Maintenance(维护保养)

SANY Heavy Industry Co., Ltd. Quality Changes the World

 Content (目录)
Chapter 1 General Description(总的原则)
1.1 Purpose of Maintenance(保养目的)
1.2 General Rule of Maintenance (保养的一般原则)
1.3 Personal Safety (人身安全)
Chapter 2 Maintenance(维护保养)
2.1 Precautions for Maintenance (保养注意事项)
2.2 Sany Recommended Liquid (三一推荐液体)
2.3 Sany Genuine Part (三一纯正配件)
2.4 Before Maintenance(保养前)
2.5 Do Maintenance(保养中)
2.5.1 Fuel(柴油相关保养）
2.5.2 Oil(机油、齿轮油、液压油相关保养）
2.5.3 Water (冷却水相关保养）
2.5.4 Air(空气相关保养）
2.5.5 Daily Maintenance（日常保养）
2.5.6 First 50 Hours Maintenance （最初50个小时的保养）
2.5.7 Every 50 Hours/Weekly Maintenance （每 50个小时/每周的保养）
2.5.8 Every 250 Hours/Monthly Maintenance （每 250个小时/每月的保养）
2.5.9 Every 1000 Hours/Yearly Maintenance （每 1000个小时/每年的保养）
2.5.10 Every 2000 Hours Maintenance （每 2000个小时的保养）
2.5.11 Every 4000 Hours Maintenance （每 4000个小时的保养）
2.5.12 Every 8000 Hours Maintenance （每 8000个小时的保养）
2.5.13 Special Maintenance when using hydraulic breaker (使用液压破碎器时的特别维护)
2.6 After Maintenance (保养后)

SANY Heavy Industry Co., Ltd. 1/57 Quality Changes the World
Chapter 1 General Description
1.1 Purpose of Maintenance
Make
preparation
for the
operation

Reduce
Keep optimal
repair
performance
expenses

Maintenance

Prolong the Reduce

service life failure

SANY Heavy Industry Co., Ltd. 2/57 Quality Changes the World
 10%
Mechanical
failure
10%
Bad storage or protection

70%
Bad management of
FOWA

F : Fuel
O : Oil
W : Water
A : Air

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1.2 General Rule of Maintenance

•Keep track of the hour meter reading on a daily basis. Make

Hour meter sure whether it is time to perform the required maintenance.
reading

•Always use genuine Sany replacement parts listed in the

Genuine Sany Parts Manual.
replacement
parts

•Always use genuine Sany machine oil and grease. Select

machine oil and grease of suitable viscosity according to
Genuine Sany
lubricants
ambient temperature.

•Always do the maintenance in strict accordance with the

Maintenance Maintenance Schedule.
schedule

Only approved personnel can do the maintenance!

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1.3 Personal Safety

Safety First!

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Chapter 2 Maintenance
2.1 Precautions for Maintenance
1. Warning signs

When maintenance is underway, starting the

engine and touching or manipulating control levers
or pedal could lead to serious accident.

Prior to maintenance, attach the label of "No

Operation” or similar warning signs to machine's
starting switch or steering device, warning others
that this machine is under maintenance.

You may attach other warning labels around machine if necessary.

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2.2 Sany Recommended Liquid

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2.3 Sany Genuine Parts

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 2.4 Before Maintenance
Park the machine on solid, flat surface.

Lower the bucket to ground.

Place blocks under the tracks to prevent movement of machine.

Turn the fuel control dial to first gear. Run the engine unloaded at low speed for 5 minutes.

Switch the key switch to OFF position to stop the engine.

Switch the key switch to ON position. Operate the control lever for 2-3 times in forward, backward, left and right directions so
as to release internal pressure of the hydraulic system.

Remove the key from the switch.

Pull the safety lock control lever to LOCK position.

SANY Heavy Industry Co., Ltd. 9/57 Quality Changes the World
 2.5 Do Maintenance

2.5.1 Fuel

 Select the correct fuel according to the ambient temperature

 Fill the fuel tank properly everyday after work to prevent the
moisture build up in the tank.
 Drain the sediment from the fuel tank everyday before job.
 Bleed air if the fuel in the tank is exhausted or if the fuel
filter is replaced.

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 Drain the water and sediment
from the fuel water separator
everyday before job as the
method described below:
Loose the plug to drain the
sediment. Tighten the plug
until the sediment and
Drain
water are drained valve

thoroughly.
Do not over torque the plug,
otherwise, failure will
occurred, and air will
enter into the fuel system.
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 Drain the water and
sediment from the fuel
tank everyday from
before the job.
Open the cock valve
to drain the sediment
from the fuel tank.
Close the cock valve
until the sediment is
drained thoroughly.

