Sany SY195C9/ SY205C9/ SY215C9/ SY225C9 Crawler Hydraulic Excavator Shop Manual (Ver. June 2013)


Sany SY195C9/ SY205C9/ SY215C9/ SY225C9 Crawler Hydraulic Excavator Shop Manual

Type of machine: Crawler Hydraulic Excavator
Print No: ZJSYF0301EN-SY55C3/55C9/60C1, June 2013
Language and Format: English/PDF
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The Shop Manual will give you complete information on repair, servicing and preventative maintenance, for your Sany SY195C9/ SY205C9/ SY215C9/ SY225C9 Crawler Hydraulic Excavator.

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Table of contents:
1. INTRODUCTION
1.1 How to Read the Shop Manual
1.2 Terms for Maintenance Standard
1.3 Handling Electrical and Hydraulic Components
1.3.1 Points to remember when handling electric components
1.3.2 Points to remember when handling hydraulic equipment
1.4 Hose Connector
1.4.1 Type of hose connector
1.4.2 Hose connector tightening torque table
1.4.3 Connection of O-rings
1.5 Table of Standard Tightening Torques
1.6 Type of Bolts
1.7 Tightening Sequence
1.8 Maintenance of Half Flanges
1.8.1 Table of tightening torques for half fl ange bolts
1.9 Conversion Table

2. SHOP SAFETY
2.1 Hazard Alert Information
2.2 General Shop Safety
2.2.1 Rules and shop behavior
2.2.2 Housekeeping
2.2.3 Shop Liquids Storage
2.2.4 Cleaning Parts
2.2.5 Jacking Up the Machine
2.2.6 Electrical Dangers
2.2.7 Removing Attachments
2.2.8 Cleaning the Machine
2.2.9 Using the Correct Tools
2.2.10 Hoisting a Load
2.2.11 Appropriate Working Apparel
2.2.12 Safety Partners
2.2.13 Two people when engine running
2.2.14 Driving Pins
2.2.15 Aligning Parts or Components
2.2.16 Fire Extinguisher and Emergency Exits
2.2.17 Personal Protective Equipment
2.2.18 Running the Machine
2.2.19 Accumulator
2.2.20 Adding Fluids to a System
2.2.21 Track Recoil Springs
2.2.22 High-Pressure Fluid Lines
2.2.23 Safe Work Preparations
2.2.24 Mounting and Dismounting
2.2.25 Battery Hazards
2.2.26 Jump-Start Safety
2.2.27 Disconnecting the System Power
2.2.28 Lockout/tagout
2.2.29 Sequence of Procedures
2.2.30 Chemical hazard
2.2.31 Material Safety Data Sheets (MSDS)
2.3 Precautions for sling work and giving signals

3. SPECIFICATIONS
3.1 Dimensions
3.2 Working Ranges
3.3 Technical Specifi cations
3.4 Weight Table
3.5 Recommended Oil, Fuel and Coolant
3.6 Capacity Table
3.7 Engine Performance Curve

