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SANY Crawler Hydraulic Excavator SY115C9, SY135C8, SY135C9, SY155H. Safety, Operation and Manitenance Manual - page 9

Maintenance

Note:

● Never remove the cover (B) while filling the

fuel. Always fill fuel via the eight(8) external

A

B

holes (A).

● Remove the cover (B) after filling. Install

the fuel filter.

● Always fill clean fuel. Take care to keep

the fuel free from dust or dirt. Be especially

careful that the central part is clean and

never remove the cover (B) during filling.

CZ335-1104067

Always keep the central part free from con-

Fig. 5-68

tamination.

9. Tighten the filter until the seal contacts

the filter seat. Further turn it by 3/4 turn.

If the filter cartridge was over-tightened,

the seal might be damaged and fuel leak

could result. If the filter cartridge was not

tightened enough, fuel will leak through

the gap with seal. Always tighten it to the

specified torque.

10. Check drain valve (1) to see if it is tight-

ened properly.

11. Release the air after replacing filter (3).

Air-purging steps:

12. Fill fuel into the fuel tank until the float

reaches the maximum level.

13. Use a transfer pump (5) to pump the fuel in

and out until heavy resistance is felt.

Remark:

● It is unnecessary to remove the plug on the

primary fuel filter and the secondary fuel

filter.

● When fuel exhausts, operate the transfer

pump (5) to purge air.

5-69

Maintenance

Always prepare your machine as required

and lock/tag it out before proceeding. See

“Preparing the machine” on page 2-58 and

“Lock-out and tag-out” on page 2-60.

1. Open engine hood.

2. Place a fuel container under the filter.

3. Use filter wrench to turn counterclockwise

the filter (1) in order to remove it.

4. Clean the filter seat. Apply a thin layer of

1

oil to sealing surface of filter cartridge and

install filter cartridge to filter seat.

CZ335-1104089

Replace internal seal (2) with a new one.

Fig. 5-69

2

CZ335-1104090

Fig. 5-70

Note:

● Never add fuel to new filter cartridge.

B

● Remove cap (B) and install filter cartridge.

CZ335-1104091

Fig. 5-71

5-72

Maintenance

5. Tighten filter cartridge until the seal con-

tacts filter seat. Further turn it by 3/4 turn.

If filter cartridge was over-tightened, the

seal might be damaged and fuel leak could

result. If filter cartridge was not tightened

enough, fuel will leak through the gap

of seal. Always tighten it to the specified

torque.

3

6. Remove air after replacing the filter.

Air-purging steps:

7. Refill fuel tank until the float reaches the

maximum level.

8. Loosen plug (3) of fuel filter.

CZ215-1104016

Fig. 5-72

9. Turn counterclockwise the handle (4) of

start priming pump.

10. Push and pull the handle (4) to pump fuel.

11. Tighten plug (3) when fuel coming out of

plug of fuel filter contains no foam.

4

Tightening torque: 9.8±2.0 N·m {1.0±0.2

kgf·m}

12. Operate the priming pump 5-6 times and

Start priming pump

CZ215-1104017

turn handle (4) clockwise to tighten it.

Fig.

5-73

13. Completely remove overflowed fuel after

purging the air. Start the engine and run it

at low idle for 10 minutes.

Check filter cartridge for fuel leak. Check

the tightening of filter cartridge if fuel leak

4

is found.

If fuel leak still exists, repeat step 1 through

step 3 to remove the cartridge. If seal dam-

age or impurities are found, repeat step 4

Start priming pump

through step 13 to install a new cartridge.

CZ215-1104018

Fig.

5-74

5-73

Maintenance

5.8.6 Every 500 service hours

Also perform maintenance for every 100 and

250 service hours is in the meantime.

5.8.6.1 Swing bearing - lubricate

1. Lower work equipment to ground, stop

the engine and engage hydraulic lockout

control.

2. Add grease through two grease fittings

while the upper structure is kept static.

3. Start the engine, disengage hydraulic

lockout control and raise the bucket 20-30

mm off ground. Swing upper structure by

CZ135B-1104021

45 degrees and add grease through steps

1 and 2.

Fig. 5-75

4. Repeat step 3 twice to accomplish greas-

ing.

Note:

● The 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.

