QUALITY CHANGES THE WORLD

Hydraulic Crawler
Forestry Crane
SY135F

Maintenance Manual
SY135F Hydraulic Forestry Crane

SY135F
Hydraulic Forestry Crane
Maintenance Manual

Warning
 This Maintenance Manual is prepared for experienced technical personnel, and aims to
provide the technical information necessary for maintenance and repair of this machine.
 This Maintenance Manual may involve the working devices and optional equipment which
are not available in your area. You may purchase such components from local authorized
dealer of SANY heavy machinery co., ltd. The materials and technical specifications may be
modified without further notice.

Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane

Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane

SANY Group
SANY Heavy Machinery Co., Ltd.
SANY Industrial Park, Dongcheng Avenue, Kunshan Economic & Technological Development
Zone, Jiangsu Province
Post code: 215300
After-Sale Service Hotline: 4008 28 2318
Consulting and Complaint Tel.: 4008 87 9318
http: //www.sanygroup.com

Along with the continuous updating of technologies and products, the material and technical
specifications will be changed without further notice. Copyright @ 2016 All rights reserved by SANY
Group. This Manual shall not be duplicated, spreaded, sold or modified without the written approval
of SANY Group.

Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane

Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Table of Contents

Table of Contents
1. Preface ............................................................................................................... 1-1
1.1 Safety Warning ............................................................................................................... 1-3
1.2 Reading Method of Maintenance Manual ........................................................................ 1-6
1.3 Explanation on Terms for Maintenance Standards .......................................................... 1-7
1.4 Handling of Electrical Component and Hydraulic Components ..................................... 1-10
1.4.1 Handling of Electrical Component and Hydraulic Components ........................ 1-10
1.4.2 Precautions when Treating Hydraulic Parts ..................................................... 1-18
1.5 Pipe joint ....................................................................................................................... 1-20
1.5.1 Pipe joint ......................................................................................................... 1-20
1.5.2 Tightening Torque of Pipe Joint ....................................................................... 1-21
1.5.3 Connection of O-ring ....................................................................................... 1-22
1.6 Bolt and nut .................................................................................................................. 1-22
1.6.1 Bolt and nut ..................................................................................................... 1-22
1.6.2 Type of Bolt ..................................................................................................... 1-24
1.6.3 Tightening Sequence of Bolts .......................................................................... 1-24
1.7 Maintenance of Split Flange.......................................................................................... 1-25
1.7.1 Maintenance of Split Flange ............................................................................ 1-25
1.8 Conversion Table .......................................................................................................... 1-25
2. Safe ......................................................................................................................... 2-1
2.1 Instructions on Safety Signs............................................................................................ 2-5
2.1.1 Instructions on Safety Signs .............................................................................. 2-5
2.1.2 Other Signals .................................................................................................... 2-5
2.2 General Notices .............................................................................................................. 2-6
2.2.1 General Notices ................................................................................................ 2-6
2.2.2 Keeping the Work Area Tidy and Clean ............................................................. 2-7
2.2.3 Storage of Liquid ............................................................................................... 2-8
2.2.4 Cleaning of Part ................................................................................................ 2-8
2.2.5 Cleaning of this Machine ................................................................................... 2-9
2.2.6 Reasonable Dressing ........................................................................................ 2-9
2.2.7 Personal Protective Equipment ......................................................................... 2-9
2.2.8 Correct Use of Tools ........................................................................................ 2-10
2.2.9 Fire Extinguisher and Emergency Exit ............................................................. 2-10
2.3 Preparatory Work before Maintenance.......................................................................... 2-11
2.3.1 Preparatory Work before Maintenance ............................................................ 2-11
2.3.2 Warning Signs ................................................................................................. 2-12
2.3.3 Self-preparation............................................................................................... 2-12

Maintenance Manual - 01 - 2021 I

 Table of Contents SY135F Hydraulic Forestry Crane

2.4 Notices for Maintenance/Repair ................................................................................... 2-13

2.4.1 Notices for Maintenance/Repair ...................................................................... 2-13
2.4.2 Dismantlement of Machine Accessories ......................................................... 2-14
2.4.3 Operation under Machine ............................................................................... 2-15
2.4.4 Adding or Replacement of Oil ......................................................................... 2-15
2.4.5 Alignment of Components ................................................................................ v16
2.4.6 When Using Hammer ..................................................................................... 2-16
2.4.7 When Using Compressed Air .......................................................................... 2-16
2.4.8 Welding Operation .......................................................................................... 2-17
2.4.9 Tensioning Spring ........................................................................................... 2-17
2.4.10 Safe Operation of High Pressure Hose ........................................................... 2-18
2.4.11 Be Careful for High Pressure Liquid................................................................ 2-18
2.4.12 Hot Coolant .................................................................................................... 2-19
2.4.14 Safe Use of Electricity .................................................................................... 2-20
2.4.15 Interruption of Power Supply for System ......................................................... 2-20
2.4.16 Handling of Battery ......................................................................................... 2-21
2.4.17 Accumulator ................................................................................................... 2-21
2.4.18 Prevent Fire Hazard and Explosion ................................................................ 2-22
2.4.19 Correct Disposal of Waste .............................................................................. 2-22
2.5 Other Notices ............................................................................................................... 2-23
2.5.1 Other Notices ................................................................................................. 2-23
2.5.2 Notices for Use of Movable Crane .................................................................. 2-25
2.5.3 Notices for Use of Overhead Crane ................................................................ 2-25
2.5.4 Selection of Steel Wirerope ............................................................................ 2-26
3. Specification .......................................................................................................... 3-1
3.1 General assembling diagram.......................................................................................... 3-3
3.1.1 Overall Dimensions .......................................................................................... 3-3
3.1.2 Operation range ............................................................................................... 3-4
3.2 Feature curve of engine ................................................................................................. 3-4
3.3 Specification ................................................................................................................... 3-6
3.4 Table of Weight .............................................................................................................. 3-7
3.5 Engine oil, fuel and coolant ............................................................................................ 3-8
4. Structure, function and maintenance standard .................................................. 4-1
4.1 Engine and Cooling System ........................................................................................... 4-5
4.1.1 Engine and Cooling System ............................................................................. 4-5
4.1.2 Cooling system ................................................................................................. 4-6
4.2 Transmission system ...................................................................................................... 4-7

II Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Table of Contents

4.2.1 Transmission system ......................................................................................... 4-7

4.2.2 Slewing bearing................................................................................................. 4-8
4.2.3 Slewing mechanism .......................................................................................... 4-9
4.3 Lower travelling device ................................................................................................. 4-11
4.3.1 Track frame ..................................................................................................... 4-11
4.3.2 Tensioning device............................................................................................ 4-13
4.3.3 Driving wheel .................................................................................................. 4-14
4.3.4 Guide wheel .................................................................................................... 4-15
4.3.5 Carrying wheel ................................................................................................ 4-17
4.3.6 Supporting wheel ............................................................................................ 4-18
4.3.7 Track ............................................................................................................... 4-19
4.3.8 Triple track shoes ............................................................................................ 4-21
4.4 Hydraulic system (Part 1) .............................................................................................. 4-22
4.4.1 Arrangement diagram of hydraulic parts .......................................................... 4-22
4.4.2 Control system ................................................................................................ 4-25
4.4.3 Hydraulic oil tank and filter .............................................................................. 4-27
4.4.4 Hydraulic pump ............................................................................................... 4-28
4.4.4.1 Operation Instruction of Swash Plate Plunger Pump K7V63DTP........... 4-28
4.4.4.2 Pilot pump ............................................................................................. 4-32
4.4.4.3 Regulator (KR76–0E23) ........................................................................ 4-34
4.4.4.4 Adjustment of regulator ......................................................................... 4-37
4.5 Hydraulic System, Part II .............................................................................................. 4-41
4.5.1 SY135F Control Valve (KMX13RB/M45201C) ................................................. 4-41
4.5.2 Hydraulic Schematic Diagram for Control Valve in SY135F Crane .................. 4-46
4.5.3 Each Spool Operated by Control Valve in SY135F Crane ............................... 4-47
4.5.4 Central slewing connector ............................................................................... 4-77
4.5.5 Running Motor ................................................................................................ 4-79
4.5.5.1 Travelling motor (final transmission) ...................................................... 4-79
4.5.5.2 .............................................................................................................. 4-94
4.5.5.3 Preparation.......................................................................................... 4-109
4.5.5.4 Assembling.......................................................................................... 4-110
4.6 Hydraulic system (Part 3) ............................................................................................ 4-128
4.6.1 5. Disassembly stereogram of parts in reducer ............................................. 4-128
4.6.2 6. Disassembly stereogram of parts in hydraulic motor ................................. 4-129
4.6.3 Slewing motor ............................................................................................... 4-130
4.6.3.1 Slewing motor ..................................................................................... 4-130
4.6.3.2 Slewing retaining brake ....................................................................... 4-132

Maintenance Manual - 01 - 2021 III

Table of Contents SY135F Hydraulic Forestry Crane

4.6.3.3 Overflow valve section ........................................................................ 4-133

4.6.3.4 Slewing motor ..................................................................................... 4-135
4.6.3.5 Anti-swing valve .................................................................................. 4-147
4.6.4 Electromagnetic valve .................................................................................. 4-153
4.6.5 PPC accumulator.......................................................................................... 4-157
4.6.6 Pilot oil filter .................................................................................................. 4-158
4.6.7 PPC valve..................................................................................................... 4-159
4.6.7.1 PPC valve ........................................................................................... 4-159
4.6.8 Hydraulic Cylinder ........................................................................................ 4-168
4.7 Working device........................................................................................................... 4-170
4.7.1 Size of component ........................................................................................ 4-170
4.7.2 Dimension of grab arm ................................................................................. 4-172
4.7.3 Dimensions of log grapple ............................................................................ 4-174
4.8 Engine control ............................................................................................................ 4-175
4.8.1 Engine control .............................................................................................. 4-175
4.8.2 Components of System ................................................................................ 4-178
4.8.2.1 Throttle knob....................................................................................... 4-178
4.8.2.2 Distribution of Controller and Its Ports................................................. 4-180
4.9 Electrical Control System ........................................................................................... 4-182
4.9.1 Control function ............................................................................................ 4-182
4.9.1.1 Control function .................................................................................. 4-182
4.9.1.2 Engine — pump combined control function ......................................... 4-186
4.9.1.3 Control function of pump ..................................................................... 4-190
4.9.1.4 Electrical positive flowrate control ....................................................... 4-191
4.9.1.5 Valve Control Function ........................................................................ 4-194
4.9.1.6 Double-travelling-speed control .......................................................... 4-195
4.9.1.7 Control on engine preheating .............................................................. 4-197
4.9.1.8 Automatic idling function ..................................................................... 4-199
4.9.1.9 Automatic acceleration control ............................................................ 4-200
4.9.2 System components ..................................................................................... 4-200
4.9.2.1 System components ........................................................................... 4-200
4.10 Display system ........................................................................................................... 4-205
4.10.1 Displayer ...................................................................................................... 4-205
4.10.1.1 Display system ................................................................................... 4-205
4.10.1.2 Introduction to Display Partition .......................................................... 4-208
4.10.1.3 Display of Main Interface .................................................................... 4-209
4.10.1.4 Switch ................................................................................................. 4-211

IV Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Table of Contents

4.10.1.5 Operation pages of display screen ...................................................... 4-212

4.10.1.6 Introduction to pages ........................................................................... 4-213
4.10.1.7 Introduction to and operation of page “List of Information” ................... 4-218
4.10.1.8 Sensor................................................................................................. 4-226
5. Standard value of components ............................................................................ 5-1
5.1 Table of standard values for engine ................................................................................ 5-3
5.2 Table for standard value of body-related parts ................................................................ 5-3
6. Testing and Adjustment ........................................................................................ 6-1
6.1 Measurement of Color of Exhaust Gas ........................................................................... 6-3
6.2 Adjust the valve clearance .............................................................................................. 6-4
6.3 Measurement of compression pressure .......................................................................... 6-6
6.4 Measurement of engine oil pressure ............................................................................... 6-8
6.5 Adjustment of engine speed sensor ................................................................................ 6-9
6.6 Testing and adjustment of tension force of fan belt ....................................................... 6-10
6.7 Measurement of clearance of slewing support bearing ................................................. 6-10
6.8 Inspection and adjustment of crawler plate tensioning device ....................................... 6-12
6.9 Inspection and adjustment of oil pressure in oil ways for working device,
slewing and travelling.................................................................................................... 6-13
6.10 Inspection and adjustment of control oil way pressure .................................................. 6-19
6.11 Measurement of output pressure of electromagnetic valve ........................................... 6-20
6.12 Measurement of output pressure of PPC valve ............................................................. 6-22
6.13 Adjustment of working device and slewing PPC valve .................................................. 6-25
6.14 Inspection of hydraulic settlement of working device ..................................................... 6-25
6.15 Release of residual pressure in hydraulic oil way .......................................................... 6-27
6.16 Measurement of oil leakage .......................................................................................... 6-28
6.17 Air Bleeding for Every Device ....................................................................................... 6-33
7. Trouble Diagnosis .................................................................................................. 7-1
7.1 Precautions during Trouble Diagnosis ............................................................................. 7-5
7.2 Work Procedure for Trouble Diagnosis............................................................................ 7-7
7.3 Precautions for Maintenance .......................................................................................... 7-8
7.4 Inspection before Trouble Diagnosis ............................................................................. 7-16
7.5 Category and steps of trouble diagnosis ....................................................................... 7-16
7.6 Adjustment Service ....................................................................................................... 7-18
7.6.1 Adjustment service (SY135F) .......................................................................... 7-18
7.6.2 Trouble - Identity the symptoms and trouble diagnosis code ........................... 7-23
7.6.3 Position Diagram of Connectors and Wiring Diagram of System ..................... 7-25
7.6.4 Position diagram of connector ......................................................................... 7-29
7.6.5 Circuit Diagram of Electric System Components (Cab Circuit) ........................ 7-30
Maintenance Manual - 01 - 2021 V
Table of Contents SY135F Hydraulic Forestry Crane

7.6.6 Circuit Diagram of Electrical Control System (Engine Circuit) ......................... 7-32
7.6.7 Circuit Diagram of Electrical Control System (Circuit of Sensor and
Solenoid Valve)............................................................................................... 7-34
7.6.8 SWP connector............................................................................................... 7-35
7.6.9 A/AMP connector............................................................................................ 7-36
7.6.10 DT connector .................................................................................................. 7-37
7.7 Trouble diagnosis for electrical system (category-E trouble) ......................................... 7-38
7.7.1 Information in table of trouble diagnosis ......................................................... 7-38
7.7.2 E-1 The engine could not be started ............................................................... 7-38
7.7.3 E-2 The engine speed fluctuates irregularly .................................................... 7-41
7.7.4 E-3 The power supply for complete machine could not be switched off .......... 7-41
7.7.5 E-4 The automatic idling does not work .......................................................... 7-42
7.7.6 E-5 The preheating function does not work ..................................................... 7-43
7.7.7 E-6 All devices could not work ........................................................................ 7-44
7.7.8 E-7 The operating device is slow and weak .................................................... 7-45
7.7.9 E-8: The travelling acts slowly and powerlessly .............................................. 7-46
7.7.10 E-9 The display on upper portion of monitor panel is omitted.......................... 7-46
7.7.11 E-10 The display content of the monitor panel is independent of the model .... 7-47
7.7.12 E-12 The indication of fuel oil level is inaccurate............................................. 7-47
7.7.13 E-13 No response when operating the button switch on the display screen .... 7-48
7.7.14 E-14 The wiper does not work ........................................................................ 7-49
7.7.15 E-15 The alarm buzzer cannot be eliminated .................................................. 7-50
7.7.16 E-16 Inaccurate display of operating device pressure state ............................ 7-51
7.7.17 E-17 The slewing operation can’t be correctly displayed in monitoring
function...............................................................................................................52
7.7.18 E-18 “Travel Left" and “Travel Right" cannot be displayed
correctly in the monitoring function ................................................................. 7-53
7.7.19 E-19 The running speed could not be changed............................................... 7-54
7.7.20 The E-20 engine speed is not adjustable ........................................................ 7-55
7.7.21 Failure of E-21 Throttle Knob .......................................................................... 7-56
7.7.22 No oil level, speed, water temperature and other information on the E-22
display. ........................................................................................................... 7-57
7.8 Trouble diagnosis for hydraulic and mechanical systems (mode H) ............................. 7-58
7.8.1 H-1 The working device acts slowly, or the running and slewing speed is
low .................................................................................................................. 7-58
7.8.2 H-2 The engine speed is obviously reduced or the engine stalls..................... 7-58
7.8.3 H-3 The working device, running or slewing gear could not work .................... 7-59
7.8.4 H-4 The hydraulic pump has abnormal noise .................................................. 7-59
7.8.5 H-5 The automatic idling could not work ......................................................... 7-60

VI Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Table of Contents

7.8.6 H-6 The boom moves slowly ........................................................................... 7-60

7.8.7 H-7 The grab arm moves slowly ...................................................................... 7-61
7.8.8 H-8 The bucket moves slowly .......................................................................... 7-62
7.8.9 H-9 Single cylinder of working device could not act ......................................... 7-62
7.8.10 H-10 The settling volume of working device cylinder is too big ........................ 7-63
7.8.11 H-11 The action of working device is lagged.................................................... 7-64
7.8.12 H-12 Other working devices move when single oil way is overflowing ............. 7-64
7.8.13 H-13 In slewing +travelling operation, the travelling speed is obviously
reduced ........................................................................................................... 7-66
7.8.14 H-14 The excavator deviates when running .................................................... 7-66
7.8.15 H-15 The excavator runs slowly ...................................................................... 7-67
7.8.16 H-16 It is not easy for the excavator to make a turn or the power is
insufficient ....................................................................................................... 7-69
7.8.17 H-17 The running speed could not be changed ............................................... 7-70
7.8.18 H-18 The excavator could not run (only on one side) ...................................... 7-70
7.8.19 H-19 The excavator could not slew ................................................................. 7-71
7.8.20 H-20 The slewing acceleration performance is poor, or the slewing speed is
low .................................................................................................................. 7-72
7.8.21 H-21 The overrunning is too big when the slewing stops. ................................ 7-73
7.8.22 H-22 The impact is too big when the slewing stops ......................................... 7-74
7.8.23 H-23 The abnormal noise is too high when the slewing stops ......................... 7-74
7.8.24 H-24 The natural drifting of slewing is too large ............................................... 7-75
8. Disassembling and Assembling ........................................................................... 8-1
8.1 How to read this Manual ................................................................................................. 8-5
8.2 Notices for Operation ...................................................................................................... 8-5
8.3 Schematic diagrams of special tools ............................................................................... 8-8
8.4 Dismantlement and installation of radiator assembly....................................................... 8-9
8.5 Dismantlement and installation of engine and hydraulic pump assembly ...................... 8-10
8.6 Unfolding and Installation of Track Shoe Assembly ....................................................... 8-13
8.7 Dismantlement and installation of driving wheel ............................................................ 8-16
8.8 Dismantlement and installation of final transmission assembly ..................................... 8-16
8.9 Disassembling and assembling of guiding wheel assembly .......................................... 8-18
8.10 Assembling ................................................................................................................... 8-19
8.11 Disassembly and Assembly of Tension Spring .............................................................. 8-22
8.12 Assembling ................................................................................................................... 8-23
8.13 Disassembly and Assembly of Track Roller/Sprocket Assembly .................................... 8-25
8.14 Disassembling and assembling of slewing motor and slewing mechanism
assembly ...................................................................................................................... 8-26
8.15 Assembling ................................................................................................................... 8-30
Maintenance Manual - 01 - 2021 VII
 Table of Contents SY135F Hydraulic Forestry Crane

8.16 Dismantlement and installation of slewing motor and slewing mechanism assembly ... 8-34
8.17 Dismantlement and installation of central slewing joint assembly ................................. 8-36
8.18 Disassembling and assembling of Central Back slewing Joint Assembly ...................... 8-37
8.19 Dismantlement and Installation of Working Device Assembly ....................................... 8-38
8.20 Dismantlement and installation of slewing table assembly ........................................... 8-41
8.21 Dismantlement and Installation of Back slewing Bearing Assembly .............................. 8-44
8.22 Dismantlement and Installation of Hydraulic Oil Tank Assembly ................................... 8-46
8.23 Dismantlement and Installation of Control Valve Assembly........................................... 8-48
8.24 Dismantlement and installation of hydraulic pump assembly ........................................ 8-51
8.25 Dismantlement and installation of hydraulic pump input shaft oil seal........................... 8-54
8.26 Disassembling and assembling of manual pilot valve assembly ................................... 8-54
8.27 Disassembly and Assembly of Travel Pilot Valve Assembly .......................................... 8-56
8.28 Disassembling and assembling of hydraulic cylinder assembly .................................... 8-57
8.29 Dismantlement and installation of balance weight assembly ........................................ 8-66
8.30 Dismantlement and installation of cab assembly .......................................................... 8-68
8.31 Dismantlement and installation of cab glass ................................................................. 8-72
8.32 Dismantlement and installation of front window assembly ............................................ 8-88
8.33 Dismantlement and installation of display screen ......................................................... 8-96
8.34 Dismantlement and installation of controller assembly ................................................. 8-96
8.35 Radio ........................................................................................................................... 8-97
8.36 Storage battery ............................................................................................. 8-100
8.37 Key switch .................................................................................................................. 8-102
8.38 Fuse box .................................................................................................................... 8-105
8.39 Wiper ......................................................................................................................... 8-106
8.40 Relay .......................................................................................................................... 8-109
8.41 Sensor ....................................................................................................................... 8-112
8.42 Installation and dismantlement methods for terminal of plug-in part ........................... 8-112
9. Hydraulic & Electrical Diagram............................................................................. 9-1
9.1 SY135C3I2K (GB) Hydraulic Schematic Diagram .......................................................... 9-3
9.2 Schematic Diagram for electrical system ........................................................................ 9-4
9.3 Cab harness................................................................................................................... 9-6
9.4 Control switch harness ................................................................................................... 9-8
9.5 Body harness ................................................................................................................. 9-9

VIII Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Preface

Preface
1. Preface .................................................................................................................... 1-1
1.1 Safety Warning ............................................................................................................... 1-3
1.2 Reading Method of Maintenance Manual ........................................................................ 1-6
1.3 Explanation on Terms for Maintenance Standards .......................................................... 1-7
1.4 Handling of Electrical Component and Hydraulic Components ........................................ 10
1.4.1 Handling of Electrical Component and Hydraulic Components ........................ 1-10
1.4.2 Precautions when Treating Hydraulic Parts ..................................................... 1-18
1.5 Pipe joint ....................................................................................................................... 1-20
1.5.1 Pipe joint ......................................................................................................... 1-20
1.5.2 Tightening Torque of Pipe Joint ....................................................................... 1-21
1.5.3 Connection of O-ring ....................................................................................... 1-22
1.6 Bolt and nut .................................................................................................................. 1-22
1.6.1 Bolt and nut ..................................................................................................... 1-22
1.6.2 Type of Bolt ..................................................................................................... 1-24
1.6.3 Tightening Sequence of Bolts .......................................................................... 1-24
1.7 Maintenance of Split Flange.......................................................................................... 1-25
1.7.1 Maintenance of Split Flange ............................................................................ 1-25
1.8 Conversion Table .......................................................................................................... 1-25

Maintenance Manual - 01 - 2021 1-1

Preface SY135F Hydraulic Forestry Crane

Warning
Please read and fully understand the precautions in this Manual and described in the safety
nameplate on the machine. When operating or repairing the machine, please follow those
precautions strictly; otherwise, the wrong operation might lead to machine damages or personal
injuries.

1-2 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Preface

1. PREFACE
1.1 Safety Warning
The correct maintenance and repair is very important for safe operation of this machine. The
maintenance and repair technologies stated in this Manual and recommended by SANY Heavy
Machinery are effective and safe. Among them, some technologies require special tools designed
by SANY Heavy Machinery Co., Ltd. for special purposes.
In order to prevent the operation personnel from getting injured, the symbols are used in this
Manual to mark the safety notices. The notices marked with these symbols shall be implemented
carefully. If any dangerous situation occurs or may occur, please firstly consider safety, and take
necessary measures to handle such situation.
1. General Notices
Incorrect operation is very dangerous. Before operating this machine, please carefully
read the contents about safety in Service Manual.
1) Before carrying out any lubrication or repair, please read all safety signs on this machine. As
for the position of safety signs and the detailed explanation for notices, please refer to the
safety manual.
2) Please designate a place in the repair workshop for storage of tools and dismantled parts. Be
sure to store the tools and parts in correct position. Be sure to keep the operation area clean,
and make sure that the ground is free of any dirt, water or oil mark. Smoking is only permitted
in designated area. During operation, please don’t smoke.
3) When carrying out any operation, be sure to put on safety shoes and safety helmet. Don’t
wear any loose clothes or any clothes with buttons lost.
 When using a hammer to knock any part, be sure to wear the goggles
 When using grinding machine to grind any part, be sure to wear the goggles
4) When carrying out any operation involving two or more persons, be sure to reach consensus
on operational steps before commencement of operation. Before carrying out any operational
step, be sure to inform your colleagues. Before carrying out any operation, please set up the
sign “in process of repair” in the cab.
5) Only the authorized operation personnel may carry out any operation which requires license
or qualification certificate.
6) Make sure that all tools are in good conditions, study the method to correctly use them, method,
and use appropriate tools. Before carrying out the operation, thoroughly inspect the tools, this
machine, forklift and service vehicles.
7) If welding is required for repair, be sure to get the operation carried out by a duly-trained and
experienced welder, and be sure to put on the personal protective equipment.
8) Before carrying out the operation, please thoroughly warm up yourself, so as to carry out the
operation in good state.

Maintenance Manual - 01 - 2021 1-3

 Preface SY135F Hydraulic Forestry Crane

Safety Points

1 Make proper arrangement and preparation

2 Wear correct working clothes
3 Comply with the operation standards
4 Make and inspect marks
Don’t let any unauthorized personnel to carry out operation and deal with
5
relevant matters
6 Carry out safety inspection before commencement of operation
7 Wear the goggles (for cleaning or grinding operation)
8 Put on personal protective equipment and mask (for welding operation)
9 Maintain good physical conditions
10 Notices for operations with which you are familiar or not familiar
2. Preparation for Operation
1) Before filling oil or carrying out any repair, please park this machine on firm and flat ground,
apply the parking brake and insert the cushion block under wheel or crawler, so as to prevent
this machine from moving.
2) Before carrying out any operation, lower down the working device (bulldozing shovel, scarifier,
bucket and etc.) onto ground. If it is impossible to lower it down, please insert the locking pin
or use the cushion block to prevent the working device from dropping down. In addition, be
sure to lock up all control rods and set up the warning sign thereon.
3) When carrying out disassembling or assembling operation, please use cushion block, jack or
bracket to support this machine before commencement of such operation.
4) Clear away soil and oil on steps through which you will get on/off this machine. When getting
on/off this machine, be sure to use handrail, ladder or step. Be sure not to jump on or off this
machine. If it is impossible to use handrail, ladder or step, please use a platform so as to
provide a safe footing point.
3. Notices for Operation
1) When disconnecting or dismantling any component in oil, water or air circuit, please firstly
release the pressure in pipeline. When dismantling the engine oil filling port cover, drain plug
or pressure-discharging plug, please slowly loosen, so as to prevent the oil from spouting.
2) When the engine is just stopped, the coolant and engine oil in pipeline will be very hot.
Therefore, please be careful not to get scalded. Before carrying out any operation for oil or
water pipeline, please wait until the oil and coolant cool down.
3) Before carrying out any operation, please stop the engine, especially when carrying out any
operation on or near any rotating component. When inspecting this machine (such as
measuring oil pressure, speed, temperature and etc.) under the circumstance that the engine
stops, please be careful not to be drawn into any rotating component or be hooked by any
moving component.
4) Before carrying out the operation, please dismantle the wire from battery. Be sure to firstly

1-4 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Preface

dismantle the wire from negative (-) terminal.

5) When lifting a heavy component (of which the weight exceeds 25kg), please use crane or
crane. Before carrying out the operation, please inspect that the sling (steel wirerope, lifting
chain and lifting hook) is not damaged. Be sure to use the sling which has sufficient lifting
capacity, and install it at the correct position. Slowly operate the crane, so as to prevent the
component from getting collided with any other part. Don’t carry out any operation when the
part is still lifted up by crane.
6) When dismantling the cover under the circumstance that there is internal pressure or spring
force, be sure to leave 2 bolts on diagonal positions. Gradually and alternatively loosen these
bolts, so as to release the pressure, and then dismantle the cover.
7) When dismantling any component, be careful not to get any wire broken or damaged. The
damage of wire may cause electrical spark.
8) When dismantling any pipeline, please prevent the overflow of fuel or engine oil. If there is any
drop of fuel or engine oil on ground, please immediately wipe it away. The fuel or engine oil
on ground may make you slip or even cause fire.
9) As a general principle, don’t use gasoline to clean up any part. Especially don’t use it to clean
up any electrical part.
10) Be sure to assemble all parts onto their original position. Please replace all damaged or non-
reusable parts with new ones. When installing any hose or wire, please make sure that they
will not contact with and get damaged by any other part owing to the running of this machine.
11) When installing high-pressure hoses, please make sure that they are not twisted. The
damaged pipe is very dangerous. Therefore, when installing any hose used for high-pressure
pipeline, please be very careful. In addition, please inspect whether the connecting component
is correctly installed.
12) When assembling or installing any part, be sure to tightening it up to the specified torque.
When installing any protective part (such as protective plate), any violently-vibrating part or
any quickly rotating part, please carefully inspect whether it is correctly installed.
13) When aligning two holes, be sure not to insert your finger or hand therein. Be careful not to
get your finger trapped in hole.
14) When measuring the hydraulic pressure, please inspect whether the measurement tool has
been assembled correctly.
15) When dismantling or installing the crawler of this machine, please be very careful. When
dismantling the crawler, the crawler may break suddenly. Therefore, be sure not to let anybody
stand on any end of the crawler.
16) If the engine runs for long time in a place where is not well ventilated, then you may be
poisoned by exhaust gas. Therefore, open the door and windows, so as to get the place well
ventilated.

Maintenance Manual - 01 - 2021 1-5

 Preface SY135F Hydraulic Forestry Crane

1.2 Reading Method of Maintenance Manual

 It is likely that some accessories and optional parts mentioned in this Maintenance Manual
will not be transported to specific area. If you need them, please consult with the dealer of
SANY heavy machinery co., ltd.
 The materials and technical specifications may be modified by Sany without further notice
owing to technical advancement. As for the latest relevant technical information, please
consult with the authorized dealer of Sany.

1. Composition of Maintenance Manual

This Maintenance Manual contains the technical information necessary for carrying out
maintenance and repair in workshop. In order to facilitate the understanding, this Manual is divided
into the following parts.
Preface and Introduction
This Part sets forth the lists, table of contents, safety information and basic information of this
Maintenance Manual.
Overview
This Section sets forth the overall parameters of this machine.
Structure, function and maintenance standard
This Section sets forth the structure, function and maintenance value of every component. The
Part “Structure and Function” sets forth the structure and function of every component, and it will
not only help you understand the structure, but also serve as reference material for trouble
diagnosis. The Sub-section “Maintenance Standard” sets forth the standards and measures for
disassembling and maintenance.
Table of Standard Values
This Part sets forth the standard values of new machine and the judgment standards for testing,
adjustment and trouble diagnosis. This table of standard values is used to inspect the standard
values in testing and adjustment, and to judge the parts in trouble diagnosis.
Testing and Adjustment
This Section sets forth the measuring instruments used for testing and adjustment, the
measurement method, and the method to adjust every part. The standard values as well as the
judgment standards for testing and adjustment will be set forth in the Section “Testing and
Adjustment”.
Trouble Diagnosis
This Section sets forth the method to identify and repair the parts in trouble. The trouble diagnosis
falls into several trouble modes.
Disassembling and Assembling
This Section 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

1-6 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Preface

also set forth.

Others
This part mainly gives the hydraulic oil way diagrams and wiring diagrams
2. Amendment and Issuance
Any supplementation, amendment or change in other notices will be sent to authorized dealers of
SANY heavy machinery co., ltd. Before carrying out any operation, please obtain the latest
information.
3. Symbols
Important contents about safety and quality are indicated by the following symbols, so as to make
this Service Manual more practical.
Symbols Item Remarks
The special safety notices are required during
Safety
operation
Special technical notices or other standards
★ Attention
necessary for operation
Weight of component which must be considered
Weight during selection of lifting steel wirerope or is
important for operation
Locations where attention shall be paid to tightening
Tightening Torque
torque during assembling
Locations to which the adhesive must be applied
Coating
during assembling

Lubricant This symbol indicates the lubricant to be used

Locations where the oil or water must be added, and

Oil and Coolant
capacity thereof
Locations where the oil or water must be drained,
Emission
and quantity thereof

4. Unit
In this Service Manual, the units in SI system are used. The units in gravitational system given in
{ } are for reference only.

1.3 Explanation on Terms for

Maintenance Standards
The maintenance standards necessary for
judging products and parts are described by
using the following terms.
1. Standard Dimension and Tolerance
 Accurately speaking, the processing
dimension of every part is slightly different.
 In order to specify the processing
dimension of a part, please set a temporary
standard dimension, and point out the
Maintenance Manual - 01 - 2021 1-7
Preface SY135F Hydraulic Forestry Crane

permissible deviation from such dimension.

 The temporarily-set size above is called as
“standard size”, the range of deviation from
standard value is called as “tolerance”.
 On the right side of standard dimension, the
tolerance with symbol + or – is given.
Example:
Standard
Tolerance
Dimension
—0.022
120
—0.126

 The tolerance may be expressed in the

Standard dimension 60
form of [standard value (upper limit/lower
Tolerance of hole
limit of tolerance)] in text and table. For (upper side) +0.046
Standard clearance
example: 120 (-0.022/- 0.126) (maximum): 0.122
Standard clearance
Tolerance of shaft (lower
 Normally, the dimension of hole and the (minimum):
side): -0.0760.030
Tolerance of shaft (upper
side): -0.030
dimension of shaft which matches with
such hole are indicated by the same
standard dimension and tolerance. The
mounting tightness is decided by tolerance.
 Dimension indication and relationship
diagram of rotating shafts and holes.
Example:

Standard Tolerance Figure 1-1

dimension Axle/shaft Hole
—0.030 +0.046
φ60
—0.076 0

2. Standard Clearance and Standard Value

 The clearance appearing when a new part
is assembled is referred to as “standard
clearance”, and it is expressed by a range
from minimum clearance to maximum
clearance.
 As for repair of some parts, normally the
clearance is adjusted to standard
clearance.
 The performance/function value or
equivalent of new product is referred to as
“standard value”, and it is expressed by a
range or a target value.
 During repair of some parts, the
1-8 Maintenance Manual - 01 - 2021
SY135F Hydraulic Forestry Crane Preface

performance/function value is set as

standard value.
3. Standard interference
 When the dimension of hole is less than
dimension of shaft owing to standard value
and tolerance, the difference between such
dimensions is referred to as “interference”.
 The range (A-B) from difference (A)
between minimum dimension of shaft and
maximum dimension of hole to the
difference (B) between maximum
dimension of shaft and minimum dimension
of hole is the “standard interference”.
 After repairing or replacing some parts,
please measure the dimension of their
holes and shafts, and inspect whether the
interference is within the standard range.
4. Repair Limit and Permissible Value
 During use, the dimension of a part may
change owing to wear and deformation.
The changed limit of dimension is referred
to as “repair limit”.
 If a part is worn to repair limit, please
replace or repair it.
 During use, the performance and function
of component will continuously reduce. The
value below is called as “permissible
value”, and below this value, the product
can be used normally without problem.
 If a product is worn to permissible value,
please inspect or repair it. The permissible
value is estimated on the basis of various
testing or experience in most occasions.
However, please carry out judgment after
considering the operating conditions and
needs of customer.
5. Clearance limit
 The parts may be used until the clearance
between them exceeds a certain limit. The
limit under which these parts may not be
used any more is referred to as “clearance

Maintenance Manual - 01 - 2021 1-9

Preface SY135F Hydraulic Forestry Crane

limit”.
 If the clearance between parts exceeds the
clearance limit, please replace or repair
them.
6. Interference limit
 The maximum permissible interference
between the hole on a part and the shaft of
another part which is to be assembled is
referred to as “interference limit”.
 The interference limit indicates the repair
limit of part which has the less tolerance.
 If the interference between parts exceeds
the interference limit, please replace or
repair them.

1.4 Handling of Electrical

Component and Hydraulic
Components
1.4.1 HANDLING OF ELECTRICAL
COMPONENT AND HYDRAULIC
COMPONENTS
After this machine has been used for long time,
in order to ensure its operation performance and
prevent the occurrence of troubles and other
abnormal situations, please carry out operation,
maintenance, inspection, trouble diagnosis and
repair correctly. This Section mainly discusses
the correct repair methods for electrical and
mechanical components, aims to improve the
repair quality, and is mainly divided into
“handling of electrical components "and
“handling of hydraulic components” (especially
for gear oil and hydraulic oil).

1-10 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Preface

1. Handling of Harness and Connector

A harness is composed of the wires connected
from a component to another component, the
connector used to connect two wires or
disconnect a wire from another wire, and the
shield or pipe used to protect wires.
As compared with other electrical components
which are installed in box, the harness may be
directly affected by rain, water, heat or vibration.
In addition, during inspection and repair, they
may often be dismantled and installed again. As Figure 1-2
a result, they may get deformed or damaged.
Therefore, When handling any harness, please
be extremely careful.
2. Main Troubles Occurring in Harness
1) Poor contact in connector (poor contact
The connection is
between electrical plug and electrical incorrect
socket)
If the electrical plug of connector is not correctly
inserted into electrical socket, or the connector
is deformed and thus the position is not properly
aligned, or the contact surface is corroded and
oxidized, then poor contact may occur.

Figure 1-3
2) The edge or welded portion of connector is
in trouble
Edge portion
The pins of the male and female connector
contact with rolled-up terminal or welded
portion. However, if the wire undertakes too
much force, the cladding material on joint will
peel off, so that the connection will be incorrect
or break.

Figure 1-4

Maintenance Manual - 01 - 2021 1-11

Preface SY135F Hydraulic Forestry Crane

2.3) Disconnection of Wire

If you pull out a connector by holding the wire,
or use a crane to lift up a component to which
the connector is connected, or use a heavy
article to knock the wire, then the edge of
connector may get separated, or the welded
portion and wire may get damaged.

Figure 1-5
4) The high-pressure water enters into
connector
The connector is designed to be water resistant.
However, if the high-pressure water is sprayed
directly on the connector, the water may enter
into the connector according to the spray angle.
Therefore, be careful not to splash water on the
connector. It is difficult to drain when water
enters the waterproof connector. When water
enters and the pins are short circuited by water,
the connector must be dried immediately or
other appropriate measures must be taken
Figure 1-6
before energizing it.
5) Oil or oil sludge sticking to connector If the
connector is stained with oil or lubricating
grease and
a layer of oil film is generated on mating face
between pin and hole, then the current will not
be able to pass, so that the contact trouble will
occur. If the connector is stained with oil or
lubricating grease, please wipe it clean with dry
cloth and blow it dry with compressed air. The
compressed air shall be sprayed by air gun.
 When wiping the mating face of connector,
be careful not to use too large force or get Figure 1-7
the pin deformed.
 If there is oil or water in compressed air,
then the contact may become more dirty.
Therefore, before using the compressed air
to carrying out cleaning operation, please
thoroughly eliminate the oil and water in

1-12 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Preface

compressed air.
3.3. Dismantle, install and blow dry the
connector and harness
1) Disconnect the connector
 When disconnecting a connector, please Press gently when
dismantling
hold it.
Locking reed
When disconnecting a connector, please hold it.
As for any connector which is fixed by screw,
please fully loosen the screw, and then hold the
convex and concave connectors with two hands
and disconnect them. As for any connector
equipped with locking reed, please press down
the reed with thumb, and then pull out the Figure 1-8
connector
Note: Don’t pull the connector with one hand.
 When dismantling a connector from a clip
Both the connector and clip are equipped with
Both are stop blocks
stop block, and when the connector is installed,
they are engaged with each other.

Figure 1-9
When dismantling a connector from a clip,
please pull out the connector in the direction
parallel to the clip, so as to remove the stop
block.
Note: If a connector is twisted upwards and
downwards or leftwards and rightwards, the
casing may get damaged.

Figure 1-10

Maintenance Manual - 01 - 2021 1-13

Preface SY135F Hydraulic Forestry Crane

 Measures to be Taken after a Connector is

Dismantled
After dismantling any connector, please cover it
with a polythene bag, so as to prevent dust, oil
or water from entering the connector.
Note: If this machine has been in disassembled
state for long time, poor contact may occur.
Therefore, be sure to wrap the connector and
bind up the mouth of bag.
2) Connection of Connector
 Visually inspect the connector Figure 1-11
Inspect that the pins (mating face) are not
stained by oil or water.
Inspect that the pins of connector shall be free
from deformation, contact trouble, rust or
damage.
Inspect that the outside of connector shall be
free from damage or crack.
Note: If there is oil, water or oil sludge on
connector, please wipe it away with a piece of
dry cloth. If water enters into connector, please
use a drier to heat up the inside of wire, but
please be careful not to get it overheated;
otherwise short circuit may be caused.
If the connector is damaged or cracked, please
replace it.
 Fixing of connector
Correctly align the connector and then firmly
insert it. As for the connector equipped with The connector is in
place after chatter is
locking reed, please push in the connector, until heard

the reed make the sound click.

Figure 1-12

1-14 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Preface

 Correct the situation that the protective

cover bulges and the harness is not
aligned.
As for the connector equipped with protective
cover, correct the bulging of protective cover. If
the harness is not aligned, or the thimble is
displaced, please adjust it to the correct
position.
Note: If the connector can’t be corrected easily,
then dismantle clamp, and adjust position.
If the connector clamp has been dismantled, be Figure 1-13
sure to restore it to its original position. Please
also inspect whether the clamp is loosened.

Figure 1-14
3) Connection of DT Connector
Since the DT8-pin and 12-pin large-power wire
connector has two buttons, please push them in
until the chatter is heard for twice.
 Convex connector: 1
 Concave connector: 2
 Normal locking state (horizontal): a, b, d
 Incomplete locking state (diagonal): c

Figure 1-15

Maintenance Manual - 01 - 2021 1-15

Preface SY135F Hydraulic Forestry Crane

4) Dry up the harness

If there is any oil or stain on harness, please use
a piece of dry cloth to wipe it away. Don’t use
water or steam to clean it up. If it is necessary to
clean up the connector in water, please don’t
apply the high-pressure water or steam directly
onto harness. If the water is directly applied on
connector, please comply with the following
provisions.
 Disconnect the connector and use a piece
of dry cloth to wipe away the water.
Figure 1-16
The oil contained in air may lead to trouble of
contact. Therefore, before using the
compressed air, please clear away all oil and
water in compressed air.
 Use a drier to blow dry the inside of
connector.
If water enters the connector, please use a drier
to blow dry the connector.
Pay attention to the use time of drier, so as to
prevent the connector or relevant parts from
getting overheated; otherwise the connector
may get deformed or damaged. Figure 1-17
 Carry out the conductivity test for
connector.
After blowing dry the connector, keep the
harness in disconnected state, and carry out the
conductivity test to inspect whether there is any
short circuit caused by water between pins.
T-shaped
After drying up the connector, use the contact Joint

restorer to blow it dry and re-assemble it.

Figure 1-18

1-16 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Preface

4. Handling of Controller
1) The controller contains a micro-computer
and electronic control circuit. They controls
all electronic circuits on this machine.
Therefore, when handling this controller,
please be extremely careful.
2) Don’t place any article on controller.
3) Use a band or polythene bag to cover the
control connector. Please don’t touch any
contact of connector with hand.
4) In rainy days, don’t place a controller in a Figure 1-19
position exposed to rain water.
5) Even for short time, don’t place a controller
on any place where there is oil, water, soil
Toolbox
or heat. (Please place it on an appropriate
dry bench)
6) Notices for electric arc welding
When carrying out electric arc welding on body
of machine, please disconnect all harness
connectors which are connected to controllers.
Please install an arc weld earth near the welding
point.
Figure 1-20
5. Matters to be Remembered During
Diagnosis of Trouble in Electric Circuit
1) Turn off the power supply before
disconnecting or connecting the connector.
2) Inspect whether all the relevant connectors
have been inserted properly before
performing trouble diagnosis.
Note: Disconnect and connect the relevant
connectors by several times for inspection.
3) Connect all the disconnected connectors
before proceeding to the operations in the Figure 1-21
next step.
Note: It would produce unnecessary abnormal
display if turning on the power supply without
disconnecting the connector.
4) It is necessary to move the relevant wires
and connectors by several times and
inspect whether the readings of the
Maintenance Manual - 01 - 2021 1-17
Preface SY135F Hydraulic Forestry Crane

instrument change when performing trouble

diagnosis for the electrical circuit (measure
voltage, resistance, connectivity or current).
The contact trouble might exist in the
electrical circuit if the readings change.
1.4.2 PRECAUTIONS WHEN
TREATING HYDRAULIC PARTS
As the pressure of hydraulic system increases
and the precision of hydraulic components
increases, the impurities in hydraulic oil way are
often the most important cause for trouble of
hydraulic system. When filling the hydraulic oil,
or when disassembling or assembling the
hydraulic components, please be especially
careful.
1. Operating Environment
Avoid filling hydraulic oil, replace the filter or
repair the machine in the rain or wind or in the
environment with heavy dust.
2. On-site disassembling and maintenance
work
The dust might enter the parts if the hydraulic
parts are disassembled and maintain on site. It
would be very difficult to inspect the
performance after repair. Thus, it would be the
best to replace with assembly unit. The
Figure 1-22
hydraulic parts shall be disassembled and
maintained in the particularly prepared dust-
proof workshop, and the performance shall be
inspected with dedicated test equipment.
3. Sealing of Opening
After dismantling any pipe or component, please
use cover, tape or polyethylene bag to seal up
every opening, so as to prevent the entry by oil
sludge or dust. If an opening is kept open, or is
blocked up with a rag, then there is the risk that
the oil sludge will enter or the surrounding area
will be stained by leaking oil. Therefore, don’t act
like that. Don’t simply drain the oil onto ground. Figure 1-23
Please collect it and ask how the customer will
handle that.
4. During refilling operation, don’t let any oil

1-18 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Preface

sludge or dust in
When refilling in hydraulic oil, be careful to
prevent any greasy filthy or dust entering. Be
sure to keep the engine oil filter core and the
surrounding area clean, and it is necessary to
use clean pump and oil storage container. The
greasy filthy accumulated in the storage process
may be filtered out if the oil cleaning equipment
is used, which is a more effective method.
5. Replace the hydraulic oil at high
temperature
Figure 1-24
It flows easily when hydraulic oil or other oil
temperature is high. Besides, it would be easier
for the sediments to be discharged along with
the oil from the oil way. Therefore, it would be
the best to replace the oil when it is still warm.
When replacing the oil, try to drain the used
hydraulic oil thoroughly (drain oil from hydraulic
oil tank; drain oil from drain plug in the filter and
oil way). If there is any used oil, the impurities
and sediments would mix with the new oil, and
shorten the service life of hydraulic oil.
6. Flushing operation
After disassembling and assembling the
equipment or replacing the oil, it is necessary to
remove the impurities, sediments and the used Flushing oil

oil in the hydraulic oil way with flushing oil.

Usually it is necessary to flush twice: flush
mainly with flushing oil, and use specified
hydraulic oil for auxiliary flushing.
7. Cleaning operation
After any hydraulic component (pump, control
valve and etc.) is repaired or When this machine
Figure 1-25
is running, please clean up the oil, so as to clear
away the deposits or impurities in hydraulic oil
way. The oil cleaning equipment is used to clear
away the fine (about 3μ) particles, so as to
ensure that the filter in hydraulic component
can’t be dismantled. Therefore, it is a very
effective equipment.

Maintenance Manual - 01 - 2021 1-19

Preface SY135F Hydraulic Forestry Crane

Figure 1-26

1.5 Pipe joint

1.5.1 PIPE JOINT
The pipe joint is used to connect small-diameter
pipes. The metal sealing faces (4) and (5) of
joint (1) and hose (2) will mate with each other,
so as to seal up the pressure oil.

Caution
 Don’t excessively tighten up the nut (3).
Too large force will act on metal sealing
faces (4) and (5), and thus the joint (1) Joint body
may get cracked. Be sure to tighten up the
nut (3) in accordance with the technical
specifications.
Figure 1-27
 The scratch or other damage on sealing
surface (4) or (5) will lead to oil leakage at
connection. During connect/disconnecting
operation, please be careful not to
damage the sealing surface.

1-20 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Preface

Type of tube connector

Concave Convex

Figure 1-28
1.5.2 TIGHTENING TORQUE OF PIPE JOINT
Dimension of wrench mm Dimension of wrench mm Tightening torque
Type
Connecting nut Hose joint

24Concave

24Convex

Caution
 The torque given in this table is only for common use.
 Under special circumstance that the different torque is given, don’t adopt the torque given in
this table.

Maintenance Manual - 01 - 2021 1-21

 Preface SY135F Hydraulic Forestry Crane

1.5.3 CONNECTION OF O-RING

The end faces of O-ring (6) and joint (7) will
mate with each other, so as to seal up the high-
pressure oil.

Hose
coupling

Figure 1-29

Caution
 When re-connecting the pipes, be sure to replace the O-ring (6) with a new one.
 Before tightening the nut (9), please make sure that the O-ring (6) has been correctly placed
in O-ring groove (8). During tightening of nut (9), if the O-ring (6) moves, the O-ring (6) may
get damaged, and thus oil leakage may occur.
 Please don’t damage O-ring groove (8) or sealing surface (10). The damaged O-ring (6) may
lead to oil leakage.
 If it is found that the oil leakage is caused by loosing of nut (9), don’t handle the oil leakage
by tightening up the nut (9), but replace the O-ring (6) with a new one, confirm that it is reliably
mounted and then tighten up the nut (9).

Dimension of wrench Dimension of wrench Tightening torque

mm mm
(Connecting nut) (Connecting
connector)

1.6 Bolt and nut

1.6.1 BOLT AND NUT
Table of Tightening Torque for Bolts and Nuts
★ Unless otherwise stated, please tighten up the nut and bolt to the torque mentioned below.
(when the torque wrench is used)

1-22 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Preface

Dimension Hexagonal bolt Inner hexagonal bolt

Class
Thread Dimension of
of
specification of wrench hexagonal N·m kgf·m lbf·ft N·m kgf·m lbf·ft
thread
wrench
M6 10.9 10 4 13.2 1.37 9.74 13.2 1.37 9.74
M8 10.9 13 6 31 3.16 22.87 31 3.16 22.87
M10 10.9 17 8 66 6.73 48.7 66 6.73 48.7
M12 10.9 19 10 113 11.53 83.39 113 11.53 83.39
M14 10.9 22 12 177 18.06 130.6 177 18.06 130.6
M16 10.9 24 14 279 28.47 205.9 279 28.47 205.9
M18 10.9 27 14 382 38.98 281.9 382 38.98 281.9
M20 10.9 30 17 549 56.02 405.16 549 56.02 405.16
M27 10.9 41 19 1320 134.7 974.16 1320 134.7 974.16
M10 12.9 17 6 78 7.96 57.76 78 7.96 57.76
M12 12.9 19 8 137 13.98 101.1 137 13.98 101.1
M16 12.9 24 14 339 34.6 250.18 339 34.6 250.18
M20 12.9 30 17 664 67.75 490 664 67.75 490

Caution
The following provisions are applicable to fine and coarse thread.
 Please apply the lubricant (namely zinc oxide solved in bobbin oil) onto nuts and bolts, so as
to decrease its friction coefficient. The thrust bolt needs no lubricant.
 The tolerance of torque is ±10%.
 Be sure to use the bolt with correct length. If the bolt is too long, it can’t be properly tightened
up, because the top of bolt will contact the bottom of bolt hole. If the bolt is too short, the
fastening force will insufficient.
 The torque given in the table is only applicable to common purpose. If different torque is
given in special occasion, please don’t use the torque given in the table.
 Before installing any nut or bolt, be sure to ensure that its thread is clean. If there is dirt or
rust, please clear it away.

Maintenance Manual - 01 - 2021 1-23

Preface SY135F Hydraulic Forestry Crane

1.6.2 TYPE OF BOLT

 Please tighten up every nut or bolt to the
specified torque. The type and class of bolt
are indicated in right diagram.
Inner hexagonal
 When assembling this machine or any Hexagonal bolt
bolt
component, be sure to use the correct bolts,
and tighten them up correctly.

Figure 1-30
1.6.3 TIGHTENING SEQUENCE OF
BOLTS
When tightening up two or more bolts, please Tighten them up alternatively Tighten them up diagonally
and evenly
tighten them up in turn as indicated in the figure
on right side, so as to ensure that the bolts are
evenly tightened up.

Caution
 The tool used shall be suitable for the work Tighten them up from center and
diagonally
carried out. The temporary use of
inappropriate tools or rules may cause
danger.
 When screwing off or tightening up any nut
or bolt, please use dimension correct tool;
otherwise, the tightening tool may slip,
and thus personal injury may be caused.
Figure 1-31

Figure 1-32

1-24 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Preface

1.7 Maintenance of Split Flange

1.7.1 MAINTENANCE OF SPLIT
FLANGE
1. Wipe clean the sealing surface and carry
out inspection. Scratch/roughness may
lead to leakage or wear of sealing element.
The out-of-flatness may get the sealing
element pushed out. If these troubles are
not properly settled, the parts must be
replaced.
2. Be sure to use the designated O-ring,
inspect whether the O-ring is damaged, and
don’t file the surface of O-ring. When
mounting the O-ring into groove, please
use the lubricating grease to fix its position. Figure 1-33
3. Please gently tighten up the split flange,
locate the opening at center, make it vertical
to oil port, and use the locking bolt to
Wrong
maintain the position of part.

Figure 1-34
Table of Tightening Torque for Split Flange Bolt
★ Unless otherwise stated, please tighten up the split flange bolt to the following torque value.
Diameter of Thread on
Width across the flats Tightening Torque
Bolt
mm mm N·M kgf·m
10 14 59～74 6.0～7.5

12 17 98～123 10.0～12.5

16 22 235～285 23.5～29.5

1.8 Conversion Table

Using Method of Conversion Table
In this Section, the conversion table is provided, so as to enable the user to carry out the simple
conversion. For example: Use the conversion table to convert the millimeter to inch.

Maintenance Manual - 01 - 2021 1-25

 Preface SY135F Hydraulic Forestry Crane

1. Conversion of 55 millimeters into inch

1) Locate the digit 50 in vertical column on left side, mark this position as (A), and then draw a
horizontal line from (A).
2) Locate the digit 5 in horizontal line on top, mark this position as (B), and then draw a vertical
line downwards from (B).
3) Mark the junction of two lines as (C). This point (C) gives the value for conversion from
millimeter to inch. Therefore, 55mm=2.165in.
2. Conversion from 550 millimeters into inch
Since the digit 550 does not appear in the table, please search for the value corresponding to
55mm, and then multiply it by 10 (namely multiply 2.165in by 10), so as to obtain
550mm=21.65in.
Millimeter to inch

Weight
Kilogram to pound

1-26 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Preface

Volume
Liter to gallon (USA)

Liter to gallon (Britain)

Maintenance Manual - 01 - 2021 1-27

 Preface SY135F Hydraulic Forestry Crane

Torque
Kilogram meter to foot meter

1-28 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Preface

Pressure
Kilogram/square meter to pound/square inch

Maintenance Manual - 01 - 2021 1-29

 Preface SY135F Hydraulic Forestry Crane

Temperature
 If you want to convert Fahrenheit temperature into Celsius temperature, please regard the
bold-face in the central column as the Fahrenheit temperature, and read the corresponding
Celsius temperature in left column.
 If you want to convert Celsius temperature into Fahrenheit temperature, please regard the
bold-face in the central column as the Celsius temperature, and read the corresponding
Fahrenheit temperature in right column.

1-30 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Safe

Safe
2. Safe.......................................................................................................................... 2-1
2.1 Instructions on Safety Signs............................................................................................ 2-5
2.1.1 Instructions on Safety Signs .............................................................................. 2-5
2.1.2 Other Signals .................................................................................................... 2-5
2.2 General Notices .............................................................................................................. 2-6
2.2.1 General Notices ................................................................................................ 2-6
2.2.2 Keeping the Work Area Tidy and Clean ............................................................. 2-7
2.2.3 Storage of Liquid ............................................................................................... 2-8
2.2.4 Cleaning of Part ................................................................................................ 2-8
2.2.5 Cleaning of this Machine ................................................................................... 2-9
2.2.6 Reasonable Dressing ........................................................................................ 2-9
2.2.7 Personal Protective Equipment ......................................................................... 2-9
2.2.8 Correct Use of Tools ........................................................................................ 2-10
2.2.9 Fire Extinguisher and Emergency Exit ............................................................. 2-10
2.3 Preparatory Work before Maintenance.......................................................................... 2-11
2.3.1 Preparatory Work before Maintenance ............................................................ 2-11
2.3.2 Warning Signs ................................................................................................. 2-12
2.3.3 Self-preparation............................................................................................... 2-12
2.4 Notices for Maintenance/Repair .................................................................................... 2-13
2.4.1 Notices for Maintenance/Repair ...................................................................... 2-13
2.4.2 Dismantlement of Machine Accessories .......................................................... 2-14
2.4.3 Operation under Machine ................................................................................ 2-15
2.4.4 Adding or Replacement of Oil.......................................................................... 2-15
2.4.5 Alignment of Components ............................................................................... 2-16
2.4.6 When Using Hammer ...................................................................................... 2-16
2.4.7 When Using Compressed Air .......................................................................... 2-16
2.4.8 Welding Operation .......................................................................................... 2-17
Maintenance Manual - 01 - 2021 2-1
Safe SY135F Hydraulic Forestry Crane

2.4.9 Tensioning Spring ........................................................................................... 2-17

2.4.10 Safe Operation of High Pressure Hose ........................................................... 2-18
2.4.11 Be Careful for High Pressure Liquid................................................................ 2-18
2.4.12 Hot Coolant .................................................................................................... 2-19
2.4.14 Safe Use of Electricity .................................................................................... 2-20
2.4.15 Interruption of Power Supply for System ......................................................... 2-20
2.4.16 Handling of Battery ......................................................................................... 2-21
2.4.17 Accumulator ................................................................................................... 2-21
2.4.18 Prevent Fire Hazard and Explosion ................................................................ 2-22
2.4.19 Correct Disposal of Waste .............................................................................. 2-22
2.5 Other Notices ............................................................................................................... 2-23
2.5.1 Other Notices ................................................................................................. 2-23
2.5.2 Notices for Use of Movable Crane .................................................................. 2-25
2.5.3 Notices for Use of Overhead Crane ................................................................ 2-25
2.5.4 Selection of Steel Wirerope ............................................................................ 2-26

2-2 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Safe

Maintenance Manual - 01 - 2021 2-3

Safe SY135F Hydraulic Forestry Crane

Warning
Please read and fully understand the precautions in this Manual and described in the safety
nameplate on the machine. When operating or repairing the machine, please follow those
precautions strictly; otherwise, the wrong operation might lead to machine damages or personal
injuries.

2-4 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Safe

2. SAFE
2.1 Instructions on Safety Signs
2.1.1 INSTRUCTIONS ON SAFETY SIGNS
Most of accidents are caused by failure to comply with the basic process and safety rules of
maintenance and repair in the course of operation. In order to enable you to safely maintain and
repair this machine, please read and understand the maintenance and repair technologies stated
in this Manual, and some technologies require the special tools designed by SANY heavy
machinery co., ltd. for special purposes.
Safety Signals
The following signals are used to inform you of potential danger which may lead to personal injury
or damage.
In this Manual and on signs on this machine, the following signals are used to indicate the potential
degree of danger.
Danger Indicates an imminent danger, which, if not avoided, will cause death or
serious injury.
Warning Indicates a potential danger, which, if not avoided, may cause death or serious
injury.
Attention indicates a potential danger, which, if not avoided, may cause minor or
medium injury, and is also used to remind the unsafe operation which may
cause personal injury or damage to this machine and environment.
In this Manual, this symbol is used to mark the safety notices. The notices
marked with these symbols shall be implemented carefully. If any dangerous
situation occurs or may occur, please firstly consider safety, and take
necessary measures.
It is used in illustrations to warn the users of operation which may not be
carried out.
2.1.2 OTHER SIGNALS
In addition, the following signals indicate the matters which must be comply with for the purpose of
protecting this machine, or provide you with the useful information.
Note Indicates an imminent danger, which, if not avoided, will cause death or serious injury.
Remarks Indicates a potential danger, which, if not avoided, may cause death or serious injury.

Warning
 Incorrect maintenance/repair operation is very dangerous, and may cause serious
injury/death accident.
 Before maintaining or repairing this machine, be sure to read and understand this Manual.
 Never carry out the use or operation which is prohibited by this Manual. If the operation to
be carried out is not expressly prohibited, please ensure the safety of you and others.

Maintenance Manual - 01 - 2021 2-5

Safe SY135F Hydraulic Forestry Crane

 If the fuel oil volume, particle or latitude exceeds the maximum value specified for this model
and application, it might lead to injuries, and such circumstance will not be covered by the
quality warranty.
 The machine provided by SANY Heavy Machinery Co., Ltd. to the purchasing country
complies with all the applicable specifications and standards. If the machine is purchased
from another country or from the person of another country, some safety devices and
technical requirements may not be available for your country. Please contact with the
authorized agent of SANY Heavy Machinery Co., Ltd. before use if you have any doubt about
whether the machine meets the local use standards and specifications.

2.2 General Notices

2.2.1 GENERAL NOTICES
It is very important to formulate the appropriate
safety rules for all persons which enter into or
use the workshop and paste or set up such rules
in conspicuous place. If possible, provide the
working personnel with written safety rules, and
discuss with them over relevant questions or
give the answers. Properly implement of safety
rules will ensure the safety of employees, and
provide the most effective environment for work
and study.
Please make it a habit to always keep safety in
mind, and don’t study the safety rules before
carrying out any work and then forget them after
the work is completed. Most of safety accidents
are caused by carelessness, hasty operation or
ignorance of safety rules. Please remember: If
you work carefully and strictly comply with the
provisions in this Manual, the
maintenance/repair work will become safe and
pleasant.

Warning
 Incorrect operation is very dangerous.
Before operating this machine, please
carefully read the contents about safety in
Service Manual.

Safety Regulations
Before carrying out any lubrication or repair,
please read all safety signs on this machine. As
for the position of safety signs and the detailed
explanation for notices, please refer to the

2-6 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Safe

safety manual. Figure 2-1

Carefully study and comply with the safety rules
relating to work process. When encountering
any problem, please seek for help and don’t take
risk.
Only the authorized operation personnel may
carry out any operation which requires license
or qualification certificate.
Understand the work that you will carry out.
Maintaining or repairing this machine without
receiving any instruction may lead to serious
mistake. During maintenance/repair, if you can’t
confirm the specific maintenance/repair
procedure, please refer to maintenance manual.
If you have any doubt about operation contents
and operation method, please ask for help from
others.
No romping is permitted in workshop. The
temporary “comedy” may lead to lifelong
“tragedy”. The distraction and chatting during
maintenance/repair operation may increase the
possibility of injury.
If you want to smoke, please go to the
designated smoking area. Smoking in operation
area is absolutely prohibited.
2.2.2 KEEPING THE WORK AREA
TIDY AND CLEAN
The engine oil, lubricating grease, fuel, anti-
freezing fluid and other liquid on ground may
make person skid. If any liquid is found on
ground, please clear it away immediately. No
matter who is responsible therefor, every worker
in workshop is obliged to clear away the oil or
liquid splashed onto ground.
Keep the workshop clean. The waste materials
and used parts shall be cleared away in time; it
is prohibited to leave any waste material or used
part on operation platform or in workshop.
After being used, all equipment and tools shall
be stored in original place properly. In order to Figure 2-2
prevent the occurrence of any accident, be sure
to keep the workshop tidy and clean.

Maintenance Manual - 01 - 2021 2-7

Safe SY135F Hydraulic Forestry Crane

Please always remember: the good sanitary

conditions of workshop are extremely important
for creation of safe and comfortable work
environment.
2.2.3 STORAGE OF LIQUID
The liquid such as fuel, lubricating oil, coolant
and detergent shall be appropriately stored in a
place which is far away from work area. Please
keep the storage place well ventilated.
It is prohibited to randomly place the container
of liquid; otherwise the liquid may overflow and
cause fire. Please carefully read the information
about storage and handling of liquid as stated in
label on container.
Please strictly correctly store and handle the
liquid in accordance with the label on container,
and don’t pour a kind of liquid into the container
used to store another kind of liquid. The Figure 2-3
improper storage of oil and liquid may lead to
damage of equipment, fire or explosion.
Neither smoking or open flame is permitted near
oil; otherwise fire or explosion may be caused.
When handling any oil or liquid, please put on
the personal protective equipment. Please
carefully handle any oil or liquid.
2.2.4 CLEANING OF PART
It is prohibited to use gasoline, diesel oil or and
inflammable liquid clean up part, please use the
specified insoluble solvent to carry out cleaning,
otherwise fire and explosion may be caused.

Figure 2-4

2-8 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Safe

2.2.5 CLEANING OF THIS MACHINE

When cleaning up any component of this
machine, please use high-pressure hot water,
mild and nonflammable degreased soap or
detergent. Don’t use any inflammable or
corrosive detergent.
It is prohibited to use high-pressure steam to
clean up this machine. Using steam to clean up
equipment may damage the paint, rubber hose
and electrical system of this machine.
Don’t use high pressure to clean up the inside of
cab; otherwise the internal electrical elements
may get damaged. Figure 2-5
2.2.6 REASONABLE DRESSING
Improper dressing, loose clothing, leisure
clothing, jewel, unfit shoes and long hair may
cause personal injury.
Please formulate the list of dressing which is
prohibited in workshop; before any operation,
please inspect every operator in accordance
with the list.

Figure 2-6
2.2.7 PERSONAL PROTECTIVE
EQUIPMENT
If the operation workshop has clear provisions
on personal protective equipment, please put on
the personal protective equipment in the
workshop or other area where the personal
protective equipment must be put on.
Don’t let any person which has not reasonably
put on personal protective equipment stay in
operation workshop
Always ensure that the personal protective
equipment is in good conditions. If necessary,
carry out replacement in time. Figure 2-7

Maintenance Manual - 01 - 2021 2-9

Safe SY135F Hydraulic Forestry Crane

2.2.8 CORRECT USE OF TOOLS

Before carrying out any operation, please fully
inspect the tool, machinery, forklift, crane and
maintenance/repair vehicle required.
Select the correct tool for every work. The use
of any unauthorized, incorrect, defective or
damaged tool may lead to serious personal
injury.
Make sure that all tools are in good conditions,
and correctly use them.
Please keep all tools clean. After the operation
Figure 2-8
is completed, sort out the tools and properly
store them, and make sure that no tool is left on
this machine.
2.2.9 FIRE EXTINGUISHER AND
EMERGENCY EXIT
Before carrying out the operation, spend some
time to understand the workshop, and ensure
that you know the location of emergency exit
and fire extinguisher. If the maintenance/repair
operation is carried out on site, the fire
extinguisher shall be provided.
If you don’t know the using method of fire
extinguisher, please refer to the use instructions
on fire extinguisher.

