Sany SY215C/LC Crawler Hydraulic Excavator Service Manual – PDF DOWNLOAD

Sany SY215C/LC Crawler Hydraulic Excavator Service Manual – PDF DOWNLOAD

FILE DETAILS:

Sany SY215C/LC Crawler Hydraulic Excavator Service Manual – PDF DOWNLOAD

Language : English
Pages : 669
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Sany SY215C/LC Crawler Hydraulic Excavator Service Manual – PDF DOWNLOAD

1 Introduction
1 1 Safety Notice 1-3
1 2 How to Read the Shop Manual 1-13
1 3 Terms for Maintenance Standard 1-16
1 4 Handling Electrical and Hydraulic Components 1-19
1 4 1 Points to remember when handling electric components 1-19
1 4 2 Points to remember when handling hydraulic equipment 1-28
1 5 Hose Connector 1-30
1 5 1 Type of hose connector 1-31
1 5 2 Hose connector tightening torque table 1-31
1 5 3 Connection of O-rings 1-32
1 6 Table of Standard Tightening Torques 1-33
1 7 Type of Bolts 1-34
1 8 Tightening Sequence 1-34
1 9 Maintenance of Half Flanges 1-35
1 9 1 Table of tightening torques for half fl ange bolts 1-35
1 10 Conversion Table 1-36
1 10 1 Method of using conversion table 1-36
1 10 2 Temperature 1-41
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 2-11
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
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 HAZARDS 2-24
2 2 31 Material Safety Data Sheets (MSDS) 2-24
3 Specifi cations
3 1 Dimensions 3-3
3 2 Working Ranges 3-4
3 3 Technical Specifi cations 3-5
3 4 Weight Table 3-6
3 5 Fuel and Coolant 3-7
3 6 Engine Performance Curve 3-9
4 Structure and Function
4 1 Engine and Cooling System 4-3
4 1 1 Engine-related parts 4-3
4 1 2 Radiator and intercooler 4-4
4 2 Power Train 4-5
4 2 1 Power transmission system 4-5
4 2 2 Final drive AS (KYB) 4-6
4 2 3 Final drive AS (Nabtesco) 4-8
4 2 4 Swing machinery 4-10
4 2 5 Swing bearing 4-12
4 3 Undercarriage and Frame 4-13
4 3 1 Track frame and recoil spring 4-13
4 3 2 Idler 4-15
4 3 3 Carrier roller 4-17
4 3 4 Track roller 4-18
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 drawing 4-24
4 4 2 Hydraulic tank and fi lter 4-26
4 4 3 Hydraulic pump 4-28
4 4 4 Pilot pump 4-35
4 4 5 Regulator (KR3G-0E11-AV) 4-36
4 4 5 1 Control mechanism makeup 4-38
4 4 5 2 Adjustment of the regulator 4-39
4 4 5 3 Operation 4-41
4 5 Hydraulic System, Part 2 4-44
4 5 1 Control valve 4-44
4 5 2 Hydraulic circuit diagram (with bucket confl uence function) 4-47
4 5 3 Operating principle 4-48
4 5 3 1 When spool is in neutral position 4-48
4 5 3 2 Travel 4-50
4 5 3 3 Arm 4-51
4 5 3 4 Boom 4-56
4 5 3 5 Bucket 4-59
4 5 3 6 Swing 4-61
4 5 3 7 Option 4-63
4 5 3 8 Travel straight 4-64
4 5 3 9 Lock valve function 4-65
4 5 3 10 Main relief valve function 4-67
4 5 3 11 Port relief valve function 4-68
4 5 4 Section view 4-72
4 6 Hydraulic System, Part 3 4-83
4 6 1 Swing motor 4-83
4 6 2 Swing holding brake 4-85
4 6 3 Relief valve portion 4-86
4 6 4 Reverse prevention valve 4-88
4 6 4 1 Operation drawing 4-88
4 6 4 2 Explanatory drawing of effects 4-89
4 6 5 Center swivel joint 4-91
4 6 6 Travel motor 4-93
