Sany SY80U Crawler Hydraulic Excavator Maintenance Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Sany SY80U Crawler Hydraulic Excavator Maintenance Manual – PDF DOWNLOAD
1.Preface
1.1 Reading Method of Maintenance Manual
• Some accessories and optional parts covered in this manual may not be transported to particular areas.
Please consult your local Sany authorized dealers if required.
• Materials and technical specifications are subject to change without prior notice.
1. Composition of shop manual
This manual contains technical information necessary for maintenance in workshops. To facilitate the
understanding, this manual is divided into the following:
Preface
This chapter introduces the main content of this manual, how to use it and the basic reference information
of other chapters.
Safety
This chapter covers the meanings of safety signs contained herein and the basic safety information involved
in equipment maintenance.
Technical Specifications
This chapter introduces the machine performance, main parameters and related information.
Structure, function and maintenance standard
This chapter provides a structure description of each system, and explains the operating principle of
each system or part and the maintenance standard of each part.
Standard value of components
This chapter lists the standard values of parts of a new machine as a criteria and guidance for testing,
adjustment and troubleshooting.
Trouble diagnosis and troubleshooting
This chapter sets forth the method to identify and repair the parts in trouble. The trouble diagnosis is
classified into several trouble modes.
Dismantlement and installation
This chapter sets forth the special tools, procedures and notices for dismantling, installing, disassembling
and assembling every component. In addition, the tightening torque as well as the quantity and weight
of coating, engine oil, lubricating grease and coolant required for operation are also set forth.
Hydraulic and Electrical Diagrams
This chapter mainly gives the hydraulic circuit diagram and the circuit diagram.
2. Amendment and Issuance
Any additions, modifications or changes to other precautions will be forwarded to our designated dealers.
Make sure to obtain the latest information before you begin any work.
3. Archiving Method
The manual shall indicate the reference number on the back cover according to Sany Reference Version
Management System, and shall be bound in a volume and kept on file in the reference room.
● Mark of Revision
Add 1 to the accumulated version number in the reference number when a manual is revised.
4. Symbols
TABLE OF CONTENTS:
Sany SY80U Crawler Hydraulic Excavator Maintenance Manual – PDF DOWNLOAD
1 Preface1-1
11 Reading Method of Maintenance Manual 1-3
12 Explanation on Terms for Maintenance Standards 1-4
13 Handling of Electrical Component and Hydraulic Components 1-6
131 Overview 1-6
132 Notices for handling of electrical components 1-7
133 Precautions for treatment of hydraulic components 1-15
14 Pipe fitting 1-17
141 Overview 1-17
142 Type of pipe fitting 1-18
143 Tightening torque of pipe fitting 1-18
144 Connection of O-rings 1-19
15 Table of Tightening Torque for Bolts and Nuts 1-19
16 Bolt type 1-20
17 Bolt tightening sequence 1-21
18 Maintenance of Split Flnges 1-21
181 Overview 1-21
182 Table of Tightening Torques of Split Flange Bolts 1-22
19 Conversion Table 1-23
2 Safety 2-1
21 Instructions for safety decals 2-5
211 Overview 2-5
212 Safety Signals 2-5
213 Other signal 2-5
22 General Notices 2-6
221 Overview 2-6
222 Safety Regulations 2-7
223 Keeping the Work Area Tidy and Clean 2-8
224 Storage of Liquid 2-8
225 Cleaning of Part 2-9
226 Cleaning of this Machine 2-9
227 Reasonable Dressing 2-10
228 Personal protective equipment (PPE) 2-10
229 Correct use of tools 2-11
2210 Fire extinguisher and emergency exit 2-11
23 Preparatory Work before Maintenance 2-12
231 Preparation before Operation 2-12
232 Warning sign plate 2-13
233 Self-preparation 2-14
24 Notices for Maintenance/Repair 2-15
241 Operation during Engine Running 2-15
242 Dismantlement of Machine Accessories 2-16
