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SANY Crawler Hydraulic Excavator SY115C9/135C/155H. Operation and Maintenance Manual - page 8

Maintenance

2. Hold the primary air cleaner element (5),

shake it slightly and turn it in both direc-

tions in order to pull it out.

3. After removing the primary air cleaner ele-

ment (5), check the secondary air cleaner

element to see if it displaces or tilts. Push

it back to position in case of displacement

or tilting.

4. After removal of the primary air cleaner

element (5), use clean cloth or tape to

cover the secondary air cleaner element (6)

in order to prevent entering of dirt.

5. Wipe or brush off the dirt from the cover (3)

and the inside of air cleaner housing (1).

6. Wipe off the dirt built up on the cover (3)

and the vacuum valve (4).

Fig. 5-7

Note:

Never tap the air filter with any object when

cleaning it.

7. Use dry compressed air (less than 0.69

MPa (7kgf/cm2) 99.4 PSI)) to blow along

the inside of the pleats toward the primary

air cleaner element, and then direct the

compressed air along the outside of the

pleats to blow from interior to exterior.

1) Replace the primary air cleaner ele-

ments that have been cleaned six times

or used for more than a year. Replace

Fig. 5-8

the secondary air cleaner element at the

same time.

2) Remove one of the tags from the filter

after each cleaning.

5-31

Maintenance

8. Use a light to illuminate the whole primary

air cleaner element. Replace the primary

air cleaner element in case of holes or

reduced thickness found in the filter mate-

rial.

9. Remove the cloth or tape covering the

inner filter element (6).

Note:

Fig. 5-9

● Never use air cleaner elements with dam-

aged pleats, gaskets or seals.

● Using a filter that has been used for more

than a year or an O-ring that has been

cleaned could result failure. Never use

them again.

10. Check the new filter or the cleaned filter for

dirt or oil stains on the sealing area. Wipe

off the dirt or oil stains.

11. Push the primary air cleaner element

straight forward into the air cleaner hous-

ing. You can hold the primary air cleaner

element and shake it slightly in order to

insert the primary air cleaner element eas-

ily.

Note:

The air cleaner must be reinstalled correctly.

Make sure that the air cleaner cartridge's bot-

tom (the end without opening) (B) (C) faces

the cover (3). Incorrect installation could result

in air filter damage and engine damage.

Fig. 5-10

5-32

Maintenance

Note:

The latches (2) and housing of air cleaner

could be damaged when you insert filter ele-

ment with expanded rubber on the top or you

did not push it in vertically but latch the cover

(3) with force. So be careful when you reas-

semble filter element.

Fig. 5-11

12. Install the cover (3) according to the follow-

ing steps.

1) Align the cover (3) with the filter.

2) Let the end of latch (2) catch the flange

of the air cleaner housing.

3) To lock the latches (2), engage the

latches in a diagonal sequence (top -

Fig. 5-12

bottom - left - right) like tightening the

bolts.

4) The vacuum valve (4) shall face toward

the ground (A) when installing the cover

(3).

5) When the cover (3) is installed, inspect

the air cleaner housing shall not have

a larger clearance with the cover (3).

Reinstallation is necessary in case of

larger clearance.

5-33

Maintenance

Replacing filter elements

1. Open the left rear door of the machine and

loosen the four latches (2) before removing

the cover (3).

Fig. 5-14

2. Hold the outer filter element (5), shake

it slightly and turn it in both directions in

order to pull it out. Never remove the inner

filter element (6).

3. After removing the outer filter element (5),

check the inner filter element to see if it

displaces or tilts. Push it back to position in

case of displacement or tilting.

Fig. 5-15

4. Wipe or brush off the dirt from the cover (3)

and the inside of air filter housing (1).

5. Wipe off the dirt built up on the cover (3)

and the vacuum valve (4).

