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

Operation

4.17.3 After storage

Note:

If your machine has been stored for a long pe-

riod but no rusting prevention had been made

each month, please contact Sany distributor

before operating your machine again.

Before using your machine again after a long-

term storage, perform as described below:

● Wipe off the grease from the piston rod of

hydraulic cylinder.

● Apply lubricant or grease to all necessary

locations.

● The moisture of air can mix with oils when

your machine has been stored for a long

time. Check the oils before and after start-

ing the engine. If the oil contains water, re-

move the water timely.

4.17.4 Starting the engine after long-

term storage

Before starting a machine that has been

stored for a long period of time, it is important

to fully warm up the engine.

For more information see “Warm-up opera-

tion” on page 4-26.

4-56

Operation

4.18 Transportation Information

Related laws and regulations must be ob-

served when transporting the machine. Safety

must be ensured.

4.18.1 Transport methods

● Choose a method that is suitable for the

weight and dimension provided in the

section“Specification”.

● The weight and dimension provided in

"Specification" can vary due to different

type of track shoe, arm or other additional

equipment.

● For transport of the machine installed with

cab protection housing, please contact

Sany distributor for more information.

4.18.2 Loading/unloading machine to/

from a trailer

The following instruction must be followed

when loading/unloading the machine.

● Choose a hard, level ground to load and

unload your machine. Keep a safe dis-

tance to sides of road.

● Auto idle must be switched off. If the auto

idle switch is activated, the machine may

move suddenly.

● The travel speed must be set to low (Lo).

Run the engine at idle speed and operate

CZ335-1103227

your machine slowly when loading or un-

Fig.

4-97

● In a cold region, it is important to fully pre-

heat your machine and ensure a stable

rpm of the engine before loading or un-

● Never reposition your machine on the ac-

cess ramp, which may otherwise cause

your machine to tip over. If necessary, re-

position your machine on a level ground or

4-57

Operation

on the trailer.

●

It is dangerous to load or unload your ma-

chine with the work equipment. The use of

an access ramp is necessary.

●

On an access ramp, never maneuver any

other control lever except the travel control

lever.

CZ335-1103228

●

At the junction of the access ramp and

trailer, the machine's center of gravity may

Fig. 4-98

change suddenly and it is possible to loose

balance. Drive slowly when passing the

junction.

●

If you have to swing the work equipment

on the trailer, be extra careful with your

machine, which may tip over due to insta-

ble base.

If the work equipment has been installed

on the machine, it must be retracted slowly

to avoid the machine loosing balance.

●

Considering operating safety, a signal man

shall be assigned to alert preventing the

machine from falling off the ramp.

The following items must be carefully ob-

served:

● Use an access ramp with enough width,

length, thickness and strength. Ramp

grade shall not exceed 15°.

● When piling the earth to build a platform,

the platform must be fully compacted to

prevent landslide.

● To prevent the machine from skidding

on the ramp, clean its track shoes and

the ramp before loading and unloading.

The machine has the danger to skid when

the access ramp is contaminated with wa-

ter, snow, grease or ice.

4-58

Operation

4.18.2.1 Loading the machine

1. The machine shall only be loaded and

unloaded on a hard, level ground.

It is necessary to keep a safe distance to

roadside.

2. Choke the trailer and put blocks under its

wheels to prevent its moving.

Use two access ramps (2) and place them

at the left and right sides respectively. The

two ramps shall parallel each other and

have equal distance to trailer centerline (3).

Ramp grade (4) shall not exceed 15°. If the

ramps bend too much under the weight of

machine, supports must be placed under

the ramps to prevent their bending.

CZ335-1103229

Fig. 4-99

Set the travel speed selector switch to low

speed (Lo).

●

Press travel speed button

(6) to change

travel speed (Lo, Hi), which will be dis-

Sany Hydraulic Excavator

played at (5) on the display screen.

Press button (8) to turn off auto decelera-

tion. Use the fuel control dial to set engine

speed to low idle.

●

When machine is running in auto idle

09/03/05

0000h 00m

12:25:31

mode, the screen displays

at (7).

●

Press the button (8) again to cancel auto

idle. The screen will display

at (5).

ESC

Enter

●

Auto idle is the default mode after the ma-

chine is started. Press the button (8) to

toggle between auto-idle and non auto-idle

CZ135-1103006

→

Fig. 4-100

4-59

Operation

5. If the machine is installed with work equip-

ment, the work equipment must be placed

in front of the machine. Move the machine

straight forward up the ramp. Without the

90°-110°

work equipment, reverse the machine up

the ramp.

Lower the bucket on the trailer to sup-

CZ335-1103231

port the machine immediately after getting

aboard.

Fig. 4-101

Instruction and signals from a commander

must be followed, in especially reverse

travel.

6. Align your machine with the ramp before

driving up the ramp. The centerline of ma-

chine shall match the centerline of trailer.

Align your machine with the ramp and trav-

el slowly.

Lower the work equipment as low as pos-

CZ335-1103232

sible if it causes no trouble.

Fig. 4-102

On an access ramp, only the travel lever

can be maneuvered. Never maneuver any

other control levers.

7. Drive the machine slowly forward till all

tracks are on the trailer and have full

contact with trailer floor.

8. When the machine passes the rear wheels

of the trailer, the machine could lean

forward. So drive the machine slowly and

carefully in order to avoid impact with the

trailer.

9. Slightly raise the bucket, retract the arm

and maintain it in lower position, and slowly

CZ335-1103233

swing the upper structure by 180°.

Fig. 4-103

4-60

Operation

10. Fully extend the bucket cylinder and arm

cylinder, and slowly lower the boom.

11. Place a wood block under the end of the

bucket cylinder in order to prevent it from

touching the trailer floor, which could result

in damage to the cylinder.

CZ335-1103234

Fig. 4-104

4.18.2.2 Securing the machine

Note:

● Reinstall the rear view mirrors in order to

enable them to be within the sphere of ma-

chine width.

● To prevent damage to the bucket cylinder

during transit, place a wood block under

the top end of the bucket linkage so as to

prevent the bucket cylinder from touching

the trailer floor.

● Check if the engine hood is locked. Seize

the grip of engine hood and lift it slightly.