Figure 2-9

2-10 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Safe

2.3 Preparatory Work before

Maintenance
2.3.1 PREPARATORY WORK
BEFORE MAINTENANCE
Preparation before Operation
Please park this machine on flat and firm
ground. Lower down the working device onto
ground and place it safely and stably.
Put cushion block below the tracks to prevent
the machine moving.
Turn the throttle control knob to step 1, make the
engine run at low-speed under unloaded state
for 5 minutes, and then turn the key switch to the
position OFF so as to stop the engine.
Figure 2-10
Turn the key switch to the position ON, operate
the control lever to the front, rear, left or right by
2-3 times for releasing the pressure in the
system.
Pull out the key from key switch, and pull the
safety locking rod to locking position.
Make sure that no irrelated person or equipment
is in the operation area; make sure that the
operation personnel can see you (especially
when the maintenance/repair is carried out on
site).
Figure 2-11

Figure 2-12

Maintenance Manual - 01 - 2021 2-11

Safe SY135F Hydraulic Forestry Crane

2.3.2 WARNING SIGNS

When an operation is carried out by two or more
persons, before the operation, please reach
consensus on operation process and
communication signal. Before carrying out any
operational step, be sure to inform your
colleagues.
Before maintaining the machine, it is necessary
to hang the warning board “Do not Operate” or
similar warning sign on the starting switch or
direction controller to warn that other people are
maintaining the excavator.
Figure 2-13
Establish additional warning signs around the
excavator if necessary.
It would cause serious accidents if the engine
was started, or the control lever or step is
touched or operated by someone when the
machine is under maintenance.

Figure 2-14
2.3.3 SELF-PREPARATION
Only the after-sales service personnel certified
by SANY heavy machinery Co., Ltd may
maintain or repair this machine. If necessary, an
observer may be appointed.
Wear protective clothing for work and safety
shoes.
Please wear rubber apron and rubber gloves
when contacting with corrosive materials. Wear
safety gloves when handling wood material,
steel wire rope or sharp metal.
Wear protective masks when removing the Figure 2-15
springs or other elastic parts, or supplementing
acid to the storage battery. Wear safety helmets
and protective goggles when performing
welding or cutting operations.
Do not perform grinding, flame cutting or
welding operations without breather and

2-12 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Safe

ventilation equipment. Please refer to relevant

manual for proper operation procedures if
having to weld on the machine.

Figure 2-16

2.4 Notices for

Maintenance/Repair
2.4.1 NOTICES FOR
MAINTENANCE/REPAIR
Operation during Engine Running
Unless otherwise specified in this Maintenance
Manual, it is prohibited to start this machine
during maintenance/repair. If it is necessary to
start up this machine during operation, please
comply with the following basic rules:
1) The body part might get tangled into the
excavator when operating near the fan, fan
belt or other rotating parts; thus, be
particularly careful.
2) Do not drop or insert the tools or other Figure 2-17
objects into the fan or fan belt; otherwise,
the parts would be ruptured or fly out,
resulting in personal injury.
3) Move the safety locking lever to the locked
position for preventing the working device
moving accidentally.
4) When carrying out any maintenance/repair
operation under the condition that the
engine is running, make sure that a
operator is sitting in seat in cab and is ready
to turn off the engine at any time, and Figure 2-18
ensure that all personnel keep in touch with
each other.
5) The operator left in cab may not touch any
control rod. If it is necessary to operate a

Maintenance Manual - 01 - 2021 2-13

Safe SY135F Hydraulic Forestry Crane

control rod, please ensure that the

maintenance/repair personnel can always
be seen clearly, and warn them to go to safe
place before operating the control rod.
6) When this machine is running, the surface
of most of the components will become hot,
and the surface temperature of some
components may be very high. If
necessary, when carrying out operation
near any high-temperature component, be
sure to put on personal protective
Figure 2-19
equipment, so as to prevent scalding.
7) When this machine is running, the hydraulic
system, cooling system and fuel system are
in high-temperature and high-pressure
state. When carrying out operation near
these systems, please be very careful.
2.4.2 DISMANTLEMENT OF
MACHINE ACCESSORIES
When it is necessary to dismantle any large part
from this machine, be sure to use the correct
lifting equipment, and ensure that the weight of
such part is within the rated lifting capacity of
such equipment.
Please properly place the dismantled
accessories or components, and prevent them
from dropping down or moving. Make sure that
all articles are placed on stable plane steadily,
and will not block footwalk or fire passage.

Figure 2-20

2-14 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Safe

2.4.3 OPERATION UNDER MACHINE

Before repairing or maintaining this machine,
please lower down the working device onto
ground. Don’t carry out maintenance/repair
before this machine is properly supported.
It is necessary to support the excavator or
working device reliably with the cushion block or
support which is strong enough to sustain the
weight of working device and excavator when
having to lift up the excavator or working device
for repair or maintenance; neither support the
excavator with slag brick, pneumatic tires or
Figure 2-21
brackets(They will collapse under continuous
load.); nor support it with single lifting jack.
It would be very dangerous when working
beneath the excavator if it is supported only with
the working device when the track shoes are off
the ground. The working device or excavator
would drop suddenly, and it would result in
casualty accident if the hydraulic pipeline is
damaged or the control lever is touched
accidentally. Do not work beneath the excavator
unless it has been supported firmly with cushion
block or support.
2.4.4 ADDING OR REPLACEMENT
OF OIL
When adding or replacing the oil of any system,
please note that these systems may in a high-
temperature and high-pressure state.
When carrying out any operation, please firstly
turn off this machine, wait until the system cools
down, and then screw off the filling port cover;
otherwise serious scalding may occur or oil may
spout.
Please slowly loosen the oil filling port cover,
drain plug or pressure-discharging plug, so as to
prevent the oil from spouting. Figure 2-22

Maintenance Manual - 01 - 2021 2-15

Safe SY135F Hydraulic Forestry Crane

2.4.5 ALIGNMENT OF COMPONENTS

When installing or aligning any component,
please be very careful.
When aligning any round hole or mating surface,
please don’t use hand or finger, so as to prevent
your hand or finger from being squeezed or
crushed.
When aligning any component, please use the
appropriate tool, so as to prevent your hand or
finger from being injured.

Figure 2-23
2.4.6 WHEN USING HAMMER
The parts and metal fragments might fly out and
cause personal injuries when knocking hard
metal parts with the hammer such as pin, bucket
tooth, blade edge or bearing; thus, it is
necessary to wear protective goggles and
gloves, and ensure that there is no person in the
surrounding area.
If possible, don’t use metal hammer to install
any component or pin; otherwise the component
or pin may get damaged. If possible, please use
the soft or nonferrous hammer. Figure 2-24
2.4.7 WHEN USING COMPRESSED
AIR
The flying particles might cause personal
injuries when cleaning with compressed air.
Thus, it is necessary to wear protective goggles,
dust mask, gloves and other protective articles.

2-16 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Safe

2.4.8 WELDING OPERATION

There exists risks of fire hazard or electric shock
in the welding process; thus, only the competent
welder are allowed to perform welding
operations, and appropriate equipment shall be
equipped; the incompetent personnel shall not
weld.

Figure 2-25
2.4.9 TENSIONING SPRING
When maintaining or repairing the crawler,
please pay attention to the danger which may be
caused by crawler tensioning spring. The
crawler tensioning spring is always in high-
pressure state. During disassembling, the
improper operation may make the spring fly out
and cause serious personal injury.
Don’t knock the tensioning springs of crawler,
because these springs under huge pressure
may break explosively and thus cause personal
injury.
Figure 2-26
When dismantling and installing the crawler,
please be very careful. When the main chain link
of crawler is disconnected, the whole crawler
may suddenly get disconnected and cause
personal injury. When disconnecting the main
chain link of crawler, be sure to evade from the
travelling route of crawler.

Maintenance Manual - 01 - 2021 2-17

Safe SY135F Hydraulic Forestry Crane

2.4.10 SAFE OPERATION OF HIGH

PRESSURE HOSE
If the high pressure hose leaks oil, it would
cause operation trouble, and even fire hazard. If
finding that the bolt on the hose becomes loose,
it is necessary to stop the operation and tighten
the bolt to the specified torque. If finding that the
hose is damaged, it is necessary to stop
operation immediately and replace the hose in
time.
1) The hydraulic pipe connector is damaged
or leaks.
2) The cladding layer is worn out or broken, or
the steel wires of reinforcement are Figure 2-27
exposed.
3) Some positions of cladding layer are
swelled.
4) The cladding layer contains impurities.
5) The movable part is twisted or crushed.
2.4.11 BE CAREFUL FOR HIGH
PRESSURE LIQUID
The hydraulic system always contains pressure.
When inspecting or replacing the pipeline, it is
necessary to inspect whether the pressure in the
hydraulic pipeline has been released. If there is
still pressure in the oil way, it would lead to
serious accident. Thus, it is necessary to
operate according to the following provisions:
1) Before maintaining the hydraulic system,
please press the air bleeding button on
breather valve, so as to release the
pressure in system.
2) Do not use open flame around the hydraulic
system. It is necessary to clean the
splashed hydraulic oil immediately.
3) The diesel oil or pressurized hydraulic oil
could penetrate the skin or the eyes,
resulting in serious injuries, blindness or
death. It is very difficult to judge by naked
eyes whether the hydraulic oil leaks; it is
necessary to seek the leakage with a piece
of paperboard or wood chip but it is not Figure 2-28

2-18 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Safe

allowed to touch the leaking liquid directly;

it is necessary to wear masks or protective
goggles to protect the eyes. If the liquid
penetrates the skin, it is necessary to wash
with clean water and go to a doctor as early
as possible.
4) The fuel pipeline will contain high pressure
when the engine is running. When
inspecting or maintaining the fuel pipeline
system, it is necessary to turn off the engine
by at least 30s to let the internal pressure
reduce before operating.
2.4.12 HOT COOLANT
When the engine temperature increases, the
pressure of cooling system will increase. Before
taking down the radiator cover, it is necessary to
stop the engine, cool down the system and then
take down the radiator cap after the coolant
temperature reduces.

Figure 2-29
2.4.13 Air conditioning system
 Keep away from fire when repairing and
maintaining the air conditioning system.
 When adding the refrigerant, please
correctly use the refrigerant. The refrigerant
is R134a, and no other refrigerant may be
used; otherwise the A/C system may get
damaged;
 It would cause blindness if the refrigerant
enters the eyes; it would cause cold injury if
it is splashed on the skin.
 It is strictly prohibited to discharge the Figure 2-30
refrigerant directly into the atmosphere
when using the recovery and circulation
system.

Warning
Maintenance Manual - 01 - 2021 2-19
Safe SY135F Hydraulic Forestry Crane

 R134a refrigerant is nontoxic gas under

normal temperature but would become
highly toxic gas after encountering the fire.

2.4.14 SAFE USE OF ELECTRICITY

When testing the electric circuit of this machine,
be sure to understand the elements to be tested
in the system. Both high pressure and heavy
current may cause damage of equipment, or
cause electrical spark, explosion or even fire.
Before maintaining, repairing or testing the
electrical system, please understand the voltage
of such system. Before carrying out any
maintenance/repair operation, be sure to
inspect the electric circuit and ensure that the
electric circuit is in disconnected state.
Figure 2-31
When carrying out any operation near
inflammable liquid or explosive system, please
only use the specified explosion-proof lighting
lamp. The use of unauthorized lighting
equipment may cause explosion or fire.
2.4.15 INTERRUPTION OF POWER
SUPPLY FOR SYSTEM
Before carrying out any maintenance/repair
operation, please disconnect the wire of battery,
or turn off the main power switch (if equipped).
When disconnecting the battery, please firstly
disconnect the negative (-) joint, and then
disconnect the positive (+) joint.
When connecting the battery, please firstly
ensure that all switches of electrical system are
turned off, and then respectively connect the
positive (+) joint and negative (-) joint.

Figure 2-32

2-20 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Safe

2.4.16 HANDLING OF BATTERY

Carrying out operation near battery involves
certain danger, especially when the battery has
been used for a while. The following are the
notices for maintenance of battery or operation
near battery:
1) When carrying out any operation near
battery, be sure to put on personal
protective equipment.
2) The gas emitted by battery is very
explosive. After opening the battery box,
please leave sufficient time to let the gas in Figure 2-33
box escape, and then carry out the
maintenance operation.
3) When handling the battery, be sure to select
a well-ventilated place.
4) If the battery is corroded, please use the
mixture of sodium bicarbonate and warm
water to clean it up.
5) Once the electrolyte of battery splashes
onto your skin or into your eyes, please
immediately flush skin or eyes with a lot of
fresh water, and see a doctor as soon as Figure 2-34
possible.
2.4.17 ACCUMULATOR
The accumulator is charged with high pressure
nitrogen. Improper operation of accumulator
would cause explosion, resulting in serious
accident. Therefore, it is necessary to observe
the following precautions:
1) Do not disassemble the accumulator.
2) Keep the accumulator away from the fire
and do not expose it in the flame.
3) Do not drill holes, weld or apply cutting etc.
on the accumulator.
4) Do not collide or roll the accumulator, or Figure 2-35
subject the accumulator to any impact.
5) When disposing the accumulator, it is
necessary to bleed the air; please contact
with the authorized agent of SANY Heavy
Machinery Co., Ltd. for this operation.

Maintenance Manual - 01 - 2021 2-21

Safe SY135F Hydraulic Forestry Crane

2.4.18 PREVENT FIRE HAZARD AND

EXPLOSION
It is necessary to stop the engine and turn off the
electrical equipment when filling oil into the oil
tank; be particularly careful and prevent any
sparks around the grounded nozzle when
supplementing fuel to the hot engine.
Treat all solvent and dry chemicals in the well-
ventilated environment according to the steps
indicated on the container.
Clean all the dust and residue on the machine.
Do not put any greasy duster cloth or other
flammable materials on the machine.
Figure 2-36
When cleaning the parts, please use non-
flammable solvent and do not use gasoline,
diesel oil or other flammable liquid.
Store the flammable liquid and materials in the
appropriate containers according to the safety
regulations.
Inspect and maintain regularly to ensure the fire
extinguisher is readily available.
2.4.19 CORRECT DISPOSAL OF
WASTE
It would cause harm to the environment and
ecology if the wastes have not been treated
properly. Consult with the local recycling center
or the authorized agent of SANY Heavy
Machinery Co., Ltd. for the recycling or
treatment methods for wastes.
1) The potential hazardous wastes existing in
the equipment of SANY Heavy Machinery
Co., Ltd. include hydraulic oil, fuel oil,
coolant, refrigerant, filter and storage
battery etc.
2) When draining the liquid, it is necessary to Figure 2-37
use leak-proof container but it is not allowed
to use containers for food or drinks;
otherwise, it may be taken in by mistake.
3) Don’t pour the waste liquid onto ground,
into sewer or into any water source;
4) The A/C refrigerant would damage the

2-22 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Safe

atmosphere if it leaks. It is necessary to

recycle or regenerate the refrigerant
according to the relevant regulations.

Figure 2-38

2.5 Other Notices

2.5.1 OTHER NOTICES
Notices for Lifting Operation and Signaling
1) Only a designated worker may send the
signal, and all personnel involved in
Lifting weight KN (kg)

operation shall communicate with each

other frequently. The designated signaler
shall stay at such a position that the driver
and signaler can clearly see the operation,
and clearly send the specified signal. The
signaler shall stand in front of the load, and
safely instruct the driver. Lifting angle (degree)

 Don’t stand under the load.

 Don’t step on the load. Figure 2-39
2) Before carrying out any lifting operation,
please inspect the sling.
3) During the lifting operation, please always
wear the gloves. (If any, please wear
leather gloves.)
4) Visually measure the weight of load and
inspect its center of gravity.
5) In light of the weight of load and the lifting
method used, use the appropriate sling. If
too thick steel wireropes are used to lift up
any light load, then the load may slide down
or fall off.
6) Don’t separately use one steel wirerope to
lift up any load; otherwise the load will
rotate and may slide off from steel wirerope.
Maintenance Manual - 01 - 2021 2-23
Safe SY135F Hydraulic Forestry Crane

Please symmetrically use two or more steel

wireropes.
7) Normally, the limit of lifting angle is 60°.
Don’t lift up any heavy load with large lifting
angle. When using two or more steel
wireropes to lift up a load, the force borne
by every steel wirerope may increase as the
lifting angle increases. The table below
indicates the change in permissible load
expressed in kN under various lifting angles
when two steel wireropes are used to carry
out lifting and the permissible maximum
vertical lifting load of every steel wirerope is
9.8kN{1,000kg}. When two steel wireropes
are used to vertically lift up a load, the
maximum total weight which can be
supported is 19.6kN{2,000kg}. When the
lifting angle of two steel wireropes is 120°,
this weight is reduced to 9.8kN{1,000kg}. If
two steel wireropes are used to lift up the
load of which the weight is 19.6kN{2,000kg}
when the lifting angle is 150°, then the force
borne by every steel wirerope is
39.2kN{4,000kg}.
8) When installing the steel wirerope onto a
load with sharp corner, please use pad so
as to protect the steel wirerope. If the load
is smooth, please use the appropriate
material to prevent the steel wirerope from
falling off.
9) Use the specified eye bolt and U-shaped
ring with pin to fix the steel wirerope or
lifting chain.
10) Install the steel wirerope at the middle of
lifting hook.
 During any lifting operation, when the sling
Figure 2-40
is too close to top end of lifting hook, the
steel wirerope may slide off from lifting
hook. The middle portion of lifting hook has
the maximum strength.
11) Don’t use any twisted steel wirerope.
12) When lifting a load, please comply with the
following provisions.

2-24 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Safe

 Slowly lift up the load, until the steel

wirerope is tightened. When handling the
steel wireropes with hand, don’t hold them;
otherwise your finger may get crushed.
 After the steel wirerope is extended, please
stop the crane and inspect the conditions of
lifted load, steel wirerope and backer.
 If the load is unstable or the steel wirerope
or lifting chain is twisted, please lower down
the load and then lift it up again.
 Don’t slantwise lift up the load.
13) When lowering down a load, please comply Figure 2-41
with the following provisions.
 When lowering down a load, please
suspend the operation for a while after the
load is 30cm away from ground, and then
lower it down slowly.
 Inspect whether the load is stable, and then
dismantle the sling.
 Eliminate the twisting and oil sludge on
steel wireropes and lifting chains used for
lifting operation, and store them in
designated place.
2.5.2 NOTICES FOR USE OF MOVABLE CRANE
Warning
 Please carefully read the operation & maintenance manual of crane in advance, and safely
operate the crane.

2.5.3 NOTICES FOR USE OF OVERHEAD CRANE

1) Before carrying out any operation, please inspect steel wirerope, brake, clutch, controller, track,
stop device, anti-electric-shock earth leakage circuit breaker, anti-collision device of crane and
warning lamp, and carry out safety inspection.
2) Observe the signals given for lifting operation.
3) Operate the crane at a safe point.
4) Be sure to inspect the direction of indication plate (east, west, south and north) and the
direction of control.
5) Don’t slantwise lift up the load. When the load lifted rotates, don’t move the crane.
6) When the crane laterally or longitudinally moves, don’t lift up or lower down the load.
7) Don’t drag the sling.

Maintenance Manual - 01 - 2021 2-25

 Safe SY135F Hydraulic Forestry Crane

8) When lifting up a load, please lift it up only after it leaves the ground and inspect whether it is
safe.
9) Consider the travelling route in advance, and lift up the load to a safe height.
10) Place the control switch at the position where it will not become the obstacle for operation and
passage.
11) After operating the crane, don’t turn the control switch.
12) Please keep in mind the position of main switch, so that you can immediately turn off the power
supply in case of emergency.
13) If the crane stops owing to power failure, then turn the power switch to the position OFF. When
turning on the switch which has been turned off by anti-electric-shock earth leakage circuit
breaker, please inspect whether the device related to switch is not working.
14) If any obstacle is found near the crane, please stop the operation.
15) After the operation is completed, stop the care at the specified position, and lift up the lifting
hook until it is at least 2m away from ground. Don’t leave the sling mounted on lifting hook.
2.5.4 SELECTION OF STEEL WIREROPE
In light of the weight of the part to be lifted, select the appropriate steel wirerope. Please refer to
the table below.
Steel wire rope
(“Z” or “S”-twisted steel rope, ungalvanized)
Nominal Diameter of Steel
Allowable Load
Wirerope
mm kN t
10 9.8 1.0
11.5 13.7 1.4
12.5 15.7 1.6
14 21.6 2.2
16 27.5 2.8
18 35.5 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0

Caution
 The permissible load is 1/6 of breaking force of used steel wirerope. (safety coefficient: 6)

2-26 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Specification

Specification
3. Specification ........................................................................................................... 3-1
3.1 General assembling diagram .......................................................................................... 3-3
3.1.1 Overall Dimensions ........................................................................................... 3-3
3.1.2 Operation range ................................................................................................ 3-4
3.2 Feature curve of engine .................................................................................................. 3-4
3.3 Specification ................................................................................................................... 3-6
3.4 Table of Weight ............................................................................................................... 3-7
3.5 Engine oil, fuel and coolant ............................................................................................. 3-8

Maintenance Manual - 01 - 2021 3-1

Specification SY135F Hydraulic Forestry Crane

Warning
Please read and fully understand the precautions in this Manual and described in the safety
nameplate on the machine. When operating or repairing the machine, please follow those
precautions strictly; otherwise, the wrong operation might lead to machine damages or personal
injuries.

3-2 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Specification

3. SPECIFICATION
3.1 General assembling diagram
3.1.1 OVERALL DIMENSIONS
Diagram of technical specification and size

Figure 3-1
Item SY135F Forestry Crane
A Shiooing length 7756
B Tail swing radius 2282
C Shipping height 3308
D Ground clearance of up structure 1202
E Track grounding length 3160
F Upper width 2756
G Standard width of track shoe 960
H Track gauge 2050
I Min. ground clearance 620

Maintenance Manual - 01 - 2021 3-3

 Specification SY135F Hydraulic Forestry Crane

3.1.2 OPERATION RANGE

Figure 3-2
Unit: mm
Item SY135F Forestry Crane
A Max.cutting height 9185
B Max. dumping height 5505
C Max. digging depth 5165
D Max. horizontal reach 8025
E Max digging reach 8430
F Min. swing radius 2670
G Max. height at min swing radius 6805
H Grapple length 1400
I Grapple width 524
J Max. grapple opening 2040
K Min. grabbing radius 60

3.2 Feature curve of engine

Testing conditions:
 Atmospheric standard state, continuous operation time 30 hours;
 It is equipped with a generator and a fan but without air filter and noise elimination device.

3-4 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Specification

Isuzu BB-4BG1TRP

Maximum torque

Torque (nm)
Maximum power output
Power (kw)

Maximum speed under unloaded conditions

Fuel consumption rate

(Maximum power)
Fuel consumption (g/kWh)

Figure 3-3

Maintenance Manual - 01 - 2021 3-5

Specification SY135F Hydraulic Forestry Crane

3.3 Specification
Model Unit SY135F Forestry Crane
overall weight kg 16800
Standard bucket
m3 0.6
capacity
Length of boom mm 4260
Length of grab
mm 2360
arm
Model 4BG1–TABGC-03–C2
Type turbocharged
Engine Rated power KW/rpm 72.7/2200
Maximum torque N·m/rpm 349.1/1600
Displacement 4.329
Type of main pump variable plunger pump
Max.flow of main pump L/min 2×126
Hydraulic system
Type of slewing motor Fixed plunger motor
Type of travelling motor Variable plunger motor
Setting of
Pressure of working oil way MPa 34.3
overflow valve
Rotating platform Slewing speed rpm 13.8
Number of tugs on one side 1
Number of rollers on one side 6
Number of track shoes on one side 41
Running device
Travel speed km/h 4.2/2.6
Traction force KN 173
Gradeability °(%) 35(70)
track height 806
Height of sight line for driver 2330
Length of cab top 1787
Tail length 1510
Overall
Ground clearance of counter weight mm 903
dimension
Overall length (excluding working device) 3939
Length on the ground (in transportation mode) 3993
Overall height of engine hood 2047
Overall height of counter weight 1859
Maximum grabbing height 9185
Maximum unloading height 5505
Maximum grabbing depth 5165
mm
Working Maximum grabbing distance 8025
parameter Minimum slewing radius 2670
Maximum height at minimum slewing radius 6805
Excavating force of bucket 90.6
KN
Excavating force of grab arm 57.2

3-6 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Specification

3.4 Table of Weight

Model SY135F
Engine 368
Radiator assembly 56
Hydraulic oil tank assembly (excluding hydraulic oil) 125
Fuel tank assembly (excluding fuel) 128
Rotating platform 1222
Cab 320
Cab seat and control box 78
Counterweight 2501
Hydraulic pump 50
Multi-way valve 120
Back slewing reducer assembly 90
Travelling retarder assembly 2×280
Slewing connector 25
Track frame 2221
Slewing bearing 291
Guide wheel 2×113
Tensioning device 2×150
Sprocket wheel 4×40
Thrust wheel 12×40
Boom assembly 900
Grab arm assembly 450
Wood grabber assembly 538
Boom cylinder assembly 2×117
Grab arm cylinder assembly 142
Cylinder assembly of wood grabber 93
Left rocker 19
Right rocker 17

Note: this weight table is only for reference when handling components or transporting.

Maintenance Manual - 01 - 2021 3-7

 Specification SY135F Hydraulic Forestry Crane

3.5 Engine oil, fuel and coolant

Ambient temperature
Liquid
Container
variety

Engine oil pan

Slewing mechanism box

Guide wheel Engine oil

Thrust wheel

Carrier sprocket

Hydraulic system

L-HV32 low-temperature anti-wear hydraulic oil

Hydraulic oil L-HM46 anti-wear hydraulic oil

L-HM68 anti-wear hydraulic oil

Fuel tank Diesel oil GB252 premium grade - #20 diesel oil

GB252 premium grade - #35 diesel oil

Lubricating
Grease nozzle grease

Cooling system Coolant Fill in anti-freezing solution

 Engine oil recommended by Sany Heavy Machinery: above API CF-4and no lower than API
CD.
 Gear oil recommended by SANY heavy machinery co., ltd.: GL-5.
 Please purchase the genuine oil of Sany from authorized dealer of SANY heavy machinery
Co., Ltd, so as to ensure the quality of oil.

3-8 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Structure, function and maintenance

standard
4. Structure, function and maintenance standard ................................................... 4-1
4.1 Engine and Cooling System ............................................................................................ 4-5
4.1.1 Engine and Cooling System .............................................................................. 4-5
4.1.2 Cooling system ................................................................................................. 4-6
4.2 Transmission system ...................................................................................................... 4-7
4.2.1 Transmission system ......................................................................................... 4-7
4.2.2 Slewing bearing................................................................................................. 4-8
4.2.3 Slewing mechanism .......................................................................................... 4-9
4.3 Lower travelling device ................................................................................................. 4-11
4.3.1 Track frame ..................................................................................................... 4-11
4.3.2 Tensioning device............................................................................................ 4-13
4.3.3 Driving wheel .................................................................................................. 4-14
4.3.4 Guide wheel .................................................................................................... 4-15
4.3.5 Carrying wheel ................................................................................................ 4-17
4.3.6 Supporting wheel ............................................................................................ 4-18
4.3.7 Track ............................................................................................................... 4-19
4.3.8 Triple track shoes ............................................................................................ 4-21
4.4 Hydraulic system (Part 1) .............................................................................................. 4-22
4.4.1 Arrangement diagram of hydraulic parts .......................................................... 4-22
4.4.2 Control system ................................................................................................ 4-25
4.4.3 Hydraulic oil tank and filter .............................................................................. 4-27
4.4.4 Hydraulic pump ............................................................................................... 4-28
4.4.4.1 Operation Instruction of Swash Plate Plunger Pump K7V63DTP........... 4-28
4.4.4.2 Pilot pump ............................................................................................. 4-32
4.4.4.3 Regulator (KR76–0E23) ........................................................................ 4-34

Maintenance Manual - 01 - 2021 4-1

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.4.4.4 Adjustment of regulator ......................................................................... 4-37

4.5 Hydraulic System, Part II .............................................................................................. 4-41
4.5.1 SY135F Control Valve (KMX13RB/M45201C) ................................................ 4-41
4.5.2 Hydraulic Schematic Diagram for Control Valve in SY135F Crane.................. 4-46
4.5.3 Each Spool Operated by Control Valve in SY135F Crane ............................... 4-47
4.5.4 Central slewing connector .............................................................................. 4-77
4.5.5 Running Motor ................................................................................................ 4-79
4.5.5.1 Travelling motor (final transmission) ..................................................... 4-79
4.5.5.2 ............................................................................................................. 4-94
4.5.5.3 Preparation ......................................................................................... 4-109
4.5.5.4 Assembling ......................................................................................... 4-110
4.6 Hydraulic system (Part 3) ........................................................................................... 4-128
4.6.1 5. Disassembly stereogram of parts in reducer ............................................. 4-128
4.6.2 6. Disassembly stereogram of parts in hydraulic motor ................................. 4-129
4.6.3 Slewing motor ............................................................................................... 4-130
4.6.3.1 Slewing motor ..................................................................................... 4-130
4.6.3.2 Slewing retaining brake ...................................................................... 4-132
4.6.3.3 Overflow valve section ........................................................................ 4-133
4.6.3.4 Slewing motor ..................................................................................... 4-135
4.6.3.5 Anti-swing valve .................................................................................. 4-147
4.6.4 Electromagnetic valve .................................................................................. 4-153
4.6.5 PPC accumulator.......................................................................................... 4-157
4.6.6 Pilot oil filter .................................................................................................. 4-158
4.6.7 PPC valve..................................................................................................... 4-159
4.6.7.1 PPC valve ........................................................................................... 4-159
4.6.8 Hydraulic Cylinder ........................................................................................ 4-168
4.7 Working device........................................................................................................... 4-170
4.7.1 Size of component ........................................................................................ 4-170
4.7.2 Dimension of grab arm ................................................................................. 4-172
4.7.3 Dimensions of log grapple ............................................................................ 4-174
4.8 Engine control ............................................................................................................ 4-175
4.8.1 Engine control .............................................................................................. 4-175
4.8.2 Components of System ................................................................................ 4-178
4.8.2.1 Throttle knob....................................................................................... 4-178
4.8.2.2 Distribution of Controller and Its Ports................................................. 4-180
4.9 Electrical Control System ........................................................................................... 4-182
4.9.1 Control function ............................................................................................ 4-182

4-2 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.9.1.1 Control function ................................................................................... 4-182

4.9.1.2 Engine — pump combined control function ......................................... 4-186
4.9.1.3 Control function of pump ..................................................................... 4-190
4.9.1.4 Electrical positive flowrate control........................................................ 4-191
4.9.1.5 Valve Control Function ........................................................................ 4-194
4.9.1.6 Double-travelling-speed control ........................................................... 4-195
4.9.1.7 Control on engine preheating .............................................................. 4-197
4.9.1.8 Automatic idling function...................................................................... 4-199
4.9.1.9 Automatic acceleration control............................................................. 4-200
4.9.2 System components...................................................................................... 4-200
4.9.2.1 System components ............................................................................ 4-200
4.10 Display system............................................................................................................ 4-205
4.10.1 Displayer ....................................................................................................... 4-205
4.10.1.1 Display system .................................................................................... 4-205
4.10.1.2 Introduction to Display Partition ........................................................... 4-208
4.10.1.3 Display of Main Interface ..................................................................... 4-209
4.10.1.4 Switch ................................................................................................. 4-211
4.10.1.5 Operation pages of display screen ...................................................... 4-212
4.10.1.6 Introduction to pages ........................................................................... 4-213
4.10.1.7 Introduction to and operation of page “List of Information” ................... 4-218
4.10.1.8 Sensor................................................................................................. 4-226

Maintenance Manual - 01 - 2021 4-3

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Warning
Please read and fully understand the precautions in this Manual and described in the safety
nameplate on the machine. When operating or repairing the machine, please follow those
precautions strictly; otherwise, the wrong operation might lead to machine damages or personal
injuries.

4-4 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4. STRUCTURE, FUNCTION AND MAINTENANCE

STANDARD
4.1 Engine and Cooling System
4.1.1 ENGINE AND COOLING SYSTEM
Engine-related parts

Figure 4-1
1. Installation of flange 3. shock pad CZDHF-004
2. coupling 4. shock absorber CZDHF-003

Maintenance Manual - 01 - 2021 4-5

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.1.2 COOLING SYSTEM

Figure 4-2
1. Protective web of fan 7. Sheath
2. Water-inlet rubber hose of radiator 8. Fan
3. Radiator 9. Top baffle
4. Liquid storage tank 10. Hydraulic oil radiator
5. Water-outlet rubber hose of radiator 11. Radiator cap
6. Technical specification of oil inlet

Water radiator Oil cooler

Core type Plate-fin type Plate-fin type
Radiating power (kw) 49.8 30

4-6 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Flowrate (L/min) 152 240

Opening pressure of pressure valve of water
100±15 —
tank cover (kPa {kgf/cm2})
Opening pressure of vacuum valve of water
-11.2～-0.98 —
tank cover (kPa {kgf/cm2})

4.2 Transmission system

4.2.1 TRANSMISSION SYSTEM
Transmission system

Figure 4-3

Maintenance Manual - 01 - 2021 4-7

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

1. Slewing motor (M5X80CHB-10A-43A/285-61) 6. Solenoid pump

2. Back slewing reducer 7. Multi-way valve (KMX13RB/M45201C)
3. Slewing bearing 8. Travelling retarder assembly
(TM40VD-A-119/74-1)
4. Guide wheel 9. Plunger pump (K7V63DTP1X9R-
0E23-3BV)
5. Central slewing connector 10. Engine (Isuzu, State II)
4.2.2 SLEWING BEARING

Figure 4-4
1. outer ring Technical Specification
2. Steel ball Reduction ratio: 83/11=7.545
3. Inner ring Capacity of grease: 6.5 L (Grease: lithium-
based lubricating grease No. 2)
a. Position “S” on soft area of inner race
b. Position “S” on soft area of outer race
Unit: mm
Inspection Item Standard Measures
Axial clearance of bearing Standard clearance Clearance limit Replacement
0.10 ～ 0.20 0.9

4-8 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.2.3 SLEWING MECHANISM

Figure 4-5

Maintenance Manual - 01 - 2021 4-9

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

1. Plug 11. Planet wheel subassembly 2

2. Oil seal 12. Planet gear 2 (number of teeth: 13)
3. Automatic aligning bearing 13. Elastic pin
4. Tooth ring (number of teeth: 37) 14. Slewing retarder screw plug
5. Planet carrier 2 15. Grease nozzle
6. Planet carrier 1 16. Automatic aligning bearing
7. Sun gear 2 (number of teeth: 12) 17. Bearing sealing element
8. Sun gear 1 (number of teeth: 10) 18. Back slewing small gear
9. Slewing motor 19. Oil gauge
10. Planet gear 1 (number of teeth: 14)
Specification
Reduction ratio: (10+37)/10× (12+37)/12= 19.2
No. Inspection Item Standard Measures
Standard
Backlash between slewing motor shaft and sun Clearance limit
20 clearance
gear 1
0.07～ 0.18 0.4

21 Backlash between sun gear 1 and planet gear 1 0.13～ 0.31 0.6
Backlash between planet gear 1 and toothed
22 0.15～ 0.34 0.7
ring
Backlash between planet carrier 1 and sun gear
23 0.14～ 0.34 0.7
2 Replacement

24 Backlash between sun gear 2 and planet gear 2 0.13～ 0.31 0.6
Backlash between planet gear 2 and toothed
25 0.15～ 0.34 0.7
ring
Backlash between planet carrier 2 and slewing
26 0.08～ 0.19 0.4
pinion
Backlash between slewing pinion and slewing
27 0.13～ 1.16 2.3
support

4-10 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.3 Lower travelling device

4.3.1 TRACK FRAME

Figure 4-6
1. Guide wheel 5. Traveling motor
2. Track frame 6. Thrust wheel
3. Carrying wheel 7. Tensioning device
4. Driving wheel 8. Track

Maintenance Manual - 01 - 2021 4-11

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Unit: mm
No. Inspection Item Standard Measures
Standard
Clearance limit
dimension Repair
Top/bottom width of
9 Track frame 107 117
idler guide plate
Guiding wheel Repair or
105 100
support replace
Track frame 250 260 Repair
Left/right width of
10 Guiding wheel Repair or
idler guide plate 248 240
support replace
Standard dimension Repair limit
Free Installation Installation Free Installation
11 Tensioning spring length length load length load Replacement
186.2 kN 171.3 kN
616 477 566.7
{19,000 kgf} {17,480 kgf}

4-12 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.3.2 TENSIONING DEVICE

Figure 4-7
1. Guide wheel 8. Nut
2. guide 9. Valve
3. Fork 10. Grease nozzle
4. Cylinder Technical Specification
5. Tensioning spring Grease: No.2 lithium grease
6. U-ring Grease injection: 420 ml
7. Guider

Maintenance Manual - 01 - 2021 4-13

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.3.3 DRIVING WHEEL

Figure 4-8
Unit: mm
No. Inspection Item Standard Measures
Standard
Tolerance Repair limit
Wear of tooth base dimension
1
diameter +1.0
584.72 572.52
-2.0
Wear of tooth crest Repair or
2 659 ±2.2 547
diameter replace
3 Wear of tooth crest width 50 — 45
4 Wear of tooth base width 71 ±1.5 67
+0.466
5 Thickness of tooth base 91.36 85.25
-1.112

4-14 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.3.4 GUIDE WHEEL

Figure 4-9

Maintenance Manual - 01 - 2021 4-15

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Unit: mm
No. Inspection Item Standard Measures

Outside diameter Standard dimension Repair limit

1
of extruded portion 560 —
Outside diameter Carry out
2 520 508
of wheel bead welding
Difference of wheel or
3 20 25 replacement
face
4 Overall width 164 156
5 Width of wheel 39.5 44.5

Standard Tolerance Standard Clearance

Clearance between dimension Axle/shaft Hole clearance limit
6
shaft and bushing
–0.250 +0.074 0.250~
65 1.5
–0.280 0 0.354

Standard Tolerance Standard Interference

Interference dimension interference limit Replace the
Axle/shaft Hole
7 between guiding bushing
wheel and bushing +0.117 +0.030
72 0.057~0.117 —
+0.087 0
Clearance between Standard clearance Clearance limit
bushing and
8 support (sum of
clearances on both 0.18~0.38 1.5
sides)

4-16 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.3.5 CARRYING WHEEL

Figure 4-10
Unit: mm
No. Inspection Item Standard Measures

Outside diameter of Standard clearance Repair limit

1
flange 193 —
Outside diameter of
2 160 125 Carry out
wheel
bead welding
3 Thickness of wheel face 45.5 40 or
replacement
4 Width 232 —
5 Width of wheel 47.5 —
6 Width of flange 29 —

Standard Tolerance Standard Clearance

dimension Axle/shaft Hole clearance limit

Clearance between Press into

7 the base
shaft and bushing
– 0.06 hole to Replace the
65 — 0.806
– 0.106 ensure bushing
more
than 65.7

Interference between Standard Tolerance Standard Interference

8
supporting wheel and dimension Axle/shaft Hole interference limit

Maintenance Manual - 01 - 2021 4-17

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

No. Inspection Item Standard Measures

bushing +0.190 +0.046 0.19~
69 —
+0.140 0 0.094
Clearance between Standard clearance Clearance limit
bushing and collar
9 Replacement
(Sum of clearance on 0.150~0.3 1.5
both sides)

4.3.6 SUPPORTING WHEEL

Figure 4-11
Unit: mm
No. Inspection Item Standard Measures

Outside diameter of Standard clearance Repair limit

1
flange 193 —
Outside diameter of
2 160 125
wheel Carry out
bead welding
Thickness of wheel
3 45.5 40 or
face
replacement
4 Width 232 —
5 Width of wheel 47.5 —
6 Width of flange 29 —

Clearance between Standard Tolerance Standard Clearance Replace the

7
shaft and bushing dimension Axle/shaft Hole clearance limit bushing

4-18 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Press into
the base
– 0.06 hole to
65 — 0.806
– 0.106 ensure
more than
65.7

Standard Tolerance Standard Interference

Interference between dimension interference limit
Axle/shaft Hole
8 supporting wheel and
bushing +0.190 +0.093 0.19~
69 —
+0.140 0 0.094
Clearance between Standard clearance Clearance limit
bushing and collar
9 Replacement
(Sum of clearance on 0.150~0.3 1.5
both sides)

4.3.7 TRACK

Figure 4-12
Maintenance Manual - 01 - 2021 4-19
Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Unit: mm
No. Inspection Item Standard (SY135F) Standard (SY155H) Measures
Standard Standard
Distance between Repair limit Repair limit
1 dimension dimension
chain links
190 193 175 178
Standard Standard
Outside diameter of Repair limit Repair limit
2 dimension dimension
bushing
59.45 54.3 48.05 43.9
Thickness of metal
3 10.655 5.655 8.3 4.3 Repair or replace
on bushing
Standard Standard
Repair limit Repair limit
4 Height of chain link dimension dimension
105 100 90 85
Thickness of metal
on chain link
5 21.5 16.5 21.5 16.5
(pressed portion of
bushing)
6 155.57
Distance between
7 119.57
crawler plate bolts
8 59
Internal
9 82.57
width
Chain
10 Width 23
link
Width of
11 23
wheel
Adjust or replace
Extruded portion of
12 2.7
pin
13 Protrusion of bushing 3.7
14 Total length of pin 209
Total length of
15 136
bushing
Thickness of spacing
16 —
sleeve
17 Bushing 39.2 - 137.2 kN {4 - 14 t}
Common
18 Pressing 78.4 - 186.3 kN {8 - 19 t}
pin —
force
Main pin
19 39.2 - 98.1 kN {4 - 10 t}
shaft
Tightening torque (N•m{kgf·m}) Re-tightening angle (degree)
Crawler plate bolt Triple track 820±39 Repair or replace
90±10
20 shoes {83.67±4}
Number of track
SY115: 41 SY135/115C/135F: 44 SY155H : 45 —
shoes (per side)

Standard Tolerance Standard

Interference between dimension interference
Axle/shaft Hole
21 bushing and chain Adjust or replace
link Shaft:
±0.03 +0.070 0.27-0.4
59.45

4-20 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Hole: 59.08
Interference between Shaft:
22 ordinary pin and 38.26 +0.050 +0.060 0.29-0.4
chain link Hole: 37.91

Standard Tolerance Standard

Clearance between dimension Axle/shaft Hole clearance
23 ordinary pin and
bushing Shaft:
38.26 +0.050 +0.50 0.39-0.94
Hole: 38.7

Standard Tolerance Standard

Interference between dimension Axle/shaft Hole interference
24 main pin and chain
link Shaft:
38.14 +0.050 +0.060 0.17-0.28
Hole: 37.91

Standard Tolerance Standard

dimension Axle/shaft Hole clearance
Clearance between
25
main pin and bushing Shaft:
37.65 +0.10 +0.50 0.95-1.55
Hole: 38.7

4.3.8 TRIPLE TRACK SHOES

Figure 4-13
Unit: mm
Standard
No. Inspection Item Standard (SY155H) Measures
(SY115/135/155C)
Standard Standard
Height of track Repair limit Repair limit
1 dimension dimension
teeth
57 47 25 15
Total height of track
2 70 60 34.5 24.5
shoes
Carry out bead
3 Thickness 13 9.5 welding or
4 10 replacement

5 Top width —
6 —

Maintenance Manual - 01 - 2021 4-21

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.4 Hydraulic system (Part 1)

4.4.1 ARRANGEMENT DIAGRAM OF HYDRAULIC PARTS

Figure 4-14
1. Bucket cylinder 10. Radiator
2. Grab arm cylinder 11. Traveling motor
3. Boom cylinder 12. Slewing motor
4. Crushing filter 13. Left PPC valve
5. Accumulator 14. Right PPC valve
6. Hydraulic oil tank 15. Travelling PPC valve
7. Filter for hydraulic tank 16. Crushing PPC valve
8. Main valve 17. Crushing pipeline of operating device
9. Main pump

4-22 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

1. Bucket cylinder
2. Grab arm cylinder
3. Boom cylinder
4. Hydraulic oil tank
5. Hydraulic oil filter
6. Multi-way valve
7. Plunger pump
8. Radiator
9. Left travelling motor
10. Right travelling motor
11. Slewing motor
12. Safety Locking Lever
13. Left PPC valve
14. Central slewing connector
15. Right PPC valve
16. Travelling PPC valve

Figure 4-15

Maintenance Manual - 01 - 2021 4-23

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Figure 4-16

4-24 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.4.2 CONTROL SYSTEM

Figure 4-17
1. Travelling PPC valve Position of control rod
2. Left Running Control Lever (1) Holding
3. Right Running Control Lever (2) Retraction of grab arm
4. Left handle control rod (3) Extension of grab arm
5. Left PPC valve (4) Slewing RIGHT
6. Right handle control rod (5) Slewing LEFT
7. Right PPC valve (6) Holding
8. Solenoid valve block (7) Bucket unloading
9. Transition block of solenoid valve (8) Bucket excavation
10. Accumulator (9) Boom up
11. Main control valve (10) Boom lowering
12. Electrically controlled pump

Maintenance Manual - 01 - 2021 4-25

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Figure 4-18
1. Travelling PPC valve Position of control rod
2. Left Running Control Lever (1) Traveling forward left
3. Right Running Control Lever (2) Traveling backward left
4. Left handle control rod (3) Traveling forward right
5. Left PPC valve (4) Traveling backward right
6. Right handle control rod (5) Slewing LEFT
7. Right PPC valve (6) Slewing RIGHT
8. Solenoid pump (7) Outer tipping and unloading of grab arm
9. Accumulator (8) Inward retraction and digging of grab arm
10. Central slewing connector (9) Inward retraction and digging of bucket
11. Slewing motor (10) Outward tipping and unloading of bucket
12. Main valve (11) Boom lowering
13. Hydraulic oil tank (12) Boom lifting
14. Pilot filter core
15. Main pump

4-26 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.4.3 HYDRAULIC OIL TANK AND FILTER

Figure 4-19
1. Hydraulic oil tank Technical Specification
2. Liquid level meter Capacity of oil tank: 175 L
3. Oil filling port cover Effective capacity: 120 L
4. Oil return filter core Safety valve
5. Bypass valve Set pressure of bypass valve:
6. Oil suction filter core 100±30 kPa{1.0±0.3 kgf/cm2}
Flowing area of bypass valve: 13.8 cm2

Maintenance Manual - 01 - 2021 4-27

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.4.4 HYDRAULIC PUMP

4.4.4.1 OPERATION INSTRUCTION OF SWASH PLATE PLUNGER PUMP K7V63DTP
Model: K7V63DTP1X9R-0E23-3BV

Figure 4-20
Overview
 This pump is composed of two variable swashplate-type plunger pumps, two regulators and
one pilot gear pump.

4-28 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

a1: Main pressure testing port of front pump B1: Oil inlet port
a2: Main pressure testing port of rear pump B3: Oil suction port of pilot gear pump
a3: Pilot signal oil outlet port of regulator PH1: pressure sensor port at high pressure oil port for front
a4: Testing port of front pump regulator pump

a5: Testing port of rear pump regulator PH2: pressure sensor port at high pressure oil port for rear
pump
A1: Oil outlet port of front pump
1: Front pump
A2: Oil outlet port of rear pump
2: Front pump regulator
A3: Oil outlet port of pilot gear pump
2-1: Front pump electromagnetic proportional valve
Psv1: Control port of front pump regulator
3: Rear pump regulator
Psv2: Control port of rear pump regulator
3-1: Rear pump electromagnetic proportional valve
Dr1: Dr oil port
4: Pilot gear pump

Figure 4-21
1. Front shaft 9. End cover
2. Minimum displacement adjusting screw 10. Rear shaft
3. Front housing 11. Rear housing
4. Swashplate 12. Gear pump
5. Sliding shoes 13. Piston
6. Plunger 14. Maximum displacement adjusting screw
7. Cylinder body 15. Gear shaft
8. Distribution disc 16. Transmission pin

Maintenance Manual - 01 - 2021 4-29

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Figure 4-22
Function
 The torque of engine will be transmitted to shaft (1), so that the cylinder body (7) will rotate
and the 9 plunger (6) will slide along the surface of oil distribution disc (8). The plungers (6)
will carry out the reciprocating movement in cylinder body (7), so as to alternatively suck the
low-pressure oil and discharge the high-pressure oil.
 The displacement is changed by changing the inclination angle of swashplate.
Structure
 The cylinder block (7) is supported on the shaft (1) by splines (17). The shaft (1) is supported
by front and rear bearings (18)
 The top of plunger (6) is designed as concave sphere, and the sliding shoe (5) is filled so as
to form a device.
 The plunger (6) and the sliding shoe (5) constitute a spherical bearing.
 The swashplate (4) has a plane (A), and when the sliding shoe (5) makes circular movement,
it will always press against this surface.
 The swash-plate (4) guides the high pressure oil to the surface (B) and forms a static
pressure bearing as it slides.
 The plungers (6) will carry out movement in relation to axis in chamber of every cylinder body
(7).
 The cylinder body (7) will block up the pressurized oil flowing to oil distribution disc (8), and
carry out the relative rotation.
 This surface is designed so as to ensure that the balance of oil pressure is maintained at an

4-30 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

appropriate level.
 The oil in chamber of every cylinder body (7) will be sucked and discharged via oil distribution
disc (8).
Work Process
 The cylinder body (7) will rotate together
with shaft (1), and the sliding shoe (5) will
slide on plane (A).
 When such situation occurs, the
swashplate (4) will move along the
cylindrical surface (B), and thus the angle
(a) between the central line (X) of
swashplate (4) and the axis of cylinder body Figure 4-23
(7) will change.
 (A) is the inclination angle of swashplate.
 When the central line (X) of swashplate (4)
is at the inclination angle (a) in relation to
the axis of cylinder body (7), the plane (A)
will act as cam in relation to sliding shoe (5).
 In this way, the plunger (6) will slide in
cylinder body (7), and thus the difference
between capacity (E) and capacity (F) will
occur in the cylinder body (7).
 The quantity of oil sucked and discharged
by one plunger is (F) － (E).
Figure 4-24
 When the cylinder body (7) is rotating and
the capacity of chamber (E) reduces, the
pressurized oil will be discharged.
 On the other hand, when the capacity of
chamber (F) increases, the oil will be
sucked.
 When the central line (X) of swashplate (4)
coincides with the axis of cylinder body (7)
(inclination angle (a) of swashplate =0), the
difference between capacity (E) and (F) in Figure 4-25
cylinder body (7) will become 0.
 In this state, the suction and discharge of
pressurized oil are not carried out. That is,
there is no pumping movement. (however,
the swash plate angle is not actually set to
0).

Maintenance Manual - 01 - 2021 4-31

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Control on oil transfer

 If the inclination angle (a) of swash plate
increases, the difference between capacity
(E) and capacity (F) will increase, and the
quantity (Q) of oil transferred by pump will
increase.
 The piston (13) is used to change the
inclination angle a of swashplate.
 As controlled by the regulator, the piston
(13) will make straight reciprocating
movement.
 This straight movement will be transmitted Figure 4-26
to swashplate (4) via transmission pin (16)
and drive the sliding of swashplate. As a
result, the inclination angle of swashplate
will change, and then the displacement of
main pump will change.
4.4.4.2 PILOT PUMP

Figure 4-27
307: Valve rod 361: Body
308: Valve seat 433: Screw
309: Retainer ring 434: Screw
310: Spring 435: Screw

4-32 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

311: Adjusting screw 466: Plug

312: Nut 700: Washer
351: Body 710: O-ring
353: Gear shaft 725: O-ring
354: Gear shaft 732: O-ring
355: Filter element 850: Washer
Function
 The engine will drive the driving shafts of main pump and pilot pump via gearbox, and then
drive the pilot pump through engagement of gear.

Maintenance Manual - 01 - 2021 4-33

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.4.4.3 REGULATOR (KR76–0E23)

Figure 4-28

4-34 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

No. Code Name Quantity

—— 60254413 Components of regulator assembly 29100304-3715 1
—— 60254414 Components of regulator assembly 29100304-3716 1
402 60190635 Bolt OSBM616JISB1176 4
407 60018102 Bolt OSBM630 4
415 60237023 socket head cap screw OSBM840 4
418 60150556 Screw OSBM512 2
466 60008711 Plug OROH14 1
496 60008728 Fixing screw PBP116-2403 5
497 60224866 Plug OMHM7 4
541 60008884 Seal holder 2933180-0414 2
543 60008885 Retainer ring 2933260-0311 2
545 60008886 Steel ball ODW732 2
624 60118628 Seal 2903270-0868 1
627 60155069 adjusting rod 2933260-00493 1
643 60118636 Piston 2924550-0410 1
646 60197212 Spring 2903340-3080 1
656 60118625 Cover 2923150-0553 1
724 60319611 O-ring PORKP8W 5
726 60008699 O-ring OORBP12W 1
731 60008692 O-ring OORBG25W 1
733 60008702 O-ring OORBP18W 1
754 60008696 O-ring OORBP10W 2
755 60008697 O-ring OORBP11W 3
801 60118637 Nut ONM10 1
887 60008546 Pin 2953801817 1
897 60118639 Pin 38800-617 1
924 60118638 Bolt PSSSM1020 1
041 60319634 Check valve assembly 1_2953802048 2
Housing assembly of electromagnetic proportional pressure
079 60125194 1
reducing valve 50100304-3686

Maintenance Manual - 01 - 2021 4-35

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Function principle
 The regulator controls the flowrate of main
pump on the basis of various command
signals, so as to ensure that the driving
power of pump will not exceed the engine
power.
 Pumps 1 and 2 are equipped respectively
with a regulator. The main parts of the
regulator include electromagnetic
proportional pressure reducing valve (1),
servo piston (2) and servo directional valve Figure 4-29
(3). According to various command signals
and pressures, the regulator opens or
closes the oil circuit of the servo piston (2),
changes the inclination of the swash
plate, and thus controls the pump flow.
Composition of control mechanism
Positive flow control:
 By changing the current of KDRDE5
proportional solenoid valve, the inclination
angle (output flow) of the pump can be
controlled arbitrarily. The regulator is a
positive flow control (positive control) mode
in which the output flow increases with the
increase of the command pressure.
Through this mechanism, the pressure
value corresponding to the necessary flow
of the operation is output, and the
necessary flow of the main pump is
adjusted.
Power control:
 The power curve of the main pump can be
adjusted by the power adjusting spring 3.
The specific power of each gear is set by
the electronic control device.

4-36 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.4.4.4 ADJUSTMENT OF REGULATOR

Figure 4-30
531: Inclined pin
532: Servo piston
548: Feedback pin
806: Retaining nut
808: Retaining nut
953: Adjusting screw
534: Adjusting screw
 The maximum flowrate and minimum
flowrate can be adjusted by using the
adjusting screws (953, 954) on pump body
side; the power control features can be
adjusted by using the adjusting screw (C)
(628) and adjusting wheel (C) (627) on this
regulator; the flowrate control features can
be adjusted by using the hexagonal
locating screw (924).

Figure 4-31

Maintenance Manual - 01 - 2021 4-37

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Adjustment of maximum flowrate (pump body

Output flowrate Q
side)
 Loosen the hexagonal nut (808), and screw
in (or screw off) the hexagonal locating
screw (954). Other control features will
remain unchanged, and only the maximum
flowrate will change.

Pilot control pressure

Figure 4-32
Adjustment of minimum flowrate (pump body Output flowrate Q
side)
 Loosen the hexagonal nut (806), and screw
in (or screw off) the hexagonal locating
screw (953). Though the adjustment is as
same as the adjustment of maximum
flowrate and other control features remain
unchanged, if the screw is excessively
tightened, at the maximum output pressure
(overflow), the power required will increase.
Pilot control pressure

Figure 4-33
Input power
Output flowrate Q

Adjustment of inner spring

 After loosening the hexagon nut (630),
tighten (or loosen) the adjusting screw (C)
(628) for adjustment. For example, when
the adjusting screw (C) (628) is tightened,
the control line diagram moves to the right
as shown in the right figure, and the input
power increases. Moreover, if the adjusting
screw (C) (628) is rotated for N times, the Output pressure (Pd1)

setting value of the inner spring (626) will

also change. Therefore, please reverse the Figure 4-34
adjusting wheel (C) (627) to N×A in the
opposite direction.
(As for value of A, please refer to the attached
table)
4-38 Maintenance Manual - 01 - 2021
SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Adjustment of flowrate control features

 After loosening the hexangonal nut (801),
please screw in (or screw off) the
hexangonal locating screw (924) so as to
carry out adjustment. When srcewing in the
hexangonal locating screw (924), please
make sure that the line moves rightwards
as indicated in the right figure.

Figure 4-35
Explanation on action

Output flowrate Q
 As shown in the right figure, the output flow
of the pump can be controlled steplessly by
the pilot control pressure.

Pilot control pressure

Figure 4-36
Flowrate increase
 When the current of the proportional
solenoid valve KDRDE5K increases, the
pilot pressure Pi1 increases, and the servo
slide valve moves to the right. Through the
internal servo regulating linkage
mechanism of the regulator, the swash
plate angle of the main pump increases,
and the flow rate increases.

Figure 4-37

Maintenance Manual - 01 - 2021 4-39

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Reduction of flowrate
 When the current of the proportional
solenoid valve KDRDE5K decreases, the
pilot pressure Pi1 decreases, and the servo
slide valve moves to the left. Through the
internal servo regulating linkage
mechanism of the regulator, the swash
plate angle of the main pump decreases,
and the flow rate decreases.

Figure 4-38
List of Adjustment Amount for Meter Regulator
Model of Meter Regulator KR36-9P0H
Rotary speed (min-1) 2100
Screw-in amount (rotation) of adjusting screw (954) +1/4
Adjustment of maximum flowrate
Change in flowrate (L/min) 6
Tightening amount (rotation) of adjusting screw (953) +1/4
Adjustment of minimum flowrate
Change in flowrate (L/min) 5
Tightening amount (rotation) of adjusting screw (928) +1/4

Adjustment of Adjustment of internal Starting pressure of compensation control (kgf/cm2) 16

input horsepower spring Change in input torque (kgf·m) 4.3
A 1.8
Tightening amount (rotation) of adjusting screw (924) +1/4
Pressure change at the beginning of flow control
Adjustment of flowrate control features 1.5
(kgf/cm2)
Change in flowrate (L/min) 14

4-40 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.5 Hydraulic System, Part II

4.5.1 SY135F CONTROL VALVE (KMX13RB/M45201C)
Schematic Diagram of Control Valve Oil Port

Front

Spool of XBp1 bypass block

valve
Pilot oil port (P1 side)
Relief valve for AaR grab arm
Retraction of grab arm 2 for XBa
Pilot port for Pal grab arm holding valve
Relief valve for XbR boom
Retraction of XBa1 grab arm

Lowering Boom 1 for XBb 1 Lifting of Boom 2

Pilot port for PbL boom holding valve

Relief valve for AkR bucket Relief valve of AOR optional oil port
XAO optional pilot port
Relief valve for XAk bucket
Signal oil port for operating device
Backward of Zat1 left travel Xbs right rotation
Main relief valve for MR Travel signal oil port

PTa linear travel Backward pilot port for XAtr right travel

WX135-15113020

Figure 4-39

Back
Extension of grab arm 1 for XAa 1

Spool of XBp2 bypass block valve

Pilot oil port (P2 side)

Relief valve for grab arm Extension of grab arm 2 for XAa2

Lifting boom 1 for XAb1

Lifting of XAb2 boom confluence
Relief valve for BbR boom

Spare for XBo Unloading of XBk bucket

Spare relief valve for BoR Relief valve for BkR bucket

Left travel forward for XBt1

XAs left rotation

Right travel forward for XBtr

WX135-15113020

Figure 4-40

Maintenance Manual - 01 - 2021 4-41

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Left Side

Oil port 1 for CK1 confluence (P1 side)

LCAT2 check valve LCAP2 check valve

LCb check valve

Bb boom lowering
Ab boom lifting

Bk bucket unloading AK bucket digging

Forward of Bt1 left travel Backward of At1 left travel

CMR1 check valve Pressure rise of Pz main relief valve

C2 check valve

C1 check valve

CMR2 check valve

Bucket priority for Pnk boom
WX135-15113021
Figure 4-41
Right Side

Oil port side for CK2 confluence (P2)

Arm digging priority for Pna1 rotation,
and grab arm priority for boom
Aa (ROD) grab arm
Ba (HEAD) grab arm (retraction)
(extension)
DR5 oil leakage port

R2 oil replenishment
port Oil port for Lcb2 check valve

A0 spare oil port Oil port for Lc0 check valve

(B0) Spare oil port

Oil port for As rotary Rotary priority for Pns boom

motor (left turn) Oil port for Bs rotary motor (right turn)
CPG check valve

Btr right traveling motor (forward)

Atr right Cp1 check valve

D1 throttle valve
traveling
motor
(reverse)

WX135-15113022

Figure 4-42
4-42 Maintenance Manual - 01 - 2021
 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Oil inlet port

P1 pump oil port

P pump oil port

R1 oil return port

Front End Face

P3 pump oil
port

WX135-15113023

Figure 4-43

Maintenance Manual - 01 - 2021 4-43

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Oil port Installation

Conformity Name of Oil Port
size torque
Atr Oil port for right traveling motor (reverse)
Btr Oil port for right traveling motor (forward)
(Ao) Optional oil port
(Bo) Optional oil port
Ak Armless oil port for bucket cylinder (digging)
Bk Arm oil port for bucket cylinder (unloading)
Ab Armless oil port for boom cylinder (lifting)
Bb Arm oil port for boom cylinder (lowering)
AtL Oil port for left traveling motor (reverse)
BtL Oil port for left traveling motor (forward)
G3/4 150～180N▪M
As Oil port for rotary motor (left turn)
Bs Oil port for rotary motor (right turn)
Aa Armless chamber oil port for grab arm cylinder (extension)
Ba Arm chamber oil port for grab arm cylinder (retraction)
P1 Pump oil port (P1)
P2 Pump oil port (P2)
(Ck1) Oil port (P1) side for confluence
(Ck2) Oil port (P2) side for confluence
(P3) Pump oil port
(R2) Oil replenishment port
Px Signal oil port for operating device
Py Signal oil port for traveling
Pz Pilot oil port for relief valve pressurization
PG Oil port for pilot pressure source
Pnal Pilot oil port for logic control valve of grab arm 1
G1/4 34～38N▪M
Dr3 Oil leakage port
Dr5 Oil leakage port
Pilot oil port for locking valve (grab arm cylinder with grab arm
PaL
chamber)
PbL Pilot oil port for locking valve (boom cylinder without arm chamber)
G1/4 83～110N▪M R1 Oil return port
XAtr Pilot oil port for right travel (reverse)
XBtr Pilot oil port for right travel (forward)
(XAo) (Optional pilot oil port)
(XBo) (Optional pilot oil port)
G3/4 69～78N▪M
XAk Pilot oil port for bucket (digging)
XBk Pilot oil port for bucket (unloading)
XAb1 Pilot oil port for boom 1 (lifting)
XBb1 Pilot oil port for boom 2 (lowering)

4-44 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Oil port Installation

Conformity Name of Oil Port
size torque
XAa2 Pilot oil port for grab arm 2 (extension)
XBa2 Pilot oil port for grab arm 2 (retraction)
XAtL Pilot oil port for left travel (reverse)
XBtL Pilot oil port for left travel (forward)
XAs Pilot oil port for rotation (left turn)
XBs Pilot oil port for rotation (right turn)
XAa1 Pilot oil port for grab arm 1 (extension)
XBa1 Pilot oil port for grab arm 1 (retraction)
XAb2 Pilot oil port for boom confluence (lifting)
(XB-
Pilot oil port for bypass block valve spool (P1 side)
p 1)
(XB-
Pilot oil port for bypass block valve spool (P2 side)
p 2)
Dr1 Oil leakage port
Dr2 Oil leakage port
(PTa) Pilot oil port for linear travel

Maintenance Manual - 01 - 2021 4-45

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.5.2 HYDRAULIC SCHEMATIC DIAGRAM FOR CONTROL VALVE IN SY135F

CRANE

Figure 4-44

4-46 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.5.3 EACH SPOOL OPERATED BY CONTROL VALVE IN SY135F CRANE

1) Boom
a. Boom up

Figure 4-45
Action principle
 During the boom lifting operation, the pilot oil circuit XAb1 and the confluence control pilot
XAb2 are connected. The main oil flows from the main pump P1 to the boom cylinder armless
chamber through the left position of the boom spool. At the same time, the P2 oil circuit of the
main pump flows through the confluence spool (marked in the figure) to the rear end of the
boom spool, and makes confluence with the P1 oil circuit (confluence in the valve) to reach
the boom cylinder armless chamber at the same time.

Maintenance Manual - 01 - 2021 4-47

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

b. Boom lowering

Figure 4-46
Action principle
 During the boom lowering operation, the pilot oil circuit XBa1 is connected, the boom valve
spool is in the right position, and the P1 pump oil flows through the boom cylinder arm chamber
through the boom valve spool to realize the boom lowering.

4-48 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

2) Grab arm
a. Grab arm excavation

Figure 4-47
Action principle
 During the grab arm digging, the pilot oil circuit XBa2 and XBa1 and the locking unloading pilot
PaL are opened at the same time, the P2 pump passes through the right side of the grab arm
spool, and the oil of P1 pump passes through the right side of the confluence spool, after the
flow confluence, and flows through the grab armless chamber of the grab arm cylinder so as
to realize the digging action of the grab arm and realize the digging action of the grab arm.

Maintenance Manual - 01 - 2021 4-49

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

b. Grab arm unloading

Grab arm
unloading

Figure 4-48
Action principle
 When the grab arm is unloaded, the pilot oil circuit XAa2 and XAa1 are opened at the same
time. The oil supply of P2 pump flows through the left side of the grab arm spool, and the oil
supply of P1 pump flows through the grab arm unloading and confluence spool, and then the
flow confluence (flow confluence in the valve) flows through the grab arm chamber of the grab
arm cylinder, so as to realize the grab arm unloading operation.

