Sany SY55C3 SY55C9 SY60C1 Crawler Hydraulic Excavator Service Manual – PDF DOWNLOAD
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Sany SY55C3 SY55C9 SY60C1 Crawler Hydraulic Excavator Service Manual – PDF DOWNLOAD
Language : English
Pages : 794
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Sany SY55C3 SY55C9 SY60C1 Crawler Hydraulic Excavator Service Manual – PDF DOWNLOAD
1 Introduction
1 1 How to Read the Shop Manual 1-3
1 2 Terms for Maintenance Standard 1-6
1 3 Handling Electrical and Hydraulic Components 1-9
1 3 1 Points to remember when handling electric components 1-9
1 3 2 Points to remember when handling hydraulic equipment 1-18
1 4 Hose Connector 1-20
1 4 1 Type of hose connector 1-21
1 4 2 Hose connector tightening torque table 1-21
1 4 3 Connection of O-rings 1-22
1 5 Table of Standard Tightening Torques 1-23
1 6 Type of Bolts 1-24
1 7 Tightening Sequence 1-24
1 8 Maintenance of Half Flanges 1-25
1 8 1 Table of tightening torques for half fl ange bolts 1-25
1 9 Conversion Table 1-26
2 Shop Safety
2 1 Hazard Alert Information 2-3
2 2 General Shop Safety 2-6
2 2 1 Rules and shop behavior 2-7
2 2 2 Housekeeping 2-7
2 2 3 Shop Liquids Storage 2-8
2 2 4 Cleaning Parts 2-8
2 2 5 Jacking Up the Machine 2-9
2 2 6 Electrical Dangers 2-9
2 2 7 Removing Attachments 2-10
2 2 8 Cleaning the Machine 2-10
2 2 9 Using the Correct Tools 2-10
2 2 10 Hoisting a Load 2-11
2 2 11 Appropriate Working Apparel 2-12
2 2 12 Safety Partners 2-12
2 2 13 Two people when engine running 2-13
2 2 14 Driving Pins 2-13
2 2 15 Aligning Parts or Components 2-14
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Table of Contents SY55C3, SY55C9, SY60C1 Crawler Hydraulic Excavator
Shop Manual – November 2012
2 2 16 Fire Extinguisher and Emergency Exits 2-14
2 2 17 Personal Protective Equipment 2-14
2 2 18 Running the Machine 2-15
2 2 19 Accumulator 2-16
2 2 20 Adding Fluids to a System 2-16
2 2 21 Track Recoil Springs 2-17
2 2 22 High-Pressure Fluid Lines 2-17
2 2 23 Safe Work Preparations 2-18
2 2 24 Mounting and Dismounting 2-19
2 2 25 Battery Hazards 2-20
2 2 26 Jump-Start Safety 2-21
2 2 27 Disconnecting the System Power 2-21
2 2 28 LOCKOUT/TAGOUT 2-22
2 2 29 Sequence of Procedures 2-22
2 2 30 CHEMICAL HAZARDS 2-24
2 2 31 Material Safety Data Sheets (MSDS) 2-24
3 Specifi cations
3 1 Dimensions 3-3
3 2 Working Ranges 3-5
3 3 Technical Specifi cations 3-7
3 4 Weight Table 3-9
3 5 Recommended Oil, Fuel and Coolant 3-10
3 6 Engine Performance Curve 3-12
4 Structure and Function
4 1 Engine and Cooling System 4-3
3 6 1 Radiator and intercooler 4-3
4 1 1 PTO (shaft coupling) 4-4
4 1 2 Engine control system 4-5
4 2 Power Train 4-6
4 2 1 Power transmission system 4-6
4 2 2 Swing bearing 4-7
4 2 3 Swing mechanism 4-8
4 3 Undercarriage and Frame 4-9
4 3 1 Track frame 4-9
4 3 2 Idler and recoil spring 4-11
4 4 Hydraulic System 4-13
III
SY55C3, SY55C9, SY60C1 Crawler Hydraulic Excavator Table of Contents
Shop Manual – November 2012
4 4 1 Hydraulic equipment layout drawing 4-13
4 4 2 Hydraulic circuit diagram 4-14
4 4 3 Hydraulic tank and fi lter 4-15
4 4 4 Hydraulic pump 4-16
4 4 5 Control valve 4-26
4 4 6 Load sensitive system 4-29