4. STRUCTURE AND FUNCTION
4.1 Engine and Cooling System
4.1.1 Engine-related parts
4.1.2 Radiator and intercooler
4.2 Power Train
4.2.1 Power transmission system
4.2.2 Final drive assembly
4.2.3 Swing machinery
4.2.4 Swing bearing
4.3 Undercarriage and Frame
4.3.1 Track frame and recoil spring
4.3.2 Idler
4.3.3 Carrier roller
4.3.4 Track roller
4.3.5 Track shoe
4.3.6 Triple grouser shoe
4.4 Hydraulic System, Part 1
4.4.1 Hydraulic equipment layout
4.4.2 Hydraulic tank and fi lter
4.4.3 Hydraulic pump
4.4.4 Pilot pump
4.4.5 Regulator
4.4.5.1 Control mechanism makeup
4.4.5.2 Adjustment of the regulator
4.4.5.3 Operation
4.5 Hydraulic System, Part 2
4.5.1 Control valve
4.5.2 Operating principle
4.5.2.1 When spool is in neutral position
4.5.2.2 Travel
4.5.2.3 Arm
4.5.2.4 Boom
4.5.2.5 Bucket
4.5.2.6 Swing
4.5.2.7 Option
4.5.2.8 Travel straight
4.5.2.9 Lock valve function
4.5.2.10 Main relief valve function
4.5.2.11 Port relief valve function
4.5.3 Section view
4.6 Hydraulic System, Part 3
4.6.1 Swing motor
4.6.2 Swing holding brake
4.6.3 Relief valve portion
4.6.4 Reverse prevention valve
4.6.4.1 Operation drawing
4.6.4.2 Explanatory drawing of effects
4.6.5 Center swivel joint
4.6.6 Travel motor
4.6.6.1 Operation of components
4.6.7 Valve control system
4.6.8 Pilot valve
4.6.8.1 Work equipment and swing pilot valve
4.6.8.2 Travel PPC valve
4.6.9 Solenoid valve
4.6.10 Accumulator
4.6.11 Pilot oil fi lter
4.6.12 Pump oil pressure sensor
4.6.13 Hydraulic cylinder
4.6.14 Work equipment
4.7 Air Conditioning System
4.7.1 A/C components layout drawing
4.7.2 Control panel
4.7.3 Circuit diagram
4.7.4 Refrigeration principle
4.7.4.1 Refrigeration cycle diagram
4.7.4.2 Heating cycle diagram
4.7.5 Compressor
4.7.6 Clutch
4.7.8 Condenser
4.7.7 Expansion valve
4.7.9 Evaporator
4.7.10 Receiver tank
4.7.11 Pressure switch
4.7.12 Fresh air sensor
4.7.13 Refrigerant
4.7.14 Compressor oil
4.8 Engine Control
4.8.1 System operation
4.8.2 Components
4.8.2.1 Fuel control dial
4.8.2.2 Controller
4.9 Electrical Control System
4.9.1 Control function
4.9.2 Machine control system diagram
4.9.3 Engine and pump composite control function
4.9.4 Pump control function
4.9.4.1 Electrical positive fl ow control
4.9.4.2 Constant power control
4.9.5 Valve control function
4.9.5.1 Bucket fl ow control
4.9.5.2 Swing priority control
4.9.6 Duo travel speed control
4.9.7 Engine preheating/overheating alarm
4.9.7.1 Engine preheating
4.9.7.2 Engine overheating alarm
4.9.8 Engine oil under-pressure alarm
4.9.9 Auto deceleration/acceleration control
4.9.10 Engine speed calibration function
4.9.11 Electrical Components
4.9.11.1 Pump pressure sensor
4.9.11.2 Pilot pressure sensor
4.9.11.3 Engine speed sensor
4.9.11.4 Coolant temperature sensor
4.9.11.5 Fuel level sensor
4.9.11.6 Oil pressure switch
4.10 Monitoring System
4.10.1 Machine monitor
4.10.2 Monitor functions
4.10.3 Monitor operation

5. STANDARD VALUES
5.1 Standard Values of Engine – related Parts
5.2 Standard Values of Chassis-related Parts

6. TESTING AND ADJUSTING
6.1 Engine Speed – Test and Calibrate
6.1.1 Testing
6.1.2 Adjusting
6.2 Exhaust Gas Color – Test
6.3 Valve Clearance – Adjust
6.3.1 Testing
6.3.2 Adjusting
6.4 Compression Pressure – Measure
6.5 Fuel Injection Timing – Test and Adjust
6.5.1 Testing
6.5.2 Adjusting
6.6 Engine Oil Pressure – Measure
6.7 Engine Speed Sensor – Adjust
6.8 A/C Compressor Belt Tension – Test and Adjust
6.8.1 Testing
6.8.2 Adjusting
6.9 Swing Bearing Clearance – Measure
6.10 Track Tension – Test and Adjust
6.10.1 Testing
6.10.2 Adjusting
6.11 Hydraulic Pressure in Hydraulic Circuits – Test and Adjust
6.11.1 Measuring
6.11.2 Adjusting
6.12 Control Circuit Oil Pressure – Test and Adjust
6.12.1 Testing
6.12.2 Adjusting
6.13 Solenoid Valve Output Pressure – Measure
6.14 Pilot Valve Output Pressure – Measure
6.15 Pilot Valves (Work Equipment and Swing) – Adjust
6.16 Work Equipment Hydraulic Drift – Test
6.17 Residual Pressure in Hydraulic Circuit – Release
6.18 Oil Leakage – Measure
6.19 Air in Each Component – Bleed

7. TROUBLESHOOTING
7.1 Points to Remember When Troubleshooting
7.2 Troubleshooting Procedures
7.3 Connector Location and Electrical Circuit Diagram
7.3.1 Connector location layout
7.3.2 Electrical element circuit diagram (cab circuit)
7.3.3 Electrical control circuit diagram (engine circuit)
7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit)
7.3.5 SWP type connector
7.3.6 A/AMP type connector
7.3.7 DT type connector
7.4 Failure Symptoms and Troubleshooting Codes
7.5 Troubleshooting with an Event Code
7.6 Troubleshooting of Electrical System (E – Mode)
7.7 Troubleshooting of Hydraulic and Mechanical Systems (H – Mode)