● Wipe off the used grease that has been

squeezed out when greasing.

● Make sure to wipe off all used grease in

different locations. Using a grease that has

been contaminated by sand or debris can

lead to wear of rotating components.

5-74

Maintenance

5.8.6.2 Swing pinion gear grease - check/refill

Always prepare your machine as required

and lock/tag it out before proceeding. See

“Preparing the machine” on page 2-58 and

“Lock-out and tag-out” on page 2-60.

● Prepare a dipstick.

1. Remove the two bolts (1) from the swing

frame. Remove the cover (2).

2. Insert the dipstick (3) into the grease

2

through the hole for inspection and

adjustment. Check the grease level, which

1

should be 14 mm (0.6 in) at minimum, at

where the pinion gear passes.

3. Check the grease to see whether it is milk-

CZ335-1104068

white. Milk-white grease indicates that the

grease has been contaminated. Consult

Fig.

5-76

Sany distributor in order to change the

grease.

A

3

Total grease volume: 15 L (3.97 US gal)

S

CZ335-1104069

Fig. 5-77

4. Use the bolts (1) to reinstall the cover (2).

2

CZ335-1104070

Fig. 5-78

5-75

Maintenance

5.8.6.3 Coolant tank and radiator fins - inspect/clean

WARNING

If you are directly impacted by compressed air, pressurized water or steam, or you use

them to purge dirt or debris, personal injury could result. Make sure you are well protect-

ed by wearing goggles, dust-proof mask or other protective gear.

Note:

1

When compressed air is used for cleaning, it

is important to use the air at certain distance

in order to avoid damaging the radiator fins.

Damage of radiator fins will lead to water

leakage and overheating. Working in a dusty

place, the fins shall be inspected on each

workday despite of the service schedule.

CZ135B-1104023

Always prepare your machine as required

Fig. 5-79

and lock/tag it out before proceeding. See

“Preparing the machine” on page 2-58 and

“Lock-out and tag-out” on page 2-60.

1. Open engine hood (1).

4

2. Loosen screws (3) and (8). Pull up screens

(2) and (9).

8

9

3. Clean the screens.

7

CZ135B-1104024

4. Inspect the coolant tank (4), intercooler

fins (5), A/C condenser fins (6) and the

Fig. 5-80

hydraulic oil radiator fins (7). Compressed

air can be used to remove dirt and leaves

3

sticking to the fins.

6

Steam or water can also be used to clean

the fins.

5

However, a safe distance to the machine

2

shall be kept when cleaning the heat ex-

changers (of radiator, oil cooler, intercooler

CZ135B-1104025

Fig. 5-81

5-76

Maintenance

and air conditioner condenser) with power-

ful steam (from high-pressure flushing ma-

chine). With steam cleaning (high-pressure

machine flushing) at a near distance, the

heat exchanger could deform and early

plugging and cracking could be resulted.

5. Inspect rubber hoses. Replace the hoses

10

in case of cracking or aging. Check hose

clamps for looseness.

6. Remove bottom cover (10). Remove dirt,

debris and tree leaves that have been

swept to the outside.

CZ135B-1104026

7. Reinstall cleaned screens (2) and (9) and

tighten them with screws (3) and (8).

Fig. 5-82

5.8.6.4 Air conditioner filters - clean

WARNING

The dust blown by compressed air could

cause personal injury. Make sure you are

protected by goggles, dust-proof mask

and other protective gear.

Note:

The filter shall be cleaned every 500 hours,

but operating your machine in a dusty place

requires cleaning the filter more frequently.

Remark:

An air filter plugged with dust will reduce air

flow and cause the air-conditioning unit to pro-

duce noise.

Always prepare your machine as required

and lock/tag it out before proceeding. See

“Preparing the machine” on page 2-58 and

“Lock-out and tag-out” on page 2-60.

5-77

Maintenance

Cleaning the filter screen

1. Remove the screw (1) from the access

1

window located on the left rear bottom of

the cab, loosen the locking nut (2) and

remove the air recirculation filter (3).

2. Use compressed air to clean the filter. If

the filter bears oil or too much dirt, clean it

with moderate detergent. After the filter has

been flushed with water, it must be dried

completely before reuse. This filter shall

be replaced every year with a new one. If

a plugged air filter cannot be cleaned with

compressed air or flushing water, replace it

CZ335-1104075

immediately.

