Sany SY195C-9 SY205C-9 SY215C-9 SY225C-9 SY235C-9 SY265C-9 Crawler Hydraulic Excavator Safety, Operation & Maintenance Manual – PDF DOWNLOAD
FILE DETAILS:
Sany SY195C-9 SY205C-9 SY215C-9 SY225C-9 SY235C-9 SY265C-9 Crawler Hydraulic Excavator Safety, Operation & Maintenance Manual – PDF DOWNLOAD
Language : English
Pages : 435
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Sany SY195C-9 SY205C-9 SY215C-9 SY225C-9 SY235C-9 SY265C-9 Crawler Hydraulic Excavator Safety, Operation & Maintenance Manual – PDF DOWNLOAD
Introduction
1 1 Overview 1-3
1 2 Your Documentation Package 1-4
1 2 1 CD system requirements 1-4
1 2 2 Recommendations on using the documentation 1-4
1 2 3 Documentation storage 1-5
1 2 4 Manual organization 1-5
1 2 4 1 Introduction 1-5
1 2 4 2 Safety 1-5
1 2 4 3 System functions 1-5
1 2 4 4 Operation 1-5
1 2 4 5 Maintenance 1-5
1 2 4 6 Troubleshooting 1-6
1 2 4 7 Specifi cations 1-6
1 2 4 8 Optional Equipment 1-6
1 3 Your Sany Machine 1-7
1 3 1 Machine applications 1-7
1 3 2 Machine directions 1-7
1 3 3 Breaking in a new machine 1-8
1 3 4 Machine information 1-8
1 3 4 1 Product identifi cation plate 1-9
1 3 4 2 Engine identifi cation plate 1-9
1 3 4 3 Drive motors identifi cation plate 1-12
1 3 4 4 Swing motor identifi cation plate 1-12
1 3 4 5 Hydraulic pump identifi cation plate 1-12
1 3 4 6 Chassis serial number 1-13
1 3 5 Table for serial number and distributor information 1-14
1 4 Correction Request Form – Technical Publications 1-15
1 5 Contact Information 1-16
2 Safety
2 1 Foreword 2-5
2 2 Safety Messages 2-7
2 2 1 Hazard alert wording 2-8
2 2 2 Other alert wording 2-9
2 2 3 Safety decals 2-10
2 2 3 1 Textual safety decals 2-10
2 2 3 2 Graphical safety decals 2-10
2 2 4 Safety decal locations 2-11
2 3 General Precautions 2-21
2 3 1 Safety rules 2-21
2 3 2 Abnormal cases 2-21
2 3 3 Personal protective equipment 2-22
2 3 4 Fire extinguisher and fi rst aid kit 2-23
2 3 5 Safety equipment 2-24
2 3 6 Machine cleaning 2-25
2 3 7 Keeping cab clean 2-25
2 3 8 Lock the hydraulic controls before leaving the cab 2-26
2 3 9 Handholds and steps 2-27
2 3 10 Elevated work 2-28
2 3 11 No sitting on attachment 2-28
2 3 12 Articulated parts 2-28
2 3 13 Prevention of burns and scalds 2-29
2 3 13 1 Hot coolant 2-29
2 3 13 2 Hot oil 2-29
2 3 14 Fire and explosion hazard 2-30
2 3 14 1 Fire caused by fuel or oils 2-30
2 3 14 2 Fire caused by fl ammable materials 2-31
2 3 14 3 Fire caused by electric lines 2-31
2 3 14 4 Fire caused by hydraulic lines 2-31
2 3 14 5 Fire caused by illumination equipment 2-32
2 3 14 6 Fire caused by heat shield 2-32
2 3 15 In the event of fi re 2-32
2 3 16 Windshield cleaning detergent 2-33
2 3 17 Ejecting parts 2-33
2 3 18 Falling object protection 2-34
2 3 19 Attachment installation 2-34
2 3 20 Attachment combination 2-35
2 3 21 Cab windows glasses 2-35
2 3 22 Unauthorized modifi cation 2-35
2 3 23 Worksite investigation 2-36