Fig. 5-13

5-34

Maintenance

Note:

The latches (2) and housing of air cleaner

could be damaged when you insert filter ele-

ment with expanded rubber on the top or you

did not push it in vertically but latch the cover

(3) with force. So be careful when you reas-

semble filter element.

Fig. 5-17

8.

Install the filter cover (3) through the fol-

lowing steps.

1) Align the cover (3) with the filter.

2) Let the end of latch (2) catch the flange

of the air cleaner housing.

3) To lock the latches (2), engage the

latches in a diagonal sequence (top -

Fig. 5-18

bottom - left - right) like tightening the

bolts.

4) The vacuum valve (4) shall face toward

the ground (A) when installing the cover

(3).

5) When the cover (3) is installed, inspect

the air cleaner housing shall not have

a larger clearance with the cover (3).

Reinstallation is necessary in case of

larger clearance.

9.

Use a new sticker to replace sticker (7) on

cover (3).

Fig. 5-19

5-36

Maintenance

Sany recommends TEEC-L35 antifreeze. This antifreeze has a concentration of 50% and needs

no dilution.

If you buy antifreeze from the market, make sure that the antifreeze's concentration is within the

range 30-68% in order to ensure its performance against corrosion.

The ratio of mixing antifreeze with water is determined by the minimum ambient temperature, as

shown in the following table.

It is better to estimate 10℃ (18 ℉ ) lower than the actual temperature when selecting a mixture

ratio.

The mixture ratio is determined by ambient temperature. The mixture ratio shall not be lower than

30% (antifreeze/total volume of coolant ×100) in even the regions where freezing prevention is

unnecessary in order to prevent corrosion of the cooling system.

The undiluted antifreeze will freeze at -15 ℃ (5 ℉ ). Do not store the undiluted antifreeze in an

environment where is lower than -15℃ (5 ℉ ).

Minimum

℃

-10

-15

-20

-25

-30

-35

-40

atmospheric

℉

14

5

-4

-13

-22

-31

-40

temperature

L

6.75

8.1

9.23

10.35

11.25

12.15

13.05

Antifreeze

US gal

1.79

2.15

2.45

2.75

2.98

3.22

3.46

L

15.75

14.4

13.3

12.15

11.25

10.35

9.45

Water

US gal

4.18

3.82

3.53

3.22

2.98

2.75

2.51

Volume ratio (%)

30

36

41

46

50

54

58

Table 5-8

5-38

Maintenance

WARNING

● Antifreeze is flammable. Naked fire

should be kept away from antifreeze.

Antifreeze is poisonous. Be careful

when opening the drain valve in order

to prevent skin contract of the water

containing antifreeze. In case of con-

tact with your eyes, flush with large

amount of clean water and refer to

medical care immediately.

● To change the coolant or drain the ra-

diator coolant when repairing your ma-

chine, consult professional company

or your Sany distributor to dispose the

coolant containing antifreeze. Never

drain the coolant to sewage or onto

ground since the antifreeze is poison-

ous.

Use suitable water to dilute the antifreeze. (For

more information see“Coolant”on page 5-11.)

Density meter is recommended to control the

mixture ratio.

Prepare a container to hold the drained cool-

ant. The container's capacity should be larger

than the specific volume of coolant.

Prepare a hose to transfer anti-freezing cool-

ant and water.

1. Park your machine on a level ground and

then shut off the engine. Lock out and tag

out your machine before proceeding. See

“Lock-out and tag-out” on page 2-60.

2. Remove slowly the radiator cap (1) to

relieve pressure only when the coolant is

cool enough for you to touch the radiator

cap with your bare hand.

Fig.

5-20

5-39

Maintenance

3.

Remove the bottom cap and place a con-

tainer to hold the coolant under the drain

valve (2).

Open the radiator bottom drain valve (2) to

drain the coolant.

4.

Close the drain valve (2) after draining

the coolant. Add tap water to the radiator.

When the radiator is full, start the engine

at low speed in order to heat up to 90

℃

Fig. 5-21

(194 ℉ )at minimum. Continue to run the

engine for about 10 minutes.

