles lying in the operator cab.
• Do not stick objects on the window glass. These

FUNCTION
SYSTEM
may restrict your view.
NOTE: References to windows do not apply to
Fig. 2-1 a
machines with an open canopy.

OPERATION
• Do not use cell phones inside the operator cab when traveling or operating the machine.
• Never bring dangerous objects or fluids into the operator cab. These could spill, ignite or explode.
• Keep the windows clean and free of mud or film build-up. Clean the windows daily before starting your

MAINTENACE
work operations.
• If the windows are broken or cracked, replace them immediately. Never operate the machine with broken
or cracked windows.
• Never modify any operator cab components, systems or surfaces. Any modification without authorization

SPECIFICATIONS TROUBLRSHOOTING
from Sany can create a hazard. Sany will not be responsible for any injury or damage caused by any
unauthorized modifications.

EQUIPMENT
OPTIONAL

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Safety SY215 Excavator

Mount and Dismount the Machine

Mounting or dismounting could pose some
hazards. Observe the following:
• Always be sure the machine is at a full stop
before attempting to access the machine. Never
jump onto or off of the machine.
• Never exit or enter the operator cab or deck by
any other means than the provided steps (a) and
grab handles (b).

Fig. 2-2 a

• Always maintain a three-point contact (both feet

and one hand or one foot and both hands) with
the grab handles, steps and deck to ensure proper
support.
• When walking on the deck of the machine, always
try to maintain a three-point contact whenever
possible to help keep good balance.
• Wear shoes with a highly slip-resistant sole
material. Clean any mud or debris from shoes
before entering the machine cab or climbing onto Fig. 2-3
the machine superstructure.

• Do not walk on a surface of the machine if slip-resistant material is missing or excessively worn. Do
not step on surfaces of the machine that are not approved or suitable for walking and working. Keep all
walking and working surfaces of the machine clean, dry and slip-resistant.
• Always keep grab handless, steps and walkway areas clean and clear of mud, oil, grease or similar debris.
If these areas are damaged, have them repaired or replaced immediately.
• Never leave tools or similar objects on the machine deck or service areas. These could fall and get caught
in the machine operating systems.

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CONTENTS
TABLEOF
• Never climb on areas of the machine that are
not designated walk areas. A slip or fall from the
machine could result.

INTRODUCTION
• Never climb on or off the machine while holding
tools or similar objects.
• Do not modify the machine’s access system in
any way that has not been evaluated and approved
by Sany Group.

SAFETY
Unauthorized Machine
Modifications Fig. 2-4

Unauthorized modifications may adversely affect the machine’s performance and strength. If this machine
is modified without authorization from Sany, there is also a danger that performance and safety problems

FUNCTION
SYSTEM
may occur.

Job Safety
Review each of these carefully:
• It is the owner’s and/or operator’s responsibility to replace any safety decals if they are defaced or

OPERATION
removed from the machine.
• Never leave the machine running and unattended. Always park the machine in a safe level area, lower
any work equipment to a safe position, lock the controls to secure the machine to prevent tampering by
unauthorized personnel and shut down the engine before exiting the machine even for a moment.

MAINTENACE
• Before starting any work operations, travel or maintenance procedures, be sure all personnel are at a
safe distance away from all points of the machine. Never allow anyone to stand near the machine while in
operation, under maintenance or repair. Remember, the larger the machine, the more restricted the visibility
will be.

SPECIFICATIONS TROUBLRSHOOTING
• It is the responsibility of the operator’s employer to conduct periodic safety training and familiarize all
personnel with emergency procedures.
• If pedestrians are in the area, proceed slowly and sound the horn. Pedestrians have the right of way; a
loaded or smaller machine has the right away over a larger or unloaded machine.
• Never drive up to anyone standing in the path of travel. Always be sure all personnel are standing to the
side when approached and they acknowledge the approach.
• When working with another person on a job site, ensure all personnel involved understand all industry
standard hand signals that are to be used.
• The operator shall respond to operating signals from the proper signal person only but shall obey a stop
signal at any time from anybody.
EQUIPMENT
OPTIONAL

• The operator must always be able to see the point of work location. If this is not possible then a signal
person must be used. If visibility becomes blocked for any reason, stop operation immediately.

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Job Site Safety

Within the job site (also called “construction site”) is the “work area” (where the actual job function is
being performed). Within the work area are “hazard areas”, that is, areas immediately surrounding the
machine where personnel may be at risk due to machine operation or movement.
With the machine operator being responsible for the safe and correct operation of the machine, they are
responsible for safety within the hazard zones while the machine is in use. Immediate work stoppage and
machine shutdown by the machine operator is required if unauthorized personnel enter any of the hazard
areas.
Always study the job site carefully to be aware of any potentially hazardous areas. All hazard areas must be
clearly identified, marked and secured to prevent access by unauthorized personnel and must be visible to
the machine operator at all times and under all circumstances. If this is not possible, a signal person must
be assigned to supervise activities within hazard areas. Personnel within a hazard area must use increased
caution and wear suitable personal protective equipment as required.

Surface and Underground Hazards

Before starting any operations:
• Determine the safest method of entrance and
operation.
• Contact all utility companies in the area to have
them identify and mark any underground system
locations (gas lines, water lines, electrical lines,
sewer lines, etc.).
• Check the work area for any unusual ground
conditions and be sure the ground surface is stable Fig. 2-5
enough to support the machine.

NOTE: When operating on embankments, ditches near waterways or soft areas, there is a possibility that
the weight and vibration of the machine will cause the soil to collapse.
• Be sure there are no obstructions in the working area.
• Do not operate where there is a hazard of landslides or falling objects.
• If possible, never set up or operate near excavated sites. Always use extreme caution when near the edge
of a cut, ditch, waterway or similar areas, as the edge may give way causing the machine to slide or roll
over.
• Make sure the work area is as level as possible and that the machine and work equipment will be able to
maneuver easily.
• When working near a high-traffic area (pedestrians or cars), have a dedicated worker available to direct
traffic or install safety fencing around the work site.
• Always be aware of all work site dangers or distractions.

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CONTENTS
TABLEOF
High Voltage Areas
Operating the machine near high voltage towers (for example power or transmission towers) may pose an
electrical hazard. Ask the utility company to shut down the system until work is finished.

INTRODUCTION
Know the dangers of working around overhead electrical lines. High humidity may pose an electrical
hazard even if the machine clears the overhead electrical lines.
If the machine makes contact with electrical lines, stop the machine and remain on it until the power
company clears the lines and it is safe to get off or move the machine. If it is necessary to exit the machine,
keep both feet and legs together, arms and hands at your side. Jump clear from the machine, maintain
balance and land with both feet, legs, arms and hands still together. Do not touch the machine during the

SAFETY
jump. Once on the ground continue to “bunny hop” away from the affected area as far as possible.
When unsure of clearances, request the aid of another person who can guide or warn when maneuvering
the machine too close to objects.

FUNCTION
SYSTEM
Electrocution Hazard
Keep all parts of this machine away from all electrical power lines and other electrical power sources as
shown on the following table:

Minimum Distances Between Machine and Power Lines

OPERATION
Cable Voltage, kV (kilovolts) Minimum Required Clearance, ft (m)
350 or less 20 (6.10)
Over 350 - 500 25 (7.62)
Over 500 - 750 35 (10.67)
Over 750 - 1,000 45 (13.72)

MAINTENACE
Contact the power utility company for assurance that the power has been turned off before operating this
machine in the vicinity of electrical power lines or any electrical power sources.

NOTE: This machine is not insulated.

SPECIFICATIONS TROUBLRSHOOTING
Treat all overhead power lines as being energized and not insulated, unless reliable information to the
contrary from the utility company or owner is available.
The requirements stated in this manual must be followed at all times, even if the electrical power lines or
electrical power source have been turned off.
The operator is responsible for alerting all personnel of dangers associated with electrical power lines and
electrical power source. Do not allow unnecessary personnel in the vicinity during operation. The operator
must prevent everyone from touching the machine.
It is not always necessary to contact a power line or power source to become electrocuted. Depending on
magnitude, electricity can arc or jump to any part of the machine if it comes too close to an electrical power
source.
EQUIPMENT
OPTIONAL

The use of electrocution hazard devices (insulated links, insulated boom cages/guards, proximity warning
devices or mechanical limit stops) do not assure that electrical contact will not occur.

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Safety SY215 Excavator

Grounding of the machine affords little or no protection from electrical hazards. The effectiveness of
grounding is limited by the size of the conductor (wire) used, the condition of the ground, the magnitude of
the voltage and current present, and numerous other factors.
Because of the voltages involved, overhead power lines present an extremely high risk of fatal electric
shock. If contact occurs, proper safety procedures should be followed. The danger posed by overhead
power lines at the job site is often compounded by other factors, such as uneven ground that could cause
the machine to weave or bob into power lines, and windy conditions that can make the power lines sway,
reducing clearance.
To address these risks:
• Identify overhead power lines and mark safe routes where the machine must repeatedly travel.
• Operate the machine at a slower-than-normal speed in the vicinity of power lines.
• De-energize and ground overhead power lines or take other protective measures such as guarding or
insulating the lines.
• If the power lines are not de-energized, operate the machine in the area ONLY if a safe minimum
clearance is maintained.
• If maintaining safe clearance by visual means is difficult, designate a person to observe the clearance and
to give immediate warning when the machine approaches the limits of safe clearance.
• All personnel should keep away from the machine whenever it is close to power lines.
• Do not touch the machine until a signal person indicates that it is safe to do so.
• The use of electrocution hazard devices is not a substitute for de-energizing lines, or maintaining safe
clearance.

When working near transmitter/communication towers where the machine is close enough for an electrical
charge to be induced in the machine or materials being handled, the transmitter must be de-energized or the
following precautions must be taken:
• The machine must be provided with an electrical ground.
• If tag lines are used, they must be non-conductive.
If the machine or any of its components contacts an energized power source:
• Remain calm and do not panic.
• Immediately warn personnel in the vicinity to stay away.
• If in the operator cab, stay there until the power company has been contacted and the power source has
been de-energized. No one must attempt to come close to the machine until the power has been turned off.
Following any contact with an energized electrical source, your Sany dealer must be immediately advised
of the incident and consulted on necessary inspections and repairs. Should the dealer not be immediately
available, contact Sany America. The machine must not be returned to operation until it is thoroughly
inspected for any damage and all damaged parts are repaired or replaced as authorized by Sany Group or
your Sany dealer.

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CONTENTS
TABLEOF
Pre-Start Checks
Always perform a pre-start check at the beginning of a work shift and also before starting work operations
(even when taking over the machine operations from another operator) to be sure the machine is in safe

INTRODUCTION
operating condition.
If any problems are found during the pre-start check, have them repaired immediately. Never operate
a machine that is in need of repair, damaged or unsafe, or when proper maintenance records cannot be
confirmed.
NOTE: See “Pre-Start Checks” on page 4-8 to be sure it is in safe operating condition.

SAFETY
Working with damaged equipment may result in further damage to the machine or injury to the operator
and other personnel.

Start-Up Safety

FUNCTION
SYSTEM
Before normal starting:
• Verify that the maintenance log for this machine is filled out and current. Verify that the Safety, Operation
& Maintenance manual is inside the operator cab.
• Walk around the machine and check for people or objects that might be in the way. Be sure all personnel

OPERATION
are clear from the work site before starting any operations.
• Do not start the machine if lockout/tagout tags have been attached to the control levers.
• Sound the horn to warn others in the area before starting the engine, moving the machine or starting any
machine operation.

MAINTENACE
• Never allow anyone in the operators cab or on the machine during operation.
• Check the view. Be sure all work areas around the machine are clearly visible.
• Always start and operate the machine from a seated position with the seat belt fastened snuggly around

SPECIFICATIONS TROUBLRSHOOTING
your waist.
• Never start the machine by tampering with or shorting the starter terminals. Accidental movements of the
machine may result, leading to injury or possibly death. Always start the machine using only the ignition
switch. EQUIPMENT
OPTIONAL

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Safety SY215 Excavator

Personal Protective Equipment

Because safety is important, read and understand
the following:
• If the machine is equipped with operator aids,
OSHA requires this equipment to be used when
operating the machine.
• Avoid any loose fitting clothing, jewelry and
loose long hair. These can get caught in moving
parts or on the controls and could cause serious
injury. Fig. 2-6

• Before using personal protective equipment,

be sure it is in good condition and will be able to
perform its task.
• If required, wear a hard hat, safety glasses, safety
shoes, face mask and gloves when operating or
maintaining the machine.
• Wear hearing protection when working near loud
noises.

Fire Safety
Fuel, oil and various types of substances are flammable. Always observe the following:
• Keep open flames, airborne sparks and burning embers away from the machine.
• Shut down the engine and do not smoke when refueling or maintaining the machine.
• Refueling or adding oil should be done in a well-ventilated area.
• Clean up any spilled fluids immediately.
• Check the machine daily for excess debris buildup.

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CONTENTS
TABLEOF
Fluid Fires
Fuel and other machine fluids are particularly flammable and can be hazardous. Pay close attention to the
following:

INTRODUCTION
• Do not smoke or bring open flames or sparks near fuel or other fluids. Always shut down the engine
before refueling.
• Never use fuel starting aids or other unapproved cleaning solvents to clean the machine or parts.
• Never leave the machine while adding fuel or other fluids.
• Tighten all fuel and fluid caps securely.

SAFETY
• Always inspect the machine for fuel or other fluid leakage during a pre-start check. If any leakage is
found, have it repaired immediately. Never operate a machine that is leaking fuel or other fluids.
• Be careful not to spill fuel or other fluids, especially on hot parts, machine surfaces or electrical
components. Clean up fuel and other fluid spills immediately.

FUNCTION
SYSTEM
• Never overfill the hydraulic fluid or fuel tanks. During operation, hot fuel or other fluids could be spewed
out onto hot components, causing a fire or explosion.
• When adding fuel or other fluids to the machine, always perform these operations in a well-ventilated
area.

OPERATION
• Never weld, cut, drill or modify hydraulic components in any manner.
• When performing pre-start checks, always inspect hoses and tubing clamps for leaks and that they are
properly secured.

MAINTENACE
Electrical Fires
Short circuits in the electrical system, damage or overcharging batteries can cause fires. Adhere to the

SPECIFICATIONS TROUBLRSHOOTING
following:
• Never use a welder or a machine of a higher voltage to jump-start a machine.
• Check the wiring on the machine for damage when doing a pre-start check. Repair or replace any
damaged wiring.
• Never install aftermarket electrical equipment without approval from your Sany dealer.
EQUIPMENT
OPTIONAL

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Safety SY215 Excavator

Fire Extinguisher
As a precaution in case of fire or injury to personnel,
always keep a fire extinguisher in the operator’s cab
and on the job. Also, do the following:
• Be sure the fire extinguisher is in good condition and
all personnel know how to use it.
• Be sure the fire extinguisher is at least a three-pound
“A, B, C” fire-rated extinguisher (NFPA 10 Standard
for Portable Fire Extinguishers).

Fig. 2-7

In Case of Fire
If a fire occurs on the machine, escape from the machine as follows:
• Immediately turn the ignition key to the OFF position to shut down the engine and shut the machine
down. Never attempt to move or continue operating the machine.
• Exit the area immediately and remain clear of the machine until the fire department gives permission to
come near the machine.
• Immediately call for help.
• When using a fire extinguisher, always aim the extinguisher nozzle at the base of the fire. NOTE: See “Fire
Extinguisher” on page 2-17.
• Have a list of emergency phone numbers available in case of fire or an accident.

Dust and Chemical Hazards

Performing operations and/or encountering hazardous materials on the job site may release substances
that could pose a hazard. Exposure to hazardous chemicals or dusts poses a serious danger when they are
released or mishandled. All workers involved should use approved personal protective equipment and
follow all environmental safety regulations.

Dust Hazards
Dust in the air from the job operation could cause lung damage if inhaled. If there is danger of inhaling
these dusts when working on the job sites, always observe the following:
• Spray water to keep down the dust when cleaning. Do not use compressed air for cleaning.
• If there is danger that there may be asbestos dust or similar dusts in the air, always operate the machine
from an upwind position. All workers should use approved respirators.
• Always observe the rules and regulations for work site and environmental standards.
• Never allow unauthorized or improperly protected personnel in the work area.

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CONTENTS
TABLEOF
• Sany machines do not contain asbestos, but there is a possibility that non-Sany or aftermarket parts
maycontain asbestos. Always use Sany-approved replacement parts.
• All workers involved should use approved personal protective equipment and follow all environmental

INTRODUCTION
safety regulations.

Safety Data Sheets (SDS)

The Safety Data Sheet (SDS) is also known as a
Material Safety Data Sheet (MSDS).
The contractor on the job site must provide all

SAFETY
personnel access to the proper SDS data sheets
relating to the materials and chemicals the workers
could be exposed to.
SDS data sheets provide both job site personnel and
emergency personnel with the proper procedures

FUNCTION
SYSTEM
for handling or working with a particular substance.
Information includes physical data, health effects,
first aid, reactivity, storage, disposal and required
protective equipment.

OPERATION
Comply with the following:
Fig. 2-8
• Keep all SDS information conveniently placed
and available to all job site personnel and
emergency personnel.

MAINTENACE
• Be sure all personnel involved with job site operations are familiar with all SDS information as it relates
to hazardous materials they could be exposed to.
• Read and understand the provided SDS data sheet before handling hazardous materials.

SPECIFICATIONS TROUBLRSHOOTING
Maintenance Safety
All maintenance to be performed on this machine must be performed by trained and authorized personnel
only.
The machine must be inspected prior to each work shift. The owner, user, and operator must ensure that
required routine maintenance and lubrication tasks have been performed as stated in this manual.
Perform function checks after repairs have been made to ensure proper operation.
Recognize and avoid pinch-points while performing maintenance.
Direct any questions to your Sany dealer.
EQUIPMENT
OPTIONAL

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Clean the Machine

Always use hot water and mild, non-flammable grease-cutting soaps or cleaning agents to clean the
machine parts. Never use flammable or caustic cleaning agents.
Never pressure-wash or flood the operator cab. This will damage sensitive electrical components.
Never use high-pressure steam cleaners to clean the machine. Steam cleaners will damage the paint, hoses
or electrical system.
Always lubricate the machine thoroughly after cleaning to force out any water or soap residue.
NOTE: See the Maintenance section of this manual for additional information.

Use the Correct Tools

Always use the proper tools for the job.
Keep your tools clean, and when the job is complete, take inventory of the tools you were using to be sure
no tools were left in the machine.
Return shop tools to their proper storage location when finished.

Jack Up the Machine

Always do the following:
• When working under the machine, use approved jack stands that will support the weight of the machine
being worked on.
• Never rely on the hydraulics of the machine or a hydraulic jack to support the machine during repairs.
• Lower any work equipment to the ground and check the stability of the machine before going under the
machine.

Rotating Parts
Start the engine for maintenance procedures only if directed to do so in this manual. If the engine must be
running when performing maintenance, it is important to follow some basic safety rules:
• Always be aware of rotating components.
• During maintenance operations while the engine is running, one worker must remain in the operator seat
of the machine with a clear view to the person performing the maintenance on the machine at all times.
• Never touch any controls. If a control lever must be operated, always maintain a clear view to the person
performing the maintenance and signal them before moving the control lever.

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CONTENTS
TABLEOF
Remove Attachments
When removing large, heavy attachments or parts, always use the correct lifting equipment rated for the
capacity of the load being lifted.

INTRODUCTION
After the attachment or part has been removed, store it where it cannot fall or move. Always be sure the
attachment or part is stable on a solid surface and clear of all walkways or fire exits.
When installing and using optional attachments, read and follow the instruction manual for the attachment.
Do not use attachments or parts that are not authorized by your Sany dealer. Use of unauthorized
attachments could create a safety problem and adversely affect proper operation and useful life of the

SAFETY
machine.

Weld, Drill, Cut or Grind on the Machine

NOTE: Contact your Sany dealer for proper guidance on any welding being attempted.

FUNCTION
Personnel welding on the machine must be fully qualified and certified to use the processes and equipment

SYSTEM
they may operate in making these repairs. Customers are responsible for the structural integrity of any
completed repair. Sany strongly recommends against welding on connectors and fine grain hi-strength
steels. Components should be replaced if they are damaged.
Disconnect the power source prior to welding. Failure to do so may damage the machine or cause personal

OPERATION
injury.

Fluid Systems

MAINTENACE
Add Fluids to the Machine
When fluids must be added to the machine during operation, always be aware that the fluid systems are
under high pressure and hot.

SPECIFICATIONS TROUBLRSHOOTING
NOTE: See the Maintenance section of this manual before adding fluids.

Refuel
Before adding fuel, shut the machine down and allow the systems to cool to ambient temperature before
removing the fuel tank cap. Failure to do so may result in serious burns or a sudden loss of fuel. Read and
understand the following:
• Refueling the machine could pose some hazards. Fuel spills pose a hazard if not cleaned up immediately.
• Refuel only in a well-ventilated area. Never smoke or allow open flames nearby while refueling the
machine.
• Never mix gasoline with diesel fuel. Gasoline is extremely flammable and could cause an explosion.
EQUIPMENT
OPTIONAL

• Always allow room for the fuel to expand when filling the fuel tank.

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High-Pressure Fluid Lines

Replace a line or hose if a leak is found or failure occurs. Always remember that this system is highly
pressurized during normal operation.
Always do as follows:
• Check for cracks in the piping or hoses and for swelling in the hoses.
NOTE: If there is any leakage from a line or hose, the surrounding area will be wet.
• Never perform inspections or replace items while the system is under pressure. Working on a system still
under pressure could lead to serious injury.
• Never use any body part to check or feel for leaks. Always wear safety glasses and leather gloves when
checking for leaks and use a piece of wood or cardboard when checking leaks from small holes.
• If high-pressure fluids penetrate skin or get into eyes, seek medical attention immediately.

Accumulator
This machine is equipped with an accumulator charged with high-pressure nitrogen gas. Do not
disassemble the accumulator.
• Never expose the accumulator to high heat or open flames.
• Never weld on the accumulator.
• Never drill or cut on the accumulator.
• Never strike the accumulator.
If the accumulator should need maintenance, contact your Sany dealer.

Electrical System
Always clean the electrical system using only approved electrical cleaners.
Never use caustic soaps, high-pressure water or steam cleaners to clean the electrical system, as these could
damage the system or cause intermittent system failures.

Battery Safety
When working with batteries, always work in a well-ventilated area. Batteries pose a hazard, especially
when they have been in use for a long period of time. Listed below are some basic precautions to be aware
of when working around batteries:
• Always wear personal protective equipment.
• Battery gases are extremely explosive. Smoking, sparks or open flames could cause an explosion. When
opening a battery compartment always allow ample time for the gases to escape.
• If the battery is corroded, flush the area with a baking soda and warm water mix.
• If battery acid gets on skin or in eyes, flush the area immediately with fresh water and seek medical
attention.
Check battery condition only with proper test equipment. Batteries should be charged in an open, well-
ventilated area that is free of flame, smoking, sparks, and fire.
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CONTENTS
TABLEOF
Disconnect the Battery
When disconnecting the battery, always disconnect a b
the negative (-) terminal first (a), then disconnect

INTRODUCTION
the positive (+) cable (b).

SAFETY
Fig. 2-9
Jump-Start Safety
When using jumper cables to start the engine, connect the positive (+) cable first, then connect the negative
(-) cable to the engine block or a chassis location away from the battery.

FUNCTION
SYSTEM
Never use a welder or equipment with a higher voltage system to jump-start the machine. Using a higher
voltage to jump-start the engine may damage the electrical system or cause an unexpected explosion or fire.
Always jump-start the engine with equal voltages.
NOTE: See the Troubleshooting section of this manual.

OPERATION
Environmental Precautions
Recycling used oil, coolants or filters conserves a natural resource and is good for the environment. fluids
poured onto the ground, in bodies of water, into storm drains, or tossed into trash cans (even in a sealed
container) can contaminate and pollute the soil, groundwater, streams, and rivers. Recycling used fluids

MAINTENACE
reduces this pollution threat.
NOTE: Always drain fluids from the machine into an appropriate container. Dispose of fluids in accordance
with local environmental regulations.

SPECIFICATIONS TROUBLRSHOOTING
NOTE: Drain, crush and dispose of all filters properly.
Obey all appropriate laws and regulations when disposing of harmful objects such as oil, fuel, filters,
batteries, hydraulic fluid or used parts. Failure to do so may result in fines or punishment.
EQUIPMENT
OPTIONAL

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PRODUCT-SPECIFIC SAFETY
Lockout/Tagout Procedures
Never work on the machine without first ensuring
that the lockout/tagout process has been followed.
Contact supervision or your Sany dealer with
questions.
Only authorized personnel performing maintenance
on the machine shall perform Lockout/Tagout in
accordance with the procedure listed below.
If the person performing maintenance to the
machine is issued a lock and key, they will
not share the lock or keywith others until all
procedures are complete and the machine is ready
to be put back into operation.

Lock Out of Operation

Fig. 2-10
1. Notify all personnel who may be affected by
maintenance on the machine.
2. Secure the machine on a flat, level surface in a
safe location where there is no danger of falling
objects or interference with other equipment,
personnel or pedestrian traffic.
3. Shut down the engine and remove the ignition
key.
NOTE: See “Engine Shutdown Procedure” on page
4-21.
4. Identify, remove or disconnect all power or
energy sources and be sure to install a lockout/
tagout device on them.
NOTE: See “Electrical System” on page 5-21.
5. Attach a maintenance alert tag to the machine
controls.
Fig. 2-11
6. Be sure all personnel involved in the
maintenance have installed their own locks on the
power source before performing any repairs. Each
person who completes a repair must remove his
own lock and not access the machine further.

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CONTENTS
TABLEOF
Return to Operation
The authorized person who performed the Lockout/
Tagout procedure shall:

INTRODUCTION
1. Check the area around the machine to ensure that
no one is exposed to any hazard before returning
the machine to operation.
2. Ensure that all guards have been properly
reinstalled to their respective locations.

SAFETY
3. Ensure all tools, equipment and locks have been
removed.
4. Verify that all controls are in the neutral or off
position.

FUNCTION
5. Alert all personnel to the time the machine will

SYSTEM
be back in operation.
6. Remove the lockout/tagout mechanisms and all
tags and return the machine to operation. Fig. 2-12

OPERATION
7. Complete the appropriate section of the
Maintenance Log.

Machine Decals

MAINTENACE
All safety, alert and warning decals must be in place, undamaged, and visible. Become thoroughly familiar
with the location and content of all decals on the machine. Walk around the machine and review each of
them. Decals provide important instructions and warnings and must be read prior to any operational or
maintenance function. Do not remove any decal from this machine.

SPECIFICATIONS TROUBLRSHOOTING
NOTE: Your Sany dealer can supply new replacement decals if needed. Never modify or change existing
decal information unless authorized by your Sany dealer.
When replacing decals, be sure they are placed in the proper locations. Note that the decals shown in this
manual may not exactly match what is on this machine. Contact your Sany dealer if you have any questions
as to meaning and placement.
NOTE: Additional safety decals may be added to the machine if necessary.
EQUIPMENT
OPTIONAL

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Type, Location and Meaning

Accumulator
• Located behind the air filter mounted on the
hydraulic manifold.
• Identifies the accumulator.

Fig. 2-13

Back-up warning
• Located on the rear of the machine.
• Informs and warns to stay clear of the machine
moving in reverse and/or the upperworks rotates.

Fig. 2-14

Battery
• Located in the battery compartment.
• Identifies and shows the voltage of the battery.

Fig. 2-15

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CONTENTS
TABLEOF
California warning
• Located next to the battery, usually close to the
battery decal.

INTRODUCTION
• Informs of the California State Ordinance.

SAFETY
FUNCTION
SYSTEM
Fig. 2-16

OPERATION
MAINTENACE
Center of gravity
• Located on the upperworks of the machine and
centered above the midpoint of the tracks.
• Identifies the center of gravity point of the

SPECIFICATIONS TROUBLRSHOOTING
machine for loading and lifting purposes.
NOTE: See “Machine Dimensions” on page 7-2
for information on machine weight.
NOTE: See “Lift the Machine” on page 4-45.

Fig. 2-17
EQUIPMENT
OPTIONAL

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Crush hazard
• Located on either side of the arm, centered
between the top and the bottom of the length of the
arm.
• Warns against being crushed by the machine arm
or objects being lifted. Advises to stay clear of
overhead objects and machine components.

Fig. 2-18

Exit
• Located on the inside rear window of the cab,
centered toward the top.
• Identifies an emergency exit out the back window.

Fig. 2-19

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CONTENTS
TABLEOF
Fall warning
• Located on the rear deck of the machine on both
sides at the back corners behind the engine.

INTRODUCTION
• Warns personnel against the hazard of falling
from the machine and to stay clear of the edge of
the machine.

SAFETY
FUNCTION
SYSTEM
OPERATION
Fig. 2-20

MAINTENACE
Fan warning

SPECIFICATIONS TROUBLRSHOOTING
• Located on the top of the engine cover near the
latches holding the cover down.
• Warns about the rotating fan within the engine
compartment. Keep hands clear of the fan and all
rotating components.

Fig. 2-21
EQUIPMENT
OPTIONAL

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Fire extinguisher
• Located inside the cab on the upper level of the
back window.
• Shows the location of the fire extinguisher on the
machine.
NOTE: See “Fire Extinguisher” on page 2-16.

Fig. 2-22

Forward direction
• Located on the lowerworks inside the track near
the final drive.
• Used to point out the forward (front) position of Fig. 2-23
the machine.
NOTE: See “Track Direction” on page 4-26.
Front window warning
• Located on the upper right corner of the front
window.
• Warns to make sure the front window is locked in
place.
NOTE: See “Front Window Locks” on page 4-13.

Fig. 2-24

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CONTENTS
TABLEOF
Fuel tank
• Located next to the fueling point on top of the
fuel tank.

INTRODUCTION
• Identifies the fueling point to the operator and
gives the type of fuel (diesel) used.
NOTE: See “Fluids & Lubricants” on page 5-13.

SAFETY
FUNCTION
Fig. 2-25

SYSTEM
Fuel tank drain

OPERATION
• Located next to the fuel tank drain at the bottom
of the fuel tank.
• Identifies the fuel tank drain location and directs
that the handle must move to the right to open the

MAINTENACE
drain.
NOTE: See “Primary Fuel Filter” on page 5-28.

SPECIFICATIONS TROUBLRSHOOTING
Fig. 2-26 EQUIPMENT
OPTIONAL

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Safety SY215 Excavator

Fuel-water separator
• Located next to the fuel-water separator inside
the right rear access panel.
• Identifies the fuel-water separator location, shows
that the machine uses diesel fuel and that the water
could get into the system. Directs that to remove
the water the drain must be unscrewed.
NOTE: See “Primary Fuel Filter” on page 5-28.

Fig. 2-27

Grease point pressure warning

• Located next to the opening for the track
tensioning grease point on both sides of the tracks.
• Warns about grease spraying out under pressure
from the track tensioner.
• Warns to read the appropriate section of this Fig. 2-28
manual.
NOTE: See “Track Tension (Initial)” on page 5-62
for further information.

High temperature warning

• Located on top of the engine cover.
• Warns about high temperature areas, keep away
from hot components and the possibility of burns.

Fig. 2-29

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CONTENTS
TABLEOF
High voltage
• Located inside the cab on the window to the right
of the operator.

INTRODUCTION
• Identifies the danger of coming in contact with
high voltage electrical wires - stay away.

Fig. 2-30

SAFETY
Hydraulic fluid level
• Located next to the hydraulic fluid gauge.
• Identifies the hydraulic fluid check location,

FUNCTION
SYSTEM
gauge and indicates the temperature range.
• Warns to read the appropriate section of this
manual.
NOTE: See “Hydraulic Fluid/Ambient

OPERATION
Temperature Data” on page 5-15.

Fig. 2-31

MAINTENACE
Hydraulic tank
• Located next to the hydraulic fluid fill point.

SPECIFICATIONS TROUBLRSHOOTING
• Identifies the location of the hydraulic fluid fill
point.
• Warns to read the appropriate section of this
manual.
NOTE: See “Hydraulic Fluid Tank” on page 5-35.
EQUIPMENT
OPTIONAL

Fig. 2-32

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Joystick
• Located inside the cab on the window to the right
of the operator.
• Gives the button placement of the joystick on the
machine.

Fig. 2-33

Lift chart
• Located inside the cab on the window to the right
of the operator.
• Gives the parameters of safe lift ranges using the
machine.

Fig. 2-34

Lift point
• Located on the lowerworks on both ends of the
track assembly on both sides of the track.
• Shows where the machine can be safety rigged
for lifting.
NOTE: See “Lift the Machine” on page 4-43.

Fig. 2-35

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CONTENTS
TABLEOF
Lifting points
• Located on the outside of the cab, directly above
the serial number plate.

INTRODUCTION
• Shows how and where to rig the machine for
lifting.
• Warns to read the appropriate section of this
manual. Fig. 2-36

SAFETY
Lock-unlock indicator
• Located inside the cab near the cab door latch.

FUNCTION
SYSTEM
• Points out the location of the door latch.

OPERATION
Fig. 2-37

MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
Lubrication table
• Located on the lower window of the cab door.
• Shows the lubrication points on the machine.
NOTE: See “Lubricate” on page 5-52and
“Lubricate” on page 5-64.

Fig. 2-38
EQUIPMENT
OPTIONAL

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Safety SY215 Excavator

No sit warning
• Located on the shelf behind the operators seat.
• Instructs against sitting in this area.

Fig. 2-39

No step warning
• Located on top of the engine cover and the
counterweight sections.
• Warns against falling off the machine and to not
walk or step in this area.