2 3 24 Operation on loose ground 2-37
2 3 25 Overhead power cables 2-38
2 3 26 Visibility 2-39
2 3 27 Ventilation 2-39
2 3 28 Asbestos 2-40
2 3 29 Alternate exit 2-41
2 4 Safe Operation Precautions 2-42
2 4 1 Safe starting 2-42
2 4 1 1 Safe mounting 2-42
2 4 1 2 Operator seat 2-42
2 4 1 3 Seat belt 2-43
2 4 1 4 Before starting the engine 2-43
2 4 1 5 Engine starting rules 2-44
2 4 1 6 Machine starting 2-44
2 4 1 7 Starting engine in cold season 2-45
2 4 1 8 Engine starting aid 2-45
2 4 1 9 After starting the engine 2-46
2 4 2 Operation 2-47
2 4 2 1 Inspection before operation 2-47
2 4 2 2 Prior-operation precautions 2-48
2 4 2 3 Travel direction confi rmation 2-49
2 4 2 4 Safety rules for turning 2-50
2 4 2 5 Safety rules for traveling 2-52
2 4 2 6 Safe traveling 2-53
2 4 2 7 Machine operation on slope 2-54
2 4 2 8 Operation in snowy weather 2-55
2 4 2 9 Restricted operation 2-56
2 4 3 Parking the machine 2-58
2 4 3 1 Select a parking place 2-58
2 4 3 2 Machine shutdown 2-59
2 4 4 Transportation 2-60
2 4 4 1 Loading and unloading 2-60
2 4 4 2 Transportation 2-61
2 4 5 Battery 2-62
2 4 6 Towing 2-64
2 4 7 Lifting objects with the machine 2-65
2 5 Precautions for Maintenance 2-66
2 5 1 Pre-maintenance precautions 2-66
2 5 2 Select a working area 2-66
2 5 3 Prepare the machine 2-67
2 5 4 Prepare yourself 2-68
2 5 5 Lockout and tag-out measures 2-69
2 5 6 Use proper tools 2-69
2 5 7 Maintenance with engine running 2-70
2 5 8 Work under the machine 2-71
2 5 9 Track maintenance 2-72
2 5 10 Track tension adjustment 2-73
2 5 11 Recoil spring 2-73
2 5 12 Welding operation 2-74
2 5 13 High-pressure hoses 2-74
2 5 14 Pressurized fl uid 2-75
2 5 15 Hot cooling system 2-76
2 5 16 Air-conditioning system maintenance 2-76
2 5 17 High voltage precautions 2-77
2 5 18 Accumulator 2-77
2 5 19 Fire and explosion prevention 2-78
2 5 20 Regular replacement of safety-related parts 2-79
2 5 21 Maintenance operation 2-79
2 5 22 Proper disposal of wastes 2-80
3 System Functions
3 1 Machine general drawing 3-3
3 2 Monitoring System 3-4
3 2 1 Monitor functions 3-4
3 2 2 Monitor operation 3-7
3 3 Switches 3-24
3 3 1 Start switch 3-25
3 3 2 Fuel control dial 3-26
3 3 3 Work lamp switch 3-26
3 3 4 Head lamp switch 3-28
3 3 5 Windshield wiper switch 3-29
3 3 6 Washer switch 3-30
3 3 7 Horn switch 3-30
3 3 8 Cab lamp switch 3-30
3 3 9 Cigarette lighter 3-31
3 3 10 Preheat switch (If equipped) 3-31
3 3 11 Preheat indicator 3-32
3 3 12 Charging indicator 3-32
3 4 Control Levers and Pedals 3-33
3 4 1 Hydraulic lockout control 3-34
3 4 2 Travel control levers 3-35
3 4 3 Joysticks 3-36
3 5 Cab Windows and Cab Door 3-38
3 5 1 Ceiling window 3-38
3 5 2 Front window 3-39
3 5 3 Cab door window 3-45
3 6 Cup Holder 3-46
3 7 Ash Tray 3-46
3 8 Manual Pocket 3-46
3 9 Drink Box 3-47
3 10 Alternate exit 3-47
3 11 Fire Extinguisher 3-47
3 12 Electronic Control Module 3-48
3 13 Fusible Link 3-48
