Sany SY16C Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD
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Sany SY16C Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD
1 INTRODUCTION
1.1 How to Read the Manual
● Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult Sany distributors.
● Materials and specifications are subject to change without notice.
1.1.1 Shop manual organization
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
Specifications
Technical specification of work equipment and optional parts are given in this section.
TABLE OF CONTENTS:
Sany SY16C Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD
1 Introduction
11 How to Read the Manual 1-3
111 Shop manual organization 1-3
113 Symbols 1-4
114 Units 1-4
112 Revision and distribution 1-4
12 Technical Terms 1-5
121 Standard size and tolerance 1-5
122 Standard clearance and value 1-6
123 Standard interference 1-6
124 Repair limit and allowable value 1-6
125 Clearance limit 1-6
126 Interference limit 1-7
13 Handling Electrical and Hydraulic Components 1-8
131 Points to remember when handling electric components 1-8
1311 Handling wiring harnesses and connectors 1-8
1312 Main failures occurring in wiring harness 1-9
1313 Removing, installing, and drying connectors and wiring harnesses 1-11
1314 Handling the integrated control monitor 1-15
1315 Electric circuits troubleshooting precautions 1-16
132 Points to remember when handling hydraulic equipment 1-17
1321 Be careful of the operating environment 1-17
1322 Disassembly and maintenance work in the field 1-17
1323 Sealing openings 1-17
1324 Do not let any dirt or dust get in during refilling operations 1-18
1325 Change hydraulic oil when the temperature is high 1-18
1326 Flushing operations 1-18
1327 Cleaning operations 1-19
14 Hose Connector 1-19
141 Type of hose connector 1-20
142 Hose connector tightening torque table 1-20
143 Connection of O-rings 1-21
15 Table of Standard Tightening Torques 1-22
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Table of Contents SY16C Crawler Hydraulic Excavator
Shop Manual – May 2014
16 Type of Bolts 1-23
17 Tightening Sequence 1-23
18 Maintenance of Half Flanges 1-24
181 Table of tightening torques for half flange bolts 1-24
182 Temperature 1-30
2 Shop Safety
21 Hazard Alert Information 2-3
22 General Shop Safety 2-5
221 Rules and shop behavior 2-6
222 Housekeeping 2-6
223 Shop Liquids Storage 2-7
224 Cleaning the Parts 2-7
225 Cleaning the Machine 2-8
226 Appropriate Working Apparel 2-8
227 Personal Protective Equipment 2-8
228 Using the Correct Tools 2-9
229 Fire Extinguisher and Emergency Exits 2-9
2210 Electrical Dangers 2-10
2211 Hoisting a Load 2-10
23 Before Repair2-11
231 Safe Work Preparations 2-11
232 Preparing yourself 2-12
233 Lockout/Tagout 2-13
234 Two people when engine running 2-15
235 Safety Partners 2-15
24 Repair Precautions 2-16
241 Running the Machine 2-16
242 Mounting and Dismounting 2-17
243 Removing Attachments 2-18
244 Jacking Up the Machine 2-18
245 Adding Fluids to a System 2-18
246 Aligning Parts or Components 2-19
247 Driving Pins 2-19
248 When compressed air is used 2-19
249 Welding operation 2-20
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2410 Track Recoil Springs 2-20
2411 High-Pressure Fluid Lines 2-21
2412 Air-conditioning system maintenance 2-22
2413 High voltage precautions 2-22
2414 Disconnecting the System Power 2-23
2415 Accumulator 2-23
