Sany SY215CA14K Crawler Hydraulic Excavator Service Manual – PDF

Sany SY215CA14K Crawler Hydraulic Excavator Service Manual – PDF DOWNLOAD

FILE DETAILS:

Sany SY215CA14K Crawler Hydraulic Excavator Service Manual – PDF DOWNLOAD

Language : English
Pages : 655
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Sany SY215CA14K Crawler Hydraulic Excavator Service Manual – PDF DOWNLOAD

1 Introduction
1 1 How to Read the Shop Manual 1-3
1 1 1 Manual organization 1-3
1 1 3 Symbols 1-4
1 1 4 Units 1-4
1 1 2 Revision and publication 1-4
1 2 Technical Terms for Maintenance Standard 1-5
1 3 Handling Electrical or Hydraulic Components 1-7
1 3 1 Precautions for handling electrical components 1-7
1 3 2 Precautions for handling hydraulic components 1-16
1 4 Hose Joint 1-18
1 4 1 Type of hose joint 1-19
1 4 2 Hose joint tightening torque table 1-19
1 4 3 Connection of O-rings 1-20
1 5 Standard Tightening Torque Table 1-21
1 6 Type of Bolts 1-22
1 7 Tightening Sequence 1-22
1 8 Maintenance of Split Flanges 1-23
1 9 Conversion Tables 1-24
1 9 1 Length 1-25
1 9 2 Area 1-29
1 9 3 Volume 1-30
1 9 4 Mass 1-33
1 9 5 Pressure 1-35
1 9 6 Tightening Torque 1-37
1 9 7 Temperature 1-39
2 Shop Safety
2 1 Hazard Alert Information 2-3
2 2 General Shop Safety 2-4
2 2 1 Rules and shop behavior 2-5
2 2 2 Housekeeping 2-5
2 2 3 Shop Liquids Storage 2-6
2 2 4 Cleaning the Parts 2-6
2 2 5 Cleaning the Machine 2-7
2 2 6 Appropriate Working Apparel 2-7
2 2 7 Personal Protective Equipment 2-7
2 2 8 Using the Correct Tools 2-8
2 2 9 Fire Extinguisher and Emergency Exit 2-8
2 3 Before Repair 2-9
2 3 1 Safe Work Preparations 2-9
2 3 2 Lock out and tag out 2-10
2 3 3 Preparing yourself 2-11
2 4 Repair Precautions 2-12
2 4 1 Repair with engine running 2-12
2 4 2 Removing an attachment 2-13
2 4 3 Working under the Machine 2-13
2 4 4 Replenishing or changing oil 2-14
2 4 5 Aligning Parts or Components 2-14
2 4 6 When a hammer is used 2-14
2 4 7 When compressed air is used 2-15
2 4 8 Welding operation 2-15
2 4 9 Track recoil springs 2-15
2 4 10 High-pressure hose operation safety 2-16
2 4 11 Hot coolant 2-16
2 4 12 High-Pressure Fluid Lines 2-17
2 4 13 Air-conditioning system 2-18
2 4 14 High voltage precautions 2-18
2 4 15 Disconnecting the System Power 2-19
2 4 16 Accumulator 2-19
2 4 17 Battery Hazards 2-20
2 4 18 Avoiding fi re and explosion 2-21
2 4 19 Proper disposal of wastes 2-22
2 5 Other Precautions 2-23
2 5 1 Sling work and giving signals 2-23
2 5 2 Using mobile crane 2-25
2 5 3 Using overhead hoist crane 2-25
2 5 4 Selecting wire ropes 2-26
3 Specifi cations
3 1 Dimensions 3-3
3 2 Working Ranges 3-4
3 3 Technical Specifi cations 3-6
3 4 Weight Table 3-14
3 5 Engine oil, fuel and coolant 3-15
3 6 Engine Performance Curve 3-16
4 Structure and Functions
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 train 4-7
4 2 2 Final drive (KYB) 4-8