Fig. 2-40

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CONTENTS
TABLEOF
Pattern change
• Located next to the SAE/BHL selector located
behind the left rear access panel.

INTRODUCTION
• Gives guidance on how to switch the machine
from SAE to BHL mode.
• Warns about stopping the engine before switching
modes.
Fig. 2-41

SAFETY
Pattern change cards
• Located inside the cab on the widow to the right
of the operator. (Not a decal)
• Gives guidance on the movement of the controls

FUNCTION
in SAE and BHL modes.

SYSTEM
Fig. 2-42
Pattern change instruction
• Located inside the cab on the window to the right

OPERATION
of the operator.
• Explains how the controls will react in SAE or
BHL mode.
• Be sure to know what mode the machine is in

MAINTENACE
before operating to prevent unintended movement.
• Warns to read the appropriate section of this
manual. Fig. 2-43

SPECIFICATIONS TROUBLRSHOOTING
NOTE: See “SAE/BHL Selector” on page 4-9.
Quick coupler caution
• Located inside the cab on the window to the right
of the operator.
• Cautions against releasing the quick coupler
holding the bucket while the bucket is off the
ground.
• Warns to read the appropriate section of this
manual.
EQUIPMENT
OPTIONAL

Fig. 2-44
NOTE: See “Disconnect Optional Equipment” on
page 8-11.

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Safety SY215 Excavator

Radiator cap warning

• Located near the radiator cap.
• Warns against opening the radiator when it is hot
and under pressure.
• Warns to read the appropriate section of this
manual.
NOTE: See “Engine Coolant Level” on page 5-34.
Fig. 2-45

Read the manual

• Located inside the cab on the window to the right
of the operator.
• Warns to read the appropriate section of this
manual.

Fig. 2-46

Seat adjustment
• Located at the base of the seat directly under the
hydraulic lockout control lever.
• Demonstrates the proper way to adjust the seat
and that there are two different controls used in
adjusting the seat.
NOTE: See “Seat and Seat Belt” on page 3-4.
Fig. 2-47

Seat belt
• Located inside the cab on the window to the right
of the operator.
• Warns to fasten the seat belt before operating the
machine.
NOTE: See “Seat Belt” on page 4-10.

Fig. 2-48

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CONTENTS
TABLEOF
Swing bearing caution
• Located on the swing bearing ring next to the
front grease points.

INTRODUCTION
• Indicates where to grease the swing bearing.
• Warns to read the appropriate section of this
manual.
NOTE: See “Swing Bearing” on page 5-64.

SAFETY
Fig. 2-49
Tie-down points for loading
• Located on the lowerworks between the tracks,
two forward where the idler wheels are (on either
side of the machine), and two at the back where the

FUNCTION
SYSTEM
final drive is located.
• This shows the location on the machine
lowerworks frame where the machine may be
safely attached for transport.

OPERATION
Track tension

MAINTENACE
• Located next to the track tensioning points on
Fig. 2-50
both sides of the track (undercarriage).
• Shows the location of the track tensioning point.

SPECIFICATIONS TROUBLRSHOOTING
• Warns to read the appropriate section of this
manual.
NOTE: See “Track Tension (Initial)” on page 5-62.

Authorized Use of the Machine

The excavator is designed for digging, leveling,
loading and demolition purposes.

Fig. 2-51
EQUIPMENT
OPTIONAL

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Safety SY215 Excavator

Unauthorized Use of the Machine

• Using equipment or attachments not authorized for the machine.
• Driving the machine on a public road.
• Using the machine for tasks it was not designed for; damage to the machine or injury to the operator and
other personnel may result.
• Using the swinging force to compact the ground or break objects.
• Cutting the bucket into the ground and use the traveling force to excavate.
• Operating any cylinder at the very end of the stroke.
• Using the bucket landing force for excavating, digging, breaking or pile-driving.
• Using the weight of the machine to excavate hard or rocky ground.
• Dragging or pulling a load with the machine using the swing mechanism. Damage to the swing
mechanism or loss of control could result.
• Pulling a load towards the machine. If the cable should snap or the load should come free, the possibility
of an object hitting the operator cab could cause damage to the machine or injury to the operator.
• Using the dropping force of the machine for digging or breaking up material. Using the bucket as a
pickax, breaker or pile driver will damage the machine and will reduce the life of the machine or possibly
cause injury to the operator.
• Using the dropping force of the machine for digging or pulling materials from a high-level area. Damage
to the machine or injury to the operator may result.
• Using with the cylinder rod fully extended and the impact by some external force applied. The hydraulic
cylinder will be damaged and may cause personnel injury.
NOTE: Avoid operations with the hydraulic cylinder fully retracted or fully extended.

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CONTENTS
TABLEOF
Job Site Precautions
NOTE: See “Job Site Safety” on page 2-10.
In addition to the information cited on page 2-10, never allow anyone to approach the work area during

INTRODUCTION
operation or travel.
If they should approach, stop operation or travel immediately and signal them to leave immediately and do
not resume operation or travel until they have left the work area and are at a safe distance.
If they must approach, signal them to stop where they are, lower all work equipment to the ground, set the
hydraulic lockout control lever in the CLOSE position and shut the engine down.

SAFETY
When it is safe for them to approach, signal them to approach.

Surface and Underground Hazards

It is important to study the area for hazards

FUNCTION
SYSTEM
involved with the job operation before placing
the machine on a job site or starting any work
operations.
NOTE: See “Surface and Underground Hazards”

OPERATION
on page 2-10 for general hazards.

Fig. 2-52

MAINTENACE
The following is a list of what to do to avoid some of the hazards:
• Before unloading, the machine, be sure the ground surface will support the machine.
• When performing excavation operations on an embankment, cliff or a large dig area, always position the
track carriage at right angles with the machine as shown in the illustration. If the bank gives way during

SPECIFICATIONS TROUBLRSHOOTING
operations, placing the carriage in this position will allow the advantage of escaping the area easier.
• When excavating a trench, always be aware of the ground condition and never attempt to dig too close or
under the machine. The possibility of the machine falling into the excavated site becomes greater the closer
the excavation is to the machine.
• Never perform job operations under overhangs or excavated bank areas. These could collapse and damage
the machine or injure the operator.
• Keep in mind that the soil will be loose after a heavy rain, blasting or earthquakes.
• When traveling or operating in shallow water or soft ground, check the shape and condition of the
bedrock, and the depth and speed of flow of the water before starting any operations.
EQUIPMENT

• Never perform demolition work under the machine. This will cause a hazard as the machine could
OPTIONAL

become unstable or tip resulting in loss of control.

• When working on tops of structures, check the support strength before starting any operations. Keep in
mind, if these supports collapse, serious injury could result.

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Safety SY215 Excavator

Job Site Working Clearances

Listed are some basic safety precautions regarding clearance to prevent risk:
• After checking the condition of the working surfaces, be aware of the working clearances around,
above and behind. Be sure the space is available to swing the machine without interference and that work
equipment can be extended without striking any surrounding objects/areas.
• When traveling, on the job site, be sure there is room to maneuver the machine and work equipment.
• Travel at a slow, cautious speed when working or traveling in an area where clearances are a problem.
• Always maintain a clear and safe location for the machine at all times, regardless of the situation when
performing demolition operations.
• Never change a demolition plan unless authorized and agreed upon by the demolition supervisor or
structural engineer and other co-workers.
• Always study the demolition procedure before performing any operations.

• Never place personnel in harm’s way when

performing demolition operations and be sure
all personnel maintain a clear distance from the
demolition site at all times.
• If you are not sure of clearances, request the
aid of another person who can guide or warn the
operator if they get too close to objects.
• Always be aware of the work equipment position
and location. Keep all parts of the work equipment
in full view all the time when working in areas
where clearances are a problem.

Fig. 2-53

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CONTENTS
TABLEOF
Travel Precautions
Traveling with the machine may pose some hazards. When traveling with the machine, always travel in a
safe, controllable manner and remain alert at all times. Be sure all of your work equipment and areas are

INTRODUCTION
clearly visible. Remember a safety-conscious operator is the most important insurance when traveling with
the machine.

Avoid sudden travel lever shifting:

• Always maintain a firm grip on the travel levers
when traveling, stopping or changing direction

SAFETY
with the machine.
• Avoid any sudden release of the travel levers
when changing from forward movement to
backward movement. Doing so may cause the
machine to tip, rock or result in loss of control and

FUNCTION
SYSTEM
damage to the machine.

Fig. 2-54

OPERATION
Before traveling with the machine, be sure the track carriage is positioned correctly with the travel levers;
right lever, right track; left lever, left track. If necessary, reposition the track carriage so travel levers are
with the correct track.
When traveling on level ground, position the work equipment so all parts of the work equipment are clearly

MAINTENACE
visible. Keep the height of the work equipment 16 - 20 in. (40 - 50 cm) from the ground surface.
When traveling over rough ground, travel at low speed and steer carefully since there is a danger of loss of
control. Be sure the work equipment does not hit the ground surface and cause a loss of balance or machine
damage.

SPECIFICATIONS TROUBLRSHOOTING
Always avoid traveling over obstacles or raised areas if possible. Traveling over obstacles or raised areas
could result in loss of control or damage to the machine. When traveling over raised areas, always travel
at a slow speed with the work equipment as close the ground as possible. Avoid any sharp turns or sudden
stops.
During travel, always maintain a safe distance from people or surrounding objects.
Always check to be sure surface areas such as bridges or roadways will support the weight of the machine.
Before traveling on public roads or in publicly owned areas, always check with the relevant authorities and
follow their instructions. Failure to do so may result in damage, loss of control, fines or punishment.
Always be careful when traveling in tunnels, under bridges, near utility lines or in places where clearance
is a problem. Operate slowly and be extremely careful not to let the machine or work equipment come in
EQUIPMENT
OPTIONAL

contact with anything.

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Safety SY215 Excavator

Traveling on Sloped Areas

Traveling on sloped areas with work equipment
always poses a hazard. Work equipment position,
counterweight location and carriage position all
affect the stability of the machine when traveling
on sloped areas. In order to prevent tipping, loss of
control or a rollover, it is important to follow these
rules when traveling on sloped areas:
• Never turn the ignition switch off when traveling
up or down a slope. If the engine stops, lower the
work equipment to the ground immediately. Fig. 2-55

• Always keep the work equipment approximately 8 - 12 in. (20 - 30 cm) above the ground and travel at a
slow speed. Avoid moving the work equipment or shifting the position of the carriage when traveling on a
slope. Doing so will change the center of gravity on the machine.
• When traveling downhill, always face the front of the operator cab downhill, lower the engine speed and
keep the travel in low gear.
• Always face the front of the operator cab uphill when traveling up a slope.
• Always check the firmness of the surface on the slope before attempting to travel on it.
• When traveling up an extremely steep slope, extend the work equipment to the front of the machine to
help balance the machine.
• Always travel straight up or straight down a slope. Travel at an angle on a slope may cause loss of control
or the machine to tip.
• Never turn on a slope or reposition the work equipment or carriage on a slope.
• Never swing the carriage while on a slope for any reason.
Snow or Frozen Surfaces
Be careful when traveling or operating the machine on frozen or snowy surfaces. Snow-covered or frozen
surfaces are slippery. The ability to maneuver the machine is seriously affected. The machine may not
respond as expected when turning:
• Always travel at a slow speed and gently operate the controls.
• Avoid any rapid movement, acceleration or quick stopping. Always be aware of the increased stopping
distance required on these surfaces. Allow ample distance to stop the machine.
• Avoid deep snow or frozen bodies of water. The machine could get easily trapped in these areas.
• Keep in mind, even a slight slope may cause the machine to slip out of control. Be extra careful when
working on a sloped surface covered with snow or ice.
• When traveling or moving the machine on a snow-covered slope, slow down gently. To reduce the speed,
use the engine to slow the machine down. If necessary, lower the work equipment to the ground.

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CONTENTS
TABLEOF
Accumulation of Flammable
Material
Flammable material can build up within the

INTRODUCTION
machine’s operating systems. Dry leaves, wood
debris and trash could ignite when coming into
contact with hot parts.
Listed below is some information to help prevent
fires from occurring during continuous operation in
areas where the machine is exposed to these types

SAFETY
of environments:
Fig. 2-56
• Always inspect and remove any dry leaves,
wood chips, paper or any flammable material
accumulated or affixed around the engine, exhaust

FUNCTION
system, battery or under covers on the machine.

SYSTEM
• Operations such as logging, land-clearing,
mulching or landfill work may cause trash and
debris to accumulate on the machine.
• Always inspect and remove debris accumulation

OPERATION
daily.
• Clean the machine after maintaining the
hydraulic, engine or fuel system.
• Operating near burn piles or any type of open

MAINTENACE
burning could cause airborne sparks or glowing
embers to land on the machine and ignite any
accumulated debris or oil residue.
• Never place any part of the machine in direct

SPECIFICATIONS TROUBLRSHOOTING
contact with open flames or fire. Damage to the
machine or a fire on the machine may result.

Escape Tool Fig. 2-57

As a precaution in case of fire or injury to

personnel, always keep an escape tool in the
operator cab.
NOTE: Inspect the escape tool periodically and
replace it if it appears damaged or otherwise not
able to be used to break the cab window to allow
EQUIPMENT

for emergency exit.

OPTIONAL

NOTE: The escape tool is not provided with

models equipped with an open canopy.

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Safety SY215 Excavator

Crush or Pinch-Point Precautions

Never place any body part out the windows or door
during operation or travel. The movement of the
work equipment or falling objects could result in
injury.
Keep all guards on the machine in place.
Never remove the side window of the machine. If
this window becomes damaged or broken, replace
it immediately.
Fig. 2-58
Block off the area where the machine is working
and keep all unnecessary personnel out of the work
area.
Before initiating an arm swing or any other
equipment function, sound the horn and verify
that all personnel are clear of rotating and moving
parts.
Watch the path of the arm when in motion to avoid
lowering or swinging the arm into personnel,
equipment, or other objects.

Tow or Lift the Machine

Serious injury or death could result if a disabled machine is towed or lifted incorrectly or if there is a
mistake in the selection of cable or towing locations. Adhere to the following:
• Use only the designated lift points to lift the machine and designated tow points to tow the machine. Be
sure the lift and tow points are undamaged and in good working order.
• Always tow or lift in the direction indicated by the decal. If the decal is missing or damaged, contact your
Sany dealer for the proper procedures.
• Always wear leather gloves when handling wire rope.
• During the towing operation, never stand between the towing machine and the machine being towed.
• Never tow a machine on a slope.
• Never use towing equipment that is damaged, stretched or overstressed.
See the Troubleshooting section of this manual for towing operations and the Operation section for
information on lifting the machine.

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CONTENTS
TABLEOF
Optional Attachment Use
When using optional attachments, always contact your Sany dealer first. Do not use attachments that are
not authorized by your Sany dealer. Use of any unauthorized attachments could create a safety problem and

INTRODUCTION
adversely affect the performance of the machine.
When installing and using optional attachments, read the instruction manual for the attachment and
information related to the attachment.

Large or Optional Attachments

When using large attachments on the machine,

SAFETY
always be aware that the performance and handling
of the machine will be different from that of the
standard digging bucket. Before using a larger
or optional attachment always be aware of the

FUNCTION
following:

SYSTEM
• Be careful when folding the work equipment
for travel or when repositioning the machine.
The possibility of the attachment contacting the
operator cab becomes greater due to the size of the

OPERATION
attachment.
• Before using unfamiliar work equipment, check if
there is a danger of interference, then proceed with
operation in a cautious manner.

MAINTENACE
• Never operate any attachments near the operator
cab of the machine.
• Always be aware that the larger the attachment
on the machine, the more the center of gravity will

SPECIFICATIONS TROUBLRSHOOTING
change. Be careful when traveling on slopes.

Fig. 2-59
EQUIPMENT
OPTIONAL

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Safety SY215 Excavator

Operation Precautions
The operator of the machine is responsible for the safe operation of the machine at all times regardless of
the situation. Sany cannot cover or predict all operating conditions that pose a major hazard.
It is important to follow all operating procedures as shown in this manual before any excavation operations
begin.
Never use the machine to lift or transport personnel in any manner.

Always be aware of the swing circle area (a) of the

machine, especially in tight operating conditions.
Maintain a clear and visible swing circle area
during machine operations at all times.
Never use any part of the bucket or work
equipment to lift or maneuver objects if these a
implements are not equipped with the proper lifting Fig. 2-60
devices.
NOTE: For information on lifting with the
machine, refer to the lift charts posted in the
machine. See “Lift Chart - Standard Arm” on page
7-6.

Never use personnel to handle or maneuver

loads being lifted by the machine in any manner.
The possibility of getting hit by falling objects,
lowering work equipment (c) or pinning them
between the machine and surrounding objects
becomes greater the closer they are.

Fig. 2-61

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CONTENTS
TABLEOF
Operation on a Sloped Area
Always operate the machine on a flat, stable, level
surface whenever possible. But if work must be

INTRODUCTION
done on a slope or inclined surface, follow these
rules:
• Remember that, when will be working on a slope
or inclined surface of any kind, there is always a
danger that the machine may roll over when the
swing or work equipment is operated. Situations

SAFETY
like this may lead to serious injury or property
damage. Always provide a stable place when
performing these types of operations, and work
carefully. Fig. 2-62

FUNCTION
• Do not swing the work equipment from the uphill

SYSTEM
side to the downhill side when the bucket is loaded.
If the machine must be used on a slope, pile soil
to make a platform that will keep the machine
as horizontal as possible. Operate the machine

OPERATION
carefully and always be aware of the ground
conditions.
NOTE: See “Slopes” on page 4-28.

MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
EQUIPMENT
OPTIONAL

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SY215 Excavator System Fuctions

CONTENTS
TABLEOF
INTRODUCTION
System Fuctions

SAFETY
Exterior Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cab Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

FUNCTION
SYSTEM
Seat and Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Hydraulic Lockout Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Left Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

OPERATION
Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Radio Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Right Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

MAINTENACE
Indicator Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Throttle Control Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

SPECIFICATIONS TROUBLRSHOOTING
12V Power Supply Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Work Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Windshield Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Head Lamp Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
SAE/BHL Joystick Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
SAE Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Travel Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
EQUIPMENT
OPTIONAL

Auto Deceleration Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Combined Instruments Display/Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

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System Fuctions SY215 Excavator

Screen Displays - Configuration 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Main Operator Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
System Information (Password) Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Main Menu Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Running Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Failure Codes Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Throttle Help Info Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Language Selection Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Sys Clock Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Units Display Setting Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Screen Displays - Configuration 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Main Operator Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
System Information (Password) Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Main Menu Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Running Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Failure Codes Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Throttle Help Info Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Language Selection Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Sys Clock Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

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

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CONTENTS
TABLEOF
EXTERIOR COMPONENTS
3 4 5 6 7 8

INTRODUCTION
9

SAFETY
10

2
11

FUNCTION
SYSTEM
18

12

OPERATION
13
1 9 17 16 15 14

Fig. 3-1

MAINTENACE
1. Bucket 10. Cab
2. Bucket cylinder 11. Engine cover

SPECIFICATIONS TROUBLRSHOOTING
3. Arm 12. Drive sprocket
4. Arm cylinder 13. Track frame
5. Work lamp - boom 14. Idler wheel
6. Boom 15. Track shoe
7. Boom cylinder 16. Windshield wiper

8. Head lamps 17. Work lamp - chassis

9. Rear view mirror 18. Batteries

EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

CAB INTERIOR
5
4 4

3
3

2 6

7
1

Fig. 3-2

1. Left control console (See page 3-6.) 5. Combined instrument display (See page 3-22.)
2. Left joystick (See page 3-18.) 6. Right joystick (See page 3-18.)
3. Footrest 7. Ignition switch (See page 3-12.)
4. Travel control (See page 3-19.) 8. Right control console (See page 3-11.)

Seat and Seat Belt a

A multi-position, adjustable seat is provided for b
operator comfort. The front/rear positions, up/down
positions, and the front/rear incline angle seat back c
can be adjusted. d
• The headrest (a) can be raised and lowered. f

• The seat has two armrests (b).

e
• A seat belt (c) is provided to keep the operator
securely in the operator’s seat.
NOTE: See “Seat Belt” on page 4-10.
• Slider lever (d) adjusts the seat forward or back-
ward relative to the control consoles.
• The adjusting lever (e) adjusts the seat and con-
Fig. 3-3
trol consoles forward or backward.
• Weight adjustment knob (f).

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SY215 Excavator System Fuctions

CONTENTS
TABLEOF
Hydraulic Lockout Control Lever

WARNING
Always place the hydraulic lockout control lever securely in the CLOSE position before

INTRODUCTION
leaving the operator cab. If this lever is not in the CLOSE position, any unintended move-
ment of the joysticks or travel control levers may cause death or serious injury.
Avoid moving either joystick or travel control lever when you pull (up) or push (down) the
hydraulic lockout control lever. Failure to observe and follow this warning could result in
death or serious injury.

SAFETY
The hydraulic lockout control lever is used to turn
off the functions of all work equipment, including
the swing system, travel system and optional at-
tachments.

FUNCTION
• Pushing the hydraulic lockout control lever down

SYSTEM
(a) engages the machine in the CLOSE position.
The machine will not move, even if you maneuver a
the controls.

OPERATION
NOTICE
If any part of the machine moves when the
hydraulic lockout control lever is at the

MAINTENACE
CLOSE position, shut down the engine
immediately. Contact your Sany dealer to
solve this problem. Failure to do so can
result in damage to the machine. b

SPECIFICATIONS TROUBLRSHOOTING
• Pulling the hydraulic lockout control lever up (b)
engages the machine in the OPEN position. The
machine will now move in accordance with the
joysticks and other control levers.

Fig. 3-4
EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

Climate Control Panel

1 2 3 4 5

Fig. 3-5 6 7 8

1. OFF 5. Automatic temperature control selection

2. Fan speed control 6. Fresh air/recirculation selection
3. Temperature selection 7. Display screen
4. Vent mode selection 8. A/C power

OFF (1) - Press this key to stop the fan and shut off the display screen (7).
Fan speed control (2) - Press this key to set the fan speed to any of six levels.
Temperature selection (3) - Press this key to set the inside cab temperature between 65° F (18° C) and 90°
F (32°C).
NOTE: With the A/C on, press and hold both the up and down arrows for 3 seconds to toggle between
Fahrenheit (F) and Celsius (C) temperature display.

Vent mode selection (4) - Press this key to select which vent or vents should be used for air flow inside the
cab:
• Windshield vent only
• Upper body vent only
• Upper body and rear window vents
• Foot vent (located under the operator seat), upper body and rear window vents
• Foot vent only
• Windshield and foot vents

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CONTENTS
TABLEOF
Automatic temperature control (5) - Press this key to use the selected fan speed, vent outlets and fresh air/
recirculation mode to automatically maintain the selected temperature.
NOTE: With automatic temperature control selected, the fan HIGH speed will remain on until the selected
temperature is reached.

INTRODUCTION
Fresh air/recirculation selection (6) - Press these
keys to choose either recirculated air inside the cab
or fresh air from outside.
Display screen (7) - Shows the preset temperature,
fan speed and vent selection during operation.

SAFETY
a
A/C power (8) - Press this key to switch all climate
control functions either on or off.
Sunlight sensor (a) - Located on the front of the air
conditioning duct adjusts the air flow to match the

FUNCTION
SYSTEM
variation of temperature caused by direct sunlight.

OPERATION
Fig. 3-6

MAINTENACE
A/C Operation Precautions

NOTICE
When running the air conditioning system, always start with the engine running at a low

SPECIFICATIONS TROUBLRSHOOTING
speed. Starting the air conditioner when the engine is running at a high speed can result
in damage to the machine, personal property and/or the environment, or cause the ma-
chine to operate improperly.
If water gets on the control panel or sunlight sensor, a failure may result. Always keep
these components clear and free from water. Failure to do so can result in damage to the
machine, personal property and/or the environment or cause the machine to operate im-
properly.

“A/C controller failure” will be displayed on the air conditioner display screen if there is a problem with
the a/c unit. If this occurs, contact your Sany dealer to investigate and repair it.
EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

Radio Control Panel

6 5 4 3 2 1

Fig. 3-7 7 8 9 10

1. Power 6. Preset stations

2. Audio selection 7. Display screen
3. Time display 8. Tuning keys
4. AM/FM selector 9. Time adjusting keys

5. AS/PS 10. Volume control

Power (1) - Press this key to turn on the radio on or off. The currently selected radio station frequency will
appear on the display screen when the radio is turned on.
Audio selection (2) - Press this key to adjust the sound quality. Pressing the key at first allows for setting
the bass level. Pressing it once more allows for setting the treble, pressing it once more allows for setting
the balance (between the in-cab speakers) and pressing it again allows for setting the volume. The current
radio station frequency displays if the button is not pressed within 5 seconds.
NOTE: Use the VOL keys to increase and decrease the setting of the selected audio category. Time display
(3) - Press this key to display the local time for 5 seconds. The current radio station frequency displays
when the button is not pressed within 5 seconds.
AM/FM selector (4) - Press this key to toggle between AM and FM bands.
AS/PS key (5) - Use this key to automatically scan (AS) through the preset stations (PS) and also to remain
at the desired radio station.
NOTE: Pressing the AS/PS key (5) once begins the auto scan feature where each preset station will play
for 10 seconds with the station frequency blinking on and off on the display screen. Press the AS/PS key (5)
once more to remain on the current station.

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CONTENTS
TABLEOF
Preset Stations (6) - Press and hold any of these six keys to assign the current radio station to that key.
Afterwards, press and release any of the keys to select its preselected station. Pressing the ASPS key (5)
longer than 2 seconds activates the auto scanning of all preselected stations. The six radio stations with the
strongest signal will be stored to the six Preset Station keys (1-6).

INTRODUCTION
Display screen (7) - The band (either AM or FM), currently tuned radio station frequency, preset station
number and current time will be shown on the display screen.
Tuning key (8) - Press this key to move either back to the previously set radio station or on to the next pre-
viously set radio station.
Time adjusting (9) - Use these keys to set the time:

SAFETY
• H: Hour
• M: Minute
• ADJ: Set to 00 minute

FUNCTION
Volume control (10) - Use these keys to set the volume:

SYSTEM
• Press the key “+” (10) to increase sound volume.
• Press the key “-” to decrease sound volume.

OPERATION
MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

Right Control Console

The right control console is to the right of the
operator when seated and facing toward the
windshield. It contains switches,
indicator lights, throttle control dial, and a joystick.

a
Switches
The right control console contains the following
b
switches:
• Ignition switch (a) (See page 3-11.)
• Throttle control dial (d) (See page 3-11.)
• Work lamp switch (e) (See page 3-12.)
c
• Windshield wiper switch (f) (See page 3-12.)
• Windshield washer switch (g) (See page 3-12.)
d
• Head lamp switch (h) (See page 3-12.)
• Heater switch (k) (See page 3-12.)
e

f
Indicator Lights
The preheat indicator (c) is normally off. It will
g
illuminate when the ignition switch is set to
the HEAT position. The charging indicator (b)
illuminates when the ignition switch is turned to h
the ON position. It will go off when the engine is
running and the alternator is charging the batteries.
k

Fig. 3-8

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CONTENTS
TABLEOF
Ignition Switch

NOTICE
Except for emergencies, never shut down the engine while it is running at high speed.

INTRODUCTION
Stopping the engine at high speed can cause damage to the machine or cause the ma-
chine to run improperly.

The ignition switch is used for the following func- a

tions:
• OFF (a) - This position allows you to insert and

SAFETY
remove the key. The engine is shut down (or re- b
mains off) and there is no electrical current to any
of the electrical system switches (except for work
lamps). c

FUNCTION
SYSTEM
• HEAT (b) - Hold the key at this position to pre-
heat the engine for cold-weather starting as re-
quired. The key returns to the OFF position (a) d
when released.

OPERATION
• ON (c) - This position allows the engine to re-
main running (if already started) and also allows
electrical current to all of the various electrical e
system switches.

MAINTENACE
Fig. 3-9

SPECIFICATIONS TROUBLRSHOOTING
• START (d) - Hold the key at this position to start the engine, then immediately release it after the engine
has started. The key returns to the ON position (c) when released.
NOTE: See “Engine Start Procedure” on page 4-17.

Throttle Control Dial

The throttle control dial (e) is used to adjust engine speed and output power. Turn the dial clockwise to
increase engine speed and counterclockwise to decrease engine speed.
• Low Idle (MIN): Turn it fully counterclockwise.
NOTE: See “Throttle Signals Screen” on page 3-22.
• Full Speed (MAX): Turn it fully clockwise.
EQUIPMENT
OPTIONAL

NOTE: See “Throttle Signals Screen” on page 3-22.

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System Fuctions SY215 Excavator

12V Power Supply Socket

The 12-volt socket (a) is used to charge 12-volt
electronics only.

Work Lamp Switch

This switch (a) is used to turn the work lamps on/
off.
NOTE: See “Exterior Components” on page 3-3.
Fig. 3-10
Windshield Wiper Switch
This switch (b) is used to activate the wiper. a

NOTICE b
Ensure that the windshield of the cab is
closed before activating the windshield c
wiper. Failure to do so can result in dam-
age to the machine, personal property or
cause the machine to operate improperly. d

NOTICE e
Use the windshield washer switch before
using the wiper switch on a dry wind-
shield. Failure to do so can result in dam-
age to the machine or cause the machine
to operate improperly.

Fig. 3-11
Windshield Washer Switch
Press switch (c) to eject windshield washer fluid. Hold the switch down to keep ejecting windshield washer
fluid. The flow of windshield washer fluid stops and the switch returns to its off position when released.

Head Lamp Switch

This switch (d) is used to turn the head lamps on and off.
NOTE: See “Exterior Components” on page 3-3.

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CONTENTS
TABLEOF
Joystick Controls

WARNING
To prevent injury by the boom if a joystick is moved unexpectedly, never extend any part

INTRODUCTION
of your body outside the operator cab window while the machine is running. Know the
positions and functions of each joystick. Failure to observe and follow this warning may
cause unexpected movement of the machine which could result in death or serious injury.

SAE/BHL Joystick Operating Modes

There are two operating modes available for the joysticks (a):

SAFETY
• SAE (Society of Automotive Engineers) mode
• BHL (Backhoe Loader) mode

FUNCTION
SYSTEM
OPERATION
a

MAINTENACE
a

SPECIFICATIONS TROUBLRSHOOTING

Fig. 3-12
EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

BHL Mode

Fig. 3-13

NOTE: When the joystick is released, the machine goes back into neutral and machine movement stops.

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CONTENTS
TABLEOF
Travel Controls

WARNING
Take extra care when using the pedals to steer the machine. Never rest your foot on a

INTRODUCTION
pedal unless you are driving or steering the machine. Failure to observe and follow this
warning could cause an unexpected movement of the machine which could result in death
or serious injury.

WARNING
The center of gravity position and boom length is different on machines with a super long

SAFETY
reach. Take extra care when traveling with this machine and be aware of the extra clear-
ances needed when turning the machine and operating a super long reach. Failure to do
so could result in death or serious injury.
Always note the following before operating the

FUNCTION
travel controls:

SYSTEM
• The directional arrow (d) on each of the two
track frames indicates the forward direction of the
lowerworks. Check these arrows before using the
travel control levers. When possible, face the cab

OPERATION
in this direction.
d
• When the cab faces backward, the travel direction
will be the reverse of the figure shown here.
(Machine moves forward when you pull control
Fig. 3-14

MAINTENACE
levers and backward when you push them.)

The travel controls consist of the following: a

• Travel control levers (a)

SPECIFICATIONS TROUBLRSHOOTING
b
• Travel control pedals (b)
NOTE: The footrests (c) are not control devices. c
NOTE: Once you release a travel control lever or
joystick, the machine goes back into neutral and
machine movement stops.

Fig. 3-15
EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

The travel control levers and pedals are used to

change travel direction of the machine:
• Forward travel (1) - Push the control lever (pedal
tilts forward).
• Backward travel (2) - Pull the control lever (pedal
tilts backward).
• Neutral Position (N) - Machine stops.

Fig. 3-16

Auto Deceleration Function

The auto deceleration function automatically activates when the machine engine is started and acts to
reduce fuel consumption and noise levels.
NOTE: Pressing F2 toggles the auto deceleration function on and off after the engine is running. See
“Combined Instruments Display/Monitor” on page 3-18 for more information.

With the engine running, the auto deceleration b

function works as described below:
• If the joysticks (a) and travel controls (b) remain
in their neutral positions for at least 5 seconds, the
engine idle speed drops from the currently set idle
speed to the factory-set auto idle speed (approxi-
mately 1,350 +50 rpm).
NOTE: If the engine idle speed is set to below the
factory-set auto idle speed, the auto deceleration
function will not change the engine speed. Fig. 3-17 a
• If either of the joysticks or travel controls are
operated or the if throttle control dial is adjusted
while the engine is idling at the lower, factory-set
auto idle speed, the engine speed automatically re-
turns to its higher, previously set level or the newly
set level.
• If the engine is shut down and then restarted, the
auto deceleration function is automatically reacti-
vated.

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CONTENTS
TABLEOF
Fuses
The fuse box (a) is located in the cab behind the
seat.

