SANY Crawler Hydraulic Excavator SY215CLC (CUMMINS QSB6.7 engine). Shop Manual

Introduction

SY215C

1-34

1.7

Type of Bolts

Tighten nuts and bolts properly to specified
torque values. The type and grade of bolts are
illustrated on the right.

Use correct bolts and tighten them properly
when assembling machines or components.

1.8

Tightening Sequence

When two or more bolts are being tightened,
follow the tightening sequence shown on the
right to ensure even tightening.

●

Always use suitable tools for specific
work. Use of improper tools and meth-
ods may cause a hazardous situation.

●

Use tools of correct sizes when loosen-
ing or tightening the nuts or bolts. Oth-
erwise, the tools may slide and cause
personal injury.

ZX215-1000031

Hex bolt

Socket head hex bolt

10.9

12.9

8.8

ZX215-1000032

Cross tightening

Diagonal tightening

Central and diagonal tightening

ZX215-1000033

CAUTION

Introduction

SY215C

1-35

1.9

Maintenance of Half Flanges

1. Clean the sealing surface of the

ange and

check it carefully. Scratches and coarse-
ness cause leaks or abrasion of seals.
Uneven surface may squeeze the seal out.
If these faults are not corrected properly,
parts may have to be replaced.

2. Always use specified O-rings. Check that

the O-rings are not damaged. Do not file
the surface of the O-ring. Apply grease
onto the O-ring to locate it.

3. Tighten the half flanges carefully. Locate

the opening at the center so that it is
perpendicular to the oil opening. Tighten
the bolt manually to maintain the location
of the components.

1.9.1 Table of tightening torques for half fl ange bolts

Thread diameter of bolt

Width across fl ats

Tightening torque

kgm

10
12
16

14
17
22

59~74

98~123

235~285

6.0~7.5

10.0~12.5
23.5~29.5

ZX215-1000034

ZX215-1000035

Improper

★

Unless speci

ed otherwise, tighten the half

ange bolts to the torques below.

Introduction

SY215C

1-36

1.10

Conversion Table

1.10.1 Method of using conversion table

The conversion table in this section is provided to enable simple conversion of

gures. For details

of the method of using the conversion table, see the example given below.

Example:

Method of using the conversion table to convert from millimeters to inches

1. Convert 55 mm into inches

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw

a horizontal line from (A).

2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular

line down from (B).

3) Take the point where the two lines cross as (C). This point (C) gives the value when con-

verting from millimeters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point

one place to the left) to convert it to 55 mm.

2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.

3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the

decimal point one place to the right) to return to the original value. This gives 550 mm =
21.65 inches.

Introduction

SY215C

1-41

1.10.2 Temperature

Fahrenheit-Centigrade conversion: A simple
way to convert a Fahrenheit temperature read-
ing into a Centigrade temperature reading or
vice versa is to enter the accompanying table
in the center (boldface column) of figures.
These

gures refer to the temperature in either

Fahrenheit or Centigrade degrees.

If it is desired to convert from Fahrenheit to
Centigrade degrees, consider the center col-
umn to be a table of Fahrenheit temperatures
and read the corresponding Centigrade tem-
perature in the column at the left.

If it is desired to convert from Centigrade to
Fahrenheit degrees, consider the center col-
umn to be a table of Centigrade values, and
read the corresponding Fahrenheit tempera-
ture on the right.

Shop Safety

SY215C

2-1

2 Shop Safety

2.1 Hazard Alert Information .......................................................................................... 2-3

2.2 General Shop Safety ............................................................................................... 2-6

Shop Safety

SY215C

2-3

2 SHOP SAFETY

2.1

Hazard Alert Information

DANGER

WARNING

CAUTION

Most accidents are usually caused by the fail-
ure to follow fundamental repair procedures
and safety rules for the system under repair.
To avoid accidents it is important to read and
understand all information outlined in this
manual before performing repairs on the ma-
chine system.

The following (ANSI/ISO) signal words are
used to inform you that there is a potentially
hazardous situation that may lead to damage,
personal injury or even death. In this manual,
on the machine, part or component decals and
different signal words are used to express the
potential level of a hazard.

NOTICE

Indicates an imminent hazard which WILL
result in serious injury or death if message
is ignored.

Indicates a potentially hazardous situation
which COULD result in serious injury or
death if message is ignored.

Indicates a potentially hazardous situation
which COULD RESULT IN MINOR OR MA-
JOR INJURY if message is ignored.

Indicates THE MACHINE MAY BE DAM-
AGED if improperly operated or main-
tained.

Shop Safety

SY215C

2-4

SANY cannot predict every circumstance that
might involve a potential hazard in a repair of
the machine. Therefore the safety message in
this manual and on the machine may not in-
clude all possible safety precautions.

