Sany SY335C9C4K Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Sany SY335C9C4K Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD
1 INTRODUCTION
1.1 How to Read the Shop Manual
1.1.1 Organization of the 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 specifi 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.
TABLE OF CONTENTS:
Sany SY335C9C4K Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD
1 Introduction
11 How to Read the Shop Manual 1-3
111 Organization of the shop manual 1-3
113 Symbols 1-4
114 Units 1-4
112 Revision and distribution 1-4
12 Terms for Maintenance Standard 1-5
121 Standard size and tolerance 1-5
122 Standard clearance and standard 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
132 Points to remember when handling hydraulic equipment 1-17
14 Hose Connector 1-19
141 Type of hose connector 1-2
142 Hose connector tightening torque table 1-2
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 fl ange bolts 1-24
19 Conversion Table 1-25
2 Shop Safety
21 Hazard Alert Information 2-3
22 General Shop Safety 2-4
221 Rules and shop behavior 2-5
222 Housekeeping 2-5
223 Shop Liquids Storage 2-6
II Safety, Operation & Maintenance Manual – September 214
Table of Contents SY335C9C4K Crawler Hydraulic Excavator
224 Cleaning Parts 2-6
225 Jacking Up the Machine 2-7
226 Electrical Dangers 2-7
227 Removing Attachments 2-8
228 Cleaning the Machine 2-8
229 Using the Correct Tools 2-8
221 Hoisting a Load 2-9
2211 Appropriate Working Apparel 2-1
2212 Safety Partners 2-1
2213 Two people when engine running 2-11
2214 Driving Pins 2-11
2215 Aligning Parts or Components 2-12
2216 Fire Extinguisher and Emergency Exits 2-12
2217 Personal Protective Equipment 2-12
2218 Running the Machine 2-13
2219 Accumulator 2-14
222 Adding Fluids to a System 2-14
2221 Track Recoil Springs 2-15
2222 High-Pressure Fluid Lines 2-15
2223 Safe Work Preparations 2-16
2224 Mounting and Dismounting 2-17
2225 Battery Hazards 2-18
2226 Jump-Start Safety 2-19
2227 Disconnecting the System Power 2-19
2228 LOCKOUT/TAGOUT 2-2
2229 Sequence of Procedures 2-2
223 CHEMICAL HAZARDS 2-22
2231 Material Safety Data Sheets (MSDS) 2-22
3 Specifi cations
31 Dimensions 3-3
32 Working Ranges 3-4
33 Technical Specifi cations 3-5
34 Weight Table 3-6
35 Recommended Oil, Fuel and Coolant 3-7
36 Engine Performance Curve 3-8
4 Structure and Function
Safety, Operation & Maintenance Manual – September 214 III
SY335C9C4K Crawler Hydraulic Excavator Table of Contents
41 Engine and Cooling System 4-5
411 Engine-related parts 4-5
412 Radiator and intercooler 4-6
42 Power Train 4-7
421 Power transmission system 4-7
422 Final drive assembly 4-8
423 Swing mechanism 4-1
424 Swing bearing 4-12
43 Undercarriage 4-13
431 Track frame and tensioning spring 4-13
432 Standard track shoe 4-14
433 Idler 4-15
434 Carrier roller 4-17
435 Track roller 4-18
436 Track shoe 4-19
437 Triple grouser shoe 4-21
44 Hydraulic System, Part 1 4-22
441 Layout of hydraulic components 4-22
442 Hydraulic tank and fi lter 4-24
443 Hydraulic pump 4-25
444 Pilot pump 4-31
445 Regulator 4-32
4451 Adjustment of the regulator 4-36
45 Hydraulic System, Part 2 4-44
451 Control valve 4-44
452 Hydraulic circuit diagram (with bucket confl uence function) 4-46
453 When in neutral position 4-47
454 When operating the valves 4-52
4541 Boom 4-52
4542 Arm 4-56
4543 Bucket 4-61
4544 Swing 4-64