4 6 6 1 Operation of components 4-96
4 6 6 2 Operation of parking brake 4-102
4 6 6 3 Brake valve operation 4-103
4 6 7 Valve control system 4-112
4 6 8 Pilot valve 4-114
4 6 8 1 Work equipment and swing pilot valve 4-114
4 6 8 2 Travel PPC valve 4-118
4 6 9 Solenoid valve 4-122
4 6 10 Accumulator 4-123
4 6 11 Pilot oil fi lter 4-124
4 6 12 Pump oil pressure sensor 4-125
4 6 13 Hydraulic cylinder 4-126
4 6 14 Work equipment 4-128
4 7 Air Conditioning System 4-132
4 7 1 A/C components layout drawing 4-133
4 7 2 Control panel 4-134
4 7 3 Circuit diagram 4-135
4 7 4 Refrigeration principle 4-137
4 7 4 1 Refrigeration cycle diagram 4-137
4 7 4 2 Heating cycle diagram 4-137
4 7 5 Compressor 4-138
4 7 6 Clutch 4-140
4 7 7 Condenser 4-141
4 7 8 Expansion valve 4-142
4 7 9 Evaporator 4-142
4 7 10 Dehydrator 4-143
4 7 11 Pressure switch 4-144
4 7 12 Fresh air sensor 4-145
4 7 13 Refrigerant 4-146
4 7 14 Compressor oil 4-165
4 8 Engine Control 4-166
4 8 1 System operation 4-167
4 8 1 1 Engine startup 4-167
4 8 1 2 Engine speed control 4-167
4 8 1 3 Engine shutdown 4-167
4 8 2 Components 4-168
4 8 2 1 Fuel control dial 4-168
4 8 2 2 Controller 4-170
4 9 Electrical Control System 4-172
4 9 1 Control function 4-172
4 9 2 Machine control system diagram 4-173
4 9 3 Engine and pump composite control function 4-175
4 9 4 Pump control function 4-179
4 9 4 1 Electrical positive fl ow control 4-180
4 9 4 2 Constant power control 4-183
4 9 4 3 ESS control 4-184
4 9 5 Valve control function 4-185
4 9 5 1 Bucket fl ow control 4-186
4 9 5 2 Swing priority control 4-187
4 9 6 Duo travel speed control 4-188
4 9 7 Engine preheating/overheating alarm 4-190
4 9 7 1 Engine preheating 4-191
4 9 7 2 Engine overheating alarm 4-192
4 9 8 Engine oil under–pressure alarm 4-192
4 9 9 Auto deceleration/acceleration control 4-193
4 9 10 Engine speed calibration function 4-195
4 9 11 System Components 4-197
4 9 11 1 Pump pressure sensor 4-197
4 9 11 2 Pilot pressure sensor 4-198
4 9 11 3 Engine speed sensor 4-199
4 9 11 4 Coolant temperature sensor 4-200
4 9 11 5 Fuel sensor 4-201
4 9 11 6 Oil pressure switch 4-202
4 10 Monitoring System 4-203
4 10 1 Machine monitor 4-204
4 10 2 Monitor functions 4-205
4 10 3 Screen display and operation 4-209
4 10 3 1 Initializing page 4-209
4 10 3 2 Home page 4-209
4 10 3 3 System Information 4-210
4 10 3 4 Main Menu 4-211
4 10 3 5 Engine Signals 4-212
4 10 3 6 Throttle Signals 4-212
4 10 3 7 Pilot Pressure Signal – 1 4-213
4 10 3 8 Pilot Pressure Signal – 2 4-213
4 10 3 9 Main Pump Signals 4-214
4 10 3 10 Main Valve Signals 4-214
4 10 3 11 Fault Information 4-215
4 10 3 12 Throttle Help Information 4-215
4 10 3 13 Language Selection 4-216
4 10 3 14 System Clock Calibration 4-216
4 10 3 15 Unit Display Setup 4-217
4 10 3 16 Working Mode Selection 4-217
4 10 3 17 System Setup Password Entry 4-218
4 10 3 18 System Setup Menu 4-219
4 10 3 19 Machine Confi guration Password 4-220
4 10 3 20 Machine Confi guration 4-221
4 10 3 21 Service Hour Calibration Password 4-222
4 10 3 22 Service Hour Calibration 4-223
