Sany SY35U Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD

Description

Sany SY35U Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD

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DESCRIPTION:

Sany SY35U Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD

1 INTRODUCTION
1.1 How to Read the Manual

? Some attachments and optional parts presented in this shop manual may not be delivered to certain areas. Consult your Sany distributor if any of them is required.
? Materials and specif cations are subject to change without notice

1.1.1 Shop manual organization

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

TABLE OF CONTENTS:

Sany SY35U Crawler Hydraulic Excavator Shop Manual – PDF DOWNLOAD

1 Introduction
11 How to Read the Manual 1-3
111 Shop manual organization 1-3
112 Revision and distribution 1-4
113 Symbols 1-5
114 Units 1-5
12 Technical Terms 1-6
121 Standard size and tolerance 1-6
122 Standard clearance and value 1-7
123 Standard interference 1-7
124 Repair limit and allowable value 1-8
125 Clearance limit 1-8
126 Interference limit 1-8
13 Handling Electrical and Hydraulic Components 1-9
131 Points to remember when handling electric components 1-9
1311 Handling wiring harnesses and connectors 1-9
1312 Main failures occurring in wiring harness 1-10
1313 Removing, installing, and drying connectors and wiring harnesses 1-12
1314 Handling the integrated control monitor 1-16
1315 Electric circuits troubleshooting precautions 1-17
132 Points to remember when handling hydraulic equipment 1-18
1321 Be careful of the operating environment 1-18
1322 Disassembly and maintenance work in the field 1-18
1323 Sealing openings 1-18
1324 Do not let any dirt or dust get in during refilling operations 1-19
1325 Change hydraulic oil when the temperature is high 1-19
1326 Flushing operations 1-19
1327 Cleaning operations 1-20
14 Hose Connector 1-20
141 Type of hose connector 1-21
142 Hose connector tightening torque table 1-21
143 Connection of O-rings 1-22
15 Table of Standard Tightening Torques 1-23
16 Type of Bolts 1-24
17 Tightening Sequence 1-24
18 Maintenance of Half Flanges 1-25
181 Table of tightening torques for half flange bolts 1-25
182 Temperature 1-31
2 Shop Safety
21 Hazard Alert Information 2-3
22 General Shop Safety 2-5
221 Rules and shop behavior 2-6
222 Housekeeping 2-6
223 Shop Liquids Storage 2-7
224 Cleaning the Parts 2-7
225 Cleaning the Machine 2-8
226 Appropriate Working Apparel 2-8
227 Personal Protective Equipment 2-8
228 Using the Correct Tools 2-9
229 Fire Extinguisher and Emergency Exits 2-9
2210 Electrical Dangers 2-10
2211 Hoisting a Load 2-10
23 Before Repair2-11
231 Safe Work Preparations 2-11
232 Preparing yourself 2-12
233 Lockout/Tagout 2-13
234 Two people when engine running 2-15
235 Safety Partners 2-15
24 Repair Precautions 2-16
241 Running the Machine 2-16
242 Mounting and Dismounting 2-17
243 Removing Attachments 2-18
244 Jacking Up the Machine 2-18
245 Adding Fluids to a System 2-18
246 Aligning Parts or Components 2-19
247 Driving Pins 2-19
248 When compressed air is used 2-19
249 Welding operation
2410 Track Recoil Springs 2-20
2411 High-Pressure Fluid Lines 2-21
2412 Air-conditioning system maintenance 2-22
2413 High voltage precautions 2-22
2414 Disconnecting the System Power 2-23
2415 Accumulator 2-23
2417 Battery Hazards 2-24
2418 Jump-Start Safety 2-25
2419 Avoiding fire and explosion 2-26
2420 Chemical hazard 2-27
2421 Material Safety Data Sheets (MSDS) 2-27
2422 Proper disposal of wastes 2-28
25 Other Precautions 2-29
251 Sling work and giving signals 2-29
252 Using mobile crane 2-31
253 Using overhead hoist crane 2-31
254 Selecting wire ropes 2-33
3 Specifications
31 Dimension Drawing 3-3
32 Working Ranges 3-4
33 Technical Specifications 3-5
34 Weight Table 3-7
35 Capacity Table 3-8
36 Fuel and Coolant Capacities 3-9
37 Engine Performance Curve 3-10
4 Structure and Functions
41 Engine and Cooling System 4-3
411 Water cooler and oil cooler 4-3
412 Engine control device 4-5
42 Power Train 4-7
421 Power transmission system 4-7
422 Swing bearing 4-8
423 Swing motor 4-9
43 Undercarriage 4-10