2417 Battery Hazards 2-24
2418 Jump-Start Safety 2-25
2419 Avoiding fire and explosion 2-26
2420 Chemical hazard 2-27
2421 Material Safety Data Sheets (MSDS) 2-27
2422 Proper disposal of wastes 2-28
25 Other Precautions 2-29
251 Sling work and giving signals 2-29
252 Using mobile crane 2-31
253 Using overhead hoist crane 2-31
254 Selecting wire ropes 2-32
3 Specifications
31 Dimension Drawing 3-3
32 Working Ranges 3-4
33 Technical Specifications 3-5
34 Weight Table 3-7
35 Capacity Table 3-8
36 Fuel and Coolant Capacities 3-9
37 Engine Performance Curve 3-10
4 Structure and Functions
41 Engine and Cooling System 4-3
411 Water cooler and oil cooler 4-3
412 PTO (coupling) 4-4
413 Engine control device 4-5
42 Power Train 4-6
421 Power transmission system 4-6
422 Swing bearing 4-7
423 Swing drive 4-8
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43 Undercarriage 4-9
431 Track frame 4-9
432 Tensioning device 4-10
44 Hydraulic System 4-11
441 Hydraulic lines4-11
442 Hydraulic tank 4-12
443 Hydraulic pump 4-13
444 Control valve 4-23
445 Main valve section view 4-25
446 Load sensitive system 4-26
4461 Basic principle 4-27
4462 Operation and parameter of each function 4-29
4463 Operation of the whole system 4-40
447 Swing motor 4-50
448 Safety valve 4-54
449 Central swivel joint 4-56
4410 Travel motor 4-57
44101 Working process of parking brake 4-60
44102 Working process of brake valve 4-61
4411 Control system 4-63
4412 Work equipment and swing pilot valve 4-64
4413 Travel pilot valve 4-69
4414 Solenoid directional valve 4-73
4415 Oil source control valve 4-74
4416 Hydraulic cylinders 4-75
45 Electrical System 4-76
451 Electrical system layout (1/2) 4-76
452 Electrical system layout (2/2) 4-77
453 Electrical circuit diagram 4-78
46 Electronic Control System 4-79
461 System diagram 4-79
462 Electrical control system function 4-80
463 Engine control function 4-81
464 Valve control function 4-82
465 Manual preheating and overheating protection function 4-83
466 Travel control function 4-84
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467 Monitoring system 4-85
47 Integrated controller 4-87
471 Monitor 4-87
472 Ports of integrated instrument 4-88
473 Electrical circuit diagram 4-89
474 Functional definition 4-90
5 Standard Values
51 Standard Values for Engine-Related Parts 5-3
52 Standard Values for Chassis-Related Parts 5-4
53 Standard Values for Electrical Parts 5-11
6 Testing and Adjusting
61 Engine Speed – Test 6-4
62 Exhaust Gas Color – Test 6-5
621 Using a hand tester 6-5
622 Using an instrument 6-5
63 Valve Clearance – Check and Adjust 6-7
64 Compression Pressure – Test 6-9
65 Injection Timing – Test and Adjust 6-10
651 Checking fuel injection timing 6-10
652 Adjusting the fuel injection timing 6-13
66 Oil Pressure – Test 6-14
67 Alternator Belt Tension – Test and Adjust 6-14
671 Testing 6-14
672 Adjusting 6-14
68 Fuel Control Lever – Adjust 6-15
69 Hydraulic Pressure in Oil Circuits – Test and Adjust 6-16
691 Testing 6-16
692 Adjusting main relief valve pressure 6-17
610 LS Differential Pressure and LS Valve – Test/Adjust 6-18
6101 Testing with the similar pressure gauges 6-18
6102 Adjusting LS valve 6-19
611 Hydraulic Pressure in Control Circuit – Test 6-20
612 Pilot Valve Output Pressure – Test 6-21
613 Work Equipment and Swing Pilot Valve – Adjust 6-22
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614 Travel Deviation – Test 6-23
615 Oil Leakage – Test 6-24