4 10 3 23 Machine Confi guration Calibration Password 4-224
4 10 3 24 Machine Confi guration Calibration 4-225
4 10 3 25 Hydraulic Oil Temperature 4-227
4 10 3 26 System Lockout Level 1 4-228
4 10 3 27 System Lockout Level 2 4-228
5 Standard Values
5 1 Standard Values for Chassis-related Parts 5-3
6 Testing and Adjusting
6 1 Engine Speed – Test and Calibrate 6-3
6 1 2 Testing 6-3
6 1 1 Adjusting 6-3
6 2 Exhaust Gas Color – Test 6-5
6 3 Engine Speed Sensor – Adjust 6-7
6 4 A/C Compressor Belt Tension – Test and Adjust 6-8
6 4 1 Testing 6-8
6 4 2 Adjusting 6-8
6 5 Swing Bearing Clearance – Measure 6-10
6 6 Track Tension – Test and Adjust 6-12
6 6 1 Testing 6-12
6 6 2 Adjusting 6-13
6 7 Hydraulic Pressure in Hydraulic Circuits – Test and Adjust 6-14
6 7 1 Measuring 6-14
6 7 2 Adjusting 6-16
6 8 Control Circuit Oil Pressure – Test and Adjust 6-19
6 8 1 Testing 6-19
6 8 2 Adjusting 6-20
6 9 Solenoid Valve Output Pressure – Measure 6-21
6 10 Pilot Valve Output Pressure – Measure 6-23
6 11 Pilot Valves (Work Equipment and Swing) – Adjust 6-25
6 12 Work Equipment Hydraulic Drift – Test 6-26
6 13 Residual Pressure in Hydraulic Circuit – Release 6-29
6 14 Oil Leakage – Measure 6-30
6 15 Air in Each Component – Bleed 6-35
7 Troubleshooting
7 1 Points to Remember When Troubleshooting 7-3
7 2 Sequence of Events in Troubleshooting 7-6
7 3 Troubleshooting Procedures 7-7
7 4 Connectors 7-10
7 4 1 Table of connectors 7-10
7 4 2 Connector layout 7-14
7 4 3 Electrical element circuit diagram (cab circuit) 7-20
7 4 4 Electrical control circuit diagram (engine circuit) 7-22
7 4 5 Electrical control circuit diagram (sensor and solenoid valve circuit) 7-24
7 4 6 SWP type connector 7-25
7 4 7 A/AMP type connector 7-26
7 4 8 DT type connector 7-27
7 5 Failure Symptoms and Service Codes 7-28
7 5 1 Troubleshooting with an failure code 7-30
7 5 2 Troubleshooting of Electrical System (E – Code) 7-61
7 5 3 Troubleshooting of Hydraulic and Mechanical Systems (H – Code) 7-90
8 Disassembly and Assembly
8 1 Reading Guide 8-3
8 1 1 Removing and Installing an Assembly 8-3
8 1 1 1 Special tools 8-3
8 1 1 2 Removal 8-3
8 1 1 3 Installation 8-4
8 1 2 Disassembling and assembling an assembly 8-5
8 1 2 1 Special tools 8-5
8 1 2 2 Disassembly 8-5
8 1 2 3 Assembly 8-6
8 2 Operating Precautions 8-7
8 3 Radiator AS – Remove and Install 8-11
8 3 1 Removal 8-11
8 3 2 Installation 8-14
8 4 Engine and Hydraulic Pump AS – Remove and Install 8-15
8 4 1 Removal 8-15
8 4 2 Installation 8-21
8 5 Final Drive AS – Remove and Install 8-22
8 5 1 Removal 8-22
8 5 2 Installation 8-23
8 6 Final Drive AS – Disassemble and Assemble 8-24
8 6 1 Disassembly 8-24
8 6 2 Assembly 8-28
8 7 Swing Motor and Swing Drive AS – Remove and Install 8-33
8 7 1 Removal 8-33
8 7 2 Installation 8-34
8 8 Swing Motor and Swing Drive AS – Disassemble and Assemble 8-35
8 8 1 Disassembly 8-35
8 8 2 Assembly 8-40
8 9 Idler AS – Disassemble and Assemble 8-45
8 9 1 Disassembly 8-45
8 9 2 Assembly 8-46
8 10 Sprocket – Remove and Install 8-49
8 10 1 Removal 8-49
8 10 2 Installation 8-49