3 14 Air Conditioning System 3-49
3 14 1 Control panel 3-49
3 14 2 Operation method 3-55
3 14 3 Air conditioner operation precautions 3-58
3 15 Radio 3-59
3 15 1 Control panel 3-59
3 15 2 Operation 3-61
3 16 Cab door catch 3-65
3 17 Lockable Caps and Covers 3-65
3 17 1 Lockable caps 3-66
3 17 2 Lockable covers 3-67
3 18 Toolbox 3-68
3 19 Grease Pump Frame 3-68
4 Operation
4 1 Before Starting the Engine 4-5
4 1 1 Walk-around inspection 4-5
4 1 2 Inspection before starting 4-7
4 1 2 1 Water and sediment in fuel tank – drain 4-7
4 1 2 2 Water and sediment in water separator – check/drain 4-8
4 1 2 3 Hydraulic oil level – check/refi ll 4-9
4 1 2 4 Coolant level – check/refi ll 4-10
4 1 2 5 Oil level in oil pan – check/add 4-11
4 1 2 6 Electric wires – check 4-13
4 1 2 7 Fuel level – Check and add 4-14
4 1 2 8 Work lamp switches – check 4-16
4 1 2 9 Horn – check 4-16
4 1 3 Adjustment before operation 4-17
4 1 3 1 Operator seat adjustment 4-17
4 1 3 2 Rear view mirrors 4-19
4 1 3 3 Seat belt 4-21
4 1 4 Operation before engine startup 4-22
4 2 Engine Startup 4-24
4 2 1 Engine Preheating 4-27
4 2 2 Warm-up operation 4-28
4 3 Engine Shutdown 4-29
4 4 Machine Operation 4-30
4 4 1 Before moving the machine 4-31
4 4 2 Move the machine 4-32
4 4 3 Stopping the machine 4-33
4 5 Machine Turning 4-34
4 5 1 Direction change when the machine is stopped 4-34
4 5 2 Pivot turning 4-36
4 6 Work Equipment Control 4-37
4 7 Restricted Operations 4-39
4 7 1 Operation with swinging force 4-39
4 7 2 Operation with traveling force 4-39
4 7 3 Operation when hydraulic cylinder reaches its stroke end 4-40
4 7 4 Operation with bucket landing force 4-40
4 7 5 Hard rocky ground 4-40
4 7 6 Operation with machine weight 4-41
4 7 7 Sudden shift of control levers/ pedals 4-41
4 8 Permissible depth of water 4-42
4 9 Traveling on a Slope 4-43
4 9 1 Traveling downhill 4-44
4 9 2 When engine stalls on a slope 4-44
4 9 3 Cab door on a slope 4-44
4 10 Escaping from Mud 4-45
4 10 1 When one track is trapped 4-45
4 10 2 When both tracks are trapped 4-45
4 11 Recommended Application 4-46
4 11 1 Backhoe operation 4-46
4 11 2 Trenching work 4-47
4 11 3 Loading operation 4-47
4 12 Parking 4-48
4 13 Post-operation Inspection 4-51
4 14 Locking 4-52
4 15 Operation in Cold Weather 4-53
4 15 1 Fuel and lubricant 4-53
4 15 2 Coolant 4-53
4 15 3 Battery 4-53
4 15 4 After operation in cold weather 4-54
4 15 5 After cold season 4-55
4 16 Long-Term Storage 4-55
4 16 1 Before storage 4-55
4 16 2 During storage 4-56
4 16 3 After storage 4-56
4 16 4 Engine startup after long-term storage 4-56
4 17 Transportation Information 4-57
4 17 1 Transport methods 4-57
4 17 2 Loading and unloading 4-57
4 17 2 1 Loading 4-58
4 17 2 2 Securing the machine 4-61
4 17 2 3 Unloading 4-63
4 17 2 4 Lifting the machine 4-65
5 Maintenance
5 1 Maintenance Information 5-3
5 2 Oil, fuel and coolant 5-6
5 2 1 Oil 5-6
5 2 2 Fuel 5-6
