Sany SY135C9I4K Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD
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Sany SY135C9I4K Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD
1 INTRODUCTION
1.1 How to Read the Shop Manual
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
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 specif 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 troubleshooting.
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 included
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, disassembling
and assembling of each component
TABLE OF CONTENTS:
Sany SY135C9I4K Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD
1 Introduction
11 How to Read the Shop Manual 1-3
12 Terms for Maintenance Standard 1-5
13 Handling Electrical and Hydraulic Components 1-7
131 Points to remember when handling electric components 1-7
132 Points to remember when handling hydraulic equipment 1-16
14 Hose Connector 1-18
141 Type of hose connector 1-19
142 Hose connector tightening torque table 1-19
143 Connection of O-rings 1-20
15 Table of Standard Tightening Torques 1-21
16 Type of Bolts 1-22
17 Tightening Sequence 1-22
18 Maintenance of Half Flanges 1-23
181 Table of tightening torques for half f ange bolts 1-23
19 Conversion Table 1-24
2 Shop Safety
21 Hazard Alert Information 2-3
22 General Shop Safety 2-6
221 Rules and shop behavior 2-7
222 Housekeeping 2-7
223 Shop Liquids Storage 2-8
224 Cleaning Parts 2-8
225 Jacking Up the Machine 2-9
226 Electrical Dangers 2-9
227 Removing Attachments 2-10
228 Cleaning the Machine 2-10
229 Using the Correct Tools 2-10
2210 Hoisting a Load 2-11
2211 Appropriate Working Apparel 2-12
2212 Safety Partners 2-12
2213 Two people when engine running 2-13
2214 Driving Pins 2-13
2215 Aligning Parts or Components 2-14
Table of Contents
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Table of Contents SY135C9I4K Crawler Hydraulic Excavator
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2216 Fire Extinguisher and Emergency Exits 2-14
2217 Personal Protective Equipment 2-14
2218 Running the Machine 2-15
2219 Accumulator 2-16
2220 Adding Fluids to a System 2-16
2221 Track Recoil Springs 2-17
2222 High-Pressure Fluid Lines 2-17
2223 Safe Work Preparations 2-18
2224 Mounting and Dismounting 2-19
2225 Battery Hazards 2-20
2226 Jump-Start Safety 2-21
2227 Disconnecting the System Power 2-21
2228 Lockout/tagout 2-22
2229 Sequence of Procedures 2-22
2230 Chemical hazard 2-24
2231 Material Safety Data Sheets (MSDS) 2-24
23 Precautions for sling work and giving signals 2-25
3 Specifi cations
31 Overall Assembly Drawing 3-3
311 Dimension drawing 3-3
312 Working range 3-4
32 Engine Performance Curve 3-5
33 Technical Specif cations 3-6
34 Weight table 3-7
35 Lubricant, Fuel and Coolant 3-8
4 Structure, Function
41 Damping and Power Transmission system 4-5
42 Cooling System 4-6
43 Power Train 4-8
44 Swing Bearing 4-9
45 Swing Machinery 4-10
46 Track Frame 4-12
47 Tensioning device 4-14
48 Sprocket 4-15
49 Idler 4-16
V
SY135C9I4K Crawler Hydraulic Excavator Table of Contents
Shop Manual – October 2016
410 Carrier Roller 4-18
411 Track Roller 4-19
412 Track shoe 4-20
413 Triple grouser shoe 4-23
414 Hydraulic System Layout 4-24
415 Control System 4-26
416 Hydraulic Tank and Filter 4-28
417 Hydraulic Pump 4-29
4171 Pilot pump 4-35
4172 Adjustor (KR36-9P0H) 4-36
41721 Function 4-39
41722 Controller makeup 4-39
