Sany SY215CAI4K Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD
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DESCRIPTION:
Sany SY215CAI4K 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. lf 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.
lntroduction
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 infor- mation relating to this equipment. lt also de- scribes
what the hazard alerts mean that are used throughout the manual.
Specifications
Technical specification of work equipment and optional parts are given in this section.
Structure and functions
This section explains the structure and func- tion of each component. lt helps the reader to get a
better understanding of the machine structure, and also serves as a reference for
troubleshooting.
TABLE OF CONTENTS:
Sany SY215CAI4K Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD
1 lntroduction
11 How to Read the Manual
111 Shop manual organization
112 Revision and
distribution 1-4
113 Symbols
12 Technical Terms
121 Standard size and tolerance
122 Standard clearance and value
123 Standard interference
124 Repair limit and allowable value
125 Clearance limit
13 Handling Electrical and Hydraulic
Components 1-9
131 Points to remember when handling electric components 1-9
1311 Handling wiring harnesses and connectors 1-9
1312 Main failures occurring in wiring harness 1-10
1313 Removing, installing, and drying connectors and wiring harnesses 1-12
1314 Handling the integrated control monitor
1-16
1315 Electric circuits troubleshooting precautions 1-17
132 Points to remember when handling hydraulic equipment 1-18
1321 Вe careful of the operating environment 1-18
1322 Disassembly and maintenance work in the field 1-18
1323 Sealing openings
1-18
1324 Do not let any dirt or dust get in during refilling operations 1-19
1325 Change hydraulic oil when the temperature is high 1-19
1326 Flushing
operations 1-19
1327 Cleaning operations
1-20
14 Hose
Connector
1-20
141 Type of hose
connector 1-21
142 Hose connector tightening torque table
1-21
143 Connection of O-rings
1-22
15 Table of Standard Tightening Torques
1-23
Shop Manual – October 2017
Тa le of Contents
Excavator
16 Type of Вolts
1-24
17 Tightening Sequence
1-24
18 Maintenance of Half Flanges
1-25
181 Table of tightening torques for half flange bolts
1-25
182 Temperature
1-31
2 Shop Safety
21 Hazard Alert lnformation
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 Вefore Safe Work
Preparations2-11
232 Preparing
yourself
Lockout/Tagout
234 Two people when engine running
235 Safety Partners
24 Repair Precautions
241 Running the Machine
242 Mounting and Dismounting
243 Removing Attachments
244 Jacking Up the
Machine 2-18
245 Adding Fluids to a System
246 Aligning Parts or Components
247 Driving
Pins
248 When compressed air is
used 2-19
249 Welding operation
2-20
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 Вattery 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 2-33
3 Specifications
31 Dimensions
3-3
32 Working
ranges
3-4
33 Technical
Specifications
3-5
34 Table of Weights
3-7
35 Engine Oil, Fuel and
Coolant 3-8
36 Engine Performance Curve
3-10
4 Structure and Functions
41 Engine and Cooling System
4-5
411 Engine-relate
parts 4-5
412 Radiator and
intercooler 4-6
42 Power
Train
4-7
421 Power
train
4-7
422 Travel reducer AS
4-8
423 Swing reduction mechanism
4-10
424 Swing bearing
4-12
43 Undercarriage
488 Expansion
valve
4-140
489 Evaporator
4-140
4810 Dehydrator
4-141
4811 Pressure switch
4-142
4812 Refrigerant
4-143
48121 Evacuation
4-146
48122 Refrigerant filling operation
4-148
48123 Troubleshooting with manifold pressure gauge 4-153
4813 Compressor
oil 4-162
49 Engine Control
4-163
491 System operation
4-164
492 System components
4-165
4921 Fuel control
dial 4-165
4922 Engine control unit (ECU)
4-166
410 Electrical Control
System 4-170
4101 Control
function
4-170
4102 Diagram of machine control system
4-171
4103 Engine-pump combination control
4-173
4104 Valve control
function 4-176
4105 Travel control
function 4-177
4106 Low engine oil pressure alarm and protection
4-178
4107 High engine coolant temperature alarm and protection 4-179
4108 Engine preheating control
4-180
4109 Engine starting and energizing delay control
4-181
41010 System parts and components
4-182
410101 Pump pressure sensor
4-182
410102 Pilot pressure sensor
4-183
410103 Engine speed sensor
4-184
410104 Coolant temperature sensor
51 Standard Values for Engine-Related Parts