INTRODUCTION
Open the fuse box door to access the fuses (b). a

Fuse Locations, Circuits & Amperages

F2. Charging lamp, 5A F1. Starting circuit, 20A
F4. Working lamp, 15A F3. Horn, 5A

SAFETY
F6. Travel alarm, 2A F5. Cab lamp, 10A
F8. Radio, 10A F7. 12V converter, 15A
F9. Diagnostic terminal,
F10. Air conditioner, 20A
5A

FUNCTION
SYSTEM
F12. Lighter, 10A F11. Hydraulic shear, 5A
F14. Pilot control, 10A F13. Fueling, 20A
F16. Display, 5A F15. Washer & wiper, 5A

OPERATION
F18. Dome lamp, 5A F17. KPM controller, 10A b

F20. Ignition (ECM), 5A F19. ECM power, 30A

MAINTENACE
NOTICE

SPECIFICATIONS TROUBLRSHOOTING
A fuse should be replaced if it is corroded,
produces white powder or becomes loose
in the fuse panel.
Before replacing a fuse, make sure that the
ignition switch is in the OFF position and
the batteries disconnected.
Always replace a fuse with one of the same
capacity. Never replace a fuse with one of
a higher capacity.
Failure to observe and follow this notice
can result in damage to the machine or
cause the machine to operate improperly.
EQUIPMENT
OPTIONAL

Fig. 3-18

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System Fuctions SY215 Excavator

COMBINED INSTRUMENTS DISPLAY/MONITOR

When the ignition switch is at the ON position, the Combined Instrument Display is energized. A display of
the Combined Instrument Display home screen is shown below:

6
8
5
9
4 10

3 11
12
2
1 13

14
15

Fig. 3-19

1. Auto deceleration function 9. Failure code

2. Working mode (S, H, L or B) 10. Local date
3. Total service hours 11. Local time
4. Fuel gauge 12. System information (blue) & failure codes (red)
5. Coolant temperature 13. Enter indicator
6. Working mode (S, H, L or B) 14. Travel speed
7. Warning and signal indicators 15. Key pad
8. Throttle setting (1 - 11)

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CONTENTS
TABLEOF
Screen Displays - Configuration 1
NOTE: Configuration 1 models of the SY215 do not include the identifier DP in the eighth and ninth digits
of the serial number, for example, 14SY021DP2788. For machines with DP in the serial number, see “Screen
Displays - Configuration 2” on page 3-30.

INTRODUCTION
NOTE: See “Serial Number Location” on page 1-6 to find the machine serial number.

Main Operator Screen

This is the default screen after the machine has
been started. It consists of three sections:

SAFETY
Warning and Signal Indicators
The warning signal indicators (A) will illuminate as
needed to warn the operator of an alarm condition.

FUNCTION
SYSTEM
OPERATION
Fig. 3-20

MAINTENACE
In the warning and signal indicator section (A): d
• If there is a power problem, the power indicator (d)

SPECIFICATIONS TROUBLRSHOOTING
illuminates.
• If a problem occurs with the CAN Bus, the CAN
indicator (e) illuminates.
• If a general fault occurs, the alarm indicator (f) e
illuminates.
Fig. 3-21
f g
• If there is a problem with a backup system, the
backup indicator (g) illuminates.
EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

Display Screen
The display screen (item B, Fig. 3-19, page 3-17) displays information about the condition of the machine.
The type of information displayed is selected by the operator using the keypad below the screen.

The display screen shows:

• Working mode indicator (h)
h q
• Coolant temperature gauge (k)
• Fuel level gauge (m) k

• Failure codes (n)

• Total service hours (o) m
• Function icons (p)
n r
• Engine speed level (q) (levels 1 through 11) o s
• Date (r) stated as YY/MM/DD p
• Time (s) stated as hours:minutes:seconds
Fig. 3-22
Key Pad
The key pad (See “Main Menu Screen” on page 3-20) is used by the operator to select different screens and
functions.
The key pad is composed of five function keys (t) and six navigation keys (u).
Pressing F1 cycles through the four working
modes:
t
• S: Standard duty - Used for normal excavating.
• H: Heavy duty - Used for excavating in hard or-
u
rocky ground.
• L: Light duty - Used for light tasks such as dig-
gingin soft soil. Fig. 3-23

• B: Breaker mode - Used when operating with attachments such as a jackhammer.

NOTE: Breaker mode cannot be used with a super long reach.
Pressing F2 toggles the automatic deceleration function on and off.
NOTE: See “Auto Deceleration Function” on page 3-18.
Pressing F3 toggles between the fast and slow travel modes.
Pressing F4 displays the failure codes screen.
NOTE: See “Failure Codes Screens” on page 3-26.
Pressing F5 displays the System Information (Password) screen.

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CONTENTS
TABLEOF
NOTE: See “System Information (Password) Screen” on page 3-21.

System Information (Password) Screen

A password must be entered before accessing the

INTRODUCTION
system information screens. Attempting to display
any screen other than the Failure Codes screen will
display the Password screen.
NOTE: If you do not know the password, contact
the supervisor or Sany dealer.

SAFETY
Each digit is indicated by an asterisk (*) standing
for a value from 0 to 9. A number appears at the
digit where the cursor is located, while the other
four digits remain as asterisks.
Pressing the up or down arrow increases/decreases

FUNCTION
SYSTEM
the number displayed.
Pressing the right or left arrow moves between
positions.
Pressing Enter or F3 enters the password into the

OPERATION
system. Fig. 3-24
Pressing F5 returns to the previous screen.

MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

Main Menu Screen

Once the password is entered, the Main Menu dis-
plays. The list of options includes:
• Running Information
• Failure Information
• Throttle Help Info
• Language Selection
• System Clock Calibration
• Unit Selection
Pressing F1 or the up or down arrow scrolls
through the list of display options.
Pressing F2 or Enter selects the highlighted option
and displays the corresponding screen.
Pressing F4 displays another password screen used
by maintenance personnel.
Pressing F5 displays the Main Operator screen.
Details of each of the displays follow.
Fig. 3-25

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CONTENTS
TABLEOF
Running Information
There are six separate Running Information
screens:

INTRODUCTION
• Engine Signals (See page 3-21.)
• Throttle Signals (See page 3-22.)
• Pilot Press Signals 1 (See page 3-22.)
• Pilot Press Signals 2 (See page 3-23.)
• Main Pump Signals (See page 3-24.)

SAFETY
• Main Valve Signals (See page 3-25.)
Press F1 or the up or down arrow to scroll through
these screens.

FUNCTION
Engine Signals Screen

SYSTEM
The Engine Signals screen displays:
• Coolant Temp - Displays in °F or °C, depending
Fig. 3-26
on settings made on the Unit Selection screen.

OPERATION
• Fuel Level% - Displays as % full
• Engine oil press - Displays in psi or kPa,
depending on settings made on the Unit Selection
screen.

MAINTENACE
NOTE: See “Units Display Setting Screen” on
page 3-33.
Pressing F1 or the up or down arrow cycles through
the other running information screens.

SPECIFICATIONS TROUBLRSHOOTING
Pressing F5 displays the Main Operator screen.

EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

Throttle Signals Screen

The Throttle Signals screen displays:
• Throttle Gear N - Displays 1 to 11, depending on
the setting of the throttle dial.
NOTE: See “Throttle Control Dial” on page 3-11.
• Engine Speed rpm - Displays current engine
speed.
• Gear Position V - Displays voltage of throttle
selection.
Pressing F1 or the up or down arrow cycles
through the other running information screens.
Pressing F5 displays the Main Operator screen.

Fig. 3-27

Pilot Press Signals 1 Screen

The Pilot Press(ure) Signals 1 screen displays:
• Boom UP - Displays in psi or kg/cm2, depending
on settings made on the Unit Selection screen.
• Boom DOWN - Displays in psi or kg/cm2, de-
pending on settings made on the Unit Selection
screen.
• Arm IN - Displays in psi or kg/cm2, depending
on settings made on the Unit Selection screen.
• Arm OUT - Displays in psi or kg/cm2, depending
on settings made on the Unit Selection screen.
NOTE: See “Units Display Setting Screen” on
page 3-29.
Pressing F1 or the up or down arrow cycles Fig. 3-28
through the other running information screens.
Pressing F5 displays the Main Operator screen.

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CONTENTS
TABLEOF
Pilot Press Signals 2 Screen
The Pilot Press(ure) Signals 2 screen displays:
• Bucket DIG - Displays in psi or kg/cm2,

INTRODUCTION
depending on settings made on the Unit Selection
screen.
• Bucket DUMP - Displays in psi or kg/cm2,
depending on settings made on the Unit Selection
screen.
• Swing - Displays in psi or kg/cm2, depending on

SAFETY
settings made on the Unit Selection screen.
• Travel Left - Displays in psi or kg/cm2,
depending on settings made on the Unit Selection
screen.

FUNCTION
SYSTEM
• Travel Right - Displays in psi or kg/cm2,
depending on settings made on the Unit Selection
screen.
Fig. 3-29
NOTE: See “Units Display Setting Screen” on

OPERATION
page 3-29.

Pressing F1 or the up or down arrow cycles through the other running information screens.

MAINTENACE
Pressing F5 displays the Main Operator screen.

SPECIFICATIONS TROUBLRSHOOTING
EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

Main Pump Signals Screen

The Main Pump Signals screen displays:
• Pump 1 Main - Displays in psi or kg/cm2, de-
pending on settings made on the Unit Selection
screen.
• Pump 2 Main - Displays in psi or kg/cm2, de-
pending on settings made on the Unit Selection
screen.
• Proportional Valve 1 Current mA- Displays in
milliamps.
• Proportional Valve 2 Current mA- Displays in
milliamps.
• Bucket Confluence valve
• Swing Priority valve
• Boom Priority valve
• High/Low Speed Shift Fig. 3-30
NOTE: See “Units Display Setting Screen” on
page 3-29.

Pressing F1 or the up or down arrow cycles through the other running information screens.
Pressing F5 displays the Main Operator screen.

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CONTENTS
TABLEOF
Main Valve Signals Screen
The Main Valve Signals screen displays:
• Bucket Confl(uence) valve

INTRODUCTION
• Swing Priority valve
• Boom Priority valve
• High/Low Speed Shift
Pressing F1 or the up or down arrow cycles through
the other running information screens.

SAFETY
Pressing F5 displays the Main Operator screen.

FUNCTION
SYSTEM
Fig. 3-31

OPERATION
MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

Failure Codes Screens

Failure codes (See “Combined Instruments
Display/ Monitor” on page 3-20) are displayed
as a number near the center bottom of the home
screen. There are two Failure Codes screens. Each
displays the current failure code, if any. The first
one displays failure codes 11 through 27 and their
explanations; the second displays failure codes 28
through 60 and their explanations.
Pressing F1 toggles between the two screens.

Fig. 3-32

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CONTENTS
TABLEOF
Numerical failure codes (a), if any, appear on the Main Operator screen of the Combined Instruments
Display ( page 3-26).

Code Description

INTRODUCTION
11 Controller failure
12 Motor current / connection abnormal
13 Motor operation paused
14 Motor working range improper
15 Power supply volt over 36V
16 Internal temp of controller abnormal

SAFETY
17 Sensor power supply abnormal
18 Abnormal communications with monitor
19 Backup battery voltage low
20 Front pump output pressure abnormal
21 Rear pump output pressure abnormal
22 Arm-in pilot pressure abnormal

FUNCTION
SYSTEM
23 Arm-out pilot pressure abnormal
24 Boom-up pilot pressure abnormal
25 Boom-down pilot pressure abnormal
26 Bucket-dig pilot pressure abnormal
27 Bucket-dump pilot pressure abnormal

OPERATION
28 Swing pilot pressure abnormal
29 Left travel pilot pressure abnormal
30 Right travel pilot pressure abnormal
31 Potentiometer (for motor setup) abnormal
32 Motor built-in potentiometer abnormal

MAINTENACE
33 Backup pilot pressure abnormal
37 Oil temp sensor volt abnormal
39 Coolant temp resistance abnormal
40 Fuel gauge abnormal
41 Engine speed low

SPECIFICATIONS TROUBLRSHOOTING
50 Front pump current abnormal
51 Rear pump current abnormal
52 Swing priority current abnormal
53 Bucket confluence current abnormal
54 Bucket priority 1 current abnormal
55 Bucket priority 2 current abnormal
60 Speed shift abnormal

Pressing F5 displays the Main Operator screen.

EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

Screen Displays - Configuration 2

NOTE: Configuration 2 models of the SY215 do include the identifier DP in the eighth and ninth digits
of the serial number, for example, 14SY021DP2788. For machines that do not include DP in the serial
number, see “Screen Displays - Configuration 1” on page 3-21.
NOTE: See “Serial Number Location” on page 1-6 to find the machine serial number.
Main Operator Screen
This is the default screen after the machine has been started.
NOTE: See “Main Operator Screen” on page 3-21 for details.

System Information (Password) Screen

A password must be entered before accessing the
system information screens. Attempting to display
any screen other than the Failure Codes screen will
display the password screen.
NOTE: If you do not know the password, contact
your Sany dealer.
NOTE: See “System Information (Password)
Screen” on page 3-23 for details.

Fig. 3-33

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CONTENTS
TABLEOF
Main Menu Screen
Once the password is entered, the Main Menu
displays. The list of options includes:

INTRODUCTION
• Running Information
• Failure Information
• Throttle Help Info
• Language Selection
• System Clock Calibration

SAFETY
• Unit Selection
• Sheer and Breaker Flow Set-up
Pressing F1 or the up or down arrow scrolls

FUNCTION
through the list of display options.

SYSTEM
Pressing F2 or Enter selects the highlighted option
and displays the corresponding screen.
Pressing F4 displays another password screen used Fig. 3-34

OPERATION
by maintenance personnel.
Pressing F5 displays the Main Operator screen.
Details of each of the displays follow.

MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

Running Information
There are three separate Running Information screens:
• Engine Signals (page 3-30)
• Pilot Press Signals 1 (page 3-31)
• Main Pump Signals (page 3-24)
Press F1 or the up or down arrow to scroll through these screens.

Engine Signals Screen

The Engine Signals screen is the first to display
when accessed from the Main Menu screen. The
Engine Signals screen displays:
• Coolant Temp - Displays in °F or °C, depending
on settings made on the Unit Selection screen.
• Fuel Level% - Displays as % full
• Engine oil press - Displays in psi or kPa, depend-
ing on settings made on the Unit Selection screen.
• Throttle Gear N - Displays 1 to 11, depending on
the setting of the throttle dial.
NOTE: See “Throttle Control Dial” on page 3-12.
• Engine Speed rpm - Displays current engine
speed in revolutions per minute.
• Gear Position V - Displays voltage of the throttle
selection.
Fig. 3-35
• Hydraulic Oil Temp - Displays current hydraulic
oil temperature in either °F or °C.
NOTE: See “Units Display Setting Screen” on
page 3-33.
Pressing F1 or the up or down arrow cycles
through the other running information screens.
Pressing F5 displays the Main Operator screen.

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SY215 Excavator System Fuctions

CONTENTS
TABLEOF
Pilot Press Signals 1 Screen
The Pilot Press(ure) Signals 1 screen displays:
• Boom UP - Displays in psi or kg/cm2, depending

INTRODUCTION
on settings made on the Unit Selection screen.
• Boom DOWN - Displays in psi or kg/cm2,
depending on settings made on the Unit Selection
screen.
• Arm IN - Displays in psi or kg/cm2, depending
on settings made on the Unit Selection screen.

SAFETY
• Arm OUT - Displays in psi or kg/cm2, depending
on settings made on the Unit Selection screen.
• Bucket DIG - Displays in psi or kg/cm2,
depending on settings made on the Unit Selection

FUNCTION
SYSTEM
screen.
• Bucket DUMP - Displays in psi or kg/cm2,
depending on settings made on the Unit Selection
screen.

OPERATION
Fig. 3-36
• Swing - Displays in psi or kg/cm2, depending on
settings made on the Unit Selection screen.
• Travel Left - Displays in psi or kg/cm2,
depending on settings made on the Unit Selection

MAINTENACE
screen.
• Travel Right - Displays in psi or kg/cm2,
depending on settings made on the Unit Selection
screen.

SPECIFICATIONS TROUBLRSHOOTING
NOTE: See “Units Display Setting Screen” on
page 3-33.
Pressing F1 or the up or down arrow cycles through
the other running information screens.
Pressing F5 displays the Main Operator screen.

Main Pump Signals Screen

NOTE: See “Main Pump Signals Screen” on page
3-24 for details.
EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

Failure Codes Screens

NOTE: See “Failure Codes Screens” on page 3-26 for details.

Throttle Help Info Screen

NOTE: See “Throttle Help Info Screen” on page 3-28 for details.

Language Selection Screen

NOTE: See “Language Selection Screen” on page 3-28 for details.

Sys Clock Calibration Screen

NOTE: See “Sys Clock Calibration Screen” on page 3-29 for details.

Units Display Setting Screen

NOTE: See “Sys Clock Calibration Screen” on page 3-29 for details.

Shear & Breaker Flow Setup Screens

NOTE: The breaker and shear attachments can be used only with the standard arm. Do not attempt to attach
either a breaker or a shear to a super long reach. There are no hydraulic fluid points on the super long reach
for breaker or shear use.
The Shear and Breaker Flow Setup screen displays information used to set the hydraulic flow parameters
for both the shear and breaker optional equipment tools.

NOTICE
Do NOT attempt to change the flow for either the shear or the breaker while operating
either optional tool. Lower the equipment to the ground and adjust the flow while the
engine is idling. Failure to do so can damage the machine or can cause the machine to
operate improperly

There are two unique function icons on the Shear

& Breaker Flow Setup screen; shear (a) and break-
a
er (b).
• Pressing F2 displays the shear (a) screen. b
• Pressing F3 displays the breaker (b) screen.

Fig. 3-37

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SY215 Excavator System Fuctions

CONTENTS
TABLEOF
Shear Screen

NOTICE
Do not exceed manufacturer’s specifications for maximum hydraulic flow or pressure to

INTRODUCTION
optional equipment. Doing so can cause damage to the machine or can cause the machine
to operate improperly.

The shear screen displays the flow setup for the shear in both gallons per minute (GPM) and liters per
minute (L/ M). Increasing the flow will increase the power/torque of the activity chosen below; decreasing
the flow will decrease the power/torque of the activity.

SAFETY
• Opening/Closing Flow - shows the hydraulic flow for opening and closing the shear.
• Rotating Flow - shows the hydraulic flow for rotating the shear.

NOTE: To move within and between the Opening/

FUNCTION
Closing Flow and the Rotating Flow, press F1.

SYSTEM
NOTE: To increase the flow rate, press the up arrow
(c). Make sure the cursor is next to the element to
be changed before pressing the up arrow.
NOTE: To decrease the flow rate, press the down

OPERATION
arrow (d). Make sure the cursor is next to the
element to be changed before pressing the down
arrow.

MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
c

Fig. 3-38
d
EQUIPMENT
OPTIONAL

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System Fuctions SY215 Excavator

Breaker Screen

The breaker screen displays the flow setup for the

breaker in gallons per minute (GPM) and liters per
minute (L/M). Increasing the flow will increase the
power/torque of the breaker; decreasing the flow
will decrease the power/torque of the breaker.
NOTE: To increase the flow rate, press the up arrow
(c). Make sure the cursor is next to the element to
be changed before pressing the up arrow.
NOTE: To decrease the flow rate, press the down
arrow (d). Make sure the cursor is next to the
element to be changed before pressing the down
arrow.

Fig. 3-39

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SY215 Excavator Operation

CONTENTS
TABLEOF
INTRODUCTION
Operation

SAFETY
Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
General Job Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

FUNCTION
Job Site Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

SYSTEM
Work Crew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Supervisor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Owner and Other Authorized Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

OPERATION
Mount and Dismount the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Seat Belt Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
New Machine Run-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Safety, Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

MAINTENACE
Daily Maintenance Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

SPECIFICATIONS TROUBLRSHOOTING
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Lamps and Warning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Escape Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Front Window Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Combined Instruments Display/Monitor Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
First-Time Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Access the Main Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Language Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
System Clock Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
EQUIPMENT
OPTIONAL

Units Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Engine Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Cold-Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Engine Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

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Operation SY215 Excavator

Idle the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Engine Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Machine Warm-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Travel Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Before Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Track Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Right Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Left Turn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Straight Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Left Zero-Degree Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Right Zero-Degree Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Operations in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Release Machine from Mud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
One Track Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Two Tracks Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Control Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
SAE Control Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
BHL Control Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Backhoe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Digging a Trench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Loading Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Bucket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
End-of-Workday Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Park and Store the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Overnight Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Short-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
During Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Lift the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Load the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Unload the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

4-2 Safety, Operation & Maintenance Manual - January 8 2016

SY215 Excavator Operation

CONTENTS
TABLEOF
WARNING
Read and understand all safety precautions and instructions in this manual before read-
ing any other manuals provided with this machine and before operating or maintaining it.

INTRODUCTION
Failure to do this could result in death or serious injury.

SAFETY
FUNCTION
SYSTEM
WORK AREA
The “work area” is where the actual job function is being performed. Included within the work area are
“hazard areas”, that is, areas immediately surrounding the machine where personnel may be at risk due to
machine operation or movement.

OPERATION
NOTE: See “Job Site Safety” on page 2-9.

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

WARNING
Do not move the machine onto a surface or area that has not been approved for the machine. The machine
is heavy and could possibly break through surfaces that are not strong enough to support the machine. Fail-
ure to observe and follow this warning could result in death or serious injury.

Those within the work area must wear personal protective equipment.
NOTE: See “Personal Protective Equipment” on page 2-15.
The safety of all personnel within the work area is the responsibility of the machine operator.

General Job Safety

NOTE: See “Job Safety” on page 2-10.
EQUIPMENT
OPTIONAL

Job Site Safety

NOTE: See “Job Site Safety” on page 2-9.
NOTE: See “Job Site Precautions” on page 2-40.

Safety, Operation & Maintenance Manual - January 8 2016 4-3

Operation SY215 Excavator

WORK CREW
Supervisor
This person is the legal representative of the machine owner and has overall responsibility for the safe and
proper use of the machine. They are required to be at the machine during inspection, preparation for opera-
tions and postwork procedures.
The supervisor also has overall responsibility for personnel and safety matters. This means they must en-
sure that:
• Only qualified or properly instructed persons work on or with the machine.
• This Safety, Operation & Maintenance (SOM) manual and other instructions are always available and
have been read and understood by the work crew.
In addition, the supervisor is responsible for producing operating procedures unique to the job at hand and
which may not be included in this technical publication but are of national import.
These procedures must cover the duties involved in supervising and notifying special organizational fea-
tures, e.g., organization of work, working procedures or the personnel entrusted with the work.
Also, there must be reference to other general, valid, legal and also required regulations regarding accident
prevention and environmental protection. These may also include how to handle hazardous substances (for
instance, Safety Data Sheets), distribution and proper wearing of personal protective equipment or with
national road traffic regulations.
NOTE: See “Safety Data Sheets (SDS)” on page 2-18.
NOTE: See “Personal Protective Equipment” on page 2-15.
Familiarize yourself with the job site and learn how to operate fire extinguishers. Observe the fire alarm
and firefighting procedures.
NOTE: See “Fire Safety” on page 2-15.
Finally, the supervisor must be aware of and follow regulations as issued by legal authorities in the job site
county, national supervisory bodies, and the responsible commercial liability insurance company.

Owner and Other Authorized Personnel

Only those personnel who have read and understand the instructions in the Safety section of this manual
can be allowed to operate and maintain this machine. All operating and maintenance personnel must be
periodically tested on machine and safety knowledge to maintain their qualifications to use the machine.
Operations must cease if any safety defect is found, and any accident, especially those concerning serious
injury and/or property damage, must be reported to Sany group.

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SY215 Excavator Operation

CONTENTS
TABLEOF
The machine must be maintained and repaired in accordance with maintenance intervals indicated in this
manual. Inspections mandated by the manufacturers must be performed as stated in this manual in addition
to other inspections mandated by relevant national and local regulations.
NOTE: See “Maintenance Log” on page 1-4.

INTRODUCTION
Operator
NOTE: See “Operator Safety Information” on page 2-6, “Operator is Important” on page 2-7 and “Operator
Qualifications” on page 2-7.
This individual is trained in and responsible for the safe and correct operation of the machine. The operator

SAFETY
reports directly to the supervisor.
The machine can only be operated by:
• An operator who is physically capable, has passed the exam for this machine and holds a valid operator’s
certificate.

FUNCTION
SYSTEM
• Maintenance and operating personnel needing to operate the machine for their tasks.
The machine operator must do the following:
• Reject the work site if they have doubts regarding safety.
• Become familiar with the work area and surroundings before beginning work.

OPERATION
• Read and completely understand the instructions in this manual prior to first-time operation.
• Know and obey the operating procedures, relevant laws and regulations.
• Know and follow the requirements for safe operation.

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

• Know and use the required safety precautions and protective devices.
• Know basic information about the systems of this machine.
• Know and use the correct hand signals between the machine operator and a signal person.
• The operator must concentrate solely on machine operation when using the machine.
• Stop machine operations in case any defects endangering safety are found.
• The operator must control the machine to protect the personnel or other facilities in the vicinity of the ma-
chine.
• Ensure that all control devices are set to neutral or idle position before supplying power to the drive com-
ponents.
• Ensure that the control devices are set to neutral or idle position and the power supply is shut off before
leaving the operator cab.
• The operator must give warning signals when necessary.
• The operator must be provided with necessary personal protective equipment.
EQUIPMENT
OPTIONAL

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Operation SY215 Excavator

Mount and Dismount the Machine

NOTE: See “Mount and Dismount the Machine” on page 2-9.

Seat Belt Usage

Always wear the seat belt when operating the machine.

WARNING
The seat belt is designed to protect the operator from danger, especially when the ma-
chine is traveling. Failure to wear a seat belt when operating the machine could result in
death or serious injury.

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CONTENTS
TABLEOF
NEW MACHINE RUN-IN
Your machine has been thoroughly tested and
adjusted before shipment. However, initial opera-

INTRODUCTION
tion 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 run-
in period of 100 service hours for a new machine.
NOTE: See “Combined Instruments Display/

SAFETY
Fig. 4-1
Monitor” on page 3-16 for information on service
hours.

Properly running in a new machine is crucial for guaranteeing a long service life of the machine by allow-

FUNCTION
SYSTEM
ing time for new cylinder piston rings and other internal engine parts to wear in properly. Ensure that the
machine is in a normal working condition before proceeding with the running-in.
Refer to the applicable engine manual for details on running-in the engine.
The following points are not limitations but instead guidelines for the machine run-in period:

OPERATION
• Operate as much as possible in the half to three-quarters throttle or load range.
• Keep the engine speed at or near idle until the engine reaches its normal operating temperature.
• Avoid long periods of operation with the engine at idle or continuous maximum horsepower levels.

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

• Avoid sudden starts, movements or stops.
• Manage engine power to a point that allows acceleration to governed speed when conditions require more
power. Do not over rev the engine.
• Monitor the instruments frequently — especially the engine oil and coolant temperatures. Shut down the
machine at the first indication of an abnormal reading.
• Shift down to a lower speed setting, to keep the engine speed elevated, before climbing up a slope.
• Check all components frequently for proper operation, unusual noises, and excessive heating.
• Frequently check all operating temperatures. Determine the cause if overheating occurs and perform ad-
justments or repairs immediately.
• Always let the engine cool down before shutting off the engine at the end of the working day.
• Frequently check the bolts and screws for tightness.
• After running-in has been completed, check: “Track Shoe Connecting Bolts” on page 5-51, “Track
Support
EQUIPMENT
OPTIONAL

Roller Mounting Bolts” on page 5-52, and “Track Tension (Initial)” on page 5-62.

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Operation SY215 Excavator

PRE-START CHECKS
CAUTION
Perform this inspection and have needed issues resolved before operation. Failure to ob-
serve and follow this caution could result in minor or moderate injury.

Always complete a walk-around visual inspection

of the machine with special attention to structural
damage, loose equipment, leaks or other conditions
that require immediate correction for safe opera- a
tion.

Fig. 4-2

Safety, Operation & Maintenance Manual

Ensure that the Safety, Operation and Maintenance manual is in the cab (a).

Daily Maintenance Record

Check the Maintenance Log to verify that all required maintenance checks have been performed before
operating the machine. If these checks and actions have not been performed, notify your supervisor.
NOTE: See “Maintenance Log” on page 1-4.
NOTE: See “Daily Maintenance” on page 5-18.
NOTE: Checking fluids may be an operator function. When this is the case, see:
• “Engine Oil Level” on page 5-21.
• “Swing Gearbox” on page 5-23.
• “Primary Fuel Filter” on page 5-28.
• “Fuel Level” on page 5-29.
• “Engine Coolant Level” on page 5-30.
• “Hydraulic Fluid Tank” on page 5-33.
• “Air Conditioner” on page 5-34.
• “Final Drive Gearbox Oil Level” on page 5-61.
• “Windshield Washer and Windshield Wiper” on page 5-70.

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CONTENTS
TABLEOF
Clean
Make sure these items are cleaned:
• Windows (a) and mirrors (b)

INTRODUCTION
• Grab handles (c)
NOTE: Wipe the grab handles to remove grease b
or dirt to help ensure a firm grip is possible when
entering or exiting the cab area.
• Steps (d)

SAFETY
NOTE: See “Accumulation of Flammable
Material” on page 2-43. Fig. 4-3

FUNCTION
SYSTEM
OPERATION
a

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

b

Fig. 4-4
c d
EQUIPMENT
OPTIONAL

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Operation SY215 Excavator

Interior
Operator Cab

CAUTION
Never allow other personnel to ride with you inside the operator cab. Never bring objects
into the operator cab that could restrict your movement or vision in any manner. Failure to
observe and follow this caution could result in minor or moderate injury.

Remove all trash from inside the cab (a) to avoid

interference with operation of the machine. a
NOTE: See “Keep the Operator Cab Clean” on
page 2- 7.

Fig. 4-5

Seat Belt
1. Check the seat belt by fastening it snuggly
around your waist.

Fig. 4-6

2. Ensure the latch plate (a) and the buckle (b) con-
nect together and click. a

Fig. 4-7

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CONTENTS
TABLEOF
3. Check that the belt fits securely and that there is
no slack in the belt (c).

WARNING

INTRODUCTION
Keep any belt slack to no more than 1 in.
(25 mm). Belt slack beyond this amount
could significantly reduce your protection
in an accident. Failure to observe and fol-
low this warning could result in death or
serious injury.

SAFETY
Fig. 4-8
c
4. Ensure that the belt releases when the red button
(d) is pressed at the end of the buckle (b).
d

FUNCTION
NOTE: Seat belt assemblies are maintenance-free;

SYSTEM
however, they should be inspected every 500 hours
to ensure that they are not damaged and are in
proper operating condition, especially if they have
been subjected to severe stress.

OPERATION
b

WARNING

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

Contact your Sany dealer if the seat belt
fails any of these checks or fails to fasten Fig. 4-9
or unfasten. Failure to observe and follow
this warning could result in death or
serious injury.

Mirrors
Adjust both of the outside rear view mirrors for
clear vision and safe driving.
a
NOTE: This mirror (a) is cab-mounted. The other
mirror is attached to the right-side chassis. See
“Exterior Components” on page 3-3 for mirror
locations.
EQUIPMENT
OPTIONAL

Fig. 4-10

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Operation SY215 Excavator

Operator Controls
Check all operator control lever movements for
smooth operation with the ignition switch at the
OFF position. The control levers should return to
neutral freely and there should not be any exces-
sive play in the control levers.
NOTE: See “Cab Interior” on page 3-4 for controls
information.
Fig. 4-11

Lamps and Warning Devices c

Check the following for proper operation with the
ignition switch (a) set to the ON position:
• Work lamps (b)
• Horn (c)
• Head lamps (d)

Fig. 4-12
d

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CONTENTS
TABLEOF
Fire Extinguisher
Check the fire extinguisher (a) is on the back wall
of the cab.

INTRODUCTION
NOTE: Be sure the fire extinguisher is at least a
threepound “A, B, C” fire-rated extinguisher (NFPA b
10 Standard for Portable Fire Extinguishers).

Escape Tool
Check that the escape tool (b) is on the back wall

SAFETY
of the cab

Fig. 4-13
a

FUNCTION
SYSTEM
WARNING
Front Window Locks
Push up on the handles (a) to make sure that the
front window locks (b) are fully engaged. Make
b

OPERATION
sure the window does not move while operating
the machine.

WARNING

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

Failure to lock the front window in place
could cause the window to open without
warning. Failure to observe and follow this
warning could result in death or serious Fig. 4-14 b
a
injury.

EQUIPMENT
OPTIONAL

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Operation SY215 Excavator

COMBINED INSTRUMENTS DISPLAY/MONITOR SETTINGS

The Combined Instruments Display (a) is mounted
in the front right of the cab.

Fig. 4-15 a

First-Time Setup
a
Access the Main Menu
1. Turn the ignition switch (a) to the ON position.

Fig. 4-16
NOTE: The Main Operator screen displays.

Fig. 4-17

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CONTENTS
TABLEOF
2. Press F5 and the System Information (Password)
screen displays.
3. Enter the password digits.

INTRODUCTION
NOTE: See “System Information (Password)
Screen” on page 3-30.

SAFETY
FUNCTION
SYSTEM
OPERATION
Fig. 4-18

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

4. Press Enter and the Main Menu screen displays.

EQUIPMENT
OPTIONAL

Fig. 4-19

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Operation SY215 Excavator

ENGINE PROCEDURES
WARNING
Never attempt to start the machine if it has
been locked out by maintenance person-
nel. If in doubt, contact the maintenance
supervisor. Failure to observe and follow
this warning could result in death or seri-
ous injury.
NOTE: Check the work area to be sure all person-
nel and equipment are clear from your machine.
Before starting the machine, sound your hornto
warn others you are about to start the machine.

Start-up and shut-down procedures for most diesel

engines are generally the same. Therefore, use the
following procedures except where specific differ-
ences are noted. (Refer to the OEM engine manual
for detailed procedures.)
Fig. 4-20

WARNING
Diesel engine exhaust can be harmful to your health or even fatal. Operate the engine only
in a well-ventilated area or vent the exhaust to the outside. Failure to observe and follow
this warning could result in death or serious injury.