If it is not open, it indicates that the hood

catch is engaged. If the hood is not locked,

it might be swung open during transit.

Secure the machine to the trailer through the

following steps:

1. Fully extend the bucket cylinder and arm

cylinder, and slowly lower the boom.

CZ335-1103235

Fig. 4-105

4-61

Operation

Place the hydraulic lockout control to the

LOCK position (L).

Stop the engine and remove the key from

the start switch.

Close all doors, windows and covers

properly.

CZ335-1103251

Lock the covers, caps and doors.

Fig. 4-106

Chock the tracks on both ends in order to

prevent the machine from moving during

transportation. Tie down the machine

with chains or wire ropes with sufficient

strength.

It is important to keep the machine in a

proper position in order to ensure that the

machine could not slip to the sides.

CZ335-1103237

Fig. 4-107

4.18.2.3 Rear view mirrors

The rear view mirror is located in the position

shown in the right illustration.

● If the rear view mirror is broken or it is nec-

essary to reinstall the mirror after disas-

sembling for shipping purpose, the follow-

ing procedure must be observed.

● The rear view mirror must be readjusted

after installation. For more information

see“Rear view mirrors” on page 4-17.

CZ335-1103238

Fig. 4-108

4-62

Operation

Removal

1. Loosen bolt (2) and remove the rear view

mirror (1) from the bar (3).

2. Loosen bolt (4) and remove the bar (3) and

the clasp (5).

CZ335-1103239

Fig. 4-109

Installation

1. Install the bar (3) and the clasp (5) to the

handhold, and tighten bolt (4).

2. Install the rear view mirror (1) to the bar (3),

and tighten the bolt (2).

4.18.2.4 Unloading the machine

Load and unload the machine only on

a hard, level ground, and keep a safe

distance from roadside as well.

Apply braking to the trailer and chock the

trailer under its wheels to prevent moving.

CZ335-1103240

Use two access ramps (2) and place them

at the left and right sides respectively. The

Fig.

4-110

two ramps shall parallel each other and

have equal distance to trailer centerline (3).

Ramp grade (4) shall not exceed 15°. If the

ramps bend too much under the weight of

machine, supports must be placed under

the ramps to prevent their bending.

Remove the chains and wire ropes fasten-

ing the machine.

CZ335-1103236

Start the engine and warm it up fully.

Fig.

4-111

Move the hydraulic lockout control to FREE

position (F).

4-63

Operation

Set the travel speed selector switch to low

speed (Lo).

●

Press travel speed button

(6) to change

A B C

travel speed (Lo, Hi), which will be dis-

Sany Hydraulic Excavator

played at (5) on the display screen.

Press button (8) to turn off auto decelera-

tion. Use the fuel control dial to set engine

speed to low idle.

●

When machine is running in auto idle

09/03/05

0000h 00m

12:25:31

mode, the screen displays

at (7).

●

Press the button (8) again to cancel auto

idle. The screen will display

at (5).

ESC

Enter

●

Auto idle is the default mode after the ma-

chine is started. Press the button (8) to

toggle between auto-idle and non auto-idle

CZ135-1103006

→

Fig. 4-112

Raise the work equipment, retract the arm

below the boom, and drive the machine

slowly.

Stop the machine when it comes to the

rear wheels of the trailer and is positioned

horizontally.

CZ335-1103242

Fig. 4-113

Remark:

● Make sure to keep an angle of 90 - 110°

between the arm and the boom when un-

loading the machine.

90°-110°

● The machine could be damaged if it is un-

loaded with retracted arm.

When the machine runs on the access

ramp, never penetrate the bucket into

CZ335-1103243

ground, which could damage the hy-

Fig. 4-114

draulic cylinder.

10. While the machine is on the ramp, it is

4-64

Operation

important to keep an angle of 90 - 110°

between the arm and the boom. Lower

the bucket to the ground and move the

machine slowly.

11. When the machine is going down the

ramp, slowly operate the boom and arm,

CZ335-1103244

and carefully drive the machine off the

ramp.

Fig. 4-115

4.18.3 Lifting the machine or its com-

ponents

WARNING

Using a single rope to lift an object is pos-

sible to cause turning of the load and un-

fastening or slipping of the rope. Serious

accidents could result.

4.18.3.1 Lifting precautions

1. Put wire rope on the middle of hook.

If wire rope is hooked near hook end, the

rope may slide off the hook, causing seri-

100%

88%

79%

71%

41%

ZX215-1000002

ous accident. The middle part of hook is

stronger than the rest parts.

Fig. 4-116

2. Never lift an object when wire rope forms

a bigger sling angle with the hook. If two

or more ropes are used, the load on each

rope increases with sling angle. The fol-

(kg)

19.6

lowing table shows variation of allowable

(2000)

18.6

16.7

(1900)

(1700)

13.7

load kN(kg) with different angles when

19.6

(1400)

(2000)

9.8

two ropes are used to lift a load. If a single

(1000)

4.9

rope is capable of lifting 9.8 kN(1000 kg)

9.8

(500)

(1000)

in vertical position, two ropes will be able

to lift

19.6 kN(1000 kg) perpendicularly.

120

150

However, when the two ropes forms a sling

Lifting angle (°)

ZX215-1000001

angle of 120 degrees, its lifting capacity

becomes 9.8 kN(1000 kg). On the other Fig. 4-117

4-65

Operation

hand, if the sling angle is 150 degrees, to lift a load of 19.6 kN(1000 kg), each rope has to

bear 39.2 kN(1000 kg).

3. Never use a single rope to lift an object. It’s better to bind the object with two or more rope

symmetrically.

4.18.3.2 Choosing a wire rope

Select a suitable wire rope according to the object to be lifted. See the table below.

Wire Rope

(Standard bright wire rope “Z”)

（JISG3525，No.6，6X37-A type）

Wire Rope

Allowable Load

Nominal Diameter

Ton

8.8

0.9

12.7

1.3

17.3

1.7

22.6

2.3

28.6

2.9

35.3

3.6

55.3

5.6

79.6

8.1

141.6

14.4

221.6

22.6

318.3

32.4

Table

4-1

Note:

The allowable load equals to one sixth of the breaking force of wire rope. (Safety factor: 6)

4-66

Operation

4.18.3.3 Lifting the machine

WARNING

● Only eligible, experienced operator with official license (according to local laws) is al-

lowed to operate a crane.