5.

Stop the engine and open the drain valve

(2) to discharge water.

6.

Use detergent to clean the radiator after

draining the water. Refer to the detergent

instruction for cleaning method.

7.

Close the drain valve (2).

8.

Reinstall the bottom cap.

Fig. 5-22

9.

Fill the coolant containing antifreeze till the

fluid overflows from the filler opening. The

mixture ratio of antifreeze and water is to

be determined according to the chart of

mixing values of antifreeze and coolant.

10. Run the engine at low speed for about five

minutes and then at high speed for five

minutes in order to eliminate the air from

the coolant. (The radiator cap (1) shall be

left open at the moment.)

11. Clean the auxiliary reservoir (3) after

completely draining the coolant from it. Add

water till the coolant level reaches a level

between the high and the low marks.

Replace the auxiliary tank with a new one

if the old one is hard to clean.

12. Stop the engine. Wait about three minutes

before adding water through the filler open-

ing. Screw on the radiator cap tightly.

5-40

Maintenance

5.8.2.3 Track shoe bolts - inspect/tighten

If your machine is operated with loose track

shoe bolts (1), the bolts can break. Tighten

any loose bolts immediately.

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.

Tightening

Fig.

5-23

Three-grouser track shoe

1. Tighten the bolts to torque values of

600N·m - 680N·m (61.2kgf - 69.4kgf or

441Ibft - 500Ibft). Make sure that the nuts

and track shoe are in close contact with

the link mating surface.

2. Inspect and tighten again by 120º±10º.

Tightening sequence

Tighten the bolts in the sequence shown in the

right illustration. After tightening, make sure

that the nuts and track shoe are in close con-

tact with the link mating surface.

Fig. 5-24

5-41

Maintenance

5.8.2.4 Track tension - inspect/adjust

The wear of undercarriage pin rolls and pin

bushings may vary according to operating

condition and soil type. Therefore, the ten-

sion of track shall be checked often in order to

maintain standard tension.

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.

Inspection

1. Run the engine at low idle speed. Travel

the machine forward a distance that is

equivalent to the length of an unfolded

track. Park your machine.

2. Place a straight edge on top of the track

grousers between the idler (1) and the

carrier roller (2), as shown in the right

illustration.

3. Measure the maximum amount of sag in

Fig.

5-25

the track. The sag is measured from the

highest point of the track grouser to the

bottom of the straight edge.

The standard value of sag (a) should be10

- 30 mm (0.4 -1.2in).

5-42

Maintenance

If the track tension is beyond the standard

range, adjust the track tension through the fol-

lowing procedure.

Adjustment

CAUTION

● The screw plug (1) is possible to fly out

under high-pressurized grease. Never

loosen the screw plug (1) over one

turn.

● Never loosen any other components

except the screw plug (1). Never face

the installation direction of the screw

plug (1).

● If the track does not loosen with the

following method, contact your Sany

Fig. 5-26

distributor.

Increasing track tension

To increase the track's tension, prepare a

grease gun.

1. Add grease with the grease gun through

the grease fitting (2). (The grease fitting (2)

and the screw plug (1) are integral.)

2. Slowly travel the machine forward (7-8 m

Fig.

5-27

(23 ft - 26 ft 3 in)) in order to check whether

the track tension is suitable.

3. Check the track tension again. Readjust

the tension if it is still beyond the standard

range.

4. Continue to add grease till the distance

(S) becomes null (0). If the tension is still

loose, it is probably because the pin roll

and bushing are overworn. The pin rolls or

bushings must be swapped or replaced.

Fig.

5-28

Contact your Sany distributor for repair.

5-43

Maintenance

Reducing track tension

WARNING

● Never loosen the valve (1) quickly or

excessively. The grease under pres-

sure can squirt out of the track tension-

ing cylinder. Carefully loosen the valve

(1) and keep your body and face away

from the valve (1).