5 2 3 Coolant 5-7
5 2 4 Grease 5-8
5 2 5 Oil and fuel storage 5-8
5 2 5 1 Filter element 5-9
5 2 6 Electrical system 5-9
5 3 Wear Parts 5-10
5 4 Recommended Fuel, Coolant and Lubricant 5-12
5 4 1 Table of recommended fuel, oil and coolant 5-13
5 4 2 Table of capacities 5-14
5 5 Tightening Torque Table 5-15
5 6 Safety Critical Parts 5-17
5 7 Maintenance Schedule 5-18
5 8 Maintenance Procedures 5-20
5 8 1 Lockout and tag-out measures 5-20
5 8 2 Initial 50 hours of operation 5-20
5 8 3 When Required 5-21
5 8 3 1 Track shoe bolts – inspect/tighten 5-21
5 8 3 2 Track tension – inspect/adjust 5-22
5 8 3 3 Bucket – replace 5-25
5 8 3 4 Bucket tips – replace 5-28
5 8 3 5 Bucket clearance – adjust 5-30
5 8 3 6 Window washer fl uid level – check/fi ll 5-32
5 8 3 7 Refrigerant level – check 5-33
5 8 3 8 Ceiling window gas spring – inspect 5-35
5 8 4 Inspection Prior to Startup 5-37
5 8 5 Every 100 service hours 5-38
5 8 5 1 Lubrication 5-38
5 8 6 Every 250 service hours 5-41
5 8 6 1 Air fi lter element – inspect/clean/replace 5-41
5 8 6 2 Engine pan oil and fi lter element – change/replace 5-44
5 8 6 3 Fan belt tension – inspect/adjust 5-46
5 8 6 4 Compressor belt tension – inspect/adjust 5-47
5 8 6 5 Oil return check valve – check 5-48
5 8 6 6 Pipe clamps of hydraulic system – check 5-49
5 8 7 Every 500 service hours 5-50
5 8 7 1 Swing bearing – lubricate 5-50
5 8 7 2 Swing pinion gear grease level – inspect/fi ll 5-51
5 8 7 3 Primary fuel fi lter element – replace 5-52
5 8 7 4 Secondary fuel fi lter element – replace 5-55
5 8 7 5 Prmiming pump strainer – Clean 5-58
5 8 7 6 Radiator and oil cooler fi ns – inspect/clean 5-59
5 8 7 7 Air conditioner fresh air/recirculation fi lter – clean 5-61
5 8 7 8 Swing drive oil level – check/fi ll 5-63
5 8 7 9 Final drive oil level – check/fi ll 5-64
5 8 7 10 Breather valve – service 5-65
5 8 8 Every 1000 service hours 5-66
5 8 8 1 Hydraulic oil fi lter element – replace 5-66
5 8 8 2 Swing drive oil – change 5-68
5 8 8 3 Cab door lock and front window lock catch – inspect/tighten 5-69
5 8 8 4 Cab door hinge and front window slide rail – inspect/add grease 5-70
5 8 8 5 Windshield wiper arm nut – Inspect/tighten 5-71
5 8 8 6 Engine exhaust pipe clamps – check 5-71
5 8 8 7 Fan belt tension – check/replace 5-71
5 8 8 8 Nitrogen pressure in accumulator (breaker) – check 5-71
5 8 8 9 Fan belt tension – check/replace 5-72
5 8 8 10 Nitrogen pressure in accumulator (breaker) – check 5-72
5 8 8 11 Swing mechanism grease – check and add 5-72
5 8 9 Every 2000 service hours 5-73
5 8 9 1 Final drive oil – change 5-73
5 8 9 2 Hydraulic tank fi lter strainer – clean 5-75
5 8 9 3 Nitrogen pressure in accumulator (control oil circuit) – check 5-76
5 8 9 4 Hydraulic tank oil – change 5-80
5 8 9 5 Cooling system interior – clean 5-82
5 8 9 6 Alternator – inspect 5-84
5 8 9 7 Engine valve clearance – check/adjust 5-84