● Never lift the machine when someone is riding on it.

● Nobody shall be allowed to enter the area below or around the lifted machine.

● Make sure that the wire cables used for lifting the machine are strong enough to bear

the weight of machine. Never use damaged or aged wire cable or sling.

● Never lift the machine when its upper structure has swung aside. Before lifting, it is

important to move the work equipment to the final drive end and keep the longitudinal

centerlines of the upper structure and the lower structure parallel.

● Before lifting, the lockout control must be put to "locked" position in order to prevent

unexpected movement of the machine.

● Keep the machine parallel to the ground during lifting.

● Never lift the machine at fast speed, which may otherwise overload the wire cables or

slings and result in rupture.

Besides the attitudes recommended in the following procedure, never use any other at-

titudes to lift the machine. Never use the type of lifting equipment other than the ones

specified in the following procedure. Otherwise it may have the danger to loose balance.

Note:

The lifting procedure is applicable to machines of standard dimension.

The lifting methods may vary according to actual additional and optional components installed.

Contact Sany distributor for suitable lifting methods.

For more information on the weight of machine see the section "Specification".

When lifting the machine, operate on a level ground according to the following steps.

4-67

Operation

Machine of standard dimension

Start the engine and swing the upper

structure in order to position the work

equipment at the side of the sprocket (1).

Fully extend the bucket cylinder and the

arm cylinder, and use the boom cylinder to

lower the work equipment to the ground,

CZ335-1103245

as shown in the right illustration.

Fig. 4-118

Move the hydraulic lockout control to

"locked" position (L).

Shut off the engine. Check the surrounding

of the cab before leaving the machine.

Close the cab door and windows properly.

CZ335-1103251

Fig. 4-119

Run a wire rope between the first two track

rollers and between the last two track

rollers. For machines installed with roller

guard, the ropes shall go through under

the tracks.

Adjust the wire rope lifting angle (A) to 30 -

40°, and lift the machine slowly.

When the machine is above the ground,

make sure that the hook condition and

the lifting condition are normal, and lift the

machine slowly.

CZ335-1103246

Fig. 4-120

4-68

Maintenance

5 Maintenance

5.1 Maintenance Information

5-5

5.2 General Service

5-9

5.2.1 Oil, fuel and coolant

5-9

5.2.1.1 Oil

5-9

5.2.1.2 Fuel

5-10

5.2.1.3 Coolant

5-11

5.2.2 Grease

5-12

5.2.3 Oil and fuel storage

5-13

5.2.4 Filter element

5-13

5.2.5 Electrical system

5-14

5.2.6 Hydraulic system

5-14

5.3 Replacement Parts

5-16

5.4 Recommended Fluids

5-17

5.4.1 Fluid capacities

5-19

5.4.2 Recommended oils:

5-20

5.5 Tightening Torque Specification

5-22

5.6 Safety-Related Parts

5-24

5.7 Maintenance Schedule

5-25

5.7.1 List of maintenance schedule

5-25

5.7.2 Hydraulic Breaker Service Interval

5-27

5.8 Maintenance Procedures

5-28

5.8.1 Maintenance after initial 50 service hours

5-28

5.8.1.1 Engine oil and filter - change/replace

5-28

5.8.1.2 Fuel filter - replace

5-28

5.8.2 When Required

5-29

5-1

Maintenance

5.8.2.1 Air cleaner - clean/replace

5-29

5.8.2.2 Cooling system - clean

5-37

5.8.2.3 Track shoe bolts - inspect/tighten

5-41

5.8.2.4 Track tension - inspect/adjust

5-42

5.8.2.5 Bucket tips (lateral pin) - replace

5-45

5.8.2.6 Bucket Replacement

5-47

5.8.2.7 Bucket clearance - adjust

5-49

5.8.2.8 Window washer fluid - check/refill

5-51

5.8.2.9 Air conditioner - inspect/service

5-52

5.8.2.10 Gas spring - inspect

5-54

5.8.2.11 Air in hydraulic system - purge

5-55

5.8.2.12 Hydraulic circuit internal pressure - release

5-58

5.8.3 Checks before starting

5-59

5.8.4 Every 100 service hours

5-60

5.8.4.1 Lubrication

5-60

5.8.5 Every 250 service hours

5-63

5.8.5.1 Compressor belt tension - inspect/adjust

5-63

5.8.5.2 Oil in engine oil pan and oil filter - change/replace

5-65

5.8.5.3 Primary fuel filter - replace

5-67

5.8.5.4 Secondary fuel filter - replace

5-71

5.8.6 Every 500 service hours

5-74

5.8.6.1 Swing bearing - lubricate

5-74

5.8.6.2 Swing pinion gear grease - check/refill

5-75

5.8.6.3 Coolant tank and radiator fins - inspect/clean

5-76

5.8.6.4 Air conditioner filters - clean

5-77

5.8.6.5 Swing drive oil - check/refill

5-80

5.8.6.6 Final drive oil - check/fill

5-81

5.8.7 Every 1000 service hours

5-82

5.8.7.1 Hydraulic oil filter - replace

5-82

5.8.7.2 Swing drive oil - change

5-84

5.8.7.3 Engine exhaust pipe clamps - check

5-85

5.8.7.4 Fan belt tension - check/replace

5-85

5.8.7.5 Nitrogen pressure in accumulator (breaker) - check

5-85

5.8.8 Every 2000 service hours

5-86

5.8.8.1 Final drive oil - change

5-86

5.8.8.2 Hydraulic tank filter screen - clean

5-88

5-2

Maintenance

5.8.8.3 Nitrogen pressure in accumulator (control oil circuit) - check

5-89

5.8.8.4 Hydraulic circuit internal pressure - release

5-92

5.8.8.5 Oil in hydraulic tank - change

5-93

5.8.8.6 Alternator - inspect

5-95

5.8.8.7 Engine valve clearance - check/adjust

5-95

5.8.9 Every 4000 service hours

5-95

5.8.9.1 Coolant pump - inspect

5-95

5.8.9.2 Start motor - check

5-95

5.8.9.3 Accumulator (control oil circuit) - replace

5-96

5.8.9.4 High-pressure tube clamps and rubber - check

5-97

5.8.9.5 Compressor working condition - inspect

5-97

5.8.10 Every 8000 service hours

5-98

5.8.10.1 High-pressure tube clamps - replace

5-98

5.8.11 Every 10000 service hours

5-98

5-3

Maintenance

5 MAINTENANCE

5.1 Maintenance Information

Never conduct any inspection and mainte-

nance work other than the scope specified in

this manual.