4545 Travel 4-65
4546 Straight travel 4-66
455 Relief valve operation principle 4-68
4551 Main relief valve 4-68
4552 Port relief valve 4-7
456 Lock valve operation principle 4-73
IV Safety, Operation & Maintenance Manual – September 214
Table of Contents SY335C9C4K Crawler Hydraulic Excavator
4561 When boom spool is in neutral position (the same with arm spool) 4-73
4562 When lowering the boom (arm IN) 4-74
457 Drawings 4-76
4571 Sectional view 4-76
4572 Right travel and left travel (B – B) 4-78
4573 Right travel, straight travel (C – C) 4-79
4574 Swing, Left travel (D – D) 4-8
4575 Boom 1 and Boom 2 (E – E) 4-81
4576 Option and Bucket (F – F) 4-82
4577 Arm 1 and Arm 2 (G – G) 4-83
4578 Bypass cutoff (H – H) 4-84
46 Hydraulic System, Part 3 4-86
461 Swing motor 4-86
462 Swing holding brake 4-88
463 Relief valve 4-89
464 Reverse prevention valve 4-91
4641 Operation drawing 4-91
4642 Explanatory drawing of effects 4-92
465 Center swivel joint 4-94
466 Travel motor 4-95
4661 Operation of components 4-96
467 Control system 4-112
468 Pilot valve4-114
4681 Work equipment and swing pilot valve 4-114
4682 Travel PPC valve 4-118
469 Solenoid valve 4-122
461 Accumulator 4-123
4611 Pilot oil fi lter 4-124
4612 Pump oil pressure sensor 4-125
4613 Hydraulic cylinders 4-126
4614 Work equipment 4-128
47 Air Conditioning System 4-134
471 A/C components layout drawing 4-134
472 Control panel 4-135
473 Circuit diagram 4-136
474 Refrigeration principle 4-138
4741 Refrigeration cycle diagram 4-138
4742 Heating cycle diagram 4-139
Safety, Operation & Maintenance Manual – September 214 V
SY335C9C4K Crawler Hydraulic Excavator Table of Contents
475 Compressor 4-14
476 Clutch 4-142
478 Condenser 4-143
477 Expansion valve 4-143
479 Evaporator 4-144
471 Receiver tank 4-144
4711 Pressure switch 4-145
4712 Fresh air sensor 4-146
4713 Refrigerant 4-146
4714 Compressor oil 4-165
48 Engine Control 4-166
481 System operation 4-167
482 Components 4-168
4821 Fuel control dial 4-168
4822 Monitor port 4-17
49 Electrical Control System 4-171
491 Control function 4-171
492 Machine control system diagram 4-172
493 Engine and pump composite control function 4-174
494 Pump control function 4-178
4941 Constant power control 4-179
495 Valve control function 4-18
496 Duo travel speed control 4-182
497 Engine preheating/overheating alarm 4-184
4971 Engine preheating 4-185
4972 Engine overheating alarm 4-185
498 Auto deceleration/acceleration control 4-186
499 Electrical Components 4-188
4991 Pump pressure sensor 4-188
4992 Pilot pressure sensor 4-189
4993 Fuel level sensor 4-19
41 Monitoring System 4-191
411 Working principle 4-191
412 Monitor overview 4-192
413 Monitor components 4-193
4131 Main display area 4-194
4132 Operation keys 4-196
414 Monitor operation 4-197
VI Safety, Operation & Maintenance Manual – September 214
Table of Contents SY335C9C4K Crawler Hydraulic Excavator
4141 Welcome page 4-197
4142 Home page 4-197
4143 System Information – password entry 4-198
4144 System information 4-199
4145 Main pump signal 4-199
4146 Engine signals 4-2
4147 Pilot pressure signals 4-2
4148 Maintenance information 4-21
4149 Fault information 4-21
4141 System setup 4-22
41411 System language setup 4-22
41412 System time setup 4-23
41413 Brightness adjustment 4-24
41414 System unit setup 4-25
41415 Time format setup 4-25
41416 Machine confi guration 4-26
41417 Machine S/N setup 4-26
