Sany SY80U Crawler Hydraulic Excavator Maintenance Manual 20200608 – PDF DOWNLOAD
FILE DETAILS:
Sany SY80U Crawler Hydraulic Excavator Maintenance Manual 20200608 – PDF DOWNLOAD
Language : English
Pages : 497
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Sany SY80U Crawler Hydraulic Excavator Maintenance Manual 20200608 – PDF DOWNLOAD
1 Preface 1-1
1 1 Reading Method of Maintenance Manual 1-3
1 2 Explanation on Terms for Maintenance Standards 1-4
1 3 Handling of Electrical Component and Hydraulic Components 1-6
1 3 1 Overview 1-6
1 3 2 Notices for handling of electrical components 1-7
1 3 3 Precautions for treatment of hydraulic components 1-15
1 4 Pipe fitting 1-17
1 4 1 Overview 1-17
1 4 2 Type of pipe fitting 1-18
1 4 3 Tightening torque of pipe fitting 1-18
1 4 4 Connection of O-rings 1-19
1 5 Table of Tightening Torque for Bolts and Nuts 1-19
1 6 Bolt type 1-20
1 7 Bolt tightening sequence 1-21
1 8 Maintenance of Split Flnges 1-21
1 8 1 Overview 1-21
1 8 2 Table of Tightening Torques of Split Flange Bolts 1-22
1 9 Conversion Table 1-23
2 Safety 2-1
2 1 Instructions for safety decals 2-5
2 1 1 Overview 2-5
2 1 2 Safety Signals 2-5
2 1 3 Other signal 2-5
2 2 General Notices 2-6
2 2 1 Overview 2-6
2 2 2 Safety Regulations 2-7
2 2 3 Keeping the Work Area Tidy and Clean 2-8
2 2 4 Storage of Liquid 2-8
2 2 5 Cleaning of Part 2-9
2 2 6 Cleaning of this Machine 2-9
2 2 7 Reasonable Dressing 2-10
2 2 8 Personal protective equipment (PPE) 2-10
2 2 9 Correct use of tools 2-11
2 2 10 Fire extinguisher and emergency exit 2-11
2 3 Preparatory Work before Maintenance 2-12
2 3 1 Preparation before Operation 2-12
2 3 2 Warning sign plate 2-13
2 3 3 Self-preparation 2-14
2 4 Notices for Maintenance/Repair 2-15
2 4 1 Operation during Engine Running 2-15
2 4 2 Dismantlement of Machine Accessories 2-16
2 4 3 Operation under Machine 2-16
2 4 4 Adding or Replacement of Oil 2-17
2 4 5 Alignment of Components 2-17
2 4 6 When Using Hammer 2-18
2 4 7 When Using Compressed Air 2-18
2 4 8 Welding Operation 2-18
2 4 9 Tensioning Spring 2-19
2 4 10 Safe Operation of High Pressure Hose 2-19
2 4 11 Be Careful for High Pressure Liquid 2-20
2 4 12 Hot Coolant 2-21
2 4 13 Air conditioning system 2-21
2 4 14 Safe Use of Electricity 2-22
2 4 15 Interruption of Power Supply for System 2-22
2 4 16 Handling of Battery 2-23
2 4 17 Accumulator 2-23
2 4 18 Prevent Fire Hazard and Explosion 2-24
2 4 19 Correct Disposal of Waste 2-25
2 5 Other Notices 2-25
2 5 1 Notices for Lifting Operation and Signaling 2-25
2 5 2 Notices for Use of Movable Crane 2-27
2 5 3 Notices for Use of Overhead Crane 2-27
2 5 4 Selection of Steel Wirerope 2-28
3 Technical Specifications 3-1
3 1 Specified Size 3-3
3 1 1 Overall Dimensions 3-3
3 1 2 Working Ranges 3-4
3 2 Technical Specifications 3-5
3 3 Table of Weight 3-6
3 4 Capacity Table 3-7
3 5 Engine oil, Fuel and Coolant 3-7
3 6 Feature Curve of Engine 3-8
4 Structure and Function 4-1
4 1 Engine and Cooling System 4-5
4 1 1 Engine-related parts 4-5
4 1 2 Radiator and intercooler 4-6
4 2 Power Train 4-7
4 2 1 Powertrain 4-7
4 2 2 Drive reducer assembly (GT40D50B-F1H1U) 4-7
4 2 3 Swing reduction mechanism 4-9
4 2 4 Swing bearing 4-10
4 3 Lower structure 4-11
4 3 1 Track frame 4-11
4 3 2 Guide wheel tensioning device 4-13
4 4 Hydraulic System, Part 1 4-15
4 4 1 Arrangement diagram of hydraulic parts 4-15
4 4 2 Hydraulic tank and filter 4-16
4 4 3 Hydraulic pump 4-16
4 4 3 1 Overview 4-16