Hour meter reading

Keep track of the hour meter reading on a

daily basis. Make sure whether it is time to

perform the required maintenance.

Genuine Sany replacement parts

Always use genuine Sany replacement parts

listed in the Parts Manual.

Genuine Sany lubricants

Always use genuine Sany engine oil and

grease. Select engine oil and grease of suit-

able viscosity according to ambient tempera-

ture.

Window washer fluid

Use automotive windshield washer fluid only,

which shall not be contaminated by foreign

substances.

Oil and lubricants

Always use clean oils and greases. Keep the

oil reservoir and grease reservoir clean, which

shall be free from any impurities.

Drained oil and used filter element

After changing the oil and replacing the filter

element, check the used oil and filter element

for signs metal particles and foreign mate-

rial. If large amount of metal particles and/or

impurities are found in the used oil and filter

element, report to the personnel in charge and

take proper measures.

5-5

Maintenance

Primary fuel filter

Primary Fuel Filter must be installed before fill-

ing the fuel.

Welding instruction

● Turn off the engine start switch and wait for

1 minute before disconnecting the negative

(-) terminal of the battery.

● Connect the ground cable of the welder at

least 1 m (3.3 ft.) away from the place be-

ing welded.

● If the ground cable is connected to any

electrical components (instrument, con-

nector, etc.), the instrument will be out of

function. If there are any seals or bearings

between the weld and the grounding point,

choose another grounding point away from

these parts.

● Never use a grounding point in the vicinity

of the work equipment pin or hydraulic cyl-

inder .

● Never apply more than 200V continuously.

Preventing things from falling into machine

● When opening the access window or tank

filler for inspection, make sure that the

nuts, bolts or tools are not left inside the

machine. Failure to do so could result in

unexpected failure or damage to the ma-

chine, or accidents. In case that any mate-

rials fall into the machine, remove it imme-

diately.

● Never carry unnecessary items in your

pockets except those necessary for inspec-

tion.

Dusty work site

Observe the following items before working in

a dusty place.

● When inspecting your machine or chang-

ing the oil, park your machine in a dust-

5-6

Maintenance

free place in order to prevent dust from

getting into the oil.

● Clean the air filter cartridge immediately if

the filter's alarm indicates clogging.

● Clean the fins and other heat exchanger

parts frequently to avoid them being

clogged.

● Clean and replace the fuel filter frequently.

● Clean the electrical components, espe-

cially the start motor and the alternator, to

prevent dust from building up on them.

Lubricants of different brands

Never mix lubricants of different brands and/or

grades together. If you need to use the lubri-

cant of another brand or grade, drain the old

lubricant completely and replace with the new

brand.

Securing access cover

When servicing the machine with the access

covers open, use a locking lever to secure the

cover to certain position. Otherwise, the cover

can be swung close by wind and cause bodily

injury.

Purging air from hydraulic system

When any hydraulic units have been repaired

or replaced or any hydraulic lines have been

removed or installed, always bleed the air from

the system. For more information see "Air in

hydraulic system - purge."

Connecting hydraulic hoses

● In removal of parts with O-rings or gaskets,

clean the installation surfaces and replace

with new parts. Remember to install the O-

rings or gaskets.

● Never twist or bend the hydraulic hoses

when assembling. Failure to do so could

cause damage to the hoses and consider-

ably reduce their service life.

5-7

Maintenance

After inspection and maintenance

If no checks have been made after inspection

and maintenance, unexpected failure may oc-

cur, causing severe injury or damage. The fol-

lowing items must be observed:

●

Checks when machine is running.

● For more information on checks during

engine operation see "Maintenance dur-

ing Engine Running." Be alert to your

safety in the meantime.

● Whether the checked or maintained

parts work normally.

● Whether oil leakage occurs when the

engine speed increases and the oil is

under pressure.

●

Checks after the operation (when the en-

gine has been shut down)

● Whether you have missed the items to

be checked or maintained.

● Whether all the checks and mainte-

nance have been performed correctly.

● Whether any tools and parts are left in

the machine. It is very dangerous to

have a foreign object blocked in the link-

age.

● Whether leakage of water or oil occurs;

whether all the bolts have been screwed

tightly.

Closing engine hood properly

When the engine hood is closed after inspec-

tion and maintenance, hold the lever and lift

the engine hood slightly in order to check

whether the lock is securely engaged. An un-

locked hood may be opened and cause acci-

dents.

5-8

Maintenance

5.2 General Service

● Use genuine Sany replacement parts,

grease and oil.

● Never change or refill oil with a different

type. When different oil is to be used, the

used oil must be drained completely before

filling the fresh oil. Meanwhile, the oil filter

must be replaced. (A small amount of used

oil remaining in the lines would affect noth-

ing.)

● Unless specified otherwise, your machine

contains the following oils and coolants

when delivered from the factory.

Item

Type

Engine Oil Pan

Diesel Oil CH-4 15W-40

Swing Drive

Gear Oil 85W/140

Final Drive

Hydraulic System

Caltex HDZ46

Radiator

TEEC-L35 antifreeze

Table 5-1

5.2.1 Oil, fuel and coolant

5.2.1.1 Oil

● The oils in engine and hydraulic units keep

deteriorating when operating your machine

under extreme conditions, such as high

pressure and high temperature.

● Always use the type of oil recommended

in the "Maintenance Section", which shall

also be applicable under extreme ambient

temperatures.

● Within the specified oil change interval, the

oil must be changed even if it is not dirty.