41418 Work equipment selection 4-27
41419 Breaker fl ow setup 4-27
4142 Shear swing and opening/closing fl ow setup 4-28
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
611 Measure with a smoke meter 6-3
612 Measure with an opacimeter 6-4
62 Valve Clearance – Adjust 6-5
621 Testing 6-5
622 Adjusting 6-7
63 Compression force – Measure 6-8
64 Fuel Injection Timing – Test and Adjust 6-1
641 Testing 6-11
642 Adjusting 6-15
65 A/C Compressor Belt Tension – Test and Adjust 6-16
651 Testing 6-16
Safety, Operation & Maintenance Manual – September 214 VII
SY335C9C4K Crawler Hydraulic Excavator Table of Contents
652 Adjusting 6-16
66 Swing Bearing Clearance – Measure 6-18
67 Track Tension – Test and Adjust 6-2
671 Testing 6-2
672 Adjusting 6-21
68 Hydraulic Pressure in Hydraulic Circuits – Test and Adjust 6-22
681 Measuring 6-22
6811 Preparatory work 6-22
6812 Measurement of unloading pressure 6-23
6813 Measurement of work equipment pressure at relief 6-23
6814 Measurement of swing pressure at relief 6-23
6815 Measurement of travel pressure at relief 6-24
682 Adjusting 6-24
6821 Main relief pressure adjustment 6-24
6822 Swing relief pressure adjustment 6-26
69 Control Circuit Oil Pressure – Test and Adjust 6-27
691 Testing 6-27
692 Adjusting 6-27
61 Solenoid Valve Output Pressure – Measure 6-28
611 Pilot Valve Output Pressure – Measure 6-3
612 Pilot Valves (Work Equipment and Swing) – Adjust 6-31
613 Work Equipment Hydraulic Drift – Test 6-32
6131 Boom and bucket cylinders 6-32
6132 Arm cylinder 6-32
6133 Checking the pilot valve 6-33
614 Residual Pressure in Hydraulic Circuit – Release 6-34
615 Oil Leakage – Measure 6-35
6151 Measure oil leakage from boom cylinder 6-35
6152 Measure oil leakage from arm cylinder 6-36
6153 Measure oil leakage from bucket cylinder 6-37
6154 Measure oil leakage from swing motor 6-38
6155 Measure oil leakage from travel motor 6-39
616 Air in Each Component – Bleed 6-4
6161 Bleeding air from hydraulic pump 6-4
6162 Bleeding air from hydraulic cylinder 6-41
6163 Bleeding air from swing motor 6-41
6164 Bleeding air from travel motor 6-41
7 Troubleshooting
VIII Safety, Operation & Maintenance Manual – September 214
Table of Contents SY335C9C4K Crawler Hydraulic Excavator
71 Points to Remember When Troubleshooting 7-3
72 Troubleshooting Procedures 7-5
73 Fault symptoms and troubleshooting codes 7-8
74 Connector locations and electrical diagrams 7-1
741 Connector layout drawing 7-14
742 Diagram of electrical elements (switch control system) 7-19
743 Diagram of electrical control system (sensor & solenoid valve) 7-2
744 Diagram of electrical control system (controller & monitor) 7-21
745 Diagram of electrical control system (engine control) 7-22
746 SWP connectors 7-23
747 A/AMP connectors 7-24
748 DT connectors 7-25
749 Troubleshooting with an failure code 7-26
741 Troubleshooting of Electrical System (E-Mode) 7-49
7411 Troubleshooting of Hydraulic and Mechanical Systems (H – Mode) 7-73
8 Disassembly and Assembly
81 Reading Guide 8-5
811 Removing and Installing an Assembly 8-5
8111 Special tools 8-5
8112 Removal 8-5
8123 Installation 8-6
812 Disassembling and assembling an assembly 8-6
8121 Special tools 8-6
8122 Disassembly 8-6
8124 Assembly 8-7
82 Operating Precautions 8-8
83 Start Motor AS 8-12
831 Removal 8-12
832 Installation 8-12
84 Injection Pump AS 8-13
841 Removal 8-13
842 Installation 8-14