Fig. 5-83

2

3

CZ335-1104076

Fig. 5-84

5-78

Maintenance

Cleaning the fresh air filter

1.

Unlock the rear cover (4) on the left side

of the cab with the start switch key. Open

the cover (4) with your hand, remove the

locking nut (5) and take out the fresh air

filter (6).

4

2.

Use compressed air to clean the filter. If

the filter bears oil or too much dirt, clean it

with moderate detergent. After the filter has

been flushed with water, it must be dried

completely before reuse. This filter shall

CZ335-1104077

be replaced every year with a new one. If

a plugged air filter cannot be cleaned with

Fig.

5-85

compressed air or flushing water, replace it

immediately.

3.

After cleaning, restore the filter (6), tighten

the nut (5) and close the cover. Lock the

cover with your start switch key and then

remove the key.

4

5

6

CZ335-1104078

Fig. 5-86

Remark:

The fresh air filter must be installed correctly.

S

To install the filter, the long end (L) of the filter

(6) must be inserted first into the filter box. By

L

inserting the short end (S), the cover (4) will

not be closed.

6

4

CZ335-1104079

Fig. 5-87

5-79

Maintenance

5.8.6.5 Swing drive oil - check/refill

WARNING

When the engine has just been stopped,

the parts and oil are still hot and can

cause serious burn. Wait until they are

cool enough before doing the job.

Always prepare your machine as required

and lock/tag it out before proceeding. See

F

“Preparing the machine” on page 2-58 and

“Lock-out and tag-out” on page 2-60.

G

1.

Remove the dipstick (G) and wipe off the

oil.

2.

Insert the dipstick (G) completely into the

filter tube.

CZ135B-1104027

Fig. 5-88

3.

Take out the dipstick (G) and check

whether the oil level is between the H and

L marks.

4.

If the oil level is lower than the L mark on

the dipstick (G), remove the filler cap and

add oil.

H

5.

If the oil level is higher than the H mark on

the dipstick (G), loosen the drain valve (P)

L

CZ335-1104083

to drain excessive oil.

Fig. 5-89

● If the oil level is too high, consult Sany

distributor for inspection.

● Place a container under the drain valve

before draining the oil.

P

6.

After checking the oil level or refilling the

oil, insert the dipstick (G) into the hole and

restore the filler cap.

CZ335-1104084

Fig. 5-90

5-80

Maintenance

5.8.6.6 Final drive oil - check/fill

WARNING

● When the engine is shut down, the oil is still hot. Wait until the oil is cool enough be-

fore operation.

● Remaining pressure in the tank can cause oil to squirt out or the screw plug to fly out.

Slowly loosen the screw plug in order to release the pressure.

● When the screw plug is loosen, do not stand in front of the screw plug.

Always prepare your machine as required

and lock/tag it out before proceeding. See

“Preparing the machine” on page 2-58 and

“Lock-out and tag-out” on page 2-60.

●

Refilling volume: 5.5 L (1.45 US gal)

●

Prepare a 10 mm wrench.

F

1.

Adjust the filler cap screw (F) to the upper

position in order to make the line through

L

the oil inspection screw plug (L) and the

P

drain screw plug (P) perpendicular to the

ground.

2.

Use a proper screwdriver to eliminate the

dirt from the hexagonal socket of screw

Level mark

plug in order to avoid damage to the bolt.

3.

Use a spanner to remove the screw plug

(L). When the oil level reaches the point 10

mm (0.4 in) below the bottom of the screw

plug (L) opening, the amount of oil added

is just perfect.

4.

If the oil level is too low, reinstall the screw

CZ335S-1104020

plug (L), operate the travel level and slowly

travel your machine forward or backward in

Fig. 5-91

order to run the sprocket one turn. Repeat

step 2 and check again.

5.

If the oil level is low, fill oil through the

opening of the screw plug (F) till the oil

overflows through the opening of the screw

plug (L).

5-81

Maintenance

1.

Park your machine on a hard, level ground.

Adjust the work equipment to an attitude

ready for service, as shown in the right

illustration. Lower the work equipment to

ground and turn off the engine.

2.

Lock out and tag out your machine before

CZ335-1104086

proceeding. See “Lock-out tag-out” on

Fig. 5-92

page 2-60.