● Like the blood in human body, lubricant

shall be handled carefully in order to pre-

vent impurities such as water, metal par-

ticles and dust.

5-9

Maintenance

●

Most troubles of the machine are caused

by impurities.

Pay special attention to the prevention of

any impurities when storing or filling the oil.

●

Fill the amount of oil as specified. Failure

to do so could result in abnormality.

●

Never mix oils of different grades or brands

together.

●

Contact your Sany distributor when the oil

in your work equipment has been contami-

nated by water or air.

●

To know the condition of your machine,

regular oil quality analysis is recommend-

ed. Contact your Sany distributor if you

need such service.

●

Related filter elements must be replaced

when changing the oil. In replacement of

engine oil filter element, acceptable clean

oil shall be filled into the new filter element

prior to installation.

●

Use the oils approved by Sany.

●

Never use the hydraulic oil that has not

been approved by Sany, which can block

filter cartridge.

●

Remove the remaining oil as much as pos-

sible from the lines and cylinders when

changing the hydraulic oil. A small amount

of different residual is acceptable.

5.2.1.2 Fuel

● To prevent the moisture in air from con-

densing in the fuel tank, the tank must be

fully refueled after each workday.

● The fuel injection pump is a precise com-

ponent, which may not work normally if the

fuel contains water or other foreign sub-

stances.

● The sediment and water in the fuel tank

must be drained before starting the engine

or after 10 minutes since injection of oil.

5-10

Maintenance

● Flush the fuel tank and the fuel system

in case of any impurities found in the fuel

tank.

● The air in fuel path must be eliminated in

case that the engine runs out of fuel or the

filter cartridge has been replaced.

● Always use the type of fuel specified in the

"Maintenance Section."

● The fuel can freeze below the speci-

fied temperature (especially lower than

-15°C (5°F)).

● When the fuel is used above the speci-

fied temperature, its viscosity and out-

put power will decrease .

● Pay special attention to prevention of

impurities when storing or refilling the

fuel.

Note:

Always use diesel oil as the fuel.

To ensure favorable consumption and exhaust

of the fuel, the engine installed to your ma-

chine uses high-pressure oil injection unit with

mechanical control. The unit contains high-

precision components that require high-quality

lubrication. Therefore, the use of low-viscosity

fuel with low lubricating capability will consid-

erably reduce the service life of the unit.

5.2.1.3 Coolant

● The coolant is also an important fluid

against corrosion and freezing.

Anti-freezing coolant is also necessary in

regions where freezing prevention is un-

necessary.

Sany machines are prefilled with TEEC-

L35 antifreeze, which has excellent perfor-

mance in anticorrosion, anti-freezing and

cooling, and can last for 1 year or 2000

5-11

Maintenance

hours.

As a basic principle, we do not recommend

you using coolants other than TEEC-L35

antifreeze. The use of other coolants is

possible to cause serious problems, such

as corrosion of the light metal parts of the

engine and cooling system.

●

Use distilled water or tap water (softened

water) to dilute anti-freezing coolant.

Natural water, such as river water and well

water (hard water), contains large amount

of minerals (calcium, magnesium, etc.),

which can easily scale in the engine and

radiator. The scale is hardly removed once

formed in the engine and radiator. Over-

heat can occur due to unfavorable heat

exchange. The water with overall hardness

lower than 10 PPM is recommended when

diluting the coolant.

●

Precautions in this manual must be fol-

lowed when using antifreeze.

●

Anti-freezing coolant is flammable. There-

fore, it must be kept away from naked fire.

●

If the engine is overheating, wait for the

engine to cool down before refilling cool-

ant.

●

Overheat can be caused if the coolant

level is low. In addition, the air trapped in

coolant can result in corrosion problem.

5.2.2 Grease

● Grease is used to prevent distortion and

noise of joints.

● It is necessary to add grease to any com-

ponent that appears inflexible or noisy after

operation for a long period.

● Always use the recommended greases.

Select the grease according to change

interval and ambient temperature recom-

5-12

Maintenance

mended in this manual.

● Wipe off the used grease that has been

squeezed out when greasing. Make sure

to wipe off the used grease that has been

contaminated by sand or debris, which can

otherwise lead to wear of rotating compo-

nents.

5.2.3 Oil and fuel storage

● Store the oils and fuel indoors in order to

keep them free from water, dust and other

foreign substances.

● To store the barrel of oil or fuel for a

long period, it is necessary to place the

barrel with its opening facing the side

in order to prevent intake of moisture.

If you have to place the barrels outdoors,

cover them properly with waterproof can-

vas or take other protective measures.

● To prevent deterioration of oil or fuel during

long-term storage, use the oil or fuel that

has been stored earlier than others.

5.2.4 Filter element

● Filter element is extremely important for

safety. It can prevent failures by keep-

ing important devices free from impurities

coming from oil path or air path. All filter el-

ements must be replaced regularly. When

operating in unfavorable conditions, the

filter elements shall be replaced more fre-

quently according to the sulfur content in

lubricant and fuel.

● Never use an element that has been

cleaned. Replace it with a new one.

● In replacement of filter element, check the

element for attached metal particles. Con-

tact your Sany distributor if metal particles

are found.

● Never open the package of a spare ele-

ment when it is in storage.

5-13

Maintenance

● Use genuine Sany elements.

5.2.5 Electrical system

●

Humid electrical devices or damaged wire

can cause short circuit and machine fail-

ure. Never flush the interior of your cab

with water. When flushing your machine,

be careful with water, which shall not pen-

etrate into the electrical components.

●

Electrical system maintenance correlates

to checking the tension, damage or wear of

fan belt.

●

Never install any other electrical compo-

nents except those specified by Sany.

●

External electromagnetic interference can

cause failure of system controller. Contact

your Sany distributor before installing radio

receiver or other wireless devices.

●

Operating on beach requires cleaning the

electrical system thoroughly in order to

prevent corrosion.

●

When installing an electrical device,

connect it to dedicated power source.

Never connect other power sources to the

fuse, start switch or battery relay.

5.2.6 Hydraulic system

During operation and immediately after opera-

tion is ended, the temperature of the hydraulic

system still remains high.