5 8 10 Every 4000 service hours 5-85
5 8 10 1 Water pump – inspect 5-85
5 8 10 2 Start motor – check 5-85
5 8 10 3 Accumulator – replace 5-86
5 8 10 4 High-pressure tube clamps and rubber – check 5-87
5 8 10 5 Compressor working condition – inspect 5-88
5 8 11 Every 8000 service hours 5-88
5 8 11 1 High-pressure tube clamps – replace 5-88
5 8 12 Every 10000 service hours 5-88
6 Troubleshooting
6 1 Troubleshooting Preparation 6-3
6 1 1 Checks before troubleshooting 6-3
6 1 2 Troubleshooting precautions 6-4
6 1 3 Electrical circuits troubleshooting precautions 6-6
6 1 4 Hydraulic components handling precautions 6-7
6 2 Measures Taken When Failure Occurs 6-9
6 2 1 Failure-like phenomena 6-9
6 2 2 Towing the machine 6-10
6 2 3 Towing hook for light loads 6-12
6 3 Engine Failures 6-13
6 3 1 Engine troubleshooting table 6-13
6 3 2 Coolant temperature high 6-18
6 3 3 Engine oil pressure low 6-20
6 3 4 When fuel runs out 6-21
6 3 5 When engine rotates reversely 6-24
6 4 Failures of the Electrical System 6-25
6 4 1 Electrical system troubleshooting table 6-25
6 4 2 Failure codes 6-29
6 5 Battery 6-31
6 5 1 Battery removal and installation 6-31
6 5 2 Battery charging 6-32
6 5 3 Starting engine with jumper cable 6-33
6 5 3 1 Connecting jumper cables 6-34
6 5 3 2 Starting engine 6-35
6 5 3 3 Disconnecting jumper cables 6-35
6 6 Failures of the Hydraulic System 6-36
6 7 Other Common Failures 6-40
7 Specifi cations
7 1 Machine Dimensions 7-3
7 2 Working Ranges 7-4
7 3 Operating Parameters 7-5
8 Optional Equipment
8 1 Safety Information 8-3
8 1 1 Optional equipment selection 8-3
8 1 2 Read equipment instruction 8-3
8 1 3 Optional equipment removal and installation precautions 8-3
8 1 4 Optional equipment operation precautions 8-4
8 2 Hydraulic Control Elements and Oil Circuit 8-5
8 2 1 Component locations 8-5
8 2 1 1 Stop valve 8-6
8 2 1 2 Selector valve 8-6
8 2 1 3 Attachment control pedal 8-7
8 2 2 Hydraulic circuit 8-8
8 2 2 1 Hydraulic circuit switching 8-8
8 2 2 2 Switching between breaker and general attachment 8-8
8 2 2 3 Connecting hydraulic oil circuit 8-9
8 2 2 4 Hydraulic oil path 8-10
8 2 3 Attachment removal and installation 8-11
8 2 3 1 Removal 8-11
8 2 3 2 Installation 8-13
8 2 4 Hydraulic oil and fi lter – change/replace 8-15
8 2 5 Long-term storage 8-16
8 3 Work equipment combination 8-17
8 4 Recommended Operation 8-19
8 4 1 Hydraulic breaker 8-19
8 4 2 Hydraulic breaker operation 8-20
8 4 3 Restricted operations 8-22
8 4 4 Hydraulic breaker greasing 8-25
8 5 Quick Coupler 8-26
8 5 1 Quick coupler control 8-26
8 5 2 Precautions for quick coupler safe operation 8-28
8 6 Fueling System 8-30
8 6 1 Introduction 8-30
8 6 2 Fueling system makeup 8-30
8 7 Central Lubrication System 8-32
8 7 1 Lubrication scheme and system makeup 8-32
8 7 2 Working principle 8-34
8 7 3 Lubrication time setup 8-35
8 7 4 Technical description 8-37
8 7 5 Grease fi lling 8-38
S.S 07/24