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After replacing the Air bleed plug

fuel filter, bleed air as

following steps: top up
the tank → loose the Fuel filter

air bleed plug →using

the priming pump to
fill the fuel filter, until
there is no air bleed
out →tighten the air
bleed plug properly.

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 Not drain the water and sediment timely, using poor fuel or poor fuel filter

Plungers of Rusted Filter Delivery Transfer Needle valve of the

the fuel plugged valve worn pump worn injector will worn
injection pump
will be worn,
injection
pressure will
decrease.

Road sign of fuel contamination

Fuel tank primary filter separator transfer pump filter

injection pump injector

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 Sand and dust in fuel
Oil in fuel
Parts worn rapidly, injection pressure decrease,
emit black smoke, engine power decreased, pump Heavy carbon build up will block the fuel
service life shortened. injection nozzle.

One injection hole of this injector is

plugged
Delivery valve worn abnormally, has to
replace it with a new one.

Water in fuel
Plungers, sleeves, and needle valve will be worn
rapidly. Injection pressure decrease,
atomization will poor, emit black smoke, and This plunger worn abnormally due to
engine power will be reduced. water enters into the fuel.

SANY Heavy Industry Co., Ltd. 15/57 Quality Changes the World
 2.5.2 Oil

 Lubrication oil includes engine oil, hydraulic oil, and gear

oil. Do not mix the different oil during the usage.
 Lubrication oil of different brands will have different
additives in it.
 Keep the lubrication oil away from the contamination of fuel,
water, and other foreign materials.
 Select the correct viscosity of the lubrication oil according
to the ambient temperature. If the ambient temperature is
high, the high viscosity oil should be used. If the ambient
temperature is low, the low viscosity oil should be used.
Viscosity of the gear oil is a little high to suit the load
transfer. Viscosity of the hydraulic oil is a little low to
reduce the flow resistance.
 Using the genuine lubricate oil, and fill the related system
with the proper capacity as Sany recommended.
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 Maintenance——Engine oil

 Open the engine hook, pull out the dipstick and clean
it. Insert the dipstick back completely. Pull the
dipstick out again to check the oil level which should
be between the mark H and L.
 After the engine started, waiting for at least 15
minutes on the flat ground to check the oil level.

Oil filter
L

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 Maintenance——Hydraulic oil

 Put the machine on the flat ground as the picture indicated.

 Shut off the engine and operate all the pilot levers in all
directions to release the residual pressure in the hydraulic system.
 Check the oil level, if it is located between the mark H and L, the
oil level is normal.（If the oil temperature is between 50℃ and
80℃, oil level should be near the mark H.）
 If the oil level is above the mark H, shut down the engine and wait
for cooling completely and then drain the excessive hydraulic oil.
 If the oil level is lower than the mark L, fill the hydraulic tank
to the normal level.

Level gauge

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 Replace the hydraulic oil filters

 Remove the filling cap slowly to release the residual pressure in

the hydraulic system.
 Replace the filter ① inside the cap.
 Replace the pilot oil filter.

Pilot oil
filter

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 Replace the hydraulic oil filters

 Remove the filling cap slowly to release the residual pressure in the
hydraulic system. Replace the suction screen.
 Loose the bolt and remove the cover slowly to release the spring
force, and replace the return oil filter of the hydraulic system.

Cover

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 Replace the swing drive oil
 Refill capacity: refer to the maintenance manual for the capacity.
 Open the drain valve and drain the used oil into a container. After the
used oil drained thoroughly, close the drain valve.
 Remove the filler cap, add new oil into the swing drive
 Pull out the dipstick and clean it. Insert it back and wait for about one
minutes. Pull out the dipstick again and check the oil level which should
be between the mark H and L.

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 Replace the swing drive oil

If the oil level is lower

than the mark L, adds oil
into the swing drive to the
normal level. If the oil
level is higher than mark
H, drain the excessive oil.

F G

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 Replace the final drive oil

 Refill capacity: refer to the

maintenance manual.
 Stop the machine on the flat
ground and to let the vertical A
line pass through the center of
plug B and plug C. B
 Remove the plug A to bleed air,
and then remove the plug C to C
drain oil.
 Install and tighten the plug C.
Fill the oil from the plug A. and
install the plug B when new oil
flows out from the plug hole.
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 Lubricate the swing bearing

 Lower the bucket to the

ground.
 Pump grease into the fitting.
 Do not pump grease too fast
to prevent the o-ring seal
damage.
 After the grease pumping is
finished, clean the overflow
grease.