431 Track frame 4-10
432 Tensioning device 4-11
433 Tensioning device 4-12
44 Hydraulic System 4-13
441 Hydraulic lines 4-13
442 Hydraulic tank 4-14
443 Hydraulic pump 4-15
444 Control valve 4-24
445 Load sensitive system 4-28
4451 Operation and parameter of each function 4-31
4452 Operation of the whole system 4-41
446 Swing motor 4-51
447 Safety valve 4-55
448 Central swivel joint 4-57
449 Travel motor 4-58
4491 Working process of parking brake 4-61
4492 Working process of brake valve 4-62
4410 Control system 4-64
4411 Pilot valve 4-65
4412 Travel pilot valve 4-71
4413 Oil source control valve 4-75
4414 Backup pilot valve 4-76
4415 Hydraulic cylinders 4-80
45 Air Conditioner System 4-81
451 Electric circuit 4-81
452 Component locations 4-82
453 Checking condenser fins 4-84
454 Refrigerant-filling operation 4-85
455 Troubleshooting with a manifold pressure gauge 4-86
46 Electrical System 4-95
461 Electrical circuit diagram 4-97
47 Electronic Control System 4-99
471 General view 4-99
472 Functional overview of electrical control system 4-100
473 Engine control function 4-101
474 Valve control function 4-103
475 Auto deceleration function 4-104
476 Manual preheating and overheating protection function 4-106
477 Travel speed selection 4-108
478 Machine monitoring system 4-109
48 Integrated-controlled Monitor System 4-111
481 Monitor 4-111
482 Page introduction and operation 4-114
4821 Main menu 4-114
4822 Alert information 4-115
4823 History fault information 4-116
4824 System information 4-116
4825 Maintenance information 4-117
4826 GPS monitoring and rpm calibration 4-117
4827 Machine configuration setup 4-118
4828 System lockout 4-119
4829 Password entry 4-120
48210 System lockout 4-121
48211 One-key call 4-122
5 Standard Values
51 Standard Values for Engine-Related Parts 5-3
52 Standard Values for Chassis-Related Parts 5-4
53 Standard Values for Electrical Parts 5-11
6 Testing and Adjusting
61 Engine Speed – Test 6-4
62 Exhaust Gas Color – Test 6-5
621 Using a hand tester 6-5
622 Using an instrument 6-6
63 Valve Clearance – Adjust 6-7
64 Compression Pressure – Test 6-8
65 Injection Timing – Test and Adjust 6-9
651 Checking injection timing 6-9
652 Adjusting the injection timing 6-12
66 Engine Oil Pressure – Test 6-13
67 Alternator Belt Tension – Test and Adjust 6-13
68 Hydraulic Pressure in Oil Circuits – Test and Adjust 6-14
69 LS Differential Pressure and LS Valve – Test/Adjust 6-16
691 Testing LS differential pressure 6-16
692 Adjusting LS valve 6-17
610 Hydraulic Pressure in Control Circuit – Test 6-18
611 Pilot Valve Output Pressure – Test 6-19
612 Work Equipment and Swing Pilot Valve – Adjust 6-20
613 Travel Deviation – Test 6-21
614 Oil Leakage – Test 6-22
6141 Work equipment cylinder 6-22
6142 Swing motor 6-24
6143 Travel motor 6-25
615 Residual Pressure in Hydraulic Circuit – Release 6-26
616 Swing Bearing Clearance – Check 6-27
617 Track Tension – Check and Adjust 6-28
6171 Checking track tension 6-28
6172 Adjusting track tension 6-28
61721 When the tension is high 6-28
61722 When the tension is low 6-29
618 Air Purging 6-30
6181 Purging air from hydraulic pump 6-30
6182 Purging air from hydraulic cylinder 6-31
6183 Purging air from swing motor 6-31
6184 Purging air from travel motor 6-31
7 Troubleshooting
71 Troubleshooting Precautions 7-3
72 Checks Before Troubleshooting 7-5
73 Connector Locations and System Diagrams 7-6
74 Number of Pins Required for Connection 7-9
75 Electric Wire Specifications 7-16
76 How to Use the Judgement Chart 7-18
77 How to Use a Schematic Diagram for Troubleshooting 7-20
78 Troubleshooting the Electrical System 7-21
79 Troubleshooting the Engine 7-28
710 Troubleshooting the Hydraulic and Mechanical System 7-53
8 Disassembly and Assembly
81 Operating Precautions 8-7
82 Engine and Main Pump AS 8-10
821 Removal 8-10
822 Installation 8-15
83 Central Swivel Joint AS 8-16
831 Removal 8-16
832 Installation 8-17
833 Disassembly 8-18
834 Assembly 8-18
84 Sprocket 8-19
841 Removal 8-19
842 Installation 8-19
85 Travel Motor AS 8-20
851 Removal 8-20
852 Installation 8-21
853 Sectional view of travel motor 8-22
854 An exploded view of the reducer 8-24
