SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual - page 1

 

  Index      Manuals     SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual (2013)

 

Search            copyright infringement  

    

 

   

 

    

 

Content      ..      1       2         ..

 

 

 

SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual - page 1

 

 



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 speci

fi

 cation is subject to change without prior notice.

SANY HEAVY MACHINERY LIMITED

318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, 
Shanghai, P.R. of China 201413

Tel: (86) 21 5700 8518
Service hotline:(86) 4006 098 318
E-mail: crd@sany.com.cn  

Documentation No.: ZJSYF0301EN(07-12)-SY55C3/55C9/60C1

Crawler Hydraulic 
Excavator

SY195C9

SY205C9

SY215C9

SY225C9

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. 

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 

fl

 ange 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

II

Table of Contents

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 Specifi cations

3.1 Dimensions .............................................................................................................. 3-3
3.2 Working Ranges ...................................................................................................... 3-4
3.3 Technical Speci

fi

 cations ........................................................................................... 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

III

Table of Contents

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 

fi

 lter ............................................................................... 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

IV

Table of Contents

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 

fi

 lter ...............................................................................................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

V

Table of Contents

4.9.4.1 Electrical positive 

fl

 ow 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 

fl

 ow 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

VI

Table of Contents

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

VII

Table of Contents

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

VIII

Table of Contents

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

IX

Table of Contents

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

X

Table of Contents

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

Introduction

Introduction

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 

fl

 ange bolts ........................................... 1-23

1.9 Conversion Table ................................................................................................... 1-24

Introduction

1-2

 

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.

1-3

Introduction

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.

Specifi cations

Technical speci

fi

 cation 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

1-4

Introduction

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.

 

 

 

 

 

 

 

 

Content      ..      1       2         ..

 

//////////////////////////////////////////