● Never loosen the grease fitting (2).

● The grease is to be released through

the following steps. If the tension of

track is still tight, contact your Sany

Fig. 5-29

distributor for repair.

●

If gravels or mud falls between the sprock-

et and track link, remove it before you re-

duce track tension.

●

To reduce track tension, slowly turn valve

(1) counterclockwise with a long socket

wrench. The grease will come out of the

grease fitting.

●

Loosening valve (1) only one turn is

enough to reduce track tension.

Fig.

5-30

●

If grease does not come out smoothly,

drive your machine back and forth for a

short distance.

●

When suitable sag of track is achieved,

turn valve (1) clockwise to 78.4 N·m (8

kgf·m).

●

To check if you have got desired track

tension, run the engine at low idle speed,

drive your machine forward (at a distance

that is equivalent to the length of an un-

folded track), and then park the machine.

Fig.

5-31

●

Check track tension again. Readjust the

tension if it is still beyond the standard

range.

5-44

Maintenance

5.8.2.5 Bucket tips (lateral pin) - replace

Replace the bucket tip before the tip adapter

is worn.

WARNING

● Place the work equipment firmly before

replacing the bucket tips. Stop the en-

gine and engage the hydraulic lockout

control. If the hydraulic lockout control

is free, unexpected movement of the

work equipment could cause sever ac-

cident.

● If you drive the pin with great force, the

pin may fly out and cause an accident.

Keep irrelevant people a safe distance

from the area.

● Debris may fly out during replacement.

Always wear safety goggles, gloves

and other necessary protective gear.

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. Place a block beneath the bucket in order

to remove the pin and keep the bucket

bottom leveling.

Fig. 5-32

2. Make sure the work equipment is stable

and the hydraulic lockout control is in

LOCK position.

Fig. 5-33

5-45

Maintenance

3. Place a metal stick against one end of the

pin (1) and hammer the metal stick in order

to drive the pin (1) out and remove the

bucket tip (2).

Remark:

● The metal stick shall have a smaller diam-

eter than the pin.

● If the tip cannot be removed safely in this

Fig. 5-34

way, consult Sany distributor for replace-

ment.

4. Remove the tip and check the latch for

any damage. Replace it if necessary.

The latches and tips worn short must be

replaced with new ones.

5. Clean the installation surface. Mount the

new bucket tip (2) to its adapter. Push part

of the pin (1) into the tip and hammer it in

completely in order to lock the bucket tip

Fig. 5-35

onto its adapter.

No.

Item

No.

Item

1

Bucket

8

Latch

2

Plate

9

Bush

3

Plate

10

Bolt

4

Plate

11

Washer

5

Adaptor

12

Spacer

6

Tip

13

Side cutter (left)

7

Pin

14

Side cutter (right)

Table 5-9

Fig. 5-36

5-46

Maintenance

1. Place the bucket on a level ground.

Remark:

Before removing the pin roll, slowly lower the

bucket to a level where it just contacts the

ground.

Fig.

5-37

If a larger force is used to lower the bucket to

the ground, resistance could increase on the

pin roll, causing difficulties while removing it.

Note:

Make sure the pin roll is free from mud or sand

after removal.

Both ends of the bushing are installed with

seals against dust. Be careful not to damage

Fig.

5-38

them.

2. Remove the nuts and screws on the plate

retaining arm pin (A) and link pin (B), take

out arm pin (A) and link pin (B), and then

remove the bucket.

3. Align arm (5) with the bore for bucket

replacement and the link (6) with bore (2).

Insert the greased pin rolls (A) and (B) into

bore (1) and bore (2) respectively.

Fig.

5-39

5-48

Maintenance

Remark:

When mounting the bucket, place the O-ring

(3) of bucket (4) to the position, as shown in

the right illustration, corresponding to the arm

pin (A). After the pin roll is inserted, align it to

the standard notch.

4. Reinstall the nuts and bolts onto the plate

retaining the pin rolls. Add grease to the

pin rolls.