If any procedures or actions not speci

ed, rec-

ommended or allowed in this manual are used,
you must be sure that you and others can
perform such procedures and actions safely
and without damaging the machine. If you are
unsure about the safety of some procedures,
contact your SANY representative.

This is to alert the user of a hazard. It is
usually used in a graphic.

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

Shop Safety

SY215C

2-5

WARNING

●

Improper repair procedures on this ma-
chine can be hazardous and could re-
sult in serious injury or even death.

●

All personnel involved with the repair
of this machine must read this manual
thoroughly before performing any pro-
cedures on this equipment.

●

Some actions involved in the operation
or repair of this machine could cause
a serious accident if they are not per-
formed in the manner described in this
manual.

●

All precautions outlined in this manual
apply only to intended repair proce-
dures of the machine or system. If you
perform any repairs not specifi cally pro-
hibited, you must be sure that it is safe
for you and others. In no event should
you or others engage in prohibited uses
or actions as described in this manual.

●

SANY delivers machines that comply
with all applicable regulations and
standards of the country to which the
machines have been shipped. If this
machine has been 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 product complies with the appli-
cable standards and regulations of your
country, contact your SANY representa-
tive before performing repairs on this
machine.

Shop Safety

SY215C

2-6

2.2 General Shop Safety

It's important to establish good shop safety
rules for everyone who enters or uses the
shop area. Implementing shop safety rules
will keep employees safe and provide the
most productive environment for working or
learning. Post rules where they can clearly be
viewed at all times. If necessary, provide shop
personnel with a written copy of the rules and
discuss any questions or confusion with them.

Always keep in mind, shop safety is NOT
something to be studied at the start of a proj-
ect and then forgotten; most accidents are
caused by carelessness, being in a hurry or by
simply disreguarding safety rules. Remember
this, if you are DILIGENT and follow instruc-
tions outlined in this shop manual with care,
repair operations can be safe and enjoyable.
Safe work practices, should become a force of
habit.

WARNING

Mistakes in operation are extremely haz-
ardous. Read the Safety, Operation &
Maintenance Manual that came with the
machine carefully before operating the
machine. Failure to follow this alert could
result in serious injury or death.

Shop Safety

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2-7

2.2.1 Rules and shop behavior

●

Study all shop rules relating to the proce-
dure carefully and constantly apply them.
When in doubt about any task, get help!
DO NOT take chances.

●

Know your job. It is foolish, and often di-
sastrous, to make repairs to a machine
without first receiving proper instructions.
Always use the shop manual when per-
forming any repair tasks. Get additional
help if you are NOT sure what must be
done or how a task should be performed.

●

The shop is a place to work, not play. It is
NOT a place for “horseplay”. A “joker” in a
repair shop is a “walking hazard” to every-
one. Daydreaming or socializing on the job
also increases your chances of injury.

●

If you must smoke, smoke only in the area
provided for smoking. Never smoke while
on the shop

oor or work area.

2.2.2 Housekeeping

●

Oils, grease, fuel, antifreeze or any fluid
spills should be mopped up immediately.
These items pose a serious slip hazard.
Regardless of who was responsible for the
spill, it is your job as a shop employee to
secure and clean up the spill area.

●

Keep the shop clean. Scrap or old parts
should be disposed of properly. Never al-
low them to remain on the bench or shop

oor.

●

All equipment and tools must be put back
in their proper storage areas after each
use. It's imperative that you do not let a
shop become cluttered and disorganized in
order to prevent accidents.

●

Always keep in mind, proper house clean-
ing is vital for a safe and pleasant work en-
vironment.

Shop Safety

SY215C

2-8

2.2.3 Shop Liquids Storage

●

Liquids, cleaning solvents or machine flu-
ids should be properly stored in an area
away from work locations. These storage
areas should be ventilated to an outdoor
location to avoid any vapor accumulation
in a con

ned shop area. Follow all OSHA

regulations regarding

uid storage.

●

Never leave open containers of liquids sit-
ting around. These could spill or catch

re.

Always read the container label for infor-
mation on storage and handling of the liq-
uids.

●

Never store liquids in containers that are
not properly labeled for that liquid. Confu-
sion could result in equipment damage,

or an unexpected explosion.

●

Never smoke or bring open

ames around

liquids, doing so could result in an unex-
pected

re or explosion.

●

Never handle liquids without using person-
al protective equipment. Treat all liquids
with caution.

2.2.4 Cleaning Parts

Never use gasoline, diesel fuel or similar

am-

mable liquids to clean parts. Always use ap-
proved non-

ammable solvents to clean parts.

Failure to do so could result in explosion or

re.

Shop Safety

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2-9

2.2.5 Jacking Up the Machine

●

If you will be working under the machine
always use approved jack stands that will
support the weight of the machine you are
working on.