Cold-Weather Operation
The following recommendations are for operating Sany excavators in very low (i.e., sub-zero) tempera-
tures.
NOTE: See “Ignition Switch” on page 3-11 for details on using the ignition switch to preheat the engine
for cold-weather starting.
NOTE: Detailed cold-weather starting and operating procedures are covered in the OEM engine manual
and in “Inspection and Maintenance in Adverse Environments” on page 5-8.
The correct grade of oil for the prevailing temperature must be used in the crankcase. Diesel fuel must have
a pour point of 10° F (6° C) less than the lowest expected temperature.
NOTE: See “Engine Oil Viscosity/Temperature Data” on page 5-14 and “Fuel” on page 5-14.
This machine must have appropriate hydraulic fluid, lubricants and other auxiliary items required for op-
eration in sub-zero temperatures. Individual machine functions should be operated to ensure they are suf-
ficiently warmed prior to performing work.
NOTE: See “Location, Capacity and Type” on page 5-13.

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CONTENTS
TABLEOF
Operation of machine at full-rated capacities in temperatures between 0° F (-18° C) and -40° F (-40° C) or
lower should be accomplished only by competent operators who possess the skill, experience and dexterity
to ensure smooth operation. Shock-loading must be avoided.
Cold weather operation requires additional cautions:

INTRODUCTION
• Do not touch metal surfaces that could cause you to be frozen to them.
• Keep the machine clear of all ice and snow.
• Allow sufficient time for the hydraulic fluid to warm up.
• Park the machine in an area where it cannot freeze to the ground.

SAFETY
Engine Start Procedure
CAUTION
Do not spray starting fluid into the air inlet. The spray will contact the heater elements and

FUNCTION
SYSTEM
could explode. Failure to observe and follow this caution could result in minor or moder-
ate injury.
Perform the following steps to start the engine:
NOTE: See “Cold-Weather Operation” on page 4-16 for more information.

OPERATION
1. Set the hydraulic lockout control lever (a) to the
CLOSE position.
NOTE: See “Hydraulic Lockout Control Lever” on
page 3-5.

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

a

Fig. 4-21
EQUIPMENT
OPTIONAL

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Operation SY215 Excavator

2. Set the throttle (b) to the MIN position.

WARNING d
The machine should not move when the
hydraulic lockout control lever is at the
CLOSE position. If it does so contact your
Sany dealer to solve this problem. Failure
to observe and follow this warning could
result in death or serious injury.

3. Turn the ignition key (c) from OFF to ON.

NOTE: The monitor (d) displays the Main Opera-
tor screen two seconds after the key is turned to the
ON position.

Fig. 4-22

NOTE: The rounded-headed key (e) operates the

ignition switch, the cab door lock and the access e
panel locks. The square-headed key (f) operates
only the cab door lock and the access panel locks.

Fig. 4-23

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CONTENTS
TABLEOF
The display includes:
• Engine coolant temperature gauge (g)
m
• Fuel level gauge (h)

INTRODUCTION
• Failure code (k) (if any)
NOTE: The warning indicator (m) illuminates if
a failure is detected. A failure code (k) displays
near the bottom of the display. See “Failure Codes g
Screens” on page 3-28. Contact your Sany dealer
to correct any failure code issue.

SAFETY
4. Turn the ignition key to START and release it h
immediately when the engine starts.

NOTICE k

FUNCTION
SYSTEM
Never crank the engine for more than 15
seconds. If the engine fails to start after 15
seconds, stop and allow the starter motor
to cool for at least 10 seconds before at-
tempting another start. Failure to observe

OPERATION
and follow this notice can cause damage
to the machine or cause the machine to
operate improperly.
Fig. 4-24
NOTE: If the engine fails to start after five attempts, contact your Sany dealer.

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

Immediately check the engine instruments and monitor for any failure codes after starting. Shut down the
engine if a failure code is shown on the display screen.
NOTE: See “Combined Instruments Display/Monitor” on page 3-18.

Idle the Engine

Idling the engine unnecessarily for long periods of time wastes fuel and fouls injector nozzles. Unburned
fuel causes carbon formation, oil dilution, formation of lacquer or gummy deposits on the valves, pistons,
and rings, and rapid accumulation of sludge in the engine.

NOTICE
Never race the engine during the warm-up period and never operate the engine beyond its
design levels. Engine bearings, pistons, and valves may be damaged if these precautions
are not taken. Failure to observe and follow this notice can cause damage to the machine
or cause the machine to operate improperly.
EQUIPMENT
OPTIONAL

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Operation SY215 Excavator

ENGINE SHUTDOWN PROCE-

DURE
1. Park the machine on a flat, level, stable surface
away from people, traffic or other machines.
2. Retract the arm and bucket cylinders, then lower
the boom bucket to rest on the ground.

NOTICE
Except for emergencies, never shut down Fig. 4-25
the engine while it is running at high
speed. Stopping the engine at high speed
can cause damage to the machine or cause
the machine to operate improperly.

3. Run the engine at idle speed (about 1,050 rpm)

for about 5 minutes. a
NOTE: See “Throttle Help Info Screen” on page
3-32.
4. Turn the ignition key (a) to the OFF position.
5. Set the ignition key to the ON position.
6. Operate all functional controls to relieve pres-
sure on the systems.
7. Turn the ignition key to the OFF position and
remove the key from the switch.

Fig. 4-26

8. Place the hydraulic lockout control lever (b) in

the CLOSE position. b

NOTE: See “Hydraulic Lockout Control Lever” on

page 3-5.

Fig. 4-27

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CONTENTS
TABLEOF
MACHINE WARM-UP
1. Start the engine.
NOTE: See “Engine Start Procedure” on page 4-17.

INTRODUCTION
NOTICE
Do not begin machine operation immediately after starting the engine. Perform the follow-
ing warm-up procedures to prepare the system for operations. Failure to do so can cause
damage to the machine, personal property and/or the environment, or cause the machine
to operate improperly.

SAFETY
2. Adjust the throttle to run the engine unloaded at low speed (about 1,050 rpm) for about five minutes.
NOTE: See “Throttle Help Info Screen” on page 3-29.

FUNCTION
SYSTEM
3. Place the hydraulic lockout control lever in the
OPEN position (a).
4. Adjust the throttle to run the engine at moderate

OPERATION
speed (about 1,400 rpm), then slowly operate the
bucket for five minutes.
NOTE: See “Control Work Equipment” on page
4-32.

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

5. Adjust the throttle to run the engine at high
speed (about 2,000 rpm), then operate the boom,
arm and bucket for 5-10 minutes.
6. Cycle each action of the machine several times
before ending the warm-up operation.

Fig. 4-28
a

CAUTION
The center of gravity and boom length is different on machines equipped with a super
long reach. Take extra care when traveling with this machine and be aware of the extra
clearances needed when turning the machine and operating a super long reach. Failure to
do so could result in minor injury or moderate injury.

7. Continue to warm-up the machine until the coolant temperature reaches the middle of the display on the
monitor panel.
EQUIPMENT
OPTIONAL

NOTE: See “Combined Instruments Display/Monitor” on page 3-18.

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Operation SY215 Excavator

8. Check for black exhaust smoke, very loud noise,

or excessive vibration.
NOTE: If found, notify your Sany dealer immedi-
ately for assistance.
b
9. Press F1 (a) to select the desired working mode.
Working mode (b) options are:
• S: Standard duty - Used for normal excavating.
• H: Heavy duty - Used for excavating in hard or
rocky ground.
• L: Light duty - Used for light tasks such as dig-
ging in soft soil.
• B: Breaker mode - Used when operating with at-
tachments such as a jackhammer.
NOTE: Breaker mode cannot be used with a super
long reach. See “Combined Instrument Display
Super Long Reach” on page 8-15. a

Fig. 4-29

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CONTENTS
TABLEOF
TRAVEL OPERATIONS
WARNING
Never allow any personnel to be within 26 ft. (8 m) of the machine. Never allow any

INTRODUCTION
personnel to be around the machine while it is moving.
Be aware of all crush points on the machine and ensure that all personnel keep clear of
these areas.
Moving any control lever or pedal to abruptly change the direction of the machine.
Stopping the machine suddenly by releasing the lever or pedal while traveling at high
speed.

SAFETY
The center of gravity and boom length is different on machines equipped with a super
long reach. Take extra care when traveling with this machine and be aware of the extra
clearances needed when turning the machine and operating a super long reach.
Failure to observe and follow these warnings could result in death or serious injury.

FUNCTION
SYSTEM
NOTE: See “Crush or Pinch-Point Precautions” on page 2-44 and “Operation Precautions” on page 2-46.

NOTICE

OPERATION
Avoid sudden lever release when traveling at top speeds to stop the machine. Failure to
follow this notice can cause damage to the machine, personal property or cause the ma-
chine to operate improperly.

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

NOTE: See “Travel Precautions” on page 2-41.

EQUIPMENT
OPTIONAL

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Operation SY215 Excavator

Before Travel
NOTE: See “Engine Start Procedure” on page 4-17.
1. Turn the throttle control dial (a) clockwise to
increase the engine speed.
a

Fig. 4-30

2. Place the hydraulic lockout control lever in the

OPEN position (b).
NOTE: See “Hydraulic Lockout Control Lever” on
page 3-5.

Fig. 4-31 b

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CONTENTS
TABLEOF
3. Retract the boom to ensure good visibility to the
right.

INTRODUCTION
SAFETY
FUNCTION
SYSTEM
OPERATION
SPECIFICATIONS TROUBLRSHOOTING MAINTENACE
Fig. 4-32
4. Retract the working equipment until it is 16 - 20
in. (40 - 50 cm) above the ground, dimension “A”.

EQUIPMENT
OPTIONAL

Fig. 4-33

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Operation SY215 Excavator

Track Direction
The directional arrow (a) on each of the two track
frames indicates the forward direction of the lower-
works. Check these arrows before using the travel
control levers. When possible, face the cab in this
direction. his is the normal position.
When traveling in areas where the machine will be
exposed to surrounding hazards, rough surfaces or
tight maneuvering, travel with the carriage in the
normal position.

Fig. 4-34
a
Travel With Carriage Reversed
When the cab faces backward, the machine moves forward when you pull control levers and backward
when you push them.
Sany does not recommend traveling with the carriage reversed.
Always keep in mind the travel lever controls will be working in the opposite direction from normal travel.

CAUTION
Travel with the carriage reversed could pose a hazard. Failure to observe and follow this
caution could result in minor or moderate injury.

Right Turn
Move the left travel control lever to cause the left
track to move forward or backward depending on
which direction the control is moved.
NOTE: Forward direction of the left track is shown
in the illustration.
NOTE: See “Track Direction” on page 4-26.
The further the control is moved in either direction,
the faster the left track moves.
Fig. 4-35

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CONTENTS
TABLEOF
Left Turn
Move the right travel control lever to cause the
right track to move forward or backward, depend-

INTRODUCTION
ing on which direction the control is moved.
NOTE: Forward direction of the right track is
shown in the illustration.
NOTE: See “Track Direction” on page 4-26.
The further the control is moved in either direction,

SAFETY
the faster the right track moves.
Fig. 4-36

FUNCTION
Straight Travel

SYSTEM
Move both controls at the same time to cause both
tracks to move forward or backward, depending on
which direction the controls are moved.

OPERATION
NOTE: Forward direction of both tracks is shown
in the illustration.
NOTE: See “Track Direction” on page 4-26.
The further the controls are moved in either direc-

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

tion, the faster each track moves.
Fig. 4-37

Left Zero-Degree Rotation

Push the right lever forward and pull the left lever
rearward to cause a left zero-degree rotation of the
machine.
NOTE: See “Track Direction” on page 4-26.
NOTE: The center of gravity and boom length is
different on machines equipped with a super long
reach. Take extra care when traveling with this ma-
chine and be aware of the extra clearances needed
when turning the machine and operating a super
EQUIPMENT

Fig. 4-38
OPTIONAL

long reach.

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Operation SY215 Excavator

Right Zero-Degree Rotation

Push the left lever forward and pull the right lever
rearward to cause a right zero-degree rotation of
the machine.
NOTE: See “Track Direction” on page 4-26.
NOTE: The center of gravity and boom length is
different on machines equipped with a super long
reach. Take extra care when traveling with this ma-
chine and be aware of the extra clearances needed
when turning the machine and operating a super
long reach.
Fig. 4-39

Slopes
Observe the following when operating a machine on a slope:
• Do not travel on a slope exceeding 15° (26.8%) side-to-side or 35° (70%) fore-and-aft.
NOTE: See “Traveling on Sloped Areas” on page 2-40.
• The hydraulic tank must be over half full.
NOTE: See “Hydraulic Fluid Tank” on page 5-35.
• Avoid holes, rocks, extremely soft surfaces, and other obstacles that might subject the machine to undue
stresses and possible tipover.
• Position the bucket 16 - 20 in. (20 - 30 cm) above the ground while traveling.
• Always set the throttle control dial to maintain a slow speed while traveling up or down a slope.
• Do not turn the machine while on a slope.
• Do not travel in reverse on a slope.
• The center of gravity and boom length is different on machines equipped with a super long reach. Take
extra care when traveling with this machine and be aware of the extra clearances needed when turning the
machine and operating a super long reach.

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CONTENTS
TABLEOF
Operations in Water
Observe the following when operating the machine
in water:

INTRODUCTION
• Do not drive the machine into water where the
water level could reach the center of the carrier
rollers (a).
• Do not operate the machine in water unless the
foundation of the work site is strong enough to
properly support the machine.

SAFETY
Fig. 4-40 a
• An escape tool is available for use in emergen-
cies.
NOTE: See “Escape Tool” on page 4-13.

FUNCTION
NOTICE

SYSTEM
If the swing bearing and swing gearbox have been submerged in water, the swing gearbox
drain plug should be removed to drain mud and water. Refill the swing gearbox and lubri-
cate the swing bearing. Failure to follow this notice can cause damage to the machine, the

OPERATION
environment, or cause the machine to operate improperly.

NOTE: See “Hydraulic System Breather Filter” on page 5-79.

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

EQUIPMENT
OPTIONAL

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Operation SY215 Excavator

Release Machine from Mud

If the machine becomes stuck in the mud, drive it out of the mud using the following methods:

One Track Stuck

1. Position the boom and arm at an angle between 90° and 110°.
NOTE: See “Operator Controls” on page 4-12.
2. Pivot the upperworks to position the boom over the track that is stuck.
3. Curl the bucket so that the back of the bucket contacts the ground.
NOTE: Use cribbing to provide a firm surface if necessary.
4. Lower the boom to lift the track.
5. Place cribbing under the track.
6. Drive the machine out of the mud.

Two Tracks Stuck

1. Position the boom and arm at an angle between 90° and 110°.
2. Pivot the upperworks to position the boom over the front of the machine.
3. Curl the bucket so that the back of the bucket contacts the ground.
NOTE: Use cribbing to provide a firm surface if necessary.
4. Lower the boom to lift the front of the tracks.
5. Place cribbing under the tracks.
6. Cut the bucket into the ground in front of the machine.
7. Retract the arm as done with normal excavating while driving the machine forward out of the mud.

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CONTENTS
TABLEOF
Arm
Move the left joystick forward to extend the arm.
Move the left joystick rearward to retract the arm.

INTRODUCTION
SAFETY
Fig. 4-41

FUNCTION
SYSTEM
Boom
Move the right joystick forward to lower the boom.
Move the right joystick rearward to raise the boom.

OPERATION
SPECIFICATIONS TROUBLRSHOOTING MAINTENACE
Fig. 4-42

Bucket
Move the right joystick to the left to curl the buck-
et. Move the right joystick to the right to dump the
bucket.
NOTE: The bucket function is the same for SAE
and BHL.
EQUIPMENT
OPTIONAL

Fig. 4-43

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Operation SY215 Excavator

BHL Control Pattern

NOTE: See “BHL Mode” on page 3-14.

Swing
Move the left joystick to the left to swing the work
equipment to the left. Move the left joystick to the
right to swing the work equipment to the right.
NOTE: The swing function is the same for SAE
and BHL.

Fig. 4-44

Arm
Move the right joystick forward to extend the arm.
Move the right joystick rearward to retract the arm.

Fig. 4-45

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CONTENTS
TABLEOF
Boom
Move the left joystick forward to lower the boom.
Move the left joystick rearward to raise the boom.

INTRODUCTION
SAFETY
Fig. 4-46

FUNCTION
SYSTEM
Bucket
Move the right joystick to the left to curl the buck-
et. Move the right joystick to the right to dump the
bucket.

OPERATION
NOTE: The bucket function is the same for SAE
and BHL.

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

Fig. 4-47

EQUIPMENT
OPTIONAL

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Operation SY215 Excavator

RECOMMENDED APPLICATIONS
WARNING
Contact the site supervisor before any digging to ensure that all underground hazards
have been located. Failure to observe and follow this warning could result in death or seri-
ous injury.

WARNING
Never allow any personnel to be within 26 ft. (8 m) of the machine.
Never allow any personnel to be around the machine while it is moving.
Be aware of all crush points on the machine and ensure that all personnel keep clear of
these areas.
Moving any control lever or pedal to abruptly change the direction of the machine.
The center of gravity and boom length is different on machines equipped with a super
long reach. Take extra care when traveling with this machine and be aware of the extra
clearances needed when turning the machine and operating a super long reach.
Failure to observe and follow these warnings could result in death or serious injury.

NOTE: See “Operating Ranges” on page 7-4, “Authorized Use of the Machine” on page 2-37, “Crush or
Pinch-Point Precautions” on page 2-44, and “Lift Chart - Standard Arm” on page 7-6 prior to operating the
machine.
NOTE: For super long reach operation, see “Super Long Reach Option” on page 8-14.

Backhoe Operation
Backhoe operation is for digging an area lower
than the machine. The digging range of the arm is
from 30° and 45°. The angle may vary according to
the digging depth.

Fig. 4-58

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CONTENTS
TABLEOF
Maximum digging force can be obtained when the
angle between the boom and the arm and the buck-
et cylinder and the bucket bracket are both 90°.

INTRODUCTION
SAFETY
Fig. 4-49

Digging a Trench
Trench work can be done efficiently by using a
suitable bucket and positioning the tracks parallel

FUNCTION
SYSTEM
to the trench line. When digging a wider trench,
excavate the sides first then remove the middle.

OPERATION
Fig. 4-50

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

Loading Operations
It is more convenient to load material if the truck is
loaded from the rear than from the side.

Fig. 4-51 EQUIPMENT

OPTIONAL

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Operation SY215 Excavator

BUCKET REPLACEMENT

CAUTION
Driving a pin with a hammer can cause metal pieces to fly off, leading to severe injuries.
Wear goggles, a hard hat, protective gloves and other personal protective equipment dur-
ing these operations.
Make sure that the surrounding area is clear of personnel when hammering any of the
pins; the pins could fly out and cause personal injury.
Do not stand behind the bucket when removing pins.
Do not to place your foot under the bucket.
Do not put your finger into the bore during alignment.
Failure to observe and follow these cautions could result in minor or moderate injury.

NOTE: See “Optional Attachment Use” on page

2-45.
b
1. Park the machine on hard, level ground.
2. Place the bucket (a) on level ground.
c
NOTE: Before removing the pins, slowly lower
the bucket (a) to a level where it just contacts the
ground. If a larger force is used resistance could
increase on the pin causing difficulty when remov-
ing it. a
3. Remove the nuts and screws on the plate retain-
ing the arm pin and link pin. (Pin installed (b))
4. Remove the arm pin and link pin, and then re-
move the bucket. (Pin removed (c))

Fig. 4-52

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CONTENTS
TABLEOF
5. Align arm (d) and the link (e) with bore (f).
Insert the greased pins into bore (g) and bore (h) d
respectively.
NOTE: Make sure the pins are free of mud or e

INTRODUCTION
sand after removal. Both ends of the bushing are
f
installed with seals against dust. Be careful not to
damage them.
6. Reinstall the nuts and bolts onto the plate retain-
g
ing the pins.

SAFETY
7. Add grease to the pins. h
NOTE: Inject grease until the grease is squeezed
out of the plate.

FUNCTION
SYSTEM
NOTICE
Replace any broken seals when replacing a
bucket. The usage with broken seals could Fig. 4-53
allow sand or dust to penetrate through to

OPERATION
the pins and cause abnormal wear. Failure
to follow this notice can cause damage to
the machine or cause the machine to oper-
ate improperly

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

EQUIPMENT
OPTIONAL

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Operation SY215 Excavator

END-OF-WORKDAY CHECKS
1. Collect any trash or debris from the cab and
deposit it into a trash can.

Fig. 4-54

2. Remove all built-up mud or debris on the lower-

works and machine exterior.

Fig. 4-55

3. Inspect the machine work equipment, machine

exterior, and lowerworks for signs of fluid leaks or
damage.
4. Near ocean (salt air) environments, thoroughly
wash away any salt residue, apply grease where
rust is found and carefully perform maintenance on
the electrical components to prevent corrosion.

Fig. 4-56

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CONTENTS
TABLEOF
PARK AND STORE THE MACHINE
Overnight Storage
1. Park the machine on a flat, level, stable surface

INTRODUCTION
away from people, traffic or other machines.
2. Lower the work equipment to the ground.
3. Run the engine at idle speed (1,050 rpm) for
about five minutes to allow for heat dissipation.
Extend this cool-down time in hot weather.

SAFETY
NOTE: See “Throttle Control Dial” on page 3-11.
4. Turn the ignition key (a) to the OFF position.
5. Remove the ignition key when the engine comes Fig. 4-57
to a complete stop.

FUNCTION
SYSTEM
NOTICE a

OPERATION
Always remove the ignition key and take
it with you, even if you are leaving the ma-
chine for only a moment. Keep it with you
to prevent unauthorized operation of the
machine. Failure to follow this notice can

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

cause damage to the machine, personal
property and/or the environment.

6. Set the hydraulic lockout control lever (b) to the Fig. 4-58
CLOSE position.
7. Close and lock the windows.
8. Exit the cab and lock the cab door.
NOTE: See “Mount and Dismount the Machine”
on page 2-8.
b
9. Fill the fuel tank to the maximum level.
NOTE: See “Refuel” on page 2-19 if fuel level is
low and “Fuel Level” on page 5-33.
EQUIPMENT
OPTIONAL

Fig. 4-59

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Operation SY215 Excavator

10. Ensure that the following items are secured and

locked:
• Cab door (c)
• A/C fresh air inlet door (d)
• Engine cover (e)
• Left rear access panel (f)
• Right rear access panel (g)
• Fuel tank cap (k)

Fig. 4-60 c f
d e

Fig. 4-61 g

Short-Term Storage
Complete the Overnight Storage procedure (see page 4-39), and then:
• Clean the machine.
• Keep it dry.
• Keep it fully lubricated.
• Cover it to protect from dust.
NOTE: Short-term storage is defined as a storage period of 30 days or less.
Long-Term Storage
Proper preparation for long-term storage will reduce the chances for damage or deterioration of the ma-
chine.
NOTE: Long-term storage is defined as a storage period of more than 30 days.

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CONTENTS
TABLEOF
Preparation
1. Park the machine in a secure location and posi-
tion the work equipment with the arm and bucket

INTRODUCTION
fully extended.
2. Run the engine at idle speed for about five min-
utes to avoid increasing internal temperatures and
Fig. 4-62
to allow for heat dissipation. Extend this cool-
down time in hot weather.
3. Shut down the engine.

SAFETY
NOTE: See “Engine Shutdown Procedure” on page
4-20.
a
4. Turn the ignition key (a) to the ON position.

FUNCTION
5. Operate all controls in all directions to relieve

SYSTEM
stored pressure within the hydraulic system.

CAUTION

OPERATION
Unplanned movement of a joystick or
travel control lever with the hydraulic ac-
cumulator still pressurized could result in
unexpected movement of the machine or
work equipment. Failure to observe and Fig. 4-63

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

follow this caution could result in minor or
moderate injury.

6. Turn the ignition key (a) to the OFF position.

7. Remove the ignition key.

NOTE: Always remove the ignition key and take it with you, even if you are leaving the machine for only
a moment. Keep it with you to prevent unauthorized operation of the machine.
EQUIPMENT
OPTIONAL

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Operation SY215 Excavator

8. Set the hydraulic lockout control lever to the

CLOSE position (b).
NOTE: See “Hydraulic Lockout Control Lever” on
page 3-5.
9. Close and lock the windows.
b

Fig. 4-64

10. Exit the cab (c) and lock the cab door.
NOTE: See “Mount and Dismount the Machine”
on page 2-8.

Fig. 4-65
c
11. Turn both of the outside rear view mirrors
inward so that they are within the perimeter of the
machine.
NOTE: This mirror (d) is cab-mounted. The other
mirror is attached to the right-side undercarriage;
see “Exterior Components” on page 3-3 for mirror
locations. d
12. Fill the fuel tank to the maximum level.
NOTE: See “Refuel” on page 2-19 if fuel level is
low and “Fuel Level” on page 5-33.

Fig. 4-66

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CONTENTS
TABLEOF
13. Ensure that the following items are secured and
locked:
• Cab door (e)

INTRODUCTION
• A/C fresh air inlet door (f)
• Engine cover (g)
• Left rear access panel (h)
• Right rear access panel (k)
• Fuel tank cap (n)

SAFETY
14. Apply spray lubricant to any exposed cylinder Fig. 4-67 e
f g h
rods.
NOTE: See “Fluids & Lubricants” on page 5-13
for additional information.

FUNCTION
SYSTEM
15. Change the engine oil.
NOTE: See “Engine Oil and Filter (Initial)” on
page 5- 57.

OPERATION
16. Disconnect the battery negative terminal and
reinstall the battery cover or remove the batteries
and store them in a separate location.
NOTE: See “Battery Safety” on page 2-20 for
further information.

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

k

Fig. 4-68
n

EQUIPMENT
OPTIONAL

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Operation SY215 Excavator

During Storage
WARNING
When operating the machine inside a building and to prevent asphyxiation, it is necessary
to open doors and windows to provide adequate ventilation. Failure to observe and follow
this warning could result in death or serious injury.

Once a month:
1. Start the machine.
NOTE: See “Engine Start Procedure” on page 4-17.
2. Drive the machine a short distance.
NOTE: See “Machine Warm-Up” on page 4-21.
3. Cycle each cylinder a few times to coat cylinder rods with oil and exercise the seals.
4. Coat the exposed parts of the cylinder rods with spray lubricant to prevent corrosion.
NOTE: See “Fluids & Lubricants” on page 5-13 for additional information.
5. Turn on the air conditioner and allow it to run for 3 to 5 minutes to lubricate the compressor and related
parts.
6. Return the machine to the proper storage location and condition.
NOTE: See “Preparation” on page 4-41.
Return to Service
1. Check the fuel and engine oil for water contamination. Drain water or replace fluids as necessary.
NOTE: See “Primary Fuel Filter” on page 5-28.
NOTE: See “Engine Oil and Filter (Initial)” on page 5-57.
2. Examine the exterior of the machine for signs of rust or damage and repair as necessary.
3. Start the machine and test all operations.
NOTE: See “Pre-Start Checks” on page 4-8.
NOTE: See “Engine Start Procedure” on page 4-17 and “Machine Warm-Up” on page 4-21.

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CONTENTS
TABLEOF
TRANSPORT
Follow all local, state, and federal regulations and laws regarding transporting the machine.

WARNING

INTRODUCTION
To avoid a machine tip-over condition, do the following when loading or unloading:
• Select a location that is firm and level and a safe distance from any road or structure.
• Ensure that the trailer is properly chocked to prevent any movement.
• Use an access ramp with enough length, strength, and width to properly support the ma-
chine. The ramp grade should not exceed 15°.

SAFETY
• Drive slowly at the junction of the ramp and the trailer. The machine may shift suddenly
due to change in center of gravity.
• Use a signal person to observe and alert the operator of any potential hazards.
• The center of gravity and boom length is different on machines equipped with a super
long reach. Take extra care when traveling with this machine and be aware of the extra

FUNCTION
SYSTEM
clearances needed when turning the machine and operating a super long reach.
Failure to observe and follow these warnings could result in death or serious injury.

OPERATION
NOTE: See “Machine Dimensions” on page 7-2 for further information.
NOTE: See “Travel Precautions” on page 2-41 for further information.

Lift the Machine

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

To lift the machine on to or off of a trailer, use the
lift/tiedown points (a) identified on both sides of
the machine as well as the center of gravity point
(b) on both sides of the machine. Contact your
Sany dealer for assistance in rigging and lifting the
machine.
NOTE: See “Tow or Lift the Machine” on page 2-44
for additional information.

Fig. 4-69
a b a
EQUIPMENT
OPTIONAL

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Operation SY215 Excavator

Load the Machine

Contact your Sany dealer for proper cab protection to be used during transport of the machine.

1. Clean the tracks (a) to prevent slipping during

loading.
2. Position the machine so that the centerline of the
machine matches the centerline of the trailer.
a
NOTE: See “Travel Operations” on page 4-23.

Fig. 4-70

3. Press F2 on the Main Operator screen to set the

auto idle (b) to OFF.
4. Press F3 on the Main Operator screen to set the
travel speed (c) to LOW.

Fig. 4-71

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CONTENTS
TABLEOF
NOTE: If work equipment is attached to the ma-
chine, the equipment should be positioned in front
of the machine during loading.

INTRODUCTION
Fig. 4-72
NOTE: If no work equipment is attached, back the

SAFETY
machine onto the trailer.

FUNCTION
SYSTEM
Fig. 4-73

5. Drive the machine slowly until the tracks have

full contact with the trailer.

OPERATION
NOTE: The machine may lean forward when it
passes over the trailer wheels.
6. Raise the work equipment slowly. Ensure you
Fig. 4-74
raise the equipment high enough to avoid hitting

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

the trailer or truck.
7. Rotate the upperworks so that the work
equipment faces the back of the trailer.

Fig. 4-75
EQUIPMENT
OPTIONAL

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Operation SY215 Excavator

8. Place a support block (d) on the trailer under the

work equipment.
9. Fully extend the bucket cylinder arm and arm
cylinder. d
10. Lower the work equipment onto the support
block (d).
NOTE: For machines equipped with a super long
reach, connect the brace attachment (e). Do not
transport the super long reach without the brace in Fig. 4-76
place.

Fig. 4-77

11. Shut down the machine.

NOTE: See “Engine Shutdown Procedure” on page 4-20.
12. Close and lock the windows.
13. Exit the cab.
NOTE: See “Mount and Dismount the Machine” on page 2-8.

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CONTENTS
TABLEOF
14. Turn both of the outside rear view mirrors
inward so that they are within the perimeter of the
machine.
NOTE: This mirror (f) is cab-mounted. The other

INTRODUCTION
mirror is attached to the right-side undercarriage;
“Exterior Components” on page 3-3 for mirror
locations. f

SAFETY
FUNCTION
SYSTEM
Fig. 4-78

OPERATION
15. Ensure that the following items are secured and
locked:
• Cab door (g)
• A/C fresh air inlet door (h)

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

• Engine cover (k)
• Left rear access panel (m)
• Right rear access panel (n)
• Fuel tank cap (p)
Fig. 4-79 g
h k m

n
EQUIPMENT
OPTIONAL

Fig. 4-80
p

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Operation SY215 Excavator

16. Cover the exhaust opening (q) to prevent for-

eign material from entering during transport.

Fig. 4-81

17. Secure the machine to the trailer with suitable

tiedowns (r) in accordance with all applicable laws
and regulations.

Fig. 4-82

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CONTENTS
TABLEOF
Unload the Machine
1. Chock the trailer wheels to ensure that the trailer will not move during unloading.
2. Attach or construct ramps of suitable strength, width and length to unload the machine.

INTRODUCTION
3. Remove all tie-downs (a) and blocks securing
the machine to the trailer.
NOTE: If the machine is equipped with a super
long reach, disconnect the brace from the arm and

SAFETY
boom.
4. Turn the exterior rear view mirror so that the
operator has a clear view to the front and rear of
the machine. a

FUNCTION
SYSTEM
5. Unlock and start the machine and allow it to
Fig. 4-83
warm-up fully.
NOTE: See “Machine Warm-Up” on page 4-21.
6. Press F2 on the Main Operator screen to set the

OPERATION
automatic deceleration (b) to OFF.
7. Press F3 on the Main Operator screen to set the
travel speed (c) to LOW.

SPECIFICATIONS TROUBLRSHOOTING MAINTENACE

EQUIPMENT
OPTIONAL

Fig. 4-84 b c

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Operation SY215 Excavator

8. Set the hydraulic lockout control lever (d) to the

OPEN position.
9. Raise the work equipment to clear the trailer.
NOTE: See “Control Work Equipment” on page
4-32.

Fig. 4-85 d

10. Drive the machine slowly off the trailer.

NOTE: See “Machine Warm-Up” on page 4-21.
11. Lower the bucket and move slowly down the
ramp while operating the boom and arm inward to
provide support as the machine moves forward off
the ramp.
Fig. 4-86
12. Park the machine at the desired location.
13. Shut down the engine.
NOTE: See “Engine Shutdown Procedure” on page
4-20.