Fig. 5-40

Remark:

● Inject sufficient amount of grease till the

grease is squeezed out of the end face.

● Replace any broken seals when replacing

a bucket. The use of broken seals could

allow sand or dust to penetrate through to

the pin roll and cause its abnormal wear.

5.8.2.7 Bucket clearance - adjust

The bucket linking clearance must be readjust-

ed after your machine has been operated for

a period of time. When the linking clearance

is excessively large or small, it is necessary to

install or remove the spacer.

WARNING

Place the work equipment firmly before ad-

justing bucket clearance. Stop the engine

and engage the hydraulic lockout control.

If the hydraulic lockout control is free,

unexpected movement of the work equip-

ment could cause severe accident.

5-49

Maintenance

1.

Park your machine on a level ground.

Lower the bucket to the ground, in an at-

titude shown in the right illustration.

2.

Run the engine at low speed. Fix the

bucket on the ground. Slowly turn the

upper structure counterclockwise till the

inside of the left side of the bucket contact

closely with the left end surface of the arm.

3.

Shut off the engine. Lock out and tag out

Fig.

5-41

your machine before proceeding. See

“Lock-out tag-out” on page 2-60.

4.

Move the O-ring (1) and measure the

clearance (a). It is easy to obtain accurate

result with a feeler gauge.

5.

Loosen the four plate-mounting bolts (2) in

order to detach the plate (3). The spacer

has an opening, so it is unnecessary to

remove the bolt when making adjustment.

6.

Remove the spacer equivalent to the

measured clearance (a).

Fig.

5-42

(For example)

If the clearance is 3 mm (0.118 in), remove

two 1.0 mm (0.039 in) spacers and one 0.5

mm (0.02 in) spacer, or one 2.0 mm (0.078

in) spacer and one 0.5 mm (0.02 in) spac-

er. The clearance is reduced to 0.5 mm

(0.02 in). The spacers (4) include three

types, 2.0 mm (0.078 in), 1.0 mm (0.039 in)

and 0.5 mm (0.02 in). When the clearance

(a) is less than one spacer, no adjustment

shall be made.

7.

Tighten the four bolts (2).

If it is difficult to tighten the bolts (2), re-

move the pin-retaining bolt (5) before tight-

ening the bolts (2).

5-50

Maintenance

5.8.2.8 Window washer fluid - 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.

If the washer fluid contains air, check the fluid

level in the reservoir (1). Add washer fluid if

necessary.

To prevent dirt from entering the reservoir, be

Fig. 5-43

careful when filling the washer fluid.

Select a mixture ratio according to ambient

temperature. Therefore, the detergent is to be

diluted with water according the ratios listed

below.

Operating Regions

Mixture Ratio

Anti-Freezing Temperature

Detergent 1/3:

General

- 10℃ (14ºF)

Water 2/3

Detergent 1/2:

Cold regions in winter

- 20℃ (- 4ºF)

Water 1/2

Frigid regions in winter

Pure detergent

- 30℃ (- 22ºF)

Table 5-10

There are two types of detergent: one for

-10℃ (4°F) (common) and one for -30℃ (-22ºF) (frigid

regions), which can be selected according to the operating region.

5-51

Maintenance

5.8.2.9 Air conditioner - inspect/service

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.

Checking refrigerant (gas) level

WARNING

● The refrigerant getting into your eyes

or on your skin can cause blindness

or freezing injury. Never touch the re-

frigerant. Never loosen any parts of the

refrigerant lines.

● Keep any naked fire away from the

leaking position of refrigerant gas.

Insufficient refrigerant (R134a) will severely

impair the cooling performance.

When the engine is running at high speed, op-

erate the air conditioner for strong refrigeration

and observe through the sight glass (1) on the

condenser reservoir (2) in order to inspect the

condition of refrigerant gas flowing to the tube.

