Sany SY26U Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Sany SY26U Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD
1 INTRODUCTION
1.1 How to Read the Manual
Some attachments and optional parts presented in this shop manual may not be delivered to certain areas. Consult your Sany distributor if any of them is required.
Materials and specif cations 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 are used throughout the manual
TABLE OF CONTENTS:
Sany SY26U Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD
1 Introduction
11 How to Read the Manual 1-3
111 Shop manual organization 1-3
112 Revision and distribution 1-4
113 Symbols 1-5
114 Units 1-5
12 Technical Terms 1-6
121 Standard size and tolerance 1-6
122 Standard clearance and value 1-7
123 Standard interference 1-7
124 Repair limit and allowable value 1-8
125 Clearance limit 1-8
126 Interference limit 1-8
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 Be careful of the operating environment 1-18
1322 Disassembly and maintenance work in the f eld 1-18
1323 Sealing openings 1-18
1324 Do not let any dirt or dust get in during ref lling 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
Table of Contents SY26U Crawler Hydraulic Excavator
II Shop Manual – September 2017
16 Type of Bolts 1-24
17 Tightening Sequence 1-24
18 Maintenance of Half Flanges 1-25
181 Table of tightening torques for half f ange bolts 1-25
182 Temperature 1-31
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
SY26U Crawler Hydraulic Excavator Table of Contents
Shop Manual – September 2017 III
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
2416 Battery Hazards 2-24
2417 Jump-Start Safety 2-25
2418 Avoiding f re and explosion 2-26
2419 Chemical hazard 2-27
2420 Material Safety Data Sheets (MSDS) 2-27
2421 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 Speci cations
31 Dimension Drawing 3-3
32 Working Ranges 3-4
33 Technical Specif cations 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 Engine control device 4-5
42 Power Train 4-7
421 Power transmission system 4-7
422 Swing bearing 4-8
423 Swing motor 4-9
43 Undercarriage 4-10
Table of Contents SY26U Crawler Hydraulic Excavator
IV Shop Manual – September 2017
431 Track frame 4-10
432 Tensioning device 4-11
433 Tensioning device 4-12
44 Hydraulic System 4-13
441 Hydraulic lines 4-13
442 Hydraulic tank 4-14
443 Hydraulic pump 4-15
444 Control valve 4-24
445 Load sensitive system 4-28
4451 Operation and parameter of each function 4-31
446 Swing motor 4-41
447 Safety valve 4-45
448 Central swivel joint 4-47
449 Travel motor 4-48
4491 Working process of parking brake 4-51
4492 Working process of brake valve 4-52
4410 Control system 4-54
4411 Pilot valve 4-55
4412 Travel pilot valve 4-61
4413 Oil source control valve 4-65
4414 Backup pilot valve 4-66
4415 Hydraulic cylinders 4-70
45 Air Conditioner System 4-71
451 Electric circuit 4-71
452 Component locations 4-72
453 Removal 4-72
454 Installation 4-73
46 Electrical System 4-74
461 Electrical circuit diagram 4-75
47 Electronic Control System 4-77
471 General view 4-77
472 Functional overview of electrical control system 4-78
473 Engine control function 4-79
474 Valve control function 4-81
4611 Electrical circuit diagram-US 4-75
4612 Electrical circuit diagram-EU 4-76
SY26U Crawler Hydraulic Excavator Table of Contents
Shop Manual – September 2017 V
475 Automatic preheating and overheating protection function4-82
476 Travel speed selection 4-83
477 Machine monitoring system 4-84
48 Integrated-controlled Monitor System 4-86
481 Monitor 4-86
482 Input and output signals 4-87
483 Failure Information4-88
484 Maintenance 4-88
485 Change of the Monitor 4-89
4851 The operation of modify the system time 4-89
4852 The operation of selecting system language 4-90
