SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual

2-6

Shop Safety

2.2 General Shop Safety

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

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

WARNING

●

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

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Shop Safety

2.2.1 Rules and shop behavior

●

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

●

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

●

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

●

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

oor or work area.

2.2.2 Housekeeping

●

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

●

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

oor.

●

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

●

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

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Shop Safety

2.2.3 Shop Liquids Storage

●

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

ned shop area. Follow all OSHA

regulations regarding

uid storage.

●

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

re.

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

●

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

or an unexpected explosion.

●

Never smoke or bring open

ames around

liquids, doing so could result in an unex-
pected

re or explosion.

●

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

2.2.4 Cleaning Parts

Never use gasoline, diesel fuel or similar

am-

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

ammable solvents to clean parts.

Failure to do so could result in explosion or

re.

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Shop Safety

2.2.5 Jacking Up the Machine

●

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

●

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

●

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

2.2.6 Electrical Dangers

●

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

re.

●

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

●

When working around

ammable liquids or

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

re.

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Shop Safety

2.2.7 Removing Attachments

●

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

●

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

re exits.

2.2.8 Cleaning the Machine

●

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

●

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

●

Never pressure-wash or

ood the inside of

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

2.2.9 Using the Correct Tools

●

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

●

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

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Shop Safety

2.2.10 Hoisting a Load

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

●

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

●

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

●

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

●

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

●

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

●

Keep your tools clean, and when the job is
complete, take inventory of the tools you
were using to be sure no tools were left in
the machine.

●

Always put shop tools back in there proper
storage location when

nished.

●

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

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Shop Safety

2.2.11 Appropriate Working Apparel

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

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

2.2.12 Safety Partners

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

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

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

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Shop Safety

2.2.13 Two people when engine run-

ning

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

●

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

●

Set the safety lock control lever to the lock
position.

●

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

●

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

2.2.14 Driving Pins

When using a hammer to drive pins, metal
particles may

y off. This may lead to serious

eye injuries. Always do the following:

●

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

●

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

●

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

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Shop Safety

2.2.16 Fire Extinguisher and Emer-

gency Exits

●

It is important to know where all emergen-
cy exits and fire extinguishing equipment
are located if a fire should occur in the
shop.

●

Before preparing for work, take time and
walk around the shop to make a mental
note of where all exits and

re equipment

are located. If you are performing repairs
in the

eld, always have a

re extinguisher

handy and within reach.

●

If you do not know how to use a

re extin-

guisher contact someone who can instruct
you in the proper use of this equipment.

2.2.17 Personal Protective Equipment

If your shop speci

es the use of safety equip-

ment, OSHA requires this equipment to be
used when on the shop floor or in the area
where this equipment is required.

Never allow personnel in the shop area with-
out the proper personnel protective equipment
even for a moment.

Always keep personnel protective equipment
in good condition and replace them as re-
quired.

2.2.15 Aligning Parts or Components

●

Be careful when installing or aligning parts
or components.

●

Avoid using your

ngers or hands to posi-

tion holes or part mating surfaces, serious
injury could result if your hand or fingers
should get ought between the surfaces.

●

Always use tools to align a part or compo-
nent to avoid any

nger or hand injuries.

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Shop Safety

●

Keep in mind that during running opera-
tions, hydraulic systems, cooling systems
and fuel systems will be under extremely
high pressure and at high temperatures.

●

Always use caution when working on or
near these systems.

2.2.18 Running the Machine

Run the machine during repair procedures
ONLY if directed to do so in this shop manual.
If the machine must be run when making re-
pairs, it is important to follow some basic safe-
ty rules.

●

Always be aware of rotating components.

●

During repair operations while the engine
is running, one worker must remain in the
operator seat of the machine with clear
contact between the person performing the
repairs on the machine at all times.

●

If equipped, all lock levers must be in the
LOCK position or the parking brake must
be in the PARK position.

●

The person in the cab must never touch
any controls. If a control lever must be op-
erated, always maintain a clear view to the
person doing the repair and signal them
when you are about to move the control le-
ver.

●

Be aware of hot surfaces. During running
operations, most surfaces will be hot, and
some surfaces will be extremely hot. If
necessary, use personnel protective equip-
ment when working around high tempera-
ture surfaces.

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Shop Safety

2.2.19 Accumulator

If the machine is equipped with an accumula-
tor charged with high-pressure nitrogen gas, it
is important to follow these basic precautions.

●

Do not disassemble the accumulator.

●

Never expose the accumulator to high heat
or open

ames.

●

Never weld on the accumulator.

●

Never drill or cut on the accumulator.

●

Never strike the accumulator.

●

Use only nitrogen gas to charge the ac-
cumulator. Unapproved gases could be
explosive.

2.2.20 Adding Fluids to a System

If it should be necessary to add fluids to a
system during running operations, always be
aware that these systems may be hot and un-
der high pressure.