● The refrigerant flows without bubble: per-

fect

● The refrigerant flow contains bubbles that

Fig. 5-44

pass continuously: refrigerant level low

● Colorless and transparent: no refrigerant

Remark:

The appearance of bubbles indicates low re-

frigerant level. Please consult Sany distributor

to add refrigerant. Running the air conditioner

with low refrigerant level could damage its

compressor.

Inspection during idle period

Fig. 5-45

5-52

Maintenance

When the air conditioner will not be used for a long period of time, the air conditioner

shall be operated for 3-4 minutes each month in order to lubricate the compressor com-

ponents.

Components

Description

Service Interval

Twice a year (spring and au-

Refilling

tumn)

Refrigerant (gas)

Tube connections and internal leakage of parts

Daily

and components

Condenser

Radiator fins plugged

Every 500 hours

Compressor

Function

Every 4000 hours

Loose and bent

Every 250 hours

V-belt

Deterioration, wear, scratch and cracking

Every 250 hours

Noise, odor smell or abnormal heat

When required

Fan motor and fan

Function (check for abnormal noise)

When required

Air conditioner air

Air flow control switch and switching function

Daily

flow switch

Control unit

Function (make sure the function is normal)

When required

Loose connections and loose or detached nuts

Joining bolts

Every 6 months

and bolts

Installation condition, loose connections, air

Connection tubes

When required

leakage or any damage

Reservoir dryer

Temperature difference indicates a blocked

temperature differ-

Every year

dryer.

ence

Table 5-11

5-53

Maintenance

5.8.2.10 Gas spring - inspect

WARNING

The Gas Spring contains high-pressurized

nitrogen. Wrong operation can cause ex-

plosion and result in machine damage and

personal injury or death. The following

items shall be observed when dealing with

the Gas Spring.

● Be away from naked fire.

● Never drill or weld the Gas Spring.

● Never hammer the Gas Spring or ex-

pose it under any impact.

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.

The air springs are located on top of the cab (at

both the left and right sides).

Contact your Sany distributor for inspection,

repair and replacement in case of the following

conditions.

● The cab roof hatch cannot be opened eas-

ily.

● The cab roof hatch cannot be kept open.

Fig. 5-46

● Oil or air leaks from the air spring.

5-54

Maintenance

5.8.2.11 Air in hydraulic system - purge

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. Purging air from the pump

1) Loosen air vent plug (1) and check for

oil leak.

2) If no oil leaks, disconnect drain hose

from hydraulic pump and add hydraulic

oil to hydraulic pump through drain port

(2).

Well secure the disconnected hose. To

prevent overflow, hose opening must be

higher than oil level in hydraulic tank.

3) Tighten the plug (1) and reconnect the

drain hose after purging the air.

Fig.

5-47

Note:

If drain hose is reconnected before tightening

the plug (1), oil will squirt out of the plug (1).

If the pump is operated when it is not fully filled

with hydraulic oil, extra heat will be generated

and pump damage could result.

2. Starting the engine

See “Engine Starting” on page 4-22.

After starting the engine run it at low speed

for 10 minutes before you perform any op-

eration.

3. Purging air from hydraulic cylinders

1) Run the engine at low idle speed.

Extend and retract oil cylinder 4-5 times.

Note that the piston shall not reach its

5-55

Maintenance

stroke end. Keep it 100 mm (3.9 in)

from stroke end.

2) Operate each cylinder 3-4 times to its

stroke end.

3) Operate each cylinder 4-5 times to its

stroke end in order to purge air com-

pletely.

Note:

If you instantly run the engine at high speed or

operate a cylinder to its stroke end, air in cylin-

der could damage piston seal.

4. Purging air from swing motor

1) Run the engine at low speed. Loosen

the hose (3) at the port S. Check if oil

comes out of the hose (3) from the port

S.

Note:

Do not operate the swing drive under any cir-

cumstances.

2) If no oil is seen, shut off the engine.

Remove the hose (3) from the port S

and add hydraulic oil to the motor shell.

