SANY SY195C9 Install guide

SANY HEAVY MACHINERY LIMITED
318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District,
Shanghai, P.R. of China 201413
Tel: [phone]
Service hotline:[phone]
E-mail: [e-mail]
Documentation No.: ZJSYF0301EN(07-12)-SY55C3/55C9/60C1
www.sanygroup.com
Quailty Changes the World
Crawler Hydraulic
Excavator
SY195C9
SY205C9
SY215C9
SY225C9
Shop Manual
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SANY LATIN AMERICA
SY195/205/215/225C9
Crawler Hydraulic Excavator
Shop Manual
●Compiled for experienced technicians, this shop manual aims to provide technical information
required for maintenance and repair of the machine.
●Work equipment or optional components not available locally may be included in this shop
manual. Consult authorized Sany dealers for information on these parts and components. Ma-
terial or technical specification is subject to change without prior notice.
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WARNING
Read and follow the safety precautions and
instructions in this manual and on the ma-
chine decals. Failure to do so may cause
serious injury, death or property damage.
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SY195/205/215/225C9 Crawler Hydraulic Excavator Table of Contents
Shop Manual - June 2013
Table of Contents
1 Introduction
1.1 How to Read the Shop Manual................................................................................ 1-3
1.2 Terms for Maintenance Standard............................................................................. 1-5
1.3 Handling Electrical and Hydraulic Components....................................................... 1-7
1.3.1 Points to remember when handling electric components .............................. 1-7
1.3.2 Points to remember when handling hydraulic equipment ............................ 1-16
1.4 Hose Connector..................................................................................................... 1-18
1.4.1 Type of hose connector................................................................................ 1-19
1.4.2 Hose connector tightening torque table ....................................................... 1-19
1.4.3 Connection of O-rings.................................................................................. 1-20
1.5 Table of Standard Tightening Torques .................................................................. 1-21
1.6 Type of Bolts .......................................................................................................... 1-22
1.7 Tightening Sequence............................................................................................. 1-22
1.8 Maintenance of Half Flanges................................................................................. 1-23
1.8.1 Table of tightening torques for half flange bolts ........................................... 1-23
1.9 Conversion Table ................................................................................................... 1-24
2 Shop Safety
2.1 Hazard Alert Information.......................................................................................... 2-3
2.2 General Shop Safety ............................................................................................... 2-6
2.2.1 Rules and shop behavior ............................................................................... 2-7
2.2.2 Housekeeping................................................................................................ 2-7
2.2.3 Shop Liquids Storage..................................................................................... 2-8
2.2.4 Cleaning Parts ............................................................................................... 2-8
2.2.5 Jacking Up the Machine................................................................................. 2-9
2.2.6 Electrical Dangers.......................................................................................... 2-9
2.2.7 Removing Attachments................................................................................ 2-10
2.2.8 Cleaning the Machine .................................................................................. 2-10
2.2.9 Using the Correct Tools................................................................................ 2-10
2.2.10 Hoisting a Load...........................................................................................2-11
2.2.11 Appropriate Working Apparel ..................................................................... 2-12
2.2.12 Safety Partners .......................................................................................... 2-12
2.2.13 Two people when engine running .............................................................. 2-13
2.2.14 Driving Pins................................................................................................ 2-13
2.2.15 Aligning Parts or Components ................................................................... 2-14
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SY195/205/215/225C9 Crawler Hydraulic Excavator
Table of Contents
Shop Manual - June 2013
2.2.16 Fire Extinguisher and Emergency Exits..................................................... 2-14
2.2.17 Personal Protective Equipment.................................................................. 2-14
2.2.18 Running the Machine................................................................................. 2-15
2.2.19 Accumulator ............................................................................................... 2-16
2.2.20 Adding Fluids to a System ......................................................................... 2-16
2.2.21 Track Recoil Springs .................................................................................. 2-17
2.2.22 High-Pressure Fluid Lines.......................................................................... 2-17
2.2.23 Safe Work Preparations............................................................................. 2-18
2.2.24 Mounting and Dismounting ........................................................................ 2-19
2.2.25 Battery Hazards ......................................................................................... 2-20
2.2.26 Jump-Start Safety ...................................................................................... 2-21
2.2.27 Disconnecting the System Power .............................................................. 2-21
2.2.28 Lockout/tagout ........................................................................................... 2-22
2.2.29 Sequence of Procedures ........................................................................... 2-22
2.2.30 Chemical hazard........................................................................................ 2-24
2.2.31 Material Safety Data Sheets (MSDS) ........................................................ 2-24
2.3 Precautions for sling work and giving signals........................................................ 2-25
3 Specifications
3.1 Dimensions.............................................................................................................. 3-3
3.2 Working Ranges ...................................................................................................... 3-4
3.3 Technical Specifications........................................................................................... 3-5
3.4 Weight Table ............................................................................................................ 3-8
3.5 Recommended Oil, Fuel and Coolant...................................................................... 3-9