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CONTENTS
TABLEOF
INTRODUCTION
Maintenance

SAFETY
Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Checks Before Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Checks After Maintenance or Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

FUNCTION
SYSTEM
Hour Meter Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Genuine Sany Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Sany-Approved Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Weld, Drill, Cut or Grind on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

OPERATION
Clean Parts or the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Covers and Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Hydraulic Fluid Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Inspection and Maintenance in Adverse Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Mud, Rain or Snow Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

MAINTENACE
Near Ocean (Salt Air) Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Dusty Environments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Rocky Ground Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Cold Environments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

SPECIFICATIONS TROUBLRSHOOTING
Other Weather Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Specific Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
General Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Fluids & Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Location, Capacity and Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Engine Oil Viscosity/Temperature Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Lubricating Grease/Temperature Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
EQUIPMENT
OPTIONAL

Industrial Gear Oil/Temperature Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Hydraulic Fluid/Ambient Temperature Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Safety, Operation & Maintenance Manual - January 8 2016 5-1

Maintenance SY215 Excavator

Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Supplemental Coolant Additive (SCA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Windshield Washer Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Secure the Machine for Maintenance (Power Off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Safety, Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Escape Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Engine Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Engine Serpentine Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Pump Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Hydraulic Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Idler Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Sheet Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Primary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Secure the Machine for Maintenance (Power On). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Operating Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Engine Coolant Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Hydraulic Fluid Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
50-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Secure the Machine for Maintenance (Power Off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Engine Air Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Muffler and Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Track Shoe Connecting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Track Support Roller Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Final Drive Motor Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

5-2 Safety, Operation & Maintenance Manual - January 8 2016

SY215 Excavator Maintenance

CONTENTS
TABLEOF
Secure the Machine for Maintenance (Power On). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Engine Oil and Filter (Initial). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61

INTRODUCTION
Final Drive Gearbox Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Track Tension (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-64
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

SAFETY
250-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Secure the Machine for Maintenance (Power Off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
Hydraulic Pilot Line Filter Element (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66

FUNCTION
SYSTEM
Hydraulic Fluid - Breaker-Equipped (400 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Air Conditioner Compressor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Windshield Washer and Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
Track Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72

OPERATION
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
Supplemental Coolant Additive (SCA) Levels (if used) . . . . . . . . . . . . . . . . . . . . . . . 5-72
Grab Handles and Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Cab Door, Access Panels and Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Secure the Machine for Maintenance (Power On). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74

MAINTENACE
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Hydraulic Tank Return Filter (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77

SPECIFICATIONS TROUBLRSHOOTING
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
500-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
Secure the Machine for Maintenance (Power Off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
Hydraulic System Breather Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
Radiator, Oil Cooler, and A/C Condenser Fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
Air Conditioning Fresh Air & Recirculation Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
EQUIPMENT

Swing Gearbox Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84

OPTIONAL

Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85

Upperworks and Lowerworks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
Swing Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87

Safety, Operation & Maintenance Manual - January 8 2016 5-3

Maintenance SY215 Excavator

Swing Gearbox Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88

Secure the Machine for Maintenance (Power On). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
Swing Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
Primary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
1,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
Secure the Machine for Maintenance (Power Off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
Hydraulic Pilot Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
Hydraulic Tank Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
Engine Exhaust Pipe Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
Fuel Tank Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
Secure the Machine for Maintenance (Power On). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
Accumulator Function Check (Breaker-Equipped only) . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
2,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
Secure the Machine for Maintenance (Power Off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
Final Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
Secure the Machine for Maintenance (Power On). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Accumulator Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Swing Bearing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Lockout/Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
Short-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115

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SY215 Excavator Maintenance

CONTENTS
TABLEOF
WARNING
Read and understand all safety precautions and instructions in this manual before read-
ing any other manuals provided with this machine and before operating or maintaining it.

INTRODUCTION
Failure to do this could result in death or serious injury.

MAINTENANCE INFORMA-
TION
Do not perform any maintenance and/or repairs not

SAFETY
authorized in this Safety, Operation & Maintenance
manual.
Always observe and follow all safety precautions.

FUNCTION
SYSTEM
Checks Before Maintenance
Read and understand the Safety section of this
manual,including the Lockout/Tagout procedure, Fig. 5-1
before proceeding with any inspection or
maintenance procedures.

OPERATION
NOTE: See “Lockout/Tagout Procedures” on page
2- 22.
Review the Maintenance Log and follow these
points to ensure your safety:

MAINTENACE
• Do not perform any maintenance not authorized
in this manual’s Maintenance section for this ma-
chine. If maintenance is required that is not listed
within this manual, contact your Sany dealer before

SPECIFICATIONS TROUBLRSHOOTING
proceeding.
• Avoid working on the machine while the engine is
running unless required to do so in the procedure.
If the engine must remain running during a pro-
cedure, always have a person in the cab who can
correctly operate the machine and who is in clear
contact with you at all times.
• Contact your Sany dealer if you are unable to
perform the procedures listed in this manual or if
additional procedures are required.
• Always use the proper tools when performing any
EQUIPMENT
OPTIONAL

maintenance procedures.

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Maintenance SY215 Excavator

Checks After Maintenance or Repairs

Always do the following after performing any maintenance to the machine.
With the engine off:
• Ensure all steps listed in this book have been followed.
• If necessary, have a coworker inspect your work for correct and proper completion.
• Complete the Maintenance Log for this machine and return it to its storage location.
• Follow the Lockout/Tagout procedure for returning the unit to service.
NOTE: See “Lockout/Tagout Procedures” on page 2-22.
With the machine running:
• Check for leaks in the system you have maintained.
• Be sure there are no abnormal sounds coming from the engine or hydraulic system.
• Check for any loose or abnormal movement in the system you have maintained.
• Check for any overheating in the system you have maintained.
After performing maintenance or repairs to the machine, always take time to inventory your tools, parts
used and nuts and bolts to be sure none of these items were left on or inside the machine.

Hour Meter Reading

Keep track of the hour meter reading on a daily basis. Confirm meter readings with the required
maintenance intervals listed in this manual.
NOTE: See “Combined Instruments Display/Monitor” on page 3-16.

Genuine Sany Replacement Parts

Use genuine Sany replacement parts when repairing or replacing a part on the machine. Failure to do so
may result in premature system or part failure.

Sany-Approved Lubricants
Always use Sany-approved lubricants and coolants. Never mix different lubricant brands or viscosities. The
use of unapproved lubricants and coolants or mixing different lubricant brands or viscosities may result in
shortened service life or system failure of the machine.
NOTE: See “Fluids & Lubricants” on page 5-13.

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CONTENTS
TABLEOF
Weld, Drill, Cut or Grind on the Machine
NOTE: Contact your Sany dealer for proper guidance on any welding being attempted.

INTRODUCTION
CAUTION
Disconnect the battery prior to welding. Failure to disconnect the battery could result in
minor or moderate injury.

NOTICE

SAFETY
Failure to disconnect the battery could result in damage to the machine, personal prop-
erty, or cause the machine to operate improperly.

Personnel welding on the machine must be fully qualified and certified to use the processes and equipment
they may operate in making these repairs. Owners are responsible for the structural integrity of any

FUNCTION
SYSTEM
completed repair.
Sany strongly recommends against welding on connectors and fine-grain, hi-strength steels. Components
should be replaced if they are damaged.
NOTE: See “Weld, Drill, Cut or Grind on the Machine” on page 2-19.

OPERATION
Clean Parts or the Machine
Never clean the machine with caustic chemicals or steam cleaners. Instead, use mild soaps and a pressure
washer to clean the machine. Always protect electrical parts when cleaning the machine. Never flood
or pressure-wash the inside of the operator’s cab. Use only nonflammable cleaning solvents. Never use

MAINTENACE
flammable liquids to clean parts or systems.

SPECIFICATIONS TROUBLRSHOOTING
NOTICE
Failure to protect the electrical system when cleaning the machine may damage the ma-
chine or cause it to operate improperly.

Covers and Locks

When servicing the machine with the covers open, be sure they are properly supported in place. Also be
sure the covers close tightly and latch securely in place. If a lock is present, be sure the lock is properly
latched for security.
EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

Hydraulic Fluid Inspection

Inspect hydraulic fluid for any signs of contamination. Contact your Sany dealer for an oil analysis or
replacement if any abnormality is found. Inspect the filters for signs of metal particles and foreign material
and replace the abnormal ones.

NOTICE
Failure to inspect hydraulic fluid for contamination may damage the hydraulic system or
cause the machine to operate improperly.

Inspection and Maintenance in Adverse Environments

If the machine will be operating under adverse conditions:
• Check and clean any electrical components to avoid any accumulated corrosion.
• Check and clean any areas where extreme heat is present, such as the exhaust system, manifold and
turbocharger.
For heavy-load operation and deep excavation, add grease to the pins of the work equipment prior to each
operation. Cycle the operation of the boom, arm and bucket several times before refilling with additional
grease.

Mud, Rain or Snow Conditions

Before operating the machine, inspect each connector for looseness.
After operating the machine, clean the machine, inspect for missing or loose bolts and nuts. Add oil and
lubricating grease as needed.
NOTE: See “Snow or Frozen Surfaces” on page 2-42.

Near Ocean (Salt Air) Environments

Before operating the machine, inspect each plug and pin for looseness. Apply grease where rust is found,
especially at cylinder rods and control levers.
After operating the machine, thoroughly wash away the salt residue, apply grease where rust is found, and
perform maintenance carefully on the electric components to prevent corrosion.

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SY215 Excavator Maintenance

CONTENTS
TABLEOF
Dusty Environments
Clean the following components:
• Engine air filter: Clean the dust evacuator frequently.

INTRODUCTION
NOTE: See “Engine Air Filter System” on page 5-43.
• Radiator: Clean the radiator core frequently to prevent blockage.
NOTE: See “Radiator, Oil Cooler, and A/C Condenser Fins” on page 5-80.
• Fuel equipment: Clean the filter parts frequently.

SAFETY
NOTE: See “Primary Fuel Filter” on page 5-28.
• Fresh-air and recirculation filters: Clean the filters frequently.
NOTE: See “Air Conditioning Fresh Air & Recirculation Filters” on page 5-82.

FUNCTION
SYSTEM
Rocky Ground Surface
Track should be set slightly loose from what is required for other environments. While track tension is
normally 0.75 - 1.75 in. (20 - 45 mm), Sany recommends that you loosen the track tension to 1.75 in. (45
mm) for rocky ground surfaces only. Inspect the tracks for damage, such as cracks, abrasions and scars on
the travel mechanism and loose or missing bolts or nuts.

OPERATION
Cold Environments
In extremely cold environments (32° F (0° C)), lubricate only with the oils shown in “Engine Oil Viscosity/
Temperature Data” on page 5-16. Sany recommends the use of fuels identified in “Fluids” on page 5-14 for

MAINTENACE
extremely cold environments. Prior to starting the engine, ensure that the battery is fully charged and that
the battery case and the cables have not cracked.

Other Weather Environments

SPECIFICATIONS TROUBLRSHOOTING
NOTE: If there is evidence of overheating of bearings or bushings, loose parts or rust during regular
inspection, increase the frequency of lubrication.
Based on past experience and suggestions by lubricating oil suppliers, the lubricating intervals listed in the
following tables apply only to normal operating conditions. In harsh environments, including dusty and
corrosive air, abnormal external temperature, extremely heavy overload, frequent operating times, long-
time duty cycle, etc.,lubricating intervals should be shortened.
EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

TORQUE VALUES
NOTICE
Nuts, bolts or other parts not tightened to specific torque values may lead to loose or
damaged parts. This situation can cause damage to the machine, personal property, or
cause the machine to operate improperly.

Specific Torque Values

Bolts Torque (ft•lb) Torque (N•m)

Hydraulic pump mounting bolts 36 49

Hydraulic line attachment bolts (at tank and pump) 86 -106 116-144

Battery pole clamp bolts 7 10

Track track shoe retaining bolts 440 - 500 598 - 677

Track support roller mounting bolts 399 - 485 540 - 658

Track gearbox level check plug and drain plug 50 68

Track final drive motor mounting bolts 738 1,000

Track track tension grease valve 35 47

Hydraulic tank drain plug 43.4 - 57.9 58.8 - 78.5

*Swing bearing bolts 975.8 +97 1,323 +147

* Torque these bolts only if replacing them or if a bolt is loose.

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SY215 Excavator Maintenance

CONTENTS
TABLEOF
General Torque Values
Always refer to the chart on this page if the tight-
ening torque value is not listed in the table on the

INTRODUCTION
previous page.
Unless specified otherwise, the nuts and bolts shall
be tightened to the values given in the following Fig. 5-2
table. The tightening torque is determined by the
width of the screw cap or nut. In replacement of the
bolts or nuts, use genuine Sany parts of equivalent

SAFETY
size.

Hardware
Tightening Torque
Thread Dia. “a” Hex Size “b”

FUNCTION
Target Value Acceptable Range

SYSTEM
(mm) (mm)
ft•lb N•m ft•lb N•m

M6 10 9.8 13.2 8.7 - 10.8 11.8 - 14.7

M8 13 23.1 31 20.3 - 25.3 27 - 34

OPERATION
M10 17 48.5 66 43.4 - 54.2 59 - 74

M12 19 83.2 113 72.3 - 90.4 98 - 123

MAINTENACE
M14 22 130.2 117 115.7 - 144.7 157 - 196

M16 24 206.1 279 180.8 - 227.8 245 - 309

SPECIFICATIONS TROUBLRSHOOTING
M18 27 282.1 382 253.2 - 314.6 343 - 425

M20 30 405 549 361.7 - 448.4 490 - 608

M22 32 549.7 745 488.2 - 611.2 662 - 829

M24 36 683.5 927 607.6 - 759.5 824 - 1030

M27 41 976.5 1320 868.0 - 1085.0 1180 - 1470

M30 46 1265.8 1720 1121.1 - 1410.4 1520 - 1910

M33 50 1627.4 2210 1446.6 - 1808.3 1960 - 2450

EQUIPMENT
OPTIONAL

M36 55 2025.2 2750 1808.3 - 2242.2 2450 - 3040

M39 60 2423.1 3280 2133.7 - 2676.2 2890 - 3630
NOTE: The torques shown in the chart above are for Grade 10.9 bolts.

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Maintenance SY215 Excavator

Hoses
Hydraulic hoses are tightened according to the
torque values shown below:
Fig. 5-3
NOTE: The item marked with is used for tightening the hose on top of the swivel joint.
Fittings
Port Tightening Torque Value Tube Tightening Torque Value
Fitting N•m ft•lb or (in•lb) Fitting N•m ft•lb or (in•lb)
M14 34.3 ± 5 25 ± 4 G1/8 16.7 ± 2 (148 ± 18)

M16 54 ± 5 40 ± 4 G1/4 36.7 ± 2.5 27.1 ± 2

M18 70 ± 10 52 ± 7 G3/8 73.5 ± 5 54 ± 4

M20 93 ± 10 69 ± 7 G1/2 107.8 ± 7.8 80 ± 6

M22 125 ± 10 92 ± 7 G3/4 161.7 ± 14 119 ± 10

M24 142 ± 20 105 ± 15 G1 220 ± 25 162 ± 18

M24 68.6 ± 10 51 ± 7

M26 180 ± 20 133 ± 15

M20 49 ± 5 36 ± 4

G3/8 68.6 ± 20 51 ± 15

G3/4 (A) 1,661.7 ± 14 1,226 ± 10

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CONTENTS
TABLEOF
FLUIDS & LUBRICANTS
Always use Sany-approved lubricants, coolants and filters. Sany is not responsible for damage caused by
using unauthorized lubricants and coolants.

INTRODUCTION
NOTICE
Never mix fluids of different brands or viscosities (weights) and never overfill the system
you are servicing. Failure to follow these standards can cause damage to the machine
or cause the machine to operate improperly.

SAFETY
Location, Capacity and Type
Location Approx. Capacity* Lubricant/Coolant
See “Engine Oil Viscosity/Temperature

FUNCTION
Data” on page 5-14. Oils of this type

SYSTEM
Engine 5.3 gal. (20 L)
include Valvoline Premium Blue or
Valvoline Premium Blue Extra.

See “Fuel” on page 5-14. Use #2 Diesel

Fuel tank 90.0 gal. (340 L) Fuel or mixture of #2 Diesel and #1 Diesel

OPERATION
Fuels in cold weather conditions.

See “Engine Coolant” on page 5-16. Sany

Engine cooling system 5.8 gal. (22 L) recommends brands that include ES
Compleat, Fleetcool EX, and ES Optimax.

MAINTENACE
Swing gearbox 1.0 gal. (4.0 L) See “Industrial Gear Oil/Temperature Data”
on page 5-17 for additional information.
Recommended brands are produced by
1.5 gal. (5.5 L)

SPECIFICATIONS TROUBLRSHOOTING
Final drive Mobil and Chevron.
(each side)
See “Hydraulic Fluid/Ambient Temperature
Data” on page 5-17 for additional data.
Hydraulic tank 61 gal. (230 L) Recommended brands are produced by
Conoco, Mobil, Shell, Chevron, Exxon and
Texaco.
See “Lubricating Grease/Temperature
Swing bearing 75 lb. (34 kg)
Data” on page 5-17 for further details.
Any anaerobic sealant having properties
Anaerobic sealant N/A
similar toLOCTITE 243 (Blue).

Spray lubricant N/A Any lithium grease-based spray lubricant.

EQUIPMENT
OPTIONAL

Type II odorless mineral spirit and/or Class

Mineral spirits N/A
1 (high flash point).
NOTE: The capacities in the above table are approximations. For exact capacities, use the inspection
points,inspection plugs, dipsticks, and sight glasses.

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Maintenance SY215 Excavator

Fuel
DANGER
Never maintain the fuel system near an open flame or while smoking. Failure to follow this
rule will result in death or serious injury.
NOTE: See “Fluid Fires” on page 2-15 and “Location, Capacity and Type” on page 5-13.
Sany recommends the use of No. 2 ultra-low sulfur diesel (ULSD) fuel for all normal operations. Use of
No. 1 diesel fuel in a blend with No. 2 diesel fuel is permitted in cold weather environments (below 32° F (0°
C)).
NOTE: Sany does not recommend the use of any diesel fuel with a cetane level less than 40.
NOTE: Do not use gasoline, kerosene or any unapproved fuels in the fuel system.
NOTE: If fuel waxing or bacteria should occur in the fuel system, contact your Sany dealer.
Be sure that there is no water or any foreign material in the fuel.
Take appropriate precautions to prevent fuel contamination during refueling.

NOTICE
Never dilute fuels. Damage to the injection system can result which causes the ma-
chine to operate improperly.
NOTE: B20 Biodiesel blend with ULSD is approved by Cummins® for Tier 3 and Tier 4 engines. See your
Cummins® Engine Owners Manual for details.

Engine Oil Viscosity/Temperature Data

Temperature
-22 -4 5 32 50 68 86 104 122
° F (° C)
(-30) (-20) (-15) (0) (10) (20) (30) (40) (50)
Oil Type
SAE 15W-40

SAE 10W-30

SAE 5W-30

SAE 5W-40

SAE 40W

NOTE: Any engine oil meeting Cummins® Engine Standard (CES) 20081 is acceptable. Due to its com-
paratively better lubricating characteristics (including improved oil consumption, engine operation in
frigidclimates, and continued lubrication in high temperatures), SAE 5W-40 is recommended for a majori-
ty ofclimates. In some circumstances, short-term use of low-viscosity engine oil in cold temperatures (below
23° F /-5° C) is acceptable; however, long-term use can reduce engine life.

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SY215 Excavator Maintenance

CONTENTS
TABLEOF
Lubricating Grease/Temperature Data

Temperature
° F (° C) Summer Winter

INTRODUCTION
Grease Type

NGLI #2 molybdenum disulfide

lithium-based grease

SAFETY
NGLI #1 molybdenum disulfide
lithium-based grease
NOTE: Always use clean EP (extreme pressure) grease when greasing the machine. Avoid using low
viscosity greases. Sany recommends Chevron Starplex® Grease EP 2 or equivalent. See “Grease” on page

FUNCTION
SYSTEM
5-17.

Industrial Gear Oil/Temperature Data

OPERATION
Temperature
-4 14 32 50 68 86 104 122
° F (° C)
(-20) (-10) (0) (10) (20) (30) (40) (50)
Oil Type
220 LS2 (85W-140)

MAINTENACE
NOTE: Any brand meeting AGMA standard 9005-D94, ISO 3448 grade 220 is acceptable.
Short-term use of low-viscosity engine oil in cold temperatures (below 23° F / -5° C)
promotes engine life; long-term use of lowviscosity engine oil can reduce engine life.
Hydraulic Fluid/Ambient Temperature Data

SPECIFICATIONS TROUBLRSHOOTING
Temperature
-22 -4 14 32 50 68 86 104 122
° F (° C)
(-30) (-20) (-10) (0) (10) (20) (30) (40) (50)
Oil Type
ISO VG 46 antiwear hydraulic
fluid
ISO VG 32 low temperature
antiwear hydraulic fluid
NOTE: Selection of the proper hydraulic fluid is based on local operating climate and conditions:
• Use ISO VG 46 antiwear hydraulic fluid in generally temperate climates.
EQUIPMENT
OPTIONAL

• Use ISO VG 32 low-temperature antiwear hydraulic fluid (pour point is -43.6° F (-42° C)) in generally
arctic areas where ambient temperatures can reach -22° F (-30° C) during operation.
See next page for additional information.

Safety, Operation & Maintenance Manual - January 8 2016 5-15

Maintenance SY215 Excavator

NOTICE
To prevent damage to the hydraulic system, perform the following warm-up procedure in
ambient temperatures below 32° F (0° C):
Start the engine and run it at idle speed for 7 - 10 minutes; then increase the engine speed
to 1,200 rpm and perform only no-load traveling for at least 30 minutes or until the hydrau-
lic fluid temperature is at least 68° F (20° C).
Proceed with normal operation only after completing warm-up as described above or else
adjust the warm-up period according to the ambient temperature. During normal construc-
tion operation, take care to operate the controls slowly and observe the traveling system
for any signs of trouble. Operation with oil temperature of 68° F (20° C) or below may dam-
age the hydraulic system.

Engine Coolant
Engine coolants used can be any brand meeting the Cummins® Engine Standard Classification (CES)
14603.Brands meeting these requirements include ES Compleat, Fleetcool EX, and ES Optimax.

Supplemental Coolant Additive (SCA)

Cummins® recommends using the following Fleetguard® products for coolant additive and glycol level
testing: 3-Way™ Heavy-Duty Coolant Test Kits part number CC2602B and for contamination/replacement
limits, part number CC2607B. Perform the tests in accordance with the instructions included with the test
kits.
If the SCA concentration level is between 1.2 and 5.0 units/gal. (0.3 and 1.3 units/L), either install a
chemical filter containing the appropriate amount of SCA or add the equivalent amount of liquid SCA and
install a chemical-freefilter.
If the SCA concentration level is less than 1.2 units/gal. (0.3 units/L), add 5 oz. (0.15 L) of Fleetguard®
DCA4 orFleetcool liquid per 1 gal. (3.8 L) of cooling system capacity and install a chemical-free filter.
If the SCA concentration level is greater than 5.0 units/gal. (1.3 units/L), install a chemical-free filter. Do
not install a chemical coolant filter or add liquid Extender/SCA.
Test the SCA level at each oil change. When SCA units drop below 5.0 units/gal. (1.3 units/L), resume
installing chemical filters or using the equivalent liquid SCA dosage and installing chemical-free filters.
Consult your Sany dealer or Cummins® Filtration Customer Assistance for detailed Fleetguard® product
information and assistance at 800-223-4583 or http://www.cumminsfiltration.com.
Cummins® recommends using (Restore or Restore Plus) by Fleetguard® for cleaning and flushing the
coolingsystem. Follow the instructions on the flushing solution label.

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SY215 Excavator Maintenance

CONTENTS
TABLEOF
Lubricants
Sany recommends using only those lubricants listed in “Fluids & Lubricants” on page 5-15.

NOTICE

INTRODUCTION
Commercially available lubricants and additives may cause harm. Use only those lubri-
cants recommended in this manual. Using other lubricants can cause damage to the ma-
chine and could cause the machine to operate improperly.

Contact your Sany dealer for assistance if the machine will be operated in subzero temperatures where the

SAFETY
aid of an auxiliary heating device is needed.

Grease
Always use clean EP (extreme pressure) grease when greasing the machine. Avoid using low viscosity
greases.

FUNCTION
SYSTEM
Sany recommends Chevron Starplex® Grease EP 2 or equivalent designed for:
• Heavy-duty bearings and general industrial lubrication.
• Heavy-duty plain and rolling element bearings operating under severe conditions, including shock loading

OPERATION
in wet environments.

Windshield Washer Fluid

Use automotive windshield washer fluid only.

MAINTENACE
CAUTION
Never use flammable liquids that could ignite or explode. If not avoided, this could result

SPECIFICATIONS TROUBLRSHOOTING
in minor or moderate injury.

NOTICE
Never use tap water, dirty water or fluids that could freeze, clog or damage the system.
Using these fluids could result in damage to the machine and improper machine opera-
tion.
EQUIPMENT
OPTIONAL

Safety, Operation & Maintenance Manual - January 8 2016 5-17

Maintenance SY215 Excavator

DAILY MAINTENANCE
NOTICE
Failure to perform the following procedures when and how directed could result in ma-
chine damage and improper machine operation.

Secure the Machine for Mainte-

nance (Power Off)
1. Obtain the Maintenance Log for this machine
and complete it at the close of all maintenance pro-
cedures.
2. Read and understand all of the tasks listed in this
section.
Fig. 5-4

3. Follow the Lockout/Tagout procedure in the

Safety section of this manual.
NOTE: See “Lockout/Tagout Procedures” on page
2-22 for details.
NOTE: Allow the systems time to cool down be-
fore proceeding with any maintenance.
4. With the machine secured, proceed with the fol-
lowing:
Check:
• Safety, Operation & Maintenance Manual (See
page
5-19.)
• Fire Extinguisher (See page 5-19.)
• Escape Tool (See page 5-19.)
• Electrical System (See page 5-19.)
• Air Intake (See page 5-21.)
Fig. 5-5
• Engine Oil Level (See page 5-21.)
• Engine Serpentine Belt (See page 5-21.)
• Swing Gearbox (See page 5-23.)
• Pump Mounting Bolts (See page 5-25.)
• Hydraulic Line Connections (See page 5-26.)

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SY215 Excavator Maintenance

CONTENTS
TABLEOF
• Idler Wheel (See page 5-27.)
• Sheet Metal (See page 5-27.)
• Decals (See page 5-27.)

INTRODUCTION
Drain:
• Primary Fuel Filter (See page 5-28.)

a
Check
Safety, Operation & Maintenance Manual

SAFETY
Be sure the Safety, Operation & Maintenance
manual is in the operator cab. Fig. 5-6
b
NOTE: If damaged or missing, contact your Sany
dealer.

FUNCTION
SYSTEM
Fire Extinguisher
Check to be sure the fire extinguisher (a) is in-
stalled on the machine and in proper working

OPERATION
order. Follow the instructions on the extinguisher
to check the operation and condition.
NOTE: See “Fire Extinguisher” on page 2-16 for
more information.

MAINTENACE
Escape Tool
Check to be sure the escape tool (b) is installed on
the machine.

SPECIFICATIONS TROUBLRSHOOTING
Electrical System
The electrical system should be inspected starting
with the fuse box. The fuse box (a) is located at the
left rear of the operator’s seat.
NOTE: See “Fuses” on page 3-20 for fuse location
and other data.
If a fuse is corroded or if a white powder can be
seen on it, contact your Sany dealer for repair
information regarding the electrical circuit in ques-
tion.
EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

Electrical Power Disconnect Process

NOTE: See “Battery Safety” on page 2-20.
a
1. Locate the batteries under the cover (a) behind
the left rear access panel.
2. Remove the four nuts and washers (b) securing
the cover over the batteries
3. Remove the black (ground) cable (c) from the
battery post first, then remove the red (power)
cable (d) from the battery post.

WARNING Fig. 5-7 b

When working with any open electrical
power source, ensure that your hands are
free of any metal objects (rings, watches, d
jewelry, etc.) that could come in contact
with electrical power points. Failure to
avoid this hazardous situation could result
in death or serious injury.

Fig. 5-8 c

4. To reconnect power, reverse the process shown in step 3 connecting the red cable first followed by the
black cable.
5. Reinstall and secure the battery cover.
Other Electrical Inspection Points
• Inspect all electrical equipment. If necessary, remove and replace all faulty items, including loose
connectors, worn or degraded wiring, cables, etc.
• Locate and remove the cause of any electrical faults.
• Use only genuine Sany parts and fuses.
• Shut down the engine immediately if a fault occurs with the power supply.
• Do not modify the electrical system without prior authorization from Sany.

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SY215 Excavator Maintenance

CONTENTS
TABLEOF
Air Intake
Check the air intake (a) to ensure it is clear of all
debris.

INTRODUCTION
a

SAFETY
Fig. 5-9

Engine Oil Level

FUNCTION
SYSTEM
1. Open the engine cover (a).

OPERATION
a

MAINTENACE
Fig. 5-10

SPECIFICATIONS TROUBLRSHOOTING

2. Locate the engine oil dipstick (b) in the engine

compartment.
3. Remove the dipstick from the engine and note
the oil level.
EQUIPMENT
OPTIONAL

Fig. 5-11

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Maintenance SY215 Excavator

NOTE: The oil level should be within the etched

area(c).
4. Replace the dipstick.

Fig. 5-12 c
5. If necessary, remove the oil filler cap (d), add oil
as needed, then reinstall the cap.
NOTE: See “Fluids & Lubricants” on page 5-13
for details on engine oil types.

NOTICE
Do not overfill the engine with oil. This
could result in machine damage and im-
proper machine operation.

Fig. 5-13
6. Close the engine cover.

Engine Serpentine Belt

1. Open the engine cover (a).

Fig. 5-14

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CONTENTS
TABLEOF
2. Locate the engine serpentine belt (b), then in-
spect it for the following:
• Abrasion: The belt appears shiny, glazed or fabric
is exposed. This is a sign that the belt is in contact

INTRODUCTION
with an object such as a flange or bolt.
• Chunk-out: Chunks of rubber material have
broken off from the belt. At this stage, the belt can
fail at any moment. Heat, age and stress are the
primary contributors. b

SAFETY
• Pulling: Belt material is sheared off from the ribs.
Lack of tension, misalignment, worn pulleys or a Fig. 5-15
combination of these are factors.

FUNCTION
• Uneven rib wear: Belt shows damage to the side with the possibility of breaks in the tensile cord or jag-

SYSTEM
ged-edged ribs. A thumping/grinding noise may also be heard when running.
• Improper installation: A belt rib begins separating from the strands. If left unattended, the cover will often
separate, causing the belt to unravel.
• Cracking: Small visible cracks along the length of a rib or ribs. With continuous exposure to high

OPERATION
temperatures, the stress of bending around the pulley leads to cracking.
• Misalignment: Sidewalls of the belt may appear glazed or the edge-cord may become frayed. A noticeable
noise may result.

MAINTENACE
• Gravel penetration: Small pinholes are visible on the backside of the belt. Bumps may be visible and
fabric around the holes can be frayed, indicating damage from foreign objects such as dirt, gravel or similar
debris.

3. Contact your Sany dealer to replace a damaged

SPECIFICATIONS TROUBLRSHOOTING
belt.
Swing Gearbox
NOTE: See “Environmental Precautions” on page
2-21 before proceeding with this procedure.
1. Locate and inspect the swing gearbox (a) for
physical damage of any kind.
a
NOTE: Contact your Sany dealer if any damage is
found.
EQUIPMENT
OPTIONAL

Fig. 5-16

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Maintenance SY215 Excavator

2. Remove the dipstick (b) from the swing gearbox

and note the oil level.

Fig. 5-17

NOTE: The oil level should be within the etched

area (c).
3. Replace dipstick.

Fig. 5-18
c
4. If necessary, remove the oil filler cap (d), add oil
as needed, then reinstall the cap.

NOTICE
Do not overfill. This could result in
machine damage and improper machine
operation.

NOTE: See “Fluids & Lubricants” on page 5-13

for additional information.

Fig. 5-19
d

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CONTENTS
TABLEOF
Pump Mounting Bolts
1. Locate the hydraulic pump (a) behind the right
rear access panel (b).

INTRODUCTION
SAFETY
Fig. 5-20 a b
2. Inspect the hydraulic pump for loose, broken or
missing pump mounting bolts (c).

FUNCTION
SYSTEM
3. Inspect for leaks or cracking at these mounting
bolt locations.
NOTE: Not all pump mounting bolts (c) are shown

OPERATION
here.
Be sure to inspect all pump mounting bolt loca-
tions.
4. Tighten any loose bolts. c

MAINTENACE
NOTE: See “Specific Torque Values” on page 5-10.
NOTE: Contact your Sany dealer if any abnormal-
ity is found.

SPECIFICATIONS TROUBLRSHOOTING

NOTICE
Do not overtighten the mounting bolts.
This could result in machine damage and
improper machine operation.

c
EQUIPMENT
OPTIONAL

Fig. 5-21

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Maintenance SY215 Excavator

Hydraulic Line Connections

1. Open the right rear access panel (a). a

2. Examine the hydraulic hose (b) between the Fig. 5-22

tank and the hydraulic pump for cracks, damage or
abnormal wear.

NOTE: Replace the hose if it is cracked, damaged

or worn.

3. Check fittings (c) at both ends of all flexible

hoses.
4. Inspect all bolt locations. Fig. 5-23

5. Replace any damaged or defective bolts.

6. Tighten any loose bolts. c
NOTE: See “Specific Torque Values” on page 5-10.
NOTE: These bolts/screws at each end of these
hoses may loosen occasionally due to vibration.

NOTE: Do not use thread sealant when reinstalling

loose bolts and installing new bolts.

Fig. 5-24

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CONTENTS
TABLEOF
Idler Wheel
a
Check the idler wheel (a) for cracks and distortion.
NOTE: If cracked or distorted, contact your Sany

INTRODUCTION
dealer for replacement or repair.

SAFETY
Fig. 5-25
Sheet Metal
Check the sheet metal panels and covers (a) for loss, damage, loose connections or missing bolts.

FUNCTION
SYSTEM
OPERATION
MAINTENACE
b

SPECIFICATIONS TROUBLRSHOOTING

Fig. 5-26
a

NOTE: Repair or replace sheet metal parts as needed using Sany-approved parts.