Fig.

5-48

3) Tighten the hose (3) at the port S after

purging the air from the swing motor.

4) With the engine running at low idle

speed, swing evenly and slowly to the

left side and the right side at least two

times. The air will be expelled from the

swing drive oil path.

Note:

● The air in the swing motor could damage

the motor bearing.

● To replace the relief valve of the travel mo-

5-56

Maintenance

tor, consult Sany distributor for replace-

ment and air elimination.

5. Eliminate air from the travel motor (only

when the oil has been discharged from the

travel motor shell)

1) Run the engine at low speed. Loosen

the air vent screw plug (4). Tighten the

screw plug if oil is seen.

2) Run the engine at low speed. Swing the

work equipment 90 degrees in order to

place it at the track side.

3) Raise the machine with the force of the

Fig. 5-49

work equipment. With the track lifted

just above the ground, run the track

unloaded for two minutes. Repeat this

operation for both tracks and run the

tracks back and forth uniformly.

6. Eliminate air from attachment (if equipped)

If a breaking hammer or other attachment

has been installed, run the engine at low

idle speed and operate the attachment

control pedal repeatedly (about 10 times)

Fig.

5-50

till the air is expelled from the oil path com-

pletely.

Note:

● If manufacturer of the attachment has pro-

vided instruction on eliminating air from

the attachment, the instruction shall be fol-

lowed to eliminate the air.

● Turn off the engine after air elimination.

Wait five minutes before operation in order

to eliminate the bubbles in hydraulic cylin-

der.

● Check for oil leakage and wipe off the oil

overflowed.

● Check the oil level after purging the air.

Add oil if the oil level is low.

5-57

Maintenance

5.8.2.12 Hydraulic circuit internal pressure - release

WARNING

● The hydraulic circuit is always under

pressure. In this case, the pressure in

hydraulic circuit is to be released when

checking or replacing the hoses or fit-

tings. Without doing so, the pressur-

ized oil will squirt out and cause seri-

ous personal injury.

● After the engine is stopped, the com-

ponents and oil are still hot and can

cause serious burn. Wait until the tem-

perature comes down before operating.

● The oil may squirt out when remov-

ing the oil filler cap. Therefore, slowly

remove the cap in order to release the

internal pressure.

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

2. Within 15 minutes since the engine is shut

off, turn the start switch to ON position and

cycle the work equipment control lever and

the travel control lever in all directions in

order to release the internal pressure.

3. Lock/tag it out before proceeding. See

“Lock-out tag-out” on page 2-60.

Fig. 5-51

4. Slowly loosen the oil filler cap on top of

the hydraulic tank in order to release the

internal pressure.

Fig. 5-52

5-58

Maintenance

5.8.4 Every 100 service hours

5.8.4.1 Lubrication

NOTICE

● If the lubricated components produce abnormal noise, additional lubrication is re-

quired besides regular maintenance.

● A new machine shall be greased every 10 hours within the initial 50 hours.

● After operating in water, the machine's wet pin rolls are to be greased.

1. Adjust your machine to a to-be-greased attitude shown in the illustration below, lower the work

equipment to the ground and then turn off the engine.

2. Lock/tag it out before proceeding. See “Lock-out tag-out” on page 2-60.

3. Use a grease gun to inject grease through the greasing points indicated in Fig. 5-53.

4. Finally, wipe off the used grease that has been squeezed out.

Fig. 5-53

5-60

Maintenance

(1) Boom cylinder root pin (2)

Fig. 5-54

(2) Boom root pin (2)

(3) Boom cylinder piston rod end (2)

(4) Arm cylinder root pin (1)

Fig. 5-55

(5) Boom-arm joining pin (2)

Fig. 5-56

5-61

Maintenance

(6) Arm cylinder piston rod end (1)

(7) Bucket cylinder root pin (1)

Fig. 5-57

(8) Arm-Bucket joining pin (1)

Fig. 5-58

(9) Rod joining pin (2)

(10) Bucket cylinder piston rod end (1)

(11) Bucket-rod joining pin (1)

Fig. 5-59

5-62

Maintenance

5.8.5 Every 250 service hours

5.8.5.1 Compressor belt tension - inspect/

adjust

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.