In addition, high hydraulic pressure is applied

to the system. Take care when inspecting and

maintaining the hydraulic system.

Stop the machine on lever ground; lower the

bucket to the ground, then set so that there is

no pressure applied to the cylinder circuit.

Always stop the engine Immediately after op-

erations, the hydraulic oil and lubricating oil

5-14

Maintenance

are at high temperature and high pressure, so

wait for the oil temperature to go down before

starting maintenance.

Even when the temperature goes down, the

circuit may still be under internal pressure, so

when loosening the plug or screw, or the hose

joint, do not stand in front of the part. Loosen it

slowly to release the internal pressure before

removing it.

When carrying out inspection or maintenance

of the hydraulic circuit, always bleed the air

from the hydraulic tank to remove the internal

pressure.

Periodic maintenance includes the inspection

of the hydraulic oil lever, replacement of the

filter and refilling of hydraulic oil.

When the high pressure hose, etc. Is removed,

check the O-ring for damage. If necessary, re-

place it.

After the hydraulic filter element and strainer

are cleaned or replaced, or after the hydraulic

system is repaired of replaced or the hydraulic

piping is removed, bleed air from the hydraulic

circuit.

The accumulator is charged with high-pres-

sure nitrogen gas. Incorrect handling may be

dangerous.

For the handling procedure “Accumulator”

on page 2-67.

5-15

Maintenance

5.3 Replacement Parts

● Replacement parts, such as filter element and bucket tips, should be replaced according to

maintenance schedule or before the wearing limits are reached.

● Replacement parts shall be replaced properly in order to use your machine economically.

● Select Sany genuine quality parts for replacement.

● Check the part number in the Parts Manual when ordering a part.

Also replace the part in brackets.

Component

Part Number

Part

Qty

Interval

Fuel filter, pri-

60064761(SY115C9, SY135C8/C9, SY155H)

Filter element

Every 250 hours

mary

60033346(SY135C8(M))

B222100000453(SY115C9, SY135C8/C9,

Fuel filter, sec-

SY155H)

Filter

Every 250 hours

ondary

B222100000415(SY135C8(M))

B222100000488(SY115C9, SY135C8/C9,

Oil filter

SY155H)

Filter

Every 250 hours

B222100000386(SY135C8(M))

Filter element

Pilot filter

B229900000063

Every 500 hours

(O-ring seal)

(1)

Filter element,

Hydraulic oil

60101257

oil suction

Every 1000 hours

filter

60101256

Filter element,

(1)

oil return

Air filter, main

B222100000500

Filter element

─

Air filter, safety

B222100000501

Filter element

─

Breather valve

60174894

Filter element

Every 1500 hours

filter element

Lateral pin

60102737

Bucket tips

(60102738)

(Pin group)

(5)

Bucket

A229900007131

Left cutter

─

(SY115C)

A229900007130

Right cutter

(A210111000301)

(Bolt)

(8)

(A210307000006)

(Nut)

(8)

Lateral pin

10143956

Bucket tips

(10143975)

(Pin)

(4)

Bucket

A229900007131

Left cutter

─

(SY135C8)

A229900007130

Right cutter

(A210111000301)

(Bolt)

(8)

(A210307000006)

(Nut)

(8)

5-16

Maintenance

Component

Part Number

Part

Qty

Interval

Lateral pin

60100572

Bucket tips

(10143975)

(Pin)

(4)

A229900005244

Tip adaptor

Bucket

A229900005241

Tip pin

─

(SY135C9)

A229900007131

Left cutter

A229900007130

Right cutter

A210111000301

(Bolt)

(8)

60012073

(Nut)

(8)

Lateral pin

60100572

Bucket tips

(A229900005241)

(Pin)

(4)

Bucket

A229900007131

Left cutter

─

(SY155H)

A229900007130

Right cutter

(A210111000301)

(Bolt)

(8)

(A210307000006)

(Nut)

(8)

5.4 Recommended Fluids

● To keep your machine at the maximum state for a long period of time, it is necessary follow

the oil instructions described in this manual. Failure to do so can cause overwear and service

life reduction of the engine, power train, cooling system and other components.

● The additives available in market could benefit your machine, but they could impair your ma-

chine as well. We do not recommend any lubricant additives.

● The specific capacity refers to the overall oil volume in tanks and lines. Supplementary vol-

ume refers to the amount of oil used to make up the system in inspection and maintenance.

● The use of multigrade oils is strongly recommended when starting the engine at temperatures

below 0°C (32°F), even if the daytime temperatures rise above 0°C(32°F).

● Use the recommended oils according the ambient temperatures given in the following table.

● When the sulfur content of fuel is less than 0.5%, change the fuel according to the required

maintenance interval given in this manual. If the sulfur content is more than 0.5%, change the

fuel according to the following table:

Sulfur Content in Fuel

Oil-Change Interval - Engine Oil Pan

0.5

- 1.0%

1/2 of standard interval

More than 1.0%

1/4 of standard interval

Table 5-2

5-17

Maintenance

5.4.1 Fluid capacities

Engine Oil

Hydraulic

Cooling Sys-

Swing Drive

Final Drive

Fuel Tank

Pan*

System

tem

13.2(*)

3.0

2.5

150

240

US gal

3.5

0.79

0.66

39.62

4.23

63.4

Note:

* Capacity of engine oil pan on SY135C8M is 15 L (3.98 US gal).

Always use diesel oil as the fuel.

To ensure favorable consumption and exhaust of the fuel, the engine installed to your machine

uses high-pressure oil injection unit with mechanical control. The unit contains high-precision

components that require high-quality lubrication. Therefore, the use of low-viscosity fuel with low

lubricating capability will considerably reduce the service life of the unit.

Note 1: The HTHS (high-temperature high-shear viscosity at 150°C) required by ASTM D4741

must be equal to or more than 3.5 mPa-S. Sany strongly recommend the use of engine

oil 15W-40.

Note 2: Coolant

1) The coolant is also an important fluid against corrosion and freezing.

Antifreezing coolant is also necessary in regions where freezing prevention is unnecessary.

Sany machines are prefilled with TEEC-L35 antifreeze, which has excellent performance in

anticorrosion, antifreezing and cooling.

