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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I
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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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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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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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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Table of Contents
Shop Manual - June 2013
8.12.1 Removal..................................................................................................... 8-46
8.12.2 Installation.................................................................................................. 8-47
8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble......................... 8-48
8.13.1 Disassembly............................................................................................... 8-48
8.13.2 Assembly.................................................................................................... 8-53
8.14 Idler AS - Disassemble and Assemble................................................................. 8-58
8.14.1 Disassembly............................................................................................... 8-58
8.14.2 Assembly.................................................................................................... 8-59
8.15 Sprocket - Remove and Install............................................................................. 8-62
8.15.1 Removal..................................................................................................... 8-62
8.15.2 Installation.................................................................................................. 8-62
8.16 Track AS - Remove and Install ............................................................................ 8-63
8.16.1 Removal..................................................................................................... 8-63
8.16.2 Installation.................................................................................................. 8-65
8.17 Swing Bearing AS - Remove and Install.............................................................. 8-66
8.17.1 Removal..................................................................................................... 8-66
8.17.2 Installation.................................................................................................. 8-67
8.18 Swing Platform AS - Remove and Install............................................................. 8-68
8.18.1 Removal..................................................................................................... 8-68
8.18.2 Installation.................................................................................................. 8-71
8.19 Swivel Joint AS - Remove and Install .................................................................. 8-72
8.19.1 Removal..................................................................................................... 8-72
8.19.2 Installation.................................................................................................. 8-74
8.20 Swivel Joint AS - Disassemble and Assemble..................................................... 8-75
8.20.1 Disassembly............................................................................................... 8-75
8.20.2 Assembly.................................................................................................... 8-76
8.21 Hydraulic Tank AS - Remove and Install.............................................................. 8-77
8.21.1 Removal..................................................................................................... 8-77
8.21.2 Installation.................................................................................................. 8-79
8.22 Control Valve AS - Remove and Install................................................................ 8-80
8.22.1 Removal..................................................................................................... 8-80
8.22.2 Installation.................................................................................................. 8-84
8.23 Hydraulic Pump AS - Remove and Install............................................................ 8-85
8.23.1 Removal..................................................................................................... 8-85
8.23.2 Installation.................................................................................................. 8-89
8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install .................... 8-90
8.24.1 Removal..................................................................................................... 8-90
8.24.2 Installation.................................................................................................. 8-90
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Shop Manual - June 2013
8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble ......................... 8-91
8.25.1 Assembly.................................................................................................... 8-91
8.26 Pilot Valve AS (Travel) - Disassemble and Assemble.......................................... 8-93
8.26.1 Assembly.................................................................................................... 8-93
8.27 Hydraulic Cylinder AS - Disassemble and Assemble........................................... 8-94
8.27.1 Disassembly............................................................................................... 8-95
8.27.2 Assembly.................................................................................................. 8-100
8.28 Work Equipment AS - Remove and Install......................................................... 8-105
8.28.1 Removal................................................................................................... 8-105
8.28.2 Installation................................................................................................ 8-107
8.29 Air Conditioner AS - Remove and Install............................................................ 8-108
8.29.1 Removal................................................................................................... 8-108
8.29.2 Installation.................................................................................................8-112
8.30 Counterweight AS - Remove and Install.............................................................8-113
8.30.1 Removal....................................................................................................8-113
8.30.2 Installation.................................................................................................8-114
8.31 Cab AS - Remove and Install..............................................................................8-115
8.31.1 Removal....................................................................................................8-115
8.31.2 Installation.................................................................................................8-119
8.32 Cab Window Glass – Disassemble and Assemble............................................ 8-120
8.32.1 Removal................................................................................................... 8-121
8.32.2 Installation................................................................................................ 8-125
8.33 Front Window AS - Disassemble and Assemble................................................ 8-138
8.33.1 Disassemble ............................................................................................ 8-138
8.33.2 Assemble ................................................................................................. 8-141