5-3
52 Standard Values for Chassis-Related Parts
5-4
6 Тesting and Adjusting
61 Exhaust Gas Color – Test
6-3
62 Valve Clearance –
Adjust
6-5
63 Compression Force –
Test 6-8
64 Fuel lnjection Timing – Test and Adjust
6-10
65 Engine Oil Pressure – Test
6-11
66 Engine Speed Sensor –
Adjust 6-12
67 A/C Compressor Вelt Tension – Check and
Adjust 6-13
68 Swing Вearing Clearance –
Check 6-14
69 Track Tensioning device – Check and Adjust
6-16
610 Oil in hydraulic circuits – Test and Adjust
6-18
611 Control Oil Circuit Pressure – Check and Adjust
6-22
612 Solenoid Valve Output Pressure – Test
6-23
613 Pilot Valve Output Pressure – Test
6-25
614 Work Equipment and Swing PPC Valves – Adjust
6-26
615 Hydraulic Drift of Work Equipment – Test
6-27
616 Remaining Pressure in Hydraulic Lines –
Relieve 6-29
617 Oil Leakage Amount –
Test 6-30
618 Air in Each Component – Purge
6-34
619 Sensors – Test
steps 7-6
73 Connectors
7-8
731 List of
connectors
7-8
732 Connector locations
7-12
733 SWP connectors
7-14
734 A/AMP connectors
7-15
735 DT
connectors
7-15
74 Troubleshooting with an Event Code
7-17
75 Troubleshooting the Electrical System
(E-Mode) 7-31
76 Troubleshooting the Hydraulic and Mechanical System (H-Mode) 7-51
8 Disassem ly and Assem ly
81 Operating Precautions
8-5
82 Start Motor AS
8-8
821 Removing sequence
8-8
822 lnstalling sequence
8-8
83 Fuel lnjection Pump AS
8-9
831
Removal
8-9
84 Engine Rear Oil Seal
8-14
841
Removal
8-14
842
lnstallation
8-15
85 Cylinder Head AS
8-16
851
Removal
8-16
852
lnstallation
8-19
86 Engine Rear Oil Seal
8-21
862
Removal
8-22
861
lnstallation
8-22
1lnstall the flywheel
housing 8-22
2lnstall the flywheel housing
support 8-22
87 Cylinder Head AS
8-25
871
Removal
8-26
872
lnsallation
8-27
• Assembling operation is to be performed in the reverse order of disassembling
operation
814 Swing Motor and Swing Drive AS
8-73
8141
Removal
8-73
8142
lnstallation
8-74
8143
Disassembly
8-75
8144
Assembly
8-79
815 ldler AS
Disassembly
8-85
8152
Assembly
8-86
816 Sprocket
8-89
8161
Removal
8-89
8162
lnstallation
8-89
817 Track AS
8171
Removal
8-90
8172
lnstallation
8-91
818 Swing Вearing AS
8-93
8181
Removal
8-93
8182
lnstallation
8-94
819 Swing frame AS
Removal
8-95
8192
lnstallation
8-97
820 Swivel Joint AS
Removal
8-98
8202
lnstallation
8-99
821 Central Swivel Joint AS
8-100
8211
Disassembly
8-100
8212
Assembly
8-101
822 Hydraulic Tank AS
8-102
8221
Removal
8-102
8222
lnstallation
8-104
823 Control Valve AS
8-105
8231
Removal
8-105
8232
lnstallation
8-109
824 Hydraulic Pump AS
8-110
8241
Removal
8-110
8242
lnstallation
8-113
825 Middle Oil Seal (Hydraulic Pump lnput Shaft)
8-114
8251
Removal
8-114
8252
lnstallation
8-114
826 lndependent Radiator
AS8-115
8261
Removal
8-115
8261
lnstallation
8-116
827 Work Equipment Pilot Valve AS
8-117
8271
Assembly
8-117
828 Travel Pilot Valve AS
8-118
8281
Assembly
8-118
829 Hydraulic Cylinder AS
8-119
8291
Disassembly
8-120
8292
Assembly
8-125
830 Work Equipment AS
8-131
8301
Removal
8-131
8302
lnstallation
8-133
831 Air Conditioner
AS
8-134
8311
Removal
8-134
8312
lnstallation
8-137
832 Counterweight AS
8-138
8321
Removal
8-138
8322
lnstallation
8-139
Shop Manual – October 2017 lX
SY265C9C5K Crawler Hydraulic
Тa le of Contents
Excavator
833 Cab AS
8-140
8331
Removal
8-140
8332
lnstallation
8-143
834 Monitor
Removal
8-144
8342
lnstallation
Removal
8-145
8352
lnstallation
8-145
836 Radio
8-146
8361 Structure
8-146
8362
Removal
8-147
8363
lnstallation
8-147
8364 Connector model and wiring
8-148
837 Вattery
8-149
8371 Structure
8-149
838 Вattery
8-150
8381 lnstallation and
Removal 8-150
8382
lnstallation
8-150
8383
Replacement
8-151
839 Start
Switch
8-152
8391 Structure
8-152
8392
Removal
8-153
8393
lnstallation
8-153
8394 Working principle and wiring
8-154
840 Electrical Power Center
8-155
8401 lnstallation and Removal
8-155
8402
lnstallation
8-155
841 Wiper
8-156
8411 Structure
8-156
8412 Working principle
8-156
8413
Removal
8-157
8414
lnstallation
8-157
8415 Wiper arm angle adjustment
8-158
842
Relays
8-159
8411 Engine relays
8-159
8421 Other load
relays 8-160
843 Connector Terminals
8-162
8431 lnsertion
8-162
8432
Removal
8-163
9 System Schematics
91 Hydraulic Circuit Diagram
9-3
92 Electrical Diagram
9-4
93 Cab harness
9-16
94 Control Switch Harness
9-17
95 Tool box Harness
9-18
96 Pump room
Harness
9-19
97 Vehicle Вody
Harness
9-20
98 Вoom Harness
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