2) For more information on diluting TEEC-L35 antifreeze with water see “Cooling system -

clean” on page 5-37.

3) The proper concentration of coolant must be kept in order to ensure the coolant's performance

against corrosion.

Recommended brands and quality of recommended products besides Sany genuine oils

Consult your Sany distributor before using any oils other than those recommended by Sany.

5-19

Maintenance

5.4.2 Recommended oils:

Engine oil

Select the oil of proper viscosity according

to the temperature range given in the oil

change schedule.

Engine oil grade: Above API CF-4

Recommended engine oil brand and type:

Caltex CH-4 15W-40

Engine fuel

Light diesel oil (GB252.81)

● In most cases, the use of fuel ASTH2

and the diesel oil (minimum cetane

number is 40) can achieve the best

economic result and operating perfor-

mance. At where the elevation is high or

the ambient temperature is too low, it is

necessary to use the fuel whose cetane

number is more than 40 in order to pre-

vent flameout and too much smoke.

● When the fuel of low sulfur content is

used, its cloud point shall be at lease

10°C lower than the expected minimum

fuel temperature. Cloud point is the

temperature at which the waxy crystals

begin to form.

● The universal diesel fuel of commercial

brands shall contain sulfur that is less

than 0.5%.

● Clean fuel free from water and/or impu-

rities shall be ensured before refueling.

Hydraulic oil

The hydraulic system uses Caltex HDZ46

hydraulic oil (code B420106000036).

When the ambient temperature is below

0°C, the following items have to be fol-

lowed to heat the hydraulic system in order

5-20

Maintenance

to ensure the safety of the hydraulic sys-

tem.

●

Run the engine at idle speed for 7-10

minutes before increasing its rpm to

1000 - 1200. Never operate your exca-

vator except running the engine unload-

ed for 30-40 minutes or longer in order

to heat the hydraulic oil to a tempera-

ture above 20°C.

●

Now your machine can be used for

normal construction operation after the

hydraulic oil temperature rises above

20°C. However, the heating time shall

be adjusted according to ambient tem-

perature. In normal construction work,

the joystick controls and pedals shall be

maneuvered slowly while paying close

attention to the system's running condi-

tion. Operating your machine with the

hydraulic oil temperature being below

20°C could damage the hydraulic ele-

ments.

●

Anti-friction hydraulic oil L-HM46 is

widely used in temperate zones.

●

Low-temperature, anti-friction hydraulic

oil L-HV32, whose pour point is -42°C,

is used in extremely cold regions (below

-30°C) such as Russia and Northeast

China.

●

Anti-friction hydraulic oil L-HM68 is gen-

erally used in torrid regions such as the

Middle East and India.

●

Select proper hydraulic oil according to

the region where your machine is to be

operated. The machine has been filled

with hydraulic oil of suitable brand and

type before it is delivered. User is re-

sponsible to change the oil after the ma-

chine is delivered. You may consult our

after-sale service personnel to obtain

correct brand and type of the hydraulic

oil.

5-21

Maintenance

5.5 Tightening Torque Specification

NOTICE

● The nuts, bolts or other parts having not been tightened to specific torque values can

lead to loose or damaged parts, hence resulting in machine failure and operating trou-

bles.

● Special attention shall be paid when tightening any parts.

Unless specified otherwise, the metric nuts

and bolts shall be tightened to the values giv-

en in the following table.

The tightening of torque is determined by the

width of screw cap or nut.

CZ335-1104001

In replacement of the bolts or nuts, use Sany

Fig. 5-1

genuine parts of equivalent size.

Tightening Torques

Thread

Square

Diameter

Size

Target Values

Torque Limits

(mm)

N·m

kgf·m

lbft

N·m

kgf·m

lbft

13.2

1.35

9.8

11.8

- 14.7

1.2

- 1.5

8.7

- 10.8

3.2

23.1

27 - 34

2.8

- 3.5

20.3

- 25.3

6.7

48.5

59 - 74

6.0

- 7.5

43.4

- 54.2

113

11.5

83.2

98 - 123

10.0

- 12.5

72.3

- 90.4

177

130.2

157 - 196

16.0

- 20.0

115.7

- 144.7

279

28.5

206.1

245 - 309

25.0

- 31.5

180.8

- 227.8

382

282.1

343 - 425

35.0

- 43.5

253.2

- 314.6

549

405

490 - 608

50.0

- 62.0

361.7

- 448.4

745

549.7

662 - 829

67.5

- 84.5

488.2

- 611.2

927

94.5

683.5

824 - 1030

84.0

- 105.0

607.6

- 759.5

1320

135

976.5

1180 - 1470

120.0

- 150.0

868.0

- 1085.0

1720

175

1265.8

1520 - 1910

155.0

- 195.0

1121.1

- 1410.4

2210

225

1627.4

1960 - 2450

200.0

- 250.0

1446.6

- 1808.3

2750

280

2025.2

2450 - 3040

250.0

- 310.0

1808.3

- 2242.2

3280

335

2423.1

2890 - 3630

295.0

- 370.0

2133.7

- 2676.2

Table 5-4

5-22

Maintenance

Hydraulic hoses are tightened according to the

torques given below.

Fig. 5-2

Nominal Thread

Tightening Torques

Square Size

Number

Target Values

Permissible Range

(b)(mm)

(a)

N·m

kgf·m

lbft

N·m

kgf·m

lbft

9/16-18UNF

4.5

32.5

35-63

3.5-6.5

25.3-47

11/16-16UN

7.5

54.2

54-93

5.5-9.5

39.8-68.7

13/16-16UN

103

10.5

75.9

84-132

8.5-13.5

61.5-97.6

1-14UNS

157

16.0

115.7

128-186

13.0-19.0

94-137.4

13/16-12UN

216

22.0

159.1

177-245

18.0-25.0

130.2

-180.8

☆ 1 -7/16 - 12UN

215

22.0

159.1

176-234

18.0-24.0

130.2-180.8

- 2B

Table 5-5

Note: The item marked with ☆ is used for tightening the hose on top of the swivel joint.