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 Check the grease of pinion gear

 Remove the bolts ① and cover ②.

 Insert a steel ruler into the grease, the grease level should
be at least 14mm，if the grease level is lower than the
specified height, add grease into the swing gear.
 If the grease is emulsified, replace the grease.
Cover
 Grease capacity is 14.6L（13.1kg）

SANY Heavy Industry Co., Ltd. 25/57 Quality Changes the World
 Maintenance —— Engine oil

Lubrication system Not change

oil timely Poor filter

Engine oil deteriorated.

Lubrication ability decreased.
Foreign material enters into oil.

Engine parts worn severely

crank turbo camshaft gear Piston ring pushrod

Shutdown failure

Oil functions: cooling,

Downtime lost Repair cost Others
lubrication, and cleaning
increased

SANY Heavy Industry Co., Ltd. 26/57 Quality Changes the World
 Maintenance —— Engine oil

Bearing of the
turbo is worn
Engine oil deteriorated severely，
clearance
between the shaft
and the bearing
increased. Blades
impact with the
housing.

Scratched
bearing

Turbo shaft
Piston & liner failed due to overheating： was worn
1、oil emulsified or not changed timely. severely
2、dust enters into oil, cooling jet plugged.

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 Maintenance --- Coolant

2.5.3 Water

 Engine coolant consists of antifreeze and soft water.

 The function of the antifreeze is listed below:
 Reduce the frozen point of the coolant.
 Get a higher boiling point.
 Prevent air bubble formed in the cooling system.
 Prevent erosion.
 Chang interval of the coolant used in Sany excavator
is 2000 hours or one year which occur first. Genuine
Sany coolant should be used to change the coolant.
 Frozen point of Sany coolant filled in the excavator
cooling system in the factory is -45℃.

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 Maintenance --- Coolant

 Check the coolant level when the engine is cooled completely.

 Open the left service door to check the coolant level which
should be located between the mark H and L.
 If the coolant level is lower than the mark L, add coolant to
the plastic tank and then cap the tank properly.

Tank location

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 Maintenance --- Coolant

Rust and scale

If the cap is failed, boil Will cause heating
point will be decreased. Lower than75℃：to water pump.

Regulator adjust the Higher than 95℃：to radiator

coolant temperature 75℃ - 95℃：both
When the coolant
level is too low Temperature Water pump
gauge

Bubble broken Pitting appears on the liner

bubble Due to the bubbles broken.

fan

Crankcase

Coolant build up in
the core which cause
the overheating.
Residual coolant
Oil cooler

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 Maintenance --- Coolant
水 管 理 不 好

Problems caused by coolant Failure case

SY230C8 usually has the high coolant
temp alarm, crankshaft seized finally.
Root cause of the failure：
rust erosion Pump failed Core blocked Flow slowly
Spring water was used for long time.
Severe scale built up in the water
passage which the overheating problem.

Overheating
Damage of poor cooling

Piston seized and smeared

Liner seized due to severely due to overheating Severe pitting on the
overheating liner

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 Maintenance --- Air

2.5.4 Air
 Air cleaner：filtrate the air which will enter into
the combustion chamber. Paper type air cleaner is used
in the engineering machines.
 Vacuum valve：when the engine is shut down, the vacuum
in the air inlet passage disappeared. Vacuum valve
will open, and the dust collected will be dropped out
from the vacuum valve automatically.
 When the air clean is dirty, the sensor will send the
signal to the monitor, to remind the operator to do
the maintenance for the air cleaner.
 Using the genuine Sany air cleaner to do the
maintenance always.

Genuine Counterfeit

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 Maintenance --- Air

Inlet and exhaust system

Air circuit：

Pre-cleaner air cleaner turbo ATAAC Cylinder turbo muffler

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 Maintenance --- Air

 Open the left service door, unlock the clamp ② and remove the
cap ③，pull out the air cleaner elements. Using a clean cloth
to cover the opening to prevent dust and foreign material
enters into the inlet hose.
 Clean the inside surface of the air cleaner housing.
 Using the air with the pressure lower than 7kg/cm2 to clean
the element from the inside.
 After cleaning, using a lamp to check whether the element is
damaged or not. If not, install the elements and the cover.