Before adding fluids, shut the machine down
and allow the systems to cool down to outdoor
ambient temperatures before removing any
caps. Failure to do so may result in serious
burns or a sudden loss of

uid.

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Shop Safety

2.2.21 Track Recoil Springs

If you are making repairs to a machine
equipped with tracks, always be aware of the
dangers involved with track recoil springs. This
spring is under extreme pressure at all times.
If it is disassembled by mistake, the spring
may

y out and cause serious injury or death.

Be careful when removing or installing tracks
on track-type machines. When removing the
master track link the track system may sepa-
rate suddenly and cause possible injury.

Always stand clear of the track travel path
when separating the master link section of the
track.

2.2.22 High-Pressure Fluid Lines

Always keep in mind that these systems are
under high pressure. When inspecting or re-
placing piping or hoses, always check to be
sure the pressure in the system has been
relieved before proceeding. Working on a sys-
tem still under pressure could lead to serious
injury, always do as follows:

●

If you will be removing a line or component
with fluid in the system, always cap and
seal the opening to avoid leakage or sys-
tem contamination.

●

Never carry out inspections or replace
items while the system is under pressure.

●

Never use any part of your body to check
or feel for leaks. Always wear safety
glasses and leather gloves when checking
for leaks and use a piece of wood or card-
board when checking for leaks from small
holes.

●

If high pressure fluids should penetrate
your skin or get into your eyes, seek medi-
cal attention immediately.

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Shop Safety

2.2.23 Safe Work Preparations

Before starting any repairs, be sure the ma-
chine is sitting on a level stable surface.

Lower all the work equipment to a safe and
stable position on the ground. Turn the engine
OFF and neutralize the work equipment con-
trols by rotating them to the left and right (joy-
stick control) or moving them back and forth
(lever control). This function will relieve system
pressure.

Block the tracks (if equipped) or wheels (if
equipped) with chocks to prevent the machine
from moving.

If equipped, set the hydraulic lock lever in the
LOCKED position. If equipped, set the parking
brake in the PARK position.

Be sure all personnel and equipment is clear
of your work area and you can be seen by all
working personnel especially if performing re-
pairs in the

eld.

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Shop Safety

2.2.24 Mounting and Dismounting

It is important to follow these procedures when
mounting or dismounting the equipment:

●

Use all hand-holds and step plates on your
equipment.

●

Never jump off or onto the equipment.

●

Wipe off any oil, grease, or mud from your
shoes, rails, steps or platforms before get-
ting on the equipment; always keep these
areas clean and in good condition.

●

Never get on or off moving equipment.
These actions may lead to serious injury.
Always bring the equipment to a full stop
and turn the engine OFF.

●

When getting on or off the equipment,
always face the equipment and maintain
a three-point contact (both feet and one
hand or one foot and both hands) with the
handrails, steps and platforms to ensure
that you support yourself correctly.

●

Never climb on areas of the machine that
are not designated walk areas.

●

Never climb on or off the machine with
tools, parts or similar objects in your
hands.

●

Never use machine controls or non-spec-
i

ed points on the equipment to get on or

off the machine.

●

Use all hand-holds when on the machine.

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Shop Safety

2.2.25 Battery Hazards

Working around batteries always poses a haz-
ard, especially if the battery has been in ser-
vice for a long period of time.

Listed below are some basic precautions to
be aware of when servicing or working around
batteries.

●

Always wear personal protective equip-
ment when working around batteries.

●

Battery gasses are extremely explosive.
When opening a battery compartment, al-
ways allow ample time for the gasses to
escape before servicing the battery.

●

When working with batteries, always work
in a wellventilated area.

●

If the battery is corroded, flush the area
with a baking soda and warm water mix.

●

If battery acid should get on your skin or in
your eyes,

ush the area immediately with

fresh water and seek medical attention.

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Shop Safety

2.2.26 Jump-Start Safety

When using jumper cables to start the ma-
chine, connect the positive (+) jumper first,
then the negative (-) jumper to a remote loca-
tion on the chassis away from the battery.

2.2.27 Disconnecting the System

Power

Before starting any repair operations, remove
the battery leads from the battery or set the
main disconnect on the machine in the OFF
position.

For the location of the machine main electri-
cal disconnect switch, refer to the machines
Safety, Operation & Maintenance Manual for
location and procedures.

If the battery must be disconnected, remove
the negative (-) terminal clamp first then re-
move the positive (+) clamp last.

When reconnecting the battery, be sure every
electrical system switch is in the OFF position,
connect the positive clamp (+) first, then the
negative clamp(-) last.

CAUTION

Never use a welder or a machine with a
higher voltage system to jump-start the
machine. Doing so may damage the ma-
chine’s electrical system or cause an unex-
pected explosion or fi re resulting in minor
or major injury.

SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual - page 4