8.34 Monitor - Remove and Install............................................................................. 8-146
8.34.1 Removal................................................................................................... 8-146
8.34.2 Installation................................................................................................ 8-146
8.35 Controller AS - Remove and Install.................................................................... 8-147
8.35.1 Removal................................................................................................... 8-147
8.35.2 Installation................................................................................................ 8-147
8.36 Radio ................................................................................................................. 8-148
8.36.1 Structure .................................................................................................. 8-148
8.36.2 Removal................................................................................................... 8-149
8.36.3 Installation................................................................................................ 8-150
8.36.4 Connector model and wiring .................................................................... 8-150
8.37 Battery ............................................................................................................... 8-151
8.37.1 Structure .................................................................................................. 8-151
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Shop Manual - June 2013
8.37.2 Removal................................................................................................... 8-152
8.37.3 Installation................................................................................................ 8-153
8.37.4 Replacement............................................................................................ 8-153
8.38 Start Switch........................................................................................................ 8-154
8.38.1 Structure ................................................................................................. 8-154
8.38.2 Removal................................................................................................... 8-155
8.39 Fuse Box............................................................................................................ 8-157
8.39.1 Removal................................................................................................... 8-157
8.40 Wiper ................................................................................................................. 8-158
8.40.1 Structure .................................................................................................. 8-158
8.40.2 Working principle ..................................................................................... 8-158
8.40.3 Removal................................................................................................... 8-159
8.40.5 Installation................................................................................................ 8-160
8.40.4 Angle adjustment of wiper arm................................................................. 8-160
8.41 Relay.................................................................................................................. 8-161
8.41.1 Engine relays ........................................................................................... 8-161
8.41.2 Other relays ............................................................................................. 8-162
8.42 Sensor ............................................................................................................... 8-165
8.43 Connector Terminals - Insert and Remove ........................................................ 8-167
8.43.1 Insertion ................................................................................................... 8-167
8.43.2 Removal................................................................................................... 8-168
9 System Schematics
9.1 Hydraulic System Diagram ...................................................................................... 9-3
9.2 Air-Conditioning Electrical Circuit Diagram.............................................................. 9-4
9.3 Fuse Box Relay ....................................................................................................... 9-5
9.4 Control Switches and Monitor Electrical Diagram ................................................... 9-6
9.5 Operator Cab Electrical Circuit Diagram.................................................................. 9-7
9.6 Chassis Electrical Circuit Diagram........................................................................... 9-8
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Introduction
SY195/205/215/225C9 Crawler Hydraulic Excavator Introduction
Shop Manual - June 2013 1-1
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
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SY195/205/215/225C9 Crawler Hydraulic Excavator
Introduction
1-2 Shop Manual - June 2013
WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.
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1-3
SY195/205/215/225C9 Crawler Hydraulic Excavator Introduction
Shop Manual - June 2013
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a work-
shop. For ease of understanding, the manual is divided into the following sections.
Introduction
This section provides an overview of what is covered in the rest of this manual and how to use
this manual,.
Shop Safety
This section covers basic shop safety information relating to this equipment. It also describes
what the hazard alerts mean that are used throughout the manual.
Specifications
Technical specification of work equipment and optional parts are given in this section.
Structure and function
This section explains the structure and function of each component. It helps the reader to get a
better understanding of the machine structure, and also serves as a reference for troubleshoot-
ing.
Standard Values
This section explains the standard values for a new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section details the inspection before and after repair work as well as the adjustment during
inspection and repair work. Troubleshooting table that involves “Fault”and “Cause”are also in-
cluded in this section.
Troubleshooting
This section explains the way to detect faulty parts and the method to repair them. This section is
divided into the following parts: Electrical system, Engine, Hydraulic and mechanical system and
Monitoring system.
Disassembly and assembly
This section explains the procedures as well as precautions for removing, installing, disassem-
bling and assembling of each component.
1 INTRODUCTION
1.1 How to Read the Shop Manual
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SY195/205/215/225C9 Crawler Hydraulic Excavator
Introduction
Shop Manual - June 2013
2. Revision and distribution
Any additions, revisions, or other change of notices will be sent to Sany distributors. Get the most
up-to-date information before you start any work.
Symbol Item Remarks
Safety Special safety precautions are necessary when performing
work.
Caution Special technical precautions or other precautions for pre-
serving standards are necessary when performing work.
kg Weight
Weight of parts of component or parts. Caution necessary
when selecting hoisting wire, or when working posture is
important, etc.
Tightening
torque
Places that require special attention for tightening torque
during assembly.
Coat Places to be coated with adhesives, etc. during assembly.
Oil, Coolant Places where oil, etc. must be added, and capacity.
Drain Places where oil, etc. must be drained, and quantity to be
drained.