4 2 3 Final drive assembly (Nabtesco) 4-10
4 2 4 Swing drive 4-12
4 2 5 Swing bearing 4-14
4 3 Undercarriage 4-16
4 3 1 Track frame and tensioning mechanism 4-16
4 3 2 Standard track shoe 4-17
4 3 3 Idler 4-18
4 3 4 Carrier roller 4-20
4 3 5 Track roller 4-22
4 3 6 Track 4-24
4 3 7 Three-grouser track shoe 4-27
4 4 Hydraulic System (Part I) 4-28
4 4 1 Layout of hydraulic components 4-28
4 4 2 Hydraulic tank and fi lter 4-30
4 4 3 Hydraulic pump 4-32
4 4 4 Pilot pump 4-38
4 4 5 Regulator (KR3G-0E11-AV) 4-40
4 5 Hydraulic System (Part II) 4-48
4 5 1 Control valve 4-48
4 5 2 Hydraulic circuit diagram (with bucket confl uence function) 4-50
4 5 3 Working principle 4-51
4 5 3 1 When spool in neutral position 4-51
4 5 3 2 Travel 4-52
4 5 3 3 Arm 4-53
4 5 3 4 Boom 4-58
4 5 3 5 Bucket 4-61
4 5 3 6 Swing 4-63
4 5 3 7 Standby spool 4-64
4 5 3 8 Straight travel 4-66
4 5 3 9 Lock valve function 4-67
4 5 3 10 Function of main relief valve 4-70
4 5 3 11 Functions of port relief valve 4-71
4 5 4 General sectional view 4-75
4 5 5 Right travel and straight travel, section (C-C) 4-78
4 5 6 Swing and left travel, section (D-D) 4-79
4 5 7 Boom 1 and boom 2, section (E-E, L-L) 4-80
4 5 8 Standby spool and bucket, section (F-F) 4-81
4 5 9 Arm 1 and arm 2, section (G-G) 4-82
4 5 10 Bypass stop 1 and bypass stop 2, section (H-H) 4-83
4 6 Hydraulic System (Part III) 4-85
4 6 1 Swing motor 4-85
4 6 2 Swing holding brake 4-87
4 6 3 Relief valve portion 4-89
4 6 3 1 Structure 4-89
4 6 3 2 Function 4-89
4 6 3 3 Operation 4-89
4 6 4 Anti-jerk valve 4-91
4 6 4 1 Operation drawing 4-91
4 6 4 2 Explanatory drawing of effects 4-92
4 6 4 3 Outline 4-93
4 6 4 4 Operation 4-93
4 6 5 Center swivel joint 4-94
4 6 6 Travel motor 4-96
4 6 6 1 Operation of components 4-98
4 6 6 2 Operation of parking brake 4-103
4 6 6 3 Brake valve operation 4-104
4 6 7 Control system 4-114
4 6 8 Pilot valves 4-116
4 6 8 1 Manual pilot valve 4-116
4 6 8 2 Travel pilot valve 4-121
4 6 9 Solenoid valve 4-127
4 6 10 Accumulator 4-128
4 6 11 Pilot oil fi lter 4-129
4 6 12 Pump delivery pressure sensor 4-130
4 6 13 Hydraulic cylinders 4-131
4 6 13 1 Boom cylinder 4-131
4 6 13 2 Arm cylinder 4-131
4 6 13 3 Bucket cylinder 4-132
4 7 Work Equipment 4-134
4 8 Air Conditioning System 4-137
4 8 1 A/C components layout drawing 4-138
4 8 2 Control panel 4-139
4 8 3 Circuit diagram 4-140
4 8 4 Refrigeration principle 4-142
4 8 4 1 Refrigeration cycle diagram 4-142
4 8 4 2 Heating cycle diagram 4-143
4 8 5 Compressor 4-144
4 8 6 Clutch 4-146
4 8 7 Condenser 4-147
4 8 8 Expansion valve 4-148
4 8 9 Evaporator 4-148
4 8 10 Receiver tank 4-149
4 8 11 Pressure switch 4-150
4 8 12 Fresh air sensor 4-151
4 8 13 Refrigerant 4-152
4 8 14 Compressor oil 4-170
4 9 Engine Control 4-171
4 9 1 System operation 4-172
4 9 1 1 Engine startup 4-172
4 9 1 2 Engine speed control 4-172
4 9 1 3 Engine shutdown 4-172
4 9 2 Components 4-173