4-50 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

c. Operation of crushing hammer

Quartering
hammer

Accumu
lator

Oil return
filter

Oil radiator

Figure 4-49
Action principle
 During the crushing operation, XAo is connected, and the main spool of the main valve
crushing joint moves to the left under the action of pilot oil XAo so that P2 main oil circuit is
connected with the crushing hammer so as to realize the crushing hammer operation. High
pressure ball valve

Maintenance Manual - 01 - 2021 4-51

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Figure 4-50
1. Straight through transition joint at SIDB-36-5. O-ring 33.7×3.5
16WDX end
2. WD-B16ED Washer 6. Valve body ￠60×85.5
3. Valve body 105×75×60 7. Elastic retainer ring for shaft GB/T894
1-40
4. O-ring 39.7×3.5

4-52 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Oil return filter

Oil inlet
Oil outlet

18041606
Figure 4-51
1. CMS-M5×35(0.5Mpa) differential pressure 13. GB/T 1235 O O-ring 90 × 3.1 (hard 90)
transmitter
2. GB/T 1235 O-ring 12 × 1.9 14. PLF-E240.1 Casing
3. B/T 70.1 Screw M12×40, Grade 12.9 15. JB/T982Combination washer 14
4. PLF-C160-2 Cover 16. JB/T1000 Outer hexagonal plug
M14×1.5 17.GB/
5. O-ring 65×3.1
6. GB/T 3452.1 O-ring 73×3.55 Technical parameter
7. GB/T 1235 O-ring 14×2.4 1. Nominal flow rate: 240 L/min.
8. PLF-C160.1 Bypass valve 2. Filtration precision: 10 μm
9. GB/T 70.1 Screw M5×16 3. Nominal pressure H = 32, e = 16, C = 6.3,
MPa.
10. GB/T 93Spring pad 5
4. Transmitter power 220/50 (V/W)
11. PLF-C240-1 Filter head
5. Connection type: flange connection
12. LH0240D010BN3HC Filter element

Maintenance Manual - 01 - 2021 4-53

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Crushing Foot Valve

Figure 4-52
1. TB-001 footboard 7. GB/T91 Pin 2.5×25
2. TB-002 Adjustment block 8. GB 882 8×50 Pin shaft 8×50
3. Bolt M10×45 galvanized 9. 890235011-1 Foot valve assembly
4. Nut M10 10. Screw GB/T70.1 M6 × 16, Grade 10.9, Dacromet
5. JTB-003 Fixed block 11. Spring gasket GB/T93 6, stainless steel
6. GB 882 10×60 Pin shaft 10×60 12. Tread plate 232×74×14

4-54 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Accumulator

O-ring

Figure 4-53
1. TB-001 footboard Technical parameters
2. TB-002 Adjustment block 1. Nominal volume: 0.3L.
3. Bolt M10×45 galvanized 2. Nitrogen filling pressure: 15 Bar; high operating pressure:
70 Bar.
4. Nut M10
3. Operating temperature range: - 10 ~ + 80 ℃.
5. JTB-003 Fixed block
4. Galvanized surface.
6. GB 882 10×60 Pin shaft
10×60 5. O-ring: 1A-P18 (17.8 × 2.4), made of NBR.
6. There is a white plastic cap to block the accumulator
screw teeth.

Maintenance Manual - 01 - 2021 4-55

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Overflow valve
Plug-in relief valve
LARPGE

O-ring 22.41.8

Retaining ring
22.219.21.25

O-ring 191.8 

HIP-YL200-5 valve
body

Figure 4-54

4-56 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

3) Bucket
a. Bucket excavation

Arm confluence

Grab
arm
Boom up Grab arm
Boom excavation
Boom lowering
Extension of
grab arm

Bucket unloading
Bucket Bucket
excavation

Traveling RIGHT
Rotation

Straight travelling valve

Traveling LEFT

Figure 4-55
Action principle
 When the bucket is digging, the pilot oil circuit reaches the right control position of the bucket
valve spool through PBc, opens the bucket valve spool and stays on the right position. The
P1 pump supplies oil through the right position of the bucket valve spool and flows through
the armless chamber of the bucket cylinder through BC port to realize the digging action of
the bucket.

Maintenance Manual - 01 - 2021 4-57

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

b. Bucket unloading

Arm confluence

Grab
arm
Boom up Grab arm
excavation

Boom
Boom
lowering Extension of
grab arm

Bucket
unloading Bucke
Bucket t
excavation

Traveling
RIGHT Rotation

Traveling
Straight travelling valve
LEFT

Figure 4-56
Action principle
 When the bucket is unloaded, the pilot oil circuit reaches the left control position of the bucket
valve spool through the PAc, opens the bucket valve spool and stays on the left position, and
the P1 pump supplies oil through the right position of the bucket valve spool through the AC
port and flows through the armless chamber of the bucket cylinder to realize the digging action
of the bucket.

4-58 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4) Traveling

Arm confluence

Grab
arm
Boom up Grab arm
Boom excavation
Boom
lowering Extension of
grab arm

Bucket
unloading
Bucket
Bucket
excavation

Traveling
RIGHT Rotation

Straight travelling valve Traveling

LEFT

Figure 4-57
Action principle
 During the traveling operation, the operating oil output from the hydraulic pump P1 is supplied
to the left traveling motor, and the operating oil output from the hydraulic pump P2 is supplied
to the right traveling motor. Through the pilot control oil circuit PAL, PBL, PAR and PBR of the
left and right traveling motor, the left and right travel main spool is switched so as to realize
the traveling action through the main oil circuit.

Maintenance Manual - 01 - 2021 4-59

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

5) Back swing

Arm confluence

Grab
arm
Boom up
Grab arm
Boom excavation
Boom
lowering Extension of
grab arm

Bucket
unloading Bucket
Bucket
excavation

Traveling
RIGHT Rotation

Straight travelling valve Traveling

LEFT

Figure 4-58
Action principle
 During the rotary operation, the operating oil output from the hydraulic pump P2 is supplied to
the rotary motor, and the main spool of the rotary motor is switched by the pilot control oil
circuit PAS and PBS of the rotary motor, thus the main oil circuit is connected to realize the
rotary action. Main relief valve

4-60 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Figure 4-59
Work Process
 The operating oil from the hydraulic pumps P1 and P2 flows into the control valve from their
respective interfaces P1 and P2, and is led into the main relief valve MR (601) through the
check valves CMR1 (511) and CMR2 (511). When the pressure of the passage (11) reaches
the set pressure of the main relief valve MR (601), then the main relief valve MR (601) acts.
Operation Principle of Main Relief Valve

Figure 4-60

Maintenance Manual - 01 - 2021 4-61

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Mouthpiece overflow valve

Figure 4-61
Action principle
 The interface relief valve is set at the oil cylinder interface of each operating device (boom,
grab arm and bucket). When the spool is in the neutral state and when the piston rod side of
the oil cylinder acts the external force, there is too much pressure in the oil cylinder. The
interface relief valve (602)/(603) is a valve that prevents the pressure from rising above the
set pressure.
 In addition, the interface relief valve also has the oil replenishment function. When there is any
external force acting on the cylinder, there will be insufficient flow supply to the cylinder for the
speed of the cylinder. Then, the inside of the cylinder will become negative pressure, which
will cause cavitation. The oil replenishment function is to supply the operating oil of the oil tank
passage to the oil cylinder to eliminate the negative pressure.
 The operating oil of the cylinder interface (6) is applied to the interface relief valve (602)/(603).
The operating oil of the cylinder interface (g) flows into the spring chamber (3) through the
internal passage (4) of the plunger (10). When the pressure is lower than the set pressure, the
pilot valve spool (2) is closed by the pre-load of the spring (1), and the cylinder interface (6)
and the spring chamber (3) are under the same pressure. Because the pressure bearing area
between the valve seat (8) and the main spool (9) on one side of the spring chamber (3) is
larger than that on one side of the oil cylinder interface (6), the valve seat (8) and the main
spool (9) are pushed to the right, and the operating oil flow path of the oil cylinder interface (6)
to the oil tank is cut off.

4-62 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

a. When the Interface Relief Valve Starts the Overflow Operation

Figure 4-62
 When the pressure of the cylinder interface (6) rises to the set pressure, the pilot valve spool
(2) is pushed open against the resistance of the spring (1). The operating oil in the chamber
(II) flows into the oil tank passage (5) through the passage (13). Push the plunger (10) to the
left through the pressure of the cylinder interface (6) until it touches the bushing (7). Thus, the
operating oil of the cylinder interface (6) flows into the chamber (11) through the internal
passage (4) of the plunger (10) and the spring chamber (3). The operating oil passes through
the throttle part of the clearance formed by the outer diameter of the end of the plunger (10)
and the inner diameter of the main spool (9), so the pressure difference between the oil
cylinder interface (0) and the internal passage (4) is generated. When the pressure of the
spring chamber (3) drops, the main spool (9) moves to the left, the valve seat (12) of the main
spool (9) opens, and the operating oil of the oil cylinder interface (6) flows to the oil tank
passage.

Maintenance Manual - 01 - 2021 4-63

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

a. When the Interface Relief Valve Plays the Role of Oil Replenishment Operation

Figure 4-63
 When the negative pressure is generated at the oil cylinder interface, the operating oil is
replenished from the oil tank passage. When the pressure of the oil cylinder interface (6)
becomes negative, and the pressure of the spring chamber (3) also becomes negative through
the passage (4). Then, the pressure of the oil tank passage (5) acts on the valve seat (8).
Because the pressure at the side of the spring chamber (3) is negative, the valve seat (8)
moves to the left under the action of the oil tank pressure. Thus, the operating oil of the oil
tank starts to flow into the oil cylinder interface (6) so that the negative pressure at the oil
cylinder interface (6) is eliminated.
Action Principle of Locking Valve
 Locking valves are installed between the interfaces of the control valves connected with the
piston rod side of the grab arm cylinder and the piston head side of the boom cylinder, the
grab arm spool and the boom spool. The leakage is reduced by withstanding the holding
pressure of each cylinder.

4-64 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Figure 4-64
When the Boom Spool Is in the Middle Position (the same as the grab arm spool)
 When the arm spool (303) is in the neutral position, the selection spool (l511) of the locking
valve is kept on the left side in the figure. In this position, the passage Sa and the passage Sb
conduct in the valve sleeve (l541) and the outer circumference of the selection spool (l511).
Therefore, the spring chamber (RH) of the locking valve spool (516) bears the holding
pressure on the piston head side of the slave boom cylinder, which is connected from the
passage Sa through the valve sleeve (l541), the spool (l511) and through the passage Sb.
Therefore, the locking valve spool (516) is pushed on the right valve seat as shown in the
figure in a closed state so that the leakage can be suppressed to a minimum.

Maintenance Manual - 01 - 2021 4-65

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Action Principle of Locking Valve

On the piston head side

of the boom cylinder

Figure 4-65
When the Boom Spool Is in the Middle Position (the same as when the grab arm is retracted)
 The pilot pressure of the boom lowering also acts on the selection spool (l511) of the locking
valve, and the spool (l511) moves to the right as shown in the figure. Through the movement
of the spool (L511), the orifice (a) of the valve sleeve (L541) is first closed, so the passage SA
and the passage SB are cut off, and the holding pressure on the piston head side of the boom
cylinder has no effect on the spring chamber (RH) of the locking valve spool (516).
 Then, due to the movement of the spool (L511), the inside of the valve sleeve (L541) is
connected with the spring chamber, and the spring chamber \(L512) is led into the low-
pressure circuit from the interface Dr4.
 Thus, the spring chamber (RH) of the locking valve spool (516) is led into the low-pressure
circuit from the orifice (b) of the valve sleeve (l541) through the passage Sb. Therefore, the
force of pushing the locking valve spool (516) to the right as shown in the figure becomes
4-66 Maintenance Manual - 01 - 2021
 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

weaker. In addition, the holding pressure on the piston head side of the boom cylinder acts on
the annular pressure bearing part composed of the guide diameter of the locking valve spool
(51fi) and the valve seat diameter, so the locking valve spool (516) is pushed to the left to
release the locking function.
 When the above action is performed during the boom lowering operation, the return oil on the
piston head side of the boom cylinder of the slave boom spool (303) returns to the opening
part of the oil tank (with an outlet throttle type opening). Because it is carried out before
opening, the operability of the boom lowering operation will not be affected. Figure

Figure 4-66

Maintenance Manual - 01 - 2021 4-67

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Section (A-A)

Section A-A

Figure 4-67

4-68 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Section (B-B)

Section B-B

Figure 4-68

Maintenance Manual - 01 - 2021 4-69

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Section of Linear Travel and Left Travel (C-C)

Cross-section C-C

Figure 4-69

4-70 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Section of Right Travel and Rotation (D-D)

Cross-section D-D

Figure 4-70

Maintenance Manual - 01 - 2021 4-71

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Section of Bucket and Boom Lifting (E-E)

Cross-section E-E

Figure 4-71

4-72 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Section of Boom and Arm (F-F)

Section F-F

Figure 4-72

Maintenance Manual - 01 - 2021 4-73

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Section (G-G)

Section G-G

Figure 4-73

4-74 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Section of Arm Confluence (L-L)

Section L-L

Figure 4-74

Maintenance Manual - 01 - 2021 4-75

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Section (H-H)

Section H-H

Figure 4-75
Section (K-K)

Cross-section K-K

Figure 4-76

4-76 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.5.4 CENTRAL SLEWING CONNECTOR

Figure 4-77

Maintenance Manual - 01 - 2021 4-77

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

1 Hexagonal bolt ZH0632A001-0014 12 Slewing shaft ZH0632A001-0002

2 Standard spring washer ZH0632A001-0015 13 Tapered plug ZH0632A001-0012
3 O-ring ZH0632A001-0010 14 Tapered plug ZH0632A001-0013
4 End cover ZH0632A001-0003 15 Baffle ZH0632A001-0004
5 Gasket ZH0632A001-0006
6 Elastic retainer ring for shaft ZH0632A001-0011
7 Rotating sealing ring ZH0632A001-0007 A: Traveling left (forward)
8 Slewing body ZH0632A001-0001 B: Traveling right (forward)
9 Anti-wear ring ZH0632A001-0016 C: Traveling left (backward)
10 Anti-wear ring ZH0632A001-0016 D: Traveling right (backward)
11 O-ring ZH0632A001-0009 E: Motor oil drain port

No. Inspection Item Standard Measures

Standard
Clearance between Standard clearance Clearance limit
16 dimension Replacement
rotor and shaft
80 0.056–0.105 0.111

4-78 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.5.5 RUNNING MOTOR

4.5.5.1 TRAVELLING MOTOR (FINAL TRANSMISSION)

Figure 4-78
A: Main oil port of motor (main pressure oil port)
B: Main oil port of motor (main pressure oil port)
C1: To hydraulic tank (drain port of left traveling motor)
Screw plug (right traveling motor)
C1: To hydraulic tank (drain port of right traveling motor)
Screw plug (left traveling motor)
D: Double-speed travel control port

Maintenance Manual - 01 - 2021 4-79

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Tightening Torque

Figure 4-79
Specification
Type TM40VD
Name Type Parameter

Theoretical displacement of High speed 73.8

motor (ml/r) Low speed 119.3
High speed 2100.3
Rated speed of motor (r/min)
Low speed 1299.2
Volumetric efficiency (ηω) ━ 97

Model efficiency (ην) ━ 87

Reduction ratio (i) ━ 49.95

System pressure (MPa) ━ 34.3

Rated fuel supply (L) ━ 126

4-80 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Figure 4-80
1. Screw plug 13. Spring 25. Principal axis
2. One-way valve spring 14. Swashplate 26. Plunger
3. One-way valve 15. Pivot 27. Floating Seal
4. resilience spring 16. Crankshaft 28. Plate
5. Balance valve 17. RV gear A 29. Disc
6. Safety valve 18. RV gear B 30. Oil distribution disc
7. Spring of safety valve 19. Cover 31. Spring
8. End cover 20. Driven gear 32. Plunger
9. Regulating valve 21. Driving gear 33. Screw plug
10. Spring 22. Drain screw plug 34. One-way valve
11. Brake piston 23. Hub
12. Cylinder 24. Adjusting plunger

Maintenance Manual - 01 - 2021 4-81

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Overview
Selection of Travelling Speed

Figure 4-81
 The swash plate (14) has two faces (x, y) behind it and is supported by a pivot (15).
 When the pressure of the control chamber (a) rises, it pushes the adjusting plunger (24), thus
minimizing the swash plate angle and speeding up the traveling speed.

4-82 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Operations
At a low speed (with the maximum motor swash plate angle)

Brake
valve

Central slewing
connector

Travelling control valve Selection

solenoid valve
of 2-stage
traveling speed

Figure 4-82
 Due to the demagnetization of the travel second speed selection solenoid valve, the pressure
oil from the hydraulic pump cannot flow to the oil port D.
 Therefore, the spring (10) has pressed the regulating valve (9) to the left.
 Therefore, the regulating valve (9) interrupts the main pressure oil from the control valve to
the end cover by pushing the check valve (34).
 The pressure oil in the control chamber is discharged into the motor housing through the
passage B of the regulating valve (9).
 In order to travel slowly, the pressure oil from the cylinder C pushes the swash plate (14)
towards the maximum swash plate angle, and the motor capacity increases to the maximum.
At a high speed (with the minimum motor swash plate angle)

Maintenance Manual - 01 - 2021 4-83

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Brake
valve

Central slewing
connector

Travelling control valve Selection solenoid

valve of 2-stage
traveling speed

Figure 4-83
 When the selection solenoid of the second traveling speed is energized, the pilot pressure
from the hydraulic pump flows into port D and pushes the control valve (9) in the right direction.
 Therefore, the main pressure oil from the control valve flows through the passage B of the
regulating valve (9) into the control chamber (a) and pushes the regulating plunger (24) on the
left side.
 In order to travel at a high speed, the swash plate (14) is squeezed towards the minimum
swash plate angle, and the motor capacity is minimized.

4-84 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

1. Operation of brake valve

Control valve
 The control valve is composed of the check
valves (3a) and (3b), the balance valve (5)
and the safety valve (6). Refer to the right
figure for the oil circuit structure.
 The functions and operations of these
components are as follows:

Figure 4-84
2. Function of balance valve and check
valve Control valve

 In downhill travel, the falling force of the self

weight will make the machine travel faster
than the motor rotation. Therefore, it is very
dangerous to reduce the engine speed
because the motor is idling and out of
control. These valves allow the machine to
travel close to the engine speed (pump
displacement) to avoid this hazard.
Operation during Oil Supply
 When the travel control lever is operated,
pressure oil from the control valve is
supplied to the port PA, which pushes and
opens the check valve (3a) and flows from
the port MA on the inlet side of the motor to Figure 4-85
the port MB on the outlet side of the motor.
However, since the motor outlet oil is closed
by the check valve (3b) and the balance
valve (5), the supply side pressure will
increase.

Maintenance Manual - 01 - 2021 4-85

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

3. Operation during Oil Supply


Control valve
Pressure oil on the supply side flows from
the orifice E1 of the balance valve (5) into
the chamber S1. When the pressure in the
chamber S1 rises beyond the switching
pressure of the balance valve, the balance
valve (5) will be squeezed in the right
direction. Therefore, the oil circuit between
the outlet side oil port MB and the oil port
Pb will be opened, the motor outlet oil circuit
will be opened, and the motor will start to
rotate.

Figure 4-86
4. Braking Operation in Downhill Travel
 In downhill travel, if the machine is out of Control valve

control, the motor will idle through the

orifice E1 to reduce the oil pressure at the
inlet side of the motor and the pressure in
the chamber S1. When the pressure in the
chamber S1 is lower than the switching
pressure of the balance valve, the balance
valve (5) will return together with the return
spring (4) in the left direction, and the outlet
side oil port MB will be throttled. Therefore,
the pressure on the outlet side will rise and
there will be resistance to the rotation of the
motor to prevent the machine from being
out of control. This means that the
counterbalance valve (5) is moved to the
position (a), where the weight of the
Figure 4-87
machine and the pressure at the inlet side
are balanced with the pressure at the outlet
side port MB, and the outlet oil circuit is
throttled to control the speed to the speed
of the pump flow.

4-86 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

5. Safety valve
Control valve
Function
 When the travel stops (or the downhill
travel), the balance valve (5) will close the
inlet and outlet oil circuits of the motor.
However, due to the inertia of the motor, the
pressure on the outlet side of the motor will
rise abnormally and may damage the motor
and pipeline. Therefore, the relief valve
guides the abnormal high pressure to the
inlet side of the motor to prevent any
equipment damage.
Operations
 When the pressure oil supplied from the
port PA stops flowing when the travel stops,
the return spring (4) will return the
counterbalance valve (5) from the right side
to the left side (at the middle position).
 Although the balance valve (5) closes the Figure 4-88
chamber (a) of the oil circuit on the outlet
side, the inertia makes the motor rotate and Control valve
the pressure in the chamber (a) rises.
 The high pressure oil in the chamber (a)
flows through the throttle valve B of the
safety valve (6a) and enters the chamber
(d) from the chamber (c). The pressure oil
entering the chamber (d) moves the
plunger (32) to the left. Meanwhile, the
safety valve (6a) is pushed open by the
pressure oil in the chamber (a), and the
pressure oil in the chamber (a) flows into
the chamber (f) through the port (e).
Therefore, the pressure oil in the chamber
(a) flows into the chamber (f) at a rather low
speed to control the pressure in the
chamber (a) and prevent any cavitation in
the chamber (f).
 When the plunger (32) reaches the end of
the stroke, the pressure in the cavities (d Figure 4-89
and c) will rise, the relief valve (6a) will be
closed again, and the pressure in the
chamber (a) will rise further.
 Therefore, the relief valve (6b) will open and
the pressure oil in chamber a will flow from
Maintenance Manual - 01 - 2021 4-87
Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

the chamber (g) to the chamber (f). As

mentioned above, the pressure oil in the
chamber (a) can be controlled by two
stages, and the hydraulic motor can be
braked evenly to stop.
6. Operation of parking brake
In Travel Operation
 When the travel control lever is operated,
the pressure oil from the pump will affect
the balance valve (5), open the oil circuit (a)
to the parking brake and flow into the
chamber (b) of the brake plunger (11).
 The pressure in the chamber (b)
overcomes the spring (31) and pushes the
brake plunger (11) to the left.
 In this way, the extrusion force on the plate
(28) and the disc (29) can be eliminated, the
plate (28) and the disc (29) will be
separated, and the braking force will be
Control valve
released.

Figure 4-90
7. In the Travel Center
 When the travel control lever is in the center
position, the counterbalance valve (5) will
return to the center position and the oil
circuit (a) to the parking brake will be
closed.
 The pressure oil in the chamber (b) of the
brake plunger (11) is discharged into the
housing, and the spring (31) pushes the
brake plunger to the right.
 Therefore, the disc (28) and the disc (29)
will push each other and the brake will start
to operate.

Control valve

Figure 4-91

4-88 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Hydraulic Schematic Diagram of Traveling Motor

Figure 4-92
Operating Principle of Traveling Motor Control Valve
1. If the oil is fed from the motor port (a).
2. In Travel, open the check valve 327 to enter the right motor chamber.
3. Then, it enters the valve stem 329 through the orifice to move it to the left, open the oil circuit
of the travel brake, and release the travel brake. Through this action, the oil return circuit of
the motor port B is also opened.
4. Then, the buffer piston 381 is pushed to the left by entering the buffer piston chamber through
the middle orifice of the right safety valve (f1). Then, the safety valve f1 has a short opening

Maintenance Manual - 01 - 2021 4-89

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

action.
5. If the motor is in the overspeed state during the downhill period, the pressure of the port (a)
will be reduced due to the insufficient oil supply from the pump, and the valve stem 329 will
move to the right under the action of spring force to close the oil return passage of the motor
so as to limit the speed of the motor. So the stem 329 is called as a balance valve.
Orifice

1. The motor stops when the port (a) does not supply oil. The inertia effect of the machine makes
the motor continue to rotate, and the function of the motor is converted to that of a pump. The
sealing of the main valve stem causes the pressure of the port B to rise. The pressure oil
4-90 Maintenance Manual - 01 - 2021
 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

enters the buffer chamber through the orifice in the middle of the left safety valve F, and pushes
the buffer piston 391 to move right. At the same time, the safety valve f opens to supply oil to
the chamber A, which eliminates the pulse pressure of the port B and prevents the motor port
A from sucking.
2. The buffer piston is a stepped structure, and the area of pressure oil is gradually increased,
which can further play a buffer role.
3. When the piston moves to the rightmost end, the pressure in the chamber B rises and the left
safety valve F is completely closed.
4. When the pressure increases further, the pressure in the chamber B acts on the right relief
valve F1, which limits the maximum pressure of the motor. This pressure is the maximum
braking pressure.
Orifice

Maintenance Manual - 01 - 2021 4-91

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

1. Important note: when the motor stops rotating, the port A becomes an oil suction chamber,
and the pressure is the minimum.
2. When the motor stops initially, the pressure at the port B of the motor acts on the port A (the
whole round area) of the left safety valve (f), and the valve stem moves to the left to drain the
oil to the port (b) (Note: the port (b) is connected with the port A of the motor). When the buffer
piston moves to the rightmost end, the pressure at the port (c) rises. Due to the diameter
difference of the valve stem, the valve stem moves to the right under the action of spring force
and pressure difference force, and the safety valve (f) closes. The pressure here is called the
primary pressure.
3. This process is very short, the purpose is to eliminate the pulse pressure of the port B and
prevent the port A from sucking.
Connect to the Drain to the port A of the
buffer piston motor Oil from the port B of the
motor

Large diameter Small diameter

Valve rod

As the buffer piston moves to the rightmost

end, the pressure in the chamber increases
gradually. a → b, the opening pressure is 10.2 MPa 

1. Important note: when the motor stops rotating, the port A becomes an oil suction chamber,
and the pressure is the minimum.
2. After the safety valve (f) is completely closed, the pressure at the port B of the motor acts on
the port (b) of the right safety valve (f1) (the large diameter minus the circular area of the
small diameter) to drain the oil to the port (a) (Note: the port (a) is connected with the port A
of the motor). Then, the pressure is called as the secondary pressure, which is the maximum
braking pressure.
3. This process shows that the valve also has a short opening process during the normal Travel
process, but it is closed immediately. It plays a role, that is, starting smoothly and absorbing
pressure pulse when braking.

4-92 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Connect to the
Oil from the port B of
buffer piston the motor
Drain to the port A of
the motor

Large diameter Small diameter

The chamber becomes an oil

suction chamber with the
b → a, the opening pressure is
lowest pressure. 41.2 MPa 

Principle of Reducer
1. Action: the reducer is composed of a two-stage planetary gear mechanism, which decelerates
the high-speed rotary motion of the hydraulic motor, and finally outputs the low-speed and
high torque rotation through the ring gear [1].
2. Action description: the rotary motion of the hydraulic motor is transmitted through the first
stage sun gear (1)[4] combined with the spline part of the shaft [102]. Then, the first stage
planetary gear (1)[5] is engaged with the sun gear (1)[4], and the planetary gear (1)[5] is
engaged with the hub[1] for revolution while doing the rotation motion. The planetary gear
(1)[5] is fixed on carrier[3], and the revolution motion drives carrier[3] and the second
stage sun gear (2)[6] connected with carrier[3] to rotate. Through the rotation of the second
stage planetary gear (2)[9] fixed on the shaft[2] column, the ring gear [1] (ring gear) rotates,
and the output of the reducer rotates. (The first stage planetary gear (1)[5] also rotates at the
same time)

Maintenance Manual - 01 - 2021 4-93

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Planet gear (2) [9]

Ring gear [1]

Planet gear (1) [5]

Spring [2]

Shaft [102]

Sun gear (2)[8]

Sun gear (1)[4]

Figure 4-93
(1) Disassembly and Assembly of Travel Reducer Part:
① Place the traveling motor horizontally. (make the discharge outlet facing down)
② Loosen the plug of the oil supply port, release the pressure in the reducer, and then gently
tighten the plug. (Note: if the pressure is applied inside the reducer, when the plug at the outlet
is released, the lubricating oil will be ejected).
③ First, loosen the plug of the discharge outlet and drain the lubricating oil. (Note: for the amount
of lubricating oil in the reducer, select a container that can be filled with 2.1 L)
④ If the lubricating oil can not come out, slowly loosen the plug of the oil supply port.
⑤ Remove the O-ring from the plug. (Note: the removed O-ring cannot be used any more
because it may cause oil leakage)
4.5.5.2
(2) Remove the cover.
① Turn over the traveling motor. (make the
reducer face up)
② Loosen and take out 12 M10 bolts [35]
③ The contact surface of hub[1] and the
cover[14] is coated with sealant. The
cushion rod is against the convex part of the
cover, and the cover is removed by tapping
from the top.

4-94 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Warning Figure 4-94

Warning: when you hit the cover diagonally, the

cover may jump up and fall down. Be careful
not to hit your feet.

④ Install the eye-bolt into the port PF1/2, lift

the cover up and move it out of the hub.

Figure 4-95
(3) Remove the thrust plate.
① Remove the thrust plate[13].

Figure 4-96
(4) Take out the first stage reduction gear.
① Take out the sun gear (1)[4] by hand.
Note: if there is lubricating oil, be careful not to
slide the sun gear.

Figure 4-97

Maintenance Manual - 01 - 2021 4-95

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

② Screw M12 lifting rings into the three

threaded holes of the carrier (1)[3], and lift
the carrier (1) assembly upward with a
crane.
Note: when lifting the carrier (1) assembly, make
the hub[1] and carrier (1) assembly center pair
coincide and slowly lift so as not to let the end
face of planetary gear (1)[5] scratch the inner
gear of the hub,
Figure 4-98
(5) Remove the coupling.
① Remove the coupling[15] from the
shaft[102].

Figure 4-99
(6) Take out the second reduction gear.
① Screw on the M12 lifting ring at 3 threaded
holes of the carrier (2)[7] and lift the carrier
(2) assembly up with a crane.
Note: when lifting the carrier (2) assembly, make
the hub[1] coincide with the center of the carrier
(2) assembly and lift it slowly not to let the end
face of the planetary gear (2)[9] scratch the
inner gear of the hub.
Figure 4-100
② Remove the sun gear (2)[8] from the carrier
by hand.
Note: if there is lubricating oil, pay attention to
the sun gear (2) not to slip.
(7) Remove the lock washer.
① The φ 14 hole of the hub[1] is fixed with the
turnover table.

Figure 4-101

4-96 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

② Hold one of the two pieces of lock

washer[22] in the clearance with a driver,
and tap the lock washer diagonally
downward with a hammer to take out it.

Figure 4-102
(8) Remove the hub.
① Take out the bolts from the fixed hub and
the turnover table.
② Screw on the (M10) lifting ring on the hub
and lift the hub with a crane.

Warning
Overlap the spindle axis with the hub axis, and
then lift up them slowly. If lift up them in tilting,
the lifting force will be too much, which will Figure 4-103
cause the sling for lifting loads, ring and others
to break, causing the sling for lifting loads and
others to hit your body and resulting in injury.
Therefore, when it can’t be taken out, do not lift
it by force, and take it out safely with a press.

(9) Remove the floating seal.

① Put your hand on the inner diameter side of
floating seal [29], lift up and take out the
floating seal.
Note: the edge of the floating seal will cut your
hand, so it is best for you to wear gloves when
taking it. If mud and sand enter and form solid
adhesion, they should be pried out with the lever
principle by using a screwdriver and other
similar tools. Figure 4-104

Maintenance Manual - 01 - 2021 4-97

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

(10) Take out the angular contact ball bearings.

① Hold the outer ring of angular thrust bearing
[24] with a chisel, divide the circumference
into three or four equal parts, and tap and
take out with a hammer.
Note: tapping on the inner ring will damage the
track surface of the ball bearing so that the
bearing can no longer be used. Therefore, do
not remove the angular contact ball bearing
unless it must be replaced. When the outer ring Figure 4-105
fitting part of the angular contact ball bearing
[24] is taped out of the hub[1], the whole bearing
will fall from the hub [1]. In order to avoid parts
damage, put a container under the operating
table, and lay a layer of rubber pad on the
container.
(11) Removal of rear flange
① Turn over the traveling motor. (Make the
motor side facing up)
Note: the purpose of writing down is to easily
remove the plug when disassembling the rear
flange. Then, loose the plug until it can be
removed by hand. Don't loosen the plug when
you don't decompose the rear flange
components.
Figure 4-106
② Loosen two plugs [324].
Note: the purpose of writing down is to easily
remove the plug when decomposing the rear
flange. Then, loose the plug until it can be
removed by hand. Don't loosen the plug when
you don't decompose the rear flange
components. When the plug [324] is loosened,
be careful that the plug [324] and spring [328]
may fly out due to the action of the spring [328].

4-98 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

③ Loosen two plugs [380].

④ Loosen two plugs [352].
⑤ Loosen the plug [357].

Figure 4-107
⑥ Loosen two safety valve assemblies [20
others].

Figure 4-108
⑦ Take out two safety valve assemblies
[20 others].
Note: the removed O-rings [207], [209], [212]
and backup rings [208], [210] can be used no
longer.

Figure 4-109
⑧ Loosen 10 hexagon bolts [343] and take
them out from the rear flange.
⑨ Remove the rear flange [301] from the
spindle [2].
Note: hold the rear flange by hands and lift up
and take out it smoothly. Note: if it is pried and
taped in force, this will make the timing plate
[109] fall down and cause injury.

Figure 4-110

Maintenance Manual - 01 - 2021 4-99

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

⑩ Remove two pins [34] from the spindle [2].

Figure 4-111
⑪ Remove the O-RING [32], [33] (2 psc) from
the SPINDLE.
Note: the removed O-rings [32] and [33] can be
used no longer.

Figure 4-112
(12) Disassembly of rear flange components
① The joint surface of rear flange and spindle
[2] is placed upward on the platform.
② Remove the timing plate [109] from the rear
flange [301].
Note: there is oil on the joint surface of rear
flange [301], and the timing plate is absorbed on
the joint surface of the rear flange [201]. Insert a
round blade into the casting slot of the rear
Figure 4-113
flange [301], gently pry up and take away the
timing plate [109]. If sharp tools such as
screwdrivers are used, the joint surface will be
injured and oil leakage will occur.
③ Take out the deep slot ball bearing [150]
from the rear flange [301].

4-100 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Figure 4-114
④ Remove the pin [341] from the rear flange
[301].

Figure 4-115
(13) Disassembly of brake valve components in
rear flange
① Remove the PLUG [324] (2 pcs) from
REAR FLANGE [301].
② Take out two washers [325] and two springs
[328] from the rear flange [301].

Figure 4-116
③ Remove the SPOOL [323] from REAR
FLANGE [301].
Note: the plug port side of the rear flange [301]
inclines downward, and the spool will slide
down. Pay attention to holding the top before
taking it out.

Figure 4-117
④ Remove the SPOOL [323] from REAR
FLANGE [301].
Note: the plug port side of the rear flange [301]
inclines downward, and the spool will slide
down. Pay attention to holding the top before
taking it out.

Figure 4-118

Maintenance Manual - 01 - 2021 4-101

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

(14) Disassembly of spool in Speed-2 switching

① Remove the PLUG [357] from REAR
FLANGE [301].
② Remove the O-RING [359] from PLUG
[357].
Note: the removed O-RING [359] can be used
no longer.

Figure 4-119
③ Remove the SPOOL[363] and
SPRING[366] from REAR FLANGE [301].

Figure 4-120
(15) piston disassembly
① Remove the PLUG [380] (2 pcs) from
REAR FLANGE [301].
② Remove the O-RING[383] from PLUG[380].
Note: the removed O-RING [383] can be used
no longer.

Figure 4-121
③ Remove the PISTON [381] from REAR
FLANGE [301].

Figure 4-122

4-102 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

(16) Disassembly of check valve components

① Remove the PLUG [380] (2 pcs) from
REAR FLANGE [301].
② Remove the O-RING [358] from PLUG
[352].
Note: the removed O-RING [358] can be used
no longer.

Figure 4-123
③ Take out the steel balls [353] from the rear
flange [301].
Note: when it is difficult to take out the steel
balls, use a magnetic rod to suck them out.

Figure 4-124
(17) Disassembly of parking brake components

Warning
If compressed air is injected sharply, the piston
[112] will fly out of the spindle [2], which may
cause injury. Therefore, it is necessary to cover
the piston [112] for protection.

① Compressed air is injected into the access

hole of the parking brake of the spindle [2],
and the piston [112] is blown out from the Figure 4-125
spindle [2].
② Take out the O-rings [135] and [139] from
the piston [112].
Note: the removed O-rings [135] and [139] can
be used no longer.

Figure 4-126

Maintenance Manual - 01 - 2021 4-103

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

(18) Disassembly of hydraulic motor

components
Note: if you turn the traveling motor to the
horizontal direction, the oil in the chamber will
flow out. Please place a container under the
traveling motor.
① Turn the traveling motor over 90°.
② Drain the oil from the traveling motor.
③ Take out four mesh plates [116] and three Figure 4-127
friction plates [115].
④ Hold the cylinder block [104] by hand, rotate
it clockwise and counterclockwise
alternatively for 2~3 times, then pull out
the cylinder block, separate and adsorb the
shoe [106] on the swash plate [103].
Note: if you directly pull out the cylinder block
[104], the SHOE [106] will stay on the swash
plate [103], and the middle part (piston [105],
shoe [106] and others) of the cylinder block will
fall off from the cylinder block and fall into the Figure 4-128
spindle [2] chamber. Please be careful about it.
⑤ Remove the CYLINDER BLOCK [104] from
SHAFT[102].
⑥ Remove the piston components (piston
[105], shoe [106] and retainer plate [107])
from the cylinder block [104].
Note: when taking out, hold the retainer plate
[107] by hands and take it out together with the
piston [105]. The piston [105] and the shoe [106]
are twisted into one at the ball part of the piston.
In order to prevent any shoe [106] damage, it is Figure 4-129
not allowed to disassemble the piston [105] and
the shoe [106]. If it is necessary to replace, the
replacement shall be carried out in one group.
(hereinafter referred to as the piston
component)

4-104 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

⑦ Take out the piston components [105] and

[106] from the retainer plate [107]. (Group
9)

Figure 4-130
⑧ Remove the thrust ball [108] from the
cylinder block [104].

Figure 4-131
⑨ Remove three pins [151] from the cylinder
block.

Figure 4-132
(19) Remove the spring from the cylinder block.
① Place the cylinder block [104] on the
pressurization platform.
Note: it can be taken out only when the spring
[114] is replaced. When the spring [114] is taken
out, the shaft center of the metal pressing tool
(I) should coincide with the shaft center of the
washer [110] to prevent any damage caused by
the contact with the cylinder block. Apply a thin
layer of film on the cylinder block to avoid any Figure 4-133
surface damage of the cylinder block [104].

Maintenance Manual - 01 - 2021 4-105

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

② Put the pressing tool (I) on the washer Pressing tool (I)
Press
[110], press the pressing tool (I) with a machine

presser while taking out the snap ring [145]

from the middle ring slot of the cylinder
block [104].

Warning
If the pressing pressure is released rapidly, the
spring [114] will fly out, which may cause injury.
Pay attention to releasing the pressure slowly.
Figure 4-134

③ Take out the snap ring [145], washer [110],

spring [114] and washer [110] for holes from
the cylinder block [104].

Figure 4-135
(20) Removal of swash plate
① Remove the swash plate [103] from the
shaft [102].
Note: be careful that the pivot [167] will be
attached to the swash plate [103] when the
swash plate [103] is removed.

Figure 4-136
② Remove the shaft [102] from the spindle [2].

Warning
If the pressing pressure is released rapidly, the
spring [114] will fly out, which may cause injury.
Pay attention to releasing the pressure slowly.

③ Take out two pivots [167] and two pins [171]

respectively from the spindle.

Figure 4-137

4-106 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

④ Remove the FLOATING SEAL[29] from

SPINDLE [2].

Figure 4-138
⑤ Remove the FLOATING SEAL[29] from
SPINDLE [2]. Press machine

Warning and then press the

pressing tool (II).

The removed deep slot ball bearings can be

used no longer.

⑥ Press the top of the shaft with pressure, and

take out the ball bearing [149] from the shaft
[102].
Figure 4-139
⑦ Place the pressing tool (II) on the
pressurization platform,
(21) Removal of deep slot ball bearing
Note: disassemble ball bearings only when
exchanging them.
① piston components (shoe (162), piston
(161))

Figure 4-140
② Take out Speed-2 switching piston
components and the spring [185] from the
spindle [2].

Figure 4-141

Maintenance Manual - 01 - 2021 4-107

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

③ Remove the oil seal [132]1 from the spindle.

Note: the removed floating seal [29] and oil seal
[132] can be used no longer.

Figure 4-142
(22) Cleaning of components
① Distinguish the components of hub [1],
spindle [2], cover [14], rear flange [301]
from other components (hereinafter
referred to as internal components).
② Push the hub [1], spindle [2], cover [14],
rear flange [301] into a cleaning tank, and
then clean them.
Note: there is sand on the outside of each
Figure 4-143
component. Therefore, clean and remove the
sand. Kerosene for cleaning is combustible. Pay
great attention to any fire and the burns and
injuries caused by the fire.
③ Put the internal components into a crude
cleaning container with kerosene for
cleaning.

Figure 4-144

4-108 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

(23) Fine cleaning

① The internal components are put into a fine
cleaning container with kerosene, and each
component is slowly rotated and cleaned
from the outside to the inside.
② Dry the kerosene on each component with
some return wires.
Note: the inner surface of the hub [1] and spindle
[2] shall be free of dust and moisture, and shall
Figure 4-145
be dried with compressed air. After each
component is dried, apply hydraulic oil on each
component. The internal surface of the rear
flange [301], hydraulic motor components,
gears, parts that are forbidden with dust and
moisture shall be dried naturally. Apply hydraulic
oil on each component after drying them.
4.5.5.3 PREPARATION
When the GM motor is disassembled and checked, it should be prepared according to the
following benchmark. Especially the moving and sliding parts should not be injured.
3 – 1. Sealed class
Once the sealing parts (O-ring, oil seal, floating seal) are disassembled, they should be replaced
with new ones even if they are not damaged.
3-2. Reference for preparing worn components
1. All components that are obviously damaged in appearance shall be replaced.
2. If there are the following abnormalities in each component, replace it.
Reference Allowable
Component value value
Component name Phenomenon
number (standard (judgment
size) value)
- Major damage to appearance
- There is pitting on ring rear gear
[1] HUB — —
surface
- Abnormal wear such as scratch, etc
- Major damage to appearance
[2] SPINDLE — —
- Abnormal wear such as scratch, etc
[3]
CARRIER ASSY - Abnormal wear such as scratch, etc — —
[7]
[4] SUN GEAR1
- There is pitting on the gear surface
[8] SUN GEAR2
- There is pitting and spalling on the — —
[5] PLANETARY GEAR1
rotating surface of bearing.
[9] PLANETARY GEAR2
- There are indentations
[24] Ball bearing - There is surface spalling — —
- There is partial wear
[301] REAR FLANGE - The sliding parts of the spools [323], — —

Maintenance Manual - 01 - 2021 4-109

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Reference Allowable
Component value value
Component name Phenomenon
number (standard (judgment
size) value)
[363] and the piston [381] are injured.
- The contact surface with the oil seal
[102] SHAFT [132] is worn — —
- Wear of spline
[103] SWASH PLATE - There is burn — —
- Spline wear
- Much wear on inner surface
[104] CYLINDER BLOCK - There is damage or partial wear on — —
the sliding surface of the timing plate
[109].
- There is axial clearance between the
piston components
[105] piston and the shoe. Clearance: Clearance
PISTON
[106] - There is abnormal or partial wear on 0.05 mm 0.15mm
SHOE
the shoe.
- There is partial wear on the sliding
surface of the shoe [106].
[107] RETAINER PLATE — —
- Scratch and partial wear on sliding
surface with thrust ball [108]
- Partial wear on spherical sliding part
[108] THRUST BALL — —
of retainer plate [107]
- There is burn and partial wear on the
[109] TIMING PLATE — —
sliding surface
Braking
Braking
- There is partial wear on the two torque
torque
[115] Meshing piece of friction friction surfaces 206N・m
206N・m
[116] plate - Failure to meet the specified torque (21.0kgf・
(21.0kg・m)
- There is burn m)
and more
and more
- There are indentations on the
[112] PISTON — —
periphery
- There are indentations
[149]
Deep slot ball bearing - Surface spalling occurs — —
[150]
- It is worn
PISTON - Abnormal wear on the periphery
[161]
SEAL - There is abnormal or partial wear on — —
[162]
SHOE shoe
[323] - Partial wear on the periphery
SPOOL — —
[363] - There is a scratch on the periphery
[381] PISTON - There is a scratch on the periphery — —

4.5.5.4 ASSEMBLING
The assembly sequence is opposite to the disassembly one.
4 – 1. Preparation
As the disassembly 2, prepare platform, tools and materials.
4 – 2. General operation precautions
(1) Pay attention to these operations just like the general precautions of the disassembly 2.
(2) During the assembly, all metal fragments and foreign matters on the parts shall be removed,
4-110 Maintenance Manual - 01 - 2021
 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

and there shall be no burr or scar on the parts. If there is burr or scar, polish it with oilstone.
(3) O-ring, oil seal and floating seal must be replaced with new ones.
(4) Remove the residual thread glue M 10 P 1.5 in 12 hub [1] thread holes with a screw tap,
then clean and degrease the thread hole, and remove the cleaning fluid with an air gun.
Replace the hexagon BOLT [35] with a new one.
(5) When installing O-ring, oil seal and floating seal, pay attention not to damaging the parts. (you
can apply a little grease to make them smooth)
(6) The moving and sliding parts of the hydraulic motor and VALVE parts must be coated with
clean hydraulic oil (NAS Grade 9 or above) before the assembly.
(7) Do not use cloth gloves during the assembly (falling off fibers can cause some poor movement).
(8) For the tightening torque of bolts and plugs, refer to the tightening torque table in P9 1-2.
(9) After the assembly, all holes should be sealed with screw plugs to prevent any garbage
intrusion.
(10) Record representative conditions with photos and drawings. Even if the product is different
from some parts, it has no effect on the assembly sequence.
4 – 3. Assembly sequence
Note: it is necessary to adjust the preload of angular contact ball bearings when the replaced
components are reassembled. Therefore, it is necessary to confirm whether the following
Components are replaced before the assembly.
(11) The replaced components that affect the preloading adjustment of angular contact ball
bearings are the hub [1], spindle [2] and angular contact ball bearing [24].
Note: when replacing the above components for reassembly, each Component that has been
adjusted must be used for reassembly. If you use the components that have not been adjusted and
reassembled, this will cause poor action and early damage of the traveling motor. Therefore, you
should pay attention to the above.
(1) Assembly of hub component Press machine

① Assemble the hub [1] on the pressurized

Pressing tool
platform. for main
bearing

② The angular contact ball bearing [24] is

placed on the hub [1], and the bearing
Main
pressing tool is placed on the outer ring of bearing

the ball bearing [24] and pressed down on Bearing platform

the hub [1]. Press platform

③ Flip up and down the hub [1].

Figure 4-146
④ Press the bearing [24] onto the hub [1] as
described above.
Note: please pay attention to the installation
direction of the angular contact ball bearing [24].

Maintenance Manual - 01 - 2021 4-111

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

⑤ Apply lubricating oil to the O-ring of the FS pressing tool (II)

floating seal [29] and install the floating seal

[29] into the floating seal slot of the hub [1].
FS pressing tool (I)

Note: when the lubricating oil is applied to the O-

ring of the floating seal [29], the O-ring is taken
out from the floating seal [29], and the whole
surrounding of the O-ring is coated thinly with
lubricating oil.
Note: for the assembly of the floating seal [29],
place the tools in the following order: FS loading Figure 4-147
tool (I), floating seal [29] and FS loading tool (II).
Press the FS loading tool (II) into the FS loading
tool (I) until it is loaded completely. Take out the
FS loading tool and make sure that the hub end
face and the floating seal face are parallel within
1 [mm].
(2) Assembly of spindle component FS pressing tool (II)

① Apply lubricating oil on the O-ring of the

floating seal [29], and install the floating
seal [29] into the floating seal slot of the FS pressing tool (III)

spindle [2].
Note: the tools of the floating seal [29] can be
placed in the following order: FS loading tool
(III), floating seal [29] and FS loading tool (II).
Press the FS loading tool (II) into the FS loading
tool (III) until it is loaded. Take out the FS loading Figure 4-148
tool, and make sure that the end face of the
spindle slot and floating seal face are parallel
within 1 [mm].
② Install two eye bolts in symmetrical position
on the spindle [2].
③ Install the spindle [2] on the operating
platform and fix it with bolts. The fixing bolts
should be symmetrical.

Caution
Tighten the hexagon bolts. If they are not
tightened, they may fall and cause injury when
the traveling motor is operating reversely.

Figure 4-149

4-112 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

(3) Preloading adjustment of main bearing

Note: when replacing the hub [1], main bearing
[24] or spindle [2], please adjust the preload. If
the preloading is not appropriate, the main
bearing will be damaged for a short period.
① Assemble the lock washer [22] on the
spindle [2] and measure the dimension C.
② Measure the loading width D of the main
bearing.
Figure 4-150
③ Calculate the gravitational force of the
dimension from C to D, and the clearance
is + 0.13 - + 0.17 [mm]. According to the
grade in the following table, select the SHIM
[23].
Symbols T(mm) Symbols T(mm)
A 0.9 G 1.5
B 1.0 H 1.6
C 1.1 I 1.7
D 1.2 J 1.8
Figure 4-151
E 1.3 K 1.9
F 1.4 L 2.0

④ Install the SHIM [23] on the spindle [2].

Figure 4-152
(4) hub assembly
① Keep the central axes of the lifted hub [1]
and spindle [2] coincident, then lower the
hub [1] slowly, and insert the main bearing
[24] of the hub [1] into the spindle [2].

Figure 4-153

Maintenance Manual - 01 - 2021 4-113

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

② Tighten hexagon bolts to the operating

platform with the φ14 hole of the hub, and
fix them.
③ Place a spacer on the inner ring end face of
the main bearing [24] on the reduction side,
and tap the spacer gently with a hammer to
make the inner ring float no longer.

Figure 4-154
④ Put the lock washer [22] into the slot of the
spindle [2].

Figure 4-155
⑤ Press the lock washer [22] into the slot of
the spindle with a tool.
Note: when installing the carrier (2) [7], fully
press the lock washer [22] into the slot bottom
so that it does not interfere with the lock washer.
⑥ Take out the hexagon bolts connecting the
hub [1] to the operating platform.
⑦ Rotate the hub for 2~3 times.
Note: rotate the hub [1] to prevent the sliding Figure 4-156
surface of the floating seal ring from seizing or
suspected leakage.
⑧ Rotate the operating platform to make the
motor side face upward.

4-114 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

(5) Assembly of motor components in spindle

① Press the oil sealing [132] into the spindle Pressing tool (III)

[2] hole with an oil seal pressing tool and a

hammer.
Note: when installing the oil seal, apply lithium
grease on the lip of the oil seal. Pay attention to
the loading direction of the oil seal [132].
② Install two pins [171] into the pin hole of the
spindle[2].
Figure 4-157
③ Apply grease on the hemispherical surface
of the pivot [167], and insert it into the pin
[171] of the spindle [2].
④ Apply lubricating oil to the spring [185], and
assemble the piston assembly {piston [161]
and shoe [162]}.
⑤ Apply hydraulic oil on the sliding part of the
piston assembly, and install it into the piston
hole on the spindle [2].
⑥ Insert the pin [34] into the pin hole on the
rear flange joint surface of the spindle [2].

Figure 4-158
(6) Assembly of shaft Press

Caution
You may get scalded. So please wear leather Deep slot ball
bearing
gloves when carrying out the pressing and then press the
pressing tool (II).
operation to avoid scalding.

① Put the deep ball bearing [149] into the

heating groove with the temperature of
100±10 [ ℃], heat it for 10 minutes, and
Figure 4-159
press into the shaft [102].
② Tilt the traveling motor 90°.
③ Insert the shaft [102] into the spindle [2].
Note: when inserting the shaft [102], please pay
attention not to damaging the lip of the oil seal,
which has been installed in the spindle [2]. Insert
the shaft [102] slowly and smoothly into the
spindle [2]. Please pay attention to the reason
that the damage of the lip will lead to oil leakage,
which will cause the early damage of the

Maintenance Manual - 01 - 2021 4-115

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

traveling motor. Figure 4-160

④ Install the swash plate [103] into the
spindle.
Note: apply lubricating oil on the joint surface of
the spindle [2] of the swash plate [103]. Push the
swash plate [103] into the spindle [2] chamber,
align the pivot mounting holes of the swash plate
[103] with two pivots [167], and insert them into
the spindle [2].

Figure 4-161
(7) Components in cylinder block
Note: install the snap ring [145] with the sharp
corner face upward. Connect the washer [110]
on the snap ring [145] side, and turn the sharp
side of the corner toward the retaining ring [145]
side.
① Insert the components such as washer
[110], spring [114], washer [110], THS snap
ring [145] into the cylinder block [104] in
sequence. Figure 4-162

② Place the cylinder block [104] on the

pressurization platform.

Caution
Assemble the snap ring [145], put the tip of the
pliers into the slot of the retaining ring, and
install it into the slot of the retaining ring.
Please note that the retaining ring may fly out.

Note: the pressure of the spring [114] is more

Figure 4-163
than 1128 [N] (115 [kgf]). In order to prevent the
contact surface between the cylinder block [104]
and the timing plate [109] from being damaged,
the film is covered on the cylinder block [104] for
protection.
③ Put the pressing tool (I) on the washer
[110], press the pressing tool (I) while
installing the THS snap ring [145] with a pair
of pliers for the retaining ring into the
retaining ring slot of the cylinder block [104].

4-116 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

(8) Assembly of hydraulic motor components

① Insert three roller [151] into the holes of the
cylinder block [104], and then put the thrust
ball [108] on it.

Figure 4-164
② Insert nine piston components into the
retainer plate [107].
Note: after the assembly, immerse all
components in hydraulic oil.
③ Install the retainer plate [107] and nine
piston components into the cylinder block
[104].
Note: align the retainer plate [107] with the ball
face of the thrust ball [108].
Figure 4-165
④ Insert the cylinder block [104] into the shaft
[102].
Note: align the spline hole of the cylinder block
[104] with the spline shaft of the shaft [102], and
insert it.

Figure 4-166
⑤ After assembling the cylinder block [104],
rotate the cylinder block [104] by hand to
confirm that it is not tilted or shaken. If there
is any tilt or shaking, check them.
Note: do not hold the cylinder block [104]
upward after assembling. If the thrust ball is
lifted upward, it will fall off, causing it rotate
abnormally.

Figure 4-167

Maintenance Manual - 01 - 2021 4-117

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

(9) Assembly of parking brake components

Note: the friction plate [115] can be assembled
after being immersed into hydraulic oil.
① Flip over the operating platform with 90°,
and tilt it.
② Insert four meshing plates [116] and three
friction plates [115] alternatively on the
cylinder block [104].
③ Install the O-rings [135] and [139] into the
Figure 4-168
O-ring slot of the piston [112]. Then, apply
a thin layer of lubricating oil on the O-rings
[135] and [139].
④ Install the piston [112] into the spindle [2].
Note: due to the resistance of the O-rings [135]
and [139], it is difficult to install the piston [112]
into the spindle [2]. Knock the end face of the
piston [112] gently with a plastic hammer to
install it.

Figure 4-169
(10) Assembly of spool with quick switching
in rear flange
① Insert the spring [366] and the spool [363]
into the rear flange [301].
② Install the O-ring [359] onto the plug [357].
Note: apply lubricating oil on the O-ring [359].

Figure 4-170
③ Install the plug [357] on the rear flange
[301].
④ Pre-tighten the PLUG [357] to REAR
FLANGE [301] with a hexagon wrench.

Figure 4-171

4-118 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

(11) Assembly of check valve components

① Install two O-rings [358] on two plugs [352].
Note: apply lubricating oil on the O-ring [358].
② Install the steel ball [353] into the rear
flange [301].

Figure 4-172
③ Pre-tighten the plug [352] to the rear flange
[301] with a hexagon wrench.

Figure 4-173
(12) Assembly of piston component
① Install two O-rings [383] into two plugs
[380].
Note: apply grease on the O-ring [383].
② Insert the piston [38] into the rear flange
[301].

Figure 4-174
③ Pre-tighten the PLUG [380] to REAR
FLANGE [301] with a hexagon wrench.

Figure 4-175

Maintenance Manual - 01 - 2021 4-119

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

(13) Re-assembly of brake valve components

① Insert the spool [323] into the rear flange
[301].
Note: apply hydraulic oil on the spool [323], and
insert the spool [323] into the rear flange [301].
During the installation of the spool [323],
coincide the hole center of the rear flange [301]
with the axis core of the spool [323] so as to
prevent the damage of the inner surface of the
rear flange [301] and the outer surface of the Figure 4-176
spool [323] due to the contact. If there is
damage, it will cause internal leakage after
reassembly. Please note that the performance
of the walking motor will deteriorate.
② Install the O-ring [336] onto the plug [324].
Note: apply lubricating oil on the O-ring [336].
③ Install the washer [325] and the spring [328]
into the plug [324].

Figure 4-177
④ Tighten two plugs [324] to the rear flange
[301].
Note: when tightening two plugs [324] to the rear
flange [301], pay attention not to deforming the
spring [328] in the plug.
⑤ Pre-tighten two plugs [324] to the rear
flange [301].

Figure 4-178

4-120 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

(14) Assembly of rear flange components

① Apply hydraulic oil to the deep slot ball
bearing [150], and then insert the deep slot
ball bearing [150] into the rear flange [301].
② Insert the pin [341] into the pin hole of the
rear flange [301].
③ Apply lubricating oil to the joint surface of
the rear flange [301] on the timing plate
[109].
Figure 4-179
④ Place the hole of the timing plate [109] on
the pin [341], which is used as a guide to
install it on the surface of the rear flange
[301].
Note: install the timing plate [109] until it is close
to the rear flange [301]. The purpose of being
close is to prevent the timing plate [109] from
falling from the rear flange [301] when it is
installed on the spindle [2].
Figure 4-180
⑤ Install ten springs [113] on the rear flange
[301].
Note: in order to fix the spring and prevent it
from falling off the rear flange [301], apply
enough grease to the spring [113].

Figure 4-181
(15) Connection between rear flange and
spindle
① Install two O-rings [32] and [33] into the O-
ring slot of the spindle [2].
Note: when installing the O-rings [32] and [33],
do not apply grease. When the traveling motor
is in operation, the grease will seep out from the
joint surface of the rear flange [301] and the
spindle [2]. Grease leakage state will be
misunderstood as oil leakage. Therefore, do not Figure 4-182
apply grease.

Maintenance Manual - 01 - 2021 4-121

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

② Put 1.0 L hydraulic oil into the spindle [2].

③ When insert the rear flange [301] into the
spindle [2], align two pins [34] with the pin
holes of the rear flange [301], and then
install them on the spindle.
④ Pre-tighten 10 hexagon bolts [343] to the
spindle [2] with a hexagon wrench.

Figure 4-183
(16) Tighten all parts with the specified torque.
① Tighten a hexagon bolt [343] to the spindle
[2] with the specified torque.
Tightening torque: 102 ± 15.7 [N-m] (10.4±1.6
[kgf-m]))

Figure 4-184
② Tighten the plug [325]with the specified
torque.
Tightening torque: 441 ± 39.2 [N-m] (45.0±4.0
[kgf-m]))

Figure 4-185
③ Tighten PLUG [380]with the specified
torque.
Tightening torque: 58.8 ± 9.81 [N-m] (6.0±1.0
[kgf-m]))

Figure 4-186

4-122 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

④ Tighten PLUG [352]with the specified

torque.
Tightening torque: 12.3 ± 2.45 [N-m] (1.25±0.25
[kgf-m]))

Figure 4-187
⑤ Tighten PLUG [357]with the specified
torque.
Tightening torque: 98.1 ± 19.6 [N-m] (10.0±2.0
[kgf-m]))

Figure 4-188
(17) Assembly of relief valve assembly
① Install two relief valve assemblies [20].

Figure 4-189
② Assemble two relief valve assemblies [20]
with the specified torque.
Tightening torque: 98.1 ± 19.6 [N-m] (10.0±2.0
[kgf-m]))

Figure 4-190

Maintenance Manual - 01 - 2021 4-123

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

(18) Assembly of gears in the second stage

① Rotate the operating platform and turn the
reducer side up.
② Assemble two sun gears [8] to two carriers
[7].
③ Screw the M12 lifting rings into three
threaded holes of the carrier (2) [7] and lift
the assembly in it.
Note: when assembling the carrier (2) assembly, Figure 4-191
avoid the end face of the planetary gear (2) [9]
from damaging the inner gear surface of the hub
[1]. The center of the hub [1] coincides with the
central axis of the carrier (2) assembly, and lift it
in slowly.
Note: see the figure on the left for the port Tubing port
position relationship between the planetary gear
(2) [9] and the rear flange [301].

Speed-2 piston hole

Figure 4-192
(19) Assembly of coupling
① Assemble the coupling [15] to the shaft
[102].

Figure 4-193

4-124 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

(20) Assembly of gears in the first stage

① Assemble the carrier (1) assembly to the
hub [1].
Note: when assembling the carrier (1) assembly,
avoid damaging the inner hub gear on the end
face of the planar gear (1) [5], coincide the hub
[1] center with the center of the carrier (2)
assembly, and lift it in slowly.

Figure 4-194
② Align the spline of the coupling [15] while
installing the sun gear (1) [4].
Note: for the position of the gear, the spline of
the sun gear (1) [4] interferes with the gear top
of the planar gear (1) [5]. If it cannot be
assembled, lift the sun gear (2) [8] of the carrier
(1) assembly to engage with the coupling again
until they are separated, and then install the sun
gear (1) [4].
Figure 4-195
③ Install the thrust plate [13] on the carrier (1)
[3].

Figure 4-196
(21) Assembly of cover
① Apply sealant (Loctite 515) on the joint
surface of the cover [14] for the hub [1].
Note: the sealant shall not be disconnected in
applying.

Figure 4-197

Maintenance Manual - 01 - 2021 4-125

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

② Install the lifting ring on the PF1/2 port, align

the bolt holes, and put the cover [14] on the
hub [1].

Figure 4-198
③ Apply glue (Loctite 242) to the top of six
bolts, and then tighten the glued bolts with
the specified torque.
Tightening torque: 66.7 ± 3.92 [N-m] (6.8±0.4
[kgf-m]))

Figure 4-199
(22) Refueling of lubricating oil
① Fill gear oil from the oil filling port.
Note: fill 2.1 L of gear oil.

Figure 4-200
② Install the plug [30] on each oil filling port,
and tighten them with the specified torque.
Tightening torque: 98.1 ± 19.6 [N-m] (10.0±2.0
[kgf-m]))
(23) Removal of traveling motor
① Turn over the traveling motor. (Make the
motor side facing up)
② Remove the bolts fixing the traveling motor
from the operating platform. Figure 4-201
③ Screw the lifting ring (M16) into the thread
hole of the spindle [2].

4-126 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

④ Hang the lifting ring on the hook and steel

rope, and remove the traveling motor from
the operating platform with a lifting
appliance.

Maintenance Manual - 01 - 2021 4-127

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.6 Hydraulic system (Part 3)

4.6.1 5. DISASSEMBLY STEREOGRAM OF PARTS IN REDUCER

Figure 4-202

4-128 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.6.2 6. DISASSEMBLY STEREOGRAM OF PARTS IN HYDRAULIC MOTOR

Figure 4-203

Maintenance Manual - 01 - 2021 4-129

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.6.3 SLEWING MOTOR

4.6.3.1 SLEWING MOTOR
Model: M5X80-RG08E20B

Figure 4-204
A1: To the control valve (main pressure oil Technical Specification
filling port of motor) Model M5X80-RG08E20B

B1: To the control valve (main pressure oil Theoretical displacement 121 L/min

filling port of motor) Set pressure of safety 25 MPa

valve
C1: Oil filling port
Rated engine speed 1860 rpm
D1: Overflow valve Braking releasing 1.7 MPa
pressure
E1: Port A: pressure-measuring port
Figure 4-205
F1: Port B: pressure-measuring port
G1: Oil draining outlet
PG: Release port of brake
SH: Command port of brake

4-130 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

L: level stick

Figure 4-206
1. Separating collar 6. One-way valve spring 11. Plate
2. Casing 7. One-way valve 12. Piston
3. Disc 8. Oil distribution disc 13. Driving axle
4. Brake spring 9. Cylinder body
5. Housing 10. Brake piston

Maintenance Manual - 01 - 2021 4-131

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.6.3.2 SLEWING RETAINING BRAKE

 The port PG is directly connected with pilot gear pump, and always has the pressure of 3.9mpa;
 The port SH and the port PX of main valve will be connected with each other, and once there
is any action other than travelling on main valve, the port PX will build up the pressure, the
port PG will be connected with the oil chamber a under piston 7, the pressure oil will push
upwards the brake piston and compress the brake spring 1, the disc 5 will separate from disc
6, and the brake will be released.

Pump

Main
valve

Figure 4-207
 Otherwise, the port PX will have no pressure, the port PG will be disconnected from the oil
chamber a under piston 7, the brake spring 1will push the brake piston, the disc 5 and disc 6
will be pushed together, and the brake will be applied.

Pump

Main
valve

4-132 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Figure 4-208
4.6.3.3 OVERFLOW VALVE SECTION
Structure
 The overflow valve is composed of overflow valve (1) and (2), one-way valve (3) and (4).
Function
 When this machine is in the slewing holding mode, the control valve (5) will close the outlet oil
way of motor, but owing to the inertial force, the motor will continue to run. Therefore, the
output of motor will increase abnormally, so that the motor may get damaged.
 In order to prevent the motor from getting damaged, the overflow valve will overflow the
abnormally-high pressure from outlet side (high-pressure side) of motor to oil port (M).
Operations
When the slewing commences (It is assumed From oil port M
that the high-pressure oil flows into port A)
 When the slewing control rod is operated
for right slewing, the pressure oil from pump
will be provided to oil port (A) via control
valve (5).
 The pressure at oil port (A) will increase, the
start torque will be generated in motor, and
the motor will begin to rotate.
 The pressure oil from motor outlet will
return to the oil tank via oil port (B) and
control valve (5).

Figure 4-209

Maintenance Manual - 01 - 2021 4-133

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

When the slewing stops From oil port M

 When the slewing control rod returns to the

middle position, the supply of pressure oil
from pump to oil port (A) will be cut off.
 Since the oil return way from control valve
(5) to oil tank will be closed, the pressure oil
from outlet of motor can’t return to oil tank,
so that the pressure at oil port (B) will
increase.
 The slewing resistance will be generated on
motor, and the brake will begin to work.
 When the pressure at oil port (B) increases
to the set value for pressure of overflow
valve (2), the overflow will occur.
Figure 4-210
 The large braking torque will act on motor,
so as to stop the motor.
 When the overflow valve (2) acts, the
overflowing pressure oil and the pressure
oil from oil port (M) will be provided to oil
port (B) via one-way valve (4).
 In this way, the cavitation at oil port (B) will
be prevented.

4-134 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.6.3.4 SLEWING MOTOR

Model: M5X80-RG08E20B

Schematic diagram for slewing motor

Figure 4-211
A1: To control valve (main pressure oil port of Technical Specification
motor) Model M5X80-RG08E20B

B1: To control valve (main pressure oil port of Theoretical displacement 121 L/min

motor) Set pressure of safety valve 25 MPa

Rated engine speed 1860 rpm
C1: Oil filling port
Braking releasing pressure 1.7 MPa
D1: Overflow valve
Figure 4-212
E1: Port A: pressure-measuring port
F1: Port B: pressure-measuring port

Maintenance Manual - 01 - 2021 4-135

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

G1: Oil draining outlet

PG: Release port of brake
SH: Command port of brake
L: Level rod
 Inspection essentials and replacement criteria of parts

1) Sun gear, planetary gear and inner gear ring

Putting corrosion occurred on the gear surface.
(when the size of single pitting corrosion and dent is more than 1 mm, or the area ratio is more
than 5%) 
2) Oil seal
If the lip surface is damaged or worn, it should be replaced.
When the reducer is disassembled for inspection, it is recommended that it must be replaced.
3) Support bearing for drive shaft (front side)
Do not pull out from the drive shaft, please check according to the following essentials.
1. In the visible range, confirm whether the race surface and roller of the bearing are uneven
or damaged.
2. Next, please confirm further according to the following essentials.
a) Check gear oil for excessive worn powder.
b) Check for excessive wear powder sticking between the roller and the carrier.
c) Check for smooth rotation by hand.
If there is any abnormality after the above confirmation, please replace it.