41723 Adjustment of the regulator 4-41
41724 Power input 4-43
41725 Adjustment of f ow control features 4-43
41726 Power control (in an emergency) 4-45
41728 Power change control (reducing power control) 4-48
41727 Priority mechanism of small inclination (small f ow) command 4-48
418 Control valve 4-50
4181 Control valve ports 4-50
4182 Hydraulic Circuit Diagram 4-55
4183 When in neutral position 4-56
4184 Valve Spool Operation 4-59
41841 Boom 4-59
41842 Arm 4-61
41843 Bucket 4-63
41844 Travel 4-65
41845 Swing 4-66
41846 Dozer blade 4-67
4185 Relief valve operation principle 4-69
41851 Main relief valve 4-69
41852 Port relief valve 4-71
4186 Lock valve operation principle 4-74
4187 Drawings 4-78
41871 Sectional view 4-78
41872 Straight travel, left travel (C-C) 4-81
41873 Right travel, swing (D-D) 4-82
41874 Bucket, boom raise conf uence (E-E) 4-83
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Table of Contents SY135C9I4K Crawler Hydraulic Excavator
Shop Manual – October 2016
41875 Boom, arm (F-F) 4-84
41876 Section view (G-G) 4-85
41877 Arm conf uence 2 (L-L) 4-86
41878 Section view (H-H,K-K) 4-87
419 Center swivel joint 4-88
420 Travel motor (Final drive) 4-90
4201 Outline 4-93
42011 Travel speed selection 4-93
4202 Operation 4-94
42021 Motor operation 4-94
42022 Brake valve operation 4-96
42023 Counterbalance valve and check valve 4-96
42024 Safety valve 4-98
42025 Parking brake operation 4-100
421 Swing Motor 4-101
4211 Swing holding brake 4-103
4212 Relief valve portion 4-105
42122 Structure 4-105
42123 Function 4-105
42121 Operation 4-105
4213 Reverse prevention valve 4-107
42131 Operation drawing 4-107
42132 Drawing of effects 4-108
42133 Outline 4-108
42134 Operation 4-109
422 Solenoid Valve 4-115
423 PPC Accumulator4-117
424 Pilot Oil Filter 4-118
425 PPC valve 4-119
4251 For swing and work equipment 4-119
4252 Travel 4-123
426 Hydraulic Cylinder 4-127
4261 Boom cylinder 4-127
4262 Arm cylinder 4-127
4263 Bucket cylinder 4-127
4264 Dozer blade cylinder 4-128
427 Work Equipment 4-129
4271 Dimensions 4-129
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SY135C9I4K Crawler Hydraulic Excavator Table of Contents
Shop Manual – October 2016
428 Air Conditioning System 4-135
4281 A/C Components Layout Drawing 4-137
4282 Control panel 4-138
4283 Electrical Circuit Diagram 4-139
4284 Refrigeration principle 4-141
42841 Refrigeration cycle diagram 4-141
42842 Heating cycle diagram 4-141
4285 Compressor 4-142
4286 Clutch 4-144
4287 Condenser 4-145
4288 Expansion valve 4-145
4289 Evaporator 4-146
42810 Receiver tank 4-146
42811 Pressure switch 4-147
42812 Pressure switch 4-148
42813 Fresh air sensor 4-149
42814 Refrigerant 4-149
42815 Compressor oil 4-168
429 Engine Control 4-169
4291 Engine control system diagram 4-169
4292 System operation 4-170
4293 Components 4-171
42931 Fuel control dial 4-171
42932 Engine controller 4-173
42933 Input and output port 4-174
430 Electrical Control System 4-175
4301 Control function 4-175
4302 Control system diagram 4-176
4303 Engine and pump composite control function 4-178
4304 Pump control function 4-182
43041 Straight travel control 4-184
4305 Duo travel speed control 4-185
4306 Engine preheating and overheating alarm 4-187
4307 Engine oil underpressure alarm 4-189
4308 Auto idle function 4-190
4309 Auto acceleration control 4-191
43010 Engine speed calibration control 4-191
43011 System components 4-192