3.6 Capacity Table ....................................................................................................... 3-10
3.7 Engine Performance Curve ....................................................................................3-11
4 Structure and Function
4.1 Engine and Cooling System .................................................................................... 4-5
4.1.1 Engine-related parts....................................................................................... 4-5
4.1.2 Radiator and intercooler................................................................................. 4-6
4.2 Power Train.............................................................................................................. 4-7
4.2.1 Power transmission system .......................................................................... 4-7
4.2.2 Final drive assembly ...................................................................................... 4-8
4.2.3 Swing machinery...........................................................................................4-11
4.2.4 Swing bearing .............................................................................................. 4-13
4.3 Undercarriage and Frame...................................................................................... 4-14
4.3.1 Track frame and recoil spring....................................................................... 4-14
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SY195/205/215/225C9 Crawler Hydraulic Excavator Table of Contents
Shop Manual - June 2013
4.3.2 Idler.............................................................................................................. 4-16
4.3.3 Carrier roller................................................................................................. 4-18
4.3.4 Track roller ................................................................................................... 4-19
4.3.5 Track shoe ................................................................................................... 4-20
4.3.6 Triple grouser shoe ...................................................................................... 4-23
4.4 Hydraulic System, Part 1 ....................................................................................... 4-24
4.4.1 Hydraulic equipment layout.......................................................................... 4-24
4.4.2 Hydraulic tank and filter ............................................................................... 4-26
4.4.3 Hydraulic pump ................................................................................................... 4-27
4.4.4 Pilot pump.................................................................................................... 4-34
4.4.5 Regulator .................................................................................................... 4-35
4.4.5.1 Control mechanism makeup ............................................................... 4-37
4.4.5.2 Adjustment of the regulator................................................................. 4-38
4.4.5.3 Operation ............................................................................................ 4-40
4.5 Hydraulic System, Part 2 ....................................................................................... 4-43
4.5.1 Control valve................................................................................................ 4-43
4.5.2 Operating principle....................................................................................... 4-46
4.5.2.1 When spool is in neutral position ........................................................ 4-46
4.5.2.2 Travel .................................................................................................. 4-48
4.5.2.3 Arm...................................................................................................... 4-49
4.5.2.4 Boom................................................................................................... 4-54
4.5.2.5 Bucket ................................................................................................. 4-57
4.5.2.6 Swing .................................................................................................. 4-59
4.5.2.7 Option ................................................................................................. 4-61
4.5.2.8 Travel straight ..................................................................................... 4-62
4.5.2.9 Lock valve function ............................................................................. 4-63
4.5.2.10 Main relief valve function .................................................................. 4-65
4.5.2.11 Port relief valve function.................................................................... 4-66
4.5.3 Section view................................................................................................. 4-70
4.6 Hydraulic System, Part 3 ....................................................................................... 4-81
4.6.1 Swing motor................................................................................................. 4-81
4.6.2 Swing holding brake..................................................................................... 4-83
4.6.3 Relief valve portion ...................................................................................... 4-84
4.6.4 Reverse prevention valve ............................................................................ 4-86
4.6.4.1 Operation drawing............................................................................... 4-86
4.6.4.2 Explanatory drawing of effects............................................................ 4-87
4.6.5 Center swivel joint........................................................................................ 4-89
4.6.6 Travel motor ................................................................................................. 4-91
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SY195/205/215/225C9 Crawler Hydraulic Excavator
Table of Contents
Shop Manual - June 2013
4.6.6.1 Operation of components.................................................................... 4-95
4.6.7 Valve control system .................................................................................. 4-107
4.6.8 Pilot valve.................................................................................................. 4-109
4.6.8.1 Work equipment and swing pilot valve.............................................. 4-109
4.6.8.2 Travel PPC valve ...............................................................................4-113
4.6.9 Solenoid valve.............................................................................................4-117
4.6.10 Accumulator ..............................................................................................4-118
4.6.11 Pilot oil filter...............................................................................................4-119
4.6.12 Pump oil pressure sensor ........................................................................ 4-120
4.6.13 Hydraulic cylinder..................................................................................... 4-121
4.6.14 Work equipment....................................................................................... 4-123
4.7 Air Conditioning System....................................................................................... 4-129
4.7.1 A/C components layout drawing ................................................................ 4-130
4.7.2 Control panel.............................................................................................. 4-131