8. DISASSEMBLY AND ASSEMBLY
8.1 How to Read This Manual
8.1.1 Removing and Installing an Assembly
8.1.2 Disassembling and assembling an assembly
8.1.3 Special tools
8.2.1 The symbols used in this section
8.2 Operating Precautions
8.3 Start Motor AS – Remove and Install
8.3.1 Removal
8.3.2 Installation
8.4 Injection Pump AS – Remove and Install
8.4.1 Removal
8.4.2 Installation
8.5 Engine Front Seal – Remove and Install
8.5.1 Removal
8.5.2 Installation
8.6 Engine Rear Seal – Remove and Install
8.6.1 Removal
8.6.2 Installation
8.7 Cylinder Head AS – Remove and Install
8.7.1 Removal
8.7.2 Installation
8.8 Radiator AS – Remove and Install
8.8.1 Removal
8.8.2 Installation
8.9 Engine and Hydraulic Pump AS – Remove and Install
8.9.1 Removal
8.9.2 Installation
8.10 Final Drive AS – Remove and Install
8.10.1 Removal
8.10.2 Installation
8.11 Final Drive AS – Disassemble and Assemble
8.11.1 Disassembly
8.11.2 Assembly
8.12 Swing Motor and Swing Drive AS – Remove and Install
8.12.1 Removal
8.12.2 Installation
8.13 Swing Motor and Swing Drive AS – Disassemble and Assemble
8.13.1 Disassembly
8.13.2 Assembly
8.14 Idler AS – Disassemble and Assemble
8.14.1 Disassembly
8.14.2 Assembly
8.15 Sprocket – Remove and Install
8.15.1 Removal
8.15.2 Installation
8.16 Track AS – Remove and Install
8.16.1 Removal
8.16.2 Installation
8.17 Swing Bearing AS – Remove and Install
8.17.1 Removal
8.17.2 Installation
8.18 Swing Platform AS – Remove and Install
8.18.1 Removal
8.18.2 Installation
8.19 Swivel Joint AS – Remove and Install
8.19.1 Removal
8.19.2 Installation
8.20 Swivel Joint AS – Disassemble and Assemble
8.20.1 Disassembly
8.20.2 Assembly
8.21 Hydraulic Tank AS – Remove and Install
8.21.1 Removal
8.21.2 Installation
8.22 Control Valve AS – Remove and Install
8.22.1 Removal
8.22.2 Installation
8.23 Hydraulic Pump AS – Remove and Install
8.23.1 Removal
8.23.2 Installation
8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install
8.24.1 Removal
8.24.2 Installation
8.25 Pilot Valve AS (Work Equipment) – Disassemble and Assemble
8.25.1 Assembly
8.26 Pilot Valve AS (Travel) – Disassemble and Assemble
8.26.1 Assembly
8.27 Hydraulic Cylinder AS – Disassemble and Assemble
8.27.1 Disassembly
8.27.2 Assembly
8.28 Work Equipment AS – Remove and Install
8.28.1 Removal
8.28.2 Installation
8.29 Air Conditioner AS – Remove and Install
8.29.1 Removal
8.29.2 Installation
8.30 Counterweight AS – Remove and Install
8.30.1 Removal
8.30.2 Installation
8.31 Cab AS – Remove and Install
8.31.1 Removal
8.31.2 Installation
8.32 Cab Window Glass – Disassemble and Assemble
8.32.1 Removal
8.32.2 Installation
8.33 Front Window AS – Disassemble and Assemble
8.33.1 Disassemble
8.33.2 Assemble
8.34 Monitor – Remove and Install
8.34.1 Removal
8.34.2 Installation
8.35 Controller AS – Remove and Install
8.35.1 Removal
8.35.2 Installation
8.36 Radio
8.36.1 Structure
8.36.2 Removal
8.36.3 Installation
8.36.4 Connector model and wiring
8.37 Battery
8.37.1 Structure
8.37.2 Removal
8.37.3 Installation
8.37.4 Replacement
8.38 Start Switch
8.38.1 Structure
8.38.2 Removal
8.39 Fuse Box
8.39.1 Removal
8.40 Wiper
8.40.1 Structure
8.40.2 Working principle
8.40.3 Removal
8.40.5 Installation
8.40.4 Angle adjustment of wiper arm
8.41 Relay
8.41.1 Engine relays
8.41.2 Other relays
8.42 Sensor
8.43 Connector Terminals – Insert and Remove
8.43.1 Insertion
8.43.2 Removal

9. SYSTEM SCHEMATICS
9.1 Hydraulic System Diagram
9.2 Air-Conditioning Electrical Circuit Diagram
9.3 Fuse Box Relay
9.4 Control Switches and Monitor Electrical Diagram
9.5 Operator Cab Electrical Circuit Diagram
9.6 Chassis Electrical Circuit Diagram