Sany SY75C9I4K Crawler Hydraulic Excavator Service Manual – PDF DOWNLOAD
FILE DETAILS:
Sany SY75C9I4K Crawler Hydraulic Excavator Service Manual – PDF DOWNLOAD
Language : English
Pages : 583
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Sany SY75C9I4K 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 1-5
1 3 Handling Electrical and Hydraulic Components 1-7
1 3 1 Points to remember when handling electric components 1-7
1 3 2 Points to remember when handling hydraulic equipment 1-16
1 4 Hose Connector 1-18
1 4 1 Type of hose connector 1-19
1 4 2 Hose connector tightening torque table 1-19
1 4 3 Connection of O-rings 1-20
1 5 Table of Standard Tightening Torques 1-21
1 6 Type of Bolts 1-22
1 7 Tightening Sequence 1-22
1 8 Maintenance of Half Flanges 1-23
1 8 1 Table of tightening torques for half f ange bolts 1-23
1 9 Conversion Table 1-24
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
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 hazard 2-24
2 2 31 Material Safety Data Sheets (MSDS) 2-24
2 3 Precautions for sling work and giving signals 2-25
3 Specifi cations
3 1 Dimension Drawings 3-3
3 2 Working Ranges 3-4
3 3 Technical Specif cations 3-5
3 4 Weight Table 3-6
3 5 Fuel and Coolant Capacity 3-8
3 6 Engine Performance Curve 3-9
4 Structure and Function
4 1 Engine and Cooling System 4-3
4 1 1 Radiator, oil cooler and intercooler 4-3
4 1 2 PTO 4-4
4 1 3 Engine control unit 4-5
4 2 Power Train 4-7
4 2 1 Power transmission system 4-7
4 2 2 Swing bearing 4-8
4 2 3 Swing mechanism 4-9
4 3 Undercarriage and Frame 4-10
4 3 1 Track frame 4-10
4 3 2 Idler wheel tensioner 4-11
4 4 Hydraulic System 4-13
4 4 1 Layout of hydraulic lines 4-13
4 4 1 Hydraulic circuit diagram 4-14
4 4 2 Hydraulic tank 4-15
4 4 3 Hydraulic pump 4-16
4 4 3 1 Main pump 4-17
4 4 3 2 Regulation of pressure, f ow and power 4-20
4 4 4 Control valve 4-27
4 4 4 1 General 4-27
4 4 4 2 External view 4-28
4 4 4 3 Section view 4-29
4 4 5 Oil source control valve 4-30
4 4 6 Load sensitive system 4-32
4 4 6 1 Load sensitive system 4-32
4 4 6 2 Basic principle 4-33
4 4 6 3 Operation of each function 4-35
4 4 6 4 Operation of the whole system 4-47
4 4 7 Swing motor 2-57
4 4 8 Safety valve 2-58
4 4 9 Swing brake 2-60
4 4 10 Central swivel joint 2-61
4 4 11 Travel motor 2-63
4 4 12 Travel motor operating process 2-65
4 4 13 Parking brake operating process 2-67
4 4 14 Counterbalance valve operating process 2-68
4 4 15 Control system 2-70
4 4 16 Work equipment and swing pilot valve 2-71
4 4 17 Travel pilot valve 2-76
4 4 18 Hydraulic breaker pilot valve 2-77
4 4 19 Dozer blade pilot valve 2-81
4 4 20 Anti-blast valve 2-85
4 4 21 Hydraulic cylinder 2-86
4 4 22 Work equipment 2-87
4 5 Electrical Control System 2-88
4 5 1 General 2-88
4 5 2 Diagram of electrical control system 2-89
4 5 3 Diagram of electrical circuit 2-90
4 5 4 Engine control function 2-91
4 5 5 Valve control function 2-93
4 5 6 Auto deceleration function 2-94
4 5 7 Auto preheating and overheating protection function 2-95
4 5 8 Travel control function 2-97
4 6 Integrated Control Monitoring System 2-99
4 6 1 Monitor 2-99
4 6 2 Monitor introduction 2-102
4 6 3 Monitor operation 2-104
5 Standard Values
5 1 Standard Values for Engine-Related Parts 5-3
5 2 Standard Values for Chassis-Related Parts 5-4
5 3 Standard Values for Electrical Parts 5-10
6 Testing and Adjusting
6 1 Engine Speed – Test 6-3
6 2 Exhaust Gas Color – Test 6-4
6 2 1 Test with a portable smoke tester 6-4
6 2 2 Test with a smokemeter 6-4
6 3 Valve Clearance – Adjust 6-6
6 4 Compression Pressure – Test 6-8
6 5 Injection Timing – Test and Adjust 6-9
6 6 Oil Pressure – Test 6-11
6 7 Alternator Belt Tension – Test and Adjust 6-12