4853 The operation of modify the machine S/N 4-91
4854 The operation of modify the working hours 4-92
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 6-6
63 Valve Clearance – Adjust 6-7
64 Compression Pressure – Test 6-8
65 Injection Timing – Test and Adjust 6-9
651 Checking injection timing 6-9
652 Adjusting the injection timing 6-12
66 Engine Oil Pressure – Test 6-13
67 Alternator Belt Tension – Test and Adjust 6-13
68 Hydraulic Pressure in Oil Circuits – Test and Adjust 6-14
69 LS Differential Pressure and LS Valve – Test/Adjust 6-16
691 Testing LS differential pressure 6-16
692 Adjusting LS valve 6-17
Table of Contents SY26U Crawler Hydraulic Excavator
VI Shop Manual – September 2017
610 Hydraulic Pressure in Control Circuit – Test 6-18
611 Pilot Valve Output Pressure – Test 6-19
612 Work Equipment and Swing Pilot Valve – Adjust 6-20
613 Travel Deviation – Test 6-21
614 Oil Leakage – Test 6-22
6141 Work equipment cylinder 6-22
6142 Swing motor 6-24
6143 Travel motor 6-25
615 Residual Pressure in Hydraulic Circuit – Release 6-26
616 Swing Bearing Clearance – Check 6-27
617 Air Purging 6-29
6171 Purging air from hydraulic pump 6-29
6172 Purging air from hydraulic cylinder 6-30
6173 Purging air from swing motor 6-30
6174 Purging air from travel motor 6-30
7 Troubleshooting
71 Troubleshooting Precautions 7-3
72 Checks Before Troubleshooting 7-5
73 Connector Locations and System Diagrams 7-6
74 Number of Pins Required for Connection 7-9
75 Electric Wire Specif cations 7-16
76 How to Use the Judgement Chart 7-18
77 How to Use a Schematic Diagram for Troubleshooting 7-20
78 Troubleshooting the Electrical System 7-21
79 Troubleshooting the Engine 7-29
710 Troubleshooting the Hydraulic and Mechanical System 7-53
6161 Track Tension – Check and Adjust 6-27
6162 Adjusting track tension 6-27
61621 When the tension is high 6-27
61622 When the tension is low 6-28
711 Troubleshooting the Machine Monitoring System 7-76
SY26U Crawler Hydraulic Excavator Table of Contents
Shop Manual – September 2017 VII
8 Disassembly and Assembly
81 Operating Precautions 8-7
82 Engine and Main Pump AS 8-10
821 Removal 8-10
822 Installation 8-15
83 Central Swivel Joint AS 8-16
831 Removal 8-16
832 Installation 8-17
833 Disassembly 8-18
834 Assembly 8-18
84 Sprocket 8-19
841 Removal 8-19
842 Installation 8-19
85 Travel Motor AS 8-20
851 Removal 8-20
852 Installation 8-21
853 Sectional view of travel motor 8-22
854 An exploded view of the reducer 8-24
855 An exploded view of the reduction device AS 8-25
856 An exploded view of the hydraulic motor AS 8-26
857 Parts catalogue 8-27
858 Table of maintenance standard
8-38
8571 Preparatory work 8-27
8572 General precautions for disassembling 8-27
8573 Disassembling procedure 8-28
859 Assembly 8-41
8591 Preparatory work 8-41
8592 General precautions 8-41
8593 Assembly procedure 8-42
8594 Performance test 8-56
86 Swing Motor and Swing Mechanism AS 8-57
861 Removal 8-57
862 Installation 8-58
87 Swing Motor AS 8-59
871 Disassembly 8-59
Table of Contents SY26U Crawler Hydraulic Excavator
VIII Shop Manual – September 2017
8711 Separation of motor from reducer 8-59
8712 Motor disassembly 8-59
8713 Disassembling the reducer 8-65
8714 Assembling the motor 8-68
8715 Assemble the reducer 8-76
8716 Assembling the swing motor assembly 8-80
88 Swing Mechanism AS 8-81
881 Disassembly 8-81
882 Assembly 8-84
89 Swing Platform AS 8-88
891 Removal 8-88
892 Installation 8-90
810 Swing Bearing AS 8-91
8101 Removal 8-91
8102 Installation 8-91
811 Idler and Tension Spring AS 8-92
8111 Removal 8-92
8112 Installation 8-92
812 Tension Spring AS 8-93
8121 Disassembly 8-93
8122 Assembly 8-94
813 Idler AS 8-95
8131 Disassembly 8-95
8123 Assembly 8-95
814 Track Roller AS 8-96
8141 Removal 8-96
8142 Installation 8-96
815 Track Roller AS 8-97