Decals
EQUIPMENT
OPTIONAL

All safety decals (b) should be visible and complete.

NOTE: See “Machine Decals” on page 2-23 for additional information.

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Maintenance SY215 Excavator

Drain
Primary Fuel Filter
NOTE: See “Environmental Precautions” on page 2-22 before proceeding with this procedure.

DARNGER
Never maintain the fuel system near an open flame or while smoking. Failure to follow this
rule will result in death or serious injury.

1. Locate the primary fuel filter (a) behind the right

rear access panel.
a
2. Place an appropriately sized container beneath
the fuel filter.

3. Turn the purge pump knob (b) one-quarter turn

counterclockwise.
4. Open the drain valve (c) to allow all water and/ Fig. 5-27
or contaminated fuel to drain from the filter.

NOTICE
Dispose of the contaminated fuel in
accordance with local environmental
regulations. Failure to do so could result in
damage to the environment.

NOTE: Avoid draining the fuel filter completely.

Air could enter the fuel system. See “Purge the
Fuel System” on page 6-4 if necessary.
5. Close the drain valve (c) when the flow from the
primary fuel filter is free of water and contamina- Fig. 5-28
tion.

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CONTENTS
TABLEOF
6. Turn the purge pump knob (b) one-quarter turn
clockwise.
NOTE: If an excessive amount of water or con-
taminant was found while draining the fuel filter,

INTRODUCTION
Sany recommends draining the fuel tank.Fuel Tank
Drain

1. Locate the drain valve (d) for the fuel tank below
the engine oil filter on the right side of the com-

SAFETY
partment.
2. Place an appropriately sized container under the
Fig. 5-29
drain hose (e). e d
NOTE: See “Fluids & Lubricants” on page 5-13

FUNCTION
SYSTEM
for capacity size.
3. Open the drain valve (d).

4. Close the valve (d) when the fuel flow is free of

OPERATION
water and contaminants.
NOTE: See “Purge the Fuel System” on page 6-4
for information on removing air from the system.

MAINTENACE
NOTICE
Dispose of the contaminated fuel in accordance with local environmental regulations. Fail-
ure to do so could result in damage to the environment.

SPECIFICATIONS TROUBLRSHOOTING
5. Add fuel to the system as necessary
NOTE: See “Fuel Level” on page 5-33.

6. Start the engine and allow it to run at idle speed.

7. Check for leaks in the fuel system.

EQUIPMENT
OPTIONAL

8. Repair any leaks.

9. Close and lock the access panel.

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Secure the Machine for Maintenance (Power On)

Connect the battery to start the engine or provide power to the machine as stated in the following checks.

WARNING
Do not remove the Lockout/Tagout tags from the machine when you connect the
battery.These tags notify others that the machine is not to be used during maintenance.
Failure to keep the tags in place could create a hazardous situation which, could
result in death or serious injury.

Check:
• Operating Functions (See page 5-30.)
• Fuel Level (See page 5-33.)
• Engine Coolant Level (See page 5-34.)
• Hydraulic Fluid Tank (See page 5-35.)
• Air Conditioner (See page 5-38.)

Check

Operating Functions

1. Turn the ignition key to the ON position to

provide power to the machine and check that all Fig. 5-30
functions in the operator cab work correctly.

NOTE: Do not start the engine.

NOTE: See “Right Control Console” on

page 3-10.

NOTE: See “Left Control Console” on page

3-6.

NOTE: If any component is damaged or

inoperable,contact your Sany dealer.

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CONTENTS
TABLEOF
2. Ensure that the following lamps and other
devices work properly:
• Horns (a)

INTRODUCTION
SAFETY
Fig. 5-31 a

FUNCTION
SYSTEM
• Chassis work lamp (b)

OPERATION
b

MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
Fig. 5-32

• Head lamps (c)

EQUIPMENT
OPTIONAL

Fig. 5-33

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Maintenance SY215 Excavator

• Boom work lamps (d)

Fig. 5-34
• Windshield wiper (e) and washer (f)

Fig. 5-35

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CONTENTS
TABLEOF
Fuel Level
NOTE: See “Environmental Precautions” on
page 2-21 before proceeding with this procedure.

INTRODUCTION
1. With the ignition key still at the ON position,
check the fuel level display (a) on the system moni-
tor.

SAFETY
NOTE: If the fuel level is low, shut down the
engine and proceed to step 2.

FUNCTION
SYSTEM
OPERATION
Fig. 5-36
2. Locate the fuel tank on the right side of the ma-
chine.

MAINTENACE
3. Remove fuel tank cap (b).

4. Add fuel as needed until the tank is full.

SPECIFICATIONS TROUBLRSHOOTING
NOTE: See “Fuel” on page 5-14 for type.

NOTE: See “Refuel” on page 2-19 for safety

information.

5. Reinstall the fuel tank cap.

b
EQUIPMENT
OPTIONAL

Fig. 5-37

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Engine Coolant Level

NOTE: See “Environmental Precautions” on page 2-21 before proceeding with this procedure.

DANGER
Inhaling or ingesting coolant is toxic. If not avoided, this will result in death or serious
injury.

WARNING
Do not remove the radiator cap while the engine is hot. Engine coolant is under pressure
when hot and will spray out. Always wait for the engine to cool to outdoor ambient tem-
peratures before removing the radiator cap. Failure to follow this warning could result in
death or serious injury.

NOTICE
Dispose of the coolant in accordance with local environmental regulations. Failure to do
so could result in damage to the environment.

NOTE: See “Engine Coolant” on page 5-16 for

type.

1. Locate the coolant recovery tank (a) behind the a

left rear access panel.

2. Add coolant as necessary to a level between the

L and H marks on the recovery tank (a).

NOTE: Lift the tank up to see the H mark that is

covered by the bracket. Fig. 5-38
a

NOTE: See “Fluids & Lubricants” on page 5-13

for coolant capacity.
3. Start the engine and run it at low idle speed
(1,050 rpm) for five minutes.

4. Shut down the engine.

5. Recheck the coolant level.

6. Add more coolant if necessary.

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CONTENTS
TABLEOF
Hydraulic Fluid Tank
NOTE: See “Environmental Precautions” on page 2-21 before proceeding with this procedure.

INTRODUCTION
CAUTION
Hydraulic fluid may be hot and under pressure. Always wait for the machine to cool
down to below 160° F (71° C) before attempting to open the hydraulic fluid system. Failure
to follow this process could result in minor or moderate injury.

SAFETY
NOTE: See “High-Pressure Fluid Lines” on page
2-20.
1. Position the machine work equipment as shown
here.

FUNCTION
SYSTEM
Fig. 5-39

OPERATION
2. Open the right rear access panel to access the
hydraulic fluid tank (a).

MAINTENACE
a

SPECIFICATIONS TROUBLRSHOOTING
3. Check the tank for leaks, exterior rust and other
damage.
EQUIPMENT
OPTIONAL

Fig. 5-40

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Maintenance SY215 Excavator

4. Check the fluid level using the sight glass (b)

on the side of the tank. Ensure that the fluid level is
between the level marks on the sight glass decal (c). b
5. Shut down the engine.
6. If necessary, add hydraulic fluid to the system. c

NOTE: See “Add Hydraulic Fluid” below.

7. Check tightness of the various hydraulic fittings.
8. Replace any fittings that are defective.
Add Hydraulic Fluid

Fig. 5-41

CAUTION
Hydraulic fluid may be hot and under pressure. Always wait for the machine to cool
down to below 160° F (71° C) before attempting to open the hydraulic fluid system. Failure
to follow this process could result in minor or moderate injury.

NOTE: See “High-Pressure Fluid Lines” on page

2-20.
1. Set the hydraulic lockout control lever (a) to the
CLOSE position.

Fig. 5-42 a

2. Remove the butterfly nut (b) from the breather

valve. b

Fig. 5-43

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CONTENTS
TABLEOF
3. Press the venting button (c) to relieve the pres-
sure on the hydraulic tank.

INTRODUCTION
4. Reinstall the butterfly nut (item b, Fig. 5-43,
page 5-36).

SAFETY
5. Remove the bolts and then remove the filler

FUNCTION
SYSTEM
cover (d).
Fig. 5-44
NOTE: The cover may move up while the bolts
are loosened due to the action of an internal spring.
Press down on the cap when removing the bolts.

OPERATION
6. Add fluid until the hydraulic fluid level is be-
tween the level marks on the sight glass decal (b).

NOTE: See “Fluids & Lubricants” on page 5-13

MAINTENACE
for capacity and “Hydraulic Fluid/Ambient
Fig. 5-45 d
Temperature Data” on page 5-15 for type.

NOTICE SPECIFICATIONS TROUBLRSHOOTING

Do not overfill the hydraulic tank. This
could result in machine damage and
improper machine operation.

7. Reinstall the filter cover and bolts.

EQUIPMENT

8. Start the engine.

OPTIONAL

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Maintenance SY215 Excavator

9. Set the hydraulic lockout control lever (a) to the

OPEN position.
10. Run the engine at low idle (1,050 rpm) for 10
minutes in order to vent the air from the hydraulic
system.
11. Shut down the engine.

Fig. 5-46 a
Air Conditioner
CAUTION
This system is under pressure and working on it could create a hazardous situation
which could result in minor or moderate injury. Contact your Sany dealer for repairs.

1. With the engine running, press the air condition-

ing fan key (a) inside the cab to check startup, air
flow and fan speed control.

Fig. 5-47
a

2. Locate the receiver dryer (b) behind the left rear

access panel.

Fig. 5-48

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CONTENTS
TABLEOF
3. Check the sight glass (c) on top of the receiver
dryer (b) for refrigerant quantity. c

INTRODUCTION
NOTICE
The engine must be running to get a
d
correct reading on the sight glass. Fail-
ure to run the engine when inspecting
the sight glass could result in machine
damage and improper machine operation.

SAFETY
FUNCTION
NOTE: If the flow of the refrigerant contains

SYSTEM
bubbles,the quantity of refrigerant is low. Fig. 5-49

OPERATION
4. Check the air conditioner condenser (d) for

MAINTENACE
leaks.
5. Shut down the engine.

SPECIFICATIONS TROUBLRSHOOTING
Fig. 5-50

CAUTION
Ensure the engine is off before continu-
ing with this procedure. Failure to do so
could result in minor or moderate injury
EQUIPMENT
OPTIONAL

Fig. 5-51

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Maintenance SY215 Excavator

6. Open the engine cover (e).

Fig. 5-52

7. Check the air conditioner compressor (f) for the

following:
• Refrigerant leaks at the pipeline connections (g).
• Loose, worn or twisted drive belt (h).

Fig. 5-53

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CONTENTS
TABLEOF
Maintenance Log
Record the completion of all of the maintenance tasks from this section.

INTRODUCTION
Lockout/Tagout
Fully activate the machine and remove all lockout/tagout warnings and machine securing elements. Return
the machine to operation.

SAFETY
FUNCTION
SYSTEM
OPERATION
MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

50-HOUR MAINTENANCE
NOTICE
Failure to perform the following procedures when and how directed could result in ma-
chine damage and improper machine operation.

Secure the Machine for Mainte-

nance (Power Off)

1. Obtain the Maintenance Log for this machine

and complete it at the close of all maintenance
procedures.
2. Read and understand all of the tasks listed in this
section.

Fig. 5-54

3. Follow the Lockout/Tagout procedure in the

Safety section of this manual.
NOTE: See “Lockout/Tagout Procedures” on
page 2-22 for details.
NOTE: Allow the systems time to cool down
before proceeding with any maintenance.
4. With the machine secured, proceed with the fol-
lowing:
Check:
• Engine Air Filter System (See page 5-43.)
• Muffler and Exhaust System (See page 5-45.)
• Hydraulic Hoses (See page 5-46.)
• Batteries (See page 5-47.)
• Track Shoe Connecting Bolts (See page 5-49.)
• Track Support Roller Mounting Bolts (See
page 5-50.)
• Final Drive Motor Mounting Bolts (See page
5-50.) Fig. 5-55

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CONTENTS
TABLEOF
Lubricate:
• Work Equipment (See page 5-52.)

INTRODUCTION
Check a

Engine Air Filter System

1. Locate the air intake system (a) behind the left
front access panel.

SAFETY
Fig. 5-56

FUNCTION
SYSTEM
2. Squeeze the dust evacuator (b) mounted on the

OPERATION
end cap of the filter housing (c) to release any dust
or debris.
b

MAINTENACE
c

SPECIFICATIONS TROUBLRSHOOTING
Fig. 5-57

EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

3. Check the condition of the dust evacuator (b)

and replace if required.
NOTE: If the dust evacuator is cracked, torn,
remains open or is missing, dust particles that are
normally expelled can deposit themselves onto the
filter and will shorten air filter service life. b

4. Open the air filter housing (c) and remove the

primary air filter (d).
5. Inspect the air filter for damage, dampness or Fig. 5-58
dust.
NOTE: If you find any damage, moisture or dust
in the filter replace it.
c

Fig. 5-59

e
NOTICE
Do not attempt to clean the air filter.
Failure to replace a damaged, damp or
clogged air filter could result in machine
damage and improper machine operation.

6. Clean the inside of the air filter housing (e) with

a clean cloth before you replace the primary air
filter.

Fig. 5-60

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CONTENTS
TABLEOF
7. Close the air filter housing (c), making sure that
the dust evacuator is pointing down (b).

INTRODUCTION
b

SAFETY
Fig. 5-61

FUNCTION
SYSTEM
Muffler and Exhaust System
CAUTION
Ensure that the engine is off and that the exhaust components have cooled down to a

OPERATION
point where they can be touched without burning. Failure to avoid this could result
in minor or moderate injury.

NOTE: See “Diesel Engine Exhaust” on page

MAINTENACE
2-6.
1. Open the engine cover (a).
2. Locate the muffler (b) and exhaust pipe (c) on a

SPECIFICATIONS TROUBLRSHOOTING
the left side of the engine compartment.
3. Inspect the muffler (b) and its mount for leaks or
signs of damage.
c
4. Be sure the exhaust pipe (c) is clear and not
restricted.

b
EQUIPMENT

Fig. 5-62
OPTIONAL

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Maintenance SY215 Excavator

5. Check the connection to the expansion pipe (d)

for leaks or signs of damage.
NOTE: If any abnormality is found, contact your
Sany dealer for repairs.
6.Close the engine cover d
NOTE: See “Diesel Engine Exhaust” on page 2-5.

Fig. 5-63

WARNING
Never operate a machine with a defective exhaust system. Exhaust leaks or a restricted
or damaged exhaust system could result in death or serious injury.

Hydraulic Hoses
Check all hoses for leaks and replace damaged or
leaking
hoses immediately. Any hydraulic pump lines and
connectors connected to the engine compartment
must be replaced if they are damaged.
Ensure that there is a sufficient distance between
all lines and hoses and the high-temperature engine
components (for example, the exhaust system) and
that there is no frictionbetween them. Fig. 5-64

NOTE: See “High-Pressure Fluid Lines” on page 2-20.

Examine hoses for the following:
• Hose couplings that are cracked or become loose.
• Damage, cuts or abrasions in the external rubber layer.
• Hardening, chapping or burning of hose.
• Cracks, damage or serious corrosion on the couplings.
• Leaks at the hose couplings.
• Twisted, broken, flat or distorted hose.
• Blisters or softness in the external hose layer.
Besides the defects listed above, also look for these signs of problems when performing a visual inspec-
tion:
• Oil leaks from the engine block.
• Clogging by debris.
NOTE: If any damage is found, contact your Sany dealer.

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CONTENTS
TABLEOF
Batteries
NOTE: See “Environmental Precautions” on page 2-21 before proceeding with this procedure.

CAUTION

INTRODUCTION
Before proceeding with any battery maintenance procedure, follow and remember
thesepoints:
• 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.

SAFETY
• If battery acid contacts your skin or your eyes, flush the area immediately with fresh
water and seek medical attention.
Failure to observe and follow this caution could result in minor or moderate injury.

FUNCTION
SYSTEM
1. Locate the batteries under the cover (a) behind
the left rear access panel. a

OPERATION
2. Remove the four nuts and washers (b) securing
the cover over the batteries.
NOTE: Allow several minutes for any accumulated
battery gases to clear before servicing the batteries.
See “Battery Safety” on page 2-20.

MAINTENACE
3. Check the top surfaces and all the battery con- Fig. 5-65
nections (c) for signs of corrosion or dirt build-up. b
Use a clean rag to wipe any dirt from the batteries.

SPECIFICATIONS TROUBLRSHOOTING
NOTE: If corrosion is found, flush the area with a
mix of baking soda and warm water.
4. Remove any trash, tools, parts or debris from the
battery compartment.
5. Reinstall the cover (a) and fasteners.
6. Close the access panel.
EQUIPMENT
OPTIONAL

Fig. 5-66
c

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Maintenance SY215 Excavator

Replacement (If Needed)

1. With the compartment access cover open, re-
move the
nuts and washers (a), then remove the cover (b). b

Fig. 5-67
a

2. Disconnect the black ground (-) battery cables

first, then
disconnect the red positive (+) cables afterwards.

3. Remove the nuts from the retaining bolts and lift

the battery hold-down bracket (c) off of the battery.
Fig. 5-68
4. Remove the failed battery.

5. Install the new battery (or batteries).

Fig. 5-69

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CONTENTS
TABLEOF
6. Connect the red positive (+) cables first.
Connect the black ground (-) cables last.
NOTE: The two 12-volt batteries are attached
in series. Be sure they are installed in the

INTRODUCTION
same manner.
NOTE: See “Specific Torque Values” on page
5-10.
NOTE: Dispose of the old batteries properly.

SAFETY
Fig. 5-70

NOTICE

FUNCTION
SYSTEM
Dispose of batteries in accordance with
local environmental regulations. Failure to
do so could result in damage to the envi-
ronment.
a

OPERATION
7. Reinstall the battery hold-down bracket (c) over
the battery and secure it in place with nuts.
8. Reinstall the cover (b) and nuts and washers (a).
b

MAINTENACE
Track Shoe Connecting Bolts Fig. 5-71
1. Ensure that all retaining bolts (a) are properly in
place at each pair of track shoes (b) and not broken,

SPECIFICATIONS TROUBLRSHOOTING
bent, damaged or loose.

2. If any of the bolts are broken, bent or damaged,

replace them. If any are loose, re-tighten them.
NOTE: See “Specific Torque Values” on page
5-10.
EQUIPMENT
OPTIONAL

NOTE: Tighten the bolts in sequence (c), ensur-

ing that the nuts and track shoe are in close contact
with the link mating surface. Fig. 5-72 c

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Maintenance SY215 Excavator

Track Support Roller Mounting

Bolts
1. Inspect the mounting bolts (a) that secure the
support rollers to the side frame for rust, damage or
looseness.

2. Replace any damaged or defective bolts and

tighten any loose bolts.

NOTE: Use anaerobic sealant when tightening

loose bolts and installing new bolts.
NOTE: See “Specific Torque Values” on page
5-10.

Fig. 5-73

Final Drive Motor Mounting Bolts

1. Locate the drive motor (a) on one of the track
assemblies.

Fig. 5-74
b

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CONTENTS
TABLEOF
2. Remove the final drive motor cover (b).

INTRODUCTION
SAFETY
3. Inspect all of the final drive motor mounting
bolts (c) for rust, damage or looseness. Fig. 5-75
b

4. Replace any damaged or defective bolts and

FUNCTION
tighten any loose bolts.

SYSTEM
NOTE: Use anaerobic thread sealant when re-
tightening loose bolts and installing new bolts.
NOTE: See “Specific Torque Values” on page

OPERATION
5-10.
NOTE: Contact your Sany dealer if any abnor-
malities are found.

MAINTENACE
Fig. 5-76

SPECIFICATIONS TROUBLRSHOOTING
c

EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

Lubricate
NOTE: See “Environmental Precautions” on page 2-22 before proceeding with this procedure.

Work Equipment
Inject grease through the work equipment greasing points as indicated in the following illustration and as
shown in the decal next to the cab door.
NOTE: See “Lubricating Grease/Temperature Data” on page 5-15 and “Grease” on page 5-17.

The following is a summary of lubrication points on the machine.

Fig. 5-77

1. Boom foot pin (2) 7. Rod joining pin (2)

2. Boom cylinder rod end (2) 8. Arm-bucket joining pin (1)

3. Arm cylinder foot pin (1) 9. Bucket-rod joining pin (1)

4. Boom cylinder foot pin (1) 10. Bucket cylinder foot pin (1)

5. Bucket-rod joining pin (1) 11. Arm cylinder rod end (1)

6. Bucket cylinder rod end (1) 12. Boom-arm joining pin (2)

The following pages provide additional information on each lubrication point. The additional information
is presented in the same order as appears on the above figure.

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CONTENTS
TABLEOF
1. Inject grease into the two boom foot pin fittings.
2. Inject grease into the two boom cylinder rod end
3
pin fittings.

INTRODUCTION
3. Inject grease into the arm cylinder foot pin fit-
ting.

NOTE: These fittings are mounted on the top of

the boom near the base with lines leading to the
bearings

SAFETY
Fig. 5-78
1 2
4. Inject grease into the two boom cylinder foot pin
fittings.

FUNCTION
SYSTEM
OPERATION
MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING

Fig. 5-79
4
EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

5. Inject grease into the bucket-rod joining pin fit-

ting.
7
6. Inject grease into the bucket cylinder rod end fit-
ting.
7. Inject grease into the two rod joining pin fittings.

Fig. 5-80
5

8. Inject grease into the two arm-bucket joining pin

fittings.
9. Inject grease into the single bucket-rod joining
pin fitting.

Fig. 5-81
9

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CONTENTS
TABLEOF
10. Inject grease into the bucket cylinder foot pin
fitting.

INTRODUCTION
SAFETY
Fig. 5-82 10

FUNCTION
SYSTEM
11

OPERATION
MAINTENACE
11. Inject grease into the arm cylinder rod end fit-
ting.

SPECIFICATIONS TROUBLRSHOOTING

Fig. 5-83
EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

12. Inject grease into the two boom-arm joining pin

fittings.

12

Secure the Machine for Mainte-

nance (Power On) Fig. 5-84
Connect the battery to start the engine or provide
power to the machine as stated in the following
checks.

WARNING
Do not remove the Lockout/Tagout tags from the machine when you connect the battery.
These tags notify others that the machine is not to be used during maintenance. Failure to
keep the tags in place could create a hazardous situation which, if not avoided, could re-
sult in death or serious injury.

Change:
• Engine Oil and Filter (Initial) (See page 5-57.)
Check:
• Final Drive Gearbox Oil Level (See page 5-61.)
• Track Tension (Initial) (See page 5-62.)
Lubricate:
• Swing Bearing (See page 5-64.)

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CONTENTS
TABLEOF
Change
Engine Oil and Filter (Initial)
NOTE: See “Environmental Precautions” on page 2-21 before proceeding with this procedure.

INTRODUCTION
NOTE: Replace the engine oil after the initial 50 hours of service, then every 500 hours.
NOTE: Inspect the drained oils and filter for signs of metal particles and foreign material. Contact your
Sany dealer for an oil analysis if any abnormality is found.
NOTE: See “Add Fluids to the Machine” on page 2-19.

SAFETY
WARNING
Do not perform this task when the engine is hot. Wait for the engine to cool to outdoor
ambient temperature before proceeding. Failure to do so could result in burns or other
serious injury.

FUNCTION
SYSTEM
OPERATION
MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING

Fig. 5-85
EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

2. Open the engine cover (b).

3. Loosen the engine oil filler cap (c).

Fig. 5-86

Fig. 5-87

4. Place an appropriately sized container under the

drain valve (d).
NOTE: See “Fluids & Lubricants” on page 5-13
for capacity information, “Engine Oil Viscosity/
Temperature Data” on page 5-14 for type.
5. Slowly open the valve (d) to drain all of the oil.
6. Close the valve (d) when all of the oil has
drained from the engine.
7. Reinstall the belly plate (a) when complete. d

Fig. 5-88

NOTICE
Dispose of the drained oil in accordance with local environmental regulations. Failure to
do so could result in damage to the environment.

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CONTENTS
TABLEOF
8. Locate the engine oil filter (e) behind the right
rear access panel.
9. Place a container under the engine oil filter.

INTRODUCTION
e

SAFETY
10. Remove the oil filter (e).
11. Clean the engine oil filter mount (f). Fig. 5-89

NOTE: Check the underside of the mount (f)

FUNCTION
for any of the previous seal from the old filter. If

SYSTEM
found,remove the used seal to prevent oil leaks
when a new filter (e) is mounted in place.
12. Clean the oil filter mounting surface.

OPERATION
13. Coat the new filter seal ring with a thin layer of
engine oil.
14. Thread the new filter into place on its mount (f) f
until the filter gasket contacts the filter mount, then
tighten the filter 3/4 turn more.

MAINTENACE
15. Remove the engine oil filler cap (item c, Fig.
5-87, page5-58).
f
16. Add oil as needed.

SPECIFICATIONS TROUBLRSHOOTING
NOTE: See “Fluids & Lubricants” on page 5-13
for additional information on engine oil capacity
and type. Fig. 5-90

NOTICE
Do not overfill the engine with oil. Failure to observe and follow this could result in ma-
chine damage and improper machine operation.
EQUIPMENT
OPTIONAL

17. Reinstall the engine oil filler cap (c).

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18. Locate the engine oil dipstick (g) in the engine

compartment.
c
19. Remove the dipstick (g) from the engine and
note the oil level.

g
NOTE: The oil level should be within the etched
area(h). Fig. 5-91
20. If the oil is not within the etched area (h), re-
move the engine oil filler cap, then add engine oil
until the oil level is within the etched area (h).
21. Reinstall the oil filler cap (c).
22. Close the engine cover (b).
23. Start and run the engine at idle speed for a short
time and check for oil leaks.
24. Shut down the engine, wait for several minutes,
then remove the dipstick (g) from the engine and
note the oil level.
NOTE: The oil level should be within the etched
area (h).
25. If necessary, remove the oil filler cap (c), add
oil as needed, then reinstall the cap. Fig. 5-92

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CONTENTS
TABLEOF
Check
Final Drive Gearbox Oil Level

INTRODUCTION
NOTE: See “Environmental Precautions” on page
2-21 before proceeding with this procedure.
1. Drive the machine onto a flat, level surface, plac- c
ing the final drive cover so that the oil level line (a)
is parallel with the ground.
2. Shut down the engine.

SAFETY
3. Remove the filler plug (b) first to relieve system
Fig. 5-93
pressure. d
4. Remove the check plug (c) and visually check to
be sure the oil level is within 0.4 in. (10 mm) of the

FUNCTION
SYSTEM
bottom of the check plug hole (c).

5. If the oil level is low, add oil through the filler plug hole
(b) until the level is within 0.4 in. (10 mm) of the bottom of the check plug hole (c).

OPERATION
NOTE: See “Fluids & Lubricants” on page 5-13 for capacity and “Industrial Gear Oil/Temperature Data”
on page 5-15 for type.

NOTICE

MAINTENACE
Overfilling the final drive case may damage the case seals. This could result in machine
damage and improper machine operation.

6. Reinstall and tighten both plugs.

SPECIFICATIONS TROUBLRSHOOTING
NOTE: See “Specific Torque Values” on page 5-10.
7. Check for external leaks.

NOTICE
If oil leaks are found during the oil level inspection, stop the inspection, locate and repair
the cause of the oil leaks. Failure to avoid doing this could result in machine damage and
improper machine operation.
EQUIPMENT
OPTIONAL

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Track Tension (Initial)

1. If track tension is noticeably loose, operate the
machine with the engine at idle speed.
2. Travel forward a distance of about 13 ft. (4 m)
on a flat,level surface.
3. Stop the machine.
4. Shut down the engine.
Measure Track Tension
NOTE: Be sure the ground surface is flat and
stable.
Fig. 5-94
1. Place a straightedge (a) on the track above the
idler wheel (b) and rollers (c).
2. Measure the track-droop value (distance between
the straightedge and the track) using a ruler (d) as
shown.
NOTE: The acceptable range is 0.4 - 1.2 in. (10 -
30mm).
3. If the tension is outside the acceptable range, a
adjust as needed.

c
Fig. 5-95
b
d
Increase Track Tension
1. Add grease through the grease fitting (a).

Fig. 5-96

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CONTENTS
TABLEOF
2. Slowly move the machine forward 23 - 26 ft. (7 - 8 m).
3. Stop the machine.
4. Recheck to see if the track tension now meets the requirement in “Measure Track Tension” under “Track

INTRODUCTION
Tension (Initial)” on page 5-62.
5. Add additional grease through the grease fitting if it is still out of the acceptable range.
NOTE: If the tension is still loose, the contact your Sany dealer to determine the cause and remedy.
Reduce Track Tension

SAFETY
WARNING
Do not loosen the grease fitting (a)! The grease fitting is under extreme pressure and can
exit the grease valve (b) quickly and forcefully.
Do not place yourself or others directly in front of the grease valve (b) when loosening the

FUNCTION
valve.

SYSTEM
Wear suitable personal protective equipment in the form of protective clothing, gloves,
safety glasses and head protection to protect against the sudden release of pressurized
grease.
Failure to observe and follow these warnings could result in death or serious injury.

OPERATION
1. Ensure that there is no gravel or mud between
the sprocket and the track link before decreasing
track tension.
2. Position yourself off to the side, not in front of

MAINTENACE
the grease valve (b). a

3. Using the proper tools, slowly loosen the grease

valve(b) counterclockwise, in 90° increments (one-
quarter turn) to decrease track tension.

SPECIFICATIONS TROUBLRSHOOTING
NOTE: The grease will come out from behind the
grease valve.
4. If the grease does not come out smoothly, move
the machine back and forth for a short distance.
5. Check track tension; when it is correct, turn the
grease valve (b) clockwise.
b
NOTE: See “Specific Torque Values” on page 5-10.
Fig. 5-97
6. Move the machine forward at low idle speed
for a distance that is equivalent to the length of an
unfolded track.
EQUIPMENT
OPTIONAL

7. Park the machine.

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8. Check track tension again. Readjust if it is still out of the acceptable range.
9. Tighten grease valve (b) using the proper tool, moving the grease valve clockwise in 90° increments
(onequarter turn).
NOTE: See “Specific Torque Values” on page 5-10.

Lubricate

Swing Bearing
NOTE: See “Environmental Precautions” on page
2-21 before proceeding with this procedure.
1. Inject lubricating grease at the fittings (a) on the
swing bearing until the grease seeps out of the seal
(b).
NOTE: See “Lubricating Grease/Temperature Fig. 5-98
Data” on page 5-15 for the correct type of grease. a b
2. Check the seal (b) condition.
NOTE: If it leaks, replace the seal immediately.
Contact your Sany dealer.
3. Start the engine.
4. Lift the arm off the ground.
5. Rotate the upperworks 90° and repeat steps 1
and 2.
6. Repeat until a full 360° rotation has been made.
7. Shut down the engine.

Maintenance Log
Record the completion of all of the maintenance tasks from this section.

Lockout/Tagout
Fully activate the machine and remove all lockout/tagout warnings and machine securing elements. Return
the machine to operation.

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CONTENTS
TABLEOF
250-HOUR MAINTENANCE
NOTICE
Failure to perform the following procedures when and how directed could result in ma-

INTRODUCTION
chine damage and improper machine operation.
NOTE: Ensure all 50-hour maintenance tasks have been completed before proceeding with the 250-hour
maintenance tasks.

Secure the Machine for

Maintenance (Power Off)

SAFETY
1. Obtain the Maintenance Log for this machine
and complete it at the close of all maintenance
procedures.
2. Read and understand all of the tasks listed in this

FUNCTION
SYSTEM
section.

Fig. 5-99

OPERATION
3. Follow the Lockout/Tagout procedure in the

MAINTENACE
Safety section of this manual.
NOTE: See “Lockout/Tagout Procedures” on page
2-23 for details.
NOTE: Allow the systems time to cool down before

SPECIFICATIONS TROUBLRSHOOTING
proceeding with any maintenance.
4. With the machine secured, proceed with the
following:
Change:
• Hydraulic Pilot Line Filter Element (Initial) (See
page 5-66.)
• Hydraulic Fluid - Breaker-Equipped (400 Hours)
(See page 5-67.)
EQUIPMENT
OPTIONAL

Fig. 5-100

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Maintenance SY215 Excavator

Check:
• Air Conditioner Compressor Belt (See page 5-68.)
• Windshield Washer and Windshield Wiper (See page 5-70.)
• Track Assemblies (See page 5-72.)
• Fuses (See page 5-72.)
• Supplemental Coolant Additive (SCA) Levels (if used) (See page 5-72.)
• Grab Handles and Steps (See page 5-73.)
• Cab Door, Access Panels and Locks (See page 5-73.)

Change
Hydraulic Pilot Line Filter Element (Initial)
NOTE: See “Environmental Precautions” on page 2-21 before proceeding with this procedure.
NOTE: Perform this procedure every 1,000 service hours after this first-time replacement or at least
once each year, whichever occurs first.
NOTE: Ensure that the machine is on flat, level ground before proceeding.

1. Locate the hydraulic pilot line filter (a) behind the right rear access panel.

Fig. 5-101 a

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CONTENTS
TABLEOF
2. Use a wrench on the hex end (b) at the bottom of
the filter casing to loosen the casing.
3. Place an appropriately sized container under-
neath the filter casing to catch any oil that may leak

INTRODUCTION
out.

NOTICE
Dispose of the drained oil in accordance b
with local environmental regulations. Fail-

SAFETY
ure to do so could result in damage to the
environment.
Fig. 5-102
c

FUNCTION
SYSTEM
4. Remove the filter casing (c).
5. Remove the filter element (d) from the housing
(e).
6. Install a new gasket and O-ring.