4 4 3 2 Pilot pump 4-17
4 5 Hydraulic System, Part 2 4-18
4 5 1 Control valve 4-18
4 5 2 4-28
4 6 Hydraulic System, Part 3 4-33
4 6 1 Swing motor 4-33
4 6 1 1 Swing motor 4-33
4 6 1 2 Oil-filling One-way Valve and Safety Overflow Valve 4-38
4 6 1 3 Components of Safety Valve 4-40
4 6 2 Central slewing connector 4-42
4 6 3 Running Motor 4-43
4 6 3 1 Structure of Traveling Motor 4-43
4 6 3 2 Work Process of Motor 4-44
4 6 3 3 Work Process of Parking Brake 4-46
4 6 3 4 Work Process of Brake Valve 4-47
4 6 4 Control system 4-49
4 6 5 Leading valve 4-50
4 6 5 1 Manual pilot valve 4-50
4 6 5 2 Traveling leading valve 4-55
4 6 6 Oil source control valve 4-59
4 7 Working Device 4-60
4 7 1 Part size 4-60
4 7 2 Arm size 4-62
4 7 3 Hydraulic Cylinder 4-63
4 7 4 Bucket size 4-64
4 8 Air Conditioning System 4-65
4 8 1 Arrangement diagram of A/C elements 4-65
4 8 2 Layout of A/C elements 4-66
4 8 3 Principle for refrigeration 4-66
4 8 4 Refrigerant 4-67
4 8 5 Compressor oil 4-83
4 8 6 Defrosting Sensor 4-84
4 9 Engine Control 4-85
4 9 1 Engine Control 4-85
4 9 2 Components of System 4-87
4 9 2 1 Fuel control knob 4-87
4 9 2 2 Engine control unit (ECU) 4-88
4 10 Electrical Control System 4-90
4 10 1 Control function 4-90
4 10 1 1 Warning and protection for too low engine oil pressure 4-90
4 10 1 2 Warning and protection for too high engine water
temperature 4-91
4 10 1 3 Control on engine preheating 4-92
4 10 2 System components 4-93
4 10 2 1 Pump pressure sensor 4-93
4 10 2 2 Leading pressure sensor 4-94
4 10 2 3 Fuel oil level sensor 4-95
4 11 Display System 4-96
4 11 1 Overview of display screen 4-96
4 11 2 Fault inquiry 4-98
4 11 3 Maintenance operations 4-102
4 11 4 Replacement of display screen 4-103
5 Standard Value of Components 5-1
5 1 Table of standard values for engine-related parts 5-3
5 2 Table for Standard Value of Body-related Parts 5-5
6 Testing and Adjusting 6-1
6 1 Overview 6-5
6 2 Measurement of Engine Speed 6-5
6 3 Measurement of Color of Exhaust Gas 6-6
6 4 Adjust the valve clearance 6-8
6 5 Measurement of Compression Pressure 6-10
6 6 Testing and Adjustment of Injection Timing 6-10
6 7 Measurement of engine oil pressure 6-14
6 8 6-15
6 9 Testing and Adjustment of Generator Belt Tension 6-15
6 10 Adjustment of engine speed sensor 6-16
6 11 6-16
6 12 Measurement of clearance of slewing support bearing 6-17
6 13 Inspection and adjustment of crawler plate tensioning device 6-18
6 14 Inspection and adjustment of hydraulic pressure in hydraulic oil ways for
working device, slewing and travelling 6-20
6 15 Measurement of LS Differential Pressure and Adjustment of LS Valve 6-21
6 16 Measurement of output pressure of pilot valve 6-23
6 17 Adjustment of working device and slewing PPC valve 6-24
6 18 Measurement of Travelling Deviation 6-24
6 19 Inspection of hydraulic settlement of working device 6-25
6 20 Release of residual pressure in hydraulic oil way 6-27
6 21 Measurement of oil leakage 6-28
6 22 Air Bleeding for Every Device 6-32
6 23 Inspection and adjustment of oil pressure in control oil line 6-32
6 24 Measuring the output pressure of solenoid valve 6-33
6 25 Inspection of the drift of hydraulic cylinder for work equipment 6-35
6 26 Release of residual pressure from hydraulic lines 6-38
6 27 Oil Leakage Amount – Test 6-39
6 28 Bleeding air from each system 6-43
6 29 Coolant temperature sensor 6-45
7 Trouble Diagnosis and Troubleshooting 7-1
7 1 Trouble diagnosis and troubleshooting 7-5