6151 Work equipment cylinder 6-24
6152 Swing motor 6-26
6153 Travel motor 6-26
616 Residual Pressure in Hydraulic Circuit – Release 6-27
617 Swing Bearing Clearance – Check 6-28
618 Track Tension – Check and Adjust 6-29
6181 Checking track tension 6-29
6182 Adjusting track tension 6-30
61821 When the tension is high 6-30
61822 When the tension is low 6-30
619 Air Purging 6-31
6191 Hydraulic Pump 6-31
6192 Hydraulic cylinder 6-32
6193 Swing motor 6-32
6194 Travel motor 6-33
7 Troubleshooting
71 Troubleshooting Precautions 7-5
72 Checks Before Troubleshooting 7-7
73 Connector Locations and System Diagrams 7-8
74 Number of Pins Required for Connection 7-11
75 Electric Wire Specifications 7-18
751 Type, Symbol and Material 7-18
752 Dimensions 7-19
76 How to Use the Judgement Chart 7-20
77 How to Use a Schematic Diagram for Troubleshooting 7-22
78 Troubleshooting the Electrical System 7-23
781 The whole machine does not react 7-23
782 Unable to shift travel speed 7-24
783 Engine does not start 7-25
784 Unable to stop the engine 7-26
79 Troubleshooting the Engine 7-27
791 How to use the chart of troubleshooting 7-27
792 Poor starting performance 7-33
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SY16C Crawler Hydraulic Excavator Table of Contents
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793 Engine fails to start 7-36
7931 Engine fails to rotate 7-36
7932 The engine rotates but produce smoke 7-37
7933 Fume is seen but the engine does not start 7-38
794 Engine acceleration is instable 7-39
795 Engine stops during operation 7-40
796 Engine rotates unstably (vibrates) 7-41
797 Low power output (lack of power) 7-42
798 Black exhaust gas (incomplete combustion) 7-43
799 Engine oil consumed excessively or exhaust gas turned blue 7-44
7910 Engine oil is contaminated quickly 7-45
7911 Fuel consumption is excessive 7-46
7912 Coolant contains engine oil, water sprays back or water level drops 7-47
7913 Engine oil pressure alert indicator lights up 7-48
7914 Higher oil level 7-49
7915 Higher coolant temperature (overheated) 7-50
7916 Abnormal noise 7-51
7917 Violent vibration 7-53
710 Troubleshooting the Hydraulic and Mechanical System 7-54
7101 Work equipment, swing drive and final drive move slowly or is weak 7-54
7102 Engine speed drops sharply or engine stalls 7-56
7103 Work equipment, final drive and swing drive do not work 7-57
7104 Abnormal noise occurs (around the pump) 7-57
7105 Poor precise control performance or bad sensitivity 7-58
7106 Boom moves slowly or power is weak 7-58
7107 Arm moves slowly or power is weak 7-60
7108 Bucket moves slowly or power is weak 7-62
7109 Work equipment does not work (but travel and swing are normal) 7-63
71010 Excessive hydraulic drift (of boom, arm and bucket) 7-63
71011 Work equipment with greater load moves slowly in combined operation 7-64
71012 Boom raises slowly during swing + boom UP operation 7-65
71013 Travel speed drops considerably during travel + swing operation 7-65
71014 Machine cannot make a straight travel 7-66
71015 Travel deviation is big at beginning 7-68
71016 Travel speed is low or power is weak 7-68
71017 It Is difficult to change direction 7-69
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71018 Travel speed cannot be changed 7-70
71019 Travel system fails (only at one side) 7-70
71020 Swing operation fails 7-71
71021 Poor swing acceleration 7-72
71022 Excessive overrunning upon swing stoppage 7-74