OPERATION
e
NOTE: See “Hydraulic Fluid Inspection” on page
5-8.
7. Clean the inside of the filter casing.

MAINTENACE
8. Install a new filter element inside the casing.
9. Reinstall the casing.
NOTE: Be careful not to cross-thread the filter cas-
ing during installation so that the mating surfaces

SPECIFICATIONS TROUBLRSHOOTING
seal correctly.

Fig. 5-103 d

Hydraulic Fluid - Breaker-Equipped (400 Hours)

Machines using the optional breaker attachment consume hydraulic fluid at a faster rate than those using
the bucket or shear. Breaker-equipped machines need to have the hydraulic fluid changed every 400 hours.
NOTE: See “Hydraulic Fluid” on page 5-104.
EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

Check
Air Conditioner Compressor Belt
Inspection
1. Open the engine cover (a).
NOTE: The air conditioner compressor is located
on the upper left of the engine compartment near
the radiator.

CAUTION
Ensure that the engine is off and that all
rotating parts inside the engine compart-
ment have stopped moving. Failure to do
so could result in minor or moderate injury.
Fig. 5-104
NOTE: See “High-Pressure Fluid Lines” on page
2-20.
2. Remove the bolts (b) securing the shroud around
the compressor and drive belt.

3. Examine the belt (c) for signs of damage.

4. Press down on the belt (c) halfway between the Fig. 5-105
compressor pulley and the drive pulley.
NOTE: The belt should deflect 0.20 - 0.31 in. (5 - 8
mm)
when pressed with a force of 43 ft•lb (19.5N•m).
NOTE: If using a tension meter to check the belt
tension of the compressor, the tension should mea-
sure 470 ft•lb (637 N•m).
5. Adjust belt tension if necessary.
6. Reinstall the shroud and secure it in place.

Fig. 5-106 c

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CONTENTS
TABLEOF
Adjustment
1. Loosen the two compressor bracket bolts (a).

INTRODUCTION
SAFETY
2. Loosen the jam nut (b) on the tension adjustment
bolt (c).
3. Check for damaged pulleys, worn V-groove and

FUNCTION
V-belt.

SYSTEM
In addition, make sure that the V-belt does not rub Fig. 5-107
against the bottom of the V-groove.
4. Turn the adjustment bolt (c) to adjust the belt

OPERATION
tension.
NOTE: The belt should deflect 0.20 - 0.31 in. (5 - 8
mm)
when pressed with a force of 43 ft•lb (19.5N•m).

MAINTENACE
NOTE: If using a tension meter to check the belt
tension of the compressor, the tension of a new belt
should measure 470 ft•lb (637 N•m). (An oldbelt
will measure 318 ft•lb (441 N•m)).

SPECIFICATIONS TROUBLRSHOOTING
5. Tighten the tension bolt jam nut (b) to lock the
adjustment bolt (c) in place.
6. Tighten the two compressor bracket bolts (a). EQUIPMENT
OPTIONAL

Fig. 5-108

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Maintenance SY215 Excavator

7. Press down on the belt (d) halfway between the

compressor pulley and the drive pulley.
NOTE: The belt should deflect 0.20 - 0.31 in. (5
- 8 mm) when pressed with a force of 43 ft•lb
(19.5N•m).
NOTE: If using a tension meter to check the belt
tension of the compressor, the tension should mea-
sure 470 ft•lb (637 N•m).
Replace the belt if:
• It has stretched and there is little margin left for
adjustment.
• Cuts or cracks are found in the belt.
• The belt slips or squeals.
NOTE: Newly installed V-belts need to be read-
justed after the first hour of operation.
Fig. 5-109
8. Reinstall the shroud and secure it in place.
Windshield Washer and Windshield Wiper
NOTE: See “Environmental Precautions” on page
2-21 before proceeding with this procedure.
1. Check the washer fluid level inside the wind-
shield washer tank (a) located behind the left front
access panel.
NOTE: Use washer fluid appropriate for use in
very cold or winter climates as required.
NOTE: See “Windshield Washer Fluid” on page
5-17 for more information.

Fig. 5-110

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CONTENTS
TABLEOF
2. Remove the cap (b) and add windshield washer
fluid (or water with a small amount of appropriate
window cleaner) as necessary.

INTRODUCTION
SAFETY
Fig. 5-111 b a

FUNCTION
3. Check the operation of the windshield washer

SYSTEM
nozzle (c) and wiper (d) to ensure there is no
smearing across the windshield during operation.
Replace the wiper blade with a new one if smearing
does occur.

OPERATION
4. If necessary, adjust the spray nozzle (c) to ensure
that the fluid spray is properly directed.

MAINTENACE
NOTICE
SPECIFICATIONS TROUBLRSHOOTING
Do not operate the wiper on a dry window.
Failure to observe and follow this could
result in machine damage and improper c
machine operation.

d
EQUIPMENT
OPTIONAL

Fig. 5-112

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Maintenance SY215 Excavator

Track Assemblies

Inspection and Lubrication

NOTE: Use a pry bar to shift and/or lift the track shoes as-needed to perform this procedure.

1. Check the track pads (a) for damage, wear, unevenness, looseness, raised sections, and tightening of
track pads or any other abnormality. Replace track pads as necessary.

Fig. 5-113

2. Check the idler wheel (b), track rollers (c) and supporting rollers (d) for wear and proper operation.
NOTE: If damaged, contact your Sany dealer for repair/replacement.
3. Check the track final drive motors (e) for wear and proper operation.
NOTE: If damaged contact your Sany dealer for repair/replacement.
4. Remove as much accumulated dirt as possible from the track assemblies. Excess dirt requires more
energy to operate the tracks and causes severe wear of moving parts of the track.

Fuses
NOTE: See “Electrical Power Disconnect Process” on page 5-22 for additional information.
Supplemental Coolant Additive (SCA) Levels (if used)
Check the SCA fluid.
NOTE: See “Supplemental Coolant Additive (SCA)” on page 5-18 for additional information.

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CONTENTS
TABLEOF
Grab Handles and Steps
1. Check the mounting bolts on the grab handles (a).
2. Replace any missing or damaged mounting bolts

INTRODUCTION
and tighten any loose bolts.
3. Remove any tools, lubricants or debris from the
steps(b). Never allow loose items to remain on the
machine.

SAFETY
a

FUNCTION
SYSTEM
Cab Door, Access Panels and Locks
1. Inspect the cab door (a), access panels (b) and
locks to be sure they close and lock properly.
Fig. 5-114
NOTE: This is important for the security of the b

OPERATION
machine.
2. Repair or replace any damaged doors, access
panels or locks immediately.

MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
a

NOTICE
Failure to secure the machine could result in
damage to the machine.

Fig. 5-115 b
EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

Secure the Machine for Maintenance (Power On)

Connect the battery to start the engine or provide power to the machine as stated in the following checks.

WARNING
Do not remove the Lockout/Tagout tags from the machine when you connect the battery.
These tags notify others that the machine is not to be used during maintenance. Failure to
keep the tags in place could create a hazardous situation which could result in death or
serious injury.

Change:
• Hydraulic Tank Return Filter (Initial) (See page 5-74.)
Check
• Track Tension (See page 5-77.)

Change
Hydraulic Tank Return Filter (Initial)
NOTE: See “Environmental Precautions” on page 2-21before proceeding with this procedure.

CAUTION
Hydraulic fluid is hot and under pressure. Always wait for the machine to cool down to
below 160° F (71° C) before attempting to open the hydraulic fluid system. Failure to do so
could result in minor or moderate injury.

NOTE: See “Add Fluids to the Machine” on page 2-19.

NOTE: Perform this procedure every 1,000 service hours after this first-time replacement or at least once
each year, whichever occurs first.

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CONTENTS
TABLEOF
1. Lower the work equipment (a) to the ground.
2. Shut down the engine.

INTRODUCTION
a

SAFETY
Fig. 5-116

FUNCTION
SYSTEM
OPERATION
3. Remove the butterfly nut (b) from the breather
valve.

MAINTENACE
Fig. 5-117

SPECIFICATIONS TROUBLRSHOOTING

c
4. Press the venting button (c).
5. Reinstall the butterfly nut (b).
EQUIPMENT
OPTIONAL

Fig. 5-118

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Maintenance SY215 Excavator

6. Loosen and remove the four bolts from the

hydraulic return filter cover (d) located next to the
breather valve,then remove the vent cover.
NOTE: The air vent cover may move up while the
bolts are being removed due to the action of an in- d
ternal spring beneath the cover. Press down on the
cover while removing the bolts.

Fig. 5-119
7. Remove the spring (e), then pull the filter
removal rod out from the filter and withdraw the
filter (f).
8. Check the bottom of the filter box and remove
any dirt.
f
NOTE: Keep the hydraulic fluid free from any dirt.

Fig. 5-120 e
9. Check O-ring (g) for cuts and abrasions.
NOTE: Replace if damaged.
10. Install the rod inside the new filter element (f), e
then place inside the tank until it seats on top of the
filter.
11. Position the spring (e) on top of the filter (f). g
12. Reinstall the filter cover (d) and the bolts.
NOTE: Hold down the vent cover to compress
the spring while tightening the bolts. See “Torque
Values” on page 5-10.
Fig. 5-121

Fig. 5-122 d

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CONTENTS
TABLEOF
13. Set the hydraulic lockout control lever (h) to
the OPEN position.
NOTE: See “Hydraulic Lockout Control Lever” on
page 3-5 for additional information.

INTRODUCTION
14. Start and run the engine at low idle (1,050 rpm)
for 10 minutes in order to vent the air from the
hydraulic system.
15. Check for leaks.
16. Shut down the engine.

SAFETY
Fig. 5-123
h

FUNCTION
SYSTEM
Check

OPERATION
Track Tension
NOTE: See “Track Tension (Initial)” on page 5-62.
Maintenance Log

MAINTENACE
Record the completion of all of the maintenance tasks from this section.
Lockout/Tagout
Fully activate the machine and remove all lockout/tagout warnings and machine securing elements. Return
the machine to operation.

SPECIFICATIONS TROUBLRSHOOTING
EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

500-HOUR MAINTENANCE
NOTICE
Failure to perform the following procedures when and how directed could result in ma-
chine damage and improper machine operation.

NOTE: Ensure all 50 and 250-hour maintenance

tasks have been completed before proceeding with
the 500-hour maintenance tasks.

Secure the Machine for Mainte-

nance (Power Off)
1. Obtain the Maintenance Log for this machine
and complete it at the close of all maintenance pro-
cedures.
Fig. 5-124
2. Read and understand all of the tasks listed in this
section.

3. Follow the Lockout/Tagout procedure in the

Safety section of this manual.
NOTE: See “Environmental Precautions” on
page 2-21 for details.
NOTE: Allow the systems time to cool down
before proceeding with any maintenance.
4. With the machine secured, proceed with the fol-
lowing:
Change
• Hydraulic System Breather Filter (See page 5-79.)
• Engine Air Filter (See page 5-80.)
Check:
• Radiator, Oil Cooler, and A/C Condenser Fins (See
page 5-80.)
• Air Conditioning Fresh Air & Recirculation Fil-
ters
Fig. 5-125
(See page 5-82.)

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CONTENTS
TABLEOF
• Seat Belt (See page 5-84.)
• Swing Gearbox Bolts (See page 5-84.)
• Hydraulic Hoses (See page 5-85.)

INTRODUCTION
• Upperworks and Lowerworks (See page 5-86.)
• Final Drive (See page 5-87.)
• Swing Pinion Gear (See page 5-87.)
• Swing Gearbox Bearing (See page 5-88.)

SAFETY
Change
Hydraulic System Breather Filter
NOTE: Depending on the work environment and a

FUNCTION
the degree of contamination, the filter may need to

SYSTEM
be replaced more frequently than every 500 hours.
1. Locate the hydraulic tank breather valve (a) on
the top of the hydraulic tank.
2. Clean the top of the hydraulic tank around the

OPERATION
Fig. 5-126
breather valve (a).
3. Remove the black butterfly nut (b) and spacer
from the top of the breather valve.
4. Unscrew and remove the filter element cover (c)

MAINTENACE
off of the filter (d).
5. Pull the filter (d) up and free from the valve
body.

SPECIFICATIONS TROUBLRSHOOTING
NOTICE
b
Dispose of the filter in accordance with
local environmental regulations. Failure to
do so could result in damage to the envi- c
ronment.

d
EQUIPMENT
OPTIONAL

Fig. 5-127

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6. Install the new breather filter (d).

7. Reinstall the breather filter cover (c). d
8. Secure it in place with the spacer and butterfly
nut (b).

Fig. 5-128

Engine Air Filter

Replace the engine primary air filter.
NOTE: See “Engine Air Filter System” on page 5-43 for instructions on replacing the engine primary air
filter.
NOTE: Depending on the work environment and the degree of contamination, the filter may need to be
replaced more frequently than every 500 hours.

Check
Radiator, Oil Cooler, and A/C Condenser
Fins
1. Open the left rear access panel (a).

Fig. 5-129
a

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CONTENTS
TABLEOF
2. Open the engine cover (b).
3. Remove the wing nuts (c) securing the protec-
tion screen

INTRODUCTION
(d) mounted in front of the engine coolant radiator.
b

SAFETY
Fig. 5-130
c

FUNCTION
SYSTEM
OPERATION
MAINTENACE
4. Pull the protection screen (d) away from the
radiator.

SPECIFICATIONS TROUBLRSHOOTING
5. Clean the protection screen (d) using compressed
air.

d
EQUIPMENT
OPTIONAL

Fig. 5-131

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6. Clean the radiator (e), hydraulic fluid cooler (f),

and A/C condenser fins (g) using compressed air. e

NOTICE g

Use low pressure compressed air and h

point the nozzle away from the radiator
fins to avoid damaging the fins or causing
other engine damage.
Fig. 5-132

7. Remove the cover (h) below the radiators.

8. Clean out any debris that has accumulated dur-
ing operations and cleaning.
9. Reinstall the cover (h)
10. Reinstall the protection screen (d).
11. Close the engine cover.
12. Close the left rear access panel.
Air Conditioning Fresh Air & Recirculation Filters
1. Unlock and open the fresh air filter access panel
(a).

Fig. 5-133 a

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CONTENTS
TABLEOF
2. Remove the three nuts and washers (b) securing
the fresh air filter (c) in place.
3. Remove the filter (c).
c

INTRODUCTION
4. Clean the filter (c) using compressed air.
NOTE: After cleaning the filter five times or if the
filter cannot be cleaned, replace the filter with a
new one.
5. Reinstall the filter (c).

SAFETY
6. Reinstall the nuts and washers (b).
7. Close and lock the access panel (a).

FUNCTION
SYSTEM
8. Remove the two bolts (d) securing the cabin air
filter cover (e) in place. Fig. 5-134

NOTE: This air filter is located behind the seat near b

the fuse access panel.

OPERATION
MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
d

Fig. 5-135
e
EQUIPMENT
OPTIONAL

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9. Remove the two nuts (f) securing the cabin air

filter (g).
10. Remove the cabin air filter (g).
11. Clean with compressed air.
NOTE: After cleaning the filter five times or if the
filter cannot be cleaned, replace the filter with a
new one. g

12. Reinstall the filter (g) and nuts (f).

13. Reinstall the filter cover (e) and bolts (d).
NOTE: See “High-Pressure Fluid Lines” on page f
2-20.
If you discover any abnormalities contact your
Sany dealer, do not repair the A/C system
beyond the tasks described in this manual.

Seat Belt Fig. 5-136

Ensure that the seat belt is not damaged (cut,

frayed, etc.) and is in proper working condition,
especially if it has
been subjected to severe stress.
NOTE: Contact your Sany dealer for replacement
if needed.

Swing Gearbox Bolts

1. Locate the swing gearbox (a). a

Fig. 5-137

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CONTENTS
TABLEOF
2. Check the swing gearbox for missing or broken
mounting bolts (b).
NOTE: If missing or broken, contact your Sany
dealer for repair information.

INTRODUCTION
3. Tighten loose bolts.
NOTE: See “General Torque Values” on page 5-11
for specifications.

SAFETY
b

FUNCTION
SYSTEM
OPERATION
Fig. 5-138

Hydraulic Hoses

MAINTENACE
NOTE: See “Hydraulic Hoses” on page 5-46 and “High-Pressure Fluid Lines” on page 2-20.

SPECIFICATIONS TROUBLRSHOOTING
EQUIPMENT
OPTIONAL

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Upperworks and Lowerworks

The machine consists of two major component groups:
• The lowerworks with its various components and assemblies.
• The upperworks with its various components and assemblies.
Check all structural components identified below for cracks or distortion.
NOTE: Notify your Sany dealer if any cracks or distortion is found.

2 3

5
1

Fig. 5-139

1. Arm (upperworks) 4. Engine compartment (upperworks)

2. Boom (upperworks) 5. Swing turntable (lowerworks)

3. Operator cab (upperworks) 6. Track (track) assembly (lowerworks)

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CONTENTS
TABLEOF
Final Drive
1. Locate the final drive covers (a).
2. Remove the covers (a).

INTRODUCTION
3. Inspect the final drive (b) to ensure that all hoses
are connected tightly.
4. Ensure that all bolts are present and tight.
NOTE: Replace any damaged or defective bolts
and tighten any loose bolts. Use anaerobic thread

SAFETY
sealant when reinstalling loose bolts and installing Fig. 5-140 a
new bolts.
NOTE: See “Specific Torque Values” on page 5-10.
5. Check for leaks.

FUNCTION
SYSTEM
NOTE: Contact your Sany dealer if any abnormali-
ties are found.
Swing Pinion Gear
NOTE: See “Environmental Precautions” on page

OPERATION
2-20 before proceeding with this procedure.
1. Locate the swing pinion gear grease check point
(a).
Fig. 5-141
b

MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING

a
EQUIPMENT
OPTIONAL

Fig. 5-142

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2. Remove the cover (b) to open the inspection/

filler hole.
3. Insert a ruler into the grease through the inspec-
tion/filler hole.
4. Check the grease level.
NOTE: The minimum level is 0.75 in. (19 mm).
5. If the grease level is low, add grease through the
inspection/filler hole as needed.
NOTE: See “Fluids & Lubricants” on page 5-13
and“Lubricating Grease/Temperature Data” on Fig. 5-143
b
page 5-15 for additional information on grease
type.
6. Check the grease color to see if it is milk-white.
NOTE: Milk-white grease indicates that the grease
has been contaminated. Contact your Sany dealer
for information on changing the grease.
NOTE: See “Lubricating Grease/Temperature
Data” on page 5-17 for additional information on
grease type.
7. Reinstall the cover (b).

Swing Gearbox Bearing

NOTE: See “Environmental Precautions” on page
2-21 before proceeding with this procedure.
Inject grease into the swing gearbox bearing fitting
(a).
NOTE: See “Lubricating Grease/Temperature
Data” on page 5-15 for additional information on
grease type.

Fig. 5-144 a

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CONTENTS
TABLEOF
Secure the Machine for Maintenance (Power On)
Connect the battery to start the engine or provide power to the machine as stated in the following checks.

INTRODUCTION
WARNING
Do not remove the Lockout/Tagout tags from the machine when you connect the battery.
These tags notify others that the machine is not to be used during maintenance. Failure to
keep the tags in place could create a hazardous situation which, could result in death or
serious injury.

SAFETY
Change:
• Swing Gearbox Oil (See page 5-89.)
• Engine Oil and Filter (See page 5-92.)

FUNCTION
SYSTEM
• Primary Fuel Filter (See page 5-93.)
Check:
• Hydraulic Pump (See page 5-95.)

OPERATION
Change
Swing Gearbox Oil
NOTE: See “Environmental Precautions” on page 2-21 before proceeding with this procedure.

MAINTENACE
1. Start the engine.
2. In an open area, rotate the upperworks 90° in both directions five times to warm the oil. If cold weather
conditions 0° F (-18° C) exist, rotate the upperworks 90° in both directions 10 times.

SPECIFICATIONS TROUBLRSHOOTING
CAUTION
Because the engine and oil are hot, be sure to wear protective clothing. Failure to observe
and follow this caution could result in minor or moderate injury.

NOTE: See “Personal Protective Equipment” on page 2-14.

3. Shut down the engine.
EQUIPMENT
OPTIONAL

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4. Locate the swing gearbox (a).

5. Loosen the gearbox oil fill cap (b).

Fig. 5-145

6. Remove the belly plate (c) to access the drain

hose (d) if necessary.
Fig. 5-146 b

Fig. 5-147 c d

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CONTENTS
TABLEOF
7. Place an appropriately sized container beneath
the oil drain hose (d).
NOTE: See “Fluids & Lubricants” on page 5-13
for information on capacity and “Industrial Gear

INTRODUCTION
Oil/Temperature Data” on page 5-15 for type.

SAFETY
Fig. 5-148

FUNCTION
NOTICE

SYSTEM
Dispose of the drained oil in accordance with local environmental regulations. Failure to
do so could result in damage to the environment.

9. Close the drain valve after oil stops draining from the gearbox.

OPERATION
10. Reinstall the belly plate (c).
11. Remove the gearbox oil fill cap (b).
12. Fill the swing gearbox with clean oil through the oil fill cap hole.

MAINTENACE
NOTE: See “Fluids & Lubricants” on page 5-13 for capacity and “Industrial Gear Oil/Temperature
Data” on page 5-15 for type.

NOTICE

SPECIFICATIONS TROUBLRSHOOTING
Do not overfill the gearbox with oil. Failure to observe and follow this notice could result
in damage to the gearbox.

EQUIPMENT
OPTIONAL

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13. Remove the gearbox oil dipstick (f) and note

the oil level.

NOTE: The oil level should be within the etched

area (g). If not, add oil as necessary.
Fig. 5-149 b

Fig. 5-150
14. Reinstall and tighten the oil fill cap (b).

NOTICE
If oil leaks are found during the oil level inspection, stop the inspection. Locate and repair
the cause of the oil leak. Failure to do so could result in damage to the gearbox.

Engine Oil and Filter

NOTE: See “Engine Oil and Filter (Initial)” on page 5-57 for procedure.

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CONTENTS
TABLEOF
Primary Fuel Filter
NOTE: See “Environmental Precautions” on page 2-21 before proceeding with this procedure.

DANGER

INTRODUCTION
Never maintain the fuel system near an open flame or while smoking. Failure to follow this
rule will result in death or serious injury.
1. Locate the filter (a) behind the right rear access
panel.

SAFETY
a

FUNCTION
SYSTEM
c

OPERATION
Fig. 5-151

2. Place an appropriately sized container under the

MAINTENACE
fuel filter.
3. Loosen the priming pump knob (b).
4. Open the drain valve (c) to allow all water and
fuel to drain from the filter.

SPECIFICATIONS TROUBLRSHOOTING
5. Remove the primary fuel filter.

NOTICE
Dispose of the filter and fuel in accordance b
with local environmental regulations. Fail-
ure to do so could result in damage to the
environment.

Fig. 5-152
EQUIPMENT
OPTIONAL

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6. With the new primary fuel filter upright and plug

(d) in the center hole of the filter, fill the filter with
clean diesel fuel through inlet holes (e) until the
filter is completely full.
NOTE: Leave plug (d) in place until the filter has
been filled with clean fuel and you are ready to
install it on the filter support.

7. Remove plug (d) from the center hole of the

filter.
8. Install the filter on the filter support.
NOTE: Follow the manufacturer’s instructions on Fig. 5-153
the fuel filter body when installing the filter.
9. Tighten the priming pump knob (b).

10. Once the filter is installed, start the engine and

allow it to run at idle speed.
11. Check for leaks in the fuel system.
12. Shut down the engine.

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CONTENTS
TABLEOF
Check
Hydraulic Pump

INTRODUCTION
CAUTION
Hydraulic fluid is hot and under high pressure. Always wait for the machine to cool down
to below 160° F (71° C) before attempting to open the hydraulic fluid system. Failure to do
so could result in minor or moderate injury.

SAFETY
a
NOTE: See “High-Pressure Fluid Lines” on page
2-21.
1. Locate the hydraulic pump (a) behind the right

FUNCTION
rear access panel.

SYSTEM
2. Start the engine.
3. Check for leaks, function and noise.
4. Shut down the engine.

OPERATION
NOTE: Contact your Sany dealer if any abnormal-
ity is found.
5. Close the access panel.

MAINTENACE
Maintenance Log
Record the completion of all of the maintenance
tasks from this section.
Fig. 5-154

SPECIFICATIONS TROUBLRSHOOTING
Lockout/Tagout
Fully activate the machine and remove all lockout/
tagout warnings and machine securing elements.
Return the machine to operation. EQUIPMENT
OPTIONAL

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1,000-HOUR MAINTENANCE
NOTICE
Failure to perform the following procedures when and how directed could result in ma-
chine damage and improper machine operation.

NOTE: Ensure all 50, 250, and 500-hour maintenance tasks have been completed before proceeding with
the 1,000-hour maintenance tasks.

Secure the Machine for Maintenance

(Power Off)
1. Obtain the Maintenance Log for this machine
and complete it at the close of all maintenance pro-
cedures.
2. Read and understand all of the tasks listed in this
section.
3. Follow the Lockout/Tagout procedure in the
Safety section of this manual.
NOTE: See “Lockout/Tagout Procedures” on page Fig. 5-155
2-23 for details.
NOTE: Allow the systems time to cool down be-
fore proceeding with any maintenance.
4. With the machine secured, proceed with the fol-
lowing:
Change:
• Hydraulic Pilot Line Filter (See page 5-97.)
• Hydraulic Tank Return Filter (See page 5-97.)
Check:
• Engine Exhaust Pipe Clamps (See page 5-97.)
• Fuel Tank Strainer (See page 5-98.)
• Fuel Lines (See page 5-99.)

Fig. 5-156

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CONTENTS
TABLEOF
Change

Hydraulic Pilot Line Filter

INTRODUCTION
NOTE: Hydraulic Pilot Line Filter Element (Initial) (See page 5-66.)
Hydraulic Tank Return Filter
NOTE: Hydraulic Tank Return Filter (Initial) (See page 5-74.)

Check

SAFETY
Engine Exhaust Pipe Clamps
1. Open the engine cover (a).

FUNCTION
CAUTION

SYSTEM
Ensure that the engine is shut down and
that the exhaust has cooled down to a
point where it can be touched without a
burning. Failure to do so could result in

OPERATION
minor or moderate injury.

NOTE: See “Diesel Engine Exhaust” on page 2-5.

MAINTENACE
Fig. 5-157

SPECIFICATIONS TROUBLRSHOOTING
2. Check the clamps (b) on the exhaust system for
tightness.
NOTE: Tighten as required. Replace damaged or
missing clamps.
NOTE: See “General Torque Values” on page 5-11
for the proper tightening values.

b
EQUIPMENT
OPTIONAL

Fig. 5-158

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Fuel Tank Strainer

NOTE: See “Environmental Precautions” on page 2-21 before proceeding with this procedure.
1. Unlock and remove the fuel tank filler cap (a).

Fig. 5-159
a

b
2. Lift the fuel tank strainer element (b) out of the
tank filler neck.
3. Clean and inspect the fuel tank strainer.
NOTE: Replace a damaged or missing fuel strainer
with a new one.
4. Install the new (or cleaned) fuel tank strainer (b).
5. Reinstall and lock the fuel tank filler cap.

Fig. 5-160

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CONTENTS
TABLEOF
Fuel Lines
Inspect all steel, plastic and rubber fuel lines including those on the engine.

CAUTION

INTRODUCTION
Failure to perform this procedure as directed could result in a fire during operation which
could result in minor or moderate injury.

NOTE: See “High-Pressure Fluid Lines” on page 2-20 and “Refuel” on page 2-19.
NOTE: Replace any fuel lines which show signs of deterioration, wear, damage or leaks.

SAFETY
NOTE: Contact your Sany dealer for repairs on the fuel system.

Secure the Machine for Maintenance (Power On)

Connect the battery to start the engine or provide power to the machine as stated in the following checks.

FUNCTION
SYSTEM
WARNING
Do not remove the Lockout/Tagout tags from the machine when you connect the battery.
These tags notify others that the machine is not to be used during maintenance. Failure to

OPERATION
keep the tags in place could create a hazardous situation which, could result in death or
serious injury.

Check:

MAINTENACE
• Accumulator Function Check (Breaker-Equipped only) (See page 5-100.)

SPECIFICATIONS TROUBLRSHOOTING
EQUIPMENT
OPTIONAL

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Check
Accumulator Function Check (Breaker-Equipped only)

CAUTION
Hydraulic fluid is hot and under high pressure. Always wait for the machine to cool down
to below 160° F (71° C) before proceeding. Failure to do so could result in minor or moder-
ate injury.

NOTE: See “High-Pressure Fluid Lines” on page

2-20.
1. Lower the work equipment to 18-24 in. (0.45-0.6
m) from the ground.
2. Shut down the engine.
3. Turn the ignition switch to the ON position.
Fig. 5-161
4. Set the hydraulic lockout control lever to the
OPEN position (a).
5. Fully cycle each pedal, joystick and travel con-
trol lever two to three times within 15 seconds in
order to release the internal pressure remaining in
the hydraulic lines.
NOTE: If there is no movement by the machine or
if there is still movement within 15 seconds of the
start of movement end, contact your Sany dealer.
6. Start the engine and run it at idle speed for about
5 minutes and allow the coolant level to drop.
7. Shut down the engine.

Fig. 5-162 a

Maintenance Log
Record the completion of all of the maintenance tasks from this section.

Lockout/Tagout
Fully activate the machine and remove all lockout/tagout warnings and machine securing elements. Return
the machine to operation.

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CONTENTS
TABLEOF
2,000-HOUR MAINTENANCE
NOTICE

INTRODUCTION
Failure to perform the following procedures when and how directed could result in ma-
chine damage and improper machine operation.

NOTE: Ensure all 50, 250, 500 and 1,000-hour maintenance tasks have been completed before proceeding
with the 2,000-hour maintenance tasks.

Secure the Machine for Mainte-

SAFETY
nance (Power Off)
1. Obtain the Maintenance Log for this machine
and complete it at the close of all maintenance pro-
cedures.

FUNCTION
SYSTEM
2. Read and understand all of the tasks listed in this
section.
3. Follow the Lockout/Tagout procedure in the
Safety section of this manual.

OPERATION
NOTE: See “Lockout/Tagout Procedures” on page Fig. 5-163
2-23 for details.
NOTE: Allow the systems time to cool down be-
fore proceeding with any maintenance.

MAINTENACE
4. With the machine secured, proceed with the fol-
lowing:
Change:

SPECIFICATIONS TROUBLRSHOOTING
• Final Drive Oil (See page 5-102.)
Check:
• Hydraulic Hoses (See page 5-103.)
EQUIPMENT
OPTIONAL

Fig. 5-164

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Change

Final Drive Oil

NOTE: See “Environmental Precautions” on page 2-21 before proceeding with this procedure.

CAUTION
When the engine has just shut down, the oil and final drive components are still hot and
can cause burns. Wait until the oil in 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 with extreme force. Slowly loosen the screw plug in order to gradually release the
pressure. Failure to follow this process could result in minor or moderate injury.

1. Drive the machine onto a flat, level surface, plac-

ing the final drive cover so that the oil level line (a)
is parallel with the ground. b
2. Remove any dirt from the hexagonal socket of
plugs (b,c, and d) to avoid damaging the bolts.
a
3. Loosen plug (b) first to relieve pressure within
the final drive.
c
4. Place an appropriately sized container under the
drain plug (d).
NOTE: See “Fluids & Lubricants” on page 5-13
for capacity and “Industrial Gear Oil/Temperature
Data” on page 5-15 for type. Fig. 5-165 d
5. Remove the drain plug slowly, taking care not to
stand in front of the drain plug.
6. Allow the oil to drain completely.

Fig. 5-166

NOTICE
Dispose of drained oil in accordance with local environmental regulations. Failure to do
so could result in damage to the environment.

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CONTENTS
TABLEOF
7. Check the O-ring (e) on each screw plug.
NOTE: Replace the O-ring if damaged.
8. Reinstall and tighten drain plug (d).

INTRODUCTION
9. Remove plugs (b and c).
10. Add new oil through the filler cap plug hole (b).
NOTE: See “Fluids & Lubricants” on page 5-13
for capacity and “Industrial Gear Oil/Temperature
Data” on page 5-15 for type.

SAFETY
e
11. When the oil is seen coming out of the final
drive oil check plug hole (c), reinstall both plugs (b
and c).
NOTE: See “Specific Torque Values” on page 5-10.

FUNCTION
SYSTEM
12. Repeat this process for the other final drive. Fig. 5-167

Check
Hydraulic Hoses

OPERATION
NOTE: See “Hydraulic Hoses” on page 5-46 for d
procedure.
Secure the Machine for Maintenance (Power
On)

MAINTENACE
Connect the battery to start the engine or provide
power to the machine as stated in the following
c
checks.

SPECIFICATIONS TROUBLRSHOOTING
Fig. 5-168

WARNING
Do not remove the Lockout/Tagout tags from the machine when you connect the
battery.These tags notify others that the machine is not to be used during maintenance.
Failure to keep the tags in place could create a hazardous situation which could
result in death or serious injury.
EQUIPMENT
OPTIONAL

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Change:
• Hydraulic Fluid (See page 5-104.)
• Engine Coolant (See page 5-110.)
Check:
• Accumulator Function Check (See page 5-114.)
• Swing Bearing Bolts (See page 5-114.)

Change

Hydraulic Fluid
NOTE: See “Environmental Precautions” on page 2-21 before proceeding with this procedure.