4 9 2 1 Fuel control dial 4-173
4 9 2 2 Controller 4-175
4 10 Electrical Control System 4-178
4 10 1 Control functions 4-178
4 10 1 1 Machine control system diagram 4-179
4 10 1 2 Engine and pump composite control function 4-181
4 10 1 3 Pump control function 4-185
4 10 1 4 Valve control function 4-190
4 10 1 5 Duo travel speed control 4-192
4 10 1 6 Engine preheat/overheat alarm 4-194
4 10 1 7 Engine oil under-pressure alarm 4-196
4 10 1 8 Auto deceleration/acceleration control 4-196
4 10 2 System Components 4-198
4 10 2 1 Pump pressure sensor 4-198
4 10 2 2 Pilot pressure sensor 4-199
4 10 2 3 Coolant temperature sensor 4-200
4 10 2 4 Fuel level sensor 4-201
4 11 Monitoring System 4-203
4 11 1 Monitoring system 4-204
4 11 2 Monitor screen 4-205
4 11 3 Screen display and operation 4-208
5 Table of Standard Values
5 1 Standard Values for Engine-related Parts 5-3
5 2 Standard Values for Chassis-related Parts 5-4
5 3 Machine Attitudes for Measuring Performance and Procedures 5-10
6 Testing and Adjusting
6 1 Exhaust Gas Color – Test 6-3
6 1 1 Testing with a smokemeter 6-3
6 1 2 Testing with an opacimeter 6-4
6 2 Valve Clearance – Adjust 6-5
6 3 Compression Pressure – Measure 6-8
6 4 Fuel Injection Timing – Test and Adjust 6-10
6 4 1 Testing 6-11
6 4 2 Adjusting 6-12
6 5 Engine Oil Pressure – Check 6-14
6 6 Engine Speed Sensor – Adjust 6-16
6 7 A/C Compressor Belt Tension – Test and Adjust 6-17
6 7 1 Testing 6-17
6 7 2 Adjusting 6-17
6 8 Swing Bearing Clearance – Measure 6-18
6 9 Track Tensioning Device – Test and Adjust 6-20
6 9 1 Testing 6-20
6 9 2 Adjusting 6-21
6 10 Pressure in Hydraulic Lines – Test and Adjust 6-22
6 10 1 Testing 6-22
6 10 1 1 Preparatory work 6-22
6 10 1 2 Measuring the unloading pressure 6-23
6 10 1 3 Measuring work equipment relief pressure 6-23
6 10 1 4 Measuring swing relief pressure 6-23
6 10 1 5 Measuring travel relief pressure 6-24
6 10 2 Adjusting 6-25
6 10 2 1 Adjusting the main relief pressure 6-25
6 10 2 2 Adjusting swing relief pressure 6-26
6 11 Control Circuit Oil Pressure – Test and Adjust 6-27
6 11 1 Testing 6-27
6 11 2 Adjusting 6-28
6 12 Solenoid Valve Output Pressure – Measure 6-29
6 13 Pilot Valve Output Pressure – Measure 6-31
6 14 Pilot Valves (Work Equipment and Swing) – Adjust 6-32
6 15 Work Equipment Hydraulic Drift – Check 6-33
6 15 1 Checking boom and bucket cylinders 6-33
6 15 2 Checking the arm cylinder 6-34
6 15 3 Checking the pilot valve 6-35
6 16 Residual Pressure in Hydraulic Circuit – Release 6-36
6 17 Oil Leakage – Measure 6-37
6 17 1 Measuring oil leakage from boom cylinder 6-37
6 17 2 Measuring oil leakage from arm cylinder 6-38
6 17 3 Measuring oil leakage from bucket cylinder 6-39
6 17 4 Measuring oil leakage from swing motor 6-40
6 17 5 Measuring oil leakage from travel motor 6-41
6 18 Air in Each Component – Bleed 6-42
6 17 6 Bleeding air from hydraulic pump 6-42