4 4 6 1 Outline 4-29
4 4 6 2 Basic principle 4-30
4 4 6 3 Operation of each function 4-32
4 4 6 4 Operation of the whole system 4-44
4 4 7 Swing motor 4-54
4 4 8 Center swivel joint 4-58
4 4 9 Travel motor 4-60
4 4 10 Travel motor operating process 4-63
4 4 11 Parking brake operating process 4-65
4 4 12 Counterbalance valve operating process 4-66
4 4 13 Control System 4-68
4 4 13 1 Work equipment pilot valve 4-69
4 4 13 2 Travel pilot valve 4-73
4 4 13 3 Option pilot valve 4-76
4 4 14 Hydraulic cylinder 4-79
4 5 Electrical Control System 4-80
4 5 1 General function 4-85
4 5 2 Engine control function 4-86
4 5 3 Valve control function 4-87
4 5 4 Auto deceleration function 4-88
4 5 5 Engine preheating and overheating protection function 4-89
4 5 6 Travel control selection 4-90
4 5 7 Monitoring System 4-91
4 6 Integrated Control Monitoring System 4-93
4 6 1 Monitor 4-93
4 6 2 Monitor items and display 4-96
4 6 3 Main screen function 4-98
4 6 4 Special functions 4-111
5 Table of Standard Values
5 1 Standard Values for Engine-Related Parts 5-3
5 2 Standard Values for Chassis-Related Parts 5-4
IV
Table of Contents SY55C3, SY55C9, SY60C1 Crawler Hydraulic Excavator
Shop Manual – November 2012
5 3 Standard Values for Electrical Parts 5-11
6 Testing and Adjusting
6 1 Engine Speed – Test 6-3
6 2 Exhaust Gas Color – Test 6-4
6 3 Valve Clearance – Adjust 6-6
6 4 Compression Pressure – Measure 6-8
6 5 Fuel Injection Timing – Test and Adjust 6-9
6 5 1 Injection timing confi rming steps 6-9
6 6 Engine Oil Pressure – Measure 6-12
6 7 Alternator Belt Tension – Test and Adjust 6-13
6 7 1 Testing 6-13
6 7 2 Adjusting 6-13
6 8 Fuel Control Lever – Adjust 6-14
6 9 Hydraulic Pressure in Oil Circuit – Test and Adjust 6-15
6 10 LS Differential Pressure – Measure 6-17
6 10 1 LS valve – Adjust 6-17
6 11 Hydraulic Pressure in Control Circuit – Test 6-19
6 12 Pilot Valve Output Pressure – Test 6-20
6 13 Work Equipment and Swing Pilot Valve – Adjust 6-21
6 14 Travel Deviation – Test 6-22
6 15 Oil Leakage – Test 6-23
6 16 Residual Pressure in Hydraulic Circuit – Release 6-26
6 17 Swing Bearing Clearance – Check 6-27
6 18 Track Tension – Check and Adjust 6-28
6 19 Air in Each Component – Bleed 6-30
7 Troubleshooting
7 1 Points to Remember When Troubleshooting 7-3
7 2 Troubleshooting Procedures 7-5
7 3 Connector Locations and System Circuit Diagram 7-8
7 4 Electric Wire Specifi cations 7-18
7 5 How to Use the Judgement Chart 7-20
7 6 How to Use Troubleshooting Table 7-21
7 7 Troubleshooting of Electrical System 7-24
7 8 Troubleshooting of Engine 7-31
7 9 Troubleshooting of Hydraulic and Mechanical System 7-57
7 10 Troubleshooting of Machine Monitoring System 7-83
V
SY55C3, SY55C9, SY60C1 Crawler Hydraulic Excavator Table of Contents
Shop Manual – November 2012
8 Disassembly And Assembly
8 1 How to Read This Manual 8-3
8 2 Operation Precautions 8-4
8 3 Engine and Main Pump Assembly – Remove and Install 8-6
8 3 1 Remove 8-6
8 3 2 Install 8-11
8 4 Radiator, Hydraulic Oil Cooler Assembly – Remove and Install 8-12
8 4 1 Remove 8-12
8 4 2 Install 8-14
8 5 Fuel Tank Assembly – Remove and Install 8-15
8 5 1 Remove 8-15
8 5 2 Install 8-16