3.

Turn the butterfly nut on the breather valve

Butterfly nut

1

Breather valve

and press the venting button.

4.

Loosen the four bolts and remove the cap

(1). When the cap is removed, it may fly

out due to the action of the spring (2). In

this case, hold down the cap when remov-

ing the bolts.

5.

Remove the spring (2), valve (3) and

strainer (4) before disassembling the filter

(5).

CZ335-1104087

● Check the bottom of the filter box and

Fig. 5-93

remove the dirt if any. Keep the hydrau-

lic oil free from any dirt.

6.

Clean the disassembled parts with clean-

1

ing oil.

2

7.

Install a new filter.

3

4

8.

Restore the valve (3), strainer (4) and

spring (2).

5

9.

Install the cap (1) to its position. Hold down

the cap and tighten the bolts.

CZ335-1104088

10. In order to vent the air, start the engine

Fig. 5-94

(see "Engine Starting" in the Operation

Section) and run the engine at low idle for

10 minutes.

11. Stop the engine.

5-83

Maintenance

5.8.7.2 Swing drive oil - change

WARNING

When the engine has just been stopped,

the parts and oil are still hot and can

cause serious burn. Wait until they are

cool enough before doing the job.

Always prepare your machine as required

and lock/tag it out before proceeding. See

“Preparing the machine” on page 2-58 and

“Lock-out and tag-out” on page 2-60.

● Tank capacity:

3.5 L (1.06 US gal)

P

1. Place a container under the drain valve (P)

in order to contain the gear oil drained.

2. Loosen the drain valve (P) beneath the

machine to drain the gear oil. Tighten the

drain valve upon completion of the drain-

ing.

CZ335-1104084

Fig. 5-95

Remark:

● If the gear oil flows out in a thin thread pat-

tern, you can end the draining operation.

● When the temperature is low, you can

swing the work equipment to slightly in-

crease the oil temperature before draining

the oil. However, the work equipment shall

not be swung during draining, which may

otherwise damage the swing unit.

5-84

Maintenance

3. Remove the filler cap (F) and fill the oil as

required through the filler opening (F).

F

4. Check the oil level. For more information

G

see “Swing drive oil - check/refill” on

page 5-80.

5. For information on selection of oil and tem-

perature see “Recommended Fluids”

CZ135B-1104027

on page 5-17.

Fig. 5-96

5.8.7.3 Engine exhaust pipe clamps - check

Consult Sany distributor to check the fastening

conditions of the air cleaner - turbocharger -

post cooler - engine clamps.

5.8.7.4 Fan belt tension - check/replace

Check the tension of fan belt. Replace the fan

belt in case of cracks or damage. Contact your

Sany distributor if you have any troubles.

5.8.7.5 Nitrogen pressure in accumulator

(breaker) - check

(If equipped)

Special tools will be used in order to check the

accumulator and inject nitrogen.

Please consult Sany distributor, if possible, to

conduct related inspection and inflating opera-

tion.

5-85

Maintenance

5.8.8 Every 2000 service hours

Also perform maintenance for every 100, 500

and 1000 service hours in the meantime.

5.8.8.1 Final drive oil - change

WARNING

● When the engine is just shut down, the

oil and components are still hot and

can cause burn. Wait until the oil is cool

enough before servicing.

● Remaining pressure in the tank can

cause oil to squirt out or the screw plug

to fly out. Personal injury could result.

Slowly loosen the screw plug in order

to release the pressure. Never stand in

front of the screw plug.

Always prepare your machine as required

and lock/tag it out before proceeding. See

“Preparing the machine” on page 2-58 and

F

“Lock-out and tag-out” on page 2-60.

L

● Refilling capacity:

See “Fluid capacities” on page 5-19.

P

● Prepare a wrench.

1. Adjust the filler cap screw (F) to the upper

position in order to make the line through

Level mark

the oil inspection screw plug (L) and the

drain screw plug (P) perpendicular to the

ground.

2. Use a proper screwdriver to eliminate the

dirt from the hexagonal socket of screw

plug in order to avoid damage to the bolt.

3. Place under the drain plug (P) a container

CZ335S-1104020

used to contain the oil.