5-23

Maintenance

5.6 Safety-Related Parts

To ensure your safety during operating or driving the machine, user shall carry out regular main-

tenance on the machine. In addition, user shall also replace the parts listed in the table in order to

further improve the safety condition. These parts are closely related to safety and fire prevention.

Since the safety-related parts may become easily worn or deteriorated due to material changing

along with the time, it is hard to judge their conditions through regular maintenance. These parts

shall be replaced as scheduled regardless of their conditions, which can effectively guarantee the

functions of these parts.

If any safety-related part becomes abnormal before its scheduled replacement, it must be re-

paired or replaced immediately.

If any hose deteriorates, such as deforming or cracking, the hose clamps shall also be replaced

while replacing the hose.

O-ring, gasket and other similar parts shall also be replaced while replacing a hose.

Consult your Sany distributor to replace the following safety-related parts on a regular basis.

No.

Safety-related parts subject to regular replacement

Quantity

Frequency

Fuel hose (fuel tank - water separator)

Fuel hose (water separator - primary filter)

Fuel return hose (engine - fuel tank)

Fuel hose (primary filter - engine)

Pump outlet hose (pump - control valve)

Work equipment hose (boom cylinder oil inlet)

Work equipment hose (Bucket cylinder line - boom root)

Every 2 years

Work equipment hose (bucket cylinder oil inlet)

or 4000 hours,

Work equipment hose (arm cylinder line - boom root)

whichever occurs

first.

Work equipment hose (arm cylinder oil inlet)

Swing drive hose (swing motor oil inlet)

Main oil suction hose

Travel control hose (control valve - swivel joint)

Travel control hose (swivel joint - travel motor)

Pump pressure hose

Accumulator (control oil)

High-pressure tube clamps

Every 8000 hours

Cover - fuel squirt prevention

Seat belt

Every 3 years

Table 5-6

5-24

Maintenance

5.7 Maintenance Schedule

If your machine is equipped with hydraulic breaker, the maintenance schedule for some parts

may vary. For more information and proper maintenance see "Hydraulic Breaker Maintenance

Schedule."

5.7.1 List of maintenance schedule

Maintenance after initial 50 service hours

5-28

Engine oil and filter - change/replace

5-28

Fuel filter - replace

5-28

When Required

5-29

Air cleaner - clean/replace

5-29

Cooling system - clean

5-37

Track shoe bolts - inspect/tighten

5-41

Track tension - inspect/adjust

5-42

Bucket tips (lateral pin) - replace

5-45

Bucket Replacement

5-47

Bucket clearance - adjust

5-49

Window washer fluid - check/refill

5-51

Air conditioner - inspect/service

5-52

Gas spring - inspect

5-54

Air in hydraulic system - purge

5-55

Hydraulic circuit internal pressure - release

5-58

Checks before starting

5-59

Every 100 service hours

5-60

Lubrication

5-60

Every 250 service hours

5-63

Compressor belt tension - inspect/adjust

5-63

Oil in engine oil pan and oil filter - change/replace

5-65

Primary fuel filter - replace

5-67

Secondary fuel filter - replace

5-71

Every 500 service hours

5-74

5-25

Maintenance

Swing bearing - lubricate

5-74

Swing pinion gear grease - check/refill

5-75

Coolant tank and radiator fins - inspect/clean

5-76

Air conditioner filters - clean

5-77

Swing drive oil - check/refill

5-80

Final drive oil - check/fill

5-81

Every 1000 service hours

5-82

Hydraulic oil filter - replace

5-82

Swing drive oil - change

5-84

Engine exhaust pipe clamps - check

5-85

Fan belt tension - check/replace

5-85

Nitrogen pressure in accumulator (breaker) - check

5-85

Every 2000 service hours

5-86

Final drive oil - change

5-86

Hydraulic tank filter screen - clean

5-88

Nitrogen pressure in accumulator (control oil circuit) - check

5-89

Hydraulic circuit internal pressure - release

5-92

Oil in hydraulic tank - change

5-93

Alternator - inspect

5-95

Engine valve clearance - check/adjust

5-95

Every 4000 service hours

5-95

Coolant pump - inspect

5-95

Start motor - check

5-95

Accumulator (control oil circuit) - replace

5-96

High-pressure tube clamps and rubber - check

5-97

Compressor working condition - inspect

5-97

Every 8000 service hours

5-98

High-pressure tube clamps - replace

5-98

Every 10000 service hours

5-98

5-26

Maintenance

5.7.2 Hydraulic Breaker Service Interval

For machines equipped with a hydraulic

5000

breaker, the hydraulic oil deteriorates faster

(H)

than that of machines operating with a bucket.

In this case, the following steps shall be fol-

4000

lowed in order to adjust the service intervals.

● Change hydraulic filter element

3000

Hydraulic oil change interval

For a new machine, the filter element is to

be replaced after the first 100-150 service

2000

hours. Subsequent replacement shall be

carried out according to the right chart.

1000

● Change the oil of hydraulic tank

Hyd filter element

500

Pilot filter element

Change the oil according to the right chart.

When unused

100

(%)

● Replace the additional filter element (if

When used

equipped) of the breaker

Additional filter element

Replace the pilot filter element (if

CZ335-1104003

equipped).

Fig. 5-3

The filter element is to be replaced accord-

ing the right chart when the breaker has

served for 250 hours (breaker operating

proportion more 50%).

Remark:

100% breaker operation means that the break-

er is used all the time, while 0% means that

the breaker never used.

5-27

Maintenance

5.8 Maintenance Procedures

5.8.1 Maintenance after initial 50 ser-

vice hours

The following maintenance is to be carried out

after initial 50 service hours.

Consult your Sany distributor for special tools

used for checks and maintenance.

5.8.1.1 Engine oil and filter - change/

replace

For the procedures of changing engine oil and

replacing oil filter see “Oil in engine oil pan

and oil filter - change/replace”on page 5-65.

5.8.1.2 Fuel filter - replace

For the procedures of replacing fuel filters see

“Primary fuel filter - replace”on page 5-67

and “Secondary fuel filter - replace” on

page 5-71.

5-28

SANY Crawler Hydraulic Excavator SY115C9, SY135C8, SY135C9, SY155H. Safety, Operation and Manitenance Manual - page 7