85 Front Seal of Engine 8-15
851 Removal 8-15
852 Installation 8-15
86 Rear Seal of Engine 8-16
861 Removal 8-16
Safety, Operation & Maintenance Manual – September 214 IX
SY335C9C4K Crawler Hydraulic Excavator Table of Contents
862 Installation 8-16
87 Cylinder Head AS 8-17
871 Removal 8-17
872 Installation 8-21
88 Radiator AS 8-22
881 Removal 8-22
882 Installation 8-25
89 Engine and Hydraulic Pump AS 8-26
891 Removal 8-26
892 Installation 8-31
81 Final Drive AS 8-32
811 Removal 8-32
812 Installation 8-33
813 Disassembly 8-34
814 Assembly 8-38
811 Swing Motor and Swing Drive AS 8-43
8111 Removal 8-43
8112 Installation 8-44
8113 Disassembly 8-45
8114 Assembly 8-5
812 Idler AS 8-55
8121 Disassembly 8-55
8122 Assembly 8-56
813 Sprocket 8-59
8131 Removal 8-59
8132 Installation 8-59
814 Track AS 8-6
8141 Removal 8-6
8142 Installation 8-62
815 Swing Bearing AS 8-63
8151 Removal 8-63
8152 Installation 8-64
816 Swing Frame AS 8-65
8161 Removal 8-65
8162 Installation 8-68
817 Swivel Joint AS 8-69
8171 Removal 8-69
8172 Installation 8-71
X Safety, Operation & Maintenance Manual – September 214
Table of Contents SY335C9C4K Crawler Hydraulic Excavator
8173 Disassembly 8-72
8174 Assembly 8-73
818 Hydraulic Tank AS 8-74
8181 Removal 8-74
8182 Installation 8-76
819 Control Valve AS 8-77
8191 Removal 8-77
8192 Installation 8-82
82 Hydraulic Pump AS 8-83
821 Removal 8-83
822 Installation 8-87
821 Middle Oil Seal (Hydraulic Pump Input Shaft) 8-88
8211 Removal 8-88
8212 Installation 8-88
822 Pilot Valve AS (Work Equipment) 8-89
8221 Assembly 8-89
823 Pilot Valve AS (Travel) 8-91
8231 Assembly 8-91
824 Hydraulic Cylinder AS 8-92
8241 Disassembly 8-93
8242 Assembly 8-98
825 Work Equipment AS 8-13
8251 Removal 8-13
8252 Installation 8-15
826 Air Conditioner AS 8-16
8261 Removal 8-16
8262 Installation 8-19
827 Counterweight AS 8-11
8271 Removal 8-11
8272 Installation 8-111
828 Cab AS 8-112
8281 Removal 8-112
8282 Installation 8-115
829 Cab Window Glass 8-116
8291 Removal 8-117
8292 Installation 8-121
83 Front Window AS 8-134
831 Disassemble 8-134
Safety, Operation & Maintenance Manual – September 214 XI
SY335C9C4K Crawler Hydraulic Excavator Table of Contents
832 Assemble 8-137
831 Controller AS 8-142
8311 Removal 8-142
8312 Installation 8-142
832 Radio 8-143
8321 Structure 8-143
8322 Removal 8-144
8323 Installation 8-145
8324 Connector model and wiring 8-145
833 Battery 8-146
8331 Structure 8-146
8332 Removal 8-147
8333 Installation 8-148
8334 Replacement 8-148
834 Start Switch 8-149
8341 Structure 8-149
8342 Removal 8-15
835 Fuse Box 8-152
836 Wiper 8-153
8361 Structure 8-153
8362 Working principle 8-153
8363 Removal 8-154
8365 Installation 8-155
8364 Angle adjustment of wiper arm 8-155
837 Relay 8-156
8371 Engine relays 8-156
8372 Other relays 8-157
83721 Function and location 8-157
83722 Removal and Installation 8-158
83723 Relay connector and wiring 8-158
838 Sensor 8-159
839 Connector Terminals 8-16
8391 Insertion 8-16
8392 Removal 8-161
9 System Schematics
91 Schematic Diagram of Hydraulic System 9-3
92 Chassis Circuit Diagram 9-4
XII Safety, Operation & Maintenance Manual – September 214
Table of Contents SY335C9C4K Crawler Hydraulic Excavator
93 Control Switches Circuit Diagram 9-5
94 Operator Station Circuit Diagram 9-6
95 Air-Conditioner Circuit Diagram 9-7
96 Monitor Circuit Diagram
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
S.M