SY215C AND SY235 Same Shop Manual.pdf

Introduction SY215CLC

7) When removing components, be careful not to break or damage electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10) Be sure to assemble all parts again in their original places. Replace any damaged parts and non-reusable part. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. 11) When installing high pressure hoses, make sure they are not twisted. Damaged hoses

SY215CL C

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Table of Contents SY215CLC

Table of Content Contents s 1 Introduction 1.1 Safety Notice ..................... ........................................... ............................................ ........................................... .......................................... ..................... 1-3 1.2 How to Read the Shop Manual ..................... ........................................... ............................................ ................................... ............. 1-13 1.3 Terms for Maintenance Standard...................... ........................................... ........................................... ................................ .......... 1-16 1.4 Handling Electrical and Hydraulic Components................................... .................. 1-19 1.4.1 Points to remember when when handling electric components components ...................... ............................ ...... 1-19 1.4.2 Points to remember when when handling hydraulic equipment equipment ...................... ............................ ...... 1-28 1.5 Hose Connector ..................... ........................................... ............................................ ............................................ .................................... .............. 1-30 1.5.1 Ty Type pe of of hose hose connector connector................... ......................................... ............................................ ....................................... ................. 1-31 1.5.2 Hose connector tightening torque table ...................... ........................................... ................................. ............ 1-31 1.5.3 Connection of O-rings ..................... ........................................... ............................................ ....................................... ................. 1-32 1.6 Table of Standard Tightenin Tightening g Torques ..................... ........................................... ............................................ ........................ 1-33


2.2.7 Removing Attachments .................... .......................................... ............................................ ...................................... ................ 2-10 2.2.8 Cleaning the Machine ................... ......................................... ............................................ ......................................... ................... 2-10 2.2.9 Using the Correct Tools Tools.................... .......................................... ............................................ ....................................... .................2-1 2-11 1 2.2.10 Hoisting a Load ................... ......................................... ............................................ ............................................ ............................2-11 ......2-11 2.2.11 2.2.1 1 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 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


3.6 Engine Performance Curve ...................... ............................................ ............................................ ......................................... ................... 3-9

4 Structure and Function 4.1 Engine and Cooling System ..................... ........................................... ............................................ ......................................... ................... 4-3 4.1.1 Engine-related parts........................ parts.............................................. ............................................ ......................................... ................... 4-3 4.1.2 Radiator and intercooler.............................. ..................... ........................................... .............................. ........ 4-4 4.2 Power Train...................................... ...................... ........................................... ........................................... ............................. ....... 4-5 4.2.1 Power transmission system .................................. ..................... ........................................ ................... 4-5 4.2.2 Final drive AS (KYB) ................... ......................................... ............................................ ............................................ ........................ 4-6 4.2.3 Final drive AS (Nabtesco) ................... ......................................... ............................................ ..................................... ............... 4-8 4.2.4 Swing machinery............................... machinery..................................................... ............................................ ..................................... ............... 4-10 4.2.5 Swing bearing ...................... ............................................ ........................................... ........................................... ............................. ....... 4-12 4.3 Undercarriage and Frame........................ Frame.............................................. ............................................ ........................................ .................. 4-13 4.3.1 Track frame and recoil spring........................ spring.............................................. ............................................ ......................... ... 4-13 4.3.2 Idler

4-15


4.5.3.1 When spool is in neutral position .................... .......................................... .................................... .............. 4-48 4.5.3.2 Travel ................... ......................................... ............................................ ............................................ ................................... ............. 4-50 4.5.3.3 Arm................... ......................................... ............................................ ............................................ ....................................... ................. 4-51 4.5.3.4 Boom.................... .......................................... ............................................ ............................................ ................................... ............. 4-56 4.5.3.5 Bucket Bucket ...................... ............................................ ........................................... ........................................... ................................ .......... 4-59 4.5.3.6 Swing ................... ......................................... ............................................ ............................................ ................................... ............. 4-61 4.5.3.7 Option ...................... ............................................ ........................................... ........................................... ................................ .......... 4-63 4.5.3.8 Travel straight ..................... ........................................... ............................................ .......................................... .................... 4-64 4.5.3.9 Lock valve function ..................... ........................................... ............................................ .................................. ............ 4-65 4.5.3.10 Main relief valve function ...................... ............................................ ............................................ ...................... 4-67 4.5.3.11 4.5.3.1 1 Port relief valve function .................... .......................................... ............................................ .......................... .... 4-68 4.5.4 Section view ...................... ............................................ ............................................ ........................................... ............................... .......... 4-72 4.6 Hydraulic System, Part 3 .................... .......................................... ........................................... ........................................... ........................ .. 4-83 4.6.1 Swing motor ...................... ............................................ ............................................ ........................................... ............................... .......... 4-83 4.6.2 Swing holding brake.............................

4-85


4.6.12 Pump oil pressure sensor ..................... ........................................... ............................................ ............................. ....... 4-125 4.6.13 Hydraulic cylinder............................. cylinder................................................... ........................................... .................................. ............. 4-126 4.6.14 Work equipment .................... .......................................... ............................................ ............................................ ........................ 4-128 4.7 Air Conditioning System........................... System................................................. ........................................... ...................................... ................. 4-132 4.7.1 A/C components layout drawing ..................... ........................................... ........................................... ..................... 4-133 4.7.2 Control panel.......................... panel................................................ ........................................... ........................................... ......................... ... 4-134 4.7.3 Circuit diagram ..................... ........................................... ........................................... ........................................... ........................... ..... 4-135 4.7.4 Refrigeration principle ...................... ........................................... ........................................... ..................................... ............... 4-137 4.7.4.1 Refrigeration cycle diagram ................... ......................................... ........................................... ..................... 4-137 4.7.4.2 Heating cycle diagram ................... ......................................... ............................................ ............................. ....... 4-137 4.7.5 Compressor ..................... ........................................... ........................................... ........................................... ............................... ......... 4-138 4.7.6 Clutch................... ......................................... ............................................ ............................................ .......................................... .................... 4-140 4.7.7 Condenser ................... ......................................... ............................................ ............................................ .................................. ............ 4-141 4.7.8 Expansion valve................... ......................................... ............................................ ........................................... .......................... ..... 4-142 4.7.9 Evaporator

4-142


4.9.3 Engine and and pump composite control control function ...................... ............................................ ...................... 4-175 4.9.4 Pump control function ................... ......................................... ........................................... ....................................... .................. 4-179 4.9.4.1 Electrical positive

SY215C AND SY235 Same Shop Manual.pdf

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