Inspection

With a force of about 58.8N (6kgf), press with

your finger the middle section of the belt be-

tween the drive pulley (1) and the compressor

pulley (2) in order to check the deflection (A),

which should be 5-8mm (0.20in-0.31in).

Fig.

5-60

Adjustment

1. Loosen the bolts (1) and (2).

2. Move the compressor (3) and its bracket (4)

in order to adjust belt tension.

3. Tighten the bolt (1) and (2) after positioning

the compressor (3).

4. Check again the belt tensioning device

after adjustment.

Fig.

5-61

Reference

Use a tension meter to check the belt tension

of the compressor.

New Belt

Used Belt

637±108 (N)

441±88.2 (N)

(65±11 (kgf))

(45±9 (kgf))

Table 5-12

5-63

Maintenance

5.8.5.2 Oil in engine oil pan and oil filter -

change/replace

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.

Prepare as the following:

Fig.

5-62

● Capacity of engine oil pan: See “Fluid

capacities” on page 5-19.

● Filter wrench

1. Remove the bottom cover of the machine.

Place a container under the drain valve.

(Choose a container of a proper size ac-

cording to the capacity table). The oil will

be drained into the container through a

piece of clean cloth.

Fig.

5-63

2. To avoid splashing of the oil, slowly open

the drain valve to discharge oil, and close

the valve after drainage.

5-65

Maintenance

3. Open the right door and turn the filter

(1) leftward with filter spanner in order to

disassemble the filter.

4. Clean the filter seat (2). Fill the new filter

with clean engine oil. Apply engine oil (or a

film of grease) to the filter sealing surface

and the threads before installing the filter

to its seat.

Fig. 5-64

Remark:

Check the filter seat (2) for presence of used

seal. The presence of used seal in the filter

seat (2) can cause oil leakage.

5. The installation requires contact of the

sealing surface with that of the filter seat

(2). Turn the filter 3/4-1 turn.

6. After replacement of the filter, open the

engine's hood and fill engine oil through

the filler to a level between the H and L

marks of the dipstick.

Fig. 5-65

7. Run the engine idly for a short time and

then turn off the engine. Check again the

oil level, which shall be between the H and

L marks of the dipstick. For more informa-

tion see “Oil in engine oil pan and oil

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

8. Reinstall the bottom cover.

Fig. 5-66

NOTICE

Contact your Sany distributor to obtain

genuine engine oil in order to guarantee

oil quality and ensure 250 service hours.

5-66

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 the door on the right side of machine.

2.

Place a fuel container under the filter.

3.

Loosen the drain valve (1) to discharge

water and sediment in the bowl (2). Also

drain the fuel in filter (3).

4.

Use a filter wrench to turn counterclock-

wise the bowl (2) in order to remove it. (The

bowl can be reused.)

5.

Use the filter wrench to turn counterclock-

wise the filter (3) in order to remove it.

6.

Install the bowl (2) to the bottom of new

filter. Always replace the O-ring seal (4).

Fig. 5-67

7.

Apply oil to seal surface during installa-

tion. Make the seal and filter have a close

contact before further tightening the filter

by 1/4 - 1/2 turn.

If the bowl (2) was over-tightened, the

O-ring seal might be damaged and fuel

leak could result. If the bowl (2) was not

tightened enough, fuel will leak through

the gap with O-ring seal. To prevent such

problems, always tighten it to the specified

torque.

8.

Clean the filter seat. Add clean fuel to new

filter. Apply a thin layer of oil to the seal

surface and install the filter to the filter

seat.

5-68

Maintenance

Note:

● Never remove the cover (B) while filling the

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

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.

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

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