6 18 1 Bleeding air from hydraulic cylinder 6-43
6 18 2 Bleeding air from swing motor 6-43
6 18 3 Bleeding air from travel motor 6-43
7 Troubleshooting
7 1 Troubleshooting Precautions 7-3
7 2 Checks Before Troubleshooting 7-5
7 3 Troubleshooting Types and Steps 7-6
7 3 1 Troubleshooting types 7-6
7 3 2 Troubleshooting steps 7-6
7 4 Failure symptoms and troubleshooting numbers 7-8
7 5 Troubleshooting the Electrical System 7-10
7 5 1 Connector locations and system electrical diagrams 7-10
7 5 1 1 Table of connectors 7-10
7 5 1 2 Connector locations 7-14
7 5 1 3 Controller, monitor and start system 7-19
7 5 1 4 Switch control system diagram 7-20
7 5 1 5 Sensor and solenoid valve system diagram 7-21
7 5 1 6 Engine control system 7-22
7 5 1 7 SWP connectors 7-23
7 5 1 8 A/AMP connectors 7-24
7 5 1 9 DT connectors 7-25
7 6 Troubleshooting with an Event Code 7-26
7 7 Troubleshooting the Electrical System (E-Mode) 7-58
7 8 Troubleshooting the Hydraulic and Mechanical Systems (H-Mode) 7-86
8 Disassembly and Assembly
8 1 How to Read This Manual 8-7
8 1 1 Removing and installing an assembly 8-7
8 1 1 1 Special tools 8-7
8 1 1 2 Removal 8-7
8 1 1 3 Installation 8-7
8 1 2 Disassembling and assembling an assembly 8-8
8 1 2 1 Special tools 8-8
8 1 2 2 Disassembly 8-8
8 1 2 3 Assembly 8-8
8 2 Operating Precautions 8-9
8 3 Start Motor AS – Remove and Install 8-12
8 3 1 Removal 8-12
8 3 2 Installation 8-12
8 4 Injection Pump AS – Remove and Install 8-13
8 4 1 Removal 8-13
8 4 2 Installation 8-14
8 5 Engine Front Oil Seal – Remove and Install 8-15
8 5 1 Removal 8-15
8 5 2 Installation 8-15
8 6 Engine Rear Oil Seal – Remove and Install 8-16
8 6 1 Removal 8-16
8 6 2 Installation 8-16
8 7 Cylinder Head AS – Remove and Install 8-17
8 7 1 Removal 8-17
8 7 2 Installation 8-20
8 8 Radiator AS – Remove and Install 8-21
8 8 1 Removal 8-21
8 8 2 Installation 8-23
8 9 Engine and Hydraulic Pump AS – Remove and Install 8-24
8 9 1 Removal 8-24
8 9 2 Installation 8-29
8 10 Final Drive AS – Remove and Install 8-30
8 10 1 Removal 8-30
8 10 2 Installation 8-31
8 11 Final Drive AS – Disassemble and Assemble 8-32
8 11 1 Disassembly 8-32
8 11 2 Assembly 8-36
8 12 Swing Motor and Swing Drive AS – Remove and Install 8-41
8 12 1 Removal 8-41
8 12 2 Installation 8-42
8 13 Swing Motor and Swing Drive AS – Disassemble and Assemble 8-43
8 13 1 Disassembly 8-43
8 13 2 Assembly 8-47
8 14 Idler AS – Disassemble and Assemble 8-51
8 14 1 Disassembly 8-51
8 14 2 Assembly 8-52
8 15 Sprocket – Remove and Install 8-55
8 15 1 Removal 8-55
8 15 2 Installation 8-55
8 16 Track AS – Remove and Install 8-56
8 16 1 Special tools 8-56
8 16 2 Removal 8-56
8 16 3 Installation 8-57
8 17 Swing Bearing AS – Remove and Install 8-59
8 17 1 Removal 8-59
8 17 2 Installation 8-60
8 18 Swing Platform AS – Remove and Install 8-61
8 18 1 Removal 8-61
8 18 2 Installation 8-63
8 19 Swivel Joint AS – Remove and Install 8-64