Fig. 5-97

4. Use the spanner to remove the drain plug

5-86

Maintenance

5.8.8.2 Hydraulic tank filter screen - clean

WARNING

When the engine has just been stopped,

the parts and oil are still hot and can cause

serious burn. Wait until they are cool

enough before doing the job.

Always prepare your machine as required

and lock/tag it out before proceeding. See

“Preparing the machine” on page 2-58 and

“Lock-out and tag-out” on page 2-60.

1.

Turn the butterfly nut on the breather valve

Butterfly nut

Breather valve

and press the venting button.

2.

Loosen the four bolts and remove the cap

(1). When the cap is removed, it may fly

out due to the action of the spring (2). In

this case, hold down the cap when remov-

ing the bolts.

CZ335-1104080

3.

Hold the top end of the rod (3) and pull it

upward in order to remove the spring (2)

Fig. 5-98

and the screen (4).

4.

Clean the screen (4) of all dirt. Flush it with

1

cleaning oil. Replace the screen if dam-

aged.

2

5.

During installation, fix the screen (4) to

3

the bigger part (5) of the oil tank before

assembling.

4

5

6.

When assembling, take advantage of the

bulged part of the cap (1) to hold the spring

(2) before tightening the bolts.

CZ335-1104093

Fig. 5-99

5-88

Maintenance

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

WARNING

The accumulator contains pressurized nitrogen, which may explode due to improper op-

eration, thus resulting in machine damage and personal injury. The following items must

be observed when handling the accumulator:

● Some pressure remains in the hydraulic circuit. Never face the opening from which oil

may squirt when disassembling a hydraulic device. In addition, loosen the bolts slowly.

● Never dismantle the accumulator.

● Be away from fire sources.

● Never punch or weld the accumulator.

● Never bump or roll the accumulator. Keep it free from any impacts.

● Vent the air completely when handling the accumulator. Consult your Sany distributor

to do this job.

Note:

In continuous operation with low nitrogen pres-

sure in the accumulator, the remaining pres-

sure in hydraulic circuit will not be released

once failure occurs to your machine.

Functions of the accumulator

The accumulator stores the pressure of the

control circuit. Even if the engine is turned off,

the control oil circuit allows you to achieve the

following operations:

● Operate the control lever to lower the work

equipment. The work equipment will fall

due to gravity.

● The pressure in hydraulic circuit can be re-

leased.

The installation location of the accumulator is

CZ135B-1104029

shown in the right illustration.

Fig.

5-100

5-89

Maintenance

Checking the functions of accumulator

NOTICE

During inspection, make sure the sur-

rounding area is clear without personnel

or any barriers.

Check the nitrogen pressure through the fol-

lowing steps:

1. Park your machine on a hard, level ground.

2. Keep the work equipment 1.5m (4ft 11in)

1.5m

above the ground at maximum reach (with

the arm fully extended and the bucket fully

CZ335-1104095

turned outward.

Fig. 5-101

The step 3 through step 5 shall be conducted

within 15 seconds.

The accumulator's pressure drops gradu-

ally since stoppage of the engine. Therefore,

check the accumulator immediately after the

engine is shut down.

3. Keep the work equipment at its maximum

A

operating radius, turn the start switch to

OFF position (A) and stop the engine.

B

C

CZ335-1104096

Fig. 5-102

5-90

Maintenance

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

A

B

C

CZ335-1104097

Fig. 5-103

5. Place the lockout control to FREE position

(F). Operate the control lever to lower the

work equipment. Check the work equip-

ment whether it reaches the ground.

F

L

CZ335-1104098

Fig. 5-104

6. A work equipment lowering and touching

the ground under gravity indicates that the

accumulator functions normally.

In case that the work equipment is unable

to lower or is held half way, the pressure in

the hydraulic circuit accumulator may have

CZ335-1104099

dropped already.

Fig. 5-105

Consult Sany distributor for such inspec-

tion.

7. After checking through the a.m. steps,

place the hydraulic lockout control to LOCK

position and turn the start switch to OFF

position.

5-91

Maintenance

5.8.8.4 Hydraulic circuit internal pressure - release

1. Low the work equipment to ground.

2. Place the work equipment lockout control

to the LOCK position (L).

F

The step 4 through step 6 shall be carried

out within 15 seconds.