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Table of Contents SY135C9I4K Crawler Hydraulic Excavator
Shop Manual – October 2016
430111 Sensor 4-192
431 Monitor System 4-196
4311 Machine monitor 4-197
4312 Monitor functions 4-198
4313 Monitor operation 4-201
5 Standard Values
51 Standard Values for Engine-related Parts 5-3
52 Standard Values for Chassis-related Parts 5-4
6 Testing and Adjusting
61 Exhaust Gas Color – Test 6-3
62 Valve Clearance – Adjust 6-5
621 Testing 6-5
622 Adjusting 6-6
63 Compression Pressure – Measure 6-7
64 Engine Oil Pressure – Measure 6-9
65 Engine Speed Sensor – Adjust 6-10
66 Fan Belt Tension- Test and Adjust 6-11
661 Test 6-11
662 Adjust 6-11
67 A/C Compressor Belt Tension – Test and Adjust 6-12
671 Test 6-12
672 Adjust 6-12
68 Swing Bearing Clearance – Measure 6-13
69 Track tension – Test and Adjust 6-15
691 Test 6-15
692 Adjust 6-15
610 Oil Pressure in Work Equipment, Swing and Travel Circuit – Test and Adjust 6-17
6101 Measure 6-17
6102 Adjust 6-19
611 Control Circuit Oil Pressure – Test and Adjust 6-22
6111 Measure 6-22
612 Solenoid Valve Output Pressure – Measure 6-23
613 PPC Valve Output Pressure – Measure 6-26
614 Work Equipment and Swing PPC Valve Play – Adjust 6-29
615 Work Equipment Hydraulic Drift – Test 6-30
616 Residual Pressure in Hydraulic Circuit – Release 6-33
IX
SY135C9I4K Crawler Hydraulic Excavator Table of Contents
Shop Manual – October 2016
617 Oil Leakage – Measure 6-35
618 Air in Each Component – Bleed 6-39
7 Troubleshooting
71 Points to Remember when Troubleshooting 7-3
72 Checks before Troubleshooting 7-5
73 Classif cation and Procedures for Troubleshooting 7-6
731 Classif cation of troubleshooting 7-6
732 Procedures for troubleshooting 7-6
74 Failure Symptoms and Troubleshooting Codes 7-8
75 Connector Location and Electrical Circuit Diagram 7-10
751 Table of connectors 7-10
752 Connector location layout 7-14
753 SWP type connector 7-19
754 A/AMP type connector 7-20
755 DT type connector 7-21
76 Troubleshooting of Electrical System (E – Mode) 7-22
77 Troubleshooting of Hydraulic and Mechanical System (H – Mode) 7-48
8 Disassembly and Assembly
81 How to Read This Manual 8-5
811 Removing and Installing an Assembly 8-5
812 Disassembling and assembling an assembly 8-5
813 Special tools 8-5
814 The symbols used in this section 8-6
82 Operating Precautions 8-7
83 Track AS – Remove and Install 8-10
831 Removal 8-10
832 Installation 8-11
84 Dozer Blade AS – Remove and Install 8-12
841 Remove 8-12
83 喷油泵总成的拆卸和安装 8-10
84 气缸盖总成的拆卸和安装拆卸 8-26
85 散热器总成的拆卸和安装拆卸 8-52
87 发动机和液压泵总成的拆卸和安装 8-54
842 Install 8-13
85 Sprocket – Remove and Install 8-14
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Table of Contents SY135C9I4K Crawler Hydraulic Excavator
Shop Manual – October 2016
87 Idler AS – Disassemble and Assemble 8-17
871 Disassemble 8-17
872 Assemble 8-18
88 Tension Spring – Disassemble and Assemble 8-21
881 Removal 8-21
882 Assemble 8-23
89 Track Roller Assembly – Disassemble and Assemble 8-25
891 Disassemble 8-25
892 Assemble 8-25
810 Carrier Roller Assembly – Disassemble and Assemble 8-26
8101 Disassemble 8-26
8102 Assemble 8-26
811 Swing Motor and Swing Drive AS – Remove and Install 8-27
8111 Removal 8-27
8112 Installation 8-28
812 Swing Motor and Swing Drive AS – Disassemble and Assemble 8-29
8121 Disassembly 8-29
8122 Assembly 8-34
813 Swivel Joint AS – Remove and Install 8-39
8131 Removal 8-39
8132 Installation 8-40
814 Swivel Joint AS – Disassemble and Assemble 8-41