7 2 Inspection before fault diagnosis 7-7
7 3 Category and steps of trouble diagnosis 7-8
7 3 1 Category of trouble diagnosis 7-8
7 3 2 Steps for trouble diagnosis 7-8
7 4 Trouble – Identity the symptoms and trouble diagnosis code 7-9
7 5 Position Diagram of Connectors and Wiring Diagram of System 7-11
7 5 1 Position Diagram of Connectors and Wiring Diagram of System 7-12
7 5 2 Connector Position Diagram 7-15
7 5 3 Wiring diagram of electrical control system (vehicle body) 7-19
7 5 4 Wiring diagram of electrical control system (control cabinet) 7-22
7 5 5 Wiring diagram of electrical control system (cab) 7-24
7 6 Trouble Diagnosis for Electrical System (Mode E) 7-27
7 6 1 Information contained in table of trouble diagnosis 7-27
7 6 2 E-1 The engine could not be started 7-28
7 6 3 E-2 No Power-off Delay Available for Engine 7-32
7 6 4 E-3 The automatic idling does not work 7-34
7 6 5 E-4 All devices could not work 7-36
7 6 6 E-7 The boom lifting is slow and powerless 7-37
7 6 7 E-6 The dual running speed function does not work 7-38
7 6 8 E-7 The wiper does not work 7-39
7 7 Trouble diagnosis for hydraulic and mechanical systems (mode H) 7-40
7 7 1 All working attachments, back slewing and travelling are slow or
powerless 7-40
7 7 2 The engine speed reduces sharply or the engine stalls 7-41
7 7 3 All working attachments, travelling and back slewing don’t move 7-41
7 7 4 There is abnormal noise (near the pump) 7-42
7 7 5 The precise control performance is poor or the sensitivity is low 7-42
7 7 6 The boom moves slowly or is powerless 7-42
7 7 7 The bucket arm moves slowly or is powerless 7-44
7 7 8 The bucket moves slowly or is powerless 7-46
7 7 9 The working attachment (boom, bucket arm, bucket) does not act (but the
travelling and back slewing are normal) 7-46
7 7 10 The hydraulic drifting is too large (boom, bucket arm, bucket) 7-47
7 7 11 In combined operation, the working attachment with larger load moves
slowly 7-47
7 7 12 In combined operation of back slewing +boom lifting, the boom lifting
action is slow 7-48
7 7 13 In travelling +back slewing operation, the travelling speed reduces
excessively 7-48
7 7 14 During travelling, this machine can’t travel in a straight line 7-48
7 7 15 At the beginning, the travelling deviation is relatively large 7-50
7 7 16 The travelling is slow or powerless 7-50
7 7 17 The steering operation is difficult 7-51
7 7 18 The travelling speed can’t be changed 7-52
7 7 19 The travelling can’t be realized (only at one side) 7-52
7 7 20 No Slewing 7-53
7 7 21 The back slewing acceleration is abnormal 7-54
7 7 22 When the back slewing stops, the limit is exceeded excessively (at both
sides, only at one side) 7-55
7 7 23 When the back slewing stops, the shaking is serious (only in one
direction) 7-55
7 7 24 When the back slewing stops, the abnormal noise is too large (only in
one direction) 7-56
7 7 25 The hydraulic drifting of back slewing is too large (when the back
slewing brake is released or applied) 7-56
7 7 26 The back slewing speed is higher than the specified speed 7-57
7 7 27 The bulldozing shovel moves slowly or powerless 7-57
7 7 28 The bulldozing shovel does not move 7-57
7 7 29 The hydraulic drifting of bulldozing shovel is too large 7-58
8 Removal and Installation 8-1
8 1 Operating Precautions 8-5
8 2 Removal and installation of radiator assembly 8-7
8 3 Removal and installation of engine and hydraulic pump assembly 8-8