243 Operation under Machine 2-16
244 Adding or Replacement of Oil 2-17
245 Alignment of Components 2-17
246 When Using Hammer 2-18
247 When Using Compressed Air 2-18
248 Welding Operation 2-18
249 Tensioning Spring 2-19
2410 Safe Operation of High Pressure Hose 2-19
2411 Be Careful for High Pressure Liquid 2-20
2412 Hot Coolant 2-21
2413 Air conditioning system 2-21
2414 Safe Use of Electricity 2-22
2415 Interruption of Power Supply for System 2-22
2416 Handling of Battery 2-23
2417 Accumulator 2-23
2418 Prevent Fire Hazard and Explosion 2-24
2419 Correct Disposal of Waste 2-25
25 Other Notices 2-25
251 Notices for Lifting Operation and Signaling 2-25
252 Notices for Use of Movable Crane 2-27
253 Notices for Use of Overhead Crane 2-27
254 Selection of Steel Wirerope 2-28
3 Technical Specifications3-1
31 Specified Size 3-3
311 Overall Dimensions 3-3
312 Working Ranges 3-4
32 Technical Specifications 3-5
33 Table of Weight 3-6
34 Capacity Table 3-7
35 Engine oil, Fuel and Coolant 3-7
36 Feature Curve of Engine 3-8
4 Structure and Function 4-1
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 Powertrain 4-7
422 Drive reducer assembly (GT40D50B-F1H1U) 4-7
423 Swing reduction mechanism 4-9
424 Swing bearing 4-10
43 Lower structure 4-11
431 Track frame 4-11
432 Guide wheel tensioning device 4-13
44 Hydraulic System, Part 1 4-15
441 Arrangement diagram of hydraulic parts 4-15
442 Hydraulic tank and filter 4-16
443 Hydraulic pump 4-16
4431 Overview 4-16
4432 Pilot pump 4-17
45 Hydraulic System, Part 2 4-18
451 Control valve 4-18
452 4-28
46 Hydraulic System, Part 3 4-33
461 Swing motor 4-33
4611 Swing motor 4-33
4612 Oil-filling One-way Valve and Safety Overflow Valve 4-38
4613 Components of Safety Valve 4-40
462 Central slewing connector 4-42
463 Running Motor 4-43
4631 Structure of Traveling Motor 4-43
4632 Work Process of Motor 4-44
4633 Work Process of Parking Brake 4-46
4634 Work Process of Brake Valve 4-47
464 Control system 4-49
465 Leading valve 4-50
4651 Manual pilot valve 4-50
4652 Traveling leading valve 4-55
466 Oil source control valve 4-59
47 Working Device 4-60
471 Part size 4-60
472 Arm size 4-62
473 Hydraulic Cylinder 4-63
474 Bucket size 4-64
48 Air Conditioning System 4-65
481 Arrangement diagram of A/C elements 4-65
482 Layout of A/C elements 4-66
483 Principle for refrigeration 4-66
484 Refrigerant 4-67
485 Compressor oil 4-83
486 Defrosting Sensor 4-84
49 Engine Control 4-85
491 Engine Control 4-85
492 Components of System 4-87
4921 Fuel control knob 4-87
4922 Engine control unit (ECU) 4-88
410 Electrical Control System 4-90
4101 Control function 4-90
41011 Warning and protection for too low engine oil pressure 4-90
41012 Warning and protection for too high engine water
temperature 4-91
41013 Control on engine preheating 4-92
4102 System components 4-93
41021 Pump pressure sensor 4-93
41022 Leading pressure sensor 4-94
41023 Fuel oil level sensor 4-95
411 Display System 4-96
4111 Overview of display screen 4-96
4112 Fault inquiry 4-98
4113 Maintenance operations 4-102
4114 Replacement of display screen 4-103
5 Standard Value of Components 5-1
51 Table of standard values for engine-related parts 5-3
52 Table for Standard Value of Body-related Parts 5-5
6 Testing and Adjusting 6-1
61 Overview 6-5
62 Measurement of Engine Speed 6-5
63 Measurement of Color of Exhaust Gas 6-6
64 Adjust the valve clearance 6-8
65 Measurement of Compression Pressure 6-10
66 Testing and Adjustment of Injection Timing 6-10
67 Measurement of engine oil pressure 6-14
68 6-15
69 Testing and Adjustment of Generator Belt Tension 6-15
610 Adjustment of engine speed sensor 6-16
611 6-16
612 Measurement of clearance of slewing support bearing 6-17
613 Inspection and adjustment of crawler plate tensioning device 6-18
614 Inspection and adjustment of hydraulic pressure in hydraulic oil ways for
working device, slewing and travelling 6-20
615 Measurement of LS Differential Pressure and Adjustment of LS Valve 6-21
616 Measurement of output pressure of pilot valve 6-23
617 Adjustment of working device and slewing PPC valve 6-24