8 11 Track AS – Remove and Install 8-50
8 11 1 Removal 8-50
8 11 2 Installation 8-52
8 12 Swing Bearing AS – Remove and Install 8-53
8 12 1 Removal 8-53
8 12 2 Installation 8-54
8 13 Swing Platform AS – Remove and Install 8-55
8 13 1 Removal 8-55
8 13 2 Installation 8-58
8 14 Swivel Joint AS – Remove and Install 8-59
8 14 1 Removal 8-59
8 14 2 Installation 8-61
8 15 Swivel Joint AS – Disassemble and Assemble 8-62
8 15 1 Disassembly 8-62
8 15 2 Assembly 8-63
8 16 Hydraulic Tank AS – Remove and Install 8-64
8 16 1 Removal 8-64
8 16 2 Installation 8-66
8 17 Control Valve AS – Remove and Install 8-67
8 17 1 Removal 8-67
8 17 2 Installation 8-71
8 18 Hydraulic Pump AS – Remove and Install 8-72
8 18 1 Removal 8-72
8 18 2 Installation 8-76
8 19 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install 8-77
8 19 1 Removal 8-77
8 19 2 Installation 8-77
8 20 Pilot Valve AS (Work Equipment) – Disassemble and Assemble 8-78
8 20 1 Assembly 8-78
8 21 Pilot Valve AS (Travel) – Disassemble and Assemble 8-80
8 21 1 Assembly 8-81
8 22 Hydraulic Cylinder AS – Disassemble and Assemble 8-82
8 22 1 Disassembly 8-83
8 22 2 Assembly 8-88
8 23 Work Equipment AS – Remove and Install 8-94
8 23 1 Removal 8-94
8 23 2 Installation 8-96
8 24 Air Conditioner AS – Remove and Install 8-97
8 24 1 Removal 8-97
8 24 2 Installation 8-100
8 25 Counterweight AS – Remove and Install 8-101
8 25 1 Removal 8-101
8 25 2 Installation 8-102
8 26 Cab AS – Remove and Install 8-103
8 26 1 Removal 8-103
8 26 2 Installation 8-107
8 27 Cab Window Glass – Disassemble and Assemble 8-108
8 27 1 Removal 8-109
8 27 2 Installation 8-112
8 28 Front Window AS – Disassemble and Assemble 8-124
8 28 1 Disassemble 8-124
8 28 2 Assemble 8-127
8 29 Monitor – Remove and Install 8-133
8 29 1 Removal 8-133
8 29 2 Installation 8-133
8 30 Controller AS – Remove and Install 8-134
8 30 1 Removal 8-134
8 30 2 Installation 8-134
8 31 Radio 8-135
8 31 1 Structure 8-135
8 31 2 Removal and installation 8-137
8 31 2 1 Removal 8-137
8 31 2 2 Installation 8-137
8 31 3 Connector model and wiring 8-138
8 32 Battery 8-139
8 32 1 Structure 8-139
8 32 2 Removal and installation 8-140
8 32 2 1 Removal 8-140
8 32 2 2 Installation 8-141
8 32 3 Replacement 8-141
8 33 Start Switch 8-142
8 33 1 Structure 8-142
8 33 2 Removal and installation 8-143
8 33 2 1 Removal 8-143
8 33 3 Working principle and wiring of start switch 8-144
8 34 Fuse Box 8-145
8 34 1 Removal and installation 8-145
8 35 Wiper 8-146
8 35 1 Structure and working principle 8-146
8 35 2 Removal and Installation 8-148
8 35 3 Angle adjustment of wiper arm 8-150
8 36 Relay 8-151
8 36 1 Engine relays 8-151
8 36 2 Other relays 8-152
8 36 2 1 Function and location 8-152
8 36 2 2 Removal and Installation 8-153
8 36 2 3 Relay connector and wiring 8-154
8 37 Sensor 8-155
8 38 Connector Terminals – Insert and Remove 8-157
8 38 1 Insertion 8-157
8 38 2 Removal 8-158
9 System Schematics
9 1 Hydraulic System Diagram 9-3
9 2 Air-Conditioning Electrical 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 Diagram 9-7
9 6 Chassis Electrical Diagram 9-8