Figure 4-213

Do not use any bearing pulled out from the shaft.

4) Drive shaft bearing (rear side)
If it is found that there is pitting corrosion or wear on the bearing race surface and roller, it should
be replaced.
5) Sliding bearing part of No. 2 planetary gear
Check whether the No.2 carrier assembly, No.2 planetary gear or No.2 pin is loose in the
circumferential direction.
If the looseness is more than 0.5, replace it.
6) Thrust plate and thrust washer
If there are obvious scars on No. star gear and sliding surface belt, it should be replaced.
7) The needle roller bearing support frame used to support No. 1 planetary gear and the
rotating surface of No. 1 pin shall be replaced in case of pitting corrosion and wear.

Figure 4-214

4-136 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

 List of parts to be replaced at the same time

Parts and components replaced at the same time
Part no. 201 401 402 203 230 282 285 910 210 231 283 403

ym
D

N
S
n
n
a
g
a
co
ln
e
d
e
2
o
p
c2
a
o
a
ca
.ln
sa
2
e
irg
p
td
ro
n
ia
e
ilp
n
rp
lrn
e
re
g
ig
o
a
rn
e
.tb
o
g
a
1
e
lo
p
rp
.a
lre
1
n
o
a
.n
n
b
a
1
e
g
e
p
te
a
ia
d
n
lre
ye
rn
g
b
g
v
y

irc
r

r
r
ir
Name

s.

.if
i

li
xi

rl
l

li

yl

li

i
201 Driving axle — 〇 〇
Self aligning roller
401 △ — △
bearing
Cylindrical roller
402 △ △ —
bearing
No. 2 planetary —
203 △ 〇 △ 〇
gear —
Parts to be replaced

—
230 No. 2 carrier △ 〇 △ 〇
—
282 No. 2 pin △ △ — △ 〇
285 side plate △ △ 〇 — 〇
910 Spring pin △ △ 〇 △ —
No. 1 planetary
210 — △ △ △
gear
231 No. 1 carrier △ — 〇 △

283 No. 1 pin △ 〇 ― △

403 Needle bearing △ △ △ —
It is necessary to replace the parts at the same time as shown in the
Note: the inner and outer rings of cylindrical
stamp △.
roller bearings must be replaced at the
It is best to replace the parts at the same time as shown in the stamp
same time.
△.

Figure 4-215
 Essentials of disassembly and assembly
Working Attentions
1. Remove the hydraulic motor with reducer from the machine, remove
the oil plug (901) at the oil drain port as shown in the outline Put the discharged gear oil into a clean
dimension drawing to drain gear oil, and then place it on the container and check for worn powder.
appropriate operating platform.
2. Loosen the hexagon socket bolt (602) and remove the hydraulic For hydraulic motor, please refer to
motor. relevant essentials.
3. Remove No. 1 sun gear A (211). (Photo 1)
4. When disassembling No. 1 carrier assembly, please take out No. 1
planetary gear A (210) together with other parts as an assembly.
(Photo 2)
5. Removal of No. 1 carrier assembly Mark and number each planetary gear
(1) Remove the retaining ring (911) and then the upper side panel and pin together, and the installation
(287). (Photo 3) method will not change.
(2) Remove No. 1 planetary gear A (210) and the needle roller
bearing (403). (Photo 4)
(3) Remove the side plate (285) under the planetary gear. (Photo 5)
(4) Remove No. 1 planetary gears A (210) at three places, and then
remove three central thrust washers (286). (Photo 6)
Do not remove No. 1 pin (283) from No. 1 carrier (231)
without any special abnormality.
6. Remove No. 2 sun gear A (204). (Photo 7)
7. Remove No. 2 carrier assembly. (Photo 8)

Maintenance Manual - 01 - 2021 4-137

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Figure 4-216
Working Attentions
8. Removal of No. 2 carrier assembly.

Do not remove No. 2 carrier further without any special

abnormality. Please confirm this state according to the
inspection essentials of parts and components indicated in
Section 5.2. As mentioned above, it is recommended to
replace No.2 bracket assembly in a complete set as far as
possible. If you have to replace a part of it, please follow the
following essentials.
(1) Remove the spring pin (910) and No. 2 pin A (282) installed further Please do not use the removed No.2
inside. (Photo 9) pin.

(2) Remove No. 2 planetary gear and the side plate (285) from the
transverse direction.
9. Remove the inner gear ring B (202). (Photo 10)
Since there are two holes on the inner gear ring and there are M12 pull-
out threads at the bottom, please use the hexagon socket bolt (602) for
motor installation as the pull-out bolt.
10. Remove the retaining ring (913) from the drive shaft. (Photo 11)

Figure 4-217
Working Attentions
Leave the cylindrical roller bearing (402)
11. Put the shaft end downward and place the shoulder on the support.
in the housing. As the drive shaft will fall
Then tap the shaft with a plastic hammer, and remove it downward.
down, please be careful not to damage it.

tapping

If No special abnormality, please do not disassemble further.

Please confirm this state according to the inspection
essentials of parts and components indicated in Section 5.2.
As mentioned above, it is recommended to replace the drive
shaft assembly in a complete set as far as possible. If you
have to replace a part of it, please follow the following
essentials.

At this stage, it is not necessary to remove if it is confirmed

that No abnormality.

12. As shown in the right figure, support the drive shaft assembly and
remove the bearing seal cover (915) and the automatic centering
roller bearing (401) by tapping.
13. Remove the oil seal (801) from the housing (102). (Photo 12)

The removed oil seal and bearing seal

cover cannot be used again.

Figure 4-218

4-138 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

 Assembly instructions
Working Attentions
1. Assembly of drive shaft assembly
(1) Insert the bearing sealing washer (915) into the drive shaft. Refer to the fixture in Section 5.3.4, the
center of the automatic self-aligning roller
(2) Apply enough grease on the inside of the self-aligning bearing (401) bearing (401) is a separated structure, so
and press it in exactly by tapping. Knock the inner ring of the bearing please fill lubricating oil from both sides
with the key until the hammer has recoil feeling, and confirm whether before the assembly of the drive shaft.
it has been installed in place. Then apply enough grease as shown
in the figure below. (Photo 13)

2. Place the housing (102) on a horizontal operating platform. When the outer ring of the bearing is
inclined, it can't get in even if it is taped
3. The threaded hole at the shaft end of the drive shaft assembly can lightly. Then, do no install it by force.
be used to vertically lift and install it into the housing. (Photo 14) After
Pull it out again, adjust the outer ring to
the outer ring of the bearing is placed in a completely horizontal
level and install it again.
shape, tap it in gently.

4. Put the shaft end downward, and place the supporting convex Use the fixture of Section 5.3.4.
shoulder on the housing.

Do not damage the lip of the oil seal and

5. Install the oil seal into the housing (102). install it horizontally.

Figure 4-219

Maintenance Manual - 01 - 2021 4-139

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Working Attentions
6. Press the inner and outer rings of the self-aligning cylindrical roller
bearing (402) into the inner and outer rings by tapping the clamp of The fixture used must be determined by
the inner and outer rings in the bearing. the dimension of shaft end and inner
bearing ring end face (See Section
7. Install the retaining ring (913). (Photo 15) 5.3.4).
8. Fill the oil filling port with lubricating grease, wrap the sealing tape on
the oil plug (902) and install it on the housing.
9. Assembly of No. 2 carrier
(1) Align the pin hole position of the side plate (285).
(2) Install the planetary gear (203).
(3) Confirm the position of the hole, align the hole of the spring
release pin (910) with the hole of No. 2 carrier from top to bottom,
and then tap in No. 2 pin (282) gently.
10. Apply liquid sealing packing on the joint surface between the housing
(102) and the inner gear ring (202).
11. Confirm the position of the match mark, and install the inner gear
wheel ring (202) on the housing (102), and fix it temporarily with the
hexagon bolt or about four M12 bolts with the length of 100 mm. (the
tightening torque is more than 800 kgf·cm) it is necessary to install the
flat washer on the bolt, and pay attention not to damaging the joint
surface of the motor. (Photo 16)
12. Install No. 2 carrier into the inner gear ring. (Photo 17)
13. Install No. 2 sun gear A (204).

Figure 4-220
Working Attentions

14. Assembly of No.1 carrier {Do not operate because there shall be a
special fixture in Section (2)}.
(1) Place No. 1 carrier (231) on a horizontal platform.
(2) Place the φ 2 oil passage of No. l pin (283) toward the outside of
the center of No. 1 carrier A (231). (as shown in the right figure)
Then clamp it with a special clamp.
(3) Install the middle among three thrust washers (286). (Photo 18)
(4) Install the side panel (285). (Photo 19)
(5) Install the needle bearing (403) and No.1 planetary gear (210).
(Photo 20)
(6) Install two side plates (287) and then the retaining ring (911).
(Photo 21)
15. Install No.1 carrier. Then confirm to insert three middle thrust washers
(286) into the convex part of No. 2 sun gear A (204). (Photo 22)
Temporarily install the oil lever and
16. Install No. 1 sun gear A (211). (Photo 23) guide pipe, and use them to confirm the
17. Remove the bolts for temporary fixing, and apply liquid sealing oil capacity.
packing on the mounting surface of the inner gear ring B (202) and
When transporting, install the PT 1/4 oil
hydraulic motor. plug on the guide pipe. After installing
18. Install the retaining ring (912) on the drive shaft of the hydraulic motor. the rotary motor on the main engine,
Then, hoist it vertically. Then, adjust the position of the spline shaft, please install the guide pipe and oil
and install the hydraulic motor. Finally, tighten the inner hexagon bolt lever.
(602).
(completely remove the sealing tape
19. Wrap the oil plug (901) of the oil drain port with sealing tape and install from the bolt and wrap it with new
it on the housing. sealing tape after degreasing)
20. Fill gear oil from the oil filling port.

Figure 4-221
4-140 Maintenance Manual - 01 - 2021
 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

 Disassembly of photos

Figure 4-222

Maintenance Manual - 01 - 2021 4-141

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Figure 4-223

4-142 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Figure 4-224

Maintenance Manual - 01 - 2021 4-143

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Figure 4-225

4-144 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Figure 4-226

Maintenance Manual - 01 - 2021 4-145

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Figure 4-227

4-146 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.6.3.5 ANTI-SWING VALVE

Work diagram

1. Spring A
2. Poppet
3. Ball
4. Plunger
5. Spring B
6. Screw plug

Figure 4-228

Maintenance Manual - 01 - 2021 4-147

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Effect diagram

With anti-swing valve

Without anti-swing valve

Reversing pressure

Pressure
MA

Restraining
pressure Reversing pressure
Pressure
MB

First reversing

Second reversing
Motor speed

Start Brake Reversing

Time

Figure 4-229
Overview
 Because of the inertia of the rotating body, the recoil force and rigidity of the mechanical
system, and the compressibility of the hydraulic oil, the machine will shake when it rotates.
The anti swing valve can effectively reduce this effect. It is very effective in preventing the
overflow of the load in the bucket and reducing the cycle time when stopping the rotation (with
the good positioning performance, it can move quickly for the next operation).
Operations
1. In the course of slewing
 The pressure oil on MA side will enter the spring chamber of anti-swing valve A via orifice 2
on anti-swing valve A, and in the anti-swing valve A, the piston and plunger will push leftwards
the spring B in accordance with the pressure difference. At that moment, though the pressure
oil on MB side acts on the surface of steel ball via hoe A in poppet, since the pressure and
action area are less than those on MA side, the plunger will press the poppet, so that the
hydraulic oil will be blocked up. In the anti-swing valve B, the pressure oil on MA side will act
on chamber N via the hole A in poppet, and the plunger will move rightwards and press the
poppet, so that the hydraulic oil will be cut off.

4-148 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Slewing motor

High pressure generated in

spring chamber Orifice 2 Orifice
Screw plug

Spring A

Poppet

Anti-swing valve Ball High pressure generated

A in chamber N
Chamber M Plunger Anti-swing valve B
Spring B

Orifice 2 Piston

Main control valve

Figure 4-230
2. When the slewing stops
 The control rod will return to middle position, the slewing core of main control valve will return
to middle position, and the motor will continue to rotate owing to inertia, so that the pressure
on MB side will increase, the pressure on MA side will reduce, the oil will be added via one-
way valve A1 on MA side, and the oil will overflow via overflow valve B2 on MB side. Meanwhile,
in the anti-swing valve A, the pressure oil on MB side will push the steel ball into chamber N
via the hole A in poppet, and the pressure oil on MA side will enter the bottom of plunger via
orifice 2, and they will jointly move the plunger leftwards, so that the plunger will be pressed
against poppet, and thus the pressure oil on MA side will be separated from the pressure oil
on MB side. In the anti-swing valve B, the pressure oil on MB side will enter the spring chamber
via orifice 2, so that the plunger will move rightwards and press the poppet, and thus the
Maintenance Manual - 01 - 2021 4-149
 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

pressure oil will be cut off.

Slewing motor

High pressure generated

in chamber N

Orifice
Orifice 2
Screw plug
Spring A

Poppet

Anti-swing valve Ball

Chamber N
A
Plunger Anti-swing valve B
Spring B Chamber M

Orifice 2 Piston

High pressure generated

in spring chamber

Main control valve

Figure 4-231
 The inertia force of the body makes the rotary motor decelerate and the pressure of pressure
oil on MB side decreases. Therefore, the pressure in chamber n decreases in the anti swing
valve A. Under the action of Spring B, the lifting head moves to the right, and the pressure oil
on MB side enters MA side through the throttle hole 2. In the anti swing valve B, the pressure
oil on MB side enters the spring chamber through the orifice 2 so that the plunger continues
to press the lifting head.

4-150 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Slewing motor

The pressure in chamber N

will reduce

Orifice 2 Orifice
Screw plug

Spring A

Poppet

Anti-swing valve Ball

A Chamber N
Plunger Anti-swing valve B
Spring B Chamber M

Orifice 2 Piston

High pressure generated

in spring chamber

Main control valve

Figure 4-232
 When the rotary motor speed is further reduced, the pressure on MB side will be further
reduced. The liquid flow in the anti swing valve A is as mentioned before, and the pressure oil
on MB side enters MA side through the throttling hole 2. In the anti swing valve B, the pressure
on the MB side decreases, and the lifting head moves to the right under the action of the spring
B. the pressure on the MB side acts on the steel ball, making the steel ball and lifting head
move to the left together.

Maintenance Manual - 01 - 2021 4-151

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Slewing motor

Orifice 2 Orifice
Screw plug

Spring A

Poppet

Anti-swing valve Ball

Chamber N
A
Plunger Anti-swing valve B
Spring B Chamber M

Orifice 2 Piston

The pressure in spring

chamber will reduce

Main control valve

Figure 4-233
 The speed of slewing motor will continue to reduce, the pressure on MA and MB sides will
continue to reduce. In the anti-swing valves A and B, the pressure of spring chamber will
reduce, the plunger will return to original position under the action of spring B, and the slewing
will stop.

4-152 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Slewing motor

Orifice
Plug Orifice 2

Spring A

Poppet

Anti-swing valve Ball Chamber N

A Spring B
Plunger Anti-swing valve B

Orifice 2 Piston

The pressure in spring

chamber will reduce

Main control valve

Figure 4-234
4.6.4 ELECTROMAGNETIC VALVE
Used for PPC locking, secondary turbocharging, straight travelling and high/low double speed.

Maintenance Manual - 01 - 2021 4-153

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Accumulator

Figure 4-235
A1: To high/low speed electromagnetic valve T1: oil return tank

A2: To secondary turbocharging electromagnetic P1: To PG electromagnetic valve and pilot fine
valve filter of slewing motor

A3: To slewing motor SH electromagnetic valve T2: Plug

A4: Plug

A5: To straight travelling valve core

A6: To PPC locking electromagnetic valve

Transition block of
sensor
Left handle Left handle Port 5 of Right handle Right handle
P1 P2 pedal valve P3 P2

Left handle Left handle Port 6 of Right handle Right handle

P3 P4 pedal valve P1 P4

Figure 4-236

4-154 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

1、2、3、4、5、6、7、8、9: To pressure sensor

Two-speed
travel

Port P of PT
block Release of
slewing brake

A1: to high/low two-speed solenoid valve T: oil return tank

A2: to secondary boost solenoid valve P: to linear travel solenoid valve and fine
P1: Port P of PT oil collection valve block pilot filter

Figure 4-237

Maintenance Manual - 01 - 2021 4-155

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Operations
When the electromagnetic coil is demagnetized
Actuation mechanism
 As long as the signal current to the
electromagnetic coil is interrupted, the
electromagnetic coil (6) is demagnetized. De-
excitation
 The slide valve (8) will be pushed by spring
(10) to left side.
 Since the oil way from oil port P to oil port A
is blocked up by slide valve, the pilot oil
pressure to actuation mechanism will also
be blocked up. Meanwhile, the oil from
actuation mechanism will be led from oil
port A to oil port T, and then be discharged
into hydraulic oil tank.
Figure 4-238
When electromagnetic coil is magnetized
Actuation mechanism
 The electromagnetic coil (6) will be
magnetized by the signal current
transmitted to it.
Excitation
 The slide valve (8) will be pushed by pin (5)
to right side.
 The pilot oil pressure is transmitted from
Port p to the actuator through the cover (7)
and Port A. At the same time, Port T is
closed. Therefore, the blocked oil flows to
the hydraulic tank.

Figure 4-239

4-156 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.6.5 PPC ACCUMULATOR

Figure 4-240
1. Air plug Technical Specification
2. Housing Gas: nitrogen
3. Lifting valve Gas capacity: 0.3 L
4. Retainer Inflation pressure: 15 bar at 80 ℃
5. Reservoir Maximum operating pressure: 33 bar
6. Oil port

Maintenance Manual - 01 - 2021 4-157

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.6.6 PILOT OIL FILTER

Model

Pressure

Precision

Figure 4-241
1. Nameplate Technical Specification
2. Top cover Maximum flowrate: 40 L/min
3. O-ring Filtration precision: 10 um
4. Seal ring Operating pressure: 20 Mpa
5. Filter Maximum working pressure: 40 Mpa
6. Casing Pressure loss: 0.05 Mpa
Maximum permissible differential pressure: 1 Mpa
Specification of O-ring for oil inlet/outlet port: 30×3.1

4-158 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.6.7 PPC VALVE

4.6.7.1 PPC VALVE
Used for slewing and working device

Left handle

Right handle

Figure 4-242
Left handle Right handle
P: To Block P P: To Block P
T: To Block T T: To Block T
1: Left turn 1: Bucket digging
2: Arm unloading 2: Boom lowering
3. Right turn 3. Bucket unloading
4. Arm digging 4. Boom lifting

Maintenance Manual - 01 - 2021 4-159

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Figure 4-243
1. Slide valve 7. Connector or joint
2. Metering spring 8. Retainer
3. Central spring 9. Valve body
4. Plunger
5. Cam
6. Nut

4-160 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Operations
1. At middle position
 The oil ports (A) and (B) of control valve as
well as the oil ports (P1) and (P2) of PPC
valve will be connected with discharge
chamber (D) via flow-through groove (f) of
valve rod (1).

Pilot pump

Control valve

Figure 4-244
2. During the fine control (middle position
→fine control)
 When the plunger (4) is pushed via disc (5),
the locator (9) will be pushed, and the valve
rod (1) will also be pushed by adjusting
spring (2) and move downwards.
 The flow-through groove (f) will be cut off
from discharge chamber (D), and will be
connected with pump pressure chamber
(PP) almost at the same time. The pilot
pressure oil of control pump will be led to oil
port (A) from oil port (P1) via flow-through
groove (f). When the pressure at oil port Pilot pump

(P1) becomes relatively high, the valve rod

(1) will be pushed back, and the flow-
through groove (f) will be cut off from pump
pressure chamber (PP). Meanwhile, it will Control valve
be connected with the discharge chamber
(D), so as to release the pressure at oil port
(P1). As a result, the valve rod (1) will move Figure 4-245
upwards and downwards, until the force of
adjusting spring (2) is balanced with the
pressure at oil port (P1).
 The position relationship between valve rod

Maintenance Manual - 01 - 2021 4-161

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

(1) and valve body (10) [The flow-through

groove (f) is located in middle between
discharge chamber (D) and pump pressure
chamber (PP)] will remain unchanged
before the locator (9) contacts the valve rod
(1).The adjusting spring (2) will contract in
proportion to the stroke of control rod. The
pressure at oil port (P1) will also increase in
proportion to the stroke of control rod. As a
result, the control valve rod will move to the
position where the pressure of chamber (A)
(as same as the pressure at oil port (P1)) is
balanced with the force of return spring in
control valve rod.
3. Fine control (when the control rod returns)
 When the disc (5) begins to return, the
valve rod (1) will be pushed upwards by the
force of central spring (3) and the pressure
at oil port (P1).
 Therefore, the flow-through groove (f) will
be connected with the discharge chamber
(D), and the pressure oil at oil port (P1) will
be released.
 If the pressure at oil port (P1) excessively
reduces, the valve rod (1) will be pushed
downwards by the adjusting spring (2).
Pilot pump
 When the flow-through groove (f) is cut off
from discharge chamber (D), it will be
connected with pump pressure chamber
(PP). Before the pressure at oil port (P1) Control valve
resumes to the level equivalent to that
indicated by position of control rod, the
pressure will be provided. Figure 4-246

 When the valve rod of control valve returns,

the oil in discharge chamber (D) will flow in
through the from flow-through groove (f) in
valve on nonworking side. This oil will flow
through oil port (P2) and enter the (B)
chamber, so as to fill this chamber with
pressure oil.

4-162 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4. At full stroke
 The disc (5) will push downwards the piston
(4), and the locator (9) will push downwards
the valve rod (1).
 The flow-through groove (f) will be cutoff at
the discharge chamber (D), and will be
connected with the pump pressure
chamber (PP).
 Therefore, the pressure oil from self-
pressure-reducing valve will flow into (A)
chamber from oil port (P1) via flow-through
groove (f), so as to push the control valve
Pilot pump
rod.
 The oil returning from chamber (B) will flow
to discharge chamber (D) from oil port (P2)
via flow-through groove (f). Control valve

Figure 4-247

Maintenance Manual - 01 - 2021 4-163

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

For travel

Figure 4-248
P: From pilot pump P4: Right forward
P1: Left backward P5: Traveling signal
P2: Left forward P6: Traveling signal
P3: Right backward T: To oil tank

4-164 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Figure 4-249
1. Baffle
2. Valve body
3. Piston
4. Protective ring
5. Central spring
6. Adjusting spring
7. Valve

Maintenance Manual - 01 - 2021 4-165

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Work Process
Operations
1) At middle position
 The oil ports (A) and (B) of control valve as
well as the oil ports (P1) and (P2) of PPC
valve will be connected with discharge
chamber (D) via fine control hole (f) of valve
rod (1). Pilot pump

Control valve

Figure 4-250
2) Fine-tuning control (middle position →fine-
tuning control)
 When the piston (4) is pushed by control
rod (5), the locator (9) and the valve rod (1)
will also be pushed by adjusting spring (2)
and move downwards.
 When the fine control hole (f) is cut off from
discharge chamber (D), it will be connected
with pump pressure chamber (PP) almost
at the same time.
Pilot pump
 The pilot pressure oil of control pump will be
led into oil port (A) from oil port (P1) via fine
control hole (f). Control valve

 When the pressure at oil port (P1) becomes

relatively high, the valve rod (1) will be Figure 4-251
pushed back, and the fine control hole will
be cut off from pump pressure chamber
(PP). Meanwhile, it will be connected with
discharge chamber (D), so as to release the
pressure at oil port (P1).
 As a result, before the force of adjusting
valve rod (2) is balanced with the pressure
at oil port (P1), the valve rod (1) will move
upwards and downwards.
 The position relationship between valve rod
(1) and valve body (10) [The fine control
hole (f) is located in middle between
discharge chamber (D) and pump pressure
chamber (PP)] will remain unchanged
4-166 Maintenance Manual - 01 - 2021
SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

before the locator (9) contacts the valve rod

(1).
 The adjusting spring (2) will contract in
proportion to the stroke of control rod.
 The pressure at oil port (P1) will also
increase in proportion to the stroke of
control rod.
 In this way, the valve rod of control valve will
move to the position where the pressure of
chamber (A) (as same as the pressure at oil
port (P1)) is balanced with the force of
return spring in rod of control valve.
3) Fine control (when the control rod returns)
 When the disc (5) begins to return, the
valve rod (1) will be pushed upwards by the
force of central spring (3) and the pressure
at oil port (P1).
 Therefore, the fine control hole (f) will be
connected with the discharge chamber (D),
and the pressure oil at oil port (P1) will be
discharged.
 If the pressure at oil port (P1) excessively Pilot pump
reduces, the valve rod (1) will be pushed
downwards by the adjusting spring (2).
Control valve
 The fine control hole (f) will be cut off from
discharge chamber (D), and be connected
with pump pressure chamber (PP). Figure 4-252

 Before the pressure at oil port (P1) resumes

to the level equivalent to that indicated by
position of control rod, the pressure will be
provided.
 When the valve rod of control valve returns,
the oil in discharge chamber (D) will flow in
from the fine control hole (f) in valve at
nonworking side. This oil will flow through
oil port (P2) and enter the (B) chamber, so
as to fill this chamber with pressure oil.

Maintenance Manual - 01 - 2021 4-167

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

At full stroke
 The disc (5) will push downwards the piston
(4), and the locator (9) will push downwards
the valve rod (1).
 The fine control hole (f) will be cut off from
discharge chamber (D), and will be
connected with pump pressure chamber
(PP).
 Therefore, the pressure oil from self-
pressure-reducing valve will flow into (A) Pilot pump

chamber via fine control hole (f) and oil port

(P1), so as to push the control valve rod.
Control valve
 The oil returning from chamber (B) will flow
to discharge chamber (D) from oil port (P2)
via fine control hole (f). Figure 4-253
4.6.8 HYDRAULIC CYLINDER

Boom cylinder

Figure 4-254

Grab arm cylinder

Figure 4-255

4-168 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Bucket cylinder

Figure 4-256
Unit:
Handling
No. Inspection Item Standard
method

Standard Tolerance Standard Clearance

Cylinder
dimension Axle/shaft Hole clearance limit

-0.030 +0.259
Boom 75 0.093〜0.335 0.435
Clearance -0.076 +0.063 Replace the
1 between piston
-0.030 +0.279 bushing
rod and bushing Grab
80 0.095〜0.355 0.455
arm -0.076 +0.065
-0.030 +0.250
Bucket 70 0.085〜0.326 0.426
-0.076 +0.055
-0.030 +0.20
Boom 70 0.030〜0.260 1.0
-0.060 +0
Clearance
between piston Grab -0.030 +0.20
2 70 0.030〜0.260 1.0
rod supporting arm -0.060 +0
pin and bushing
-0.030 +0.20 0.030 〜
Bucket 65 1.0
-0.076 +0 0.276 Replace the
pin or
-0.030 +0.20 0.030 〜 bushing
Boom 70 1.0
Clearance -0.060 +0 0.260
between
supporting pin Grab -0.030 +0.20 0.030 〜
3 70 1.0
on bottom of arm -0.060 +0 0.260
cylinder and
bushing -0.030 +0.20 0.030 〜
Bucket 65 1.0
-0.076 +0 0.276

Figure 4-257

Maintenance Manual - 01 - 2021 4-169

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.7 Working device

4.7.1 SIZE OF COMPONENT

Maintenance Manual - 01 -
2021

Figure 4-258

4-170 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Unit: mm
No. Inspection Item Standard Measures

Standard Tolerance Standard Clearance

Clearance between pin
which connects boom dimension Axle/shaft Hole clearance limit
1
with slewing table and
bushing -0.03 +0.246
70 0.23～0.306 0.8
-0.06 +0.2
Clearance between pin
which connects boom -0.03 +0.246
2 75 0.23～0.306 0.8
with grab arm and -0.06 +0.2
bushing
Clearance between the
pin connecting grab -0.030 +0.236
3 60 0.8
arm and rocker the -0.076 +0.19 0.22～0.312
bushing Replacement
Clearance between pin
which connects grab -0.030 +0.236
4 65 0.22～0.312 0.8
arm with bucket and -0.076 +0.19
bushing
Clearance between pin
which connects -0.030 +0.236
5 65 0.22～0.312 0.8
connecting rod with -0.076 +0.19
bucket and bushing
Clearance between pin
which connects rocker -0.030 +0.236
6 65 0.22～0.312 0.8
with connecting rod and -0.076 +0.19
bushing

Maintenance Manual - 01 - 2021 4-171

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.7.2 DIMENSION OF GRAB ARM

Figure 4-259
Unit: mm
No. Measurement position Standard dimension Tolerance
1 590
Minimum 1500
2
Maximum 2490
3 4600
Minimum 1700
4
Maximum 2865
—
5 680
Minimum 1378
6
Maximum 2263
7 - 2500
8 - 290
9 - 493

4-172 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

No. Measurement position Standard dimension Tolerance

10 - 422
11 - 529
12 - 1240
+0.5
Grab arm side 99.5
0
13
0
Cylinder head side 98
—0.5
+1
Boom side 226
0
14
0
Grab arm side 225
—1
0
Grab arm side 226
—0.5
15
+1
Upper claw side 227
0
0
Connecting rod side 223
—0.5
16
+1
Upper claw side 224
0

Maintenance Manual - 01 - 2021 4-173

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.7.3 DIMENSIONS OF LOG GRAPPLE

Unit: mm
No. Standard Dimension Tolerance
1 529 ±0.5
2 1225 -
+0.074
3 Φ65
0
4 224
5 385
+0.074
6 Φ65
0
7 227
8 368
9 1210 -
10 556 ±0.5
+0.074
11 Φ65
0
+0.074
12 Φ65
0
13 369
14 491
15 204
16 309

4-174 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.8 Engine control

4.8.1 ENGINE CONTROL

Figure 4-260
1. Storage battery relay Overview
2. Battery  The engine is started and stopped only by the start
switch (3).
3. Starting switch
 The controller (6) receives the signal from the fuel
4. Fuel control knob
control knob (4) and transmits the driving signal to the
5. Starting motor throttle motor (8) to control the governor lever angle of
6. Controller the fuel injection pump (7) and control the engine speed.

7. Fuel injection pump  If the start switch (3) is turned to the OFF position, the
controller (6) controls the throttle motor (8) to close the
8. Throttle motor
fuel injection port of the fuel injection pump, stop the
engine fuel supply and turn off the engine.

Maintenance Manual - 01 - 2021 4-175

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Block diagram of engine system

Pressure switch for left travel
Secondary boost Pressure switch for right travel
button
Pressure switch of operating device
Engine gear control disc Back slewing pressure switch

Sensing signal of throttle position

Display screen
Engine
H mode Controller
S mode
Mode L
B mode
Changeover between
high/low travelling Throttle motor
speed
Automatic idling mode
Coolant Temperature
Engine oil pressure
Fuel position
Engine speed

Figure 4-261
The engine control system includes
 Engine disc control (gear control);
 H mode control
 S mode control
 L mode control
 B mode control
 Automatic idling control
 Automatic acceleration control
 Control on engine speed calibration
Operation of system
Start Engine
(Power supply)

 When the start switch is turned to the Fuel control knob Engine Starting motor
Starting switch

position START, the start signal will be (Starting signal)

Speed regulator motor

transmitted to the start motor, and then the

Throttle
closed

Throttle
opened

start motor will run so as to start up the

(Potentiometer

(Driving signal)
signal)

engine. Shutdow
n device

Flameout


relay

At that moment, the controller will test the

Controller

signal voltage from fuel control knob, and (Adjusting signal)

(Start switch on signal)

set the engine speed as the level set by fuel

control knob.
Figure 4-262

4-176 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Engine speed control

(Power supply)


Starting switch
The fuel control knob will send to controller Fuel control knob
Engine
Starting motor

a signal voltage corresponding to the Speed regulator motor

(Starting signal)

rotation angle.

Throttle
closed
Throttle
opened

 According to the signal voltage, the

(Driving signal)
(Potentiometer
signal)
Shutdow
n device

controller sends a drive signal to the throttle Flameout

relay

motor to control the fuel injection pump and Controller

finally control the engine speed. (Adjusting signal)

(Start switch on signal)

Figure 4-263
Turn off Engine
(Power supply)


Starting switch
When the starting switch is turned to the Fuel control knob Engine
Starting motor

flameout position, the controller controls the (Starting signal)

Speed regulator motor

starting motor and cuts off the oil supply

Throttle
closed
Throttle

from the oil supply pump to stop the engine. opened

Shutdow
n device

Flameout
relay

Controller
(Adjusting signal)
(OFF signal of start switch)

Figure 4-264

Maintenance Manual - 01 - 2021 4-177

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.8.2 COMPONENTS OF SYSTEM

4.8.2.1 THROTTLE KNOB

1st gear
position
10th gear
position

Right limit position

Left limit position

Yellow

Blue

Red

Figure 4-265
1. Rotary knob
2. Disc
3. Spring
4. Roller
5. Potentiometer
6. Plug

4-178 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Functions
 When the throttle knob is turned, the
resistance of the sliding rheostat inside the

Turning angle of knob

knob changes so that the voltage signal
collected by the controller also changes.
The controller calculates according to the
collected value, drives the throttle motor
through the output signal, controls the
injection quantity of the injection pump, and
Voltage (V)
makes the engine achieve the ideal control
speed. At the same time, the throttle
position sensor of the throttle motor feeds Figure 4-266
back the real-time position signal to the
controller to form a closed-loop control
system to achieve an accurate control.
 When the throttle voltage is outside the
zone, the controller will send out the
warning code, and the engine will run at low
idle speed. The right figure indicates that
the slanted-line area is abnormal inspection
zone.
Note: The left limit position corresponds to is
0%, and the right limit position corresponds to
100%.

Gear Typical voltage value (V) Resistance value (k)

1 1.15 1.15
2 1.45 1.45
3 1.75 1.75
4 2.05 2.05
5 2.35 2.35
6 2.65 2.65
7 2.95 2.95
8 3.25 3.25
9 3.55 3.55
10 3.85 3.85
11 4.2 4.2

Maintenance Manual - 01 - 2021 4-179

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.8.2.2 DISTRIBUTION OF CONTROLLER AND ITS PORTS

Figure 4-267

Figure 4-268
SY115 / 135C I/O interface

4-180 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Definition of Wire Definition of Wire

Pin Name Pin Name
controller no. controller no.
1 DL_8 A3 \ \ 24V power
1 42 24V power supply
2 DL_9 A5 \ \ supply

3 DL_10 A6 \ \ 24V power

2 42 24V power supply
supply
4 DL_11 A7 \ \
3 Ground 0 0v
5 DL_1 B14 103 Air filter restriction
4 DO_1 620 Starting output
6 DL_2 B15 106 High temperature switch
5 DO_2 621 Extinction output
7 Ground 0 0v
6 DO_4 606 Output of pilot solenoid valve
Boom lifting pressure
8 AV_1 ADA6 206 Output of high/low speed
sensor 7 DO_3 607
solenoid valve
Large boom lowering
9 AV_2 ADA7 207 11 CAN- CAN- CAN-
pressure sensor
Bucket excavation pressure 12 CAN+ CAN+ CAN+
10 AV_3 ADB0 205
sensor 13 DO_7 608 Linear-travel solenoid valve
11 Ground 0 0V Secondary turbocharging
14 DO_5 605
Sensor power electromagnetic valve
12 50 5V power supply
supply Slewing unlocking
15 DO_11 602
13 DH_2 B6 62 Extinction input electromagnetic valve

14 D_18 B11 \ \ Front pump proportional

17 PWM_2 703
electromagnetic valve
15 DL_19 B13 209 Secondary boost button
18 AV_12 208 Slewing pressure sensor
16 Tl_1 B8 108 Flywheel sensor (speed)
19 AV_10 502 Rear pump pressure sensor
17 DL_6 B9 \ \
20 Ground 0 0V
18 DL_7 B10 508 Engine oil pressure sensor
21 DL 66 Low temperature switch
19 Ground 0 0V
22 RX RX RX
20 AR_1 ADB7 509 Fuel oil level sensor
23 TX TX TX
21 AV_8 ADB5 \
24 DO 68 Preheating control output
Grab arm unloading
22 AV_6 ADB3 202 Standby electromagnetic
pressure sensor 26 DO 609
valve
23 Ground 0 0V
Rear pump proportional
24 DH_1 B5 11 Starting input 28 PWM_1 702
electromagnetic valve
25 DL_17 B7 \ \ 29 AV 501 Front pump pressure sensor
26 DL_16 B3 \ \ Left travelling pressure
30 AV 201
27 PI_2 B12 \ \ sensor
28 DL_3 A8 105 Leading switch 31 Ground 0 0V
29 DL_4 A9 \ \
30 Ground \ \
31 Reset \ \
32 AR_2 ADB6 510 Coolant Temperature
Bucket unloading pressure
33 AV_4 ADB1 204
sensor
Left travelling pressure
34 AV_7 ADB4 200
sensor
Grab arm excavation
35 AV_5 ADB2 203
pressure sensor

Figure 4-269

Maintenance Manual - 01 - 2021 4-181

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.9 Electrical Control System

4.9.1 CONTROL FUNCTION
4.9.1.1 CONTROL FUNCTION

Engine — pump combined control function

Control function of pump

Control function of solenoid valve

Double-travelling-speed control

Electrical control system Engine preheating/overheating warning

Too low engine oil pressure warning

Automatic idling/acceleration control

Calibration function of engine speed

Self-diagnosis function

★ See "Fault Diagnosis" for the detailed description of self diagnosis function.

4-182 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Block diagram of control system

Fuse
Fuel oil level sensor
Battery Storage battery relay
Signal for PPC
pilot lock
Hydraulic oil temperature
sensor

Power-on signal

Starting switch

Pilot electromagnetic
valve signal
Slewing pressure sensor
Signal for high/low speed
solenoid valve
Left travelling pressure sensor
Signal for linear travel solenoid
Preheating signal

valve
Right travelling pressure sensor
Starting signal

Signal for rotary unlocking

solenoid valve
Boom lifting pressure sensor
Signal of secondary
turbocharging electromagnetic
valve Boom lowering pressure sensor
Signal of front pump
proportional electromagnetic
valve
Signal of rear pump Controller Grab arm excavation pressure sensor
proportional electromagnetic
valve
Grab arm unloading pressure sensor
Start control signal
Bucket excavation pressure sensor

Bucket unloading pressure sensor

Travelling speed selection
signal Front pump pressure sensor
Work mode signal
Starter relay Engine speed control
Rear pump pressure sensor
signal
Information monitoring
signal

Display
Network screen
communication
Display of
signal
monitoring
Engine speed sensor
information
Position feedback signal

Engine oil pressure sensor

Drive signal

Safety relay Water temperature sensor

Air filter blockage sensor

Engine
High-temperature warning sensor

Alternator
Drive Potentiomet Throttle
Starting motor er
knob
Air preheater Throttle
motor

Preheating controller

Figure 4-270

Maintenance Manual - 01 - 2021 4-183

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Right travelling pressure sensor

Left travelling pressure sensor

Boom lifting pressure sensor

Boom lowering pressure sensor

Grab arm excavation pressure sensor

PPC
Grab arm unloading pressure sensor valve

Bucket excavation pressure sensor

Bucket unloading pressure sensor

Slewing pressure sensor

Oil supply device of

front pump
Actuator of operating device
Basic pressure of PPC

PPC locking Secondary Bucket Slewing Travel speed

turbocharging interflow unlocking
electromagn electromagneti electromagneti electromagneti electromagn
etic valve c valve c valve c valve etic valve
Rear pressure sensor

Action control valve

Front pressure sensor

Proportional Proportional Main valve

valve valve

Traveling motor

Servo Servo

Traveling motor

Main pump
Oil supply device for rear Slewing
pump motor

Actuator of operating device

Figure 4-271
Note: the figure above reflects the schematic diagram of electric control, and the specific hydraulic
circuit is shown in the hydraulic knowledge section. Description of No. 1 – 16 signals in the figure
No. Signal content
1 Signal for rotary unlocking (controller output)
2 Feedback voltage of right travel pressure sensor (controller input)
3 Feedback voltage of left travel pressure sensor (controller input)
4 Feedback voltage of boom lifting pressure sensor (controller input)
5 Feedback voltage of boom lowering pressure sensor (controller input)
6 Feedback voltage of grab arm digging pressure sensor (controller input)

4-184 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

7 Feedback voltage of grab arm unloading pressure sensor (controller input)

8 Feedback voltage of bucket digging pressure sensor (controller input)
9 Feedback voltage of bucket unloading pressure sensor (controller input)
10 Feedback voltage of rotary pressure sensor (controller input)
11 Signal for high/low speed travel (controller output)
12 Pressure sensor of rear pump (controller input)
13 Pressure sensor of front pump (controller input)
14 Signal for proportional solenoid valve of front pump (controller output)
15 Signal for proportional solenoid valve of rear pump (controller output)
16 Signal for pilot solenoid valve (controller output)
17 Signal for bucket confluence solenoid valve (controller output)

Maintenance Manual - 01 - 2021 4-185

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.9.1.2 ENGINE — PUMP COMBINED CONTROL FUNCTION

Schematic diagram of control function

Pilot valve Cab

Monitor panel
Traveling Traveling

Extension or Lifting or lowering of

retraction of grab boom
arm Excavation or
unloading of bucket

Throttle knob

MC controller input
H/S/L/B Standby
Deactivate the automatic Pressure sensor
pressure
idling sensor
Changeover of travelling
speed
Warning output

Pilot oil
pressure

Main control valve

Engine compartment

Controller
Pressure sensor
Pump

Adjustment of
engine fuel
supply
capacity
Pump
proportional
pressure-
reducing
electromagnetic
valve

Control the inclination

angle of rear pump

Control the inclination angle of

front pump

Engine ECU

Fuel/water temperature and

others

Figure 4-272

4-186 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Functions
1.
 This function permits the operator to select
the work mode of system on the basis of the

Engine torque T
work contents of this machine, so as to
change the power output of engine. There
are four work modes: P, H, S and I. When
selecting the work mode, please use the
work mode selection button displayed.
 The main controller will control the pump,
Engine speed N
so as to ensure that it can absorb all output
torque from engine. The torque depends on
the specification of pump to absorb torque Figure 4-273
in every mode, the setting of fuel control
knob and the actual engine speed.

Engine power KW

Engine speed N

Figure 4-274
Pump displacement Q

Pump output pressure P

Figure 4-275

Maintenance Manual - 01 - 2021 4-187

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Control method for every mode

 Mode H
 Matching point of mode H: rated speed

Engine torque T
Model SY135F
Mode H 69KW/2200rpm

 If the load of pump increases and the

pressure increases, the engine speed will
reduce. If so, then the engine speed will Engine speed N

increase to matching point, so as to enable

the pump controller to reduce the output of
Figure 4-276
pump. If the load of pump reduces and the
pressure reduces, then the pump controller
will continue to increase the output of pump,
until the engine speed is close to matching
point.
Engine power KW

Engine speed N

Figure 4-277
Pump displacement Q

Pump output pressure P

Figure 4-278

4-188 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

2.
 Mode S/mode B/mode L
Power corresponding to each mode / Power

Engine torque T
corresponding to each mode / Output
percentage / Output percentage
Mode S L B
Power output
85% 60% 60%
percentage

Engine speed N
 At that moment, the controller will maintain
the oil-pumping torque, and will control the
engine speed along the stable horsepower Figure 4-279
curve through the joint control on engine
and pump.

Engine power KW

Engine speed N

Figure 4-280
Pump displacement Q

Pump output pressure P

Figure 4-281

Maintenance Manual - 01 - 2021 4-189

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.9.1.3 CONTROL FUNCTION OF PUMP

Pressure Pressure
Engine sensor sensor
Main pump
Fuel Speed
injection regulator
pump motor

Rotating
speed Servo Servo
sensor

Proportional Proportional
valve valve

Fuel control
knob
(Control signal)

(Control signal)
(throttle position feedback signal)

(engine speed signal)

(motor drive signal)

Monitor panel

Controller

(CAN bus)
Secondary pressurization

Grab arm excavation signal

Grab arm unloading signal
Bucket excavation signal
Bucket unloading signal

Boom lowering signal

Right travelling signal

Left travelling signal
Boom lifting signal
Slewing signal
button

Figure 4-282

4-190 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.9.1.4 ELECTRICAL POSITIVE FLOWRATE CONTROL

Pump 1
Displace
ment

Pump 1 Boom lifting pilot pressure

Displacem
ent

Grab arm excavation pilot

pressure
Pump 1
Displacem
ent

Grab arm unloading pilot

Pump 1 pressure
Displacem Pilot displacement
ent output

Bucket excavation pilot

Pump 1 pressure
Displacem
ent

Bucket unloading pilot

Pump 1 pressure
Displacem
ent

Pump 1 Slewing pilot pressure

Displacem
ent

Left travelling pilot pressure

Figure 4-283

Maintenance Manual - 01 - 2021 4-191

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Pump 2
Displace
ment

Pump 2 Boom lifting pilot pressure

Displacem
ent

Grab arm excavation pilot

pressure
Pump 2
Displacem
ent

Grab arm unloading pilot

Pump 2
pressure
Displacem Pilot displacement
ent output

Bucket excavation pilot

Pump 2
pressure
Displacem
ent

Bucket unloading pilot

Pump 2 pressure
Displacem
ent

Boom lowering pilot

Pump 2
pressure
Displacem
ent

Right travelling pilot

pressure

Figure 4-284
Function
The handle pilot pressure signal is directly used as the control signal of the hydraulic pump
displacement. On the one hand, the pilot pressure acts on the valve stem. On the other hand, it
collects data from the controller. According to the opening characteristics of the spool, the controller
gives the functional relationship between the displacement of the hydraulic pump and the pilot
pressure to keep the displacement of the hydraulic pump at the determined value under the
corresponding pilot pressure. In the compound action, the given displacement of each action
should be added.
Operations
4-192 Maintenance Manual - 01 - 2021
 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

When the working device is acting, the controller will acquire the pilot pressure sensor signal, and
will, on the basis of the pressure signal from pilot, control the displacement of pump 1 and pump
2.
Constant power control
1. Function
Q
It is mainly to calculate the maximum theoretical Flow
P-Q curve of pump
displacement of the pump. The system is
controlled by constant power, and the two
regulators are hydraulically linked, which can
keep the synchronous relationship between the
two actuators with the same specifications and
acting at the same time. The change of pump Pressure
flow is mainly determined by the sum of the
operating pressures of the two hydraulic pumps.
As long as it meets the requirements, the total
Figure 4-285
power of the two hydraulic pumps will always
remain constant but not exceed the power of the
diesel engine.
Operations
When the working device is acting, the controller
will acquire the signal from main pressure
sensor of pump 1 and pump 2, and will achieve
the constant power control for pump on the
basis of such signal.
ESS control
Function
By controlling the pump power according to the engine speed change caused by load change, the
output of the engine can be used more effectively. (prevent the engine from stalling when the
machine is operating under harsh conditions such as operating at high altitude).
Operations
The target speed of engine is controlled via engine control disc.
The controller will receive the actual speed signal sent by ECM (engine controller), and carry out
the closed-loop control on actual speed and target speed. Thereafter, the controller will make the
output of closed-loop control participate in calculation of control signal of electromagnetic valve,
and send the finally-adjusted current signal to pump proportional electromagnetic valve.
The electromagnetic valve will, on the basis of the received signal from controller, supply the pilot
pressure oil to pump regulator, so as to control the flowrate of pump.

Maintenance Manual - 01 - 2021 4-193

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.9.1.5 VALVE CONTROL FUNCTION

Secondary Straight
turbocharging travelling

Main valve

Pressure sensor Pressure sensor

Engine
Main pump
Fuel injection Speed regulator
pump motor

Rotating
speed Servo Servo
sensor

Proportional Proportional
valve valve
Fuel control
knob
(Control signal)

(Control signal)
(throttle position feedback signal)

(engine speed signal)

(motor drive signal)

Monitor panel

(CAN bus)
Grab arm excavation signal
Grab arm unloading signal
Bucket excavation signal
Bucket unloading signal

Boom lowering signal

Right travelling signal

Left travelling signal
Boom lifting signal
Slewing signal

Figure 4-286
Valve Control Function
 Secondary turbocharging control
 Linear travel control
1) Secondary turbocharging control
Functions
 Increase the engine speed so that the engine operates with 11 gears in Mode H.
 The main overflow pressure was changed from 31.4 MPa to 34.3 MPa.
4-194 Maintenance Manual - 01 - 2021
 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Operations
 When the secondary boost button is pressed, the controller detects this signal, activates the
secondary boost solenoid valve, and increases the engine speed to Gear 11 in Mode H.
2) Linear travel control
Functions
 When the traveling action and the boarding action (operating device or rotation) make a
compound action, open the linear travel valve so as to reasonably distribute the main pump
flow.
Operations
 By detecting the signal of each pilot pressure sensor, the controller makes logical judgment
and opens the linear travel solenoid valve so as to control the linear travel valve on the main
valve to open and distribute the pump flow.
4.9.1.6 DOUBLE-TRAVELLING-SPEED CONTROL

Traveling
motor
Left travelling pressure sensor

pressure sensor
Right travelling

Travel speed
Main valve electromagnetic
valve

Engine

Fuel Speed
injection regulator Main pump
pump motor

Servo Servo

Fuel control knob

(throttle position feedback

(Control signal)

(Control signal)
(motor drive signal)

signal)

Monitor panel

Controller

(CAN bus)

Figure 4-287

Maintenance Manual - 01 - 2021 4-195

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Function
 Control travel mode
Operations
 When the low-speed travelling mode is adopted, the swashplate angle of travelling motor will
be the maximum value, and the travelling speed will be slow.
 When the controller receives the signals from the travel pressure sensor under the following
conditions, the controller activates the solenoid valve. Then, the solenoid valve sends the pilot
pressure oil to the swash plate angle control valve of the traveling motor to minimize the swash
plate angle and improve the travel speed.
Operating conditions
 The fast travel function is enabled.
Note: when the crawler on one side is lifted off the ground by the operating device and rotated, the
control pressure of the pump on one side is increased to make the crawler rotate rapidly. When
the machine moves in the fast mode, even if the operating device is operated (the pressure sensor
of the operating device is turned on), the operating mode remains in the fast mode.

4-196 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.9.1.7 CONTROL ON ENGINE PREHEATING

Starting switch

Main valve
Preheat switch Preheating relay

Engine
Main pump
Coolant Heater plug
temperature
sensor
Speed regulator motor

Engine oil
Servo
pressure sensor

Fuel control
(Engine oil pressure signal)

knob

(Control signal)
(Potentiometer signal)
(Adjusting signal)

Display panel

(CAN bus) Controller

Figure 4-288
Preheating of engine
Function
 Control on preheating
Operations
 When the temperature is lower than 10℃, the water temperature switch is OFF.
1. In this case, the key start switch is only powered on but not started, that is, it is turned to ON.
1) The indicator light goes off after 8 seconds (T1).
2) The preheating relay is switched on and then released after 30 seconds (T2)
2. Start with the key switch (ST)
3) The indicator light goes off after 8 seconds (T1).

Maintenance Manual - 01 - 2021 4-197

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4) The preheating relay is switched on when it is ON, and switched on after ST for 30 seconds,
and then released (T3).
 When the temperature is higher than 10 ℃, the water temperature switch is ON.
1) In this case, the indicator light will be ON for 0.3 seconds and then OFF (T1).
2) The preheating relay does not operate.
1) Engine overheating warning
Function
 During the operation, if the water temperature is too high (higher than 105℃), the display
screen will display the warning.
Operations
 The controller collects signals from the water temperature alarm switch. If alarm information
is generated by the water temperature alarm switch sent it to the display screen, the display
screen shows the alarm information, the buzzer rings, and the speed will be reduced to the
first gear until the fault is eliminated. Operating conditions
 Power-on
 The water temperature is more than 105℃.
Too low engine oil pressure warning
Function
 Too low engine oil pressure warning.
Operations
 The controller collects signals from the oil pressure switch. When the engine speed is above
600 rpm, alarm information will be generated and sent to the display screen if the oil pressure
is too low, the display screen shows the alarm information, the buzzer rings, and the speed
will be reduced to the first gear until the fault is eliminated.
Operating conditions
 The engine has been started for 30s or the excavator is working
 The oil pressure switch is switched on, that is, the oil pressure is less than 98 kPa.

4-198 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.9.1.8 AUTOMATIC IDLING FUNCTION

Right working device control rod
Boom Bucket

Excavating

Unloading
Lifting
Low
Engine

Rotation Left working

device control rod Grab arm
Engine throttle
controller

Retraction

Unloading
Right

Left
(motor drive signal)

(Potentiometer signal)

Fuel control
knob
Traveling LEFT Traveling
Travelling rod RIGHT

Reverse

Reverse
Forward

Forward
(Throttle signal)

Controller

CAN bus

Control rod signal

Figure 4-289
Function
 When the machine is in idling mode and all control rods are at neutral position, the engine
speed will be reduced, so as to reduce the fuel consumption and noise.
 If any control rod is operated, the engine speed will immediately return to the level set by fuel
control knob.
Operations
 When the control lever returns to the neutral position for 5 seconds, the engine will
automatically enter the low speed operation (1300 rpm), which can reduce the air flow loss of
the hydraulic system and the wear of the diesel engine, and play the role of energy saving and
noise reduction. When the control lever is pulled to operate again, the diesel engine will
automatically return to the original speed state.
 If you operate any control lever while the engine speed remains at the deceleration level, the
engine speed will immediately rise to the level set by the fuel control knob. Disconnection
condition of automatic idle system
 The control rod is operated
 Press the idle cancel switch

Maintenance Manual - 01 - 2021 4-199

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.9.1.9 AUTOMATIC ACCELERATION CONTROL

Function: when the speed is less than 1400 rpm, it can automatically increase the engine speed to
meet the machine operation requirements.
Operation: when the engine control dial is set to the third gear or less, when the excavator is
operating, the controller reads the pilot pressure switch signal (travel, rotation and operating
device), drives the throttle motor, and sets the engine speed to 1300 rpm.
Engine Speed Calibration
1. Function
 The controller calibrates the speed of each
gear in the engine.
Operations
 In the calibration speed interface, press the
"F4" button, and the corresponding icon will
turn red, that is, start the standard speed.
When the icon changes from red to blue, it
means that the speed calibration is
completed. Note: during the calibration
process, do not interrupt (power off or press
F4). Otherwise, the calibration cannot be
completed, and the calibration must be
powered on again after power off.

Figure 4-290
4.9.2 SYSTEM COMPONENTS
4.9.2.1 SYSTEM COMPONENTS
1) Engine speed sensor

Figure 4-291
Function
1.

4-200 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

 The engine speed sensor is installed on the ring gear of the engine flywheel. It calculates the
number of gears passing through the front gear of the sensor and then transmits the result to
the controller.
Operations
 During the operation process, measure the resistance between Terminals 1 and 2.
 If the tightening torque of engine speed sensor is insufficient, there may be no output signal
from sensor. Please tighten up the engine speed sensor to the specified torque.
Standard value (at 25℃) 2.3±0.2kΩ

 If the measured value exceeds the standard value, please replace the sensor.
2) Coolant temperature sensor

Figure 4-292
1. Sensor
2. Connector function
 The output resistance of engine coolant temperature sensor will change as the temperature
changes, and the controller will acquire the signal and then calculate the cooling temperature.
Technical Specification
50℃ 130Ω (reference value)

80℃ 48.5±4.2Ω
Standard value
100℃ 26.7±2.5Ω

110℃ 20Ω (reference value)

Maintenance Manual - 01 - 2021 4-201

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

3) Engine oil pressure switch

Figure 4-293
1. O-ring 3. Connection
2. Sensor
Functions
 The oil pressure switch is mainly installed on the oil outlet pipe of the oil filter, which mainly
detects the oil pressure and generates an alarm signal to the controller.
Technical Specification
 Contact type: normally closed contact
 Operating pressure: 0.98 kg
4) Pump high-pressure sensor of pump

Pressure joint Body Connector

Connection diagram

Terminal No. Name of signal

Power supply (+5V)

Output
Terminal A Terminal B

Terminal C
Direction Z

Figure 4-294

4-202 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Operations
 The relationship between the pressure (P)
applied on sensor and the output voltage

Output voltage (E) of sensor

(E) is as indicated in the figure below.

Oil pressure (P)

Figure 4-295
5) Pilot low pressure sensor

Pressure joint Body Connector

Connection diagram

Terminal No. Name of signal

Power supply (+5V)

Earthling

Output
Terminal A Terminal B

Terminal C
Direction Z

Figure 4-296

Maintenance Manual - 01 - 2021 4-203

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Operations
 The relationship between the pressure (P)
applied on sensor and the output voltage

Output voltage (E) of sensor

(E) is as indicated in the figure below.

Oil pressure (P)

Figure 4-297

4-204 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.10 Display system

4.10.1 DISPLAYER
4.10.1.1 DISPLAY SYSTEM

Displayer
Throttle motor

Motor control signal Conversion signal

Fuel control knob

Warning signal
Gear voltage

Governor Pump
Every sensor controller
Sensor signal

Power source

Battery

Figure 4-298
 The display system monitors the state of the machine with sensors mounted on each part of
the machine. It processes and immediately displays the acquired information on the display
screen to inform the operator of the machine condition.
 The display is roughly divided into the following parts:
1. Warning information given when trouble occurs to this machine.
2. Conditions of this machine (temperature of coolant, temperature of hydraulic oil, and level
of fuel).
 The display panel is also equipped with various mode selector switches and has functions to
operate the machine control system.
Displayer
Maintenance Manual - 01 - 2021 4-205
 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Figure 4-299
Input and output signal of socket
Pin no. Name Input/output Pin no. Name Input/output
1 CAN- 18
2 CAN+ 19 B + Motor drive signal Output
3 20 B - Motor drive signal Output
4 21 507 Throttle position Input
5 22
6 23
7 24 Earth 0
8 Earth 0 25 43 Power supply (24 V)
50 Sensor power
9 Output 26
supply (5V)
10 A + Motor drive signal Output 27
11 28
12 29 506 Throttle knob Input
13 30
14 31
15 32
16 A - Motor drive signal Output 33 Earth 0
17 29 Power supply (24 34 43 Power supply (24 V)

4-206 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Pin no. Name Input/output Pin no. Name Input/output

V)

Pin no. Name Input/output Pin no. Name Input/output

1 18
2 19
3 20
4 21
5 22
6 23
7 24 Earth 0
8 Earth 0 25 43 Power supply (24 V)
50 Sensor power supply 26
9 Output
(5V)
27
10
28
11
29 506 Throttle knob Input
12
30
13
31
14
32
15
33 Earth 0
16
34 43 Power supply (24 V)
17 29 Power supply (24 V)

Maintenance Manual - 01 - 2021 4-207

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.10.1.2 INTRODUCTION TO DISPLAY PARTITION

Figure 4-300
No. Zone Introduction to functions
The indicators may be lighted on the basis of the different needs, so as to
1 Signal indicator
indicate the special signal.
After the system enter this page, the functions which will be displayed by means
Main display zones on
2 of icon or digit include: hour meter, work mode, work gear, work hours of
display screen
system, indication of high/low travelling speed, and automatic idling indication.
The functions of the five buttons are indicated by the corresponding icons in the
3 Function buttons interface after the display is powered on. These buttons can be used to switch
or confirm the operation.
The UP, DOWN, LEFT and RIGHT buttons are used in password setting and
4 Operation buttons item selection. The ESC and ENTER buttons are used in exit or confirmation,
and the functions of different pages are different.

Figure 4-301
4-208 Maintenance Manual - 01 - 2021
 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.10.1.3 DISPLAY OF MAIN INTERFACE

Fuel oil level

Engine water
temperature

Figure 4-302
When the information about coolant temperature or fuel level can’t be obtained owing to
disconnection of CAN, the indicating needle of meter will disappear.

Maintenance Manual - 01 - 2021 4-209

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Temperature or
Meter Indicator Warning code
capacity
The temperature is The pointer points to the
05
above 105℃. farthest right red area.
Engine coolant The temperature is The pointer points to the
temperature below 50℃. farthest left.
(Unit: ℃)
The temperature is
between 50℃ and One grid represents 5℃.
105℃.
The pointer points to the
230
Fuel oil level farthest right.
(Unit: L) The pointer points to the
19 04
farthest left.

Corresponding
Symbols Display item Display range Display method
button

Work Mode F1 Operating mode setting

Automatic
F2 Idle switch switching
idling

travel speed mode

Travel speed F3
setting

Operation Enter the equipment

F5
information operation information

Automatic
Clock 24-hour display Display the time
display

Working hour Automatic When the equipment is

Display the work time
meter display operating

Figure 4-303

4-210 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

4.10.1.4 SWITCH

Figure 4-304
The functions displayed by means of icon are as indicated in the table below:

Maintenance Manual - 01 - 2021 4-211

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Symbols Switch Item Function

F4 Enter Enter the selection setting item

Operation
F5 Enter the equipment operation information
information

F1 Work Mode Working Mode Selection

F2 Automatic idling Automatic idle mode switching

F3 Travel speed Selection of Travelling Speed

Select the item on the left (select the item on the farthest right
Select the item
after the farthest left)
Select the item on the right (select the item on the farthest left
Select the item
after the farthest right)
Select the item on the top (select the item on the bottom after the
Select the item
top)
Select the item on the bottom (select the item on the top after the
Select the item
bottom)

Return Return to the previous page

Enter Enter the selection setting item

Figure 4-305
Note:
By default, if no action is carried out within 5 seconds after the automatic idling switch is turned on,
the engine will enter the idling state. The controller will automatically adjust the speed to idle speed,
so as to save fuel and reduce noise. In the idling state, if the controller detects any action or gear-
shift operation, then the engine will be automatically resumed to the speed corresponding to such
gear.
 The automatic idle function does not work in Mode L.
 The function keys are different according to the interface display, and each indicator shows
the function of the corresponding function keys below.
 A switch without an indicator is invalid.

Warning
 When a heavy article is being lifted up, it is prohibited to use automatic idling function

4.10.1.5 OPERATION PAGES OF DISPLAY SCREEN

The following is a description of the devices required to operate the machine. In order to operate
properly and safely, it is very important to fully understand the method of operating devices and
the display meaning.

4-212 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Figure 4-306
[1] Signal indicator [9] System time display
[2] Display area [10] Fault code display
[3] Function display [11] Operating time display
[4] Function key [12] Operating mode
[5] Operation key [13] Automatic idle display
[6] Operating mode, throttle gear display [14] High/low speed travel display
[7] Water temperature display [15] Setup confirmation
[8] Oil level display [16] Information inquiry

4.10.1.6 INTRODUCTION TO PAGES

Signal indicator [1]:
 The indicators may be lighted on the basis
of actual needs, so as to indicate the
special signal.
① Reserved indicator light
② Reserved indicator light
③ Alarm indicator light. When there is any
alarm, the light will be ON.
④ Maintenance reminder indicator
Display zones on page [2]:
Figure 4-307
 This area shows what you need. The top of

Maintenance Manual - 01 - 2021 4-213

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

the two main indicators shows the fuel level,

and the bottom shows the engine water
temperature.
 The lower left corner is the operating mode,
which are H, S, L and B respectively. B is
the crushing hammer mode, and S is the
default mode of power on. F1 is used to
switch between each other.
Function button [4]:
 The functions of five buttons F1-F5 are
indicated by the icons displayed in [3].
Figure 4-308
⋆F1 - work mode changeover: By pressing this
button, you can change over the work
modes H, S, L and B.
Wherein:
Mode H – heavy load operation mode
Mode S - standard operation mode
Mode L – light load operation mode
Mode B - hammer operation mode
1.
⋆F2 -Automatic idle switch: press this key to
switch between automatic idle and non
automatic idle.
When the icon of the automatic idle mode is
blue, it is the non automatic idle mode.
When the icon of the automatic idle mode is red,
it is the automatic idle mode.

Figure 4-309

4-214 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

2.
⋆ F3- Switch between high and low speed
travels: press this key to switch between
high and low speed travels. Tortoise travels
at a low speed, and Rabbit travels at a high
speed.
⋆F4 - Alarm release: press this key to display
the alarm code and release the alarm.
⋆F5 - Related information query: press this key
to enter related information query and
system data setting.
Figure 4-310
 The functions of five buttons F1-F5 under
normal conditions are described above.
Under different operating conditions, they
have different functions.
Operation button [5]:
 Up ↑, Down ↓, Left ←, Right → password
and item selection; ESC and ENTER keys
are used when the exit or confirmation is
selected, and the functions of different
pages are different.
Operating mode and gear display [6]:
 Four modes, including S, H, L and B, are
displayed, which respectively indicate the
standard operating mode, heavy load
operating mode, light load operating mode
and crushing hammer operating mode.
 Press F1 to switch.
Cooling water thermometer [7]:
 The water temperature is displayed by the
pointer, and the indication range is 0-
120 ℃. Figure 4-311
 When the engine is just started, the display
will be as indicated by (A).
 When the temperature is 0-105 ℃ , as
shown in (B).
 When the temperature exceeds 105 ℃, the
pointer points to the red area, as shown in
(c). At the same time, the alarm indicator A
lights up and the fault code appears on the

Maintenance Manual - 01 - 2021 4-215

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

screen.
 When the temperature returns to below
105 ℃, the alarm indicator A and the fault
code go out.

Figure 4-312
Fuel level gauge [8]:
 The fuel level display is a pointer type, and
the indication range is 0% - 100%.
 When the fuel level is lower than 8%, the
pointer points to the farthest left end, as
shown in (A). At the same time, the alarm
indicator light [1] is ON, and the fault code
appears on the screen.
 When the fuel position returns to more than
8%, as shown in (B), the alarm indicator will
automatically go out and the fault code will
disappear.
 When the fuel is full, it is shown in (C).

Figure 4-313

4-216 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

System time display [9]:

 Located at the top left of the screen, it
shows the time of the local time zone. Fault
code display [10]:
 It is located at the bottom right of the
screen.
 When there is a fault, a red number will
appear, and the display value is the
corresponding fault code. At the same time,
the alarm indicator will be ON,
accompanied by a beep.
 When there is no trouble, no digit will be Figure 4-314
displayed.
The operating time of the whole machine shows
[11]:
 It is located at the top of the screen and
displays the operating time of the current
excavator.
On the home page, press down F5
(information search), so as to change over to
information search menu password input
page.

Maintenance Manual - 01 - 2021 4-217

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.10.1.7 INTRODUCTION TO AND OPERATION OF PAGE “LIST OF INFORMATION”

1. Password login interface
 Before entering the three interfaces shown in the figure below, you need to enter the password:
information query and system settings.