8151 Disassembly 8-97
8152 Assembly 8-97
816 Carrier Roller AS 8-98
8161 Removal 8-98
8162 Installation 8-98
817 Track AS 8-99
8171 Removal 8-99
8172 Installation 8-99
SY26U Crawler Hydraulic Excavator Table of Contents
Shop Manual – September 2017 IX
818 Hydraulic Tank AS 8-100
8181 Removal 8-100
8182 Installation 8-100
819 Main Pump AS 8-101
8191 Removal 8-101
8192 Installation 8-101
820 Oil Seal on Main Pump Input Shaft 8-102
8201 Removal 8-102
8202 Installation 8-102
821 Control Valve AS 8-103
8211 Removal 8-103
8212 Installation 8-103
822 Oil Source Control Valve AS 8-104
8221 Removal 8-104
8222 Installation 8-104
823 Left Pilot Valve AS (Arm and Swing Control) 8-105
8231 Removal 8-105
8232 Installation 8-105
824 Right Pilot Valve (Boom and Bucket Control) 8-106
8241 Removal 8-106
8242 Installation 8-106
825 Work Equipment Pilot Valve AS 8-107
8251 Disassembly 8-107
8252 Assembly8-108
826 Travel Pilot Valve AS 8-109
8261 Removal 8-109
8262 Installation 8-109
827 Travel Pilot Valve AS 8-110
8271 Disassembly8-110
8272 Assembly8-110
828 Boom Cylinder AS 8-111
8281 Removal 8-111
8282 Installation 8-112
829 Arm Cylinder AS 8-113
8291 Removal 8-113
8292 Installation 8-114
Table of Contents SY26U Crawler Hydraulic Excavator
X Shop Manual – September 2017
830 Bucket Cylinder AS 8-115
8301 Removal 8-115
8302 Installation 8-116
831 Def ection Cylinder AS 8-117
8311 Removal 8-117
8312 Installation 8-117
832 Dozer Blade Cylinder AS 8-118
8321 Removal 8-118
8322 Installation 8-119
833 Hydraulic Cylinder AS 8-120
8331 Disassembly 8-120
8332 Assembly 8-123
834 Work Equipment AS 8-126
8341 Removal 8-126
8342 Installation 8-127
835 Bucket-Arm AS 8-128
8351 Removal 8-128
8352 Installation 8-129
836 Bucket AS 8-130
8361 Removal 8-130
8362 Installation 8-131
837 Arm AS 8-132
8371 Removal 8-132
8372 Installation 8-133
838 Boom AS 8-134
8381 Removal 8-134
8382 Installation 8-135
839 Boom Def ector Joint AS 8-136
8391 Removal 8-136
8392 Installation 8-136
8393 Installation 8-137
840 Dozer Blade AS 8-138
8401 Removal 8-138
8402 Installation 8-138
841 Cab AS 8-139
8411 Removal 8-139
SY26U Crawler Hydraulic Excavator Table of Contents
Shop Manual – September 2017 XI
8412 Installation 8-139
842 Counterweight AS 8-140
8421 Removal 8-140
8422 Installation 8-140
843 Monitor AS 8-141
8431 Removal 8-141
8432 Installation 8-141
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 9-8
97 Work Equipment 9-10
98 Arm Dimensions9-12
99 Bucket Dimensions 9-13
910 Hydraulic Cylinder 9-14
10 System Schematics
101 Hydraulic Circuit Diagram 10-3
102 Electrical Circuit Diagram 10-9
Table of Contents SY26U Crawler Hydraulic Excavator
XII Shop Manual – September 2017
Introduction
Introduction
Shop Manual – October 2017
SY26U Crawler Hydraulic Excavator
1-1
1 Introduction
11 How to Read the Manual 1-3
111 Shop manual organization 1-3
112 Revision and distribution 1-4
113 Symbols 1-5
114 Units 1-5
12 Technical Terms 1-6
121 Standard size and tolerance 1-6
122 Standard clearance and value 1-7
123 Standard interference 1-7
124 Repair limit and allowable value 1-8
125 Clearance limit 1-8
126 Interference limit 1-8
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 Be careful of the operating environment 1-18
1322 Disassembly and maintenance work in the f eld 1-18
1323 Sealing openings 1-18
1324 Do not let any dirt or dust get in during ref lling operations 1-19
1325 Change hydraulic oil when the temperature is high 1-19
Introduction
1-2 Shop Manual – October 2017
SY26U Crawler Hydraulic Excavator
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
16 Type of Bolts 1-24
17 Tightening Sequence 1-24
18 Maintenance of Half Flanges 1-25
181 Table of tightening torques for half f ange bolts 1-25
182 Temperature
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.M