8 6 Center Swivel Joint Assembly – Remove and Install 8-17
8 6 1 Remove 8-17
8 6 2 Install 8-18
8 7 Center Swivel Joint Assembly – Disassemble and assemble 8-19
8 7 1 Disassemble 8-19
8 7 2 Assemble 8-19
8 8 Sprocket – Remove and Install 8-20
8 8 1 Remove 8-20
8 8 2 Install 8-20
8 9 Travel Motor Assembly – Remove and Install 8-21
8 9 1 Remove 8-21
8 9 2 Install 8-22
8 10 Disassembly and Assembly of Travel Motor 8-23
8 10 1 Section view 8-23
8 10 2 Exploded view of the reducer 8-25
8 10 3 Exploded view of reducer assembly 8-26
8 10 4 Exploded view of hydraulic motor assembly 8-27
8 10 5 Parts catalogue 8-28
8 10 6 Disassemble 8-30
8 10 7 Table of maintenance standard 8-41
8 10 8 Assemble 8-43
8 10 9 Performance test 8-58
8 11 Swing Motor and Swing Mechanism Assembly 8-59
8 11 1 Remove 8-59
8 11 2 Install 8-60
8 12 Swing Motor Assembly – Disassemble and Assemble 8-61
VI
Table of Contents SY55C3, SY55C9, SY60C1 Crawler Hydraulic Excavator
Shop Manual – November 2012
8 12 1 Disassemble 8-61
8 12 2 Assemble 8-71
8 13 Swing Mechanism Assembly – Disassemble and Assemble 8-84
8 13 1 Disassemble 8-84
8 13 2 Assemble 8-87
8 14 Swing Platform Assembly – Remove and Install 8-91
8 14 1 Remove 8-91
8 14 2 Install 8-93
8 15 Swing Bearing Assembly – Remove and Install 8-94
8 15 1 Remove 8-94
8 15 2 Install 8-94
8 16 Idler and Tension Spring Assembly – Remove and Install 8-95
8 16 1 Remove 8-95
8 16 2 Install 8-96
8 17 Tension Spring Assembly – Disassemble and Assemble 8-97
8 17 1 Disassemble 8-97
8 17 2 Assemble 8-100
8 18 Idler Assembly – Disassemble and Assemble 8-101
8 18 1 Disassemble 8-101
8 18 2 Assemble 8-102
8 19 Track Roller Assembly – Remove and Install 8-105
8 19 1 Remove 8-105
8 19 2 Install 8-105
8 20 Track Roller Assembly – Disassemble and Assemble 8-106
8 20 1 Disassemble 8-106
8 20 2 Assemble 8-107
8 21 Carrier Roller Assembly – Remove and Install 8-110
8 21 1 Remove 8-110
8 21 2 Install 8-110
8 22 Track Shoe Assembly – Remove and Install 8-111
8 22 1 Remove 8-111
8 22 2 Install 8-111
8 23 Hydraulic Tank Assembly – Remove Install 8-112
8 23 1 Remove 8-112
8 23 2 Install 8-113
8 24 Main Pump Assembly – Remove and Install 8-114
8 24 1 Remove 8-114
8 24 2 Install 8-115
VII
SY55C3, SY55C9, SY60C1 Crawler Hydraulic Excavator Table of Contents
Shop Manual – November 2012
8 25 Main Pump Input Shaft Oil Seal – Remove and Install 8-116
8 25 1 Remove 8-116
8 25 2 Install 8-116
8 26 Control Valve Assembly – Remove and Install 8-117
8 26 1 Remove 8-117
8 26 2 Install 8-117
8 27 Oil Source Control Valve Assembly – Remove and Install 8-118
8 27 1 Remove 8-118
8 27 2 Install 8-118
8 28 Left Pilot Valve Assembly – Remove and Install 8-119
8 28 1 Remove 8-119
8 28 2 Install 8-119
8 29 Right Pilot Valve Assembly – Remove and Install 8-120
8 29 1 Remove 8-120
8 29 2 Install 8-120
8 30 Work Equipment Pilot Valve Assembly 8-121
8 30 1 Disassemble 8-121
8 30 2 Assemble 8-121
8 31 Travel Pilot Valve Assembly – Remove and Install 8-123
8 31 1 Remove 8-123
8 31 2 Install 8-124
8 32 Travel Pilot Valve Assembly – Disassemble and Assemble 8-125
8 32 1 Assemble 8-126
8 33 Boom Cylinder Assembly – Remove and Install 8-127
8 33 1 Remove 8-127