Figure 4-315
Button Operations:
 F1: cycle to change the value of the corresponding position, and the value range is 0 ~ 9 cycle;
or press the direction key UP ↑ and DOWN ↓ to adjust the current value.
 F2: adjust the cursor position to cycle from left to right; or press the direction keys LEFT ←,
RIGHT → to adjust the position of the value to be changed.
 F5: Return to the previous page.
 UP↑ and DOWN↓ direction keys: adjust the corresponding values.
 LEFT ←, RIGHT → direction keys: adjust the cursor position.
 ESC and ENTER keys: ESC key: exit and return to the previous level; ENTER key: confirm to
enter.
The homepage means the page displayed when the excavator is working normally.

4-218 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

2. Page “List of Information”

(1) The interface is an entry to switch to the
information options shown, which is
equivalent to the information query
directory. Before entering this page, you
need to enter the information query
password. When you enter the correct
password and press ENTER to confirm, the
display will automatically enter the
information query list.
(2) Button Operations:
 F1 option switch: use F1 or UP ↑, DOWN ↓
to switch in order. When the corresponding Figure 4-316
option is selected, the item is displayed in
the bold white font with a blue background,
and the unselected item is displayed in the
white font with a black background.
 F4 - confirm key: after selecting a content
item, press this key to enter the
corresponding interface of the selected
item. The function is the same as that of the
ENTER key.
 F2 - invalid key.
 F3 - system function setting: press F4 to
enter the entrance of system function
settings (in the system setting password
page).
 F5 - return key, press this key to return to
the main screen interface. The function is
the same as that of the ESC key.
(3) Hint: When an item is selected, a line of
small green words will appear above the
corresponding icon of button, which briefly
introduces the item selected.

Maintenance Manual - 01 - 2021 4-219

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

3. Brief introduction to list

Operation information query [1]
 After entering this item, you can query
engine and throttle signal, pilot pressure
signal, main pump/valve signal, input
switch signal and output switch signal.
① Engine and Throttle Signals
Engine and throttle signals:
- Fuel level %:
- Engine oil pressure kPa:
- Oil pressure ℃:
- Throttle gear N: Figure 4-317

- Engine speed rmp:

- Gear position V:
- Throttle position V:
 Press F1 so as to achieve the changeover
of page;
 Press F1 to switch to the pilot pressure
signal page.
② Pilot pressure signal
Pilot pressure information:
- Boom lifting kg:
- Boom lowering kg:
- Arm digging kg: Figure 4-318

- Arm unloading kg:

- Bucket digging kg:
- Bucket unloading kg:
- Rotation signal kg:
- Left travel kg:
- Right travel kg:
 Press F1 so as to achieve the changeover
of page;
 Press F1 to switch to the page of Main
Pump and Main Valve Signal.
③ Signal of main pump and main valve
Information of main pump: Figure 4-319

- Main pressure of pump 1 (kg):

4-220 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

- Main pressure of pump 1 (kg):

- Current of proportional valve 1 (ma):
- Current of proportional valve 2 (ma):
 Press F1 so as to achieve the changeover
of page.
 Press F1 so as to change over to input
switch signal search page.
 Press down F5 or ESC so as to return to the
page “List of Information”.
④ Input the switch signal inquiry
Input switch signals include:
- Starting input Figure 4-320
- The water temperature is too low
- Extinction input
- The water temperature is too high
- Hydraulic pilot
- The air filter is blocked
- Secondary turbocharging
- Oil-water separation
 Press F1 so as to achieve the changeover
of page.
 Press F1 so as to change over to input
switch signal search page.
 Press down F5 or ESC so as to return to the
page “List of Information”.
⑤ Output switch signal search
Input switch signals include:
- Starter relay
- Flameout relay
- Preheating relay
- Secondary turbocharging valve
- Hydraulic pilot valve
- High/low speed change-over
- Straight travelling valve
- Slewing unlocking valve
- Rotary priority valve
- Boom priority 1 Figure 4-321

Maintenance Manual - 01 - 2021 4-221

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

- Boom priority 2
 Press F1 so as to achieve the changeover
of page.
 Press F1 to switch to the page of Input
Switch Signal Query.
 Press down F5 or ESC so as to return to the
page “List of Information”.
⑥ Excavator configuration query[2]
After entering such item on the page “List of
Information”, you can search for information
such as model of this machine, serial number of
this machine, model of engine, model of
hydraulic system, and control system.
 Press down F5 or ESC so as to return to the
page “List of Information”.

Figure 4-322
Trouble information query [3]
After entering such item on the page “List of
Information”, you can search for information
about current trouble code.
 Press down F5 or ESC so as to return to the
page “List of Information”.
When such page is entered by pressing F5 on
home page, if you press down the ESC button,
the system will return to the home page.

Figure 4-323

4-222 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Maintenance information query [4]

When the work time reaches the time when the
maintenance is required, the system will remind
the user with maintenance information. On this
page, the maintenance information can be
found.
 Press down F5 or ESC so as to return to the
page “List of Information”.

Figure 4-324
Gear speed calibration [5]
Enter this item from the "System Setting" page
to calibrate the gear. (Note: the engine is a high-
pressure common rail engine without throttle
actuator, so the speed calibration is not
required).
The information includes:
- Throttle gear (N)
- Target speed (rpm)
- Actual position (rpm)
- Allowable deviation (rpm)
- Actual deviation (rpm) Figure 4-325

 F2 switch idle/full speed; F3 Gear

calibration; F4 has no actual effect.
 Press down F5 or ESC so as to return to the
page “List of Information”.

Maintenance Manual - 01 - 2021 4-223

Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

Selection of System Language [6]

After entering such item on the page “List of
Information”, you can search the current
language environment, and can re-select the
language.
 Language selection: use the icon above the
F1 and F4 keys to display its meaning, that
is, press F1 to select the language, F4 to
select the language, and switch the
language immediately after pressing the
keys.
 Press down F5 or ESC so as to return to the
page “List of Information”. Figure 4-326
GPS monitoring information [7]
After entering such item on the page “List of
Information”, you can search current position
information and communication parameter.
The information includes:
- Longitude °
- Latitude °
- Altitude m
- Speed Km/h
- Quantity of satellites
- Communication index Figure 4-327
- Signal-to-noise ratio 1
- Signal-to-noise ratio 2
- Signal-to-noise ratio 3
- Signal-to-noise ratio 4
 Press down F5 or ESC so as to return to the
page “List of Information”.

4-224 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Structure, function and maintenance standard

Setting of system parameters

1) The system time is set in the information
query password input interface. Press F3 to
enter the system time setting interface to
set the year, month, day, hour, minute,
second and time zone.
Button Operations:
 Press the left/right button to select the item
to be changed, and then press the up/down
button to adjust the parameter.
 After the adjustment, press the F4 key to
complete the time setting.
Figure 4-328
 Press down the F5, so as to return to the
information search password page.
2) Configuration Calibration
In the "System Setting" interface, enter the
"Configuration Calibration" option, and enter the
corresponding password, you can enter the
machine configuration calibration interface, and
realize the setting of machine number.

Figure 4-329

Maintenance Manual - 01 - 2021 4-225

 Structure, function and maintenance standard SY135F Hydraulic Forestry Crane

4.10.1.8 SENSOR
After the signal from sensor is acquired by controller, the relevant information will be displayed on
the screen. As for the resistance output type sensors such as hydraulic oil temperature, fuel level
and coolant temperature sensors, the controller will acquire the processed voltage signal, carry out
calculation, and then display the relevant information on display screen.
Fuel oil level sensor

Figure 4-330
[1] Buoy [3] Housing
[2] Lever [4] Connector

4-226 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Standard value of components

Standard value of components

5. Standard value of components ............................................................................. 5-1
5.1 Table of standard values for engine ................................................................................ 5-3
5.2 Table for standard value of body-related parts ................................................................ 5-3

Maintenance Manual - 01 - 2021 5-1

Standard value of components SY135F Hydraulic Forestry Crane

Warning
Please read and fully understand the precautions in this Manual and described in the safety
nameplate on the machine. When operating or repairing the machine, please follow those
precautions strictly; otherwise, the wrong operation might lead to machine damages or personal
injuries.

5-2 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Standard value of components

5. STANDARD VALUE OF COMPONENTS

5.1 Table of standard values for engine
Model SY135F
Engine BB-4BG1TRP
Operating conditions for
Items Unit Standard value Permissible value
measurement
Maximum speed 2,520±20 2,520±20
Engine speed Idle speed rpm 1,050±20 1,050±20
Rated rotation 2200 —

Color of exhaust During suddenly acceleration Maximum 4.5 Maximum 6.5

Bosch index
gas During idling Maximum 1.0 Maximum 2.0

Valve clearance Intake valve 0.4 —

mm
(cold state) exhaust valve 0.4 —
MPa Minimum: 3.04 2.0
Compression Oil temperature: 40-60 ℃
{kgf/cm2} {Minimum: 30} {20}
pressure (engine speed)
(rpm) (250) (320 ~360)
Cooling water temperature: kPa Maximum 0.49 0.98
Blowby pressure when the rated output is within
the operating range {mmH2O} {Maximum 50} {100}

When the coolant temperature MPa 0.34 ~ 0.59 0.25

Engine oil pressure is within the operating range
(2,200 rpm) {kgf/cm2} {3.5 ~ 6.0} {2.5}

Engine oil Scope of full speed (in oil

℃ 90~ 110 120
temperature sump)
Offset when pressing with 98
Tension of fan belt mm 6.6~7.4 6.6~7.4
N{10 kg} finger force
Sagging of belt when it is
Tension of A/C
pressed by finger with the force mm 6-10 6-10
compressor belt
of about 58.8N {6kg}

5.2 Table for standard value of body-related parts

Model SY135F
Standard Permissible
Type Items Operating conditions for measurement Unit
value value
 Engine water temperature: within the
operating range
 Hydraulic oil temperature: 45-55 ℃
When the pump is
 The engine is running at high idle rpm 2,200±50 2,200±50
overflowing
speed
Engine  Heavy load operation mode (H)
speed  The grab arm is in overflow state
 The engine is running at high idle
Speed at speed
automatic  The automatic idling switch is turned rpm 1,300±50 1,300±50
deceleration on
 All control rods are at middle position
Boom control
Stroke of  The engine is turned off 8.0±0.5 8.0±0.5
slide valve mm
valve of Grab arm control IN 9.5±0.5 9.5±0.5

Maintenance Manual - 01 - 2021 5-3

Standard value of components SY135F Hydraulic Forestry Crane

Model SY135F
Standard Permissible
Type Items Operating conditions for measurement Unit
value value
control valve OUT 8.0±0.5 8.0±0.5
valve
Bucket control
8.0±0.5 8.0±0.5
valve
Back slewing
8.0±0.5 8.0±0.5
control valve
Travelling control
8.0±0.5 8.0±0.5
valve
Boom control rod 85±10 85±10
Grab arm control
85±10 85±10
rod
 The engine is turned off
Stroke of Bucket control rod  At center of control rod 85±10 85±10
control Back slewing  Take the maximum value at the end mm
rod of the stroke (except the clearance of 85±10 85±10
control rod
the rod in the middle position)
Running Control
112±15 112±15
Lever
Lever clearance 10±15 10±15
Maximum
15.7±3.9 24.5
Boom control rod
{1.6±0.4} {Maximum
2.5}
Maximum
Grab arm control 15.7±3.9 24.5
rod {1.6±0.4} {Maximum
2.5}
Maximum
 Hydraulic oil temperature: within 12.7±2.9 21.6
Operatin Bucket control rod operating range {1.3±0.3} {Maximum
g force  Engine speed: high idle speed 2.2}
of  At center of control rod N {kgf}
control  On top of pedal Maximum
rod Back slewing  Measure the maximum value at end 12.7±2.9 21.6
control rod of stroke {1.3±0.3} {Maximum
2.2}
Maximum
Running Control 24.5±5.9 39.2
Lever {2.5±0.6} {Maximum
4.0}
Maximum
Travelling control 80.4±20.1 107.9
pedal {8.2±2.0} {Maximum
11}
 Hydraulic oil temperature: 45-55℃
 Engine speed: high idle speed MPa
Unloading 2.9±0.5 2.9±0.5
pressure  Work mode: H {kgf/
{30±5} {30±5}
 Output pressure of pump when all cm2}
control rods are at middle position
Oil 31.4±1.0 30–33
pressure  Hydraulic oil Normal overflow
Boom overflow {320±10} {306–337}
temperature:
pressure MPa
45-55℃ 34.3±1.0 33–36
Maximum power {kgf/
 Engine speed:
cm2}
{350±10} {337–367}
high idle speed
Grab arm 31.4±1.0 30–33
 Work mode: H Normal overflow
overflow pressure {320±10} {306–337}

5-4 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Standard value of components

Model SY135F
Standard Permissible
Type Items Operating conditions for measurement Unit
value value
 Output pressure 34.3±1.0 33–36
Maximum power
of pump when {350±10} {337–367}
oil way
31.4±1.0 30–33
overflows Normal overflow
Bucket overflow {320±10} {306–337}
pressure 34.3±1.0 33–36
Maximum power
{350±10} {337–367}
Slewing overflow 25±1.5 25–30
pressure {295±15} {295–335}
Travelling 34.8±1.0 34.3–39.2
overflow pressure {355±10} {350–400}
 Hydraulic oil temperature: 45-55℃
 Engine speed: high idle speed MPa
Basic pressure of 3.9±0.2 3–4.1
control oil way  Output pressure of self-pressure- {kgf/
{40±2} {30 – 42}
reducing valve when all control rods cm2}
are at middle position
 Hydraulic oil temperature: 45-55℃
 The engine is running at high idle
speed
 Work mode: H
Maximum 90
Slewing  Misalignment angle of slewing Degree 75±10
(maximum
overriding support after the excavator slews for (m- m) {730±100}
870)
one round that stops
 For more information on attitude
measurement, see Rotation 1 on
Page 3-10.
 Hydraulic oil Second
90° 2.9±.3 Maximum 3.5
temperature: 45-55 ℃ s
 The engine is running at
high idle speed
 Work mode: H
Start time of  Time required for slewing
slewing by 90°or 180° from Second
start point 180° 4.0±0.4 28.6±5.8
s
 For more information on
attitude measurement,
Rotation see Rotation 1 on Page
3-10.
 Hydraulic oil temperature: 45-55 ℃
 The engine is running at high idle
speed
 Work mode: H
Slewing time  Measure the time required for slewing Second
28.6±4.8 28.6±5.8
for 5 rounds after slewing is carried s
out for one round
 For more information on attitude
measurement, see Rotation 1 on
Page 3-10.
 Hydraulic oil temperature: within
operating range
 The engine stops
The hydraulic
 Keep the upper rotation platform of
drifting in back mm 0 0
slewing operation the machine crosswise on a 15°
slope. See Rotation 2 on Page 3-10
for details.
 Leave the mating marks on inner and

Maintenance Manual - 01 - 2021 5-5

Standard value of components SY135F Hydraulic Forestry Crane

Model SY135F
Standard Permissible
Type Items Operating conditions for measurement Unit
value value
outer races of slewing support
 5 Dislocation amount of matching
mark within 5 minutes
 Hydraulic oil temperature: within
operating range
 The engine is running at high idle
Leakage of speed
ml/ min Maximum 3 Maximum 6
slewing motor  Slewing locking switch: on
 During the slewing overflow, measure
the amount of oil leaking within 1
minute
 Hydraulic oil temperature: Positio
46.1±9.2 46.1±9.2
within operating range n lo
 The engine is running at
high idle speed
 Work mode: H
Travelin Travel speed  After carrying out slewing Second
g (Without load) for one round, measure the Positio s
time necessary for slewing 21.9±2.2 23.1±3.0
n hi
for 5 rounds
 For detailed attitude
measurement, see Travel 1
on Page 3-10.
 Hydraulic oil temperature: Low 27.6±5.1 27.6±7.1
within operating range
 The engine is running at
high idle speed
 Work mode: H
 Flat ground
Travel speed Second
(True operation)  Time necessary for s
travelling for 10m after this High 13.2±1.2 13.2±1.7
machine travels for first
10m
 For detailed attitude
measurement, see Travel 2
on Page 3-10.
 Hydraulic oil temperature: within
operating range
 The engine is running at high idle
Travelin speed
g  Work mode: H
Travelling Maximum Maximum
 Travelling speed: low mm
deviation 200 200
 Firm and flat ground
 The offset when traveling 20 meters
after 10 meters of initial test run (χ)
 See Travels 2 and 3 on Page 3-10 for
detailed measurement attitudes.
 Hydraulic oil temperature: within
operating range
 The engine stops
 Park this machine on 12°slope, and
Hydraulic drifting ensure the driving wheel is located
mm 0 0
of travelling below
 Measure the sliding distance of this
machine 5 minutes later
 For detailed attitude measurement,
see Travel 4 on Page 3-11.

5-6 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Standard value of components

Model SY135F
Standard Permissible
Type Items Operating conditions for measurement Unit
value value
 Hydraulic oil temperature: within
operating range
 The engine is running at high idle
speed
Leakage of  Travelling when the sprocket is
mm Maximum 5 Maximum 10
travelling motor locked
 When the excavator is travelling
under overflow conditions, measure
the amount of oil leaking within 1
minute
 Hydraulic oil temperature: within
operating range
 Flat and firm ground
 Bucket full of soil or rated load (0.8
Bucket m3: 1440 kg)
Maximum Maximum
tooth  The boom is placed horizontally, the mm
460 700
tip grab arm is fully retracted, and the
bucket cylinder is fully extended
 The engine stops
 The working device control rod is at
Hydrau middle position
lic Boom
drifting  After the initial setting, please
Working cylinde measure the amount reduced every
of r Maximum 10 Maximum 12
device five minutes, and measure the total
workin (retracti
g amount reduced within 15 minutes
on) ★ Lowering distance of bucket tooth
device
Arm tip
cylinde ★ Boom cylinder: retraction distance
r of cylinder Maximum 80 Maximum 90
(extens ★ Grab arm cylinder: extension
ion) distance of cylinder
Bucket ★ Bucket cylinder: retraction distance
cylinde of cylinder
r  See the operating device 1 on Page Maximum 22 Maximum 40
(retracti 3-11 for detailed attitude
on) measurement.

 Hydraulic oil temperature:

within operating range
 The engine is running at high
idle speed
 Work mode: H
 Time required for operation
from the moment when the Liftin Second Maximum:
Boom bucket contacts with ground 3.7±0.5
g s 4.2
to the moment when it
Speed reaches the end of lifting
of stroke
Working
device
operati  For detailed attitude
ng measurement, see the
device operating device 2 on Page
3-11
 Hydraulic oil temperature: Retra Second
3.0±0.5 Maximum 3.6
within operating range ction s
 The engine is running at high
Grab
idle speed
arm Exten Second Maximum:
 Work mode: H 2.7±0.5
 Time required for operation d s 3.4
from end of unloading stroke

Maintenance Manual - 01 - 2021 5-7

Standard value of components SY135F Hydraulic Forestry Crane

Model SY135F
Standard Permissible
Type Items Operating conditions for measurement Unit
value value
to end of excavation
 For detailed attitude
measurement, see the
operating device 3 on Page
3-11
 Hydraulic oil temperature: Exca
Second Maximum:
within operating range vatin 3.6±0.5
s 4.1
 The engine is running at high g
idle speed
 Work mode: H
Bucket  Time required for operation
from end of unloading stroke
to end of excavation Unloa Second
2.1±0.3 Maximum 2.5
 For detailed attitude ding s
measurement, see the
operating device 4 on Page
3-11
 Hydraulic oil temperature: within
operating range
 The engine is running at low idle
speed
 Work mode: H
 Time spent from the moment when
the handle is operated to the moment Second Maximum
Boom Maximum 4.0
when the bucket contacts the ground s 3.0
and push up this machine under the
condition that the ground clearance is
less than 50mm
 for detailed attitude measurement,
see the operating device 5 on Page 3-
11.
 Hydraulic oil temperature: within
operating range
 The engine is running at low idle
speed
 Work mode: H
Delay
Working Grab  Tilt the control rod forwards and Second Maximum
Maximum 3.0
device arm backwards and change the direction s 2.0
when the grab arm acts slightly, and
measure the average operating time
 For detailed attitude measurement,
see the operating device 6 on Page 3-
12
 Hydraulic oil temperature: within
operating range
 The engine is running at low idle
speed
 Work mode: H
Bucket  Tilt the control rod forwards and Second Maximum
Maximum 3.0
backwards and change the direction s 2.0
when the bucket acts slightly, and
measure the average operation time
 For detailed attitude measurement,
see the operating device 7 on Page 3-
12
Internal Cylinde Maximum
 Hydraulic oil temperature: within ml/min 15 maximum
leakag r 3.5

5-8 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Standard value of components

Model SY135F
Standard Permissible
Type Items Operating conditions for measurement Unit
value value
e operating range
Central  The engine is running at high idle
back speed
Maximum 10 Maximum 50
slewing  During overflow, measure the oil
joint leaking from cylinder within one
minute cylinder
 Hydraulic oil temperature: within
operating range
Perform  The engine is running at high idle
ance speed
Deviation when
when
the operation of  Work mode: H
combine
working device  Travelling speed: low Maximum Maximum
d mm
operatio
and travelling are  On the hard and flat ground, after the 500 500
carried out at the excavator travels for about 10m,
n is
same time measure the deviation when the
carried
out excavator travels for another 20m
 For detailed attitude measurement,
see Travels 2 and 3 on Page 3-10.
Pump output Q L/min

Perform
ance of
hydraulic
pump

Pump
pressure

 Pump speed: at 2000 rpm, the current of pump solenoid valve is 620 mA.
Ins
Test pump Test the output Lower limit of
pec Average
output pressure of other Standard flow Q judgment
tion pressure (MPa
pressure (MPa pumps (MPa {kgf (L/min) standard Q
Ite {kgf/cm2})
\ {kgf/cm2}) /cm2}) (L/min)
m
Any
Please refer to Please refer to
poi P1 P2 (P1＋P2)/ 2
the curve the curve
nt
★ When measuring, try to make the pump output pressures P1 and P2 close to the average pressure.
★ When using the pump installed on this machine to carry out measurement, if the engine speed can’t
be set as the specified value via fuel control knob, please measure the output of pump and speed of
engine on measuring point, and then calculate the output of pump at specified speed on the basis of
such values.

Maintenance Manual - 01 - 2021 5-9

Standard value of components SY135F Hydraulic Forestry Crane

Applicable to all excavator models (posture

of this machine for measurement of
performance)
Control valve: stroke of slide valve

Figure 5-1
Slewing 1: slewing brake angle, start time of
slewing, and duration of slewing

Figure 5-2
Slewing 2: hydraulic drifting during slewing

Driving wheel

Figure 5-3
Travelling 1: travelling speed (without load)

5-10 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Standard value of components

Figure 5-4
Travelling 2: travelling speed (true operation),
travelling deviation

Figure 5-5
Travelling 3: travelling deviation

Figure 5-6
Travelling 4: hydraulic drifting during travelling

Figure 5-7
Working device 1: hydraulic drifting of working
device

Maintenance Manual - 01 - 2021 5-11

Standard value of components SY135F Hydraulic Forestry Crane

Figure 5-8
Working device 2: boom speed

Figure 5-9
Working device 3: grab arm speed

Figure 5-10
Working device 4: bucket speed

Figure 5-11
Working device 5: boom delay

Figure 5-12

5-12 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Standard value of components

Working device 6: grab arm delay

Figure 5-13
Working device 7: bucket delay

Figure 5-14
Working device 8: features of PC flowrate
control valve

Figure 5-15

Maintenance Manual - 01 - 2021 5-13

Standard value of components SY135F Hydraulic Forestry Crane

5-14 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Testing and Adjustment

Testing and Adjustment

6. Testing and Adjustment ......................................................................................... 6-1
6.1 Measurement of Color of Exhaust Gas ........................................................................... 6-3
6.2 Adjust the valve clearance .............................................................................................. 6-4
6.3 Measurement of compression pressure .......................................................................... 6-6
6.4 Measurement of engine oil pressure ............................................................................... 6-8
6.5 Adjustment of engine speed sensor ................................................................................ 6-9
6.6 Testing and adjustment of tension force of fan belt ....................................................... 6-10
6.7 Measurement of clearance of slewing support bearing ................................................. 6-10
6.8 Inspection and adjustment of crawler plate tensioning device ....................................... 6-12
6.9 Inspection and adjustment of oil pressure in oil ways for working device,
slewing and travelling.................................................................................................... 6-13
6.10 Inspection and adjustment of control oil way pressure .................................................. 6-19
6.11 Measurement of output pressure of electromagnetic valve ........................................... 6-20
6.12 Measurement of output pressure of PPC valve ............................................................. 6-22
6.13 Adjustment of working device and slewing PPC valve .................................................. 6-25
6.14 Inspection of hydraulic settlement of working device ..................................................... 6-25
6.15 Release of residual pressure in hydraulic oil way .......................................................... 6-27
6.16 Measurement of oil leakage .......................................................................................... 6-28
6.17 Air Bleeding for Every Device ....................................................................................... 6-33

Maintenance Manual - 01 - 2021 6-1

Testing and Adjustment SY135F Hydraulic Forestry Crane

Warning
Please read and fully understand the precautions in this Manual and described in the safety
nameplate on the machine. When operating or repairing the machine, please follow those
precautions strictly; otherwise, the wrong operation might lead to machine damages or personal
injuries.

6-2 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Testing and Adjustment

6. TESTING AND
ADJUSTMENT
6.1 Measurement of Color of
Exhaust Gas
★ Measurement tool for color of smoke in
exhaust gas
Mark Model Part name
Filter-paper type
1 YDJ-2006
smoke scope
Light-proof
2 SV-2TY
smoke scope

When installing or dismantling the

measurement tool, don’t contact high-
temperature part.
1. Measurement with filter-paper type smoke
scope
1) Mount the filter paper into smoke
scope.
2) Insert the exhaust gas intake pipe into
exhaust pipe.
3) Start up the engine and make it run
until the engine coolant temperature is
within the operating range.
4) When the engine accelerates suddenly Figure 6-1
or runs at high idle speed, lead the
exhaust gas into filter paper on smoke
scope by operating the filter-paper type
smoke scope.
5) Remove the filter paper on filter-paper
type smoke scope, and use the
accompanied instrument to read the
smoke value.
6) After the measurement, dismantle the
measuring tool, and ensure that this
machine returns to normal state.

Maintenance Manual - 01 - 2021 6-3

Testing and Adjustment SY135F Hydraulic Forestry Crane

2. Measurement with light-proof smoke scope

1) Mount the light-proof smoke scope on
exhaust pipe, and use the clamp to fix
it at outlet.
2) Turn on the light-proof smoke scope to
carry out preheating (about 15
minutes).

Figure 6-2
3) Start up the engine and make it run
until the engine water temperature
increases to the level within operating
range.
4) When the engine accelerates suddenly
or runs at high idle speed, use the light-
proof smoke scope to read the smoke
value of exhaust gas.
5) After the measurement, dismantle the
measuring tool, and ensure that this
machine returns to normal state.

Figure 6-3

6.2 Adjust the valve clearance

1. Turn the piston of the first or fourth cylinder
to the top dead center position of the
compression stroke. During the operation,
turn the crankshaft pulley 1 clockwise with
the rotation handle A to align mark "0" on
the crankshaft pulley with Pointer A.
Attention:
 When the piston is at the top dead center
position of the compression stroke, the
push rod of the cylinder will not lift the
rocker arm of the intake/exhaust valve.
 The pointer A here has two positions. The
mark punched on the crankshaft pulley 1
can be aligned to any position until the mark
is in the position shown in the figure.

6-4 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Testing and Adjustment

2. When No.1 piston is at top dead center,

adjust the valve clearance in sequence
according to the mark order of the black
origin (●) listed in the table below.
Cylinder
1 2 3 4
number
exhaust
● ○ ● ○
valve
Intake
● ● ○ ○
valve

Attention:
 1) When measuring with a thickness gauge,
you should feel some resistance when
moving the gauge in the clearance.
Figure 6-4
 2) If the gauge can be moved easily in the
clearance, any accurate measurement
cannot be obtained.

Valve clearance

If the measured value exceeds the specified

value (0.4mm), it should be adjusted according
to the following method.
Adjustment:

Adjustable screw

Locking nut

Valve clearance

(1) When adjusting the valve clearance, firstly

Maintenance Manual - 01 - 2021 6-5
Testing and Adjustment SY135F Hydraulic Forestry Crane

loosen the locking nut, and then turn the

adjusting screw, until the slight resistance is
felt when the thickness gauge is pulled out
from standard clearance.
(2) After the adjustment, stop the adjustment
screw with a screwdriver and tighten the
lock nut for fixing. Tightening torque of lock
nut: 16-24 N·m {1.7±2.5 kgf·m} kgf·m}
(3) Continue to the next step until all valve
clearances marked with (● have been
adjusted.
(4) Inspect the valve clearance with thickness
gauge again. If the clearance deviates from
standard value, please carry out
adjustment again.
Align Cylinder 4 with the compression top dead
center (TDC).
Attention:
 Rotate the crankshaft 360 ° from the
compression TDC of Cylinder 1 and align
Cylinder 4 to the compression TDC.
5. Adjust the remaining valve clearance to the
specified value of 0.4mm with a feeler
gauge according to the method of adjusting
Cylinder 1.

6.3 Measurement of compression pressure

★ Inspection standard
Repair item Standard value Limit value Correction method
(2.84～3.24)
Every cylinder (at 1.9 MPa {20kgf/
MPa{(29～33)kgf/ Inspection
Compression 200rpm) cm2}
cm2}
pressure
Pressure difference 294 kPa {3kgf/cm2
— Inspection
between cylinders }

★ Special tools
Name of Tool Schematic Diagram Part no. Purpose

Measurement of
Pressure gauge connector 5884028150
Compression Pressure

6-6 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Testing and Adjustment

1. Start up the engine

Note: warm up the engine.
2. Turn the ignition switch to the OFF position.
3. Disconnect the battery ground cable from
the battery.
Caution: do not disconnect the battery cable for
1 minute after turning the ignition switch to the
OFF position.
4. Disconnect the harness connectors of all
fuel injectors.
5. Remove the glow plug from the cylinder
head. Note: remove all glow plugs.
6. Connect the earthling wire of battery onto
battery.
7. Rotate the starter. Note: start the engine to
discharge the foreign matter from the
cylinder.
8. Install the pressure gauge on the cylinder
head with a special tool. (Figure 6-8) Figure 6-5
Note: insert the special tool into the installation
hole of the glow plug, and then install the
pressure gauge.
9. Measurement of Compression Pressure.
Attention:
 Rotate the starter to read the stable
compression pressure of the pressure
gauge pointer.
 Measure the compression pressure of all
cylinders.
Note:
 Use a fully charged battery.
 During the rotation, air will be ejected from
the glow plug hole.
 If the ignition switch is turned on with the
injector harness connector removed, the
diagnostic trouble code will be stored.
Therefore, clear the fault code after the
inspection.
10. Remove the special tool from the cylinder

Maintenance Manual - 01 - 2021 6-7

Testing and Adjustment SY135F Hydraulic Forestry Crane

head.
11. Disconnect the battery ground cable from
the battery.
Fuel injector harness joint
Caution: do not disconnect the battery cable for
3 minutes after turning the ignition switch to the
OFF position.
12. Install the preheating plug onto cylinder
head assembly.
Note: install all glow plugs.
Tightening torque: 18N·m{1.8kgf·m}
13. Connect the harness connector to the
injector. (Figure 6-9)
14. Connect the earthling wire of battery onto
battery. Figure 6-6

6.4 Measurement of engine oil

pressure
1. Dismantle the engine oil pressure sensor.

Engine oil pressure sensor

Figure 6-7
2. Install the engine oil pressure gauge.
3. Start the engine. Note: warm up the engine.
4. Measure and confirm that the oil pressure
is 343 kPa or higher at 2,000 rpm.
5. Turn the ignition switch to the position OFF.
6. Dismantle the engine oil pressure gauge.
7. Install the engine oil pressure sensor.
Tightening torque 40N•m.
Oil pressure gauge No.: 5-8840-2843-0
8. Start Engine。
Note: Inspect whether the engine oil leaks.

6-8 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Testing and Adjustment

Figure 6-8

6.5 Adjustment of engine speed

sensor
★ There are two speed sensors,
crankshaft position sensors and camshaft
position sensors on the engine.
 The crankshaft position sensor is installed
on the cylinder block. When the protruding
part of the rotor installed on the crankshaft
passes through the sensor, the crankshaft
position signal will be generated by the
crankshaft position sensor and sent to the
engine control unit to calculate the actual
speed of the engine.
 When the crankshaft position sensor fails, Figure 6-9
the camshaft position signal will be used.
 The camshaft position sensor is installed in
the front part of the cylinder head. When the
cam part of the camshaft passes through
the sensor, the camshaft position sensor
will generate the camshaft position signal
and transmit it to the engine control unit to
calculate the actual engine speed.
 When the camshaft position sensor fails,
the crankshaft position signal will be used.
 When it is necessary to replace any one of
the speed sensors, just remove the old part
and install the new part. Since the speed
sensor body is a plastic part, it is not
necessary to adjust it. Figure 6-10

Maintenance Manual - 01 - 2021 6-9

Testing and Adjustment SY135F Hydraulic Forestry Crane

6.6 Testing and adjustment of

tension force of fan belt
Test
1. Press the specified position on the belt with
the specified load to check the belt bending. Locking nut
Inspection position of belt


bending
Specified load: 98 N Adjustable bolt

 Belt bending: 6.6 mm～7.4 mm Fan belt pulley

Alternator
Adjustment
★ When the belt bending is abnormal or a new
belt is replaced, the belt needs to be adjusted. Crankshaft
belt pulley
Fix the bolts

1. Loosen the locking bolts and mounting

bolts of the adjusting plate at the engine
bottom.
Figure 6-11
2. Turn the adjusting bolts to adjust the belt.
3. Measure the belt bending.
4. After the adjustment, tighten the locking
bolt and mounting bolt of the adjusting plate
at the bottom of the generator with the
specified torque.
Tightening torque: 51N ·m, M10 bolt, M10 nut
25N•m. M8 bolt, M8 nut
Attention:
 When a new belt is replaced, the belt will be
initially extended.
 When replacing a new belt, press the
specified position on the belt with the
specified load to check the belt bending (the
deflection value is controlled at 4.2 mm ~ 5
mm).
 Start the engine and allow it to idle for 5
minutes or more.
 Stop the engine and adjust the belt tension
to the specified value.

6.7 Measurement of clearance

of slewing support bearing
Measuring tools
Symbols Component no. Name of

6-10 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Testing and Adjustment

component
H 60033930 Dial indicator

★ When measuring the clearance of slewing

support bearing installed on this machine,
please use the following method.
Park the excavator on the level ground,
and lower then working device to the ground.
During the measurement, don’t put
your hand or foot under the lower travelling
body.
1. Fix the dial gauge H on crawler carrier, and
make the measuring needle point at the
lower end face of outer race.

Figure 6-12
2. Set the working device at the maximum
work distance, and make the end of bucket
is as high as the lower side of slewing table.
★ At that moment, the front end of upper
slewing platform will lower and the rear end will
rise.

Figure 6-13

Maintenance Manual - 01 - 2021 6-11

Testing and Adjustment SY135F Hydraulic Forestry Crane

3. Return the indication of dial gauge H to

zero.
4. Make the grab arm vertical to ground, and
lower the boom until the front crawler plate
rises.
★ At that moment, the front end of upper
slewing platform will rise and the rear end will
lower.
5. At that moment, read the value indicated by
dial gauge H.
★ The value of the dial indicator H indicates Figure 6-14
the clearance of the bearing.
★ For detailed standard values, see
Structural, Functional and Maintenance
Standards, "Rotary Bearings".
6. Return this machine to the state specified in
Step 2, and inspect whether the indication
of dial gauge H returns to zero.
★ If the dial indicator does not return to zero,
repeat Steps 3 to 5.
7. After the adjustment is completed,
dismantle the adjusting tool and mount the
dismantled parts.

6.8 Inspection and adjustment

of crawler plate tensioning
device
Inspection
1. Make this machine travel forwards for a
distance which is equivalent to the length of
crawler on ground, maintain the engine
speed at low idle speed, and slowly stop
this machine.
2. Place a straight bar on the crawler plate
above guiding wheel (1) and first sprocket
(2).
★ It is suggested to use angle steel straight
bar with small bending. In addition, L-beam
structure also has good bending characteristics. Figure 6-15

3. Measure the maximum clearance a

between upper surface of crawler and
6-12 Maintenance Manual - 01 - 2021
SY135F Hydraulic Forestry Crane Testing and Adjustment

bottom face of straight bar.

● Maximum standard clearance a: 10~30 mm
(0.4~1.2 in)
Adjustment
★ If the tension force of crawler is incorrect,
please carry out adjustment in accordance with
the following method.
1. Reduce the tension force
1) Loosen the valve (1), drain the lubricating
grease, and then tighten up the valve.

Don’t screw off the valve for more than one

round. If the valve is excessively loosened, the
Figure 6-16
high-pressure grease in valve may eject the
valve out.
2) After the adjustment, re-inspect the tension
force of crawler plate in accordance with the
above-mentioned inspection method.
2. Increase the tension force
1) Use the lubricating grease gun to fill the
lubricating grease via lubricating grease
nozzle (2).
2) After the adjustment, re-inspect the tension
force of crawler plate in accordance with the
above-mentioned inspection method.
★ Add grease until the dimension b between
the idler guide and the end of the track frame
becomes 0 mm. If the tension is still very low, it
means that the pin shaft and bushing are
seriously worn. It is necessary to replace the pin
shaft and bushing, or cancel a track.

Figure 6-17

6.9 Inspection and adjustment

of oil pressure in oil ways
Maintenance Manual - 01 - 2021 6-13
Testing and Adjustment SY135F Hydraulic Forestry Crane

for working device, slewing

and travelling
★ Tools for inspection and adjustment of oil
pressure in oil ways for working device, slewing
and travelling
No. Part no. Part name
Pressure gauge
1 24908318
G1/4 40MPa
Pressure gauge
2 24908322
Y-60 6mpa

★ The oil pressure in the operating device,

rotary and walking oil circuit (pump discharge
pressure) can be checked with the high
pressure gauge 1.
Measurement
1. Preparatory work for measurement
Lower down the working device onto
ground and turn off the engine. After the engine
stops, operate the control rod for several times
so as to release the residual pressure in
pipeline, and then press down the breather
valve so as to release the pressure in hydraulic
oil tank.
1) Connect the pressure-measuring port (1) of
front pump and pressure-measuring port
(2) of rear pump in main pump.
2) Install the joint and connect it to the Figure 6-18
pressure gauge.
★ Use a 40 MPa {408 kgf/cm2} pressure
gauge.
3) Start the engine and keep operating until
the hydraulic oil temperature rises to 45-
55 ℃.

6-14 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Testing and Adjustment

2. Measurement of unloaded pressure

1) Start up the engine.
2) Make the engine run at high speed, set all
control rods at middle position, and
measure the oil pressure.
3. Measurement of overflow pressure of
working device
1) Start up the engine and move the cylinder
measured to the end of stroke.
2) When the engine is running at high speed
and the cylinder is in overflow state,
measure the hydraulic oil pressure. Figure 6-19
★ Measure the pressure when the main
overflow valve overflows.
★ If the secondary boost switch is released,
the main relief valve will overflow at a low
pressure. If the secondary boost switch is
pressed, the main relief valve will overflow at a
high pressure.
4. Measurement of slewing overflow pressure
1) Start up the engine, disconnect the pipe on
port of slewing brake release valve on
slewing motor, and connect a blind plug to
each of two ends of such pipe.
2) Make the engine run at high speed, connect
the joints at (3) and (4), connect them to
pressure gauge, make the slewing oil way
overflow, and measure the oil pressure.
★ Measure the pressure when the safety
valve of slewing motor overflows.
Figure 6-20
★ The overflow pressure of slewing motor is
lower than main overflow pressure.

Maintenance Manual - 01 - 2021 6-15

Testing and Adjustment SY135F Hydraulic Forestry Crane

5. Measurement of travelling oil way overflow

pressure
1) Start up the engine and lock the travelling.
Place the pin (1) between the drive wheel
and the track bracket to ensure that the travel is
locked.

Figure 6-21
2) When the engine is running at high idle
speed and the travelling oil way overflows,
measure the hydraulic oil pressure.
★ Measure the pressure when the main relief
valve shows any overflow. The oil circuit must
overflow under a high pressure.
Adjustment
★ The unloading valve can’t be adjusted.

Figure 6-22
1. Adjustment of main overflow pressure
(high-pressure setting side)
★ If the overflow pressure of the operating
device oil circuit and walking oil circuit is
abnormal, adjust the pressure set by the main
relief valve (5) according to the following steps.
★ When the secondary boost solenoid valve
is opened, the high overflow pressure is applied,
and the pilot pressure is applied to the selector
port.
1) Disconnect the pilot hose at (6).
2) Fix the retainer (7), and screw off the
locking nut (8).
3) Turn the retainer (7) so as to adjust the
pressure.
★ If the retainer is turned to right side, the
pressure will increase.
★ Adjustment amount of retainer per turn:
6-16 Maintenance Manual - 01 - 2021
SY135F Hydraulic Forestry Crane Testing and Adjustment

about 12.5 MPa {about 128 kgf /cm2} Figure 6-23

4) Fix the retainer (7), and tighten up the
locking nut (8).
Locking nut:39.2-49 N·m{4-5 kgf·m}
5) Connect the pilot hose at (6).
6) After the adjustment, inspect the pressure
again, and carry out measurement in
accordance with the above-mentioned
steps.
★ If the high-pressure side is adjusted, the
low-pressure side will change. Therefore,
please also adjust the low-pressure side. Figure 6-24
2. Adjustment of main overflow pressure (low-
pressure setting side)
★ If the low overflow pressure of the oil circuit
of the operating device is abnormal or the high
pressure setting is adjusted, adjust the low
pressure setting side of the main relief valve (5)
according to the following steps.
★ The low overflow pressure when the
secondary boost solenoid is closed is the
applied pressure, do not apply any pilot
pressure to the selector port.
1) Disconnect the pilot hose at (6).
2) Fix the retainer (9), and screw off the
locking nut (10).
3) Turn the retainer (9) so as to adjust the
pressure.
★ If the retainer is turned to right side, the
pressure will increase.
★ Adjustment amount of retainer per turn:
about 12.5 MPa {about 128 kgf /cm2}
4) Hold the retainer (9) and tighten the lock nut
(10).
Locking nut: 53.9-63.7 N•m{5.5-6.5
kgf·m}
5) Connect the pilot hose at (6).
6) After the adjustment, inspect the pressure
again, and carry out measurement in

Maintenance Manual - 01 - 2021 6-17

Testing and Adjustment SY135F Hydraulic Forestry Crane

accordance with the above-mentioned

steps.
3. Adjustment of slewing overflow pressure
★ If the rotary relief pressure is abnormal,
adjust the rotary motor relief valve (11) in the
following order.

1) Fix the adjusting screw (12) and loosen the

lock nut (13).
2) Turn the adjusting screw (12) so as to
adjust the pressure.
★ If the adjusting screw is turned
rightwards, the pressure will increase.
If the adjusting screw is turned leftwards, the
pressure will reduce.
★ Adjustment amount by every round of
adjusting screw:
About 14 MPa {About 143kgf/cm2}
3) Fix the adjusting screw (12), and tighten up
the locking nut (13).
Locking nut:
53.9-73.5 N·m {5.5-7.5 kgf·m}
4) After the testing is completed, inspect
whether the pressure is normal again in
accordance with the above-mentioned
measurement steps.

6-18 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Testing and Adjustment

6.10 Inspection and adjustment

of control oil way pressure
★ Inspection and adjustment of control oil way
pressure
No. Part no. Part name
Pressure gauge G1/4
1 24908318
40MPa
2 24908322 Pressure gauge Y-60 6mpa

Measurement
Lower down the working device onto the
ground and turn off the engine. After the engine
stops, operate the control rod for several times
so as to release the residual pressure in
pipeline, and then screw off the disc-shaped nut Figure 6-25
on breather valve, and press down the release
button, so as to release the pressure in hydraulic
oil tank.
1. Open the right side door and dismantle the
hose on hydraulic pilot pump (1).
2. Install the joint and connect it to low-
pressure gauge 2.
★ Use the 6 MPa low pressure meter.
3. Operate the engine and raise the hydraulic
oil temperature to 45-55 ℃.
4. Make the engine run at high speed, set all
control rods at middle position and measure
the oil pressure.
5. After the measurement is completed,
dismantle the measuring tool and install the Figure 6-26
dismantled parts.
★ It is prohibited to adjust the oil pressure
overflow valve of control oil way.

Maintenance Manual - 01 - 2021 6-19

Testing and Adjustment SY135F Hydraulic Forestry Crane

6.11 Measurement of output

pressure of electromagnetic
valve
★ Measurement tool for output pressure of
electromagnetic valve
No. Part no. Part name
Pressure gauge G1/4
1 24908318
40MPa
Pressure gauge Y-60
2 24908322
6mpa

★ After confirming that the initial pressure of

control oil way is normal, measure the output
pressure of electromagnetic valve.
Lower down the working device onto Figure 6-27
ground and turn off the engine. After the engine
stops, operate the control rod for several times
so as to release the residual pressure in
pipeline, and then press down the breather
valve so as to release the pressure in hydraulic
oil tank.
1. Remove the bottom cover at the lower part
of the control valve and disconnect the
solenoid valve outlet hoses (1) - (4) to be
measured.
No. Electromagnetic valve measured
1 PPC pressure locking valve
2 Linear travel valve spool
3 SH port of rotary motor
4 Secondary pressurization valve spool
4 High/low speed solenoid valve
Figure 6-28
2. Install the joint and connect the
disconnected hose again.
3. Install the pipe joint of pressure gauge and
connect it to pressure gauge.
★ Use a 6 MPa pressure gauge.
Pressure
4. Operate the engine and raise the hydraulic measuring
joint
oil temperature to 45-55 ℃.
Pressure gauge

5. The engine is operating at a high speed,

operate the lever and switch to turn the

6-20 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Testing and Adjustment

solenoid to ON or OFF and measure the oil Figure 6-29

pressure.
★ For the status of turning the solenoid valve
to ON or OFF, refer to "Operation Table of Each
Solenoid Valve".
★ The operation of the solenoid valve can also
be checked by the monitoring function of the
monitor panel (excluding the linear travel
solenoid valve).
★ When every output pressure is displayed as
the following value, it will be judged as normal.
Solenoid pump Output pressure
OFF
(demagnetizati 0 MPa {0 kgf/cm2}
on)
ON Almost the same as the control basic
(magnetization pressure (see the standard value
) table)

6. After the measurement is completed,

dismantle the measuring tool and install the
dismantled parts.
Operation table for secondary turbocharging electromagnetic valve
Operation signal State of electromagnetic valve
Touch switch (at the end of the left operating handle): ON (8-second timer)
ON
Travelling signal
Except for the above-mentioned situations OFF

Operation table of linear travel solenoid valve

Operation signal State of electromagnetic valve
Travel signal + rotary locking signal
ON
Travel signal + boarding action signal
Except for the above-mentioned situations OFF

Operation table of high/low speed solenoid valve

Operation signal State of electromagnetic valve
Travel speed switch: ON ON
Except for the above-mentioned situations OFF

Maintenance Manual - 01 - 2021 6-21

 Testing and Adjustment SY135F Hydraulic Forestry Crane

Operation table of PPC pressure locking solenoid valve

Operation signal State of electromagnetic valve
Locking position OFF
Safety Locking Lever
Opened position ON

6.12 Measurement of output

pressure of PPC valve
★ Measurement tool of PPC output pressure
No. Part no. Part name
Pressure gauge
1 24908318
G1/4 40MPa
Pressure gauge
2 24908322
Y-60 6mpa

★ Before measuring the output pressure of

PPC valve, check whether the basic pressure in
the control oil circuit is normal.
Lower down the working device onto
ground and turn off the engine. After the engine
stops, operate the control rod for several times
so as to release the residual pressure in
pipeline, and then press down the breather
valve so as to release the pressure in hydraulic
oil tank.
1. The PPC oil pressure in oil way to be
measured is as indicated in the table below.
Oil way
No. No. Oil way measured
measured
Boom lifting
1 7 Left turn (ZH)
(DBT)
Boom lowering
2 8 Right turn (YH)
(DBX)
Arm digging Traveling forward left
3 9
(DGW) (ZXQ)
Arm unloading Left travel backward
4 10
(DGX) (ZXH)
Bucket digging Right travel forward
5 11
(CDW) (YXQ)
Bucket Right travel
6 12
unloading (CDX) backward (YXH)

6-22 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Testing and Adjustment

2. Open the cover plate and measure No. (1),

(3), (6), (7), and (8) pilot oil pressures.

Figure 6-30
3. Measure No. (4) pilot oil pressure on the
shuttle valve block.

Figure 6-31
4. Remove the cab bottom cover. Measure the
oil pressure of the pilot oil circuits (9) - (12)
in the travel pilot valve under the chassis.

Figure 6-32

Maintenance Manual - 01 - 2021 6-23

Testing and Adjustment SY135F Hydraulic Forestry Crane

5. Remove the rubber hose at (13) and

measure the pilot oil pressure of No. 2
(DBX) and No. 5 (CDW) respectively during
a single action.

Figure 6-33
6. Install the joint and connect it to pressure
gauge.
★ Use a 6 MPa pressure gauge.
7. Start the engine and keep it running until
the hydraulic oil temperature rises to 45-
55 ℃. Pressure
measuring
joint
8. When the engine is running at high idle Pressure
speed, carry out measurement, and gauge

maintain the control rod of oil way

measured at the middle position or full- Figure 6-34
stroke position.
★ If the output pressure of PPC valve is
measured as shown in the table below, it is
judged as normal.
Control rod/pedal Hydraulic pressure
At middle position 0{0}
Almost same as basic control
pressure
At full stroke
(Please refer to the table of
standard value)

9. After the measurement is completed,

dismantle the measuring tool and install the
dismantled parts.

6-24 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Testing and Adjustment

6.13 Adjustment of working

device and slewing PPC
valve
★ If the play of working device or slewing
control rod is too large, please carry out
adjustment in accordance with the following
method.
1. Dismantle the working device and slewing
PPC valve assembly.
2. Dismantle the rubber sleeve (1).
3. Screw off the locking nut (2) and tighten up
the disc (3) until it contacts with top of 4
plungers (4).
★ At that moment, don’t move the plunger.
4. Fix the disc (3), and then tighten up the
locking nut (2) to the specified torque.
Locking nut: 69-88 N·m {7-9 kgf·m}
5. Install the rubber sleeve (1). Figure 6-35
6. Install the working device and slewing PPC
valve assembly.

6.14 Inspection of hydraulic

settlement of working
device
★ If the working device (cylinder) has any
hydraulic settlement, please carry out inspection
in accordance with the following procedure, and
confirm whether the trouble occurs in cylinder
seal or control valve.
1. Inspection of boom and bucket cylinder
1) When carrying out the measurement,
maintain this machine in the posture as
indicated in right figure, and stop the
engine.
★ Fill the bucket with soil or apply the rated
load onto bucket.
2) Operate the control rod, so as to set the
boom at lifted position and the bucket at
excavation position.
● If the lowering speed increase, the cylinder Figure 6-36

Maintenance Manual - 01 - 2021 6-25

Testing and Adjustment SY135F Hydraulic Forestry Crane

seal is in trouble.
● If there is no change, the control valve is in
trouble.
★ Operate the lever when the engine start
switch is in the ON position.
★ If the pressure in accumulator reduces,
make the engine run for about 10s, so as to
pressurize the accumulator again.
2. Inspection of grab arm cylinder
1) Set the machine in the posture as indicated
in right figure, set the grab arm cylinder at
the position 100m away from end of
excavation stroke, and stop the engine.
2) Operate the control rod, so as to set the
grab arm at excavation position.
 If the lowering speed increase, the cylinder
seal is in trouble.
 If there is no change, the control valve is in
trouble. Figure 6-37
★ Operate the lever when the engine start
switch is in the ON position.
★ If the pressure in accumulator reduces,
make the engine run for about 10s, so as to
pressurize the accumulator again.
[Reference] If the hydraulic settlement is caused
by trouble in seal of cylinder, then when carrying
out the above-mentioned operation, the
mechanism for reducing acceleration is as
follows:
1) If the working device displaced at the
above-mentioned position (the pressure is
applied on large chamber), the oil pressure
of large chamber will leak into small
chamber, and thus the pressure in small
chamber will also increase.
2) When the pressure in small chamber
increases, the pressure in large chamber
will have to increase so as to get balanced
with it. Repeatedly, the balance with be
reached under a certain pressure (on the
basis of the difference in leakage).

6-26 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Testing and Adjustment

3) When the pressure is balanced, the

downward movement will slow down. If the
control rod is operated in accordance with
the above-mentioned procedure, the oil
way of small chamber will be opened to the
oil discharge way (the large chamber will be
closed via the one-way valve), the oil in
small chamber will flow into oil discharge
way, and the downward movement will
speed up.
3. Inspection of PPC valve
When the accumulator is charged and the safety
locking lever is in the "LOCK" and "RELEASE"
positions,
the hydraulic settlement of the operating device
is measured respectively.
★ Operate the control lever when the engine
start switch is in the "ON" position.
★ If the pressure in accumulator reduces,
please make the engine run for about 10
seconds, and then pressurize the accumulator
again.
★ If the hydraulic settlement of the operating
device is different when the safety locking lever
is in the "LOCK" and "RELEASE" positions, it
indicates that the PPC valve is faulty (internal
fault).

6.15 Release of residual

pressure in hydraulic oil
way
1. Release of residual pressure in hydraulic oil
tank
Since the hydraulic oil tank is sealed and
pressurized, before dismantling any hose or
plug connected with oil tank, please release the
residual pressure.
1) Lower down the working device onto
ground stably, and turn off the engine.
2) Slowly press down the breather valve (1) on
oil tank, so as to bleed the air in oil tank. Figure 6-38
2. Release of residual pressure in hydraulic

Maintenance Manual - 01 - 2021 6-27

Testing and Adjustment SY135F Hydraulic Forestry Crane

cylinder oil way

Disconnect the pipeline between hydraulic
cylinder and control valve, please release the
residual pressure in pipeline in accordance with
the following steps.
1) Release the residual pressure in hydraulic
oil tank. As for relevant details, please refer
to “Release of Residual Pressure in
Hydraulic Oil Tank”.
★ Properly store the oil filler cover on
dismantled hydraulic oil tank.
2) Turn on the start switch to the power-on
state, put the safety locking lever in the free
position, and then operate the operating
device control levers FORWARD,
BACKWARD, LEFT and RIGHT on both
sides.
★ Operate the pressure operation control
valve in the accumulator. Release the pressure
in the accumulator after operating the control
valve 2-3 times.
3) Make the engine run at low speed for 10
seconds, so as to increase the pressure in
accumulator.
4) Repeat the above steps for 2-3times, so as
to fully release the residual pressure in
pipeline.
3. Release of residual pressure in slewing
motor oil way
★ Please release the residual pressure in
slewing motor oil way by releasing the residual
pressure in hydraulic cylinder oil way (The
control rod is only operated in slewing direction).
4. Release of residual pressure in travelling
motor oil way
★ Since the slide valve of control valve in
travelling motor oil way has been opened,
please release the pressure in this oil way by
releasing the residual pressure in hydraulic oil
tank.

6.16 Measurement of oil leakage

6-28 Maintenance Manual - 01 - 2021
SY135F Hydraulic Forestry Crane Testing and Adjustment

★ Measuring toll for oil leakage

Symbols Part no. Part name
Purchased from Measurement
P
market cylinder

1. Measurement of boom cylinder oil leakage

1) Start up the engine and make it run until the
hydraulic oil temperature increases to the
level within operating range, and then
extend the boom cylinder to the end of
stroke.
Release the residual pressure in pipeline.
As for relevant details, please refer to “Release
of Residual Pressure in Hydraulic Oil Way. ”
2) Disconnect the hose (1) of small chamber
of cylinder and install the blind plug on end
Figure 6-39
of hose.
Be careful not to disconnect the hose of
large chamber of cylinder.
3) Make the engine run at high idle speed, and
make the boom oil way overflow by lifting
the boom.
Be careful not to lower the boom.
4) Maintain this state for 30 seconds, and then
measure the amount of oil leaking within
one minute.
5) After carrying out the measurement, make
sure that this machine returns to normal
state.
2. Measurement of oil leakage in grab arm
cylinder
1) Run the engine and raise the hydraulic oil
temperature to 45-55 ℃, then move the
grab arm cylinder to the end of the
retraction stroke.
Release the residual pressure in top
pipeline of boom cylinder. As for relevant details,
please refer to “Release of Residual Pressure in
Hydraulic Oil Way.” (Only operate the control rod
in retraction direction of grab arm).
Figure 6-40
2) Disconnect the hose (2) on small chamber

Maintenance Manual - 01 - 2021 6-29

Testing and Adjustment SY135F Hydraulic Forestry Crane

of cylinder and install the blind plug on end

of hose.
Be careful not to disconnect the hose of
large chamber of cylinder.
3) Make the engine run at high idle speed and
make the grab arm oil way overflow by
retracting the grab arm.
Please be careful not to extend the grab
arm.
4) Maintain this state for 30 seconds, and then
measure the amount of oil leaking within
one minute.
5) After carrying out the measurement, make
sure that this machine returns to normal
state.
3. Measurement of oil leakage in bucket
cylinder
1) Make the engine run until the hydraulic oil
temperature increases to the level within
operating range, and then extend the
bucket cylinder to the end of excavation
stroke.
Release the residual pressure in pipeline.
Please refer to “Release of Residual Pressure in
Hydraulic Oil Way” in previous section (Only
operate the control rod in excavation direction of Figure 6-41
bucket).
2) Disconnect the hose (3) on small chamber
of cylinder and install the blind plug on end
of hose.
Be careful not to disconnect the hose of
large chamber of cylinder.
3) Make the engine run at high idle speed and
apply the overflow pressure onto large
chamber of cylinder.
Be careful not to unload the bucket.
4) Maintain this state for 30 seconds, and then
measure the amount of oil leaking within
one minute.
5) After carrying out the measurement, make
sure that this machine returns to normal
6-30 Maintenance Manual - 01 - 2021
SY135F Hydraulic Forestry Crane Testing and Adjustment

state.
4. Measurement of oil leakage in slewing
motor
1) Run the engine to raise the oil temperature
to 45-55℃.
2) Fully extend the working device, place the
bucket on ground so as to slightly lift up the
excavator, and stop the engine.
3) Disconnect the drain hose (4) and block it
up with plug.
4) Start up the engine. When the engine is
running at high idle speed, apply the Figure 6-42
slewing overflow pressure, and measure
the oil leakage.
★ Keep the state of Step 4) for 30 seconds
and measure the oil leakage for one minute.
★ After measuring once, rotate 180 °and then
measure again.
5) After carrying out the measurement, make
sure that this machine returns to normal
state.
5. Measurement of oil leakage in travelling
motor
1) Dismantle the travelling motor cover.
2) Start up the engine and lock the travelling.
Place the pin (5) between the drive wheel
and the track frame to prevent traveling.

Figure 6-43

Maintenance Manual - 01 - 2021 6-31

Testing and Adjustment SY135F Hydraulic Forestry Crane

3) Disconnect the discharge hose (6) of the

traveling motor and plug the hose side.
4) Start up the engine. When the engine is
running at high idle speed, apply the
travelling overflow pressure, and then
measure oil leakage.
During the measurement, any misoperation
of the control lever will lead to serious accidents.
Mark and check it carefully.
★ After keeping the above Step 4) for 30
seconds, measure the oil leakage for 1 minute.
Figure 6-44
★ Carry out measurement for several times.
Move the motor slightly every time (to change
the position of oil distribution disc, cylinder and
plunger).
5) After carrying out the measurement, please
ensure that this machine returns to normal
state.

6-32 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Testing and Adjustment

6.17 Air Bleeding for Every Device

Air Bleeding Steps
1 2 3 4 5 6

Air Bleeding Item Bleed

Bleed Bleed
Work Contents Bleed the air
the air Start the air
the air from Start of
from the from
from back operation
hydraulic engine travelling
cylinder slewing
pump motor
motor
 Replace the hydraulic oil 〇 〇 〇 〇 〇 〇
 Cleaning of filter element (Note) (Note)
 Replacement of return filter element 〇 〇
 Repair or replacement of hydraulic
pump 〇 〇 〇 〇
 Dismantlement of oil suction pipe

 Repair or replacement of control valve 〇 〇 〇

 Replacement of cylinder
〇 〇 〇
 Dismantlement of cylinder pipeline
 Replacement of back slewing motor
 Dismantlement of pipeline of back 〇 〇 〇
slewing motor
 Replacement of travelling motor
 Dismantlement of pipeline of travelling 〇 〇 〇
motor

Note: only when the oil in the motor housing is discharged, the air can be discharged from the
rotary motor and traveling motor.
1. Bleed the air from hydraulic pump.
1) Open the right side door, screw off the drain
plug (1), (2) and inspect whether oil flows
out.
2) If no oil flows out, fill the oil from oil drain
port into pump housing.
★ Fill the oil into pump housing until no bubble
is found in oil flowing out from oil drain port.
3) After the oil flowing from drain plugs (1), (2)
contains no bubble, tighten up the drain
plugs.
Air drain plug: 7.8-9.8 N·m {0.8-1.0 kgf·m}
2. Start Engine
After carrying out the Step 1, make the engine
run, and maintain the speed at low idle speed
for 10 minutes.
Figure 6-45
★ If the engine coolant temperature is low, the
automatic heating operation will start.

Maintenance Manual - 01 - 2021 6-33

Testing and Adjustment SY135F Hydraulic Forestry Crane

Temporarily turn off the engine and reset the

automatic heating operation with the fuel control
knob (set the start switch to the ON position and
keep the fuel control knob in the maximum
position for 3 seconds, and the automatic
heating operation will be reset).
3. Bleed air from hydraulic cylinder
★ If the cylinder has been replaced, before
connecting the working device, please carry out
air bleeding for cylinder, especially the boom
cylinder (If it has been installed on working
device, it can’t be moved to the end of lowering
stroke).
1) Make the engine run at low idle speed for
about 5 minutes.
2) Make the engine run at low idle speed, and
lift up and lower down the boom for 4-
5times.
★ Stop the piston rod at 100 mm before
the end of each stroke. Don't drain the oil.
3) Make the engine run at high idle speed, and
carry out the Step 2).
4) Make the engine run at low idle speed,
move the piston rod to the end of stroke and
drain the oil.
5) Exhaust from the grab arm cylinder and
bucket cylinder according to Steps 2) to 4).
4. Bleed the air from travelling motor
1) Remove the traveling motor cover and run
the engine at low idle speed.

Figure 6-46

6-34 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Testing and Adjustment

3) Run the engine at low idle speed and

support the track shoes with the operating
device.
4) Run the engine at low idle speed and slowly
turn the supported track shoes for about 2
minutes.
★ Rotate the track shoes forward and
backward as evenly as possible.
★ Also operate the track shoe on the other
side.

Figure 6-47
5. Inspect the oil level and carry out operation
1) Make the engine run, retract the grab arm
cylinder and bucket cylinder to the end of
stroke, lower down the working device onto
ground and turn off the engine.

Figure 6-48
2) Inspect the oil level in hydraulic oil tank
through observe window (4).
★ If the oil level is between Levels H and L,
the oil level is normal.
★ If the oil level is lower than Level L, add new
oil.

Figure 6-49

Maintenance Manual - 01 - 2021 6-35

Testing and Adjustment SY135F Hydraulic Forestry Crane

6-36 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

Trouble Diagnosis
7. Trouble Diagnosis .................................................................................................. 7-1
7.1 Precautions during Trouble Diagnosis ............................................................................. 7-5
7.2 Work Procedure for Trouble Diagnosis............................................................................ 7-7
7.3 Precautions for Maintenance .......................................................................................... 7-8
7.4 Inspection before Trouble Diagnosis ............................................................................. 7-16
7.5 Category and steps of trouble diagnosis ....................................................................... 7-16
7.6 Adjustment Service ....................................................................................................... 7-18
7.6.1 Adjustment service (SY135F) .......................................................................... 7-18
7.6.2 Trouble - Identity the symptoms and trouble diagnosis code ........................... 7-23
7.6.3 Position Diagram of Connectors and Wiring Diagram of System ..................... 7-25
7.6.4 Position diagram of connector ......................................................................... 7-29
7.6.5 Circuit Diagram of Electric System Components (Cab Circuit) ........................ 7-30
7.6.6 Circuit Diagram of Electrical Control System (Engine Circuit) .......................... 7-32
7.6.7 Circuit Diagram of Electrical Control System (Circuit of Sensor and
Solenoid Valve) ............................................................................................... 7-34
7.6.8 SWP connector ............................................................................................... 7-35
7.6.9 A/AMP connector ............................................................................................ 7-36
7.6.10 DT connector .................................................................................................. 7-37
7.7 Trouble diagnosis for electrical system (category-E trouble) ......................................... 7-38
7.7.1 Information in table of trouble diagnosis .......................................................... 7-38
7.7.2 E-1 The engine could not be started................................................................ 7-38
7.7.3 E-2 The engine speed fluctuates irregularly .................................................... 7-41
7.7.4 E-3 The power supply for complete machine could not be switched off ........... 7-41
7.7.5 E-4 The automatic idling does not work ........................................................... 7-42
7.7.6 E-5 The preheating function does not work ..................................................... 7-43
7.7.7 E-6 All devices could not work ......................................................................... 7-44
7.7.8 E-7 The operating device is slow and weak ..................................................... 7-45

Maintenance Manual - 01 - 2021 7-1

Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.7.9 E-8: The travelling acts slowly and powerlessly .............................................. 7-46
7.7.10 E-9 The display on upper portion of monitor panel is omitted.......................... 7-46
7.7.11 E-10 The display content of the monitor panel is independent of the model.... 7-47
7.7.12 E-12 The indication of fuel oil level is inaccurate............................................. 7-47
7.7.13 E-13 No response when operating the button switch on the display screen .... 7-48
7.7.14 E-14 The wiper does not work ........................................................................ 7-49
7.7.15 E-15 The alarm buzzer cannot be eliminated .................................................. 7-50
7.7.16 E-16 Inaccurate display of operating device pressure state ............................ 7-51
7.7.17 E-17 The slewing operation can’t be correctly displayed in monitoring
function........................................................................................................... 7-52
7.7.18 E-18 “Travel Left" and “Travel Right" cannot be displayed correctly in
the monitoring function ................................................................................... 7-53
7.7.19 E-19 The running speed could not be changed............................................... 7-54
7.7.20 The E-20 engine speed is not adjustable ........................................................ 7-55
7.7.21 Failure of E-21 Throttle Knob .......................................................................... 7-56
7.7.22 No oil level, speed, water temperature and other information on the E-22
display. ........................................................................................................... 7-57
7.8 Trouble diagnosis for hydraulic and mechanical systems (mode H) ............................. 7-58
7.8.1 H-1 The working device acts slowly, or the running and slewing
speed is low.................................................................................................... 7-58
7.8.2 H-2 The engine speed is obviously reduced or the engine stalls..................... 7-58
7.8.3 H-3 The working device, running or slewing gear could not work .................... 7-59
7.8.4 H-4 The hydraulic pump has abnormal noise .................................................. 7-59
7.8.5 H-5 The automatic idling could not work ......................................................... 7-60
7.8.6 H-6 The boom moves slowly........................................................................... 7-60
7.8.7 H-7 The grab arm moves slowly ..................................................................... 7-61
7.8.8 H-8 The bucket moves slowly ......................................................................... 7-62
7.8.9 H-9 Single cylinder of working device could not act ........................................ 7-62
7.8.10 H-10 The settling volume of working device cylinder is too big ....................... 7-63
7.8.11 H-11 The action of working device is lagged ................................................... 7-64
7.8.12 H-12 Other working devices move when single oil way is overflowing ............ 7-64
7.8.13 H-13 In slewing +travelling operation, the travelling speed is obviously
reduced .......................................................................................................... 7-66
7.8.14 H-14 The excavator deviates when running .................................................... 7-66
7.8.15 H-15 The excavator runs slowly ...................................................................... 7-67
7.8.16 H-16 It is not easy for the excavator to make a turn or the power is
insufficient ...................................................................................................... 7-69
7.8.17 H-17 The running speed could not be changed .............................................. 7-70
7.8.18 H-18 The excavator could not run (only on one side) ...................................... 7-70

7-2 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.8.19 H-19 The excavator could not slew ................................................................. 7-71

7.8.20 H-20 The slewing acceleration performance is poor, or the slewing
speed is low .................................................................................................... 7-72
7.8.21 H-21 The overrunning is too big when the slewing stops. ................................ 7-73
7.8.22 H-22 The impact is too big when the slewing stops ......................................... 7-74
7.8.23 H-23 The abnormal noise is too high when the slewing stops ......................... 7-74
7.8.24 H-24 The natural drifting of slewing is too large ............................................... 7-75

Maintenance Manual - 01 - 2021 7-3

Trouble Diagnosis SY135F Hydraulic Forestry Crane

Warning
Please read and fully understand the precautions in this Manual and described in the safety
nameplate on the machine. When operating or repairing the machine, please follow those
precautions strictly; otherwise, the wrong operation might lead to machine damages or personal
injuries.