618 Measurement of Travelling Deviation 6-24
619 Inspection of hydraulic settlement of working device 6-25
620 Release of residual pressure in hydraulic oil way 6-27
621 Measurement of oil leakage 6-28
622 Air Bleeding for Every Device 6-32
623 Inspection and adjustment of oil pressure in control oil line 6-32
624 Measuring the output pressure of solenoid valve 6-33
625 Inspection of the drift of hydraulic cylinder for work equipment 6-35
626 Release of residual pressure from hydraulic lines 6-38
627 Oil Leakage Amount – Test 6-39
628 Bleeding air from each system 6-43
629 Coolant temperature sensor 6-45
7 Trouble Diagnosis and Troubleshooting 7-1
71 Trouble diagnosis and troubleshooting 7-5
72 Inspection before fault diagnosis 7-7
73 Category and steps of trouble diagnosis 7-8
731 Category of trouble diagnosis 7-8
732 Steps for trouble diagnosis 7-8
74 Trouble – Identity the symptoms and trouble diagnosis code 7-9
75 Position Diagram of Connectors and Wiring Diagram of System 7-11
751 Position Diagram of Connectors and Wiring Diagram of System 7-12
752 Connector Position Diagram 7-15
753 Wiring diagram of electrical control system (vehicle body) 7-19
754 Wiring diagram of electrical control system (control cabinet) 7-22
755 Wiring diagram of electrical control system (cab) 7-24
76 Trouble Diagnosis for Electrical System (Mode E) 7-27
761 Information contained in table of trouble diagnosis 7-27
762 E-1 The engine could not be started 7-28
763 E-2 No Power-off Delay Available for Engine 7-32
764 E-3 The automatic idling does not work 7-34
765 E-4 All devices could not work 7-36
766 E-7 The boom lifting is slow and powerless 7-37
767 E-6 The dual running speed function does not work 7-38
768 E-7 The wiper does not work 7-39
77 Trouble diagnosis for hydraulic and mechanical systems (mode H) 7-40
771 All working attachments, back slewing and travelling are slow or
powerless 7-40
772 The engine speed reduces sharply or the engine stalls 7-41
773 All working attachments, travelling and back slewing don’t move 7-41
774 There is abnormal noise (near the pump) 7-42
775 The precise control performance is poor or the sensitivity is low 7-42
776 The boom moves slowly or is powerless 7-42
777 The bucket arm moves slowly or is powerless 7-44
778 The bucket moves slowly or is powerless 7-46
779 The working attachment (boom, bucket arm, bucket) does not act (but the
travelling and back slewing are normal) 7-46
7710 The hydraulic drifting is too large (boom, bucket arm, bucket) 7-47
7711 In combined operation, the working attachment with larger load moves
slowly 7-47
7712 In combined operation of back slewing +boom lifting, the boom lifting
action is slow 7-48
7713 In travelling +back slewing operation, the travelling speed reduces
excessively 7-48
7714 During travelling, this machine can’t travel in a straight line 7-48
7715 At the beginning, the travelling deviation is relatively large 7-50
7716 The travelling is slow or powerless 7-50
7717 The steering operation is difficult 7-51
7718 The travelling speed can’t be changed 7-52
7719 The travelling can’t be realized (only at one side) 7-52
7720 No Slewing 7-53
7721 The back slewing acceleration is abnormal 7-54
7722 When the back slewing stops, the limit is exceeded excessively (at both
sides, only at one side) 7-55
7723 When the back slewing stops, the shaking is serious (only in one
direction) 7-55
7724 When the back slewing stops, the abnormal noise is too large (only in
one direction) 7-56
7725 The hydraulic drifting of back slewing is too large (when the back
slewing brake is released or applied) 7-56
7726 The back slewing speed is higher than the specified speed 7-57
7727 The bulldozing shovel moves slowly or powerless 7-57
7728 The bulldozing shovel does not move 7-57
7729 The hydraulic drifting of bulldozing shovel is too large 7-58
8 Removal and Installation 8-1
81 Operating Precautions 8-5
82 Removal and installation of radiator assembly 8-7
83 Removal and installation of engine and hydraulic pump assembly 8-8
84 Removal and installation of final drive assembly 8-14