6 7 1 Testing 6-12
6 7 2 Adjusting 6-12
6 8 Fuel Control Lever – Adjust 6-13
6 9 Hydraulic Pressure in Oil Circuits – Test and Adjust 6-14
6 9 1 Testing 6-14
6 9 2 Adjusting the main relief valve 6-14
6 10 LS Differential Pressure and Flow Control Valve – Test and Adjust 6-15
6 10 1 Measure LS differential pressure 6-15
6 10 2 Adjust f ow control valve 6-15
6 11 Hydraulic Pressure in Control Circuit – Test 6-16
6 12 Solenoid Valve Outlet Pressure – Test 6-17
6 13 Pilot Valve Output Pressure – Test 6-18
6 14 Work Equipment and Swing Pilot Valve – Adjust 6-19
6 15 Travel Deviation – Test 6-20
6 16 Internal Oil Leakage – Test 6-21
6 16 1 Work equipment cylinder 6-21
6 16 2 Swing motor 6-23
6 16 3 Travel motor 6-23
6 17 Residual Pressure in Hydraulic Circuit – Relieve 6-24
6 18 Swing Bearing Clearance – Check 6-24
6 19 Track Tension – Check and Adjust 6-25
6 19 1 Checking 6-25
6 19 2 Adjusting 6-26
6 20 Air Bleeding 6-27
7 Troubleshooting
7 1 Troubleshooting Precautions 7-3
7 2 Electric Circuit Troubleshooting Precautions 7-5
7 3 Checks Before Troubleshooting 7-6
7 4 Connector Locations and System Circuit Diagram 7-7
7 5 Number of Pins Required For Connection 7-10
7 6 Troubleshooting with a Fault Code 7-16
7 7 Failure Mode and Diagnostic Chart 7-17
7 7 1 How to use the diagnostic chart 7-19
7 7 2 How to use troubleshooting table 7-20
7 8 Troubleshooting of Electrical System 7-21
7 9 Troubleshooting of Engine 5-28
7 10 Troubleshooting of Hydraulic and Mechanical System 5-55
7 11 Troubleshooting of Machine Monitoring System 5-81
8 Disassembly and Assembly
8 1 Operation Precautions 8-7
8 2 Engine and Main Pump AS – Removal and Installation 8-11
8 2 1 Removal 8-11
8 2 2 Installation 8-17
8 3 Radiator AS – Removal and Installation 8-18
8 3 1 Removal 8-18
8 3 2 Installation 8-20
8 4 Fuel Tank AS – Removal and Installation 8-21
8 4 1 Removal 8-21
8 4 2 Installation 8-22
8 5 Swivel Joint AS – Removal and Installation 8-23
8 5 1 Removal 8-23
8 5 2 Installation 8-24
8 6 Swivel Joint AS – Disassembly and Assembly 8-25
8 6 1 Disassembly 8-25
8 6 2 Assembly 8-25
8 7 Sprocket – Removal and Installation 8-26
8 7 1 Removal 8-26
8 7 2 Installation 8-27
8 8 Travel Motor AS – Removal and Installation 8-28
8 8 1 Removal 8-28
8 8 2 Installation 8-29
8 9 Disassembly and Assembly of Travel Motor (GM09VN) 8-30
8 9 1 Sectional view of the travel motor assembly 8-30
8 9 2 Exploded view of reducer assembly 8-32
8 9 3 Exploded view of hydraulic motor assembly 8-33
8 9 4 Parts catalogue 8-34
8 9 5 Tools 8-35
8 9 6 Tightening torques 8-42
8 9 7 Table of weights 8-42
8 9 8 Disassembly 8-43
8 9 9 Table of maintenance standard 8-69
8 9 10 Assembly 8-71
8 9 11 Table of dimensions for clearance adjustable parts 8-98
8 9 12 Conf rmation of performance test 8-99
8 10 Swing Motor and Swing Mechanism AS – Removal and Installation 8-100
8 10 1 Removal 8-100
8 10 2 Installation 8-101
8 11 Swing Motor AS – Disassembly and Assembly 8-102
8 11 1 Disassembly 8-102
8 11 2 Assembly 8-110
8 12 Swing Mechanism AS – Disassembly and Assembly 8-119
8 12 1 Disassembly 8-119
8 12 2 Assembly 8-122
8 13 Swing Platform AS – Removal and Installation 8-126
8 13 1 Removal 8-126
8 13 2 Installation 8-128
8 14 Swing Bearing AS – Removal and Installation 8-129
8 14 1 Removal 8-129
8 14 2 Installation 8-129
8 15 Idler Wheel and Tension Spring AS – Removal and Installation 8-130
8 15 1 Removal 8-130
8 15 2 Installation 8-130
8 16 Tension Spring AS – Disassembly and Assembly 8-131
8 16 1 Disassembly 8-131
8 16 2 Assembly 8-133
8 17 Idler Wheel AS – Disassembly and Assembly 8-134
8 17 1 Disassembly 8-134
8 17 2 Assembly 8-135
8 18 Track Roller AS – Removal and Installation 8-138