4.7.3 Circuit diagram........................................................................................... 4-132
4.7.4 Refrigeration principle................................................................................ 4-134
4.7.4.1 Refrigeration cycle diagram .............................................................. 4-134
4.7.4.2 Heating cycle diagram ...................................................................... 4-134
4.7.5 Compressor ............................................................................................... 4-135
4.7.6 Clutch......................................................................................................... 4-137
4.7.8 Condenser ................................................................................................. 4-138
4.7.7 Expansion valve......................................................................................... 4-138
4.7.9 Evaporator ................................................................................................. 4-139
4.7.10 Receiver tank........................................................................................... 4-139
4.7.11 Pressure switch........................................................................................ 4-140
4.7.12 Fresh air sensor....................................................................................... 4-141
4.7.13 Refrigerant ............................................................................................... 4-141
4.7.14 Compressor oil......................................................................................... 4-160
4.8 Engine Control..................................................................................................... 4-161
4.8.1 System operation ...................................................................................... 4-162
4.8.2 Components............................................................................................... 4-163
4.8.2.1 Fuel control dial................................................................................. 4-163
4.8.2.2 Controller .......................................................................................... 4-165
4.9 Electrical Control System..................................................................................... 4-167
4.9.1 Control function.......................................................................................... 4-167
4.9.2 Machine control system diagram ............................................................... 4-168
4.9.3 Engine and pump composite control function............................................ 4-170
4.9.4 Pump control function ................................................................................ 4-174
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SY195/205/215/225C9 Crawler Hydraulic Excavator Table of Contents
Shop Manual - June 2013
4.9.4.1 Electrical positive flow control ........................................................... 4-175
4.9.4.2 Constant power control ..................................................................... 4-178
4.9.5 Valve control function................................................................................. 4-180
4.9.5.1 Bucket flow control............................................................................ 4-181
4.9.5.2 Swing priority control......................................................................... 4-182
4.9.6 Duo travel speed control............................................................................ 4-183
4.9.7 Engine preheating/overheating alarm ....................................................... 4-185
4.9.7.1 Engine preheating............................................................................. 4-186
4.9.7.2 Engine overheating alarm................................................................. 4-187
4.9.8 Engine oil under–pressure alarm............................................................... 4-187
4.9.9 Auto deceleration/acceleration control....................................................... 4-188
4.9.10 Engine speed calibration function............................................................ 4-190
4.9.11 Electrical Components ............................................................................. 4-192
4.9.11.1 Pump pressure sensor .................................................................... 4-192
4.9.11.2 Pilot pressure sensor ...................................................................... 4-193
4.9.11.3 Engine speed sensor ...................................................................... 4-194
4.9.11.4 Coolant temperature sensor............................................................ 4-195
4.9.11.5 Fuel level sensor ............................................................................. 4-196
4.9.11.6 Oil pressure switch.......................................................................... 4-197
4.10 Monitoring System............................................................................................. 4-198
4.10.1 Machine monitor ...................................................................................... 4-199
4.10.2 Monitor functions...................................................................................... 4-200
4.10.3 Monitor operation..................................................................................... 4-203
5 Standard Values
5.1 Standard Values of Engine - related Parts............................................................... 5-3
5.2 Standard Values of Chassis-related Parts ............................................................... 5-4
6 Testing and Adjusting
6.1 Engine Speed - Test and Calibrate .......................................................................... 6-3
6.1.1 Testing ........................................................................................................... 6-3
6.1.2 Adjusting ........................................................................................................ 6-3
6.2 Exhaust Gas Color - Test......................................................................................... 6-6
6.3 Valve Clearance - Adjust.......................................................................................... 6-8
6.3.1 Testing............................................................................................................ 6-8
6.3.2 Adjusting ...................................................................................................... 6-10
6.4 Compression Pressure - Measure..........................................................................6-11
6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13
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SY195/205/215/225C9 Crawler Hydraulic Excavator
Table of Contents
Shop Manual - June 2013
6.5.1 Testing.......................................................................................................... 6-13
6.5.2 Adjusting ...................................................................................................... 6-15
6.6 Engine Oil Pressure - Measure.............................................................................. 6-17
6.7 Engine Speed Sensor - Adjust............................................................................... 6-19
6.8 A/C Compressor Belt Tension - Test and Adjust ................................................... 6-20
6.8.1 Testing ......................................................................................................... 6-20