85 Disassembly and reassembly of final drive assembly 8-17
86 Removal and installation of swing motor and swing mechanism assembly 8-26
87 Dismantlement and Installation of Dozer Blade Assemblies 8-27
88 Disassembly and reassembly of swing motor and swing mechanism assembly 8-28
89 Dismantlement of Back slewing Bearing Assembly 8-38
810 Dismantlement and installation of central slewing joint assembly 8-39
811 Disassembling and Assembling of Central Back slewing Joint Assembly 8-40
812 Dismantlement and Installation of Travelling Motor Assembly 8-40
813 Dismantlement and installation of slewing motor and slewing mechanism
assembly 8-42
814 Disassembling and assembling of slewing motor and slewing mechanism
assembly 8-43
815 Dismantlement and Installation of Main Pump Assemblies 8-64
816 Removal and Installation of Control Valve Assembly 8-65
817 Installation of Back slewing Bearing Assembly 8-66
818 Dismantlement of Crawler Plate Assembly 8-66
819 Installation of Crawler Plate Assembly 8-67
820 Dismantlement of Guide Wheel & Tensioning Spring Assembly 8-68
821 Installation of Guide Wheel & Tensioning Spring Assembly 8-68
822 Disassembling of Tensioning Spring Assembly 8-69
823 Assembling of Tensioning Spring Assembly 8-70
824 Disassembling of Guide Wheel Assembly 8-71
825 Assembling of Guide Wheel Assembly 8-72
826 Dismantlement of Supporting Wheel Assembly 8-75
827 Installation of Supporting Wheel Assembly 8-75
828 Disassembling of Supporting Wheel Assembly 8-76
829 Assembling of Supporting Wheel Assembly 8-79
830 Dismantlement of Supporting Sprocket Wheel Assembly 8-82
831 Installation of Supporting Sprocket Wheel Assembly 8-83
832 Dismantlement of Sprocket Wheel 8-83
833 Installation of Sprocket Wheel 8-84
834 Removal and installation of turntable assembly 8-84
835 Removal and installation of center swivel joint assembly 8-88
836 Disassembly and reassembly of center swivel joint assembly 8-91
837 Removal and installation of hydraulic tank assembly 8-93
838 Removal and installation of control valve assembly 8-95
839 Removal and installation of hydraulic pump assembly 8-100
840 Removal and installation of oil seal in the input shaft of hydraulic
pump 8-104
841 Disassembly and reassembly of pilot valve assembly of work equipment 8-104
842 Disassembly and reassembly of travel pilot valve assembly 8-106
843 Disassembly and reassembly of hydraulic cylinder assembly 8-107
844 Removal and installation of work equipment assembly 8-117
845 Removal and installation of HVAC assembly 8-120
846 Removal and installation of counterweight assembly 8-124
847 Removal and installation of cab assembly 8-126
848 Removal and installation of cab windows 8-130
849 Removal and installation of front window assembly 8-145
850 Removal and installation of display 8-155
851 Removal and installation of controller assembly 8-155
852 Installation and removal of radio 8-156
853 Battery 8-158
854 Ignition key switch 8-161
855 Fuse box 8-164
856 Wiper 8-165
857 Relay 8-167
858 Sensor 8-170
859 Terminal insertion and removal 8-171
9 Hydraulic and Electrical Diagrams9-1
91 Wiring diagram of electrical control system (vehicle body) 9-4
92 Wiring diagram of electrical control system (control cabinet) 9-7
93 Wiring diagram of electrical control system (cab) 9-9
94 Diagram of hydraulic oil way 9-12
95 A/C Wiring Diagram 9-13
1 Preface1-1
11 Reading Method of Maintenance Manual 1-3
12 Explanation on Terms for Maintenance Standards 1-4
13 Handling of Electrical Component and Hydraulic Components 1-6
131 Overview 1-6
132 Notices for handling of electrical components 1-7
133 Precautions for treatment of hydraulic components 1-15
14 Pipe fitting 1-17
141 Overview 1-17
142 Type of pipe fitting 1-18
143 Tightening torque of pipe fitting 1-18
144 Connection of O-rings 1-19
15 Table of Tightening Torque for Bolts and Nuts 1-19
16 Bolt type 1-20
17 Bolt tightening sequence 1-21
18 Maintenance of Split Flnges 1-21
181 Overview 1-21
182 Table of Tightening Torques of Split Flange Bolts 1-22
19 Conversion Table 1-23
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