7-4 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7. TROUBLE DIAGNOSIS
7.1 Precautions during Trouble Diagnosis
Park the machine on the level ground and confirm the functions of safety pins, cushion blocks
and parking brake.
When operating collaboratively, it is necessary to use uniform signals and keep any irrelevant
personnel away.
The hot water would be sprayed and cause scald if the radiator cover was removed when the
engine is still hot. Thus, it is necessary to start the overhaul after the engine cools down.
Please be extremely careful, and don’t touch any hot part, or hold any rotating part.
Be sure to remove the negative (-) terminal of storage battery when removing the electric wires.
It is necessary to release the internal pressure when removing the plug or cap of the
compartments containing oil pressure, water pressure or air pressure etc.; it is necessary to
connect properly when installing the measuring equipment.
The trouble diagnosis is performed for the purpose of determining the primary cause of the trouble,
repairing rapidly and preventing the recurrence.
It is necessary to learn about the structure and function when performing trouble diagnosis.
However, it would be a shortcut if learning about the possible causes for the trouble preliminarily
from the operating personnel for effective trouble diagnosis.
1. Do not rush to disassemble the parts when performing trouble diagnosis. If the part was
disassembled, the consequent might be:
 The disassembled part is irrelevant to the trouble, or unnecessary part is disassembled.
 The trouble cause could not be found.
The trouble causes could not be found. This would waste labor, part, oil or grease, and meanwhile
make the user or operating personnel lose confidence to the product.
Therefore, it is necessary to inspect first when performing trouble diagnosis, and carry out
according to the specified procedures.
2. Questions for the user or operating personnel:
1) Were there any problems that had not been reported?
2) Was there any abnormal phenomenon on the machine before the trouble occurs?
3) Did the trouble occur suddenly or was there any problem on the machine before?
4) Under what conditions the trouble occurred?
5) Was any repair carried out before the occurrence of trouble? When was the repair carried
out?
6) Did the same trouble occur before?
3. Inspect other inspection items.
1) Inspect engine oil level.
2) Inspect whether the oil leaks from the pipeline or hydraulic equipment.

Maintenance Manual - 01 - 2021 7-5

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

3) Inspect the stroke of control lever.

4) Inspect the stroke of control valve core.
5) Other daily maintenance items may be inspected from the appearance so that it is only
allowed to inspect the items deemed necessary.
4. Confirm the trouble
 Confirm the trouble by yourself, and judge whether it is a real trouble or a problem on use
or operation.
★ Do not perform any inspection or measurement which makes the problem worse when
operating the machine or the trouble phenomenon re-occurs.
5. Trouble Diagnosis
 According to the inspection and test results of 2-4 items, the scope of fault causes is
reduced, and then the fault location is determined according to the fault diagnosis flow chart.
★ Basic procedures for trouble diagnosis are as follows
1) Start from the simple items
2) Start from the places with high potential
3) Inspect other relevant contents.
6. Method for solving the primary trouble causes.
 If the root cause has not been removed, the same trouble still will happen again even though
the trouble was solved.
Therefore, it is necessary to ascertain the trouble causes and solve the root cause of troubles.

7-6 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.2 Work Procedure for Trouble Diagnosis

Office Working place

Step 1

Inspection and Determination of Symptom

1) When receiving the request for
maintenance/repair from customer, please firstly
make sure the following matters:
 Name of Customer
 Model No. and Serial No. of
Machine
 Details of construction site, and etc.

2) Master the details of problem through inquiry

Step 8

 Trouble conditions Carry out repair on site Faults

 Work situation when trouble occurs

 Work environment
 Maintenance/repair history and etc.

Step 2
Determine the possible position where the cause of trouble
is located

1) Refer to the contents about trouble

diagnosis in Service Manual, so as to
identify the possible position where the Step 7
cause of trouble is located.
 Determine the position of trouble (carry out
trouble diagnosis)
 Decide the repair program
Step 8
1) Before carrying out the trouble diagnosis,
Carry out repair in workshop
please determine the simple trouble position
and repair.
 Inspection items before start
 Other inspection items
Mechanical
Manual 2) Select the trouble diagnosis process on the basis of symptoms of
this machine by reference to contents about trouble diagnosis in
Service Manual, and then carry out inspection and repair.

Service Manual

Step 3
Step 6
Prepare the trouble diagnosis tool
Reproduction of trouble

1) Refer to the table of trouble diagnosis

tools in Service Manual and prepare the  Start and operate this machine, confirm the symptom of this
necessary tools. machine and judge whether there is a trouble.
 T-shaped Joint
 Hydraulic instrument and etc.
2) Refer to the catalogue of parts and
prepare the necessary replacement parts.
Step 5

Step 4 Inquire the operation personnel about detailed trouble situation

 Was there any abnormal phenomenon

Go to the site
before occurrence of trouble?
 Did the trouble occur suddenly?
 Was any repair carried out when the trouble
occurred?

Maintenance Manual - 01 - 2021 7-7

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.3 Precautions for Maintenance

In order to ensure the normal operation of the machine in a long period of time and prevent the
occurrence of faults or accidents in advance, it is necessary to operate correctly and carry out
necessary maintenance, inspection, fault diagnosis and repair. This chapter elaborates the
mechanical and electrical maintenance procedure in detail to master the correct maintenance
methods and improve the maintenance quality. For this reason, this chapter records the "Operation
of Electrical Equipment" and "Operation of Hydraulic Equipment" (some oil, hydraulic oil), etc.
1. Handling of Harness and Connector
A harness is composed of the wires connected
from a component to another component, the
connector used to connect two wires or
disconnect a wire from another wire, and the
shield or pipe used to protect wires.
As compared with other electrical components
which are installed in box, the harness may be
directly affected by rain, water, heat or vibration.
In addition, during inspection and repair, they
may often be dismantled and installed again. As
a result, they may get deformed or damaged.
Therefore, When handling any harness, please Figure 7-1
be extremely careful.
2. Main Troubles Occurring in Harness The connection is incorrect

1) Poor contact of connector (poor contact

between convex and concave connectors)
If the convex connector is not correctly inserted
into concave connector, or the connector is
deformed and the position is not aligned
correctly, or the contact surface is corroded and
oxidized, then the trouble of poor contact may
occur. Figure 7-2

2) The pin of male/female connector for Edge portion

crimping or soldering failure is in contact

with the crimped terminal or welding part.
However, if the wire bears too much force, the
coating at the joint will peel off and lead to an
incorrect connection or fracture.

Figure 7-3

7-8 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Trouble Diagnosis

3) Disconnection of Wire
If you pull out a connector by holding the wire,
or use a crane to lift up a component to which
the connector is connected, or use a heavy
article to knock the wire, then the edge of
connector may get separated, or the welded
portion and wire may get damaged.

Figure 7-4
4) The high-pressure water enters into
connector
The connector is design as waterproof type
(waterproof structure). However, if the high-
pressure water is directly sprayed onto
connector, the water may enter into the
connector, depending on direction of water
nozzle. Therefore, please be careful not to let
any water splash onto connector. The connector
is designed as waterproof. If water really enters
into connector, it will be very difficult to drain it. Figure 7-5
If water enters into connector and thus the short
circuit between pins is caused, please
immediately dry up the connector or take other
appropriate measures before energizing it.
5) Oil or oil sludge sticking to connector
If any connector is stained with oil or lubricating
grease and a layer of oil film is formed on the
mating face between male and female pins, then
the current will not pass, and thus contact
trouble will occur. If any connector is stained
with oil or lubricating grease, please wipe it
away with dry cloth or blow it away with
compressed air. The compressed air shall be
ejected by contact restorer.
Figure 7-6
★ When wiping the mating face of connector,
be careful not to use too large force or get the
pin deformed.
★ If there is oil or water in compressed air,
then the contact may become more dirty.
Therefore, before using the compressed air to
carrying out cleaning operation, please

Maintenance Manual - 01 - 2021 7-9

Trouble Diagnosis SY135F Hydraulic Forestry Crane

thoroughly eliminate the oil and water in

compressed air.
3. Dismantle, install and blow dry the
connector and harness
Press gently when
1) Disconnect the connector dismantling

a During the disconnection, please hold the Locking reed

connector.
When disconnecting a connector, please hold it.
As for any connector which is fixed by screw,
please fully loosen the screw, and then hold the
convex and concave connectors with two hands
and disconnect them. As for any connector
equipped with locking reed, please press down Figure 7-7
the reed with thumb, and then pull out the Both are stop blocks
connector.
★ Don’t pull the connector with one hand.
b When dismantling a connector from a clip
 Both the connector and clip are equipped
with stop block, and when the connector is
installed, they are engaged with each other.
 When dismantling a connector from a clip,
please pull out the connector in the Figure 7-8
direction parallel to the clip, so as to remove
the stop block.
★ If a connector is twisted upwards and
downwards or leftwards and rightwards, the
casing may get damaged.

Figure 7-9

7-10 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Trouble Diagnosis

2) Connection of Connector
a Visually inspect the connector
Inspect that the pins (mating face) are not
The connector is in place after
stained by oil or water. chatter is heard

Inspect that the pins of connector shall be free

from deformation, contact trouble, rust or
damage.
Inspect that the outside of connector shall be
free from damage or crack.
★ If there is oil, water or oil sludge on
connector, please wipe it away with a piece of
dry cloth. If water enters into connector, please
use a drier to heat up the inside of wire, but Figure 7-10
please be careful not to get it overheated;
otherwise short circuit may be caused.
★ If the connector is damaged or cracked,
please replace it.
b Fixing of connector
Correctly align the connector and then firmly
insert it. As for the connector equipped with
locking reed, please push in the connector, until
the reed make the sound click.
c Correct the situation that the protective Figure 7-11
cover bulges and the harness is not aligned.
As for the connector equipped with protective
cover, correct the bulging of protective cover. If
the harness is not aligned, or the thimble is
displaced, please adjust it to the correct
position.
★ If the connector can’t be corrected easily,
then dismantle clamp, and adjust position.
 If the connector clamp has been
dismantled, be sure to restore it to its
Figure 7-12
original position. Please also inspect
whether the clamp is loosened.

Maintenance Manual - 01 - 2021 7-11

Trouble Diagnosis SY135F Hydraulic Forestry Crane

3) Connection of DT Connector
Since the DT8-pin and 12-pin large-power wire
connector has two buttons, please push them in
until the chatter is heard for twice.
 Convex connector: 1
 Concave connector: 2
 Normal locking state (horizontal): a, b,
d
 Incomplete locking state (diagonal): c
Figure 7-13
4) Blowing and drying the wire harness
If there is any oil or stain on harness, please use
a piece of dry cloth to wipe it away. Don’t use
water or steam to clean it up. If it is necessary to
clean up the connector in water, please don’t
apply the high-pressure water or steam directly
onto harness. If the water is directly applied on
connector, please comply with the following
provisions.
a Disconnect the connector and use a piece Figure 7-14
of dry cloth to wipe away the water.
★ The oil contained in air may lead to trouble
of contact. Therefore, before using the
compressed air, please clear away all oil and
water in compressed air.
b Use a drier to blow dry the inside of
connector.
If water enters the connector, please use a drier
to blow dry the connector.
★ The hot air from drier may be used, but the Figure 7-15
duration of use must be regulated, so as to
prevent the connector or relevant parts from
getting overheated; otherwise the connector
may get deformed or damaged.
c Carry out the conductivity test for
connector.
After blowing dry the connector, keep the T-shaped
Joint
harness in disconnected state, and carry out the
conductivity test to inspect whether there is any
short circuit caused by water between pins.
★ After drying up the connector, use the

7-12 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Trouble Diagnosis

contact restorer to blow it dry and re-assemble Figure 7-16

it.
4. Handling of Controller
1) The controller contains a micro-computer
and electronic control circuit. They controls
all electronic circuits on this machine.
Therefore, when handling this controller,
please be extremely careful.
2) Don’t place any article on controller.
3) Use a band or polythene bag to cover the
control connector. Please don’t touch any
contact of connector with hand.
4) In rainy days, don’t place a controller in a
position exposed to rain water. Figure 7-17
5) Even for short time, don’t place a controller
on any place where there is oil, water, soil
or heat. (Please place it on an appropriate
dry bench)
6) Precautions for arc welding:
for arc welding on the body, disconnect all
harness connectors connected to the controller.
Install an arc welding for grounding next to the
solder joint.

Figure 7-18
5. Matters to be Remembered During
Diagnosis of Trouble in Electric Circuit
1) Turn off the power supply before
disconnecting or connecting the connector.
2) Inspect whether all the relevant connectors
have been inserted properly before
performing trouble diagnosis.
★ Disconnect and connect the relevant
connectors by several times for inspection.
3) Connect all the disconnected connectors
before proceeding to the operations in the Figure 7-19
next step.
★ It would produce unnecessary abnormal
display if turning on the power supply without
disconnecting the connector.

Maintenance Manual - 01 - 2021 7-13

Trouble Diagnosis SY135F Hydraulic Forestry Crane

4) It is necessary to move the relevant wires

and connectors by several times and
inspect whether the readings of the
instrument change when performing trouble
diagnosis for the electrical circuit (measure
voltage, resistance, connectivity or current).
★ If there is any change, there may be a
contact fault in the circuit. Precautions when
handling hydraulic components
The most common trouble cause is the greasy
filth (foreign matter) in the hydraulic oil way as
the pressure and the accuracy of hydraulic part
increase. When filling in hydraulic oil, or
disassembling or assembling the hydraulic
parts, be particularly careful.
1. Pay attention to the operating environment
Avoid filling hydraulic oil, replace the filter or
repair the machine in the rain or wind or in the
environment with heavy dust.
2. On-site disassembling and maintenance
work
The dust might enter the parts if the hydraulic
parts are disassembled and maintain on site. It
would be very difficult to inspect the
performance after repair. Thus, it would be the
best to replace with assembly unit. The
hydraulic parts shall be disassembled and
maintained in the particularly prepared dust-
proof workshop, and the performance shall be Figure 7-20
inspected with dedicated test equipment.
3. During refilling operation, don’t let any oil
sludge, dirt or dust
When refilling in hydraulic oil, be careful to
prevent any greasy filthy or dust entering. Be
sure to keep the engine oil filter core and the
surrounding area clean, and it is necessary to
use clean pump and oil storage container. The
greasy filthy accumulated in the storage process
may be filtered out if the oil cleaning equipment
is used, which is a more effective method.
4. Replace the hydraulic oil at high
temperature Figure 7-21
It flows easily when hydraulic oil or other oil
7-14 Maintenance Manual - 01 - 2021
SY135F Hydraulic Forestry Crane Trouble Diagnosis

temperature is high. Besides, it would be easier

for the sediments to be discharged along with
the oil from the oil way. Therefore, it would be
the best to replace the oil when it is still warm.
When replacing the oil, try to drain the used
hydraulic oil thoroughly (drain oil from hydraulic
oil tank; drain oil from drain plug in the filter and
oil way). If there is any used oil, the impurities
and sediments would mix with the new oil, and
shorten the service life of hydraulic oil.
5. Flushing operation
After disassembling and assembling the
equipment or replacing the oil, it is necessary to
Flushing oil
remove the impurities, sediments and the used
oil in the hydraulic oil way with flushing oil.
Usually it is necessary to flush twice: flush
mainly with flushing oil, and use specified
hydraulic oil for auxiliary flushing.

Figure 7-22
6. Cleaning operation
After any hydraulic component (pump, control
valve and etc.) is repaired or When this machine
is running, please clean up the oil, so as to clear
away the deposits or impurities in hydraulic oil
way. The oil cleaning equipment is used to clear
away the fine (about 3μ) particles, so as to
ensure that the filter in hydraulic component
can’t be dismantled. Therefore, it is a very
effective equipment.

Figure 7-23

Maintenance Manual - 01 - 2021 7-15

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.4 Inspection before Trouble Diagnosis

Items Criteria Measures
1. Confirm the level and variety of fuel oil
— Oiling
Lubricating Oil, Coolant

2. Inspect whether there are foreign matters in the

— Clean and drain
fuel oil
— Oiling
3. Inspect the hydraulic oil level
— Clean and drain
4. Inspect the filter screen of hydraulic oil
— Oiling
5. Inspect the oil level of slewing mechanism
— Oiling
6. Inspect the engine oil level (oil level of oil pan)
— Fill in water
7. Inspect the coolant level
— Sweep or replace
8. Inspect the blocking situation of dust indicator
— Replacement
9. Inspect the hydraulic oil filter core
— Oiling
10. Inspect the level of transmission oil
1. Inspect whether the terminals and wires of storage
battery are loose or corroded
equipment

— Tighten or replace
Electrical

2. Inspect whether the terminals and wires of

— Tighten or replace
alternator are loose or corroded
— Tighten or replace
3. Inspect whether the terminals and wires starting
motor are loose or corroded
mechanica
Hydraulic-

—
l device

1. Inspect the abnormal noise and odor Repair

2. Inspect oil leakage — Repair
3. Bleed off the air — Bleed off the air

1. Inspect the storage battery voltage (engine

extinction)
2. Inspect the level of battery electrolyte 24~27V
Electrics and electrical

Replacement
3. Inspect whether the electric wires are discolored, —
Add or replace
scorched or peeled off —
Replacement
equipment

4. Inspect whether the wire clips drop or whether the —

Repair
electric wires are suspended —
Remove the connector
5. Inspect whether the electric wires get wet (inspect —
and dry it
carefully the connectors or terminals) After operating for
Replacement
6. Inspect whether the fuses are blown or rusted several minutes: 28 ±
Replacement
7. Inspect the alternator voltage (the engine is 0.5V
Replacement
running at semi-throttle opening) —
8. Inspect the noise when the battery relay works (the
switch is turned ON/OFF)

7.5 Category and steps of trouble diagnosis

Category of trouble diagnosis
Mode Contents
When the service code (electrical system) and trouble code (mechanical system) are
Code display
displayed, please carry out trouble diagnosis.
Fault category (E and P) Trouble Diagnosis for Electrical System
Category-H troubles Trouble Diagnosis for Hydraulic and Mechanical Systems

Steps for trouble diagnosis

If some phenomena which look like trouble occur to this machine, please determine the relevant
trouble diagnosis code and explain the diagnosis.
You may use the following six basic steps to diagnose and analyze the trouble, so as to identify
the cause of trouble and formulate the corresponding handling method:
1. Please carefully refer to the relevant technical manual, and understand the relevant systems
and their operating principles as well as the structure, function and technical specification of
7-16 Maintenance Manual - 01 - 2021
 SY135F Hydraulic Forestry Crane Trouble Diagnosis

every component thereof.

2. Inquire the driver
Before the inspection, the relevant personnel (i.e. the driver) should be informed of all fault
scenarios.
a) Current use condition of this machine: Does this machine operate correctly?
b) Time when the trouble was found: Which operation was this machine carrying out at that time?
c) Development of trouble: Is the trouble becoming more and more serious or does it occur
suddenly for the first time?
d) What other faults did the machine have before
For example: which components have been repaired or replaced?
e) Has any handling been carried out after this trouble occurred?
f) Is the trouble reproducible? Is there any law?
3. Inspection before trouble diagnosis
Before carrying out trouble diagnosis, please inspect the records about operation and maintenance
in driver manual, inquire about whether the relevant personnel have ever carried out operation or
maintenance in violation of rules, and inspect whether there is any wrong operation or maintenance.
Inspect whether any part of mechanical equipment is abnormal; such as leakage or lack of oil or
water, loosening of pipeline, or abnormal cracking.
In addition, inspect the electrical system; for example, whether the battery voltage is normal,
whether the connector of power line falls off or is burnt out, and whether the fuse has blown. When
inspect whether the fuse has blown, please use the multimeter.
4. Operate this machine (trial operation)
If you confirm that the above-mentioned parts are not abnormal, please inspect the equipment in
accordance with the normal operation method, so as to identify the cause of trouble. If the trouble
can’t be confirmed, please stop the engine, and obtain the further information about trouble from
driver.
5. Carry out the trouble diagnosis
Please carry out detailed analysis and confirmation on the basis of the phenomena of mechanical
equipment and the information displayed.
Note:
 When the engine is running, be sure not to disconnect the harness or hydraulic pipeline,
otherwise the high-pressure and high-temperature oil water may splash and cause personal
injury. Before disconnecting the harness or hydraulic pipeline, please stop the engine.
 The trouble code displayed does not necessarily indicate the trouble of this machine, because
the temporary electrical troubles are also stored in controller, such as the trouble that the
voltage output of battery is too low or the circuit of any switch or sensor is broken. Therefore,
please carry out testing repeatedly, so as to clear the trouble codes accumulated in memory
of controller and confirm whether there is any trouble code displayed after the testing is carried

Maintenance Manual - 01 - 2021 7-17

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

out repeatedly. This means that the trouble is reproducible.

6. Identify the possible causes
Before making the conclusion, inspect the most possible causes again, and make efforts to
determine the true cause of trouble. On the basis of your conclusion, formulate the appropriate
repair program.

7.6 Adjustment Service

7.6.1 ADJUSTMENT SERVICE (SY135F)
Model Serial number Indication of hour meter
□ SY135F

Name of user Completed by: Inspected by:

//

Technical Specification
Working device Accessories Width of crawler plate
Boom □ Standard □ ( ) □ 960mm
□ Bucket
Arm □ Standard □ ( ) □ 800mm
□()
Bucket □ Standard □ ( ) □()

Inspection on level of oil and cooling water

□ When radiator water is needed
□ Oil □ Oil in damper tank □ Oil in final rotation tank
□ Hydraulic oil □ Oil in mechanical tank □ ( )

7-18 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Trouble Diagnosis

Maximum range of engine Maximum range of fuel

Ambient temperature
cooling water temperature level
℃
Altitude

Opinions of operation personnel

Result of visual inspection

Record of trouble code

Electrical system Mechanical system
frequency
Content:
The engine cooling water is too hot
Content: The engine oil pressure is abnormally low
The engine oil level is abnormally low
Content: The hydraulic oil is over-heated
The water level in radiator is abnormally low
Content: The air filter is plugged
The charging voltage is abnormally low
The automatic lubricating system is abnormal
Content:

Maintenance Manual - 01 - 2021 7-19

 Hydraulic system
Engine speed
Engine (SY115/135/155C9I3K)

7-20
Lower
Engine oil
Engine speed exhaust
pressure
pressure
Trouble Diagnosis

Engine oil pressure

Part name Quantity

Ethylene hose (4m)
Ethylene hose (4m)
Suction cup
Connector or joint
Oil filler
Measuring ruler ① Pressure of front pump
(600 K) ③ Pressure of pilot pump

Maintenance Manual - 01 - 2021

② Pressure of rear pump (60 K)
(600 K)

Lower
exhaust hose Connector or
joint

Nozzle

Figure 7-25 Figure 7-24

SY135F Hydraulic Forestry Crane
 SY135F Hydraulic Forestry Crane Trouble Diagnosis

Model Serial number Indication of hour meter Name of user Completed by: Inspected by:

1. Engine (SY115/125/135/155C9I3K/SY155C9I3KH)
Setting conditions Standard value
Measurement
No. Fuel control Work Automatic Operation of working Unit Trouble Measured value Judgment
item New machine
knob Mode deceleration device judgment
1 Engine speed rpm 2,080-2,220 Good/bad
Travelling control rod (this
Full speed Engine oil
2 machine is not travelling) MPa {kgf/cm2} 0.39-0.64 {4.0-6.5} 0.25 {2.6} Good/bad
pressure
3 Engine speed rpm 980-1,080 Good/bad
OFF All control rods are at
Low speed S Engine oil Minimum: 0.15{Minimum:
4 middle position MPa {kgf/cm2} 0.09 {0.9} Good/bad
pressure 1.5}
Grab arm (unloading)
5 Engine speed rpm 1,800-2,000 Good/bad
Full speed overflow
7 ON Engine speed Engine speed rpm 1,300-1,500 Good/bad

2. Speed of operating device (SY115/125/135/155C9I3K/SY155C9I3KH)

Measurement condition: temperature of hydraulic oil temperature (45-55 ℃)
Setting conditions Standard value

SY115/125/135/155C Measured
No. Fuel control Measurement item Unit Judgment
Work Mode Working device state value
knob
9I3K new model

1 Unloaded, fully extended Boom up 3.0-3.8 Good/bad

2 The boom is maintained Grab arm unloading 2.6-3.2
3 horizontal Grab arm excavation 3.2-4.0 Good/bad
The boom and grab arm are
6 Bucket excavation 2.4-3.4
maintained horizontal

11st gear H Front Seconds Good/bad

7 Full extending Rotation (5 turns) 21.5-27.5
Rear Good/bad
Front Good/bad
Lo 17.5-22.5
Moving forwards and Drive for 20 Rear Good/bad
8
backwards m Front Good/bad
Hi 11.5-15.5
Rear Good/bad

Maintenance Manual - 01 - 2021 7-21

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

3. Hydraulic drift of operating device (SY115/1125/35/155C9I3K/SY155C9I3KH)

Measurement condition: temperature of hydraulic oil temperature (45-55 ℃)
Setting conditions Standard value
SY115/135/155C9I3K
No. Measurement item Unit Measured value Judgment
Fuel control knob Work Mode Working device state New machine
Trouble judgment
model
The boom and grab
arm are maintained Hydraulic drifting of
1 The engine is turned off horizontal, and the bucket tooth tip (15 mm 600 Maximum 900 Good/bad
bucket is carrying out minutes)
excavation

4. Inspection of hydraulic oil circuit (SY115/125/135/155C9I3K/SY155C9I3KH) ① ② ③

Set conditions 600kgf/cm2 600kgf/cm2 60kgf/cm2

Parts to be inspected Fuel control Work Automatic Remarks
Operation of working device Main pump F Main pump R Pilot pump
knob Mode deceleration
Pilot pump overflow
Pressure of oil circuit 3.9-4.1 MPa
valve
Main overflow valve Grab arm unloading overflow
(When increasing the 34.5 MPa
power)
Middle
LS valve
LS (differential No load travel, engine at Right
pressure valve) high idle, control lever at
Full speed S OFF half stroke Left

Right overflow
Slewing safety valve Slewing locking switch ON 26.5MPa {270kgf/cm2}
Left overflow
Forward right

Main relief valve, travel Backward right

Track shoe loading 34.3MPa {350kgf/cm2}
safety valve Forward left
Backward left

7-22 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.6.2 TROUBLE - IDENTITY THE SYMPTOMS AND TROUBLE DIAGNOSIS CODE

Trouble Diagnosis
Trouble - Identify the Category of
No. Category of
symptoms Code display electrical (Engine)
hydraulic trouble
trouble
Troubles relating to engine
The engine doesn't start
easily. (it often takes
4 S-1
some time to start the
engine)
The engine could not be
5 E-1 S-2
started
The color of exhaust gas
6 is black (The combustion S-3
is incomplete)
The acceleration
7 performance of engine is S-4
poor
The engine speed is
8 E-2 S-5
irregular (fluctuated)
The output power of
9 engine is insufficient or H-2 S-6
the engine is powerless
The automatic idling does
10 E-4 H-5
not work
The consumption of
11 engine oil is too high, or S-7
blue smoke is emitted
The engine oil is
12 S-8
contaminated too early
The fuel consumption is
13 S-9
too high
There is engine oil in
14 S-10
engine coolant
The amount of engine oil
15 increases (water or fuel S-11
enter the engine oil)
16 There is abnormal noise S-12
17 There is violent vibration S-13
Troubles relating to working device, slewing and travelling
The power supply for
18 complete machine could E-3
not be switched off
The hydraulic pump has
19 H-4
abnormal noise
The working device,
20 running or slewing gear H-3
could not work
The working device acts
21 slowly, or the running and H-1 S-6
slewing speed is low
22 In slewing +travelling H-13

Maintenance Manual - 01 - 2021 7-23

Trouble Diagnosis SY135F Hydraulic Forestry Crane

operation, the travelling

speed is obviously
reduced
Troubles relating to working device
23 All devices could not work E-6
Single cylinder of working
24 H-9
device could not act
The settling volume of
25 working device cylinder is H-10
too big
The action of working
26 H-11
device is lagged
Other working devices
27 move when single oil way H-12
is overflowing
Troubles relating to travelling
The travelling is slow and
28 E-8 H-15
powerless
The dual running speed
29 E-13
function does not work
The machine deviates
30 H-14
when running
It is not easy for the
31 machine to make a turn or H-16
the power is insufficient
The running speed could
32 H-17
not be changed
The machine could not
33 H-18
run (only on one side)
Troubles relating to slewing
The machine could not
34 H-19
slew
The slewing acceleration
35 performance is poor, or H-20
the slewing speed is low
The overrunning is too big
36 H-21
when the slewing stops.
The impact is too big
37 H-22
when the slewing stops
The abnormal noise is too
38 high when the slewing H-23
stops
The natural drifting of
39 H-24
slewing is too large
Troubles relating to display screen
The display on upper
40 portion of monitor panel is E-9
omitted
The display content of the
41 monitor panel is E-10
independent of the model
42 The engine coolant E-11

7-24 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

thermometer does not

display correctly
The fuel gauge is
43 E-12
inaccurate
No response when
operating the button
44 E-13
switch on the display
screen
Inaccurate display of
45 operating device pressure E-21
state
The slewing operation
can’t be correctly
46 E-22
displayed in monitoring
function
Inaccurate display of
47 E-23
left/right travel pressure
Others
The preheating function
48 E-5
does not work
49 The wiper does not work E-14

7.6.3 POSITION DIAGRAM OF CONNECTORS AND WIRING DIAGRAM OF

SYSTEM
Number of Number of
Model Name of device
Connector Pins
T-101 Terminal 1 Positive pole of battery relay coil
T-102 Terminal 1 Negative coil of battery relay coil
T-103 Terminal 1 Main contact of battery relay (output)
T-104 Terminal 1 Main contact of battery relay (input)
T-401 Terminal 1 Groundearth
T-402 Terminal 1 Groundearth
T-108 Terminal 1 Output of preheating fuse
T-109 Terminal 1 Input of preheating fuse
CN-217F AMP 282080-1 2 Washer motor
CN-113F Plug-in elements 174 352-2 2 Rear pump proportional electromagnetic valve
Front pump proportional electromagnetic
CN-114F Plug-in elements 174 352-2 2
valve
CN-116M Plug-in elements 12078090 2 Rear main pressure sensor
CN-115M Plug-in elements 12078091 2 Front main pressure sensor
CN-474F Yazaki 7223-1824-40 2 Electronic fuel pump
CN-113M AMP 282080-1 2 Hydraulic oil temperature sensor
CN-458F Sumitomo 6188-0494 20 Plug-in part of engine
CN-458F Sumitomo 6195-0149 12 Plug-in part of engine
CN-460F Sumitomo 6195-0021 6 Plug-in part of engine
CN-460F Sumitomo 6195-0051 8 Plug-in part of engine
CN-464M Yazaki 7222-4210-40 1 Plug-in part of engine

Maintenance Manual - 01 - 2021 7-25

Trouble Diagnosis SY135F Hydraulic Forestry Crane

Number of Number of
Model Name of device
Connector Pins
T-442 Terminal 1 Terminal S of start motor
CN-438M 1300-4393 1 Compressor clutch
CN-438M 7323-1424-30 2 Terminal L/R of generator
T-412 Terminal 1 Alternator
CN-126F Plug-in elements 12078090 3 Large boom lowering pressure sensor
CN-125F Plug-in elements 12078091 3 Large boom lowering pressure sensor
CN-124F Plug-in elements 12078092 3 Bucket unloading pressure sensor
CN-127F Plug-in elements 12078093 3 Bucket unloading pressure sensor
CN-120F Plug-in elements 12078094 3 Right travelling pressure sensor
CN-121F Plug-in elements 12078095 3 Left travelling pressure sensor
CN-128F Plug-in elements 12078096 3 Grab arm excavation pressure sensor
CN-122F Plug-in elements 12078097 3 Grab arm unloading pressure sensor
CN-123F Plug-in elements 12078098 3 Slewing pressure sensor
Sumitomo Motor 6189-
CN-471F 2 Intake temperature sensor
0890
CN-105M DT04-2P 2 Air filter restriction
CN-136F Plug-in elements 174 352-2 2 Leading electromagnetic valve
CN-135F Plug-in elements 174 352-2 2 Proportional valve for linear travel
CN-133F Plug-in elements 174 352-2 2 Standby proportional valve
CN-132F Plug-in elements 174 352-2 2 Slewing unlocking proportional valve
Secondary turbocharging electromagnetic
CN-131F Plug-in elements 174 352-2 2
valve
CN-130F Plug-in elements 174 352-2 2 High/low speed electromagnetic valve
Power supply of electrical socket of inspection
T-203 Terminal 1
light
Earthling wire of electrical socket of inspection
T-204 Terminal 1
light
Plug-in elements X01FGY-
CN-101F 1 Fuel tank oil level
M/C
CN-102F 282080-1 2 Rotary desk lamp
F-104 Plug-in elements 735075 1 Horn
CN-102M 282104-1 2 Boom working light
CN-102F 282104-1 2 Boom working light
CN-104F 282104-1 2 Boom working light
CN-450F AMP 1473244-1 81 ECU
CN-451F AMP 1473252-1 40 ECU
CN-504M NMWP32M 32 Middle plug-in part
CN-505F NMWP32F 32 Middle plug-in part
CN-501M DTP06-4S 4 Middle plug-in part
CN-504F NMWP32F 32 Middle plug-in part
CN-505M NMWP32M 32 Middle plug-in part

7-26 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Trouble Diagnosis

Number of Number of
Model Name of device
Connector Pins
CN-501F DTP04-4P 4 Middle plug-in part
T-202 Terminal 1 Groundearth
T-203 Terminal 1 Groundearth
T-131 7323-3010 1 Preheating relay input
T-132 7323-3011 1 Preheating relay output
T-133 7323-2228 2 Preheating relay coil
KD YAZAKI 7323-2857-30 4 Fuel pump relay
KC Sumitomo 6098-1493 4 Start cutoff relay
KB Sumitomo 6098-1493 4 Start cutoff relay
CN-007F 6950-0111 250 4 Main relay of blower
CN-006F AMP 172134-1 250 4 Compressor clutch relay
CN-449F Yazaki 7123-1424-40 2 Start relay coil
CN-448F Yazaki 7123-4220-30 2 Atmospheric pressure sensor
CN-469F Ample 174357 2 Atmospheric pressure sensor
CN-601M AMP776164-1 35 Controller J1
CN-602M AMP776164-5 35 Controller J2
CN-005F Yazaki 7283-1180 0900 18 A/C unit
CN-003F Sumitomo 6098-0514 187 4PF 4 Blower
T-803 Terminal 1 Emergency stop switch output
T-804 Terminal 1 Emergency stop switch output
CN-205F AMP: 282104-1 2 Leading switch
CN-003F DJ7072-3-21 8 Radio
CN-008F Sumitomo 189-0094 090 2 High/low pressure switch
CN-203M DT06-12S 12 Middle plug-in part
T-201 Terminal 1 Groundearth
CN-201F AMP: 282080-1 2 Horn button
CN-202M DT04-12P 12 Middle plug-in part
CN-210M DT06-6S 6 Middle plug-in part
CN-603M DT06-12S 12 Middle plug-in part
CN-211M DT06-8S 8 Middle plug-in part
CN-004F DT06-8S 8 Middle plug-in part
CN-131F DT06-12S 12 Middle plug-in part
CN-508F DT06-12P 12 Middle plug-in part
CN-507F Hella: H8JA713631 8 Dome light switch
CN-506F Hella: H8JA713632 8 Washer Switch
CN-505F Hella: H8JA713633 8 Working light switch
CN-503F Hella: H8JA713634 8 Working light switch
CN-509M Yazaki 7123-7464-30 6 Key switch
CN-501M AMP: 282105-1 3 Control knob switch

Maintenance Manual - 01 - 2021 7-27

Trouble Diagnosis SY135F Hydraulic Forestry Crane

7-28 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.6.4 POSITION DIAGRAM OF CONNECTOR

Figure 7-26

Maintenance Manual - 01 - 2021 7-29

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.6.5 CIRCUIT DIAGRAM OF ELECTRIC SYSTEM COMPONENTS (CAB CIRCUIT)

Resistance: 120 Ω

Display
screen
Throttle
knob

Dome light
switch

Working light
switch Starting
switch

Washer Switch

Windscreen wiper
switch

Battery relay
Body
bonding

Figure 7-27

7-30 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

★ This circuit has been edited by extracting the wiper, switch control system from the general
circuit diagram.
Horn relay Headlamp relay Dome light relay

Horn switch

Overhaul light

windscreen
wiper

Washer motor

Right dome
lamp

Left dome
lamp

Horn

Slewing
platform
working light

Boom working
light

To radio panel Right stereo on

External air
radio
sensor
Left stereo on
radio

Light in cab

To air conditioning panel

Compressor clutch

Figure 7-28

Maintenance Manual - 01 - 2021 7-31

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.6.6 CIRCUIT DIAGRAM OF ELECTRICAL CONTROL SYSTEM (ENGINE

CIRCUIT)
★ This circuit has been edited by extracting the engine preheating, starting and speed regulating
circuit system from the general circuit diagram.
Body grounding

Heating indicator
light

Preheating
controller
Voltage of fuel control knob

Leading switch

Low
Battery relay temperature
Pilot valve relay
switch Starter relay

7-32 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Trouble Diagnosis

Preheating relay

Stop relay

Preheating fuse

Preheater

Parking
motor

Safety relay

Alternator

Body grounding

Start motor

Body grounding

Charging indicator light

Leading
electromagnetic valve

Throttle motor

Maintenance Manual - 01 - 2021 7-33

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.6.7 CIRCUIT DIAGRAM OF ELECTRICAL CONTROL SYSTEM (CIRCUIT OF

SENSOR AND SOLENOID VALVE)
This circuit has been edited by extracting the pressure collection and solenoid valve control system
from the general circuit diagram.

Fuel oil level sensor

Engine speed sensor

Coolant temperature sensor

Pressure switch of operating

device

Engine oil pressure switch

Pressure switch for left

travel

Pressure switch for right

travel

Back slewing pressure

switch

Proportional solenoid
valve for pump

Solenoid valve for

linear travel

High/low traveling
speed solenoid valve

Secondary pressure
rise electromagnetic
valve

Figure 7-31

7-34 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.6.8 SWP CONNECTOR

Convex (electrical plug) Concave (electrical socket)

7123-7414-40 (1 pin)

7123-1424-40 (2 pins)

7123-7464-40 (6 pins)

7123-7484-40 (8 pins)

7123-7564-40 (16 pins)

Maintenance Manual - 01 - 2021 7-35

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.6.9 A/AMP CONNECTOR

Convex (electrical plug) Concave (electrical socket)

Part no.: 282104-1 Part No. : 282080-1 (2 pins)

282087-1 (3 pins)

174352-2 (2 pins)

AMP776164 (35 pins)

7-36 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.6.10 DT CONNECTOR
Housing (electrical plug) Housing (electrical socket)

DT04-3P (The number of pins is 3)

DT04-6P (6 pins)

DT04-8P (8 pins)

DT04-12P (12 pins)

Maintenance Manual - 01 - 2021 7-37

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.7 Trouble diagnosis for electrical system (category-E trouble)

7.7.1 INFORMATION IN TABLE OF TROUBLE DIAGNOSIS
Trouble information Troubles occurring in this machine
Relevant information Information about trouble detected or trouble diagnosis

Standard value in normal state and reference value for

Causes
Estimated causes and standard value

trouble diagnosis
1 (Contents of record)
 Standard values in normal state, on the basis of which
2
the estimated causes are judged
in normal state

3  Judge and record the wire harness fault

 Broken circuit
4 Estimated causes of trouble (The number is The connector is incorrectly connected or the harness is
given for the purpose of facilitating the damaged.
writing, does not mean any priority order)  Earthling trouble
The harness is not connected with earthling circuit of chassis,
5 but only contacts with it.
 It is short-connected to power supply
The harness is not connected with circuit of power supply
(24V), but only contacts with it.

Relevant Wiring Diagrams

This is a part of the wiring diagram, and mainly displays the part in trouble
 Connector number: it indicates the connector.
 Arrow: it indicates roughly where it is installed on the machine
7.7.2 E-1 THE ENGINE COULD NOT BE STARTED
Fault Info The engine can’t be started (The engine does not rotate)
Set the safety locking rod at locking position, and start up
Relevant information
the engine

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in normal state

The capacity ★ Turn the engine start switch to the OFF position for preparation and keep the switch
1 of battery is in the OFF position for fault diagnosis.
insufficient Electric pressure of battery Voltage value More than 24V
★ Turn the engine start switch to the OFF position for preparation and keep the switch
in the OFF position for fault diagnosis.
Internal
trouble of Position OFF: between
2
starting switch More than 1M Ω
wire 22 and wire 11
for engine Resistance value
Position ON: between wire
Less than 1 Ω
22 and wire 11
★ Turn the engine start switch to the OFF position for preparation, and keep the
switch in the OFF position for fault diagnosis.
Unlocking position of
Trouble of
3 locking rod: between wire Less than 1 Ω
leading switch
105 and wire 0 Resistance value
Locking position of locking
More than 1M Ω
rod: between wire 105 and

7-38 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Trouble Diagnosis

wire 0
★ Turn the engine start switch to the OFF position for preparation, and keep the
engine running during the fault diagnosis (if all the power supply, grounding, generated
signals and engine input are normal, only the engine output is abnormal, the engine start
motor is faulty)
Trouble of Engine start motor Starting switch Voltage value
4
starting motor
Power supply: terminal B
20—30V
and earth
Start
Between input terminal S of
start motor and earth
★ Turn the engine start switch to the OFF position for preparation, and then keep it
in the START position for fault diagnosis.
Wire 22 of start switch and
Less than 1 Ω
terminal B of start motor
The wire
5 harness is No. 11 wire of starting
open-circuited switch, and Terminal S of Less than 1 Ω
Resistance value
starting motor
Terminal L of generator,
and Terminal R of safety Less than 1 Ω
relay
Terminal “+” (wire 20#) of
Trouble of
6 battery and wire 22# of Resistance value Less than 1 Ω
fuse F1
control knob
★ Turn the engine start switch to the OFF position for preparation and keep the switch
Short circuit of in the OFF position for fault diagnosis.
conductor
Between Terminal 12# and
7 harness More than 1 MΩ
the ground
(grounding Resistance value
trouble) Between input terminal S of
More than 1 MΩ
start motor and earth
★ Turn the engine start switch to the OFF position for preparation. When the fault is
diagnosed, the start switch is in the START position.
8 Starter relay
Between Terminal S and
Voltage value About 24V
the ground

Maintenance Manual - 01 - 2021 7-39

7-40
Starting switch
21n4-10430
Trouble Diagnosis

HLR Charging indicator light

Stop relay E2 generator

Parking motor

Safety relay

Maintenance Manual - 01 - 2021

Storage battery relay
Start motor

SQ1 pilot switch K3 starting relay

BAT-1 battery Leading

electromagnetic valve

Controller
SY135F Hydraulic Forestry Crane
 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.7.3 E-2 THE ENGINE SPEED FLUCTUATES IRREGULARLY

Fault Info The engine speed fluctuates irregularly
Relevant information The speed value of engine can be seen on the display

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in normal

★ Turn the engine start switch to the OFF position for preparation and keep the
switch in the OFF position for fault diagnosis.
The wire harness is
1 Unplug the controller HCU_ J1
disconnected
connector, and measure the Resistance value 2.3 ± 0.2 K Ω
resistance between Pins 16 and 7.
★ Turn the engine start switch to the OFF position for preparation and keep the
switch in the OFF position for fault diagnosis.
state

Internal trouble of
2
sensor Resistance between Pins 1 and 2
Resistance value 2.3 ± 0.2 K Ω
in CN-125F

Wiring harness ★ Turn the engine start switch to the OFF position for preparation and keep the
short circuit switch in the OFF position for fault diagnosis.
3
(contact with Resistance between Pin 1 in CN-
ground) Resistance value 1 MΩ and more
125F and the ground
Internal trouble of Since this is an internal trouble, no trouble diagnosis can be carried out. (If it is not
4
controller for the above-mentioned reasons, the controller should be in trouble)

Controller

Rotating speed sensor

Input signal of speed Signal

sensor

Ground

7.7.4 E-3 THE POWER SUPPLY FOR COMPLETE MACHINE COULD NOT BE
SWITCHED OFF
Fault Info The engine can’t be stopped
When the engine start switch is turned to the position OFF, the engine
Relevant information
stops

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard

Trouble
value in normal state

of
When the engine start switch is operated, if the operating sound is heard from contacts of
1 storage
battery relay, the battery can be judged as normal. Start switch OFF-ON-OFF.
battery
relay
★ Turn the engine start switch to the OFF position for preparation and keep the switch in
The the OFF position for fault diagnosis.
surge
2
diode is Between 20# and 21# lines of
broken Resistance value Above 1MΩ
battery relay
down

Maintenance Manual - 01 - 2021 7-41

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.7.5 E-4 THE AUTOMATIC IDLING DOES NOT WORK

Fault Info The engine has no automatic idling function
In the automatic idling mode, when the handle is at middle position, the
Relevant information
engine speed does not reduce

Causes Standard value in normal state and reference value for trouble diagnosis
★ Turn the engine start switch to the OFF position for preparation, restart
and maintain the engine starting state for fault diagnosis.
When the control rod is
No voltage output at
at middle position, the
Signal fault of the signal output
1 pressure signal is
operating device terminal.
transmitted Pressure sensor
When the control rod is There is 0.5V~4.5V
operated, the pressure voltage output at the
signal is transmitted signal output terminal.
★ Turn the engine start switch to the OFF position for preparation, restart
and maintain the engine starting state for fault diagnosis.
When the control rod is
No voltage output at
at middle position, the
the signal output
Estimated causes and standard value in normal state

2 Slewing signal trouble pressure signal is

terminal.
transmitted Pressure sensor
When the control rod is There is 0.5V~4.5V
operated, the pressure voltage output at the
signal is transmitted signal output terminal.
★ Turn the engine start switch to the OFF position for preparation, restart
and maintain the engine starting state for fault diagnosis.
When the control rod is
No voltage output at
at middle position, the
3 Left travel signal fault the signal output
pressure signal is
terminal.
transmitted Pressure sensor
When the control rod is There is 0.5V~4.5V
operated, the pressure voltage output at the
signal is transmitted signal output terminal.
★ Turn the engine start switch to the OFF position for preparation, restart
and maintain the engine starting state for fault diagnosis.
When the control rod is
No voltage output at
at middle position, the
the signal output
4 Right travel signal fault pressure signal is
terminal.
transmitted Pressure sensor
When the control rod is There is 0.5V~4.5V
operated, the pressure voltage output at the
signal is transmitted signal output terminal.
Since this is an internal trouble, no trouble diagnosis can be carried out. (If
5 Controller failure
it is not for the above-mentioned reasons, the controller should be in trouble)
Display failure (the
automatic idle button
6 Because there is an internal fault, it can not be diagnosed.
function of the display
screen is out of order)
Check whether each pressure sensor connector and the corresponding wire
7 Connector failure
pin inside the controller connector are loose.

7-42 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.7.6 E-5 THE PREHEATING FUNCTION DOES NOT WORK

Fault Info The engine preheating function does not work
Relevant information

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in normal state

★ Turn the engine start switch to the OFF position for preparation, restart
Trouble of preheating and maintain the engine starting state for fault diagnosis.
1
fuse Resistance between Wire 21 and Resistance
Less than 1 Ω
Pin 2 (contact) of preheating relay value
Trouble of preheating When the preheating function is activated, if the operating sound is heard from
2
relay contact of preheating relay, it can be judged that the relay is normal.
★ Turn the engine start switch to the ON position and disconnect the low
temperature switch for preparation. Keep the start switch at the ON position for
Trouble of preheating fault diagnosis.
3
controller
Voltage
Voltage between Wires 14 and 68 About 24 V
value
★ Turn the engine start switch to the OFF position for preparation, restart
Short-circuit trouble of and maintain the engine starting state for fault diagnosis.
4
wire (grounding) Resistance between Pin 2 (contact) Resistance
More than 1M Ω
of preheating relay and ground value
5

Preheating relay

Low temperature switch Heating indicator light

Preheating controller

Starting switch
21n4-10430

Stop relay
Parking motor

Storage battery relay

BAT-1 battery Preheater R0

Maintenance Manual - 01 - 2021 7-43

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.7.7 E-6 ALL DEVICES COULD NOT WORK

Fault Info After this machine is started, this machine does not act
Relevant information

Standard value in normal state and reference value for

Causes
trouble diagnosis
★ Turn the engine start switch to the OFF position for
preparation, restart and maintain the engine starting
Estimated causes and standard value in normal state

state for fault diagnosis.

Trouble of
1 safety locking Measurement items Safety control rod Resistance value
switch Between wire 105 and
Locking Less than 1 Ω
wire 0
Loosen More than 1M Ω
★ Turn the engine start switch to the OFF position for preparation and keep the
Short-circuit switch in the OFF position for fault diagnosis.
2 trouble of wire
(grounding) Between wire 105 and
Resistance value More than 1M Ω
earth
The internal coil ★ Turn the engine start
of PPC locking switch to the OFF position
3 electromagnetic for preparation and keep
valve is in the switch in the OFF
trouble position for fault diagnosis.
Between pin 1 and pin 2 of
Resistance value About 8 Ω
CN-136F

Leading switch

Controller

Input signal of pilot

switch

Output signal of pilot

electromagnetic valve

Leading electromagnetic valve

Figure 7-35

7-44 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.7.8 E-7 THE OPERATING DEVICE IS SLOW AND WEAK

When the excavator is acting, the working device acts slowly and the excavation is
Fault Info
powerless
Relevant information

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in normal

★ Turn the engine start switch to the OFF position for preparation, restart and maintain
the engine starting state for fault diagnosis.
When the control rod
is at middle position,
The There is no voltage output on
there is signal of
pressure output end of pressure sensor
1 sensor working device
has pressure switch
state

Pressure sensor
trouble When the control rod
is operated, there is
Output of pressure sensor:
signal of working
0.5—4.5Vvoltage
device pressure
switch
Controller Since this is an internal trouble, no trouble diagnosis can be carried out. (If it is not for the
2
failure above-mentioned reasons, the controller should be in trouble)
Connector Check whether the pressure sensor of each operating device and the pin of the
3
failure corresponding wire number inside the controller are loose.

Boom up

Boom
lowering

Bucket
excavatio
n
Controller
Bucket
unloading

Grab arm
excavatio
n

Grab arm
unloading

Figure 7-36

Maintenance Manual - 01 - 2021 7-45

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.7.9 E-8: THE TRAVELLING ACTS SLOWLY AND POWERLESSLY

Fault Info When the excavator moves, it travels slowly and excavates powerlessly.
Relevant information

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in

★ Turn the engine start switch to the OFF position for preparation, restart and
maintain the engine starting state for fault diagnosis.
Center position of
The pressure operating lever, left and There is no voltage output on
normal state

1 sensor has right travel pressure output end of pressure sensor

trouble signals Pressure sensor
Operation of operating
Output of pressure sensor: 0.5—
lever, left and right travel
4.5Vvoltage
pressure signals
Controller Since this is an internal trouble, no trouble diagnosis can be carried out. (If it is not for
2
failure the above-mentioned reasons, the controller should be in trouble)
Connector Check whether the left/right travel pressure sensor and the pin corresponding to the
3
failure wire number inside the controller are loose.

Traveling
RIGHT

Controller
Traveling
LEFT

Figure 7-37
7.7.10 E-9 THE DISPLAY ON UPPER PORTION OF MONITOR PANEL IS OMITTED
Fault Info The display on upper portion of monitor panel is omitted
Relevant information

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes
and standard value

LCD monitor panel If in the following operation of changeover switch, the LCD light on monitor
in normal state

1 (liquid crystal display) panel comes on, then the monitor panel is normal.
Trouble  Switching operation: (simultaneous switching operation)
Since this is an internal trouble, no trouble diagnosis can be carried out.
The monitor panel is
2 (If the cause of trouble is not the above-mentioned cause, the monitor
in trouble
panel is in trouble)

7-46 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.7.11 E-10 THE DISPLAY CONTENT OF THE MONITOR PANEL IS INDEPENDENT

OF THE MODEL
The contents displayed on monitor panel are not related to model of
Fault Info
machine
Relevant information

Causes Standard value in normal state and reference value for trouble diagnosis
standard value in normal
Estimated causes and

If the display on monitor panel is normal, it shall display the

corresponding trouble code.
Model code and signal
1
state

fault (internal fault) Items Norma display

Name of trouble Trouble code
Since this is an internal trouble, no trouble diagnosis can be carried out.
The monitor panel is in
2 (If the cause of trouble is not the above-mentioned cause, the monitor
trouble
panel is in trouble)

7.7.12 E-12 THE INDICATION OF FUEL OIL LEVEL IS INACCURATE

Fault Info The fuel level sensor on engine can’t correctly reflect the current fuel level
Relevant information The fuel level can be read from display screen

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in normal state

★ Turn the engine start switch to the OFF position for preparation and keep the switch
in the OFF position for fault diagnosis.
Trouble of oil Pin Fuel oil level Resistance value
1
level sensor
Full (upper limit) About 10 Ω
Between wire 509 and earth
Empty (lower limit) 85-95 Ω
★ Turn the engine start switch to the OFF position for preparation and keep the switch
The wire is in the OFF position for fault diagnosis.
2
disconnected Between 509# line and Pin 20# of
Resistance value Less than 1 Ω
controller
Short-circuit ★ Turn the engine start switch to the OFF position for preparation and keep the switch
trouble of in the OFF position for fault diagnosis.
3
wire
(grounding) Between wire 509 and earth Resistance value More than 1M Ω

The wire is ★ Turn the engine start switch to the OFF position for preparation, and make the switch
short- reach the ON position and keep it at the on position for fault diagnosis.
4
circuited to
24V Between wire 509 and earth Voltage value Less than 1V

Maintenance Manual - 01 - 2021 7-47

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

Controller

Fuel oil level

sensor

Cab Body harness

Figure 7-38
7.7.13 E-13 NO RESPONSE WHEN OPERATING THE BUTTON SWITCH ON THE
DISPLAY SCREEN
 When the work mode changeover switch is operated, the work
Trouble information (1)
mode display will not appear.
Relevant information

Standard value in normal state and reference value for trouble

Estimated causes and Causes
diagnosis
standard value in normal
state Trouble of This is an internal trouble, so that the trouble diagnosis can’t be
1
display screen carried out.

 When the automatic deceleration switch is operated, the

Trouble information (2)
automatic deceleration display will not appear.
★ If the automatic deceleration itself does not work, E-5 fault
Relevant information diagnosis should be carried out. and keep the switch in the off
position for fault diagnosis.

Standard value in normal state and reference value for trouble

Estimated causes and Causes
diagnosis
standard value in normal
state Trouble of This is an internal trouble, so that the trouble diagnosis can’t be
1
display screen carried out.

 When the travelling speed changeover switch is operated, the

Trouble information (3)
travelling speed display will not appear.
★ If the operating speed does not change, H-21 fault diagnosis
Relevant information should be carried out. and keep the switch in the off position
for fault diagnosis.

Standard value in normal state and reference value for trouble

Estimated causes and Causes
diagnosis
standard value in normal
state Trouble of This is an internal trouble, so that the trouble diagnosis can’t be
1
display screen carried out.

Trouble information (4)  When the selection switch is operated, the adjustment display

7-48 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

will not appear.

 When the LCD display screen adjustment switch is operated,
the adjustment display will not appear.
 When the maintenance switch is operated, this item will not
be displayed.
Relevant information

Standard value in normal state and reference value for trouble

Causes
Estimated causes and diagnosis
standard value in normal Trouble of
state This is an internal trouble, so that the trouble diagnosis can’t be
1 display
carried out.
screen

7.7.14 E-14 THE WIPER DOES NOT WORK

Fault Info The wiper does not work
Relevant information

Causes Standard value in normal state and reference value for trouble diagnosis
★ Turn the engine start switch to the OFF position for preparation and keep the
Internal switch in the OFF position for fault diagnosis.
1 trouble of Between wire 25 of
wiper motor windscreen wiper and Resistance value More than 10 Ω
Estimated causes and standard value in normal state

earth
★ Turn the engine start switch to the OFF position for preparation and keep the
switch in the OFF position for fault diagnosis.
Between 1 of CN-241F
Less than 1 Ω
and 2 of CN-1-110
Between No. 35L wire of
The wire is wiper switch
2 Less than 1 Ω
disconnected and No. 5 wire of CN-1-
110 Resistance value
Between No. 35H wire of
wiper switch and No. 5
wire of CN-1-110 Less than 1 Ω
and No. 4 wire of CN-1-
110
★ Turn the engine start switch to the OFF position for preparation and keep the
Short circuit switch in the OFF position for fault diagnosis.
fault of
3 Harness to ground
conductor
(grounding) between 1 of CN-241F Resistance value More than 1M Ω
and 2 of CN-1-110

Maintenance Manual - 01 - 2021 7-49

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

Windscreen wiper
switch

Power source
Cab

Figure 7-39
7.7.15 E-15 THE ALARM BUZZER CANNOT BE ELIMINATED
Fault Info The warning buzzer does not stop after sounding for 5 seconds
Relevant information

Causes Standard value in normal state and reference value for trouble diagnosis
standard value in normal
Estimated causes and

1 ★ The trouble occurs

Internal trouble of
controller It stops after 5
2 The buzzer sounds Sounding time
seconds
state

3
4
5
6

7-50 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.7.16 E-16 INACCURATE DISPLAY OF OPERATING DEVICE PRESSURE STATE

"Boom Lifting", "Boom Lowering", "Arm Digging", "Arm Unloading", "Bucket
Fault Info Digging" and "Bucket Unloading" cannot be displayed correctly in the
monitoring function
Relevant information
Estimated causes and standard value in

★ Turn the engine start switch to off position for preparation,

restart and maintain the engine starting state for fault diagnosis.
Middle position of
Pressure sensor operating lever, There is no voltage output on output
1 failure of operating
normal state

pressure sensor of Status of end of pressure sensor

device operating device pressure
Operation of operating sensor
Output of pressure sensor: 0.5—
rod, pressure sensor of
4.5V voltage
operating device
Check whether the pins of the pressure sensors in the operating device
2 Connector failure
and the corresponding wire number inside the controller are loose.

Boom up

Boom
lowering

Bucket
excavation

Controller
Bucket
unloading

Grab arm
excavation

Grab arm
unloading

Figure 7-40

Maintenance Manual - 01 - 2021 7-51

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.7.17 E-17 THE SLEWING OPERATION CAN’T BE CORRECTLY DISPLAYED IN

MONITORING FUNCTION
The slewing operation can’t be correctly displayed in monitoring
Fault Info
function
Relevant information

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard

★ Turn the engine start switch to the OFF position for preparation, restart and
maintain the engine starting state for fault diagnosis.
value in normal state

Control rod middle There is no voltage

The slewing
position, pressure output on output end of
1 pressure sensor
sensor pressure sensor
is in trouble State of pressure switch
Output of pressure
Control rod and
sensor: 0.5—4.5V
pressure sensor
voltage
Check whether the pins of the pressure sensors in the operating device and the
2 Connector failure
corresponding wire number inside the controller are loose.
3

Pressure sensor

Controller Rotation

Figure 7-41

7-52 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.7.18 E-18 “TRAVEL LEFT" AND “TRAVEL RIGHT" CANNOT BE DISPLAYED

CORRECTLY IN THE MONITORING FUNCTION
"Left Travel" and "Right Travel" cannot be displayed correctly in the
Fault Info
monitoring function
Relevant information

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard

★ Turn the engine start switch to the OFF position for preparation, restart and
maintain the engine starting state for fault diagnosis.
value in normal state

Middle position of
There is no voltage
Fault of left/right operating lever, and
output on output end of
1 travel pressure left/right travel pressure
sensor Status of pressure pressure sensor
sensor
sensor
Operation of operating Output of pressure
lever, left/right walking sensor: 0.5—4.5V
pressure sensor voltage
Connector Check whether the pins of the pressure sensors in the operating device and the
2
failure corresponding wire number inside the controller are loose.

Traveling
RIGHT

Controller
Traveling
LEFT

Figure 7-42

Maintenance Manual - 01 - 2021 7-53

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.7.19 E-19 THE RUNNING SPEED COULD NOT BE CHANGED

Fault Info The running speed could not be changed
When the travelling changeover button is pressed, the travelling
Relevant information
speed does not change

Causes Standard value in normal state and reference value for trouble diagnosis
★ Turn the engine start switch to the OFF position for preparation and
keep the switch in the OFF position for fault diagnosis.
The high/low speed
The high/low speed
1 electromagnetic valve About 24V
button is high speed
is in trouble Voltage value
The high/low speed
Less than 1V
button is low speed
★ Turn the engine start switch to the OFF position for preparation and
keep the switch in the OFF position for fault diagnosis.
Resistance between
Estimated causes and standard value in normal state

Pin 7 of CN-602M
The harness is in controller
2
trouble and Pin 607 of CN-
130F controller Resistance value Less than 1 Ω

Resistance between
No. 0 wire of CN-130F
and ground
★ Turn the engine start switch to the ON position for preparation, and
keep the switch in the ON position for fault diagnosis.
After the ‘high speed’
Internal trouble of button is pressed
3
controller down, the system will High/low speed
It is output state
enter the operation electromagnetic valve
information search
page.
The high/low speed
If the trouble is not any of the above-mentioned troubles, please refer to
4 hydraulic circuit is in
trouble diagnosis for hydraulic system (category H)
trouble

Controller HCU

High/low speed
electromagneti
c valve
High/low speed
change-over

Figure 7-43

7-54 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.7.20 THE E-20 ENGINE SPEED IS NOT ADJUSTABLE

Fault Info The engine speed is not adjustable
Relevant information The engine speed can’t be adjusted by turning the throttle knob

Causes Standard value in normal state and reference value for trouble diagnosis
★ Turn the engine start switch to the OFF position for preparation,
Coil failure of and keep the switch in the OFF position for fault diagnosis.
1
throttle motor
Pull out the connector CN-131F Resistance value about 12Ω
★ Turn the engine start switch to the OFF position for preparation,
The harness is and keep the switch in the OFF position for fault diagnosis.
2
Estimated broken and measure the resistance
causes and Resistance value about 12Ω
between Motors ③ and ⑥.
standard value in
normal state Harness short ★ Turn the engine start switch to the OFF position for preparation,
circuit fault and keep the switch in the OFF position for fault diagnosis.
3
(contact with
ground) Pull out the connector CN-131F Resistance value Above 2 MΩ

and measure
the resistance Since this is an internal trouble, no trouble diagnosis can be carried out. (If
4 between it is not for the above-mentioned reasons, the controller should be in trouble.
Motor ③ / ⑥ Please replace the controller)
and housing.

Controller Throttle motor

Green
Sensor 5V
White
Throttle feedback voltage
Red

Earthling wire
Yellow

Blue

Cab Body harness

Maintenance Manual - 01 - 2021 7-55

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.7.21 FAILURE OF E-21 THROTTLE KNOB

Fault Info The gear can’t be adjusted
Relevant information The engine gear can’t be adjusted by turning the throttle knob

Causes Standard value in normal state and reference value for trouble diagnosis
★ Turn the engine start switch to the OFF position for preparation, and then hold
5V power supply it to the ON position for fault diagnosis.
1
trouble Voltage between ① and ③ of CN-
Estimated causes and standard value in normal state

Voltage value About 5V

202M
★ Turn the engine start switch to the OFF position for preparation and keep the
Signal wire switch in the OFF position for fault diagnosis.
2
breaking trouble Resistance between ② of CN-202M
Resistance value Less than 1 Ω
and Pin 11 of controller
★ Turn the engine start switch to the OFF position for preparation and keep the
Short circuit fault of switch in the OFF position for fault diagnosis.
3 signal wire (contact
with ground) Resistance between ② of CN-202M
Resistance value More than 2 MΩ
and ground

Short circuit fault of ★ Turn the engine start switch to the OFF position for preparation, and then hold
signal circuit it to the ON position for fault diagnosis.
4
(contact with Resistance between ② of CN-202M
power supply) Resistance value Less than 5V
and ground
★ Turn the engine start switch to the OFF position for preparation and keep the
switch in the OFF position for fault diagnosis.
5 Knob trouble Pull out the connector CN-202M and
measure the resistance between ① Resistance value 5±0.1K Ω
and ③ of the knob

Yellow

Sensor 5V Blue Throttle

control
Red
knob
Earthling wire

Set voltage for throttle

control knob

Cab

Figure 7-45

7-56 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.7.22 NO OIL LEVEL, SPEED, WATER TEMPERATURE AND OTHER

INFORMATION ON THE E-22 DISPLAY.
There is no information about oil level, speed and water temperature on
Fault Info
display screen
There is no information about oil level, speed and water temperature on
Relevant information
display screen

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in normal

★ Turn the engine start switch to the OFF position for preparation and keep the switch
The CAN in the OFF position for fault diagnosis.
1 resistor is
in trouble Pull out the plug-in part of display screen, and carry Resistance
60Ω
out measurement between pin 1 and pin 2 value
★ Turn the engine start switch to the OFF position for preparation and keep the switch
in the OFF position for fault diagnosis.
The
state

Unplug the controller connector and measure the

2 harness is
broken resistance between Pin 12 and CN-603M. Resistance
Less than 1 Ω
Unplug the controller connector and measure the value
resistance between Pin 11 and CN-603M.
Internal Since this is an internal trouble, no trouble diagnosis can be carried out. (If it is not for
3 trouble of the above-mentioned reasons, the controller should be in trouble. Please replace the
controller controller)
4
5

Resistance: 120 Ω
Controller CN-
602M
Display
screen

Power Power
source source
Cab

Maintenance Manual - 01 - 2021 7-57

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.8 Trouble diagnosis for hydraulic and mechanical systems (mode

H)
7.8.1 H-1 THE WORKING DEVICE ACTS SLOWLY, OR THE RUNNING AND
SLEWING SPEED IS LOW
Fault Info  The working device acts slowly, or the running and slewing speed is low.

Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in normal state

★ Turn off the engine for making preparation. When the engine is running at high
idle speed, please carry out the trouble diagnosis.
The main Control lever Pressure of primary overflow valve
overflow valve
1 Grab arm excavation 30~31.4 MPa {306~320 kgf/cm2}
is not adjusted
properly or fails
After the adjustment is carried out, if the pressure still can’t be resumed to normal
state, maybe the main overflow valve fails or there is trouble in it. In such case,
please inspect the valve.
★ Turn off the engine for making preparation. When the engine is running at high
idle speed, please carry out the trouble diagnosis.
The leading
2 overflow valve Control lever Pilot control pressure
fails
All control rods are at “middle
3.9~4.1 MPa {40~42 kgf/cm2}
position”
The regulator
3 Maybe the regulator fails. Please inspect the regulator servo mechanism
fails
The plunger If the above-mentioned causes are not detected, maybe the plunger pump
4
pump fails deteriorates, fails or has internal trouble.

7.8.2 H-2 THE ENGINE SPEED IS OBVIOUSLY REDUCED OR THE ENGINE

STALLS
Fault Info  The engine speed obviously reduces or the engine stalls.

Relevant information  Relevant information

Standard value in normal state and reference value for trouble

Estimated causes and standard value in normal

Causes
diagnosis
Maybe the fuel injection pump is in trouble. Please inspect the fuel
1 Fuel injection pump has trouble
injection pump.
Maybe the regulator fails. Please inspect the regulator servo
2 The regulator fails
mechanism.
Maybe the fuel filter element is blocked and thus the oil way is not
3 Fuel oil filter core is plugged
state

clear. Please inspect the filter element.

Carbon is accumulated in Maybe carbon is accumulated in the nozzle. Please inspect the
4
nozzle nozzle.
Maybe the air filter is blocked and thus the intake pipeline is not clear.
5 The air filter is blocked
Please inspect the air filter.
6 The engine is abnormally worn Maybe the engine is abnormally worn. Please inspect the engine.
The fuel delivery pump has Maybe the oil transfer pump is in trouble. Please inspect the oil
7
troubles transfer pump.

7-58 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.8.3 H-3 THE WORKING DEVICE, RUNNING OR SLEWING GEAR COULD NOT
WORK
Fault Info  The working device, travelling and slewing functions can’t be activated

 Set the work mode at position 10 of mode S, so as to carry out trouble

Relevant information
diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
★ Turn off the engine for making preparation. When the engine is running at high
Speculated cause and standard number in normal state

idle speed, please carry out the trouble diagnosis.

The pilot safety Pilot safety rod Pilot overflow pressure
1 electromagnetic
valve fails Locking 0 {0}
3.9~4.1 MPa
Unlocking
{40~42 kgf/cm2}
★ Turn off the engine for making preparation. When the engine is running at high
The leading idle speed, please carry out the trouble diagnosis.
pump overflow
2 Control lever Pilot overflow pressure
valve has
trouble 3.9~4.1 MPa
All control rods are at middle position
{40~42 kgf/cm2}
The hydraulic The plunger pump may be out of order or there may be internal failure in it. The
3 pump has diagnosis was made according to the following methods. Remove the oil pressure
trouble measuring plug and start the engine. If oil flows out, it is normal.
The pump shaft cannot rotate due to the internal fault of the coupling. Check the
Value

The coupling
4 coupling. Loosen the oil outlet of the pilot pump. If no oil flows out, it may be the
has trouble
coupling failure.

7.8.4 H-4 THE HYDRAULIC PUMP HAS ABNORMAL NOISE

Fault Info  The abnormal noise is heard near hydraulic pump.
Relevant information ―

Standard value in normal state and reference value for trouble

Estimated causes and standard value in

Causes
diagnosis
The hydraulic oil level
1 Visual inspection
reduces

The hydraulic oil quality is

2 Maybe there is air in oil. Please carry out visual inspection.
poor

Maybe the vent device on top cover of hydraulic oil tank is blocked up, so
The air breather on the top
that the negative pressure is generated in oil tank. Please press down the
3 of hydraulic oil tank is
air release valve of breather valve, and inspect whether the noise
plugged
disappears.
Maybe the strainer of hydraulic oil tank is blocked up, so that the negative
normal state

The hydraulic oil tank filter

4 pressure is generated in oil suction way. Please carry out visual
screen is plugged
inspection.
The plunger pump has Maybe there is trouble in plunger pump. Please inspect the plunger
5
trouble pump.

Maintenance Manual - 01 - 2021 7-59

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.8.5 H-5 THE AUTOMATIC IDLING COULD NOT WORK

Fault Info  The automatic idling could not work.

 Set the work mode at position 10 of mode S, so as to carry out trouble

Relevant information
diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in

★ Turn off the engine for making preparation. When the engine is running
at high idle speed, please carry out the trouble diagnosis.

1 The sensor fails Every control rod Output Pressure of Leading Valve
"Neutral position" 0 {0}
Operations 3.5~4.1MPa {36~42 kgf/cm2}
★ Turn off the engine for making preparation. When the engine is running
at high idle speed, please carry out the trouble diagnosis.

2 The leading valve fails Every control rod Output Pressure of Leading Valve
normal state

"Neutral position" 0 {0}

Operations 3.5~4.1MPa {36~42 kgf/cm2}
3 Controller failure Maybe the controller is in trouble. Please inspect the controller.

7.8.6 H-6 THE BOOM MOVES SLOWLY

Fault Info  The boom moves slowly.

 Set the work mode at position 10 of mode S, so as to carry out trouble

Relevant information
diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis.
The right pilot valve (on
1 the boom circuit) is out of Boom control rod Output Pressure of Leading Valve
Estimated causes and standard value in normal state

order "Neutral position" 0 {0}

“Lifting” or “lowering ” More than 3.5MPa {36 kgf/cm2}
★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis.

Failure of positive pilot Pressure of pilot feedback to main

2 Boom control rod
feedback pump
"Neutral position" 0 {0}
“Lifting” or “lowering ” More than 3.5MPa {36 kgf/cm2}
The boom control valve
3 Maybe the valve core in boom control valve fails. Inspect the valve.
(holding valve) fails
The boom control valve
4 Maybe the holding valve in boom control valve fails. Inspect the valve.
(holding valve) fails
The boom control valve
(safety valve and oil Maybe the safety valve and oil replenishing valve in boom control valve fail or
5
filling valve) fails or the the sealing element is in trouble. Please inspect it.
sealer has trouble
★ Turn off the engine for making preparation. When the engine is running at
The boom cylinder has high idle speed, please carry out the trouble diagnosis.
6
trouble
When the load of the bucket is about 1260 kg, cut off the oil circuit on one side

7-60 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

of the high-pressure chamber of the oil cylinder, disconnect it from the main
valve, and measure the displacement of the piston for 15 minutes after the oil
cylinder is stable. If the value is greater than 10 mm, it can be judged as the oil
cylinder seal failure. For detailed measurement method, please refer to
"Inspection of Hydraulic Settlement in Operating Device" (Page 4-26).
★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis.
The boom lifting interflow Boom control rod Boom lifting interflow pilot
7
control fails
"Neutral position" 0 {0}
“Lifting” More than 3.5MPa {36 kgf/cm2}

7.8.7 H-7 THE GRAB ARM MOVES SLOWLY

Fault Info  The grab arm moves slowly.

Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis.
Left leading valve
1 (grab arm oil way) Grab arm control rod Output Pressure of Leading Valve
fails "Neutral position" 0 {0}
“Excavation” or “unloading ” More than 3.5MPa {36 kgf/cm2}
★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis.
Estimated causes and standard value in normal state

Failure of positive Grab arm control rod Pressure of pilot feedback to main pump
2
pilot feedback
"Neutral position" 0 {0}
“Excavation” or “unloading ” More than 3.5MPa {36 kgf/cm2}
The grab arm control
3 valve (valve core) Maybe the valve core in grab arm control valve fails. Inspect the valve.
fails
Failure of grab arm
4 control valve Maybe the regeneration valve in grab arm control valve fails. Inspect the valve.
(regeneration valve)
Failure of grab arm
control valve (relief Maybe the safety valve and oil replenishing valve in grab arm control valve fail or
5
valve and makeup the sealing element is in trouble. Please inspect it.
valve) or seal failure
★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis.

The grab arm For detailed measurement method, refer to "Inspection of Hydraulic Settlement in
6 Operating Device" (Page 4-26). Cut off the oil circuit on one side of high pressure
cylinder has trouble
chamber in oil cylinder, disconnect with the main valve, and measure the piston
displacement for 15 minutes after the cylinder stability. If the value is greater than
10 mm, it can be judged as a cylinder seal failure.
★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis.
The grab arm Grab arm control rod Grab arm interflow pilot
7
interflow control fails
"Neutral position" 0 {0}
“Excavation” or “unloading ” More than 3.5MPa {36 kgf/cm2}

Maintenance Manual - 01 - 2021 7-61

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.8.8 H-8 THE BUCKET MOVES SLOWLY

Fault Info  The bucket moves slowly.

 Set the work mode at position 10 of mode S, so as to carry out trouble

Relevant information
diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
★ Turn off the engine for making preparation. When the engine is running
at high idle speed, please carry out the trouble diagnosis.
The right leading
1 valve (bucket oil Bucket control rod Output Pressure of Leading Valve
way) fails "Neutral position" 0 {0}
“Excavation” or “unloading ” More than 3.5MPa {36 kgf/cm2}
★ Turn off the engine for making preparation. When the engine is running
at high idle speed, please carry out the trouble diagnosis.

Failure of positive Pressure of pilot feedback to main

2 Bucket control rod
pilot feedback pump
Estimated
causes "Neutral position" 0 {0}
and “Excavation” or “unloading ” More than 3.5MPa {36 kgf/cm2}
standard
value in The bucket control
normal 3 valve (valve core) Maybe the valve core in bucket control valve fails. Inspect the valve.
state fails
Failure of bucket
control valve (relief There may be a failure of the relief/makeup valve in the bucket control valve
4
and makeup valve) or a failure of the seal. Check it.
or seal failure
★ Turn off the engine for making preparation. When the engine is running
at high idle speed, please carry out the trouble diagnosis.
When the bucket load is about 1260 Kg, cut off the oil circuit on one side of
The bucket cylinder the high pressure chamber in the oil cylinder and disconnect it from the main
5
has trouble valve. After the oil cylinder is stable, measure the displacement of the piston
for 15 minutes. If the value is greater than 10 mm, it can be judged as the oil
cylinder seal failure. For detailed measurement method, please refer to
"Inspection of Hydraulic Settlement in Operating Device" (Page 4 – 26).

7.8.9 H-9 SINGLE CYLINDER OF WORKING DEVICE COULD NOT ACT

 When being operated separately, the boom cylinder does not act.
Fault Info  When being operated separately, the grab arm cylinder does not act.
 When being operated separately, the bucket cylinder does not act.

 Set the work mode at position 10 of mode S, so as to carry out trouble

Relevant information
diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
standard value in normal
Estimated causes and

★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis.
The leading valve Working device control rod Output Pressure of Leading Valve
state

1
fails
"Neutral position" 0 {0}
“Excavation” or “unloading ” More than 3.5MPa {36 kgf/cm2}
The working device
2 Maybe the valve core in working device control valve fails. Inspect the valve.
control valve (valve

7-62 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

core) fails

7.8.10 H-10 THE SETTLING VOLUME OF WORKING DEVICE CYLINDER IS TOO

BIG
Trouble information (1)  Boom sinking too fast.

Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in normal state

★ Turn off the engine for making preparation. When the engine is running at high
idle speed, please carry out the trouble diagnosis.

The boom When the load of the bucket is about 1260 kg, cut off the oil circuit on one side of the
1 cylinder has high-pressure chamber of the oil cylinder, disconnect it from the main valve, and
trouble measure the displacement of the piston for 15 minutes after the oil cylinder is stable.
If the value is greater than 10 mm, it can be judged as the oil cylinder seal failure. For
detailed measurement method, please refer to "Inspection of Hydraulic Settlement in
Operating Device" (Page 4-26).
The boom
2 holding valve is in Maybe the boom holding valve is worn or jammed. Please inspect it.
trouble
The sealing
element of boom
control valve Maybe the sealing element of safety valve and oil replenishing valve in boom control
3
(safety valve and valve fails. Please inspect the seal.
oil replenishing
valve) fails
The boom valve
4 Maybe the boom valve core is excessively worn. Please inspect it.
core is in trouble

Trouble information (2)  The lowering of grab arm is too quick.

Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
★ Turn off the engine for making preparation. When the engine is running at high idle
Estimated causes and standard value in normal state

speed, please carry out the trouble diagnosis.

The grab arm Refer to "Inspection of Hydraulic Settlement in Operating Device" (Page 4-26) for the
1 cylinder has detailed measurement method. Cut off the oil circuit at one side of the high pressure
trouble chamber in the oil cylinder, disconnect it from the main valve, and measure the
displacement of the piston for 15 minutes after the oil cylinder is stable. If the value is
greater than 10 mm, it can be judged as the sealing failure of the oil cylinder.
The sealing
element of grab
The seals of the relief valve and the makeup valve in the stick control valve may be
arm control
invalid. Check the seals. ★ The failure of the seals can be determined by replacing
2 valve (safety
valve and oil other safety valves and makeup valves. (do not replace the boom "lowering" safety valve
replenishing with the makeup valve. The set pressure is different)
valve) fails
The grab arm
Maybe the grab arm holding valve and leading valve are worn or jammed. Please inspect
3 holding valve is
it.
in trouble
The grab arm
4 valve core is in Maybe the grab arm valve core is excessively worn. Please inspect it.
trouble

Maintenance Manual - 01 - 2021 7-63

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

Trouble information (3)  The lowering speed of bucket is too high.

 Set the work mode at position 10 of mode S, so as to carry out trouble

Relevant information
diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in

★ Turn off the engine for making preparation. When the engine is running at high
idle speed, please carry out the trouble diagnosis.
The bucket cylinder
1
has trouble Bucket control rod Oil leakage in cylinder
Excavation overflow 20 ml/min
normal state

The sealing
element of bucket It is possible that the seals of the safety valve and the makeup valve in the bucket
control valve control lever may be invalid. Check the seals. ★ The failure of the seals can be
2
(safety valve and determined by replacing other safety valves and makeup valves. (do not replace the
oil replenishing boom "lowering" safety valve with the makeup valve. The set pressure is different)
valve) fails
The sealing
element of bucket Maybe the sealing element of valve core in bucket control valve fails. Please inspect
3
control valve (valve it.
core) fails

7.8.11 H-11 THE ACTION OF WORKING DEVICE IS LAGGED

Fault Info  The action of working device is lagged

Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and
standard value in
normal state

Maybe the safety valve and oil replenishing valve in control valve fail. Please inspect
The control them.
valve (safety
★ As for grab arm and boom, whether the valve fails can be determined by replacing
1 valve and oil
filling valve) the safety valve and oil replenishing valve.
(Don’t replace them with the safety valve and oil replenishing valve for lowering of
fails
boom, because the set pressure is different.)

7.8.12 H-12 OTHER WORKING DEVICES MOVE WHEN SINGLE OIL WAY IS
OVERFLOWING
 When a single oil circuit of a specific operating device overflows, other operating
Fault Info
devices will move.
Relevant information  Set the work mode as mode S, so as to carry out trouble diagnosis.

Standard value in normal state and reference value for trouble

Estimated Causes
diagnosis
causes and
standard value The sealer of
in normal state 1 control valve It is possible that the seal of the control valve fails. Therefore, check it.
fails

7-64 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Trouble Diagnosis

Maintenance Manual - 01 - 2021 7-65

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.8.13 H-13 IN SLEWING +TRAVELLING OPERATION, THE TRAVELLING SPEED

IS OBVIOUSLY REDUCED
Fault Info  The traveling speed is obviously reduced in the rotary + traveling operation.

 If the travelling speed is slow when only the travelling is carried out, please firstly
Relevant information
carry out inspection H-15.

Standard value in normal state and reference value for trouble

Causes
Estimated diagnosis
causes and The straight
standard value travelling If the straight travelling valve does not act, please inspect the valve
in normal state 1
valve is in core and the oil discharge port of logic oil way
trouble

7.8.14 H-14 THE EXCAVATOR DEVIATES WHEN RUNNING

Fault Info  This machine deviates during travelling.

Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
★ Turn off the engine for making preparation. When the engine is running at high idle
speed, please carry out the trouble diagnosis.

The running Running Control Lever Output Pressure of Leading Valve

1 leading Forward traveling or backward
valve fails 3.5~3.9 MPa{ 36~40 kgf/cm2}
travelling
There is difference between output
0.4 MPa {4 kgf/cm2}
on right and left sides
Estimated causes and standard value in normal state

★ Turn off the engine for making preparation. When the engine is running at high idle
speed, please carry out the trouble diagnosis.
The leading
2 overflow Control lever Control the source pressure in oil way
valve fails
All control rods are at “middle
3.5~3.9 MPa{ 36~40 kgf/cm2}
position ”
The
3 regulator Please carry out inspection by interchanging the front and rear regulators
has trouble
The running
valve core
4 Inspect whether the valve core can move smoothly
gets
clamped
The central
slewing joint
5 Use the pipeline-inter changing method to carry out inspection
internally
leaks
★ Turn off the engine for making preparation. When the engine is running at high idle
speed, please carry out the trouble diagnosis.
The running
6
motor fails Running Control Lever Oil leakage in travelling motor
Travelling overflow 27.2 ml/min
The final Maybe the final transmission is in trouble. Directly inspect the inside of final transmission.
7 transmission ★ The internal fault of the final drive can be determined by the abnormal internal noise,
is in trouble abnormal heating

7-66 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

and metal powder or debris contained in the discharged oil.

★ Turn off the engine for making preparation. When the engine is running at high idle
speed, please carry out the trouble diagnosis
Running Control Lever Pressure from pilot valve to main pump
Positive
feedback Forward traveling or backward The display screen is displayed as
8
fault of travel travelling 3.5~3.9MPa{ 36~40 kgf/cm2}
pilot
There is difference between output
0.4 MPa {4 kgf/cm2}
on right and left sides
Use the interchange method to carry out inspection

7.8.15 H-15 THE EXCAVATOR RUNS SLOWLY

Fault Info  The travelling speed of this machine is too low.

Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis.
Running Control Lever Output Pressure of Leading Valve
The running leading Forward traveling or backward
1 3.5~3.9 MPa{ 36~40 kgf/cm2}
valve fails travelling
There is difference between left
Less than 0.4 MPa \ {less than 4 kgf /
and right output or front and rear
cm2}
output
Estimated causes and standard value in normal state

★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis.
The leading overflow
2 Control lever Control the source pressure in oil way
valve fails
All control rods are at “middle
3.5~3.9 MPa{ 36~40 kgf/cm2}
position ”
★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis
Failure of positive pilot
3 The feedback pressure from
feedback
traveling pilot to main pump is 3.5
~ 3.9 MPa \ {36 ~ 40 kgf/cm2}
The running control Maybe the valve core in travelling control valve fails. Please inspect the valve
4
valve (valve core) fails core.
Travel control valve
Maybe the oil replenishing valve in travelling control valve fails. Please inspect
5 (makeup valve)
the valve.
Out of control
★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis.
The running motor has
6
trouble Running Control Lever Oil leakage in travelling motor
Travelling overflow 27.2 ml/min
Maybe the final transmission is in trouble. Directly inspect the inside of final
The final transmission transmission.
7
is in trouble ★ The trouble in final transmission can be determined through internal
abnormal noise, abnormal heating, or emission of metal powder or debris in oil.

Maintenance Manual - 01 - 2021 7-67

Trouble Diagnosis SY135F Hydraulic Forestry Crane

7-68 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.8.16 H-16 IT IS NOT EASY FOR THE EXCAVATOR TO MAKE A TURN OR THE
POWER IS INSUFFICIENT
Fault Info  It is not east to steer this machine.

Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
★ Turn off the engine for making preparation. When the engine is running at high
idle speed, please carry out the trouble diagnosis.
Running Control Lever Output Pressure of Leading Valve
The running
1 At “middle position” on both
leading valve fails 0 {0}
sides
Estimated causes and standard value in normal state

Only carry out operation on

3.5~3.9 MPa{ 36~40 kgf/cm²}
one side
★ Turn off the engine for making preparation. When the engine is running at high
idle speed, please carry out the trouble diagnosis
Running Control Lever Feedback pressure from travel pilot to main pump
Positive feedback
2 The operation is carried out on
fault of travel pilot 3.5~3.9 MPa{ 36~40 kgf/cm²}
both sides
Only carry out operation on
3.5~3.9 MPa{ 36~40 kgf/cm²}
one side
The running
3 control valve Maybe the valve core in travelling control valve fails. Please inspect the valve core.
(valve core) fails
The running
Maybe the oil replenishing valve in travelling control valve fails. Please inspect the
4 control valve (oil
valve.
filling valve) fails
Travel motor Maybe the sealing element in safety valve in travelling motor fails. Please inspect the
(safety valve) sealing element.
5
Out of ★ Whether the sealing element fails can be determined by interchanging the front
control and rear or left and right motors.
Maybe the sealing element in one-way valve in travelling motor fails. Please inspect
The running the sealing element.
6 motor (one-way
★ Whether the seal fails or not can be determined by adjusting the front/rear or
valve) fails
left/right motors

Maintenance Manual - 01 - 2021 7-69

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.8.17 H-17 THE RUNNING SPEED COULD NOT BE CHANGED

Fault Info  The running speed could not be changed

Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in

★ Turn off the engine for making preparation. When the engine is running at high
The high/low idle speed, please carry out the trouble diagnosis.
speed change- Output pressure of
1 over Travel speed Running Control Lever
electromagnetic valve
normal state

electromagnetic
valve fails Low speed Operations 0 {0}
High speed Operations 3.5~3.9 MPa{ 36~40 kgf/cm²}

Travelling motor
Maybe the gear-shift unit in travelling motor is in trouble. Please directly inspect the
2 (gear-shift) is in
gear-shift unit.
trouble

7.8.18 H-18 THE EXCAVATOR COULD NOT RUN (ONLY ON ONE SIDE)
Fault Info  The crawler plate can’t turn (only on one side).

Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
The running control
Maybe the valve set for oil replenishing valve in travelling control valve is in
1 valve (oil filling valve)
trouble. Please inspect the valve seat.
seat has trouble
The running motor
Maybe the valve set for safety valve in travelling motor is in trouble. Please
2 (safety valve) seat has
Estimated causes and standard value in normal state

inspect the valve seat.

trouble
The running motor (oil
Maybe the valve seat for one-way valve in travelling motor is in trouble. Please
3 filling valve) seat has
inspect the valve seat.
trouble
★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis.
The speed of travelling
4
motor reduces Running Control Lever Oil leakage in travelling motor
Travelling overflow 27.2 ml/min
Maybe the final transmission is in trouble. Please directly inspect the final
The final transmission transmission internal.
5
is in trouble ★ The trouble in final transmission can be determined through internal
abnormal noise, abnormal heating, or emission of metal powder or debris in oil.
★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis.
Running Control Lever Output Pressure of Leading Valve
The pilot pressure is Forward traveling or backward The test pressure is 3.5 ~ 3.9 MPa \ {36 ~
6
too low travelling 40 kgf /cm2}
There is difference between
0.4 MPa {4 kgf/cm²}
output on right and left sides
Use the interchange method to carry out inspection

7-70 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.8.19 H-19 THE EXCAVATOR COULD NOT SLEW

Trouble information (1)  This machine can’t slow leftwards and rightwards.

Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
The
slewing
1 motor fails Maybe the parking brake of slewing motor fails. Please directly inspect it.
(parking
brake)
The ★ Turn off the engine for making preparation. When the engine is running at high
slewing idle speed, please carry out the trouble diagnosis
Estimated motor
(safety Back slewing control rod Slewing overflow pressure
causes 2
and valve) is not Slewing overflow 25.5~28.5 MPa {260~291 kgf/cm²}
standard adjusted
value in properly or If the oil pressure can’t resume to normal state after the adjustment is completed,
normal fails maybe the safety valve fails, or there is trouble in it. Please inspect the valve.
state
★ Turn off the engine for making preparation. When the engine is running at high
The idle speed, please carry out the trouble diagnosis
slewing
3
motor has Back slewing control rod Oil leakage in slewing motor
trouble
Slewing overflow More than 10 ml/min
The Maybe the slewing device is in trouble. Please directly inspect slewing device.
slewing
4 ★ The trouble in slewing device can be determined through internal abnormal
gear has
noise, abnormal heating, or emission of metal powder or debris in oil.
trouble

Trouble information (2)  This machine can’t carry out slewing operation in one direction.

Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in

★ Turn off the engine for making preparation. When the engine is running at high idle
speed, please carry out the trouble diagnosis.
The leading Left control lever Output Pressure of Leading Valve
1
valve fails
"Neutral position" 0 {0}
normal state

Slewing operation More than 3.5MPa {more than 36 kgf /cm 2}

The slewing
control valve
2 Maybe the valve core in slewing control valve fails. Please inspect the valve core
(valve core)
fails
The sealer of Maybe the sealing element of oil replenishing valve in slewing motor fails. Inspect the
slewing motor sealing element.
3
(oil filling ★ Interchange the left and right oil replenishing valve, and observe whether the
valve) fails situation changes, so as to determine whether the sealing element fails.

Maintenance Manual - 01 - 2021 7-71

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.8.20 H-20 THE SLEWING ACCELERATION PERFORMANCE IS POOR, OR THE

SLEWING SPEED IS LOW
Trouble information (1)  The slewing acceleration performance is poor, or the slewing speed slow.

Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
The slewing
Estimated causes and standard value in normal state

motor fails
1 Maybe the parking brake of slewing motor fails. Please directly inspect it.
(parking
brake)
★ Turn off the engine for making preparation. When the engine is running at high idle
The slewing speed, please carry out the trouble diagnosis
motor (safety
valve) is not Back slewing control rod Slewing overflow pressure
2
adjusted Slewing overflow 25.5~28.5 MPa {260~291 kgf/cm²}
properly or
fails If the oil pressure can’t resume to normal state after the adjustment is completed, maybe
the safety valve fails, or there is trouble in it. Please inspect the valve.
★ Turn off the engine for making preparation. When the engine is running at high idle
The slewing speed, please carry out the trouble diagnosis
3 motor has
trouble Back slewing control rod Oil leakage in slewing motor
Slewing overflow More than 10 ml/min
The brake
control
4 Dismantlement, cleaning and inspection.
pipeline is
plugged

 The slewing acceleration performance is poor only on one side, or the slewing speed
Trouble information (2)
slow.
Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
★ Turn off the engine for making preparation. When the engine is running at
Estimated causes and standard value in normal state

high idle speed, please carry out the trouble diagnosis.

The leading valve Back slewing control rod Output Pressure of Leading Valve
1
fails
"Neutral position" 0 {0}
Left or right More than 3.5MPa {more than 36 kgf /cm 2}
The slewing motor
(pressure-
2 Maybe the pressure compensation valve in slewing motor fails. Please inspect it.
compensated valve)
fails
Maybe the sealing element of oil replenishing valve in slewing motor fails. Inspect
The sealer of slewing
the sealing element.
3 motor (oil filling
★ Interchange the left and right oil replenishing valve, and observe whether the
valve) fails
situation changes, so as to determine whether the sealing element fails.
★ Turn off the engine for making preparation. When the engine is running at
The shuttle valve of high idle speed, please carry out the trouble diagnosis.
slewing leading
4
pressure sensor Back slewing control rod Output Pressure of Leading Valve
leaks from one side
"Neutral position" 0 {0}

7-72 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

Left or right 3.5~3.9MPa {36~40 Kgf/cm²}

7.8.21 H-21 THE OVERRUNNING IS TOO BIG WHEN THE SLEWING STOPS.
Trouble information (1)  When the slewing stops, the working device goes beyond the stroke excessively.
Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value

★ Turn off the engine for making preparation. When the engine is running at high idle
The slewing speed, please carry out the trouble diagnosis.
motor (safety
valve) is not Back slewing control rod Slewing overflow pressure
in normal state

1
adjusted Slewing overflow 25.5~28.5 MPa {260~291 kgf/cm²}
properly or
fails After the adjustment, if the oil pressure can’t resume to normal level, then maybe the
safety valve fails or is in trouble. Please inspect the valve.
★ Turn off the engine for making preparation. When the engine is running at high idle
The slewing speed, please carry out the trouble diagnosis.
2 motor has
Control lever Oil leakage in slewing motor
trouble
Slewing overflow Less than 10 ml/min

Trouble information
 The slewing acceleration performance on one side is poor, or the slewing speed is slow.
(2)
Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in

★ Turn off the engine for making preparation. When the engine is running at high idle
speed, please carry out the trouble diagnosis.
The leading Back slewing control rod Output Pressure of Leading Valve
1
valve fails
"Neutral position" 0 {0}
Left or right More than 3.5MPa {more than 36 kgf /cm2}
The slewing
control valve
2 Maybe the valve core in slewing control valve fails. Please inspect it.
(valve core)
fails
normal state

The sealer of Maybe the sealing element of oil replenishing valve in slewing motor fails. Inspect the
slewing motor sealing element.
3
(oil filling ★ Adjust the left and right make-up valves, and judge whether the seal is invalid
valve) fails according to the observation results.

Maintenance Manual - 01 - 2021 7-73

 Trouble Diagnosis SY135F Hydraulic Forestry Crane

7.8.22 H-22 THE IMPACT IS TOO BIG WHEN THE SLEWING STOPS
Fault Info  When the slewing stops, the relatively large impact may be generated.
Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value

★ Turn off the engine for making preparation. When the engine is running at high idle
speed, please carry out the trouble diagnosis.
The slewing
1 leading Back slewing control rod Output Pressure of Leading Valve
in normal state

valve fails "Neutral position" 0 {0}

Left or right 3.5~3.9 MPa{ 36~40 kgf/cm²}
The slewing
Maybe the slewing anti-swing valve fails. Inspect the valve.
2 anti-swing
★ Determine if the valve fails by replacing it with a new one
valve fails
The slewing
3 overflow The slewing overflow valve is worn or jammed.
valve fails

7.8.23 H-23 THE ABNORMAL NOISE IS TOO HIGH WHEN THE SLEWING STOPS
Fault Info  There is abnormal noise when the rotation movement stops.
Relevant information  Set the work mode at position 10 of mode S, so as to carry out trouble diagnosis.

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value in

The
1 counterbalance Maybe the backpressure valve fails. Please inspect it.
valve fails
The slewing
2 motor (safety Maybe the safety valve in slewing motor fails. Please inspect it.
normal state

valve) fails
Maybe the sealing element of oil replenishing valve in slewing motor fails. Please
The slewing inspect the sealing element.
3 motor (oil filling
★ Interchange the left and right oil replenishing valves, on the basis of the result
valve) fails
determine sealing element whether fails.
Maybe the slewing mechanical device is in trouble. Please inspect the inside of
The slewing
mechanical device.
4 mechanical
★ The trouble in slewing device can be determined through internal abnormal noise,
device fails
abnormal heating, or emission of metal powder or debris in oil.

7-74 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Trouble Diagnosis

7.8.24 H-24 THE NATURAL DRIFTING OF SLEWING IS TOO LARGE

Trouble information
 The natural drifting during slewing is too large (when the parking brake acts).
(1)
 When the slewing is carried out and the parking brake acts, the slewing will be locked by
Relevant information
disc brake.

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes

value in normal
and standard

The slewing brake

Maybe the slewing braking control pipeline and rake leading valve are in
1 control pipeline
state

trouble. Please inspect them.

has trouble
The slewing motor
2 (parking brake) Maybe the park unit of slewing motor fails or is in trouble. Please inspect it.
fails

Trouble information (2)  The natural drifting during slewing is too large (when the parking brake is released).

 The slewing and parking brake is released, and the slewing can only be held by
Relevant information
hydraulic pressure.

Causes Standard value in normal state and reference value for trouble diagnosis
Estimated causes and standard value

The slewing
control valve Maybe the sealing element of valve core in slewing control valve fails. Please
1
(valve core) inspect it.
fails
in normal state

The slewing
motor
Maybe the sealing element of overflow valve in slewing motor fails. Please
2 (overflow
inspect it.
valve) has
trouble
The slewing
motor (oil It is possible that the seal of the makeup valve in the rotary motor fails. Therefore,
3
filling valve) check it.
has trouble

Maintenance Manual - 01 - 2021 7-75

 SY135F Hydraulic Forestry Crane Disassembling and Assembling

Disassembling and Assembling

8. Disassembling and Assembling ........................................................................... 8-1
8.1 How to read this Manual ................................................................................................. 8-5
8.2 Notices for Operation ...................................................................................................... 8-5
8.3 Schematic diagrams of special tools ............................................................................... 8-8
8.4 Dismantlement and installation of radiator assembly....................................................... 8-9
8.5 Dismantlement and installation of engine and hydraulic pump assembly ...................... 8-10
8.6 Unfolding and Installation of Track Shoe Assembly ....................................................... 8-13
8.7 Dismantlement and installation of driving wheel ............................................................ 8-16
8.8 Dismantlement and installation of final transmission assembly ..................................... 8-16
8.9 Disassembling and assembling of guiding wheel assembly .......................................... 8-18
8.10 Assembling ................................................................................................................... 8-19
8.11 Disassembly and Assembly of Tension Spring .............................................................. 8-22
8.12 Assembling ................................................................................................................... 8-23
8.13 Disassembly and Assembly of Track Roller/Sprocket Assembly .................................... 8-25
8.14 Disassembling and assembling of slewing motor and slewing mechanism assembly.... 8-26
8.15 Assembling ................................................................................................................... 8-30
8.16 Dismantlement and installation of slewing motor and slewing mechanism assembly .... 8-34
8.17 Dismantlement and installation of central slewing joint assembly .................................. 8-36
8.18 Disassembling and assembling of Central Back slewing Joint Assembly ...................... 8-37
8.19 Dismantlement and Installation of Working Device Assembly ....................................... 8-38
8.20 Dismantlement and installation of slewing table assembly ............................................ 8-41
8.21 Dismantlement and Installation of Back slewing Bearing Assembly .............................. 8-44
8.22 Dismantlement and Installation of Hydraulic Oil Tank Assembly .................................... 8-46
8.23 Dismantlement and Installation of Control Valve Assembly ........................................... 8-48
8.24 Dismantlement and installation of hydraulic pump assembly......................................... 8-51
8.25 Dismantlement and installation of hydraulic pump input shaft oil seal ........................... 8-54
8.26 Disassembling and assembling of manual pilot valve assembly .................................... 8-54
Maintenance Manual - 01 - 2021 8-1
Disassembling and Assembling SY135F Hydraulic Forestry Crane

8.27 Disassembly and Assembly of Travel Pilot Valve Assembly .......................................... 8-56
8.28 Disassembling and assembling of hydraulic cylinder assembly .................................... 8-57
8.29 Dismantlement and installation of balance weight assembly ........................................ 8-66
8.30 Dismantlement and installation of cab assembly .......................................................... 8-68
8.31 Dismantlement and installation of cab glass ................................................................. 8-72
8.32 Dismantlement and installation of front window assembly ............................................ 8-88
8.33 Dismantlement and installation of display screen ......................................................... 8-96
8.34 Dismantlement and installation of controller assembly ................................................. 8-96
8.35 Radio ........................................................................................................................... 8-97
8.36 Storage battery........................................................................................................... 8-100
8.37 Key switch .................................................................................................................. 8-102
8.38 Fuse box .................................................................................................................... 8-105
8.39 Wiper ......................................................................................................................... 8-106
8.40 Relay .......................................................................................................................... 8-109
8.41 Sensor ........................................................................................................................ 8-112
8.42 Installation and dismantlement methods for terminal of plug-in part ............................ 8-112

8-2 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

Maintenance Manual - 01 - 2021 8-3

Disassembling and Assembling SY135F Hydraulic Forestry Crane

Warning
Please read and fully understand the precautions in this Manual and described in the safety
nameplate on the machine. When operating or repairing the machine, please follow those
precautions strictly; otherwise, the wrong operation might lead to machine damages or personal
injuries.

8-4 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Disassembling and Assembling

8. DISASSEMBLING AND ASSEMBLING

8.1 How to read this Manual
Dismantlement and installation of assembly
Special tools
 The special tools for dismantling and installing the parts are listed.
 The necessity of tools is stated in the directory of special tools:
■: Special tool which can’t be substituted and must be used
●: It's a very important tool. Replace the disassembly of parts with a purchased tool.
 The contents in the section “Dismantlement” include steps, notices and amount of oil or water
to be drained.
 The symbols used in the section “Dismantlement” and their meanings are detailed as follows:
This symbol indicates the relevant safety notices which must be complied with during work.
★ This symbol indicates the methods and notices for operation.
This symbol indicates the relevant provisions and notices which must be complied with during
installation of parts.
This symbol indicates the amount of oil or water to be drained.

Installation of parts
 Unless otherwise specified, the installation sequence of parts is the reversed dismantlement
sequence.
 The marks used in the chapter "Installation" indicate the relevant regulations and
precautions for the installation of parts.
 The symbols used in the section “Installation” are detailed as follows:
This symbol indicates the relevant safety notices which must be complied with during work.
★ This symbol indicates the relevant guidelines and notices for operation.
This symbol indicates the specified coating to be used.
This symbol indicates the lubricant to be used.
This symbol indicates the specified torque.

This symbol indicates the amount of oil or water to be filled.

8.2 Notices for Operation

Notices for Operation
When dismantling or installing device, please comply with the following notices.
1. Notices for Dismantlement
 If the engine coolant contains anti-freezing agent, please dispose of it correctly.

Maintenance Manual - 01 - 2021 8-5

 Disassembling and Assembling SY135F Hydraulic Forestry Crane

 After disconnecting a hose or steel pipe, please cover it or mount a blind plug in it, so as to
avoid the entry by dirt or dust.
 When draining the oil, please prepare an appropriate container to collect the oil.
 Before the dismantlement, please leave the mating marks on necessary locations, so as to
prevent mistake during re-assembling.
 Avoid loosening the contact point of the wire and do not pull the wire. To avoid excessive
stress on the wire, hold the connector when removing the wire.
 Attach labels to the wires and hoses to determine the installation position to avoid errors in
the re-installation.
 Record and inspect the number of gaskets of different thickness, and store them in a safe
place.
 When lifting up a component, the lifting equipment selected shall have sufficient capacity and
safety.
 When using the thrust screws to dismantle the component, please evenly tighten up the
screws in order.
 Before dismantling a device, please clean up the surrounding area. After the dismantlement,
please cover the device, so as to prevent dust or dirt from entering it.
★ Notices for Handling of Pipeline during Disassembling
During disassembling operation, after a pipeline id disconnected, please mount the following blind
plugs into pipes.
A． Use the threaded hose
Inner diameter of hose (mm) Code Name
Light thread connect
6 B210780001189 End plug of pipe
8 B210780001190 End plug of pipe
10 B210780000077 End plug of pipe
12 B210780000078 End plug of pipe
15 B210780000883 End plug of pipe
20 B210780000079 End plug of pipe
22 60056667 End plug of pipe
Heavy thread connect
12 B210780001142 End plug of pipe
16 60002397 End plug of pipe
20 B210780000080 End plug of pipe
25 B210780000081 End plug of pipe

B. Use the threaded transition connector (The front and rear parts form a set)
Inner diameter of Code Name Code Name

8-6 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Disassembling and Assembling

hose (mm)
Light thread connect
6 B210780000903 Bevel hole plug 23002925 Nut
8 B210780001146 Plug B210770000011 Nut
10 B210780000088 Plug B210334000011 Nut
12 B210780000089 Plug B210334000012 Nut
15 B210780000882 Plug B210334000004 Nut
20 B210780000090 Plug B210334000010 Nut
22 B210780000091 Plug B210780000112 Nut
Heavy thread connect
12 B210780001143 Plug B210780000406 Nut
16 A820205001523 Plug B210780000405 Nut
20 B210780000902 Plug B210780000904 Nut
25 B210780001172 Plug B210334000006 Nut

2. Notices for Installation

 Tighten up all bolts and nuts (sleeve nut) to the specified torque.
 During installation, the hose may not be twisted or interfered with.
 The bushing, O-ring, split pin and locking plate shall be replaced with new ones.
 Firmly bend the split pin or locking plate.
 Before applying the adhesive, please clear away the oil and dust on parts so as to ensure that
the part is clean, and then drip two or three drops of adhesive on thread.
 Before applying the gasket sealant, please clear away the oil and dust on surface, and inspect
whether there is dirt or damage, and then even apply the gasket sealant.
 Clear away the damage, dent, burr or rust from parts.
 Apply the engine oil onto rotating parts and sliding parts.
 When installing any snap ring, please inspect whether the snap ring is correctly installed in
groove.
 Before connecting any wire connector, please clear away the oil, dirt or water on connector,
and then connect it firmly.
 Before using any eye bolt, inspect whether the eye is deformed or deteriorated, and then fully
screw it in and align it with lifting hook.
 When tightening up any split flange, please evenly tighten it up in order, so as to prevent it
from being excessively tightened up on one side.
★ After the cylinder, main pump or hydraulic equipment which has been repaired is re-assembled,
when the hydraulic cylinder is operated for the first time, it is necessary to bleed the air. The
operation is detailed as follows:
 1. Start the engine and run at low idle.
 2. Operate the operating lever of the operating device to make the hydraulic cylinder move
Maintenance Manual - 01 - 2021 8-7
 Disassembling and Assembling SY135F Hydraulic Forestry Crane

back and forth for 4-5 times.

 3. Operate the hydraulic cylinder 3-4 times continuously to the end of its stroke.
 4. After the operation, the engine can run at the normal speed.
★ When this machine is used for the first time after being repaired or stored for long time, please
follow the same procedure.
3. Notices for Completion of Operation
 After draining the engine coolant, please tighten up the drain valve, and fill the coolant to the
specified level. Run the engine so as to make the coolant circulate in system, and then inspect
the level again.
 After dismantling and then installing the hydraulic equipment, please fill the hydraulic oil to the
specified oil level. Run the engine so as to make the hydraulic oil circulate in system, and then
inspect the oil level again.
 After dismantling, repairing and re-installing any pipe or hydraulic equipment, please bleed the
air from system.
 Please refer to the contents about air bleeding in the Section “Testing and Adjustment”.
 Add the grease (molybdenum disulfide grease) of specified amount into relevant component
of working device.

8.3 Schematic diagrams of special tools

Note: Sany shall not be held liable for special tools manufactured in accordance with these
schematic diagrams.
Pushing & installing tool

Figure 8-1

8-8 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

8.4 Dismantlement and

installation of radiator
assembly
Dismantlement
1. Remove the bottom cover and drain 19L of
the coolant.
2. Disconnect the radiator outlet hose (1) and
remove the four mounting bolts (2).

Figure 8-2
3. Remove the four bolts (3), remove the
hydraulic oil inlet flexible connector (4) and
the flexible outlet connector (5), plug the
interface to prevent the hydraulic oil
leakage in the hydraulic system, and drain
the hydraulic oil in the hydraulic oil radiator.

Figure 8-3
4. Remove the four fixing bolts (6) from the air
conditioning condenser and then the
condenser.

Figure 8-4

Maintenance Manual - 01 - 2021 8-9

Disassembling and Assembling SY135F Hydraulic Forestry Crane

5. Disconnect the engine outlet pipe (7).

Figure 8-5
6. Remove the radiator fan shroud (8) and the
two retaining rods (9).
7. Lift the radiator assembly.
★ Be careful not to damage the radiator core.
Radiator assembly: 95 kg
8. Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.
 Re-fill the coolant
Fill coolant from the injector to the specified Figure 8-6
level. Run the engine so that the coolant
circulates through the system. Then check the
coolant level again.
Coolant: 19 L

8.5 Dismantlement and

installation of engine and
hydraulic pump assembly
Dismantlement
Lower down the working device onto ground so
as to ensure safety, turn off the engine, and
dismantle the cable from negative pole (-) of
battery.
Screw off the butterfly nut of breather valve, and
press down the air bleeding button, so as to
release the internal pressure.
★ Mark the pipeline, so as to avoid mistake
during re-installation.

8-10 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

1. Remove the oil suction filter element of the

hydraulic oil tank and block the oil outlet
with the tool D.
★ When the tool D is not used, remove the
drain plug and drain the oil from the hydraulic
tank.
Hydraulic oil tank: 150 L
2. Drain the engine coolant.
Coolant: about 19 L
3. Remove and plug the fuel pipeline. Figure 8-7

4. Remove the bottom cover, drain the

antifreeze, and remove the top hood (1).
Hood assembly: 30 kg

Figure 8-8
5. Remove the cover plates (2) - (4).

Figure 8-9
6. Remove the hydraulic oil pipes (5) - (10).

Maintenance Manual - 01 - 2021 8-11

Disassembling and Assembling SY135F Hydraulic Forestry Crane

Figure 8-10
7. Remove the throttle cable (11), flameout
cable (12) and two fuel pipes (13).

Figure 8-11
8. Remove the external cable (14) and ground
wire (15) from the starting motor.

Figure 8-12
9. For the machine with air conditioner,
remove the air conditioning compressor
assembly and bracket (16), external cable
(17), and cold/hot water pipe (18) of air
conditioner.

Figure 8-13
10. Remove the speed sensor external cable
(19) and two oil pipes (20).

8-12 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

Figure 8-14
11. Remove the external cable (19) of the
speed sensor, and then the two oil pipes
(20).

Figure 8-15
12. Remove the four engine foot bolts (26) and
lift the engine and main pump.
Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.
 Re-fill the coolant
Refill coolant to the radiator and storage tanks.
Run the engine so that the coolant circulates
through the system. Then check the coolant
level again. Figure 8-16

Coolant: 19 L
 Re-filling of hydraulic oil
Refill the hydraulic oil from the filling port to the
specified oil level, and run the engine to circulate
the oil in the hydraulic system. Then check the
oil level again.
Hydraulic oil: 150 L
 Bleed off the air
Refer to the chapter "Testing and Adjustment" in
this manual.

8.6 Unfolding and Installation of

Track Shoe Assembly
Special tools

Maintenance Manual - 01 - 2021 8-13

Disassembling and Assembling SY135F Hydraulic Forestry Crane

Special tools
Mark Part name Necessity Quantity
Hydraulic crawler
M dismantling/installi ●
1
ng machine

Unfold
1. Stop the machine so that the kingpin is
midway between the idler and track roller
and the track shoes can be deployed
forward and backward.
2. Lower the operating device to the ground Figure 8-17
and loosen the grease fitting (1) to release
the track.
The cylinder is under very high pressure. Don’t
screw off the oil nozzle for more than one round.
If no oil flows out, please move this machine
forwards and backwards.
3. Use the tool M to pull out the main pin (2).

Figure 8-18
4. Dismantle the tool M, move forwards this
machine until the temporary pin ② is located in
front of guiding wheel, and then place the
cushion block ①.
5. Remove the temporary pin (2), remove the
dust seal, and then drive the machine backward
to unfold the track (3).

8-14 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

Figure 8-19
Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.
1. Adjust the tension of the track shoes. For
details, refer to the inspection and
adjustment of track shoe tension in the
chapter “Testing and Adjustment”.
2. Press the kingpin with the tool M so that the
protrusion A is as follows:
Dimension a: 3 ± 1 mm a
3. ★ When pressing the dust seal, apply Figure 8-20
grease (No. 3 lithium grease) on the side
opposite to the bushing.
★ Install the track shoes as shown in the right
figure. (the arrow points to the front of the
machine)

Figure 8-21

Maintenance Manual - 01 - 2021 8-15

Disassembling and Assembling SY135F Hydraulic Forestry Crane

8.7 Dismantlement and

installation of driving wheel
Dismantlement
1. Unfold the track shoe assembly. Refer to
"Unfolding of Track Shoe Assembly" for
details.
2. Turn the operating device 90°and jack up
the machine, then put the cushion block [1]
between the track frame and the track shoe.
3. Remove 15 mounting bolts and remove the
drive wheel (1).
★ Use a rod through the bolt hole of the drive
wheel to lift the sprocket.
Driving wheel: 38.7 kg
Figure 8-22
Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.
Thread of drive wheel mounting bolt: thread
sealant (TONSAN 1277)
Driving wheel mounting bolt: 279 ±30 N·m {28.5
± 3.1 kgf·m}

8.8 Dismantlement and

installation of final
transmission assembly
Dismantlement
1. To remove the drive wheel, refer to the
section "Removal of Drive Wheel" in this
manual. Lower the operating device to the
ground to ensure safety, shut down the
engine, and press the breathing valve to
release the internal pressure.

8-16 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

2. Dismantle the motor cover plate (1).

Figure 8-23
3. Remove the four operating motor hoses (2)
- (5) and their connected fittings.

Figure 8-24
4. Remove 20 mounting bolts from the final
drive assembly (6) and remove the final
drive assembly.
★ Be careful not to damage the surface of the
hose seat pressure seal.
★ Do not use threaded holes to lift the final
drive assembly.
Final drive assembly: 144 kg
Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence. Figure 8-25

Mounting bolt of final drive assembly: 279 ± 30

N·m{28.5±3.1 kgf·m}
 Re-filling of hydraulic oil
Refill hydraulic oil from the oil filling port to the
specified oil level, and start the engine to
Maintenance Manual - 01 - 2021 8-17
Disassembling and Assembling SY135F Hydraulic Forestry Crane

circulate the oil in the hydraulic system. Then

check the oil level again.
 Bleed off the air
Exhaust the air. For details, see Exhaust Air
from Each Part in the chapter “Testing and
Adjustment”.

8.9 Disassembling and

assembling of guiding
wheel assembly
Disassembling
1. Dismantle the locating pin (1) and support
(2).
2. Remove the floating seal (3) from the
support (2) and the idler (4).
3. Dismantle the O-ring (11), and then
dismantle guide wheel (4) from shaft (5)
and support assembly (7).
★ There is 90 ml of oil in the guide wheel,
which should be drained before
decomposition. To prevent soiling the floor, lay a
layer of cloth on the floor.
Figure 8-26
4. Dismantle the floating seal (6) on the other
side from guide wheel (4), shaft (5) and
support assembly (7).

Figure 8-27

8-18 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

5. Remove the locating pin (8) so as to

remove the support (7) from the shaft (5).
6. Dismantle the bushing (4) and (9) from
guide wheel (10).

Figure 8-28

8.10 Assembling
1. Press the bushings (9) and (10) in to guide
wheel (4).

Figure 8-29
2. Assemble the O-ring, and use the locating
pin (8) mount the support (7) onto shaft (5).

Figure 8-30

Maintenance Manual - 01 - 2021 8-19

Disassembling and Assembling SY135F Hydraulic Forestry Crane

3. Mount the floating seal (6) onto the

assembly of guide wheel (4), shaft (5) and
support (7).
★ Floating Seal
Before installing the floating seal, please fully
clear away the grease on contact surface of O-
ring and floating seal (dashed area in figure). In
addition, don’t let any dust stick to the contact
surface of floating seal.

Figure 8-31
★ After installing the floating seal, make sure
that the inclination of seal is less than 1 mm, and
the protrusion a of seal is 5-7 mm.

Figure 8-32
4. Mount the shaft (5) & support (7) assembly
onto guide wheel (4).

Figure 8-33

8-20 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

5. Mount the floating seal (3) onto guide wheel

(4) and support (2).
★ Apply the oil onto sliding face of floating
seal, and don’t let any dirt or dust stick onto it.
★ Remove oil and dust from contact surfaces
of O-ring and floating seal.

Figure 8-34

Figure 8-35
6. Install the O-ring, and then use the locating
pin (1) to install the support (2).
7. Add the oil and screw in the screw plug.
Oil: about 90 mL (No. 18 hyperbolic gear oil)
Plug: 205.8±49 N•m {21±5 kgf·m}

Figure 8-36

Maintenance Manual - 01 - 2021 8-21

 Disassembling and Assembling SY135F Hydraulic Forestry Crane

8.11 Disassembly and Assembly

of Tension Spring
Special tools
Necessi Quantit
Mark Part name
ty y
Compressor ■ 1
Spacer ring ■ 1
1 Extension rod ■ 1
Cylinder ■ 1
Pump ■ 1
J
Kit for push
●
tool 1

2 Plate 1
Handle 1
Bolt 1

Dismantlement
1. Remove the locking plate (1), seat (2), and
valve (3).
2. Piston assembly
Remove the piston assembly (5) from the
tension spring assembly (4).

Figure 8-37

8-22 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Disassembling and Assembling

3. Disassembling of Tensioning Spring

Assembly
1) Install the tool J1 to the tension spring
assembly (4).
Because the installed load of the spring is large
and dangerous, it is necessary to install the
spring firmly.
★ Installation load of spring: 84,340 N{8,600
kgf}
2) Gradually apply hydraulic pressure to press
the spring and remove the nut (6). Figure 8-38
★ Press the spring until the nut is loosened.
★ Gradually release the hydraulic pressure to
completely reduce the spring tension.
★ Free length of spring: 501.4 mm
3) Remove the guide sleeve (8), the cylinder
(9) and the dust seal (10) from the spring
(7).
4. Disassembling of Piston Assembly
1) Remove the wear ring (12) from the piston
(11).
2) Remove the snap ring (13) and the U-ring
(14).

8.12 Assembling

Figure 8-39

Maintenance Manual - 01 - 2021 8-23

Disassembling and Assembling SY135F Hydraulic Forestry Crane

1. Assembly of piston assembly

1) Install the U-ring (14) on the piston (11) and
fix it with the snap ring (13).
2) Install the wear ring (12).
2. Assembly of tension spring assembly
1) Install the dust seal (10) onto the cylinder
(9) with the tool J2.
2) Install the cylinder (9) and the guide sleeve
(8) onto the spring (7) and then onto the tool
J1. Figure 8-40

Sliding parts of oil cylinder: grease (G2-LI)

3) Gradually apply hydraulic pressure to press
the spring, and then tighten the mounting
length nut (6) of the spring to a.
★ Installation length A of spring: 390 mm
4) Remove the tension spring from the tool J1.
3. Piston assembly
Install the piston assembly (5) onto the tension
spring assembly (4). Figure 8-41
Sliding surface of piston: grease (G2-LI)
Wear ring: grease (G2-LI)
★ Install the piston assembly so that the valve
can be installed outside the machine.
★ Inject 120 mL of grease (G2-LI) at least into
the cylinder and exhaust, and then check
whether the grease is extruded from the grease
hole.

Figure 8-42

8-24 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

8.13 Disassembly and Assembly

of Track Roller/Sprocket
Assembly
Special tools
Necessit
Mark Part name Quantity
y
2 Installer ■ 1
L
4 Oil pump ● 1

Disassembling
★ Refer to the right figure and disassemble
the track roller/sprocket assembly.
Assembling
★ Refer to the right figure and assemble the
track roller/sprocket assembly.
★ In this section, only the precautions for
assembling
the track/carrier roller assembly are explained.
For the items not explained below, refer to
Figure 8-43
"Assembly Procedure of Idler Assembly".
★ Install the floating seal with the tool L2.
★ The O-rings and floating seals (5) and (6)
(opening) should be degreased and dried
thoroughly before the installation. Be careful not
to contaminate the contact surface of the
floating seal.
★ After installing the floating seal, check
whether the inclination is less than 1 mm and
whether the protrusion A is 5-7 mm.
★ Fill oil with the tool L4 into the track
roller/sprocket assembly, and then tighten the Figure 8-44
plug (11).
Track roller: 75-85 mL (EO30-CD)
★ Tighten the mounting bolts of the track
roller/sprocket to the following torques.
Mounting bolts: adhesive
Mounting bolts: 279±30 N·m{28.5±3.1 kgf·m}

Maintenance Manual - 01 - 2021 8-25

Disassembling and Assembling SY135F Hydraulic Forestry Crane

8.14 Disassembling and

assembling of slewing
motor and slewing
mechanism assembly
Disassembling
1. Drainage of oil
Screw off the drain plug, and drain the oil from
slewing mechanism box.
Slewing mechanism box: about 1.2 L
2. Back slewing motor assembly
1) Place the slewing motor and slewing
mechanism assembly onto carrier, and
don’t get the driving gear damaged or
contact with ground.
2) Remove 14 mounting bolts and then the
rotary motor assembly (1). Rotary motor Figure 8-45
assembly: 29 kg
3. Sun gear 1
Dismantle the sun wheel 1 (2).

Figure 8-46
4. Planet carrier assembly 1
1 Remove the planet carrier assembly 1 (3)
and backing plate (4).
2) When disassembling No. 1 planet carrier,
first shave off the riveted part on the shaft
(8), remove the shaft (8), and take out the
gear (6), bearing (9), and backing plate (7)
in turn.

Figure 8-47

8-26 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

Figure 8-48
5. Tooth ring
Dismantle the fixing bolt and dismantle the tooth
ring (10).

Figure 8-49
6. Sun gear 2
Dismantle the fixing bolt and dismantle the tooth
ring (10).

Figure 8-50

Maintenance Manual - 01 - 2021 8-27

Disassembling and Assembling SY135F Hydraulic Forestry Crane

7. Planet carrier assembly 2

1) Dismantle the planet carrier assembly 1
(12).
2) Manually disassemble the planet carrier
assembly 2 in accordance with the
following method.
1) Knock in the pin (13) until it fully enters
the shaft (14), and push out the shaft
(14) from planet carrier (19).
★ After dismantling the shaft, pull out the
pin (13).
Figure 8-51
2) Dismantle the thrust washer (16), gear
(17), thrust washer (19).
3) Knock in the pin (15) from shaft,
remove the bearing (18), and pull out
the pin (15).

Figure 8-52
8. Snap ring
Dismantle the snap ring (20).

Figure 8-53

8-28 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

9. Disassembling of main shaft Press out

1) Place the shaft housing assembly on press

machine, and push out the shaft assembly
(21) from shaft housing assembly (22).
2) Disassemble the shaft assembly as follows.
Remove the bearing (23) from the shaft
(24).

Figure 8-54
Press out

Figure 8-55
10. Bearing
Take out the bearing (25) and oil seal (26) from
housing (27).

Figure 8-56

Maintenance Manual - 01 - 2021 8-29

Disassembling and Assembling SY135F Hydraulic Forestry Crane

8.15 Assembling
★ Clean up all parts, inspect whether any part
is dirty or damaged, and apply the engine oil
onto sliding surface of parts before assembling.
1. Bearing
Press the bearing (23) into housing (27).

Figure 8-57
2. Oil seal
Press the oil seal (26) into housing (27).
Installation surface of oil seal: gasket sealant
(Loctite 515).

Figure 8-58
3. Housing assembly
1) Place the plate (28) on shaft (24).
2) Place the housing assembly (22) on shaft
(24), and press in the bearing.

Figure 8-59

8-30 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

4. Bearing
Press in the bearing (25).
★ When pressing in the bearing, please
simultaneously press the inner and outer rings
of bearing, and don’t press the inner ring only.
★ After pressing the bearing, inspect whether
the housing can rotate smoothly.

Figure 8-60
5. Planet carrier assembly 2
Re-assemble the planet carrier 2 in accordance
with the following method.
1. Assemble the backing plate (16) into the
planet carrier (19).
2. Place the gear (17) into planet carrier (19).
Put the bearing (18) onto shaft (14), align
the pin hole, gently knock in the pin (15)
with rubber hammer, and make sure that
the pin (15) is not higher than bearing (18).
3. Push the shaft assembly into planet carrier Figure 8-61
(19), and don’t damage the gear and
backing plate. Align the pin holes on shaft
and planet carrier, install pin (13), and use
a rubber hammer to carefully knock them in.
★ When installing the shaft, please turn the
planet wheel. Please don’t damage the thrust
washer.
6. Mount the snap ring (20), planet carrier 2 Planet carrier 2
and sun wheel 2 (11) in order.

Maintenance Manual - 01 - 2021 8-31

Disassembling and Assembling SY135F Hydraulic Forestry Crane

Figure 8-62
7. Mount the tooth ring
Apply the sealant onto the mating face as
indicated by C, and then fix it with screw. Be
sure not to apply the sealant onto tooth ring (10).
Mating face: sealant (Loctite 515).

Figure 8-63
8. Planet carrier assembly 1
1) Assemble the planet carrier 1 in
accordance with the following method.
1) Place the backing plate (7) on planet
carrier (5).
2) Mount the bearing (9) onto gear, and
then place the gear (6) on backing
plate.
3) Press in the shaft (8) into gear (6) and
planet carrier (5), and rivet one end of
shaft.
★ Inspect whether the gear can rotate Figure 8-64
smoothly.
2) Install No. 1 planet carrier assembly (3) and
the backing plate 4.

Figure 8-65

8-32 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

9. Sun wheel assembly 1

Install the sun gear 1 (2).

Figure 8-66
10. Install the back slewing motor assembly
After applying the sealant onto contact faces of
tooth ring and motor cover, install the slewing
motor assembly.
Mating face: sealant (Loctite 515)
Back slewing motor assembly: 29 kg
Mounting bolt of rotary motor: 108 ± 5 N·m {11 ±
0.5 kg}
★ The 14 mounting bolt holes of the rotary
motor and rotary mechanism assembly are
distributed unevenly, and the matching direction
is unique as shown in the right figure. When
installing the rotary motor, align with the
threaded hole to ensure the installation
direction.
11. Re-filling of lubricating oil
Screw in the drain plug and re-fill the lubricating
oil via oil filling port to the specified oil level (high
level mark on oil dipstick).
Slewing mechanism box: about 1.2 L

Figure 8-67

Maintenance Manual - 01 - 2021 8-33

Disassembling and Assembling SY135F Hydraulic Forestry Crane

8.16 Dismantlement and

installation of slewing
motor and slewing
mechanism assembly
Dismantlement
Release the residual pressure in hydraulic oil
way. For relevant details, please refer to the
contents about release of residual pressure in
hydraulic oil way in the Section “Testing and
Adjustment”.
Lower down the working device onto the ground
in a stable posture, and set the locking rod at the
locking position.
1. Disconnect the hoses (1) - (6).
2. Remove eight mounting bolts (7).

Figure 8-68
3. Use the thrust screw [1] to dismantle the
slewing motor and slewing mechanism
assembly (8).
★ Make sure that the assembly will not
interfere with hose.
Back slewing motor and back slewing
mechanism assembly: 109 kg
Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.
Mounting bolt: 245-308.7 N·m {25-31.5kgf ·m} Figure 8-69

 Re-fill the oil (hydraulic oil tank)

★ Fill the oil vial oil filling port to the specified
oil level. Run the engine so as to make the oil
circulate in the system, and then inspect the oil
8-34 Maintenance Manual - 01 - 2021
SY135F Hydraulic Forestry Crane Disassembling and Assembling

level again.
 Bleed off the air
★ Exhaust the air in the oil circuit. For details,
see Exhaust from Each Part in the chapter
"Testing and Adjustment".

Maintenance Manual - 01 - 2021 8-35

Disassembling and Assembling SY135F Hydraulic Forestry Crane

8.17 Dismantlement and

installation of central
slewing joint assembly
Dismantlement
Release the residual pressure in hydraulic oil
way. For relevant details, please refer to the
contents about release of residual pressure in
hydraulic oil way in the Section “Testing and
Adjustment”.
★ All pipelines shall be attached with label so
as to prevent incorrect installation position.
1. Remove the pin (1) and then the rod (2).
2. Disconnect the hose (3) - (12).

Figure 8-70

Figure 8-71
3. Remove the bottom cover.
4. Disconnect the hose (13) - (14).
5. Remove the elbow.
6. Temporarily lift up the central slewing joint
assembly.
7. Remove the four mounting bolts (15).
8. Dismantle the central slewing joint
assembly (16).
Central rotary joint: 48.9 kg Figure 8-72
Installation
 Carry out the installation in accordance with

8-36 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Disassembling and Assembling

the reversed dismantlement sequence.

 Re-fill the oil (hydraulic oil tank)
★ Fill the oil vial oil filling port to the specified
oil level. Run the engine so as to make the oil
circulate in the system, and then inspect the oil
level again.
 Bleed off the air
★ Exhaust the air in the oil circuit. For details,
see Exhaust from Each Part in the chapter
"Testing and Adjustment".

8.18 Disassembling and assembling of Central Back slewing Joint

Assembly
Special tools
Mark Part name Necessity Quantity
C Pushing/pulling tool ● 1

Disassembling

Figure 8-73

Maintenance Manual - 01 - 2021 8-37

Disassembling and Assembling SY135F Hydraulic Forestry Crane

1. Remove the cover (3).

2. Remove the gasket (6).
3. Pull the swivel (1) and gasket (5, 6) out of
the rotating shaft (2) with the tool C.
4. Remove the O-rings (9, 10) and the sliding
seals (7) from the rotor.
Assembling
1. Install the sliding seal (7) and the O-rings
(9, 10) to the rotor.
2. Place the rotating shaft (2) on the block.
Figure 8-74
Use the push tool and gently tap the rotor
(1) with a plastic hammer to install the
rotating shaft. Contact surface of rotor and
shaft: sealant (Loctite 515)
★ When installing the rotor, pay special
attention not to damaging the sliding seal and O-
ring.
3. Install the gaskets (5, 6) and fix with the
snap ring (11).
4. Mount the O-ring and install the cover (3).
Fixing bolt: 177 N·m{18.06 kgf·m}

8.19 Dismantlement and

Installation of Working
Device Assembly
Dismantlement
Fully extend the grab arm and bucket, lower
down the working device onto ground, and set
the safety locking rod at locking position.
Release the residua pressure in hydraulic
circuit. Please refer to the contents about
release of residual pressure in hydraulic oil way
in the Section “Testing and Adjustment” in this
Manual.

8-38 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

1. Disconnect the grease pipe (1).

2. Lift up the boom cylinder assembly (2), and
dismantle the locking bolt (3).
3. Remove the retaining sleeve (4) and then
remove the pin (5).
★ Since there are gaskets, please inspect the
number and thickness of gasket, and store them
in a safe place.
4. Start up the engine and retract the piston
rod.
★ Use a steel wire rope to fix the piston rod to Figure 8-75
prevent it from sliding off, and lower down the
cylinder onto bench or place a support under
cylinder so as to support up the oil cylinder. In
the latter case, firstly dismantle the grease pipe
joint on bottom.
★ Dismantle the boom cylinder on the other
side in accordance with the same method.
5. Dismantle the bucket cylinder hoses (6), (8)
and grab arm cylinder hoses (7), (9).
★ Block up the hose so as to prevent the oil
from flowing out, and fix it on one side of valve.
6. Dismantle the middle connector a (10) for
working light.

Figure 8-76
7. Lift the operating device, remove the plate
(11) and then the bottom pin (12).
★ Since there are gaskets installed, please
don’t forget to inspect the number and
installation positions of gaskets.