8 4 Removal and installation of final drive assembly 8-14
8 5 Disassembly and reassembly of final drive assembly 8-17
8 6 Removal and installation of swing motor and swing mechanism assembly 8-26
8 7 Dismantlement and Installation of Dozer Blade Assemblies 8-27
8 8 Disassembly and reassembly of swing motor and swing mechanism assembly 8-28
8 9 Dismantlement of Back slewing Bearing Assembly 8-38
8 10 Dismantlement and installation of central slewing joint assembly 8-39
8 11 Disassembling and Assembling of Central Back slewing Joint Assembly 8-40
8 12 Dismantlement and Installation of Travelling Motor Assembly 8-40
8 13 Dismantlement and installation of slewing motor and slewing mechanism
assembly 8-42
8 14 Disassembling and assembling of slewing motor and slewing mechanism
assembly 8-43
8 15 Dismantlement and Installation of Main Pump Assemblies 8-64
8 16 Removal and Installation of Control Valve Assembly 8-65
8 17 Installation of Back slewing Bearing Assembly 8-66
8 18 Dismantlement of Crawler Plate Assembly 8-66
8 19 Installation of Crawler Plate Assembly 8-67
8 20 Dismantlement of Guide Wheel & Tensioning Spring Assembly 8-68
8 21 Installation of Guide Wheel & Tensioning Spring Assembly 8-68
8 22 Disassembling of Tensioning Spring Assembly 8-69
8 23 Assembling of Tensioning Spring Assembly 8-70
8 24 Disassembling of Guide Wheel Assembly 8-71
8 25 Assembling of Guide Wheel Assembly 8-72
8 26 Dismantlement of Supporting Wheel Assembly 8-75
8 27 Installation of Supporting Wheel Assembly 8-75
8 28 Disassembling of Supporting Wheel Assembly 8-76
8 29 Assembling of Supporting Wheel Assembly 8-79
8 30 Dismantlement of Supporting Sprocket Wheel Assembly 8-82
8 31 Installation of Supporting Sprocket Wheel Assembly 8-83
8 32 Dismantlement of Sprocket Wheel 8-83
8 33 Installation of Sprocket Wheel 8-84
8 34 Removal and installation of turntable assembly 8-84
8 35 Removal and installation of center swivel joint assembly 8-88
8 36 Disassembly and reassembly of center swivel joint assembly 8-91
8 37 Removal and installation of hydraulic tank assembly 8-93
8 38 Removal and installation of control valve assembly 8-95
8 39 Removal and installation of hydraulic pump assembly 8-100
8 40 Removal and installation of oil seal in the input shaft of hydraulic
pump 8-104
8 41 Disassembly and reassembly of pilot valve assembly of work equipment 8-104
8 42 Disassembly and reassembly of travel pilot valve assembly 8-106
8 43 Disassembly and reassembly of hydraulic cylinder assembly 8-107
8 44 Removal and installation of work equipment assembly 8-117
8 45 Removal and installation of HVAC assembly 8-120
8 46 Removal and installation of counterweight assembly 8-124
8 47 Removal and installation of cab assembly 8-126
8 48 Removal and installation of cab windows 8-130
8 49 Removal and installation of front window assembly 8-145
8 50 Removal and installation of display 8-155
8 51 Removal and installation of controller assembly 8-155
8 52 Installation and removal of radio 8-156
8 53 Battery 8-158
8 54 Ignition key switch 8-161
8 55 Fuse box 8-164
8 56 Wiper 8-165
8 57 Relay 8-167
8 58 Sensor 8-170
8 59 Terminal insertion and removal 8-171
9 Hydraulic and Electrical Diagrams 9-1
9 1 Wiring diagram of electrical control system (vehicle body) 9-4
9 2 Wiring diagram of electrical control system (control cabinet) 9-7
9 3 Wiring diagram of electrical control system (cab) 9-9
9 4 Diagram of hydraulic oil way 9-12
9 5 A/C Wiring Diagram 9-13
S.S 07/24