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 Maintenance --- Air

When replace the outer element, replace the inner

element at the same time always. After removing
the inner element, clean the air filter housing.
Install the inner element first and then the outer
element.

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 Maintenance --- Air

Failure modes of inlet and exhaust system

Air filter blocked, black

smoke emitted.
Sitting face of the valve worn
Foreign material enters, turbo
blades is broken.

Piston is scratched Liner surface is scratched

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 2.5.5 Daily Maintenance
Maintenance contents Required parts Note

Check the fuel level Grease（joint pins Do the

Drain sediment and water from the fuel tank of implement must maintenance to
Drain the sediment and water from the fuel water separator be lubricated in the air cleaner as
Grease lube the joint pins of the implement the daily per different
Check the hydraulic oil level, fill the tank if required maintenance.） working conditions.
Check the engine oil level, fill the engine if required Make sure the
Check the coolant level, fill the tank if required Replace the failed inlet air is clean to
Check the fan belt and the air conditioner belt parts as per the prolong the
Inspect/replace the bucket teeth as per the worn condition daily maintenance service life of the
Check for oil leakage, repair it timely if oil leakage is found record. engine.
Inspect for the loosen fasteners
Check the instrument’s operation
Engine smoke and sound is ok?
Pilot control levers worked normally?
Inspect the track tension
Check undercarriage for bolt loosing

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37/57
 Adjust the belt tension

1、Loose the bolt A

and the alternator
mounting bolt.
2、Screw the bolt B
to adjust the belt
tension to the B
specified value in
A
the service manual.
3、Tighten the bolt
A and the alternator
mounting bolt to the
specified torque.

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2.5.6 First 50 Hours Maintenance

Maintenance contents Required parts Note

Pump grease to the fittings of Grease
the implement joint pins.

Pump grease to the fittings of Grease

the swing bearing properly and
correctly.

Replace the engine oil and the Engine oil, engine oil
engine oil filter（initial
replacement）
filter
Drain the water and sediment Replace the parts as
from the fuel water separator
required.
Inspect the air cleaner and the Replace the parts as Unfiltered air enters into the
clamps of the inlet hoses. engine through the broken
required. filter or the loosed clamp will
cause excessive wear.

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 Lubrication of the implement

 Stop the machine on Location of the grease fittings

the ground as the
picture indicated.
Lubricate the joint
pins of the implement
with grease
thoroughly to extrude
out the used grease.
Clean the grease
which is extruded out.

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2.5.7 Every 50 Hours/Weekly Maintenance

Maintenance Required parts Note

contents
Grease lubricate the joint pins Grease
of the implement and the
swing bearing.

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1、Boom cylinder root pins (2) 2、Boom root pins (2) 3、Boom cylinder rod end (2)
4、Arm cylinder root pin (1) 5、Boom-arm joint pins (2) 6、Arm cylinder rod end (1)
7、Bucket cylinder root pin (1) 8、Bucket-rod joint pin (1) 9、Arm-bucket joint pin (1)
10、Rod joint pins (2) 11、Bucket cylinder rod end (1) 12、Bucket-rod joint pin (1)

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2.5.8 Every 250 Hours/Monthly Maintenance

Maintenance Required parts Note

contents

Fan belt and air conditioner Replace the belt as

belt – Inspect/Adjust/Replace
required
Change the engine oil and the Engine oil and the oil
engine oil filter.
filter
Change the fuel filter. Clean Fuel filter
the fuel water separator.

Check the oil level of the Gear oil as required

swing drive and the final drive

Inspect / Clean the air filter

and the engine breather

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  Replace the fuel filter
 Remove the used fuel filter
 Clean the fuel filter base
 Apply the oil film to the o-ring
seal of the fuel filter and dry
install it onto the filter base.
 Loose the air bleed plug.
 Feeding the fuel filter with the
priming pump.
 Tighten the air bleed plug
properly until there is no air
escape out.
 Operate the priming pump
several times and then lock the
priming pump.

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2.5.9 Every 500 Hours/Quarterly Maintenance

Maintenance contents Required parts Note

Carry out the 250 hours
maintenance at the same time

Lubricate the swing bearing. Grease

Inspect the swing pinion
grease level

Replace the fuel water Fuel water separator

separator

Clean the air conditioner fresh

and recirculation filter.

Service the breather of the

hydraulic oil tank.