3. Units
In this shop manual, the units are indicated with International System of units (SI). For reference,
conventionally used Gravitational System of units is indicated in parentheses { }.
System Schematics
This section provides hydraulic circuit diagrams and electrical circuit diagrams.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop
manual will be used practically.
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SY195/205/215/225C9 Crawler Hydraulic Excavator Introduction
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1.2 Terms for Maintenance Standard
1. Standard size and tolerance
●To be accurate, the finishing size of parts
is a little different from one to another.
●To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
●The above size set temporarily is called
the "standard size" and the range of differ-
ence from the standard size is called the
"tolerance".
●The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
NOTE: The tolerance may be indicated in
the text and a table as [standard size (upper
limit of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
●Usually, the size of a hole and the size
of the shaft to be fitted to that hole are
indicated by the same standard size
and different tolerances of the hole and
shaft. The tightness of fit is decided by
the tolerance.
●Indication of size of rotating shaft and
hole and relationship drawing of them.
Example
Standard size Tolerance
120 –0.022
–0.126
ZX215-1000003
Tolerance of hole
(upper):+0.046
Std.clearance (max.):0.122
Std.clearance (min.):0.030
Tolerance of shaft
(lower):-0.076
Tolerance of shaft
(upper):-0.030
Std.size F60
The maintenance standard values necessary
for judgment of products and parts are de-
scribed by the following terms.
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SY195/205/215/225C9 Crawler Hydraulic Excavator
Introduction
Shop Manual - June 2013
Example
Standard size Tolerance
Shaft Hole
φ60 -0.030
-0.076
+0.046
0
2. Standard clearance and standard value
●The clearance made when new parts are
assembled is called the "standard clear-
ance", which is indicated by the range from
the minimum clearance to the maximum
clearance.
●When some parts are repaired, the clear-
ance is generally adjusted to the standard
clearance.
●A value of performance and function of
new products or equivalent is called the
"standard value", which is indicated by a
range or a target value.
●When some parts are repaired, the value
of performance/function is set to the stan-
dard value.
3. Standard interference
●When the size of a hole is smaller than the
size of a shaft because of the standard
size and tolerance, the difference between
these sizes is called the "interference".
●The range (A – B) from the difference (A)
between the minimum size of the shaft and
the maximum size of the shaft to the differ-
ence (B) between the maximum size of the
shaft and the minimum size of the hole is
the "standard interference".
●After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value
●The size of a part changes due to wear
and deformation while it is used. The limit
of changed size is called the "repair limit".
●If a part is worn to the repair limit must be
replaced or repaired.
●The performance and function of a product
lowers while it is used. A value below which
the product can be used without causing a
problem is called the "allowable value".
●If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
5. Clearance limit
●Parts can be used until the clearance be-
tween them is increased to a certain limit.
The limit at which those parts cannot be
used is called the "clearance limit".
●If the clearance between the parts exceeds
the clearance limit, they must be replaced
or repaired.
6. Interference limit
●The allowable maximum interference be-
tween the hole of a part and the shaft of
another part to be assembled is called the
"interference limit".
●The interference limit shows the repair limit
of the part of smaller tolerance.
●If the interference between the parts ex-
ceeds the interference limit, they must be
replaced or repaired.
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SY195/205/215/225C9 Crawler Hydraulic Excavator Introduction
Shop Manual - June 2013
1.3 Handling Electrical and Hydraulic Components
To maintain the performance of the machine
over a long period, and to prevent failures or
other troubles before they occur, correct "oper-
ation", "maintenance and inspection", "trouble-
shooting", and "repairs" must be carried out.
This section deals particularly with correct re-
pair procedures for mechatronics and is aimed
at improving the quality of repairs. For this
purpose, it gives sections on "Handling electric
components" and "Handling hydraulic equip-
ment" (particularly gear oil and hydraulic oil).
1.3.1 Points to remember when handling electric components
ZX215-1000004
1. Handling wiring harnesses and connec-
tors
Wiring harnesses consist of wiring con-
necting one component to another compo-
nent, connectors used for connecting and
disconnecting one wire from another wire,
and protectors or tubes used for protecting
the wiring.
Compared with other electrical compo-
nents fitted in boxes or cases, wiring
harnesses are more likely to be affected
by the direct effects of rain, water, heat, or
vibration. Furthermore, during inspection
and repair operations, they are frequently
removed and installed again, so they are
likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.
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