71023 Considerable shaking resulted from swing stoppage 7-75
71024 Abnormally high noise resulted from swing stoppage 7-75
71025 Excessive hydraulic drift of swing 7-76
71026 Swing speed is faster than specified 7-76
71027 Dozer blade moves slowly or power is weak 7-77
71028 Dozer blade does not work 7-77
71029 Excessive hydraulic drift of dozer blade 7-78
71030 Unable to expand and contract rubber tracks 7-78
711 Troubleshooting the Machine Monitoring System 7-79
7111 Harness of machine monitoring system 7-79
7112 Engine coolant temperature reading abnormal 7-80
7113 Work lamps do not light up 7-81
7114 Horn does not sound 7-82
8 Disassembly and Assembly
81 Operating Precautions 8-7
82 Engine and Main Pump AS 8-10
821 Removal 8-10
822 Installation 8-13
83 Center Swivel Joint AS 8-14
831 Removal 8-14
832 Installation 8-15
833 Disassembly 8-16
834 Assembly 8-16
84 Sprocket 8-17
841 Removal 8-17
842 Installation 8-17
85 Travel Motor AS 8-18
851 Removal 8-18
852 Installation 8-19
853 Sectional view 8-20
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SY16C Crawler Hydraulic Excavator Table of Contents
Shop Manual – May 2014
854 Exploded view of reducer 8-22
855 Exploded view of reducer AS 8-23
856 Exploded view of the hydraulic motor AS 8-24
857 Parts catalogue 8-25
858 Disassembly 8-27
8581 Preparatory work 8-27
8582 General precautions during work 8-27
8583 Disassembling procedure 8-28
859 Table of maintenance standard 8-38
8510 Assembly 8-41
85101 Preparatory work 8-41
85102 General precautions 8-41
85103 Assembly procedure 8-42
85104 Quality assurance 8-56
86 Swing Motor and Swing Mechanism AS 8-57
861 Removal 8-57
862 Installation 8-57
87 Swing Motor AS 8-58
871 Disassembly 8-58
872 Reassembly 8-61
88 Swing Platform AS 8-62
881 Removal 8-62
882 Installation 8-63
89 Swing Bearing AS 8-64
891 Removal 8-64
892 Installation 8-64
810 Idler and Tension Spring AS 8-65
8101 Removal 8-65
8102 Installation 8-65
811 Tension Spring AS 8-66
8111 Disassembly 8-66
8112 Assembly 8-67
812 Idler AS 8-68
8121 Disassembly 8-68
8113 Assembly 8-68
813 Track Roller AS 8-69
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Table of Contents SY16C Crawler Hydraulic Excavator
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8131 Removal 8-69
8132 Installation 8-69
8133 Disassemble 8-70
8134 Assembly 8-70
814 Rubber Tracks 8-71
8141 Removal 8-71
8142 Installation 8-71
815 Hydraulic Tank AS 8-72
8151 Removal 8-72
8152 Installation 8-72
816 Main Pump AS 8-73
8161 Removal 8-73
8153 Installation 8-73
817 Main Pump Input Shaft Oil Seal 8-74
8171 Removal 8-74
8172 Installation 8-74
818 Control Valve AS 8-75
8181 Removal 8-75
8182 Installation 8-75
819 Manual Directional Valve 8-76
8191 Removal 8-76
8192 Installation 8-76
820 Oil Source Control Valve AS 8-76
8201 Removal 8-76
8202 Installation 8-76
821 Left Pilot Valve AS (Arm and Swing Control) 8-77
8211 Removal 8-77
8212 Installation 8-77
822 Right Pilot Valve (Boom and Bucket Control) 8-78
8221 Removal 8-78
8222 Installation 8-78
823 Work Equipment Pilot Valve AS 8-79
8231 Disassembly 8-79
8232 Assembly 8-79
824 Travel Pilot Valve AS 8-81
8241 Removal 8-81
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SY16C Crawler Hydraulic Excavator Table of Contents
Shop Manual – May 2014
8242 Installation 8-81
8243 Disassembly 8-82
8244 Assembly 8-82
825 Boom Cylinder AS 8-83
8251 Removal 8-83
8252 Installation 8-84