●

Never rely on the hydraulics of the ma-
chine or a hydraulic jack to support the
machine during repairs.

●

Always lower the work equipment to the
ground and check the stability of the ma-
chine before going under the machine.

2.2.6 Electrical Dangers

●

When testing electrical circuits, always be
aware of what you will be checking in these
systems. High voltage or high amp circuits
could damage your equipment or cause a
spark, explosion or possible

re.

●

Before performing any repairs or testing on
an electrical system be sure of the system
voltage dangers. Always check the circuit
to be sure it is off before performing any
repairs.

●

When working around

ammable liquids or

explosive systems, use only approved anti-
explosion proof work lamps. Non-approved
work lamps can cause an explosion or

re.

Shop Safety

SY215C

2-10

2.2.7 Removing Attachments

●

If you will be removing large heavy attach-
ments from the machine, always be sure to
use the correct lifting equipment rated for
the capacity of the load you will be lifting.

●

After the attachment or part has been
removed, store it where it cannot fall or
move. Always be sure what you are stor-
ing is sitting stable on a stable surface and
clear of all walkways or

re exits.

2.2.8 Cleaning the Machine

●

Always use high-pressure hot water and
mild, nonflammable grease-cutting soaps
or cleaning agents to clean the machine
parts. Never use flammable or caustic
cleaning agents.

●

Never use high-pressure steam cleaners
to clean the machine. Steam cleaners will
damage the paint, hoses or electrical sys-
tem.

●

Never pressure-wash or

ood the inside of

an operator cab. This will damage sensi-
tive electrical components.

Shop Safety

SY215C

2-11

2.2.9 Using the Correct Tools

●

Always use the proper authorized tools for
the job. Using tools that are not authorized,
incorrect for the job, defective or damaged
could cause serious injury.

●

Keep all tools in good condition, learn the
correct way to use them.

●

Before starting the work, thoroughly check
the tools, machine, forklift, crane, service
car, etc.

●

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.

●

Always put shop tools back in there proper
storage location when

nished.

●

If welding repairs are needed, always have
a trained, experienced or certified welder
carry out the work.

2.2.10 Hoisting a Load

If you will be lifting parts or components that
weigh more than 35 lbs (16 kg), it is important
to follow some basic rules.

●

Always use the appropriate lifting equip-
ment such as hoist, crane, forklift etc. to
handle a loads if possible.

●

Be sure the lifting equipment is in good
condition and rated for the load you are
about to lift.

●

If straps are to be used, ensure they are in
good condition and rated for the load to be
lifted with them.

●

If you must lift the load by hand, keep your
back straight and parallel with the load,
and lift the load using your leg muscles to
avoid back injuries. Always ask for a lifting
assistant.

Shop Safety

SY215C

2-12

2.2.11 Appropriate Working Apparel

Improper or loose clothing, casual dress cloth-
ing, jewelry, incorrect shoes or long hair can
result in possible injury.

Make a list of the types of clothing that are not
allowed in the shop area. Go over the list with
personnel before they start a job.

2.2.12 Safety Partners

No one should be allowed to perform work
operations in any shop alone. It should be a
general shop safety rule for a minimum of two
people in the shop area at all times when work
procedures are performed. A person alone in
the shop might not be able to get emergency
help in the event of a shop accident.

When working together always maintain clear
contact with each other at all times to avoid
the occurrence of unexpected incidents.

When carrying out any operation with two or
more workers, always agree on the operating
procedures and signals before starting.

Shop Safety

SY215C

2-13

2.2.13 Two people when engine run-

ning

In order to prevent injury, do not perform the
service while the engine is running. If the ser-
vice must be performed while the engine is
running, operate only when two people are on
the spot and follow the regulations below:

●

Always have one operator sit on the op-
eration seat and be ready to turn off the
engine at any time. All the operators must
keep in touch with each other.

●

Set the safety lock control lever to the lock
position.

●

Do not touch any control lever. If some
control lever must be operated, send signal
to other people and warn them to transfer
to safe place quickly.

●

Do not drop or insert the tools and other
objects into the fan or fan belt, or the parts
will be broken or thrown out.

2.2.14 Driving Pins

When using a hammer to drive pins, metal
particles may

y off. This may lead to serious

eye injuries. Always do the following:

●

Always wear a face shield or goggles when
striking a metal object with a metal ham-
mer.

●

Before performing any of these proce-
dures, be sure all personnel are clear of
your work area.

●

If possible, avoid using a steel hammer to
drive a component or pins in place. Dam-
age to the component may result. Always
use a soft or non-ferrous hammer to drive
a component or a pin.

SANY Crawler Hydraulic Excavator SY215CLC (CUMMINS QSB6.7 engine). Shop Manual - page 4