8 18 1 Removal 8-138
8 18 2 Installation 8-139
8 19 Track Roller AS – Disassembly and Assembly 8-140
8 19 1 Disassembly 8-140
8 19 2 Assembly 8-143
8 20 Carrier Roller AS – Removal and Installation 8-146
8 20 1 Removal 8-146
8 20 2 Installation 8-146
8 21 Track Shoe AS – Removal and Installation 8-147
8 21 1 Removal 8-147
8 21 2 Installation 8-148
8 22 Hydraulic Tank AS – Removal and Installation 6-149
8 22 1 Removal 6-149
8 22 2 Installation 6-151
8 23 Main Pump AS – Removal and Installation 6-152
8 23 1 Removal 6-152
8 23 2 Installation 6-153
8 24 Main Pump Input Shaft Oil Seal – Removal and Installation 6-154
8 24 1 Removal 6-154
8 24 2 Installation 6-154
8 25 Control Valve AS – Removal and Installation 6-155
8 25 1 Removal 6-155
8 25 2 Installation 6-156
8 26 Control Valve AS – Disassembly and Assembly 6-157
8 26 1 Disassembly 6-157
8 26 2 Assembly 6-162
8 27 Oil Source Control Valve AS – Removal and Installation 6-168
8 27 1 Removal 6-168
8 27 2 Installation 6-169
8 28 Left Pilot Valve AS – Removal and Installation 6-170
8 28 1 Removal 6-170
8 28 2 Installation 6-170
8 29 Right Pilot Valve AS – Removal and Installation 6-171
8 29 1 Removal 6-171
8 29 2 Installation 6-171
8 30 Work Equipment Pilot Valve AS – Disassembly and Assembly 6-172
8 30 1 Disassembly 6-172
8 30 2 Assembly 6-173
8 31 Travel Pilot Valve AS – Removal and Installation 6-175
8 31 1 Removal 6-175
8 31 2 Installation 6-175
8 32 Travel Pilot Valve AS – Disassembly and Assembly 6-176
8 32 2 Disassembly 6-176
8 32 1 Assembly 6-176
8 33 Boom Cylinder AS – Removal and Installation 6-177
8 33 1 Removal 6-177
8 33 2 Installation 6-178
8 34 Arm Cylinder AS – Removal and Installation 6-179
8 34 1 Removal 6-179
8 34 2 Installation 6-180
8 35 Bucket Cylinder AS – Removal and Installation 6-182
8 35 1 Removal 6-182
8 35 2 Installation 6-183
8 36 Dozer blade Cylinder AS – Removal and Installation 6-185
8 36 1 Removal 6-185
8 36 2 Installation 6-186
8 37 Hydraulic Cylinder AS – Disassembly and Assembly 6-187
8 37 1 Disassembly 6-187
8 37 2 Assembly 6-191
8 38 Work Equipment AS – Removal and Installation 6-194
8 38 1 Removal 6-194
8 38 2 Installation 6-195
8 39 Bucket AS – Removal and Installation 6-197
8 39 1 Removal 6-197
8 39 2 Installation 6-198
8 40 Arm AS – Removal and Installation 6-199
8 40 1 Removal 6-199
8 40 2 Installation 6-200
8 41 Bucket and Arm AS – Removal and Installation 6-201
8 41 1 Removal 6-201
8 41 2 Installation 6-202
8 42 Boom AS – Removal and Installation 6-203
8 42 1 Removal 6-203
8 42 2 Installation 6-205
8 43 Blade AS – Removal and Installation 6-206
8 43 1 Removal 6-206
8 43 2 Installation 6-207
8 44 Cab AS – Removal and Installation 6-208
8 44 1 Removal 6-208
8 44 2 Installation 6-211
8 45 Counterweight AS – Removal and Installation 6-212
8 45 1 Removal 6-212
8 45 2 Installation 6-213
8 46 Monitor – Removal and Installation 6-214
8 46 1 Removal 6-214
8 46 2 Installation 6-214
9 Maintenance Standard
9 1 Swing Mechanism 9-3
9 2 Swing Bearing 9-4
9 3 Track Frame 9-5
9 4 Idler Wheel 9-6
9 5 Track Roller 9-7
9 6 Track Shoe 9-8
9 7 Control Valve 9-10
9 8 Oil Source Control Valve 9-11
9 9 Swing Motor 9-12
9 10 Work Equipment and Swing Pilot Valve 9-13
9 11 Travel Pilot Valve 9-14
9 12 Work Equipment 9-15
9 12 1 Work equipment dimension 9-17
9 13 Hydraulic Cylinder 9-19
10 Miscellaneous
10 1 Hydraulic Line Layout 10-3
10 2 Hydraulic Circuit Diagram 10-4
10 3 Overall System Diagram (1/5) 10-5
10 4 Overall System Diagram (2/5) 10-6
10 5 Overall System Diagram (3/5) 10-7
10 6 Overall System Diagram (4/5) 10-8
10 7 Overall System Diagram (5/5) 10-9
10 8 Electrical Circuit Diagram 10-10
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