826 Arm Cylinder AS 8-85
8261 Removal 8-85
8262 Installation 8-86
827 Bucket Cylinder AS 8-87
8271 Removal 8-87
8272 Installation 8-88
828 Deflection Cylinder AS 8-89
8281 Removal 8-89
8282 Installation 8-89
829 Dozer Blade Cylinder AS 8-90
8291 Removal 8-90
8283 Installation 8-90
830 Hydraulic Cylinder AS 8-91
8301 Disassembly 8-91
8302 Assembly 8-94
831 Work Equipment AS 8-97
8311 Removal 8-97
8312 Installation 8-98
832 Bucket and Arm AS 8-99
8321 Removal 8-99
8322 Installation 8-100
833 Bucket AS 8-101
8331 Removal 8-101
8332 Installation 8-102
834 Arm AS 8-103
8341 Removal 8-103
8342 Installation 8-104
835 Boom AS 8-105
8351 Removal 8-105
8352 Installation 8-106
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Table of Contents SY16C Crawler Hydraulic Excavator
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836 Boom Deflection Joint AS 8-107
8361 Removal 8-107
8362 Installation 8-107
837 Dozer Blade AS 8-108
8371 Removal 8-108
8372 Installation 8-109
838 Canopy AS 8-110
8381 Removal 8-110
8382 Installation 8-110
839 Counterweight AS 8-111
8391 Removal 8-111
8392 Installation 8-111
840 Monitor AS 8-112
8401 Removal 8-112
8402 Installation 8-112
9 Maintenance Standard
91 Swing Mechanism 9-3
92 Swing Bearing 9-4
93 Track Frame 9-5
94 Idler 9-6
95 Track Roller 9-7
96 Rubber track 9-9
97 Work Equipment 9-10
98 Arm Dimensions 9-12
99 Bucket Dimensions 9-13
910 Hydraulic Cylinder 9-14
10 System Schematics
101 Hydraulic Circuit Diagram 10-3
102 General System Diagram (1/5) 10-4
103 General System Diagram (2/5) 10-5
104 General System Diagram (3/5) 10-6
105 General System Diagram (4/5) 10-7
106 General System Diagram (5/5) 10-8
107 Electrical Circuit Diagram 10-9
Sany-EuropeIntroduction
Introduction
Shop Manual – May 2014
SY16C Crawler Hydraulic Excavator
1-1
1 Introduction
11 How to Read the Manual 1-3
111 Shop manual organization 1-3
113 Symbols 1-4
114 Units 1-4
112 Revision and distribution 1-4
12 Technical Terms 1-5
121 Standard size and tolerance 1-5
122 Standard clearance and value 1-6
123 Standard interference 1-6
124 Repair limit and allowable value 1-6
125 Clearance limit 1-6
126 Interference limit 1-7
13 Handling Electrical and Hydraulic Components 1-8
131 Points to remember when handling electric components 1-8
1311 Handling wiring harnesses and connectors 1-8
1312 Main failures occurring in wiring harness 1-9
1313 Removing, installing, and drying connectors and wiring harnesses 1-11
1314 Handling the integrated control monitor 1-15
1315 Electric circuits troubleshooting precautions 1-16
132 Points to remember when handling hydraulic equipment 1-17
1321 Be careful of the operating environment 1-17
1322 Disassembly and maintenance work in the field 1-17
1323 Sealing openings 1-17
1324 Do not let any dirt or dust get in during refilling operations 1-18
1325 Change hydraulic oil when the temperature is high 1-18
Sany-Europe
Introduction
1-2 Shop Manual – May 2014
SY16C Crawler Hydraulic Excavator
1326 Flushing operations 1-18
1327 Cleaning operations 1-19
14 Hose Connector 1-19
141 Type of hose connector 1-20
142 Hose connector tightening torque table 1-20
143 Connection of O-rings 1-21
15 Table of Standard Tightening Torques 1-22
16 Type of Bolts 1-23
17 Tightening Sequence 1-23
18 Maintenance of Half Flanges 1-24
181 Table of tightening torques for half flange bolts 1-24
182 Temperature 1-30
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