CAUTION
Wait at least 24 hours after the machine has stopped for the hydraulic system to cool
down sufficiently to allow it to drain. Failure to follow this step could result in minor
or moderate injury.

NOTE: See “High-Pressure Fluid Lines” on page 2-20.

NOTICE
If you have used or are using the breaker attachment, note that you need to change
hydraulic fluid every 400 hours to avoid damage to the machine. See “Hydraulic
Tank Return Filter (Initial)” on page 5-67 for additional information.
Failure to do so could create a hazardous situation, avoiding this process could
result in machine damage or improper machine operation.

1. Swing the upperworks to position the drain plug

(a)beneath the hydraulic tank between the tracks.

Fig. 5-169
a

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CONTENTS
TABLEOF
2. Position the work equipment as shown.
3. Shut down the engine.

INTRODUCTION
Fig. 5-170

4. Turn the ignition switch (b) to ON.

SAFETY
5. Move the joysticks back and forth to relieve
system pressure.
b

FUNCTION
SYSTEM
6. Set the hydraulic lockout control lever (c) to the

OPERATION
CLOSE position. Fig. 5-171

7. Turn the ignition switch (b) to OFF and remove

the key.
c

MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
Fig. 5-172

8. Locate the hydraulic tank breather valve (d) on

the top of the hydraulic tank. d
EQUIPMENT
OPTIONAL

Fig. 5-173

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9. Remove the butterfly nut (e) from the breather

valve (d).

Fig. 5-174

10. Press the venting button (f) to release the air in

the hydraulic system.
11. Reinstall the butterfly nut (e).

Fig. 5-175

12. Remove the bolts, then remove the hydraulic

filter cover (g).
NOTE: The vent cover may move up while the
bolts are loosened due to the action of an internal
spring beneath the cover. Press down on the cover
while removing the bolts.

Fig. 5-176

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CONTENTS
TABLEOF
13. Unscrew the bolts of the hydraulic tank belly
plate (h).
14. Remove the belly plate (h) to access the bottom
of the hydraulic tank and drain plug.

INTRODUCTION
15. Place an appropriately sized container under
the drain plug.
NOTE: See “Fluids & Lubricants” on page 5-13
for capacity and “Hydraulic Fluid/Ambient
Temperature Data” on page 5-15 for type.

SAFETY
Fig. 5-177
16. Remove the drain plug, then allow the tank to
completely drain of all fluid.

FUNCTION
SYSTEM
NOTICE
Dispose of drained hydraulic fluid in accordance with local environmental regulations.

OPERATION
Failure to do so could result in damage to the environment.

17. Check the O-ring on the drain plug.

MAINTENACE
NOTE: Replace if damaged.
18. Reinstall and tighten the plug after draining.
NOTE: See “Specific Torque Values” on page 5-10.

SPECIFICATIONS TROUBLRSHOOTING
EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

19. Remove the spring, then pull the rod (k) out
from the filter (m) and withdraw the filter.
20. Clean the filter (m) of all dirt by flushing it with
mineral spirits.
k
NOTE: Replace the filter if damaged.
NOTE: See “Fluids & Lubricants” on page 5-13
for the correct type of mineral spirits.
21. Check O-ring (n) for cuts and abrasions. Re-
place if damaged.
22. Install the rod into the filter element (n), then m
insert the rod (m) and filter into the opening.

Fig. 5-178

23. Position the spring (q) on top of the filter (n).

Fig. 5-179

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CONTENTS
TABLEOF
24. Add hydraulic fluid to the system through this
opening until the hydraulic fluid level is between
the marks on the hydraulic tank level sight glass
decal (p). p

INTRODUCTION
SAFETY
Fig. 5-180

NOTE: The sight glass decal (p) is located near the

right rear access panel.

FUNCTION
SYSTEM
NOTE: See “Hydraulic Fluid/Ambient Temperature
Data” on page 5-15.

OPERATION
MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
Fig. 5-181

25. Reinstall the hydraulic filter cover (g) and the

bolts.
NOTE: Hold down the cover to compress the
spring while tightening the bolts. See “Torque g
Values” on page 5-10.
26. Start the engine.
EQUIPMENT
OPTIONAL

Fig. 5-182

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Maintenance SY215 Excavator

27. Set the hydraulic lockout control lever (c) to

the OPEN position.
NOTE: See “Hydraulic Lockout Control Lever” on
page 3-5 for additional information.
28. Run the engine for 10 minutes in order to purge
the air from the hydraulic system.
29. Shut down the engine.
30. Check for leaks.
NOTE: Tighten connections if leaks are found.

Fig. 5-183 c
Engine Coolant

DANGER
Inhaling or ingesting coolant is toxic. If not avoided, this will result in death or serious
injury.

NOTE: See “Safety Data Sheets (SDS)” on page 2-17.

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
temperature before removing the filler cap. Failure to follow this warning will result in cre-
ating a hazardous situation which could result in minor or moderate injury.

NOTE: See “Environmental Precautions” on page

2-21 before proceeding with this procedure.
NOTE: See “Fluids & Lubricants” on page 5-13
for additional information.
1. Swing the upperworks to allow easy access to
the drain valve beneath the radiator.
2. Shut down the engine.

Fig. 5-184

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CONTENTS
TABLEOF
3. Open the engine cover (a).

INTRODUCTION
a

SAFETY
Fig. 5-185

FUNCTION
SYSTEM
b

OPERATION
4. Slowly open the radiator filler cap (b) to release
the cooling system pressure.
5. Remove the cap (b) when all pressure has been

MAINTENACE
relieved.
Fig. 5-186

6. Unscrew the bolts of the radiator tank belly plate (c) and remove the plate to access the bottom of the
tank.

SPECIFICATIONS TROUBLRSHOOTING

Fig. 5-187
EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

7. Place an appropriately sized container under the

radiator drain hose (d).
NOTE: See “Fluids & Lubricants” on page 5-13
for capacity and “Engine Coolant” on page 5-16
for type.

8. Open the radiator drain valve (e).

d
9. Allow the coolant to completely drain into the
container.
Fig. 5-188

NOTICE e
Dispose of drained coolant in accordance
with local environmental regulations. Fail-
ure to do so could result in damage to the
environment.
Fig. 5-189

10. Close the drain valve (e) after the cooling system is empty.
11. Add new coolant directly into the radiator filler neck (f) until the coolant level reaches the bottom of the
filler neck inspection hole.
NOTE: See “Fluids & Lubricants” on page 5-13 for capacity and “Engine Coolant” on page 5-18 for type.
12. Start the engine and run it at idle speed for about 5 minutes and allow the coolant level to drop.
13. Shut down the engine.
14. Check the fluid level.
15. Add fresh coolant directly into the radiator filler neck (f) until the coolant level again reaches the bot-
tom of the filler neck inspection hole.
NOTE: See “Engine Coolant Level” on page 5-34.

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CONTENTS
TABLEOF
16. Add new coolant to the expansion tank (f) until
it is between the L and H marks on the tank.
17. Reinstall the radiator filler cap (item b, Fig.
5-185, page 5-110).

INTRODUCTION
18. Reinstall the radiator tank belly plate (item c, f
Fig. 5-186, page 5-110).

SAFETY
Fig. 5-190

FUNCTION
SYSTEM
OPERATION
MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
EQUIPMENT
OPTIONAL

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Maintenance SY215 Excavator

Check

Accumulator Function Check

Perform this procedure every 2,000 service hours
or once each year, whichever occurs first.
NOTE: See “Accumulator Function Check (Break-
er-Equipped only)” on page 5-100 for procedure.

Swing Bearing Bolts

1. Locate and inspect the swing bearing mounting a
bolts (a) for presence and physical damage of any
kind.
2. Turn the engine on, turn the cab 90° to the right.
Fig. 5-191
3. Turn the engine off.
4. Repeat step 1 through 3 until you have inspected
all of the bolts.
NOTE: If any bolts are missing, damaged or are
loose contact your Sany dealer.
NOTE: See “Specific Torque Values” on page 5-10.

Maintenance Log
Record the completion of all of the maintenance
tasks from this section.

Lockout/Tagout
Fully activate the machine and remove all lockout/
tagout warnings and machine securing elements.
Return the machine to operation.

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CONTENTS
TABLEOF
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,

INTRODUCTION
it is important to be aware of salt damage. Contact your Sany dealer for additional storage proce-
dures if this is case.

Short-Term Storage
NOTE: See “Short-Term Storage” on page 4-42.

SAFETY
Long-Term Storage
NOTE: See “Long-Term Storage” on page 4-42.

FUNCTION
SYSTEM
OPERATION
MAINTENACE
SPECIFICATIONS TROUBLRSHOOTING
EQUIPMENT
OPTIONAL

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SY215 Excavator Troubleshooting

CONTENTS
TABLEOF
INTRODUCTION
Troubleshooting

SAFETY
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

FUNCTION
SYSTEM
Light Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Purge the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Jump-Start the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

OPERATION
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Failure Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

MAINTENACE
SPECIFICATIONS TROUBLESHOOTING

WARNING
EQUIPMENT
OPTIONAL

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

Safety, Operation & Maintenance Manual - January 8 2016 6-1

Troubleshooting SY215 Excavator

TOWING
WARNING
Make sure that the wire ropes used for towing the machine are rated for the task.
Do not use wire ropes with broken strands, reduced diameter or knots.
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.
Move the machine slowly and avoid imposing sudden load on the wire ropes.
Failure to observe and follow this warning could result in death or serious injury.

General Information
If the machine is trapped in mud, attach wire ropes
to the pad eyes (a).
Place wood blocks or other protective materials
between where the wire rope contacts the machine
to prevent damaging the wire rope or the machine.
Keep the wire rope parallel to the ground and align
its direction with that of the track frame.
Move at a maximum speed of 0.62 mph (1 kph)
when towing the machine. Tow the machine to a
place suitable for repair. Never tow the machine
more than 100 yd. (90 m) if at all possible. Fig. 6-1 a
Towing the machine is only allowed in case of
emergency.

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SY215 Excavator Troubleshooting

CONTENTS
TABLEOF
Light Loads

WARNING

INTRODUCTION
When towing a load:
• Always use a shackle.
• Keep wire ropes parallel to the ground and aligned with the track frames.
• Move the machine slowly and avoid imposing sudden loads on the wire ropes.
Failure to observe and follow this warning could result in death or serious injury.

SAFETY
The track frame has eyes (a) which can be use
when towing light objects.
NOTE: The maximum permissible towing force is

FUNCTION
40,466 lbf (180 kN).

SYSTEM
OPERATION
Fig. 6-2
a

MAINTENACE
SPECIFICATIONS TROUBLESHOOTING
EQUIPMENT
OPTIONAL

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Troubleshooting SY215 Excavator

PURGE THE FUEL SYSTEM

If the fuel system runs dry and air has entered the system, the air must be purged from the fuel system.
Perform the following steps to purge the fuel system.
1. Fill the fuel tank.
NOTE: See “Refuel” on page 2-19 and “Fuel” on page 5-14.
2. Open the right rear access panel to access the primary fuel filter (a).
3. Ensure that the drain (b) at the bottom of the
filter is closed.
4. Twist the black handle (c) at the top of the filter
counterclockwise until it pops out. a
5. Pull the handle out as far as it will go.
6. Push the handle back in. b
NOTE: Repeat steps 5 and 6 several times to pump
fuel back into the system until resistance is felt.
7. Push the handle in fully and twist it clockwise to
lock it in place.
8. Start the machine normally. Fig. 6-3

NOTE: See “Engine Start Procedure” on page 4-17.

If the engine does not start, repeat the process up
to three times. If it still does not start, contact your
Sany dealer.

Fig. 6-4

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SY215 Excavator Troubleshooting

CONTENTS
TABLEOF
JUMP-START THE ENGINE

WARNING

INTRODUCTION
When working with any open electrical power circuit, ensure that your hands are free
of any metal objects (rings, watches, jewelry, etc.) that could come in contact with
electrical power points. Failure to observe and follow this warning could result in death or
serious injury.

CAUTION

SAFETY
Before proceeding with any battery maintenance procedure, remember and follow
these points:
• Battery gases are explosive. Never smoke around batteries or expose them to sparks
or open flames.

FUNCTION
SYSTEM
• Wear personal protective equipment when working with batteries.
• Work in a well-ventilated area.
• If battery acid contacts your skin or your eyes, flush the area immediately with fresh
water and seek medical attention.
Failure to observe and follow this caution could result in minor or moderate injury.

OPERATION
NOTICE
The starting system voltage and the battery voltage in the boosting machine should

MAINTENACE
be no more than 24VDC. Never use a welder or equipment with a higher voltage system
to jump-start the machine. Using a higher voltage to jump-start the engine may
damage the electrical system or cause an unexpected explosion or fire. Always jump-
start the engine with equal voltages.
The jumper cables and their clamps must be undamaged, have no corrosion and be suit-

SPECIFICATIONS TROUBLESHOOTING
able for the battery amperage. All clamps must be securely attached to their jumper cable
ends.
Place the hydraulic lockout control lever in the CLOSE position. If using another machine
to jump-start the engine, make sure the hydraulic control lever on this machine is in the
CLOSE position.
Set all controls to their neutral positions.
Be careful when disconnecting jumper cables after both engines are running. Never allow
the jumper cable clamps to touch each other.
Failure to observe and follow this notice could result in damage to the machine or cause
the machine to operate improperly.
EQUIPMENT
OPTIONAL

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Troubleshooting SY215 Excavator

1. Ensure that the ignition switches of both machines are in the OFF position.
NOTE: See “Right Control Console” on page 3-11 for the ignition switch location.
2. Clamp one end of a jumper cable to the positive red terminal (+) of the drained battery (a).

b a

Fig. 6-5 Charged battery Drained battery

3. Clamp the other end of the same jumper cable to the positive red terminal (+) of the charged battery (b).
4. Clamp one end of a second jumper cable to the ground black terminal (-) of the charged battery (c).
5. Clamp the other end of the second jumper cable to the engine cylinder block of the machine with the
drained battery.

NOTICE
Ensure that all jumper cables are clamped to their connections securely. Failure to
observe and follow this notice can result in damage to the machine or cause the machine
to operate improperly.

6. Start the engine of the machine with the charged battery and run it at a medium speed.
NOTE: See “Engine Start Procedure” on page 4-17.
7. Attempt to start the engine of the machine with the drained battery. Retry after 3 minutes if the engine
will not start.
NOTE: Contact your Sany dealer if the engine will not start after two attempts.
8. Disconnect the jumper cables from the machine that had the drained battery in reverse order as shown
above.
Then disconnect the cables from the machine with the charged battery in the same way

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SY215 Excavator Troubleshooting

CONTENTS
TABLEOF
FUSES
The fuse box (a) is located in the cab behind the operator’s
seat.

INTRODUCTION
NOTE: See “Fuses” on page 3-17 for specific fuse
locations and functions.

a
NOTICE

SAFETY
A fuse should be replaced if it is
corroded,produces white powder or
bcomes loose in the fuse panel.
Before replacing a fuse, make sure that

FUNCTION
the ignition switch is in the OFF position

SYSTEM
and the battery is disconnected.
Always replace a fuse with one of the
same capacity. Never replace a fuse with
one of a higher capacity.

OPERATION
Failure to observe and follow this notice
can result in damage to the machine or
cause the machine to operate improperly.
Fig. 6-6

MAINTENACE
SPECIFICATIONS TROUBLESHOOTING
EQUIPMENT
OPTIONAL

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Troubleshooting SY215 Excavator

FAILURE CODES
Numerical failure codes (a), if any, appear on the
Main Operator screen of the Combined Instruments
Display.
NOTE: See “Failure Codes Screens” on page 3-38.
a

Fig. 6-7

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SY215 Excavator Specification

CONTENTS
TABLEOF
INTRODUCTION
Specifications

SAFETY
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

FUNCTION
SYSTEM
Operating Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Lift Chart - Long Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Lift Chart - Super Long Reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

OPERATION
MAINTENACE
TROUBLESHOOTING
SPECIFICATIONS

WARNING
EQUIPMENT
OPTIONAL

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

Safety, Operation & Maintenance Manual - January 8 2016 7-1

Specifications SY215 Excavator

MACHINE DIMENSIONS

Fig. 7-1

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SY215 Excavator Specifications

CONTENTS
TABLEOF
MACHINE DIMENSIONS

Super Long Reach

Dimensions Standard Long Arm

INTRODUCTION
Option

Weight (Transport) 50,487 lb. (21,900 kg) Not available Not available

Operating Weight 51,193 lb. (23,000 kg) Not available 53, 242 lb. (24,150 kg)

SAFETY
A. Transport Length 31 ft. 9 in. (9.68 m) Not available 40 ft. 6 in. (12.357 m)

B. Transport Width 9 ft. 9 in. (2.98 m) 10 ft. 5 in. (3.18 m) 10 ft. 5 in. (3.18 m)

FUNCTION
SYSTEM
C. Transport Height 11 ft. 3 in. (3.44 m) 11 ft. 1 in. (3.37 m) 10 ft. 8 in. (3.27 m)

OPERATION
D. Upper Width 9 ft. 5 in. (2.87 m) 8 ft. 11 in. (2.71 m) 9 ft. 1 in. (2.79 m)

E. Cab Height 10 ft. (3.05 m) 10 ft. (3.05 m) 10 ft. 1 in. (3.075 m)

F. Track Shoe Width

MAINTENACE
2 ft. (0.6 m) 2 ft. 7 in. (0.8 m) 2 ft. 7 in. (0.8 m)
(Standard)

G. Track Gauge 7 ft. 10 in. (2.38 m) 7 ft. 10 in. (2.38 m) 7 ft. 10 in. (2.38 m)

TROUBLESHOOTING
H. Minimum Ground
1 ft. 5 in. (0.44 m) 1 ft. 7 in. (0.482 m) 1 ft. 6 in. (0.470 m)
Clearance

I. Tail Swing Radius 9 ft. 6 in. (2.89 m) 9 ft. 6 in. (2.89 m) 9 ft. 6 in. (2.89 m)

J. Length Center Idler to

SPECIFICATIONS

Center 11 ft. 3 in. (3.44 m) 11 ft. 11 in. (3.64 m) 11 ft. 11 in. (3.64 m)
Sprocket

K. Track Length 14 ft. (4.25 m) 14 ft. 7 in. (4.45 m) 14 ft. 7 in. (4.45 m)

Boom Length 18 ft. 8 in. (5.7 m) 18 ft. 8 in. (5.7 m) 27 ft. 10 in.(8.5 m)
EQUIPMENT
OPTIONAL

Arm Length 9 ft. 7 in. (2.93 m) Not available 19 ft. 9 in. (6.02 m)

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Specifications SY215 Excavator

Fig. 7-2

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SY215 Excavator Specifications

CONTENTS
TABLEOF
OPERATING RANGES

Super Long Reach

Dimensions Standard Long Arm

INTRODUCTION
Option

A. Maximum Digging
31 ft. 6 in. (9.6m) Not available 37 ft. (11.27 m)
Height

B. Maximum Dumping

SAFETY
22 ft. (6.73m) Not available 30 ft. 3 in. (9.27 m)
Height

C. Maximum Digging
21 ft. 8 in. (6.6 m) Not available 39 ft. 3 in. (11.97 m)
Depth

FUNCTION
SYSTEM
D. Maximum Vertical Wall
12 ft. 5 in. (6.22 m) Not available 49 ft. 3 in. (15.03 m)
Digging Depth

OPERATION
E. Maximum Digging
33 ft. 9 in. (10.28 m) Not available 39 ft. 3 in. (11.97 m)
Reach

MAINTENACE
F. Minimum Swing Radius 12 ft. 2 in. (3.73 m) 12 ft. 2 in. (3.73 m) 12 ft. 2 in. (3.73 m)

G. Maximum Height at

TROUBLESHOOTING
Minimum Swing 25 ft. 2 in. (7.68 m) Not available 31 ft. 6 in. (9.62 m)
Radius

SPECIFICATIONS
EQUIPMENT
OPTIONAL

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Specifications SY215 Excavator

LIFT CHART - STANDARD ARM (CONTINUED)

Fig. 7-3

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SY215 Excavator Specifications

CONTENTS
TABLEOF
LIFT CHART - SUPER LONG REACH

NOT AVAILABLE AT TIME OF PUBLICATION

INTRODUCTION
SAFETY
FUNCTION
SYSTEM
OPERATION
MAINTENACE
TROUBLESHOOTING
SPECIFICATIONS
EQUIPMENT
OPTIONAL

Fig. 7-5

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Specifications SY215 Excavator

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SY215 Excavator Optional Equipment

CONTENTS
TABLEOF
INTRODUCTION
Optional Equipment

SAFETY
Optional Equipment Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Optional Equipment Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

FUNCTION
SYSTEM
Read Equipment Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Removal and Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Optional Equipment Operation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

OPERATION
Optional Equipment System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Component Location and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Stop Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

MAINTENACE
Combined Instrument Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Optional Equipment Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Attach Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

TROUBLESHOOTING
Optional Equipment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Breaker Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Shear Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Disconnect Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
SPECIFICATIONS

WARNING
EQUIPMENT
OPTIONAL

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

Safety, Operation & Maintenance Manual - January 8 2016 8-1

Optional Equipment SY215 Excavator

OPTIONAL EQUIPMENT SAFETY

NOTICE
The following precautions must be strictly observed when selecting, installing and operat-
ing optional equipment. Failure to observe and follow this notice can cause damage
to the machine or cause the machine to operate improperly.
NOTE: See “Optional Attachment Use” on page 2-45.

Optional Equipment Selection

Consult your Sany dealer before installing any optional equipment on your machine. Depending on the
type of optional equipment selected, protective structures (such as front guards or top guards) may need to
be installed on the machine.
Only install Sany-approved optional equipment. Sany assumes no responsibility for accidents, loss or
failures caused by any optional equipment.

Read Equipment Instructions

Read and understand the optional equipment OEM manual before installing and operating any optional
equipment.
Do not exceed the manufacturer’s specifications for maximum flow of optional equipment.
NOTE: See “Shear & Breaker Flow Setup Screens” on page 3-38 for additional information.
If your optional equipment manual is missing or damaged, contact the manufacturer of the
optional equipment to obtain a new one.

Removal and Installation Precautions

When removing or installing optional equipment, observe the following:
• Follow the instructions in this manual and the optional equipment manual.
• Remove and install equipment only on a hard, level surface.
• Use an appropriate lifting device when handling heavy objects weighing more than 55 lb. (25 kg).
• Never stand under a suspended load.
• Ensure your machine is well-balanced and supported whenever you add or remove optional equipment. •
For more information about removal and installation, consult your Sany dealer.

Optional Equipment Operation Precautions

Keep the following procedures in mind when operating any optional equipment:
• Prior to the operation, move your machine to a safe area and test its operation.
• Become aware of how it will move with an optional piece of equipment, the machine’s center of
gravity,and working range. • Ensure the machine is well-balanced and does not lean to one side.
• Maintain a safe distance from all surrounding barriers during machine operations.
• In order to prevent the machine from tipping over, never swing, lower or stop your machine suddenly.• In
order to prevent impact that may cause the machine to tip over, never raise or lower the boom suddenly.
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SY215 Excavator Optional Equipment

CONTENTS
TABLEOF
OPTIONAL EQUIPMENT SYSTEM FUNCTIONS
There is a variety of optional equipment attachments that can be used on this machine. The two most com-
mon attachments, the breaker and the shear, are described in this section.

INTRODUCTION
Component Location and Function
The auxiliary equipment control elements include two stop valves and a selector valve. The two stop valves
are located on the arm and the selector valve is located near the boom base in the center of the machine.
Stop Valves

SAFETY
The stop valves (a) stop or allow flow of the hy-
draulic fluid:

FUNCTION
SYSTEM
OPERATION
• The OPEN position (b) (line parallel to flow) al-
lows flow of the hydraulic fluid. Fig. 8-1 a

MAINTENACE
TROUBLESHOOTING
Fig. 8-2 a b
SPECIFICATIONS

• The CLOSE position (c) (line perpendicular to

flow) stops flow of the hydraulic fluid.
EQUIPMENT
OPTIONAL

NOTE: Switch the valve to the CLOSE position

when removing or installing optional equipment. c
Fig. 8-3 a

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Optional Equipment SY215 Excavator

Selector Valve
The selector valve (a) changes the flow direction
of hydraulic fluid. The change of direction is made
based on the attached equipment.

Fig. 8-4 a

One-Way Hydraulic Attachment Dual-Action Hydraulic Attachment

This setting is used for breaker attachment. This setting is used for the shear attachment.

Fig. 8-5 Fig. 8-6

b c

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CONTENTS
TABLEOF
Combined Instrument Display
The working mode (a) must be applicable to the
installed equipment:
a

INTRODUCTION
• When working with a breaker attached, the work-
ing mode must be set to B.
• When working with a shear attached, the working
mode must be set to S.
There are four different working modes available.

SAFETY
They are:
• S: Standard duty - Used for normal excavating.
• H: Heavy duty - Used for excavating in hard or
rocky ground.

FUNCTION
SYSTEM
• L: Light duty - Used for light tasks such as dig-
ging in soft soil.
• B: Breaker mode - Used when operating with
attachments such as a jackhammer.

OPERATION
NOTE: See “Main Operator Screen” on page 3-19.
Fig. 8-7
NOTE: See “Shear & Breaker Flow Setup Screens”
on page 3-32.

MAINTENACE
TROUBLESHOOTING
SPECIFICATIONS
EQUIPMENT
OPTIONAL

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Optional Equipment SY215 Excavator

OPTIONAL EQUIPMENT OPERATION

NOTICE
The breaker and shear attachments can be used only with the standard arm. Do not
attempt to attach either a breaker or a shear to a super long reach. There are no hydraulic
fluid points on the super long reach option for breaker or shear use.

Attach Optional Equipment

1. Lower the work equipment to the ground.

Fig. 8-8

CAUTION
Do not release equipment unless it is on the ground or on a solid supportive surface. Fail-
ure to observe this could result in damage to the equipment and or personal injury.

2. Shut down the engine.

NOTE: See “Engine Shutdown Procedure” on page
4-20.
3. Turn the ignition key to the ON position.
4. Set the hydraulic lockout control lever to the
OPEN position (a).
NOTE: See “Hydraulic Lockout Control Lever” on
page 3-5.
5. Fully cycle each pedal, joystick and control lever
2 - 3 times within 15 seconds in order to release the
internal pressure remaining in the hydraulic lines.

Fig. 8-9
a

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CONTENTS
TABLEOF
6. Place the hydraulic lockout control lever in the
CLOSE position (b).
NOTE: See “Hydraulic Lockout Control Lever” on
page 3-5.

INTRODUCTION
7. Remove the existing equipment.
NOTE: See “Bucket Replacement” on page 4-36.

SAFETY
8. Remove the butterfly nut (c) from the breather Fig. 8-10 b
valve.

FUNCTION
SYSTEM
OPERATION
c

MAINTENACE
Fig. 8-11

TROUBLESHOOTING
9. Press the venting button (d) to relieve the pres-
sure on the hydraulic tank.
10. Reinstall the butterfly nut (c).
SPECIFICATIONS

d
EQUIPMENT
OPTIONAL

Fig. 8-12

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Optional Equipment SY215 Excavator

11. Check the level sight glass (e) mounted on the

side of hydraulic tank.
NOTE: The fluid should be allowed to cool to a
safe temperature.
NOTE: See “Hydraulic Fluid Tank” on page 5-35.

12. Set both stop valves (f) to the CLOSE position

(line perpendicular to flow).
NOTE: See “Stop Valves” on page 8-3.
Fig. 8-13
13. Use a wrench to loosen the screw cap (g) at the
end of one of the stop valves.
g
14. Place a container under the stop valve to catch
any hydraulic fluids.
15. Remove the screw cap (g) from the end of the
stop valve allowing any residual hydraulic fluids to
drain into the container.

Fig. 8-14 f

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SY215 Excavator Optional Equipment

CONTENTS
TABLEOF
NOTE: See “High-Pressure Fluid Lines” on page 2-20.

NOTICE
Dispose of the drained oil in accordance with local environmental regulations. Failure to

INTRODUCTION
do so could result in damage to the environment.

16. Repeat steps 13 through 15 for the other stop

valve.

SAFETY
17. Connect the optional equipment lines in accor-
dance with the manufacturer’s instructions.
NOTE: Connection sizes may vary according to
different optional equipment manufacturers.

FUNCTION
SYSTEM
18. Set the stop valves to the OPEN position (f).
NOTE: See “Stop Valves” on page 8-3. Fig. 8-15 f
19. Set the selector valve to the proper position.
NOTE: See “Selector Valve” on page 8-4.

OPERATION
20. Set the Combined Instrument Display to the
correct working mode (B for breaker operations or
S for shearoperations).
NOTE: See “Combined Instrument Display” on

MAINTENACE
page 8-5.
NOTE: Contact your Sany dealer for additional
information if necessary.

TROUBLESHOOTING
Optional Equipment Controls

WARNING
Do not touch the joystick control buttons when you are not operating the attach-
ments. Accidental operation of an attachment could result in death or serious injury.
SPECIFICATIONS

The control switch and buttons on top of the left

joystick (a) and right joystick (b) are used to
control attachment operation.
a
NOTE: See on page “Machine Decals” on page
2-23.
EQUIPMENT
OPTIONAL

Fig. 8-16 b
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Optional Equipment SY215 Excavator

Breaker Control
The attachment control rocker switch (a) on the
right joystick is used to control the breaker. Press
the upper part of this switch to operate the breaker.
Release this switch to stop the breaker. a

Shear Control
Press the upper part of switch (a) on the right joy-
stick to open the shear and press the lower part to
close the shear.

Fig. 8-17

Buttons (b) and (c) on the left joystick are used to

swing the shear attachment. b

Press button (b) to swing the shear to the left; press

button(c) to swing the shear to the right.
c

Fig. 8-18

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CONTENTS
TABLEOF
Disconnect Optional Equipment
1. Lower the work equipment to the ground.

INTRODUCTION
2. Shut down the engine.
3. Turn the ignition key to the ON position.
4. Set the hydraulic lockout control lever to the Fig. 8-19
OPEN position (a).
5. Fully cycle each pedal, joystick and control lever

SAFETY
2 - 3 times within 15 seconds in order to release the
internal pressure remaining in the hydraulic lines.

FUNCTION
SYSTEM
OPERATION
Fig. 8-20

MAINTENACE
a

6. Set the hydraulic lockout lever to the CLOSE

position (b).

TROUBLESHOOTING
SPECIFICATIONS

b
Fig. 8-21
EQUIPMENT
OPTIONAL

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Optional Equipment SY215 Excavator

7. Remove the butterfly nut (c) from the breather

valve.

Fig. 8-22

8. Press the venting button (d) to relieve the pres-

sure on the hydraulic tank.
9. Reinstall the butterfly nut (c).

Fig. 8-23

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CONTENTS
TABLEOF
10. Check the level/temperature sight glass (e)
mounted on the side of hydraulic tank.
NOTE: The fluid should be allowed to cool to a
safe temperature.

INTRODUCTION
NOTE: See “Hydraulic Fluid Tank” on page 5-35.

SAFETY
FUNCTION
SYSTEM
e

OPERATION
11. Set both stop valves (f) to the CLOSE position
(line perpendicular to flow).

MAINTENACE
12. Place a suitably sized container under the hoses
where they connect to the machine.
13. Disconnect the hoses from the side of the ma-

TROUBLESHOOTING
chine. Fig. 8-24
NOTE: See “High-Pressure Fluid Lines” on page
2-20. g
14. Install the screw caps (g) to the two outlets on
the stop valves (f).
SPECIFICATIONS

15. Remove the attachment in accordance with the

manufacturer’s instructions.
NOTE: See “Optional Equipment Safety” on page
8-2.
NOTE: Contact your Sany dealer for additional
information if necessary.
EQUIPMENT
OPTIONAL

Fig. 8-25 f

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Optional Equipment SY215 Excavator

SUPER LONG REACH OPTION

Safety

NOTICE
The following precautions must be strictly observed when operating a super long
reach.Failure to observe and follow these precautions can cause damage to the machine
or cause the machine to operate improperly.
The Super Long Reach Option is configured for bucket use only. Shear and breaker attachments cannot be
used on machines equipped with a super long reach.
Keep the following procedures in mind when operating a machine equipped with a super long reach:
• Prior to operation, move your machine to a safe area and test its operation.
• Become aware of how it will move with a super long reach, the machine’s center of gravity, and working
range.
• Ensure the machine is well-balanced and does not lean to one side.
• Maintain a safe distance from all surrounding barriers during machine operations.
• In order to prevent the machine from tipping over, never swing, lower the work equipment or stop your
machine suddenly.
• In order to prevent impact that may cause the machine to tip over, never raise or lower the boom suddenly.

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SY215 Excavator Optional Equipment

CONTENTS
TABLEOF
Combined Instrument Display -
Super Long Reach
There are only three different working modes

INTRODUCTION
which can be used with a super long reach:
a
• S: Standard duty - Used for normal excavating.
• H: Heavy duty - Used for excavating in hard or
rocky ground.
• L: Light duty - Used for light tasks such as dig-

SAFETY
ging in soft soil.
NOTE: See “Main Operator Screen” on page 3-30.

FUNCTION
SYSTEM
b

OPERATION
Fig. 8-26

MAINTENACE
TROUBLESHOOTING
SPECIFICATIONS
EQUIPMENT
OPTIONAL

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Optional Equipment SY215 Excavator

Bucket

Attach the Bucket

NOTE: See “Bucket Replacement” on page 4-36 for more information.

Disconnect the Bucket

WARNING
Do not touch the joystick control buttons when you are not operating the bucket.
Accidental operation of the bucket could result in death or serious injury.

NOTE: See “Bucket Replacement” on page 4-36 for more information.

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