L

Pressure of the accumulator will drop grad-

ually after the engine is stopped. There-

CZ335-1104100

fore, the pressure can only be released

Fig. 5-106

when the engine has just be turned off.

3. Turn off the engine.

A

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

B

C

CZ335-1104101

Fig. 5-107

5. Place the lockout control to FREE position

(F) and then cycle the work equipment

control lever in all directions in order to

release the pressure in control circuit.

F

6. Place the lockout control to the LOCK

position (L) and then turn the start switch

L

to "OFF" position.

CZ335-1104098

Fig. 5-108

5-92

Maintenance

5.8.8.5 Oil in hydraulic tank - change

WARNING

● When the engine has just been stopped,

the parts and oil are still hot and can

cause serious burn. Wait until they are

cool enough before doing the job.

● Press the breather valve venting button

to release the internal pressure before

removing the oil filler cap.

Note:

For machines equipped with a hydraulic

breaker, the hydraulic oil deteriorates faster

than that of machines operating with a bucket.

For more information see “Hydraulic Break-

er Service Interval” on page 5-27.

● For refilling capacity see“Fluid capaci-

ties” on page 5-19.

● Prepare a lever (used for 36 mm socket

wrenches)

1. Unscrew the bolts of the bottom cover

plate and remove the cover plate.

2. Swing the upper structure in order to posi-

tion the drain plug beneath the hydraulic

CZ335-1104102

tank between the tracks.

Fig.

5-109

3. Retract the arm and bucket cylinders and

lower the boom in order to enable the

bucket tips to touch the ground.

4. lace the hydraulic lockout control to the

LOCK position and turn off the engine.

5-93

Maintenance

5.

Remove the cap of the oil filler (F) .

F

6.

Place a container under the drain plug.

Remove the drain plug (P) with the lever

in order to drain the oil. Check the O-ring

on the drain plug (P) and replace it timely if

broken. Tighten the plug (P) after draining.

● Tightening torque: 927±103N·m (94.6

± 10.5 kgf·m or 683.5 ± 76.0lbft)

● Do not get oil on your body when re-

moving the drain plug (P).

P

7.

Fill the hydraulic oil as required through the

CZ335-1104103

filler (F). Check the oil level, which shall be

Fig. 5-110

between the H and L marks of dipstick.

● For more information on applicable hy-

draulic oil see “Recommended Flu-

ids” on page 5-17.

● For more information on oil level inspec-

tion see “Cooling system

- clean”

on page 5-37.

8.

Eliminate air from the hydraulic circuit.

For more information on elimination of air

from the hydraulic circuit see “Hydraulic

Breaker Service Interval” on page 5-27.

5-94

Maintenance

5.8.8.6 Alternator - inspect

Contact your Sany distributor to inspect the al-

ternator.

Check the engine every 1000 service hours if

the engine is started frequently.

5.8.8.7 Engine valve clearance - check/

adjust

Special tools are necessary for inspection and

maintenance. Consult Sany distributor to do

this job.

5.8.9 Every 4000 service hours

Also perform maintenance for every 100,

250, 500, 1000 and 2000 service hours in the

meantime.

5.8.9.1 Coolant pump - inspect

Check coolant pump for leak of water or oil. In

case of any problem, contact your Sany dis-

tributor for disassembly, repair or replacement.

CZ335-1104104

Fig. 5-111

5.8.9.2 Start motor - check

Consult Sany distributor to check the start mo-

tor. Check it every 1000 service hours if the

engine is started frequently.

5-95

Maintenance

5.8.9.3 Accumulator (control oil circuit) - replace

WARNING

The accumulator contains pressurized

nitrogen, which may explode due to im-

proper operation, thus resulting in machine

damage and personal injury. The following

items must be observed when handling the

accumulator:

● Some pressure remains in the hydrau-

lic circuit. Never face the opening from

which oil may squirt when disassem-

bling a hydraulic device. In addition,

CZ135B-1104029

loosen the bolts slowly.

● Never dismantle the accumulator.

Fig. 5-112

● Be away from fire sources.

● Never punch or weld the accumulator.

● Never bump or roll the accumulator.

Keep it free from any impacts.

● Vent the air completely when handling

the accumulator. Consult your Sany dis-

tributor to do this job.