8 33 2 Install 8-128
8 34 Arm Cylinder Assembly – Remove and Install 8-129
8 34 1 Remove 8-129
8 34 2 Install 8-130
8 35 Bucket Cylinder Assembly – Remove and Install 8-131
8 35 1 Remove 8-131
8 35 2 Install 8-132
8 36 Blade Cylinder Assembly – Remove and Install 8-133
8 36 1 Remove 8-133
8 36 2 Install 8-134
8 37 Hydraulic Cylinder Assembly – Disassemble and Assemble 8-135
8 37 1 Disassemble 8-135
8 37 2 Assemble 8-137
VIII
Table of Contents SY55C3, SY55C9, SY60C1 Crawler Hydraulic Excavator
Shop Manual – November 2012
8 38 Work Equipment Assembly – Remove and Install 8-140
8 38 1 Remove 8-140
8 38 2 Install 8-141
8 39 Bucket Assembly – Remove and Install 8-142
8 39 1 Remove 8-142
8 39 2 Install 8-143
8 40 Arm Assembly – Remove and Install 8-144
8 40 1 Remove 8-144
8 40 2 Install 8-145
8 41 Bucket and Arm Assembly – Remove and Install 8-146
8 41 1 Remove 8-146
8 41 2 Install 8-147
8 42 Boom Assembly – Remove and Install 8-148
8 42 1 Remove 8-148
8 42 2 Install 8-149
8 43 Dozer Blade Assembly – Remove and Install 8-150
8 43 1 Remove 8-150
8 43 2 Install 8-151
8 44 Cab Assembly – Remove and Install 8-152
8 44 1 Remove 8-152
8 44 2 Install 8-152
8 45 Counterweight Assembly – Remove and Install 8-153
8 45 1 Remove 8-153
8 45 2 Install 8-153
8 46 Monitor Assembly – Remove and Install 8-154
8 46 1 Remove 8-154
8 46 2 Install 8-154
9 Maintenance Standard
9 1 Swing Machinery 9-3
9 2 Swing Bearing 9-4
9 3 Track Frame 9-5
9 4 Idler 9-7
9 5 Track Roller 9-8
9 6 Track Shoe 9-9
9 7 Work Equipment 9-11
9 7 1 Work equipment dimension 9-13
9 8 Hydraulic Cylinder 9-15
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SY55C3, SY55C9, SY60C1 Crawler Hydraulic Excavator Table of Contents
Shop Manual – November 2012
10 Engine
10 1 General 10-3
10 1 1 General maintenance precautions 10-3
10 1 2 Reading guide 10-3
10 1 3 Technical data and specifi cations 10-8
10 1 4 Tightening torque 10-9
10 1 5 Fixing nuts and bolts for key parts 10-11
10 1 6 Engine maintenance and servicing 10-19
10 1 7 Lubricating system 10-20
10 1 8 Fuel system 10-21
10 1 8 1 Fuel fi lter 10-21
10 1 8 2 Water separator (optional) 10-22
10 1 8 3 Air bleeding 10-22
10 1 8 4 Fuel injector 10-23
10 1 9 Cooling system 10-26
10 1 10 Thermostat 10-27
10 1 11 Valve clearance – adjust 10-28
10 1 12 Injection timing 10-30
10 1 13 Compression pressure – measure 10-31
10 1 14 Engine repair kit 10-33
10 2 Engine Assembly – Disassemble 10-34
10 2 1 General 10-34
10 2 2 Disassemble 10-35
10 2 3 Rocker shaft and rocker arm 10-49
10 2 4 Cylinder head 10-51
10 2 5 Piston and connecting rod 10-53
10 2 6 Camshaft, camshaft timing gear and thrust plate 10-56
10 3 Engine Assembly – Inspect and Repair 10-58
10 3 1 Cylinder head 10-58
10 3 2 Valve guide 10-60
10 3 3 Valve and valve seat ring 10-62
10 3 4 Valve spring 10-66
10 3 5 Rock shaft and rocker arm 10-67
10 3 6 Cylinder block 10-70
10 3 7 Tappet and push rod 10-78
10 3 8 Camshaft 10-80
10 3 9 Camshaft and camshaft bearing 10-82
10 3 10 Crankshaft and bearing 10-85
X
Table of Contents SY55C3, SY55C9, SY60C1 Crawler Hydraulic Excavator
Shop Manual – November 2012
10 3 11 Flywheel and ring gear 10-94
10 3 12 Piston 10-95