8141 Disassemble 8-41
8142 Assemble 8-42
815 Work Equipment AS – Remove and Install 8-43
8151 Removal 8-43
8152 Installation 8-44
816 Swing Platform AS – Remove and Install 8-46
8161 Removal 8-46
8162 Installation 8-48
851 Removal 8-14
852 Installation 8-14
86 Final Drive AS – Remove and Install 8-15
861 Removal 8-15
862 Installation 8-16
817 Swing Bearing AS – Remove and Install 8-49
8171 Removal 8-49
8172 Installation 8-50
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SY135C9I4K Crawler Hydraulic Excavator Table of Contents
Shop Manual – October 2016
8192 Installation 8-56
820 Hydraulic Pump AS – Remove and Install 8-57
8201 Removal 8-57
8202 Installation 8-60
821 Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install 8-61
8211 Removal 8-61
8212 Installation 8-61
822 PPC Valve AS (Work Equipment) – Disassemble and Assemble 8-62
8221 Assemble 8-62
823 PPC Valve AS (Travel) – Disassemble and Assemble 8-64
8231 Assemble 8-64
824 Hydraulic Cylinder AS – Disassemble and Assemble 8-65
8241 Disassembly 8-66
8242 Assembly 8-71
825 Counterweight AS – Remove and Install 8-76
8251 Removal 8-76
8252 Installation 8-77
826 Air Conditioner AS – Remove and Install 8-78
8261 Removal 8-78
8262 Installation 8-82
827 Cab AS – Remove and Install 8-83
8271 Removal 8-83
8272 Installation 8-87
828 Cab Window Glass – Disassemble and Assemble 8-88
8281 Removal 8-89
8282 Installation 8-93
829 Front Window AS – Disassemble and Assemble 8-106
8291 Disassemble 8-106
8292 Assemble 8-109
830 Monitor – Remove and Install 8-114
8301 Removal 8-114
8302 Installation 8-114
818 Hydraulic Tank AS – Remove and Install 8-51
8181 Removal 8-51
8182 Installation 8-53
819 Control Valve AS – Remove and Install 8-54
8191 Removal 8-54
831 Controller AS – Remove and Install8-115
8311 Removal 8-115
XII
Table of Contents SY135C9I4K Crawler Hydraulic Excavator
Shop Manual – October 2016
8323 Installation 8-118
8324 Connector model and wiring 8-118
833 Battery 8-119
8331 Structure 8-119
8332 Removal 8-120
8333 Installation 8-121
8334 Replacement 8-121
834 Start Switch 8-122
8341 Structure 8-122
8342 Removal 8-123
835 Fuse Box 8-125
8351 Removal 8-125
836 Wiper 8-126
8361 Structure 8-126
8362 Working principle 8-126
8363 Removal 8-127
8365 Installation 8-128
8364 Angle adjustment of wiper arm 8-128
837 Relay 8-129
8371 Engine relay 8-129
8372 Other relays 8-130
838 Sensor 8-132
839 Connector Terminals – Insert and Remove 8-134
8391 Insertion 8-134
8392 Removal 8-135
9 System Schematics
91 Hydraulic Circuit Diagram 9-3
92 Electrical System Diagram 9-4
93 Air Conditioner Circuit Diagram 9-5
94 Control Switches Harness 9-6
95 Cab Harness 9-7
96 Chassis Harness 9-8
8312 Installation 8-115
832 Radio 8-116
8321 Structure 8-116
8322 Removal 8-117
1 Introduction
11 How to Read the Shop Manual 1-3
12 Terms for Maintenance Standard 1-5
13 Handling Electrical and Hydraulic Components 1-7
131 Points to remember when handling electric components 1-7
132 Points to remember when handling hydraulic equipment 1-16
14 Hose Connector 1-18
141 Type of hose connector 1-19
142 Hose connector tightening torque table 1-19
143 Connection of O-rings 1-20
15 Table of Standard Tightening Torques 1-21
16 Type of Bolts 1-22
17 Tightening Sequence 1-22
18 Maintenance of Half Flanges 1-23
181 Table of tightening torques for half f ange bolts 1-23
19 Conversion Table 1-24
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