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  Breather valve service
 The element of breather valve shall not be
cleaned with water. If the element is
contaminated heavily, use a brush and the
detergent to clean the contaminants.
 To eliminate contaminants that is hard to
remove, you use the air nozzle to blow
through the element [2] from inside to
outside. Pay attention to the air pressure to
avoid damage to the element.
 If the element [2] is aging, replace the
breather valve immediately.
 After eliminating the contaminants, Restore it
after drying.
 Tighten the hexagonal nut [5] to the specific
torque (10-14 N·m). Never over tighten it in
pursuit of better sealing effect.
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2.5.9 Every 1000 Hours/Yearly Maintenance

Maintenance contents Required parts Note

Carry out every 500 hours Refer to the information in
maintenance at the same time
the 500 H maintenance.
Replace the hydraulic oil filters: Pilot oil filter Release the residual
pilot oil filter, return oil filter,
and the suction screen.
Return oil filter pressure before the
Suction screen maintenance is done.
Replace the gear oil of the Refer to the maintenance
swing drive and the final drive
manual.
Check the clamps of engine
exhaust pipe

Check the nitrogen pressure in

accumulator

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  Change the oil of swing drive.
 Place a container under the drain valve
[P] to collect the gear oil drained.

 Open the drain valve [P] beneath the

machine to drain the gear oil.

 Close the drain valve after the oil is

drained completely.

 Remove the filler cap [F] and fill the oil

as required.

 Check the oil level and make sure that

the oil level is normal.

 Note: The information “Recommended

Fuel, Coolant and Lubricant” can be
found in page 226 of the maintenance
manual.

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2.5.10 Every 2000 Hours Maintenance

Maintenance contents Required parts Note

Carry out every 1000 hours Refer to the information in
maintenance at the same time
the 1000 H maintenance.
Change the hydraulic oil Hydraulic oil Release the residual
pressure before the
maintenance is done.
Grease lubricate the water Grease
pump

Change the coolant 1. Coolant should be replaced one

year or 2000 hours which occur first.
2. Flush the cooling system when
the coolant is replaced.
Check / adjust the engine
valve lash

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  Change the hydraulic oil
 Unscrew the bolts and remove the bottom cover.
 Swing the upper structure to position the drain plug beneath the hydraulic
tank between the tracks.
 Retract the arm and bucket cylinders and lower the boom to let the bucket
touch the ground.
 Place the lockout lever to the LOCK position and turn off the engine.
 Remove the cap of the oil filler.
 Place a container under the drain plug. remove the drain plug [P] to drain
the oil. Replace the O-ring of the drain plug. After draining. tighten the plug
to 927±103 N•m (683.5 ± 76.0 lbft)
 Fill the hydraulic oil as required through the filler. Check the oil level, which
should be between the H and L marks of level gauge.
 Eliminate air from the hydraulic circuit. For more information on elimination
of air from the hydraulic circuit see "Air in Hydraulic System - Purge" section
of the Operation and Maintenance Manual.

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2.5.11 Every 4000 Hours Maintenance

Maintenance contents Required parts Note

Carry out every 2000 hours Refer to the information in
maintenance at the same time
the 2000 H maintenance.
Inspect the water pump and
the starting motor

Replace the accumulator Accumulator

Inspect / Replace the high Clamps and hoses

pressure pipes for loose
clamps and aged rubber
as required
Inspect the compressor
working condition

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  Check the water pump for coolant leakage or
oil leakage. If the coolant is leaked out from
the weep hole of the water pump, the water
seal group might be failed. Rebuild or replace
the failed water pump immediately.

 If your machine is kept operating when the

performance of accumulator decreases, the
pressure in the hydraulic system will not be
released. Replace the failed accumulator
timely.

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2.5.12 Every 8000 Hours Maintenance

Maintenance contents Required parts Note

Carry out every 4000 hours
maintenance at the same time

Replace the high pressure

tube clamps.

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  Visual inspect for
any loose bolts
on the mounting
clamps of high-
pressure pipe
between the fuel
injection pump
and the injection
nozzle. If there is
parts loose and
missed or failed,
replace it timely.
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2.5.13 Maintenance of using hydraulic hammer
 When the hydraulic hammer is used,
maintenance interval of the
hydraulic oil and hydraulic oil
filter should be shortened.
 Initial replacement of the hyd oil
filters should be between 100 and
150 hours. After the initial
replacement, change interval of
the hydraulic oil and filters
should be changed according to the
drawing. Refer to the maintenance
manual.
 Accessional filters should be
changed every 250 hours when the
hammer using rate is higher than
50%
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2.6 After Maintenance

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 Quality Changes the World!

Thank you!

SANY Heavy Industry Co., Ltd. 57/57 Quality Changes the World