10 3 13 Piston ring 10-96
10 3 14 Piston pin 10-98
10 3 15 Connecting rod 10-100
10 3 16 Idle gear shaft and idle gear 10-101
10 4 Engine Assembly – Assemble 10-103
10 4 1 Rocker shaft and rocker arm 10-103
10 4 2 Cylinder head 10-104
10 4 3 Piston and connecting rod 10-107
10 4 4 Camshaft, camshaft timing gear and thrust plate 10-110
10 4 5 Aluminium casting type timing gear housing PTO – Assemble 10-129
10 5 Lubricating System 10-140
10 5 1 Technical data and specifi cations 10-140
10 5 2 General 10-141
10 5 3 Oil pump 10-142
10 5 4 Main oil fi lter 10-143
10 5 5 Oil pump – disassemble 10-144
10 5 6 Oil fi lter with built-in oil cooler – Disassemble 10-148
10 5 7 Oil fi lter with built-in oil cooler – Inspect and repair 10-149
10 5 8 Oil fi lter with built-in oil cooler – Assemble 10-150
10 6 Cooling System 10-152
10 6 1 Technical data and specifi cations 10-152
10 6 2 General 10-153
10 6 3 Water pump 10-154
10 6 4 Water pump – Inspect and repair 10-155
10 6 5 Water pump – Disassemble 10-156
10 6 6 Water pump – Assemble 10-159
10 6 7 Thermostat – inspect and repair 10-162
10 7 Fuel System 10-163
10 7 1 Technical data and specifi cations 10-163
10 7 2 General 10-164
10 7 3 Fuel fi lter and water separator 10-167
10 7 4 Injector – Disassemble 10-168
10 7 5 Injector – inspect and repair 10-170
10 7 6 Injector –Assemble 10-171
10 7 7 Injector – adjust 10-173
10 7 8 Dual injection type injector– Disassemble 10-174
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SY55C3, SY55C9, SY60C1 Crawler Hydraulic Excavator Table of Contents
Shop Manual – November 2012
10 7 9 Dual injection type injector – Assemble and adjust 10-176
10 7 10 Injection pump calibration data 10-188
10 7 11 Governor adjustment 10-191
10 8 Engine Electrical System 10-192
10 8 1 Starter motor 10-192
10 8 2 General 10-194
10 8 3 Electrical system – disassemble 10-195
10 8 4 Electrical system – inspect and repair 10-200
10 8 5 Electrical system – assemble 10-206
10 8 6 Selection of lube oil and tightening torque 10-207
10 8 7 Performance testing 10-208
10 9 Alternator 10-209
10 9 1 General 10-210
10 9 2 Alternator – Disassemble 10-211
10 9 3 Alternator – Inspect and repair 10-214
10 9 4 Alternator – Assemble 10-219
10 10 Troubleshooting 10-221
10 10 1 Startup failures 10-222
10 10 2 Engine unstable at idle 10-226
10 10 3 Low power 10-229
10 10 4 Excessive fuel consumption 10-233
10 10 5 Excessive oil consumption 10-235
10 10 6 Engine overheating 10-236
10 10 7 White smoke 10-238
10 10 8 Black smoke 10-239
10 10 9 Low oil pressure 10-240
10 10 10 Abnormal engine noise 10-242
10 11 List of Special Tools 10-245
10 12 Repair Standard 10-247
11 System Schematics
11 1 Hydraulic Line Layout 11-3
11 2 Hydraulic Circuit Diagram 11-4
11 3 Overall System Diagram (1/5) 11-5
11 4 Overall System Diagram (2/5) 11-6
11 5 Overall System Diagram (3/5) 11-7
11 6 Overall System Diagram (4/5) 11-8
11 7 Overall System Diagram (5/5) 11-9
XII
Table of Contents SY55C3, SY55C9, SY60C1 Crawler Hydraulic Excavator
Shop Manual – November 2012
11 8 Electrical Circuit Diagram 11-10
11 9 Electrical Component Layout 11-11
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