855 An exploded view of the reduction device AS 8-25
856 An exploded view of the hydraulic motor AS 8-26
857 Parts catalogue 8-27
858 Disassembly 8-29
8581 Preparatory work 8-29
8582 General precautions for disassembling 8-29
8583 Disassembling procedure 8-30
859 Table of maintenance standard 8-40
8510 Assembly 8-43
85101 Preparatory work 8-43
85102 General precautions 8-43
85103 Assembly procedure 8-44
85104 Performance test 8-58
86 Swing Motor and Swing Mechanism AS 8-59
861 Removal 8-59
862 Installation 8-60
87 Swing Motor AS 8-61
871 Disassembly 8-61
8711 Separation of motor from reducer 8-61
8712 Motor disassembly 8-61
8713 Disassembling the reducer 8-67
8714 Assembling the motor 8-70
8715 Assemble the reducer 8-78
8716 Assembling the swing motor assembly 8-82
88 Swing Mechanism AS 8-83
881 Disassembly 8-83
882 Assembly 8-86
89 Swing Platform AS 8-90
891 Removal 8-90
892 Installation 8-92
810 Swing Bearing AS 8-93
8101 Removal 8-93
8102 Installation 8-93
811 Idler and Tension Spring AS 8-94
8111 Removal 8-94
8112 Installation 8-94
812 Tension Spring AS 8-95
8121 Disassembly 8-95
8122 Assembly 8-96
813 Idler AS 8-97
8131 Disassembly 8-97
8123 Assembly 8-97
814 Track Roller AS 8-98
8141 Removal 8-98
8142 Installation 8-98
815 Track Roller AS 8-99
8151 Disassembly 8-99
8143 Assembly 8-99
816 Carrier Roller AS 8-100
8161 Removal 8-100
8162 Installation 8-100
817 Track AS 8-101
8171 Removal 8-101
8172 Installation 8-101
818 Hydraulic Tank AS 8-102
8181 Removal 8-102
8173 Installation 8-102
819 Main Pump AS 8-103
8191 Removal 8-103
8182 Installation 8-103
820 Oil Seal on Main Pump Input Shaft 8-104
8201 Removal 8-104
8202 Installation 8-104
821 Control Valve AS 8-105
8211 Removal 8-105
8212 Installation 8-105
822 Oil Source Control Valve AS 8-106
8221 Removal 8-106
8222 Installation 8-106
823 Left Pilot Valve AS (Arm and Swing Control) 8-107
8231 Removal 8-107
8232 Installation 8-107
824 Right Pilot Valve (Boom and Bucket Control) 8-108
8241 Removal 8-108
8242 Installation 8-108
825 Work Equipment Pilot Valve AS 8-109
8251 Disassembly 8-109
8252 Assembly8-110
826 Travel Pilot Valve AS 8-111
8261 Removal 8-111
8253 Installation 8-111
827 Travel Pilot Valve AS 8-112
8271 Disassembly8-112
8272 Assembly8-112
828 Boom Cylinder AS 8-113
8281 Removal 8-113
8282 Installation 8-114
829 Arm Cylinder AS 8-115
8291 Removal 8-115
8292 Installation 8-116
830 Bucket Cylinder AS 8-117
8301 Removal 8-117
8302 Installation 8-118
831 Deflection Cylinder AS 8-119
8311 Removal 8-119
8312 Installation 8-119
832 Dozer Blade Cylinder AS 8-120
8321 Removal 8-120
8322 Installation 8-121
833 Hydraulic Cylinder AS 8-122
8331 Disassembly 8-122
8332 Assembly 8-125
834 Work Equipment AS 8-128
8341 Removal 8-128
8342 Installation 8-129
835 Bucket-Arm AS 8-130
8351 Removal 8-130
8352 Installation 8-131
836 Bucket AS 8-132
8361 Removal 8-132
8362 Installation 8-133
837 Arm AS 8-134
8371 Removal 8-134
8372 Installation 8-135
838 Boom AS 8-136
8381 Removal 8-136
8382 Installation 8-137
839 Boom Deflector Joint AS 8-138
8391 Removal 8-138
8392 Installation 8-138
8393 Installation 8-139
840 Dozer Blade AS 8-140
8401 Removal 8-140
8394 Installation 8-140
841 Cab AS 8-141
8411 Removal 8-141
SY35U Crawler Hydraulic Excavator Table of Contents
Shop Manual – April 2014 XI
8412 Installation 8-141
842 Counterweight AS 8-142
8421 Removal 8-142
8422 Installation 8-142
843 Monitor AS 8-143
8431 Removal 8-143
8432 Installation 8-143
9 Maintenance Standard
91 Swing Mechanism 9-3
92 Swing Bearing 9-4
93 Track Frame 9-5
94 Idler 9-6
95 Track Roller 9-7
96 Rubber track 9-8
97 Work Equipment 9-9
98 Arm Dimensions9-11
99 Bucket Dimensions 9-12
910 Hydraulic Cylinder 9-13
10 System Schematics
101 Hydraulic Circuit Diagram 10-3
102 General System Diagram (1/5) 10-4
103 General System Diagram (2/5) 10-5
104 General System Diagram (3/5) 10-6
105 General System Diagram (4/5) 10-7
106 General System Diagram (5/5) 10-8
107 Electrical Circuit Diagram 10-9

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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
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