6.8.2 Adjusting ...................................................................................................... 6-20
6.9 Swing Bearing Clearance - Measure..................................................................... 6-22
6.10 Track Tension - Test and Adjust ........................................................................... 6-24
6.10.1 Testing........................................................................................................ 6-24
6.10.2 Adjusting .................................................................................................... 6-25
6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust .................................. 6-26
6.11.1 Measuring .................................................................................................. 6-26
6.11.2 Adjusting..................................................................................................... 6-28
6.12 Control Circuit Oil Pressure - Test and Adjust...................................................... 6-30
6.12.1 Testing........................................................................................................ 6-30
6.12.2 Adjusting .................................................................................................... 6-31
6.13 Solenoid Valve Output Pressure - Measure......................................................... 6-32
6.14 Pilot Valve Output Pressure - Measure................................................................ 6-34
6.15 Pilot Valves (Work Equipment and Swing) - Adjust ............................................. 6-36
6.16 Work Equipment Hydraulic Drift - Test................................................................. 6-37
6.17 Residual Pressure in Hydraulic Circuit - Release................................................ 6-40
6.18 Oil Leakage - Measure ........................................................................................ 6-41
6.19 Air in Each Component - Bleed............................................................................ 6-46
7 Troubleshooting
7.1 Points to Remember When Troubleshooting ........................................................... 7-3
7.2 Troubleshooting Procedures.................................................................................... 7-5
7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-8
7.3.1 Connector location layout ............................................................................ 7-12
7.3.2 Electrical element circuit diagram (cab circuit)............................................. 7-18
7.3.3 Electrical control circuit diagram (engine circuit).......................................... 7-20
7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit)........... 7-22
7.3.5 SWP type connector .................................................................................... 7-23
7.3.6 A/AMP type connector ................................................................................. 7-24
7.3.7 DT type connector ....................................................................................... 7-25
7.4 Failure Symptoms and Troubleshooting Codes..................................................... 7-26
7.5 Troubleshooting with an Event Code..................................................................... 7-28
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SY195/205/215/225C9 Crawler Hydraulic Excavator Table of Contents
Shop Manual - June 2013
7.6 Troubleshooting of Electrical System (E - Mode)................................................... 7-63
7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode)...................... 7-93
8 Disassembly and Assembly
8.1 How to Read This Manual ....................................................................................... 8-5
8.1.1 Removing and Installing an Assembly ........................................................... 8-5
8.1.2 Disassembling and assembling an assembly ................................................ 8-5
8.1.3 Special tools................................................................................................... 8-5
8.2.1 The symbols used in this section .................................................................. 8-6
8.2 Operating Precautions............................................................................................. 8-6
8.3 Start Motor AS - Remove and Install ..................................................................... 8-10
8.3.1 Removal....................................................................................................... 8-10
8.3.2 Installation.................................................................................................... 8-10
8.4 Injection Pump AS - Remove and Install ................................................................8-11
8.4.1 Removal........................................................................................................8-11
8.4.2 Installation.................................................................................................... 8-13
8.5 Engine Front Seal - Remove and Install................................................................ 8-15
8.5.1 Removal....................................................................................................... 8-15
8.5.2 Installation.................................................................................................... 8-15
8.6 Engine Rear Seal - Remove and Install................................................................. 8-16
8.6.1 Removal....................................................................................................... 8-16
8.6.2 Installation.................................................................................................... 8-17
8.7 Cylinder Head AS - Remove and Install ................................................................ 8-18
8.7.1 Removal....................................................................................................... 8-18
8.7.2 Installation.................................................................................................... 8-22
8.8 Radiator AS - Remove and Install.......................................................................... 8-24
8.8.1 Removal....................................................................................................... 8-24
8.8.2 Installation.................................................................................................... 8-27
8.9 Engine and Hydraulic Pump AS - Remove and Install .......................................... 8-28
8.9.1 Removal....................................................................................................... 8-28
8.9.2 Installation.................................................................................................... 8-34
8.10 Final Drive AS - Remove and Install.................................................................... 8-35
8.10.1 Removal..................................................................................................... 8-35
8.10.2 Installation.................................................................................................. 8-36
8.11 Final Drive AS - Disassemble and Assemble....................................................... 8-37
8.11.1 Disassembly............................................................................................... 8-37
8.11.2 Assembly.................................................................................................... 8-41
8.12 Swing Motor and Swing Drive AS - Remove and Install...................................... 8-46
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