8 19 1 Removal 8-64
8 19 2 Installation 8-66
8 20 Swivel Joint AS – Disassemble and Assemble 8-67
8 20 1 Disassembly 8-67
8 20 2 Assembly 8-68
8 21 Hydraulic Tank AS – Remove and Install 8-69
8 21 1 Removal 8-69
8 21 2 Installation 8-71
8 22 Control Valve AS – Remove and Install 8-72
8 22 1 Removal 8-72
8 22 2 Installation 8-76
8 23 Hydraulic Pump AS – Remove and Install 8-77
8 23 1 Removal 8-77
8 23 2 Installation 8-81
8 24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install 8-82
8 24 1 Removal 8-82
8 24 2 Installation 8-82
8 25 Pilot Valve AS (Work Equipment) – Disassemble and Assemble 8-83
8 26 Pilot Valve AS (Travel) – Disassemble and Assemble 8-85
8 27 Hydraulic Cylinder AS – Disassemble and Assemble 8-86
8 27 1 Special tools 8-86
8 27 2 Disassembly 8-87
8 27 3 Assembly 8-91
8 28 Work Equipment AS – Remove and Install 8-95
8 28 1 Removal 8-95
8 28 2 Installation 8-97
8 29 Air Conditioner AS – Remove and Install 8-98
8 29 1 Special tools 8-98
8 29 2 Removal 8-98
8 29 3 Installation 8-101
8 30 Counterweight AS – Remove and Install 8-102
8 30 1 Removal 8-102
8 30 2 Installation 8-103
8 31 Cab AS – Remove and Install 8-104
8 31 1 Removal 8-104
8 31 2 Installation 8-107
8 32 Cab Window Glass – Disassemble and Assemble 8-108
8 32 1 Removal 8-109
8 32 2 Installation 8-112
8 33 Front Window AS – Disassemble and Assemble 8-124
8 33 1 Disassemble 8-124
8 33 2 Assemble 8-127
8 34 Monitor – Remove and Install 8-132
8 34 1 Removal 8-132
8 34 2 Installation 8-132
8 35 Controller AS – Remove and Install 8-133
8 35 1 Removal 8-133
8 35 2 Installation 8-133
8 36 Radio 8-134
8 36 1 Structure 8-134
8 36 2 Removal 8-135
8 36 3 Installation 8-136
8 36 4 Connector model and wiring 8-136
8 37 Battery 8-137
8 37 1 Structure 8-137
8 37 2 Removal 8-138
8 37 3 Installation 8-139
8 37 4 Replacement 8-139
8 38 Start Switch 8-140
8 38 1 Structure 8-140
8 38 2 Removal 8-141
8 39 Fuse Box 8-143
8 39 1 Removal 8-143
8 40 Wiper 8-144
8 40 1 Structure 8-144
8 40 2 Working principle 8-144
8 40 3 Removal 8-145
8 40 4 Installation 8-146
8 40 5 Angle adjustment of wiper arm 8-146
8 41 Relay 8-147
8 41 1 Engine relays 8-147
8 41 1 1 Starter relay – check 8-147
8 41 1 2 Mains relay – check 8-147
8 41 1 3 Heater relay 8-148
8 41 1 4 Safety relay 8-148
8 41 2 Other load relays 8-149
8 41 2 1 Function and locations 8-149
8 41 2 2 Removal and installation 8-150
8 41 2 3 Relay connector and wiring 8-150
8 42 Sensor 8-151
8 42 1 Water temperature sensor – check 8-151
8 42 4 Engine speed sensor – check 8-152
8 42 2 Pressure sensor – check 8-152
8 42 3 Fuel level sensor – check 8-152
8 43 Connector Terminals – Insert and Remove 8-153
8 43 1 Insertion 8-153
8 43 2 Removal 8-154
9 System Schematics
9 1 Hydraulic System 9-3
9 2 Air-Conditioning System 9-4
9 3 Monitoring system 9-5
9 4 Control switches 9-6
9 5 Operator station 9-7
9 6 Chassis Diagram 9-8