If your machine is kept operating when the

performance of accumulator decreases, the

pressure in the hydraulic system will not be re-

leased. Consult Sany distributor to replace the

accumulator.

The accumulator's installation location is

shown in the right illustration.

5-96

Maintenance

5.8.9.4 High-pressure tube clamps and rubber - check

CZ335-1104106

Fig. 5-113

Always prepare your machine as required and lock/tag it out before proceeding. See “Preparing

the machine” on page 2-58 and “Lock-out and tag-out” on page 2-60.

Check, through visual inspection and feel, for any loose bolts on the five mounting clamps of

high-pressure tubes between feed pump and injection nozzle. Check for any aged rubber. Con-

tact your Sany distributor to replace any part that fails.

5.8.9.5 Compressor working condition - inspect

The following two items are to be inspected:

1. Whether the compressor and the magnetic clutch are switched on/off when switching on/off

the air conditioner.

2. Whether the clutch or compressor produces abnormal noise.

In case of any problem, Contact your Sany distributor for disassembly, repair or replacement

of the parts.

5-97

Troubleshooting

6 TROUBLESHOOTING

6.1 Troubleshooting Preparation

6.1.1 Checks before troubleshooting

Item

Judgement value

Remedy

1. Check fuel level and type of fuel

—

Add fuel

2. Check for impurities in fuel

—

Clean, drain

3. Check hydraulic oil level

—

Add oil

4. Check hydraulic oil strainer

—

Clean, drain

Lubricating

5. Check swing drive oil level

—

Add oil

oil, coolant

6. Check engine oil level (in oil pan)

—

Add oil

7. Check coolant level

—

Add water

8. Check dust indicator for clogging

—

Clean or replace

9. Check hydraulic filter

—

Replace

10. Check final drive oil level

—

Add oil

—

1. Check for looseness and corrosion of battery termi-

Tighten or replace

nal and wiring

—

Electrical

2. Check for looseness and corrosion of alternator ter-

Tighten or replace

equipment

minal and wiring

—

3. Check for looseness and corrosion of start motor

Tighten or replace

terminal and wiring

Hydraulic,

1. Check for abnormal noise and smell

—

Repair

mechanical

2. Check for oil leakage

—

Repair

equipment

3. Carry out air bleeding

—

Bleed air

1. Check battery voltage (engine stopped)

20-30V

Replace

2. Check battery electrolyte level

—

Add or replace

3. Check for discolored, burnt, exposed wiring

—

Replace

4. Check for missing wiring clamps and hanging wiring

—

Repair

5. Check for water leaking on wiring (be particularly

—

Electrics,

Disconnect con-

careful attention to water leaking on connectors or

electrical

nector and dry

terminals)

equipment

6. Check for blown or corroded fuses

—

Replace

7. Check alternator voltage (engine running at 1/2

After running for

Replace

several minutes:

throttle or above)

27.5~ 29.5V

8. Check operating sound of battery relay

—

Replace

(when switch is turned ON/OFF)

Table 6-1

6-3

Troubleshooting

6.1.5 Hydraulic components handling precautions

With the increase in pressure and precision

of hydraulic equipment, the most common

cause of failure is dirt (foreign material) in the

hydraulic circuit. When adding hydraulic oil, or

when disassembling or assembling hydraulic

equipment, it is necessary to be particularly

careful.

1.

Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters,

or repairing the machine in rain or high

winds, or places where there is a lot of

dust.

2.

Disassembly and maintenance work in the

field

ZX215-1000023

If disassembly or maintenance work is

Fig. 6-1

carried out on hydraulic equipment in the

field, there is danger of dust entering the

equipment. It is also difficult to confirm the

performance after repairs, so it is desir-

able to use unit exchange. Disassembly

and maintenance of hydraulic equipment

should be carried out in a specially pre-

pared dust-proof workshop, and the per-

formance should be confirmed with special

test equipment.

3.

Do not let any dirt or dust get in during

refilling operations.

Be careful not to let any dirt or dust get

in when refilling with hydraulic oil. Always

keep the oil filler and the area around it

clean, and also use clean pumps and oil

containers. If an oil cleaning device is

used, it is possible to filter out the dirt that

has been collected during storage, so this

ZX215-1000025

is an even more effective method.

Fig. 6-2

6-10

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