Figure 8-77

Maintenance Manual - 01 - 2021 8-39

Disassembling and Assembling SY135F Hydraulic Forestry Crane

8. Lift the operating device assembly (13) and

disassemble it.
Operating device assembly: 1940 kg

Figure 8-78
Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.
★ When tightening the lock nut, the clearance
a between the fixing sleeve and the nut should
be 0.5 - 1.5 mm.
Fill grease after assembling the pin: never insert
your finger into the pin hole when aligning
grease (molybdenum disulfide lithium base
grease) with the pin hole.

Figure 8-79
★ Adjust the thickness of the gasket so that
the clearance a between the piston rod head
(14) and the fixing sleeve (4) of the cylinder
meets the requirements of 0.5 < a < 1 mm.
 Thickness of standard gasket: 0.5
mm。
Fill grease after assembly: grease (molybdenum
disulfide lithium base grease)
When aligning the pin hole, be sure not to insert
your finger into the pin hole.
★ Use gaskets to adjust the clearance (a) Figure 8-80
between the boom (15) and the frame (16) to
less than 0.5 mm.

8-40 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

To less than 0.5mm.

 Standard thickness of gasket: 0.5 mm - 1.0
mm.
 Supplement hydraulic oil
Add the hydraulic oil to the specified oil level,
start up the engine so make the oil circulate in
hydraulic system, and then inspect the oil level
again and add the hydraulic oil.
 Bleed off the air
Bleed the air from travelling motor. Please refer
to “Air Bleeding for Every Device” in the Section Figure 8-81
“Testing and Adjustment” in this Manual.

8.20 Dismantlement and

installation of slewing table
assembly
Dismantlement
Fully extend the grab arm and bucket, lower
down the working device onto ground, and set
the safety locking rod at locking position.
1. Dismantle the working device assembly.
Please refer to “Dismantlement and
Installation of Working Device Assembly” in
this Manual.
2. Dismantle the balance weight assembly.
Please refer to the Section “Dismantlement
of Balance Weight Assembly” in this
Manual.
3. Dismantle the 4 boom cylinder hoses (1) -
(4).
★ Label every disconnected hose, so as to
prevent mistake during re-installation.

Figure 8-82

Maintenance Manual - 01 - 2021 8-41

Disassembling and Assembling SY135F Hydraulic Forestry Crane

4. Lift up the boom cylinder assembly (5).

Figure 8-83
5. Dismantle the plate (6) and pin (7), and then
dismantle the boom cylinder assembly (5).
★ Dismantle the boom cylinder assembly on
the other side in accordance with the same
method.

Boom cylinder assembly: 107 kg

6. Dismantle the pin (8) from central slewing

joint.

Figure 8-84
7. Disconnect the hoses (9) - (14).
8. Temporarily lift up the slewing table
assembly (15).

Figure 8-85

8-42 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

★ If the slewing table assembly interferes with

sling, please move or dismantle the sling.
9. Dismantle the 36 fixing bolt and dismantle
the slewing table assembly (15).
★ Leave 2-3 mounting bolts at the front and
rear of the turntable, and use horizontal
cushion block to adjust the balance of the
turntable in all directions. Then, remove the
mounting bolts.
When dismantling the slewing table
assembly, ensure that it will not interfere with
central slewing joint.
Figure 8-86
Slewing table assembly: 5856 kg

Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.

★ Use gaskets to adjust the clearance a

between boom cylinder (5) and frame (16) to
less than 1 mm.
 Thickness of setting gasket: 1.0 mm/2.0
mm.

Figure 8-87

Mating surface of back slewing

bearing:
Plane sealant (Tianshan 1596)
Thread on fixing bolt of slewing
table install bolt thread:
Thread adhesive (Tianshan 1277)
Slewing table fixing bolt:

4549±59N•m{55.98±6.02kgf·m}
Objective: 549 N·m {55.98 kgf ·m}
 Re-filling of hydraulic oil
Re-fill the hydraulic oil via oil filling port until the
level reached the specified level, start up the

Maintenance Manual - 01 - 2021 8-43

Disassembling and Assembling SY135F Hydraulic Forestry Crane

engine to make the oil circulate in hydraulic

system, and then inspect the oil level again.
 Bleed off the air
Bleed the air from travelling motor. Please refer
to “Air Bleeding for Every Device” in the Section
“Testing and Adjustment” in this Manual (Page
6-31).

8.21 Dismantlement and

Installation of Back slewing
Bearing Assembly
Dismantlement
1. Dismantle the slewing table assembly.
Please refer to “Dismantlement of Slewing
Table Assembly”.
2. Remove the 40 mounting bolts (1) to
remove the rotary bearing assembly.

Figure 8-88
3. Lift up the slewing support assembly (2).

Back slewing bearing assembly:

784 kg

Figure 8-89

8-44 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

Installation
● Carry out the installation in accordance with
the reversed dismantlement sequence.

Thread on fixing bolt of slewing

support: thread adhesive (Tianshan adhesive
1277)
Slewing support fixing bolt:

549±59N•m{55.98±6.02kgf·m}
Objective: 549 N·m {55.98kgf·m}

★ Make the arrow points to the front of the

machine, as shown in the figure. Place the inner
soft area a (marked with S) on the right side, and
then install it on the track frame.
★ Apply the grease onto inside of tooth ring of
slewing support.
● Apply the grease onto tooth.
Slewing bearing:

Grease (molybdenum disulfide based

lubricating grease) 9.1 L

Figure 8-90

Maintenance Manual - 01 - 2021 8-45

Disassembling and Assembling SY135F Hydraulic Forestry Crane

8.22 Dismantlement and

Installation of Hydraulic Oil
Tank Assembly
Dismantlement
1. Drain the oil from hydraulic oil tank
Hydraulic oil: about 150 L
2. Disconnect the hoses (1) - (6).

Figure 8-91
3. Dismantle the steel pipe (7), (8).

Figure 8-92
4. Dismantle the bolt (9).

Figure 8-93

8-46 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

5. Dismantle the cover plate (10).

Figure 8-94
6. Dismantle the cross-plate (11).

Figure 8-95
7. Dismantle the crossbeam (12).
8. Dismantle the oil-suction steel pipe which
connects pump and oil tank.
9. Dismantle the base plate on lower portion
of oil tank which is installed on platform.
10. Remove the bolts that connect the tank to
the platform.
11. Use the lifting lug to lift out the oil tank
assembly. Figure 8-96

Hydraulic tank assembly: 93.8 kg

kg
Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.

Maintenance Manual - 01 - 2021 8-47

Disassembling and Assembling SY135F Hydraulic Forestry Crane

Hydraulic oil tank drain plug:

58.8~78.5 Nm {6.0~8.0 kgm}

Fixing bolt:
245.2~308.9 N•m {25~31.5 kgf·m}
 Re-fill the oil (hydraulic oil tank)
★ Fill the oil vial oil filling port to the specified
oil level. Run the engine so as to make the oil
circulate in the system, and then inspect the oil
level again.

Hydraulic oil tank: 150 L

 Bleed off the air

★ See the exhaust for each device in the
chapter "Testing and Adjustment" for details.

8.23 Dismantlement and

Installation of Control Valve
Assembly
Dismantlement
Lower down the working device onto ground
so as to ensure safety, turn off the engine,
release the pressure in oil tank via breather
valve, and then set the safety locking rod at
locking position.
★ Every pipeline is attached identification
label, so as to avoid wrong installation position.
1. Open the top cover (1)
2. Remove the cover (2) from the upper part
of the control valve. Figure 8-97

8-48 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

3. Disconnect the hoses at oil ports (1) - (12)

on upper portion of control valve.

Figure 8-98
4. Disconnect the hoses at oil ports (13) - (24)
on lower portion of control valve.

Figure 8-99
5. Disconnect the hoses at oil ports (25) - (34)
of control valve on oil tank side

Figure 8-100

Maintenance Manual - 01 - 2021 8-49

Disassembling and Assembling SY135F Hydraulic Forestry Crane

6. Disconnect the hoses at oil ports (35) - (40)

of control valve on cab side

Figure 8-101
7. Disconnect the hoses at oil ports (41) - (43)
of control valve on engine side

Figure 8-102
8. Dismantle the bolt (44) which connects the
control valve with bracket.
9. Use the lifting lug on control valve to lift out
the control valve assembly.

Control valve assembly: 122 kg

Figure 8-103

8-50 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

Installation
● Carry out the installation in accordance with
the reversed dismantlement sequence.
● Re-fill the oil (hydraulic oil tank)
★ Fill oil to the specified level via oil filling port.
Start up the engine, make the oil circulate in
system, and then inspect the oil level.
● Bleed off the air
★ See the exhaust for each device in the
chapter "Testing and Adjustment" for details.

8.24 Dismantlement and

installation of hydraulic
pump assembly
Dismantlement
Lower down the working device onto
ground, turn off the engine, and then press down
the air-bleeding button on breather valve of
hydraulic oil tank, so as to release the pressure
in tank.
Oil guard
Before carrying out the work, dismantle the
cable on negative pole (-) terminal of battery.
★ Label all pipelines, so as to avoid mistake
during installation.
Figure 8-104
1. Dismantle the oil suction filter element of
hydraulic oil tank and use the oil guard to
prevent the hydraulic oil from flowing out.
★ If the oil guard is not used, please dismantle
the drain plug and drain the oil from hydraulic oil
tank and pipeline.
Hydraulic oil tank: About 150 L

2. Lift up the hood (1).

Hood assembly: 30 kg

Figure 8-105

Maintenance Manual - 01 - 2021 8-51

Disassembling and Assembling SY135F Hydraulic Forestry Crane

3. Dismantle the cover plate (2).

Figure 8-106
4. Dismantle the plate (3), (4).

Figure 8-107
5. Dismantle the crossbeam (5).

Figure 8-108

8-52 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

6. Dismantle the hoses (6) - (13).

Figure 8-109
7. Dismantle the muffler and bracket
assembly (14).

Figure 8-110
8. Disconnect the harness (15).
9. Dismantle the oil suction steel pipe of
pump.
10. Dismantle the pump fixing bolt.
11. Using the lifting lug on pump to lift out the
hydraulic pump assembly (16).

Hydraulic pump assembly: 82 kg

Figure 8-111
Installation
● Carry out the installation in accordance with
the reversed dismantlement sequence.

Drain plug of hydraulic oil tank: 549

Maintenance Manual - 01 - 2021 8-53

Disassembling and Assembling SY135F Hydraulic Forestry Crane

N·m {56.02 kgf·m}

Spline shaft of hydraulic pump:

molybdenum disulfide grease (LM-G)
Mating surface of hydraulic pump
housing: gasket sealant (LG-6)
● Re-fill the oil (hydraulic oil tank)
★ Fill oil to the specified level via oil filling port.
Start up the engine, make the oil circulate in
system, and then inspect the oil level.
Hydraulic oil tank: About 440 L
● Bleed off the air
★ See the exhaust for each device in the
chapter "Testing and Adjustment" for details.

8.25 Dismantlement and

installation of hydraulic
pump input shaft oil seal
Dismantlement
1. Dismantle the hydraulic pump assembly
(1). Please refer to the Section
“Dismantlement of Hydraulic Pump
Assembly”.
2. Use a screwdriver to pry out the oil seal (4).

★ When prying out the oil seal, be careful not

to damage the shaft.
Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.
Figure 8-112

Lip of oil seal: grease (calcium-

based lubricating grease No. 1)
Circumference of oil seal: grease
(calcium-based lubricating grease No. 1)
★ Apply a thin layer of grease onto
circumference of oil seal.

8.26 Disassembling and assembling of manual pilot valve assembly

8-54 Maintenance Manual - 01 - 2021
 SY135F Hydraulic Forestry Crane Disassembling and Assembling

★ This section only discusses the precautions to be followed when reassembling the PPC valve
assembly of the operating device.

Figure 8-113
Assembling
 Re-assemble the manual pilot valve assembly.
1. Install the port adapter plate (9) onto the housing (8) with the sealing O-ring and tighten the
hexagon socket screw (10).
Hexagon socket screw: 25~33 N•m {2.55~3.36 kgf·m}

2. Place the spring (7) into valve core hole on housing (8), place the valve core (6) into spring,
install the push rod (5) on upper portion of valve core, and manually press the push rod (5)
into valve core hole.
3. Install the mounting plate (4) onto push rod (5), and tighten up the joint (3).
4. Install the round plate (2), adjust it to appropriate position, and tighten up the fixing nut (1).
Fixed nut: 98~133 N•m {10~13.5 kgf·m}
★ The position of every oil port is punched on lower portion of valve body.
Circumference of push rod (5): Grease (No.1 calcium base grease)
Movable surface of liquid joint (3): grease (No.1 calcium base grease)
Thread part in the shell: thread locking adhesive (Tianshan 1277)

Maintenance Manual - 01 - 2021 8-55

 Disassembling and Assembling SY135F Hydraulic Forestry Crane

★ As shown in the figure below, apply thread

locking compound (Tianshan 1277) to the
internal thread at two points, and the applying
weight at each point is about 0.02 g.
Connector (3): 98 ~ 133 N•m
{10~13.5 kgf·m}
★ Strictly tighten up the joint in accordance
with the specified torque.
Contact surface of push rod (5)
and disc (2): grease 0.3-0.8 ml (G2-L1)
★ After assembling the disc, refer to the Figure 8-114
section "Adjustment of Operating Device and
Rotary PPC Valve" in the chapter "Testing and
Adjustment" in this manual (Page 4-25).

8.27 Disassembly and Assembly of Travel Pilot Valve Assembly

★ This Chapter only discusses the notices to be complied with during re-assembling of travelling
leading valve assembly.

Figure 8-115
Assembling
 Reassemble the foot pilot valve assembly.
1. Install the spring (8) into the spool hole of the body (9), then install the spool (7), place the
body (6) on the upper part of the spool, and press the body (6) by hand.

8-56 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Disassembling and Assembling

2. Align the hole, install the cover plate (4), and tighten up the hexagonal screw (1).
Hexagon socket screw: 25 ~ 33 N•m {2.55~3.36 kgf·m}

3. Mount the dust proof ring (3) onto push rod, install the cam (2), and fix it with camshaft (5).
Contact face between push rod and dust proof ring (5): grease (calcium-based
lubricating grease No. 1)

8.28 Disassembling and assembling of hydraulic cylinder assembly

Special tools
Name of
Schematic diagram Necessity Quantity
Tool

Used to
pull out
and ■ 1
press in
bushing

Used to
press in
dust ■ 1
proof
ring

Used to
correct
■ 1
sealing
ring

Insertion tool Correction tool

Used to
insert
■ 1
cylinder
cover

Used to
insert ■ 1
piston

Maintenance Manual - 01 - 2021 8-57

Disassembling and Assembling SY135F Hydraulic Forestry Crane

Disassembling
1. Drain the oil, and dismantle the pipe.
2. Fix the cylinder.
★ Please fix the oil cylinder in a vertical or
horizontal position. In a vertical position, it is
easy to disassemble and assemble.
★ Please use the pin hole on large chamber
to carry out fixing, and use the axis pin to
prevent rotation.
★ During the fixing, if any pipe interferences
with it, please dismantle such pipe.

Fix the
cylinder

Figure 8-116
3. Dismantlement of cylinder head
About 1.5 m.
★ Please use the hexagonal spanner to screw
off and dismantle the fixing bolt.
★ As indicated in the right figure, connect the
extended rod with hexagonal spanner, so as to
facilitate the operation.

Figure 8-117

8-58 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

4. Pull out the piston rod.

★ Please confirm that the cover of pipe has
been dismantled.
★ Please prepare a container to collect the oil
flowing out from oil hole.
★ Please pull out the piston rod (1) to the
longest position, then slowly release the cylinder
Sleeper
cover and pull it out.
★ Pull out the piston rod (1) and the cylinder
head (2) together and place them on the
sleeper. Figure 8-118
5. Fix the piston rod. Fixing

★ Please use the pin hole on rod head or the

plane on ear ring to fix it, so as to prevent it from
rotating.

Figure 8-119
6. Dismantlement of piston nut (5) Bit

1) Dismantle the fixing screw (3) of piston nut.

★ There are two places around the fixed
screw that need to be punched to prevent
loosening. Please remove the riveted part with
a hand drill, and then loosen and remove the set
screw (3).
2) Please dismantle the steel ball (4) in fixing
screw.
3) Dismantle the piston nut (5).
★ The piston nut (5) is tightened to a large
torque. In order to loosen the piston nut (5), be Figure 8-120
ready to use the power wrench of the hydraulic
jack or hydraulic cylinder, and prepare the
extension rod for manual removal.

Maintenance Manual - 01 - 2021 8-59

Disassembling and Assembling SY135F Hydraulic Forestry Crane

Hydraulic jack

Hydraulic cylinder

Figure 8-121
7. Dismantle the components such as piston.
Please dismantle the piston (7), cushion collar
(6) and cylinder head (2) in accordance with the
sequence.

Figure 8-122
8. Dismantlement of cushion collar (8) on no- Thread

rod chamber side

1) Please firstly dismantle the piston nut (5),
Piston rod
otherwise the dismantlement can’t be
carried out.
2) On the premise of not damaging the piston
rod and the buffer sleeve (8), gently
tap to remove the elastic retaining ring (9)
with a rubber hammer and other tools
(Two-plate type)
3) Slid the cushion collar (8) towards the There is a gap

thread on piston, and then dismantle the

spacing ring (two-plate type). Figure 8-123

4) Dismantle the cushion collar (8).

5) There is a gap on cushion seal (10). Please
use this gap to dismantle it.

8-60 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

9. Dismantle the piston seal. Screw driver

1) The sliding ring (12) and protective ring (13)

can be dismantled easily with hand. Piston

2) Please use hammer to knock the vertically-

Vise
placed flat screwdriver, so as to cut off and
dismantle the sealing ring (14).
3) Please use the crowbar to takeout the O-
ring (15).
★ The dismantled sealing element may not be
re-used.
Figure 8-124
10. Dismantlement of cushion ring (16).
★ There is cushion ring (16) mounted in
groove on inside wall of cylinder head. When
dismantling it, please use sharp tool to prick it
and lift it up, and then insert the scraper so as to
take it out.
11. Dismantle the U-ring (17) and dust proof
ring (18).
1) Please use the tool such as screwdriver to Figure 8-125
dismantle the U-ring (17).
2) Please use the tool such as screwdriver to
dismantle the dust proof ring (18).
★ The dismantled sealing element may not be
re-used.
12. Dismantlement of bushing (19)
1) Please use the screwdriver to take out the Press machine

elastic retainer ring (20), and dismantle it

from cylinder head (2).
2) Please use the fixture and press machine Cushion block
to push out the bushing (19).
13. Dismantlement of pin bushing (21)
1) Please use the tool such as screwdriver to
dismantle the dust proof ring (22) on the
side of cylinder bore and piston rod. The
method is as same as the dismantlement Supporting
method for dust proof ring of cylinder head.
2) Please use the appropriate cushion block to Figure 8-126
dismantle the pin bushing (21).

Maintenance Manual - 01 - 2021 8-61

Disassembling and Assembling SY135F Hydraulic Forestry Crane

Assembling Press machine

1. Installation of axis pin bushing (21)

Installing tool
Cushion
1) Please use the installing tool to press it into block
Piston rod
the bushing on the side of piston rod and
cylinder bore (which is previously applied
with hydraulic oil).
2) Please use the cushion block to install the
dust proof ring (22).

Figure 8-127
2. Assembling of cylinder head assembly (2)
Hydraulic
press
1) Please use the pressing tool to press in the
bushing (19).
★ Apply the hydraulic oil onto inside of
Tool
cylinder cover, and confirm whether the
shoulder of bushing (19) which has been
pressed in is raised.
2) Please use the pressing tool to press in the
dust proof ring (18).
Pressed
face

Figure 8-128
3) Please in the order of protective ring and U- Tool
U-ring groove
ring (17), mount them into the U-ring
groove. Please use the
press machine
★ Please install the U-ring (17) in the correct to press it in.
direction and confirm that the U-ring is not
damaged before the installation.
★ The installation in reversed direction may
lead to leakage of oil.
★ After the installation, please confirm Figure 8-129
whether there is any wrinkling, permanent
deformation, etc on the U-ring (17).
4) Please install the buffer ring (16).
★ Pay attention to the direction of the sealing
ring during the installation. If the oil cylinder is
installed in the opposite direction, there will be a
very high pressure between the oil cylinder and
8-62 Maintenance Manual - 01 - 2021
SY135F Hydraulic Forestry Crane Disassembling and Assembling

the U-ring (17), which may cause deformation

and damage of the oil cylinder.
5) In order to prevent the bushing (19) from
falling off, please install the elastic retainer
ring (20).

Figure 8-130
3. Assembling of piston assembly Please use the press Cushion Please use the press
machine to press it in. block machine to press it in.
1) Install the sealing ring (14).
Tool
★ Please install the O-ring and one side
protection ring (13) on the piston in advance and
place it on the press. Install the sealing ring (14) Tool Correction
tool
with the tool as shown in the right figure.
Piston
2) Please correct the sealing ring (14).
★ After the sealing ring (14) and the protective O-ring
ring (13) are installed on the other side, the
sealing ring (14) must be corrected immediately
with a straightening tool in order to prevent the
sealing ring (14) from expanding.
Figure 8-131
3) Install the sliding ring (12).
★ Please separate the cross section slightly
with two hands, and carry out installation from
the direction of shaft. If it is separated too large,
the installation can’t be carried out.
4. Assembling of piston rod assembly Tool used for assembling

1) Fix the piston rod (1).

2) Install the cylinder head (2) onto piston rod.
★ Pay attention that the lip of dust ring and U-
ring should not be caught by the part with a
shoulder. Please install the cylinder head and
piston rod with tools.

Figure 8-132

Maintenance Manual - 01 - 2021 8-63

Disassembling and Assembling SY135F Hydraulic Forestry Crane

3) If there is cushion on no-rod chamber side The opened side faces towards
thread direction
(none for bucket cylinder), please install the Thread

cushion bearing and cushion seal in

accordance with the following sequence.
Piston rod
i) Make the side of cushion seal (10) there is
a gap face towards the piston, and mount it
into groove.
ii) Please install the plane of cushion collar (8)
as indicated in the right figure.
iii) Place the spacing ring (11) into groove. There is a gap (Two-plate type)

Press the cushion collar (8) towards Cushion on no-rod chamber

side
spacing ring to the end, and then install the
elastic retaining ring. In order to prevent the Figure 8-133
piston rod and cushion bearing from getting
damaged, please use the tool such as
rubber hammer to knock them gently.
4) If there is cushion on rod chamber side,
please install the cushion collar (6) and
cushion seal (23) in accordance with the
following sequence.
iv) Before installing the piston nut, please
install the cushion bearing; otherwise, the
cushion bearing can’t be installed.
v) Make the side of cushion seal (23) with gap
face towards the piston, and install it in The opened side faces towards
piston side
groove.
Cushion on rod chamber side

vi) Please install the machined plane of

cushion collar (6) in accordance with the
Figure 8-134
right figure.
5) Fix the piston nut (5).
Piston nut (grab arm): 9600 Nm
{979.6 kgm}
Piston nut (boom and bucket):
6200 Nm {632.6 kgm}
★ If the tightening torque is insufficient, the oil
may internally leak, the nut may get loosened,
and then thread may get damaged. In addition,
if the tightening torque is too high, the cushion
bearing may expand, or the side in contact with
piston will get deformed.
★ Please fully cleanup and degrease the

8-64 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

thread on piston, nut and piston rod (banana oil

and etc.), and then fix the nut.
6) Carry out the anti-loosening treatment for
piston.
★ After tightening the piston nut (5), put in the
steel ball (4), tighten the fixing screw (3), and Punch
Riveted
use the punch to rivet the outer outside at 2
places.
Fixed screw (3): 66.9 Nm {6.8 kgm}

Figure 8-135
5. Insert the piston rod into cylinder. Tool

Nylon sleeve (two-plate

1) Vertically or horizontally fix the cylinder. type)

2) Insert the piston rod into cylinder.

★ As for vertical fixing, the piston rod will enter
the cylinder by virtue of its dead weight. (Please make the
gap misaligned by
★ When the piston enters the cylinder, make 180 degrees)

sure that the sliding ring will not fall off.

Figure 8-136

Maintenance Manual - 01 - 2021 8-65

Disassembling and Assembling SY135F Hydraulic Forestry Crane

6. Tightening of cylinder head. Please tighten

the bolts in the sequence shown in the right
figure according to the position shown in the
cylinder head assembly drawing.
Fixing bolt: 267 Nm {27.2 kgm}
7. Install the pipes.

Fixing sequence of bolts

Figure 8-137

8.29 Dismantlement and

installation of balance
weight assembly
Dismantlement
1. Remove the cover (1) from balance weight,
install the lifting bolt onto balance weight,
and lift up it.

Figure 8-138

Wire rope

Lifting bolt

Figure 8-139

8-66 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

2. Dismantle the 4 fixing bolts (2).

3. Use the steel wire rope or chain pulley to
horizontally lift up the balance weight.

★ Be careful not to collide with engine,

radiator and cooler.

Counterweight assembly: 2701

kg

Figure 8-140
Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.

Thread of counterweight fixing bolt:

thread adhesive (Tianshan adhesive 1277)
Thread adhesive (Tianshan adhesive 1277)
Counterweight mounting bolt:
1,180~1,470 N•m {120~150 kgf·m}

★ Adjust the clearance between the

counterweight and the turntable, and the
clearance between the counterweight on the left
and right sides and the outer door is 10±5 mm.

Maintenance Manual - 01 - 2021 8-67

Disassembling and Assembling SY135F Hydraulic Forestry Crane

8.30 Dismantlement and

installation of cab assembly
Dismantlement
Firstly dismantle the negative (-) cable of
battery.
1. Dismantle the floor mat (1).

Figure 8-141
2. Dismantle the back plates (2) and (3).

Figure 8-142
3. Disconnect the left harness (4), display
harness connector (5) and wind field
washer harness (6).
4. Dismantle the right air duct (7).

Figure 8-143

8-68 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

5. Dismantle the external air filter element (8).

Figure 8-144
6. Dismantle the external air duct (9).

Figure 8-145
7. Dismantle the armrest box (10).

Figure 8-146

Maintenance Manual - 01 - 2021 8-69

Disassembling and Assembling SY135F Hydraulic Forestry Crane

8. Disconnect the radio connector (11).

9. Dismantle the radio harness (12).

Figure 8-147
10. Dismantle the wind field washer reservoir
(13).

Figure 8-148
11. Dismantle the water pipe (14) of wind field
washer.

Figure 8-149

8-70 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

12. Dismantle the decorative cover (15).

Figure 8-150
13. Dismantle the 5 fixing bolts (16) and 4 fixing
nuts (17)
★ Firstly inspect the length of bolt

Figure 8-151
14. Lift up and dismantle the cab assembly
(18).

Cab assembly: 150 kg

Installation Figure 8-152

● Carry out the installation in accordance with

the reversed dismantlement sequence.

Fixing bolt: 200 Nm {20.4 kgm}

Fixing nut: 210 Nm {21.4 kgm}

Maintenance Manual - 01 - 2021 8-71

 Disassembling and Assembling SY135F Hydraulic Forestry Crane

8.31 Dismantlement and installation of cab glass

Figure 8-153
★ The cab windshields (1), (2), (5), (7), and (9)
(1): Right side window glass
are pasted.
★ Before replacing the front windshield (2),
remove the front windshield assembly (12). (when
(2): front window glass
the front windshield assembly is installed in the
cab, the front windshield cannot be replaced only)
(3): Lower glass of front window
(4): Door window glass
★ For the method of replacing the front window
assembly, see "Removal and Installation of Front (5): Door lower window glass
Windshield Assembly".
(6): Door window glass
(7): Left rear window glass
(8): Rear glass
(9): Top window glass
(10): Sealing rubber
(11): Central adjusting seal
(12): Front window assembly (front window glass + front frame)

8-72 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

Dismantlement

Figure 8-155
When dismantling any glass which is broken or
cracked, please pay attention to safety. Before
the dismantlement, please use the adhesive
tape to fix the broken or cracked glass, so as to
prevent the occurrence of any injury. Be sure to
clear away the broken glass, and use adhesive
tape to reinforce the glass. Before the Figure 8-154
dismantlement, please take the protect
measures, so as to ensure the safety in
dismantlement.
1. Removal of windshield (3).
The glass is fixed by sealing strip. During the
dismantlement, please directly and slowly draw
outwards the glass with force.
2. Removal of windshields (4) and (6).
1) Dismantle the sealing strip from window
frame and inside of door.
2) Slowly and forcefully push out the
windshield frame from the inside of the door
to remove the windshield window frame,
the windshields (4) and (6) as a whole.

Figure 8-156

Maintenance Manual - 01 - 2021 8-73

Disassembling and Assembling SY135F Hydraulic Forestry Crane

3) Remove the windshields (4) and (6) from

the window frame with a screwdriver.

Window
frame

sealing strip

Figure 8-157
3. Removal of windshield (8).
1) Remove the arrestor (rubber groove) with a
common screwdriver.
2) Insert a piece of bamboo strip into the
position A on fixing rubber, and then pry out
the fixing rubber along its circumference.
Please pat the glass with palm from inside of
cab, so as to dismantle it. This work shall be
completed by two persons.

Figure 8-158
Rubber-fixing side

Fixing rubber Glass

Inside of cab
Arrestor
(rubber
groove)

Cab

Figure 8-159

8-74 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

4. Disassembly of windshields (1), (2), (5), (7)

and (9).

Figure 8-160
1) Dismantle the resin plate, decorative strip
and fixing block around the glass.
Cab
2) Make make a hole in the adhesive with an Glass
awl (or cutter). Awl

Adhesive

Figure 8-161
3) Pass a piano wire (or steel wire) through the
hole. Piano wire (or
metal wire)

Figure 8-162

Maintenance Manual - 01 - 2021 8-75

Disassembling and Assembling SY135F Hydraulic Forestry Crane

4) Firmly tie the two ends of piano wire onto (Inside of cab)
Cab
two screwdrivers, pull the piano wire so as to cut
off the adhesive between cab and glass, and Glass
then dismantle the glass from cab. This work
shall be completed by 2-3 persons in
cooperation.
 Be sure to cut the middle of the adhesive
between the windshield and the cab.
If the piano wire part becomes hot, it will be easy Adhesive
to break. Be sure to cut the adhesive while
changing its operating position. (Outside of cab)

Installation

Figure 8-163
 The windshields (3), (4), (6) and (8) shall be
installed in the reverse order of the
disassembly. The windshields (1), (2), (5),
(7) and (9) shall be installed in the following
steps:
1. Use a knife and scraper to [5] to clear away
the residual adhesive ad sealing rubber
from metal plate (any face to which the
glass is pasted) of cab.
★ Clear away the adhesive and sealing rubber
until the adhesion of new adhesive will not be
affected. Don’t scrape any painted surface (If Figure 8-164
any painted surface is scraped, the adhesion
force of adhesive will reduce).
2. Use unleaded gasoline to wipe away oil
stain, dust and dirt from the pasting
surfaces on cab (8) and window glass (9).
★ If the surface is not properly cleaned, the
glass will not be properly pasted.
★ Clean up all black areas on back of window
glass.
★ After cleaning the surface, leave the
windshield for at least 5 minutes to dry.

Figure 8-165

8-76 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

Figure 8-166
3. Apply the primer (10). Cab

★ The primer service limit is 4 months after the

production date. Do not use any primer beyond
this service limit.
Cut on old adhesive
★ After unpacking, use primer within 2 hours. on side of cab

★ Even if the primer is repacked immediately

after unpacking, the primer should be used
within 24 hours after the first unpacking. (the
primer shall be scrapped 24 hours after
unpacking) Figure 8-167

3) Before using the paint primer or the glass

primer, please agitate it fully.
★ If the primer is stored in refrigerator, please
leave it in room-temperature environment for at
least half a day before agitation.
(If the primer is unpacked immediately after
being taken out from refrigerator, water may
condense on it. Therefore, please leave the
primer in room-temperature environment for
sufficient time.)

Maintenance Manual - 01 - 2021 8-77

Disassembling and Assembling SY135F Hydraulic Forestry Crane

4) When using the primer brusher (11) again,

please clean it up in unleaded gasoline.
★ After cleaning up the brush, inspect whether
there is any dirt or foreign matter on it.
★ Respectively prepare the brushes used to
apply the paint primer and glass primer.
5) Evenly apply the primer onto the surface
where the sealing rubber will be pasted and
the external surface (on cab (8)) where the
adhesive will be applied.
Primer: Sunrise MSI priming coating 24 Figure 8-168
★ Do not apply primer more than twice.
(If the primer is applied for more than 2 times,
the performance of primer will reduce.)
★ Application of primer: cover the whole
dimension (a) with primer.
 Primer-applying size (a): 25mm

Figure 8-169

8-78 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

★ In addition to the above-mentioned

locations, please apply the primer onto right side
window glass and door lower window glass.
 Primer-applying area on additional right
side window glass: (b)
 Primer-applying area on additional under-
door window glass: (c)
★ After applying, leave primer for at least 5
minutes (within 8 hours) to dry.
★ Don’t apply the incorrect primer.
If the glass primer is incorrectly applied, please
use unleaded gasoline to wipe away the primer.

Figure 8-170
6) Apply the glass primer onto the relevant
surface on window glass (9).
Glass primer: Sunrise MSI priming coating 35
★ Do not apply primer more than twice.
(if the application is more than twice, the
performance of the primer will be degraded)
★ Application part of primer: apply primer
around the bonding surface of the windshield
(9), which is used to seal the installation position
of the sealing rubber (6) and the cab (8).
Figure 8-171

Maintenance Manual - 01 - 2021 8-79

Disassembling and Assembling SY135F Hydraulic Forestry Crane

★ Do not apply primer on the edge about 5

mm wide between the black part and the
transparent part of the windshield.
★ After applying primer, leave for 5 minutes at
least (within 8 hours) to dry.
★ Don’t apply the incorrect primer.
If the glass primer is incorrectly applied, please
use unleaded gasoline to wipe away the primer.

Figure 8-172
4. Paste the sealing rubber (6) (there are
binding strip on both sides) along the inner
edge of area for pasting of glass.
★ Before pasting the glass, don’t dismantle
the separating strip of sealing rubber on glass
paste.
★ When pasting the sealing rubber, please
don’t touch the surface which has been cleaned
up.
★ Be careful not to make the sealing rubber
on corner float. Figure 8-173
★ When pasting the sealing rubber (6) around
the frame, do not make its tail end overlap the
starting end. Alternatively, a clearance (E) of
about 5 mm is maintained between the above
two.
7) Paste the sealing rubber (6) of right side
window glass at the position as indicated in
the right figure.

Figure 8-174

8-80 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

★ Paste additional sealing rubber (6a) on the

right windshield.
1. Position on right side window glass where
the additional sealing rubber will be pasted:
(f): 50 mm
(g): 90 mm
(h): 250 mm

Figure 8-175
8) Paste the sealing rubber (6) of left side
window glass at the position as indicated in
the right figure.

Figure 8-176
9) Paste the sealing rubber (6) of window
glass on lower portion of door at the
position as indicated in the right figure.

Figure 8-177

Maintenance Manual - 01 - 2021 8-81

Disassembling and Assembling SY135F Hydraulic Forestry Crane

★ Paste additional sealing rubber (6b) on the

lower windshield of the door.
 Position on window glass in lower portion of
door where the additional sealing rubber
will be pasted:
(j): 110 mm
(k): 90 mm
(m): 200 mm

Figure 8-178
10) Paste the sealing rubber (6) of front window
glass at the position as indicated in the
figure below.

Figure 8-179
★ Different from other sealing rubber (6), the
sealing rubber (6c) on the lower side of the front
windshield should be pasted along the outer
edge of the lower edge of the front window
frame. (if pasted along the inner edge, the
sealing rubber can be seen through the
transparent part of the windshield.)

Figure 8-180

8-82 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

5. Location of new window glass

11) Inspect the upper, lower, left and right
clearance of window glass and cab, and
then locate the window glass and ensure
that the clearance is even.
12) Paste the strip [6] between window glass
(9) and cab (8), and draw the locating line
(n).
★ In order to position the windshield, paste the
tape [6] at three points, i.e. the right
windshield, the left rear windshield and the left,
right and lower part of the windshield under the Figure 8-181
door for accurate positioning.
13) Use knife to cut off the strip between
window glass (9) and cab (8), and then
dismantle the window glass.
★ Before installing the window glass, don’t
dismantle the strip on left side of window glass.

Figure 8-182
★ When positioning the front windshield (4),
set its horizontal position to the width of the
window frame.
And then set its vertical position, until the height
difference (p) between top of window frame and
front window glass is 3 mm.

Figure 8-183

Maintenance Manual - 01 - 2021 8-83

Disassembling and Assembling SY135F Hydraulic Forestry Crane

6. Apply the adhesive.

★ Keep the adhesive in the dark at a
temperature below 25 ℃.
★ Do not heat the adhesive above 30 ℃.
★ When using the adhesive again, please
clear away al hardened adhesive from tip of
nozzle.
14) Cut off the aluminum seal (13) at the outlet
of the adhesive cylinder (12).
Adhesive: Sunrise MSI SR sealant U90
4463876 Figure 8-184

15) Cut the tip of the adhesive nozzle (14) so

that the cut-off dimensions (q) and (r) are
shown on the right.
 Size (q): 10 mm
 Size (r): 5 mm

Figure 8-185
16) Place the adhesive canister (12) in the gap-
filling gun [7], and then screw in the nozzle.
★ Electronic or pneumatic filling gun will be
more efficient.

Figure 8-186

8-84 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

17) Dismantle the separating strip of sealing

rubber on glass adhesive side.
18) Apply the adhesive (15) onto external
surface of sealing rubber (6) on cab.

Figure 8-187
★ Apply the adhesive (15) for the sealing
rubber (6) of the cab (8) to the dimensions (s)
and (t).
 Dimension (s): 10 mm
 Dimension (t): 15 mm
★ Apply the adhesive (15) higher than the
sealing rubber (6).

Figure 8-188
★ Horizontally and evenly apply the adhesive
at the same height.
★ Apply the adhesive (15) to the additional
sealing rubber (6a) of the right windshield and
the additional sealing rubber (6b) of the lower
door windshield.

Figure 8-189

Maintenance Manual - 01 - 2021 8-85

Disassembling and Assembling SY135F Hydraulic Forestry Crane

Figure 8-190
7. Installation of windshield
19) Install the window glass (9), and align it with
the locating line drawn in Step 5.
★ Since the window glass can’t be re-
dismantled and re-pasted, please paste it as
carefully as possible.
★ Paste the windshield within 5 minutes
after applying the adhesive.
20) After pasting the window glass (9), press its
circumference, until it adheres to sealing
rubber firmly. Figure 8-191
★ Please forcibly press every corner of
window glass.

8-86 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

After installing the front window glass, use the

filler to fill the clearance of window glass and
central adjusting seal (16) within the scope (s)
until the clearance reaches the size (t) and (u).
After applying the primer onto glass (4) in cross-
section A-A, apply the adhesive as filler.
 - Seam-filling size (t): 2mm
 -Seam-filling size (u): 5mm
★ When filling the seam, as indicated in
Figure, use the rubber scraper to cover the side
of glass and trim the adhesive.
★ Wipe away the excessive adhesive.
Glass primer: Sunrise MSI priming coating 35
Adhesive: Sunrise MSI SR sealant U90
4463876

Figure 8-192
8. Fix the window glass.
21) After installing the right window glass (1)
onto cab, insert the locating piece a into
bottom of glass (1-2 pieces), so as to fix the
glass.

Figure 8-193

Maintenance Manual - 01 - 2021 8-87

Disassembling and Assembling SY135F Hydraulic Forestry Crane

22) Use the polystyrene foam [9]and rubber

strip [10] to fix the window glass and sealing
rubber, so as to properly install it.
9. After installing the window glass, clear
away all the excessive primer and adhesive
from cab and window glass.
★ Before the adhesive is dried up, use
unleaded gasoline to wipe it away.
★ When cleaning up the glass, don’t apply
impact onto it.
10. Protect the properly-pasted window glass. Figure 8-194
23) Set aside the locating piece, polystyrene
foam and rubber strip for 10 hours.
(at 20 ℃ and 60% humidity)
24) After dismantling the locating piece,
polystyrene foam and rubber strip, please
wait for at least 14 hours, and then operate
this machine.

8.32 Dismantlement and

installation of front window
assembly
Lower down the working device onto ground,
and turn off the engine.
 In order to replace front window glass,
please dismantle the front window
assembly from cab. The methods to
dismantle and install front window
assembly (front window frame and front
window glass) are detailed as follows.
Dismantlement
1. Lift up the front window assembly to the
louver, and then use the rear locks (on both
sides) to fix it.
2. Dismantle the left angle plate (1) and right
angle plate (2).
 The fixing bolt (4) and washer (3) of left
angle plate will be used in Step 6 to hung
up the pull rod.

Figure 8-195

8-88 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

3. Loosen the rear lock of cab.

4. Carefully lower down the front window
assembly. From the angle plate dismantled
in Step 2 (opened portion of guide rail), take
out and hold the rollers (5) and (6) under
both sides of front window.
5. Dismantle the roller (5) and (6) under both
sides of front window.
6. Dismantle the left lower pin (7).

Figure 8-196
 Dismantle the left lower pin (7), so as to
push out the plate (8) on end of pull-up type
pull rod (9).
 Hand the plate (8) onto fixing bolt of left
angle body (please use the washer), and fix
it in place.
The load of 58.8 N {6 kg} is applied onto rear
end of cab. Therefore, when dismantling the left
lower pin (7) so as to disconnect the pull-up type
pull rod (9), please be careful.

Figure 8-197

Figure 8-198

Maintenance Manual - 01 - 2021 8-89

Disassembling and Assembling SY135F Hydraulic Forestry Crane

7. Pull out the bottom of the front windshield

assembly (10) from the rail opening and
gradually lower it.

Figure 8-199
8. Fully lower down the front window
assembly (10).
 Don’t let the front window assembly collide
with monitor.

Figure 8-200
9. Turn the front window assembly (10)
leftwards and rightwards, dismantle the two
upper rollers (11) and (12) from guide rail,
and then dismantle the front window
assembly (10).

Figure 8-201

8-90 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.
 Adjust the opening and closing of front
window assembly in accordance with the
following method.
1. Open and close the front window assembly,
and inspect whether it interferes with the
guide rail, and inspect whether the roller is
jammed.
2. If there is any problem in opening and
closing of front window, please screw off the Figure 8-202
fixing bolt of roller adjusting bracket (13),
adjust the state of front window, and then
tighten up the fixing bolt again.
 Don’t install the bracket (13) in any angle.
Mounting bolt: 34.3 N·m {3.5 kgf·m}
3. Lift up the front window assembly, and use
the rear lock (on both sides) to fix it.
 Inspect whether the lock in rear end of cab
is firmly fixed.
4. Install the right angle plate (2).
 After adjusting the “closed” position in Step
6, fully tighten up the angle plate.
 Install the right angle plate, and make sure
that the clearance (a) between guide rail
and left angle plate (2) is 0 – 2.0 mm.
Figure 8-203
 Install the right angle plate, and make sure
that there is no level difference on rolling
surface (R) of roller.

Figure 8-204

Maintenance Manual - 01 - 2021 8-91

Disassembling and Assembling SY135F Hydraulic Forestry Crane

5. Install the left angle plate (1).

 After adjusting the “closed” position in Step
6, fully tighten up the angle plate.
 Install the left angle plate, and make sure
that the clearance (b) between guide rail
and left angle plate (1) is 0 – 2.0 mm.
 Install the left angle plate, and make sure
that there is no level difference on rolling
surface (R) of roller. (Please refer to the
figure above.)
Figure 8-205
6. Adjust the “closed” position of lock of front
window assembly in accordance with the
following method.
25) At the correct position, tighten up left right
angle plates (1) and (2), and make the front
window glass (14) firmly contact with
adjusting seal (15) on one side of cab.

Figure 8-206
26) When opening or closing the front window
assembly, inspect the work state of left and
right locks (16) and (17).
 If the left and right locks (16) and (17) don’t
work normally:
i) Loosen the mounting bolt (19) of the lock,
move the lock (16) forward, and then
tighten the bolt again. ★ Carry out the
same operation on right side.
ii) After moving the lock, please re-inspect Figure 8-207
whether the front window glass (14) and the
adjusting seal (15) on cab side are
appropriate (which have been inspected in
Step 1).
 Repeat the operations in і) and і) until the
suitability of the front windshield and locks
(16) and (17) is qualified, and then tighten
the mounting bolts of the left and right
corner plates.

8-92 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

7. After the adjustment is completed, pour a

lot of water onto front window glass, and
inspect whether the water can’t leak into
cab.

Figure 8-208
8. Adjust the “closed” position of lock of front
window assembly.
27) In Steps 6 and 7, after adjust the closed
position of lock of front window assembly,
lift up the front window assembly to louver
position.
28) Set the lock of front window assembly at
“closed” position, and then carry out the
following inspection. Figure 8-209
 Inspect the work state of left lock (16) and
right lock (17) (as mentioned above).
 The front window assembly shall contact
with left and right rubber stop blocks (18),
and shall push backwards the stop blocks
for 1.5– 3.0 mm.
 The front window assembly shall push
backwards the limit switch by 4– 7mm.
29) Close the front window assembly (10).
30) Screw off the locking nut (20) on left and
right sides of rubber stop block (18), pull
back two rubber stop blocks (18), and make
sure that they will not collide with the
opened front window assembly.

Figure 8-210

Maintenance Manual - 01 - 2021 8-93

Disassembling and Assembling SY135F Hydraulic Forestry Crane

31) Adjust the position of latch hole bolt (21).

 Latch hole bolt (21): M10; inside diameter
of plate (23): ø14.5 mm

Figure 8-211
32) Adjustment of left and right rubber stop
blocks (18)
i) Make the front window assembly (10) (The
lock shall be in the “opened” position)
contact with the left and right rubber stop
blocks (18).
ii) Close the front window assembly (10).
iii) Turn the left and right rubber stop blocks
(18) one and a half turns to the left.
 Turning the rubber stop blocks (18)
leftwards for one round is equivalent to Figure 8-212
compressing the rubber for about 1.5 mm.
 When the front window assembly is
opened, the front window assembly shall
push the left and right rubber stop blocks
(18) by 1.5 – 3.0 mm.
iv) Tighten the lock nuts (20) on both sides of
the rubber stop block (18).

Figure 8-213

8-94 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

9. Adjust the stopper (24) of front window

assembly.
33) Adjust and lock both sides of stopper (24),
so that when the front window assembly is
pulled out, the surface (d) of stop block (D)
of front window assembly (10) will contact
with the surface (c) of stopper (24).

Figure 8-214

Figure 8-215
10. Inspect the operating force of lock of front
window assembly.
34) After the adjustment of Steps 6-9, check
whether the locking forces of the left and
right locks (16) and (17) are uniform.
 Inspect the locking force on closed side (on
front end of cab) and opened side (on rear
end of cab).
Left lower pin: 27 – 34 N·m {2.75 – 3.47 kgf·m}
Fixing bolt: adhesive (LT-2)
Figure 8-216

Maintenance Manual - 01 - 2021 8-95

Disassembling and Assembling SY135F Hydraulic Forestry Crane

8.33 Dismantlement and

installation of display
screen
Dismantlement
Firstly dismantle the negative (-) cable of
battery.
1. Dismantle the 3 fixing bolts (4), and
dismantle the fixing plate and display
subassembly from mounting bracket (3).
2. Loosen the fixing nut (1) and gasket (2),
and dismantle the display (5) from
mounting plate.
Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.

Figure 8-217

8.34 Dismantlement and

installation of controller
assembly
Dismantlement
Firstly dismantle the negative (-) cable of
battery.
1. Dismantle the back plates (1), (2).

Figure 8-218

8-96 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Disassembling and Assembling

2. Remove the controller wiring connector

HCU_J1 (3)、HCU_J2 (4).
3. Dismantle the 2 fixing bolts and dismantle
the controller assembly (5).
Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.

Figure 8-219

8.35 Radio
Structure
1) Main structure

Figure 8-220

Maintenance Manual - 01 - 2021 8-97

 1)

8-98
The red is input of left sound track

Wiring

Figure 8-221
Audio input

The white is input of right sound track

The red is the ACC ignition wire

Disassembling and Assembling

output
The yellow is BATT

The black is earthling wire

Power supply, earth and audio

+ Blue is for right channel output

- The grey black is output of right

Maintenance Manual - 01 - 2021

Rear panel of machine

soundtrack

+ White is for left channel output

+ Black is for left channel output.

Radio Antenna
SY135F Hydraulic Forestry Crane
 SY135F Hydraulic Forestry Crane Disassembling and Assembling

Installation and dismantlement

Dismantlement
1) Remove the armrest box cover
Armrest box
Caution cover

 Before the dismantlement, please turn off

the power supply.

Radio

Figure 8-222
2) Dismantle the plug-in part CN-003F of radio

Plug-in part CN-

Cab harness
003F

Figure 8-223
3) Dismantle the four fixing screws and
washers, and dismantle the radio and radio
mounting bracket from armrest box hood.
4) Dismantle the four fix screws and washers,
Armrest box
and dismantle the radio from mounting
bracket.
Installation
Radio
Washer
 Carry out the installation in accordance with Radio mounting bracket
Screw
the reversed dismantlement sequence.

Figure 8-224
Model and wiring of plug-in part

Maintenance Manual - 01 - 2021 8-99

 Disassembling and Assembling SY135F Hydraulic Forestry Crane

Binding terminal of radio Harness socket terminal

Model: Deutsch DJ7072-3-21

Figure 8-225
8.36 STORAGE BATTERY
Structure

Figure 8-226
1. End post 7. Active plaster
2. Charge state densitometer 8. Bag-type spacing plate
3. Thermally-sealed top cover 9. Pole group
4. Polypropylene housing 10. Liquid-vapor separator
5. Central ear 11. Central bus bar
6. Forged plate grille

8-100 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

Installation and dismantlement

Caution
 Before the dismantlement, please turn the
key switch to the position OFF
 It is prohibited to dismantle the charge
state densitometer. If it is loosened,
please use the appropriate tool to forcibly
fix it clockwise.

1) Dismantle the earthling wire of battery

Terminal
 Lift up the water-proof cap, loosen the fixing Fixed bolt of battery Earthling wire of battery
bolt, and dismantle the terminal from
binding post of battery.

Caution
 The battery gas may cause explosion.
Don’t let any spark or flame get close to Battery
battery.

Figure 8-227
2) Dismantle the connecting wire of battery
Connecting wire of
and the wire of battery circuit breaker. battery

Wire of battery circuit

Battery breaker

Figure 8-228

Maintenance Manual - 01 - 2021 8-101

 Disassembling and Assembling SY135F Hydraulic Forestry Crane

3) Dismantle the 4 fixing bolts and gaskets, Battery

dismantle the battery box from base plate,

and take out the battery.
Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.
Replacement
There are two negative (-) grounded 12 V Battery box
batteries on the machine. If one of the batteries Fix the bolts Gasket

in the 24 V system is out of service and the other

is in good condition, replace the disabled battery Figure 8-229
with the same type of battery. The charging
speed of different types of batteries may be
different. This difference may cause one of the
batteries to lose its function due to overload.

Caution
 During installation, please apply the
vaseline onto terminals of battery so as to
avoid corrosion.

8.37 Key switch

Structure

Figure 8-230
1- Casing 8- Door 15- Spring cover 22- Contact- SPR- A
2- Key 9- Door pin 16- Resetting spring 23- Contact B

8-102 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

3- Key ring 10- Door spring 17- Ball 24- Terminal

4- Key knob 11- Rotating disc 18- Ball spring 25- Bolt
5- Nut 12- Rotating disc spring 19- Contact- SPR- B 26- O-ring
6- Barrel 13- Plug 20- Contact A 27- Harness assembly
7- End cap 14- Rotation body 21- Terminal seat 28- Washer

Installation and dismantlement

Dismantlement
1) Dismantle the locking screw, and dismantle
the armrest box cover.

Key switch Armrest box cover Locking screw

Figure 8-231
2) Dismantle the two locking screws, and Armrest box cover
Locking screw
dismantle the mounting plate and key
switch from armrest box hood.

Caution
 Before the dismantlement, please
disconnect the plug-in part of key switch.

Mounting plate Key switch

Figure 8-232

Maintenance Manual - 01 - 2021 8-103

 Disassembling and Assembling SY135F Hydraulic Forestry Crane

3) Dismantle the nut, and dismantle the key

switch from mounting plate.

Nut
Key switch Mounting plate

Figure 8-233
Internal principle and wiring of key switch
Internal principle

Conductivity
Gear

Figure 8-234
Wiring

Harness plug terminal

Model of protective sleeve: Yazaki 7123-7464-30

Connecting terminal of key switch

Sheath model: Yazaki 722-7464-30

Figure 8-235

8-104 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Disassembling and Assembling

8.38 Fuse box

Hood

Figure 8-236
Installation and dismantlement
Dismantlement
1) Dismantle the hood.

Rear cover plate Fuse box cover

Fastening bolt

Figure 8-237

Maintenance Manual - 01 - 2021 8-105

 Disassembling and Assembling SY135F Hydraulic Forestry Crane

2) Dismantle the fixing bolt, and dismantle the rear hood and fuse box together

Fuse box harness

Fastening bolt

Rear cover plate

Figure 8-238
3) Dismantle the fixing bolt, and dismantle the fuse box and fuse box harness from rear cover
plate.

8.39 Wiper
Installation and dismantlement
Main composition

Wiper blade

Rotating mechanism

Wiper arm

Windscreen wiper
motor

Plug-in elements

Mounting bracket

Figure 8-239

8-106 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Disassembling and Assembling

Internal Schematic Diagram

Green wire (low

speed)

Yellow wire (resetting)

Blue wire (high speed)

Red wire (power supply

+)

Black wire (power supply

-)

Figure 8-240
Installation and dismantlement
Dismantlement
Interior tri
1) Dismantle the interior trim clamp, and then clamp
dismantle the interior trim.

Interior trim

Figure 8-241

Maintenance Manual - 01 - 2021 8-107

Disassembling and Assembling SY135F Hydraulic Forestry Crane

2) Dismantle the action mechanism and motor

 Dismantle the fixing bolt, and dismantle the Fastening bolt

wiper motor and action mechanism from

cab.
Action
mechanism

Wiper motor

Locking bolt

Figure 8-242
3) Dismantle the arm and wiper blade
 Loosen the fixing nut, and dismantle the
windscreen wiper arm and wiper blade from
cab. Arm mounting
bracket
Installation
 Carry out the installation in accordance with Protective cover

the reversed dismantlement sequence,

Retaining nut

Cab

Figure 8-243
Adjustment of angle of windscreen wiper arm
 Before the wiper blade reaches the
mechanical limit, the arm shall stop. Mechanical limit

 If the arm continues to act when the

windscreen wiper blade reaches the Wiper blade
mechanical limit or the arm stops before the
windscreen wiper blade reaches the
mechanical limit, please adjust the action
Arm
angle of windscreen wiper, so as to prevent
the windscreen wiper from getting
damaged.
 The adjustment method is to loosen the Clamping nut
locking nut, and adjust the work angle
leftwards or rightwards on the basis of the
actual situations, so as to ensure when the
windscreen wiper blade reaches the
mechanical limit, the wiper motor will just Figure 8-244
stop.

8-108 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

8.40 Relay
Engine relay
1) Inspection on starter relay
 Carry out the inspection on conductivity and
action. If any trouble is found, please
replace the relay.

Figure 8-245
2) Inspection on main power relay
 Carry out the inspection on conductivity and
action. If any trouble is found, please
replace the relay.
(+) Terminal of batter

Figure 8-246
3) Heating plug relay
 Carry out the inspection on conductivity and
action. If any trouble is found, please
replace the relay.

Figure 8-247

Maintenance Manual - 01 - 2021 8-109

 Disassembling and Assembling SY135F Hydraulic Forestry Crane

4) Safety relay
Terminal B

 Carry out the inspection on conductivity and Terminal C

action. If any trouble is found, please Terminal S.R.E
replace the relay.

Figure 8-248
Other load relay
1) Function and position

Working light relay

Horn relay

Flameout delay relay Compressor relay

Dome light relay Fan relay

Preheating relay

Fuel pump relay

Main relay

Starter relay

Start cutoff relay

Figure 8-249

8-110 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Disassembling and Assembling

Installation and dismantlement Relay harness Mounting plate

Dismantlement
(a) Pull out the relay from relay seat.
(b) Dismantle the fixing screw, and dismantle
the relay seat and relay harness from
mounting plate.
Installation
 Carry out the installation in accordance with
the reversed dismantlement sequence.
Set screw Relay
Relay seat

Figure 8-250

3) Plug-in part and wiring of relay

Relay terminal
Relay model: HELLA RD 007 903 - 207

Boom light Dome light

Horn relay Flameout relay
relay relay

Harness socket terminal

Relay base model: relay socket sheath 8JA003526-00

Figure 8-251

Maintenance Manual - 01 - 2021 8-111

Disassembling and Assembling SY135F Hydraulic Forestry Crane

8.41 Sensor
1) Inspection on fuel level sensor
 Swing the buoy upwards and downwards, Buoy
and measure the effective radius and
rotation angle of lever. The rotation angle of
connection line between buoy and rotation Lever
point shall be 105°.
 Swing the buoy upwards and downwards.
The vertical distance between upper Terminal R
position and lower position of buoy shall be Casing

500±5mm.
Plug-in
 Move the buoy to the upper end, and elements

measure the resistance between the

sensor R terminal and the ground with a
multimeter. The resistance value Ru should Figure 8-252
be (Ru ≤ 4+1 Ω).
 Move the buoy to the lower end and
measure the resistance between the
sensor R terminal and the ground with a
multimeter. The resistance value Rd should
be (Rd ≥ 88±3 Ω).

8.42 Installation and

dismantlement methods for
terminal of plug-in part
Installation of terminal
1) Hold the wire at the position about 25mm
behind the pressed portion of terminal.

Figure 8-253

8-112 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Disassembling and Assembling

2) Hold the connector, and make the sealing

ring on its rear end face towards you.

Figure 8-254
3) Alight the terminal with the hole on sealing
ring and insert it vertically to the end. Gently
pull back the wire in opposite direction, so
as to confirm whether the terminal is locked
in place.

Figure 8-255
Removal of terminal
1) Make the rear end of connector face
towards you, select the tool suitable for the
wire, and wrap the wire.

Figure 8-256

Maintenance Manual - 01 - 2021 8-113

Disassembling and Assembling SY135F Hydraulic Forestry Crane

2) Push the tool onto connector along the wire,

use it to expand the locking shoulder of
terminal, and reach the flange on terminal.

Figure 8-257
3) Pull outwards the tool, so as to take out the
wire together with terminal.

Figure 8-258

8-114 Maintenance Manual - 01 - 2021

 SY135F Hydraulic Forestry Crane Hydraulic & Electrical Diagram

Hydraulic & Electrical Diagram

9. Hydraulic & Electrical Diagram ............................................................................. 9-1
9.1 SY135C3I2K (GB) Hydraulic Schematic Diagram ........................................................... 9-3
9.2 Schematic Diagram for electrical system ........................................................................ 9-4
9.3 Cab harness ................................................................................................................... 9-6
9.4 Control switch harness.................................................................................................... 9-8
9.5 Body harness .................................................................................................................. 9-9

Maintenance Manual - 01 - 2021 9-1

Hydraulic & Electrical Diagram SY135F Hydraulic Forestry Crane

Warning
Please read and fully understand the precautions in this Manual and described in the safety
nameplate on the machine. When operating or repairing the machine, please follow those
precautions strictly; otherwise, the wrong operation might lead to machine damages or personal
injuries.

9-2 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Hydraulic & Electrical Diagram

9. HYDRAULIC & ELECTRICAL DIAGRAM

9.1 SY135C3I2K (GB) Hydraulic Schematic Diagram

Maintenance Manual - 01 - 2021 9-3

 Hydraulic & Electrical Diagram SY135F Hydraulic Forestry Crane

9.2 Schematic Diagram for electrical system

Figure 9-1
原文 译文
蓄电池 Battery
启动马达 Starting motor
点火开关 Ignition switch
蓄电池继电器 Storage battery relay
安全继电器 Safety relay
发电机 Alternator
预热继电器 Preheating relay
预热塞 Heater plug
喇叭开关 Horn Switch
喇叭 Horn
阅读灯 Reading lamp
检修灯 Overhaul light
音响 Audio equipment
工作灯继电器 Working light relay
工作灯 Working lamp
平台灯 Platform light
动臂灯 Boom lamp
雨刮器 windscreen wiper
清洗器 Washer
驾驶室顶灯继电器 Dome light relay in cab
驾驶室顶灯 Dome light in cab
压缩机 Compressor
空调控制面板 A/C control panel
鼓风机 Air blower

9-4 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Hydraulic & Electrical Diagram

显示屏电源 Power supply for display screen

控制器电源 Controller power supply
GPS 电源 GPS power supply
点烟器 Cigar lighter
传感器电源输出 Sensor power output
油门位置传感器 Throttle position sensor
油门旋钮 Throttle knob
地 Ground
控制器电源 Controller power supply
启动控制 Start control
熄火控制 Flameout control
控制器电源 Controller power supply
二次增压 Secondary turbocharging
先导 Pilot
高速行走 High-speed Traveling
直线行走 Straight travelling
回转解锁 Slewing unlocking
前泵比例电磁阀 Front pump proportional electromagnetic valve
后泵比例电磁阀 Rear pump proportional electromagnetic valve
回转 Rotation
左行走 Traveling LEFT
传感器电源输出 Sensor power output
铲斗卸载 Bucket unloading
斗杆挖掘 Grab arm excavation
斗杆卸载 Grab arm unloading
右行走 Traveling RIGHT
铲斗挖掘 Bucket excavation
动臂上升 Boom lifting
动臂下降 Boom lowering
机油压力 Engine oil pressure
油位传感器 fuel sensor
A+信号输出 A+ signal output
A-信号输出 A- signal output
B+信号输出 B+ signal output
B-信号输出 B- signal output
液压油温传感器 Hydraulic oil temperature sensor
前泵压力传感器 Front pump pressure sensor
后泵压力传感器 Rear pump pressure sensor
低温开关 Low temperature switch
预热信号输出 Preheating signal output
启动信号 Starting signal
熄火信号 Extinction signal
空滤传感器 Air filter sensor
先导限位开关 Pilot limit switch
高温开关 High temperature switch

Maintenance Manual - 01 - 2021 9-5

Hydraulic & Electrical Diagram SY135F Hydraulic Forestry Crane

串口通讯 1 Serial communication 1

转速传感器 Rotating speed sensor

9.3 Cab harness

SY135C3I2K Cab Harness

原文 译文
喇叭按钮 Horn button
至控制开关线束 CN-131F To control switch harness CN-131F
德驰 Deutsch
线径 Wire diameter
至雨刮器线束 To wiper harness
至显示屏线束 To display harness
德驰：DT06-8S Deutsch: DT06-8S
保险盒盖标签白底黑字 The label on the cover of the fuse box is black on a white
background
启动 Start
回喇叭 Back to the horns
回路驾驶室 Circuit cab
检修灯 Overhaul light
备用 Reserve
充电指示 Indication of charging
工作灯 Work light
雨刮器 windscreen wiper

9-6 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Hydraulic & Electrical Diagram

蓄电池 Battery
空调 Air conditioner (A/C)
显示屏 Display screen
控制器 Controller
顶灯 Dome light
保险盒底座侧面标签 Side label for fuse box base
德驰：DT06-12S Deutsch: DT06-12S
至控制开关线束 To control switch harness
至高低压开关 To high/low voltage switch
熔断器盒 Fuse box
保险盒盖 Fuse box cover
预热继电器 Preheating relay
至压缩机离合器继电器 To compressor clutch relay
至风机主继电器 To main relay for fan
采用布胶带包扎 Wrapped with cloth tape
贴标签处 Location where the label is to be attached
先导开关 Leading switch
二次升压按钮 Secondary boost button
到空调单元 To air conditioning unit
至风机 To fan
技术要求 Technical Requirements
1.分散器件的连接导线必须外套塑料套管，各电线上 1. The connecting wires of dispersive devices must be
每隔 30 mm 印上图中标识的相应线号。 covered with plastic sleeve, and the corresponding wire
number marked in the figure above shall be printed on each
wire every 30 mm.
2. 各圆片端子配加相应大小的橡皮帽，各接插侦探 2. Each wafer terminal shall be equipped with rubber cap of
端子、附套、防水塞等其它附件除特殊说明均采用进 corresponding size, and other accessories such as plug-in
口件。 terminal, accessory sleeve and waterproof plug shall be
3. 线束除特殊标注为 PVC 管外，其他都包扎波纹 imported parts unless otherwise specified.
管，包括单根电线。除 CN-504qh 采用护套外，其他 3. Except for PVC pipe, the wire harness shall be wrapped
波纹管 PVC 管与插接件之间留有 30mm 距离 with corrugated pipe, including single wire. In addition to
4.护套上有编号的接插件线号排列顺序以编号为准， sheaths in CN-504qh, other corrugated PVC pipes and
护套上无编号的若无特殊说明全部从端子侧接插件正 connectors have a distance of 30 mm.
面看。 4. The wire number of the connector with number on the
5. 除图中另标注的电线线径外，无特珠说明的线号 sheath shall be arranged according to the number, and the
线径均为 AVX-0.85mm 2 的电线，0 号线为黑色线。 connector without number on the sheath shall be viewed from
6. A+、A-号线为屏蔽双绞线 B+、B-号线为屏蔽双绞 the front of the connector on the terminal side without special
线。 instructions.
7.在线束贴标签处贴上对应的线束标签，标签两端阴 5. Except the wire diameter otherwise indicated in the
影区域为胶带粘贴区域，各厂家选择不同颜色胶带区 drawing, the wire number and wire diameter without special
别利电，蓝色大地；绿色虹桥浅绿色条形码区域为选 description are all AVX-0.85mm2 wires, and the wire 0 is black
用区域。 wire.
8. 满足《三一重机挖掘机线束制作技术协议》要 6. No. A+/A cables are the shielded/twisted pair, and No.
求。 B+/B-line are shielded twisted pair.
7. Paste the corresponding harness label on the label. The

Maintenance Manual - 01 - 2021 9-7

 Hydraulic & Electrical Diagram SY135F Hydraulic Forestry Crane

shadow area at both ends of the label is the adhesive tape

pasting area. Manufacturers choose different colors of
adhesive tape to distinguish; Lidian: blue; Dadi: green;
Hongqiao: light green. Bar code areas are the selection ones.
8. It shall meet the requirements of Technical Agreement on
Harness Production of Sany Excavator.

9.4 Control switch harness

Figure 9-2
原文 译文
至钥匙开关 To key switch
至控制旋钮开关 To control knob switch
工作灯开关 Working light switch
雨刮器开关 Windscreen wiper switch
洗涤器开关 Washer Switch
顶灯开关 Dome light switch
至驾驶室线束 To cab harness
技术要求 Technical Requirements
1.分散器件的连接导线必须外套塑料套管，各电线上每隔 1. The connecting wires of dispersive devices must be
30 mm印上图中标识的相应线号。 covered with plastic sleeve, and the corresponding wire
2. 各圆片端子配加相应大小的橡皮帽，各接插侦探端 number marked in the figure above shall be printed on
子、附套、防水塞等其它附件除特殊说明均采用进口件。 each wire every 30 mm.
3. 除图中另标注的电线线径外，无特珠说明的线号线径 2. Each wafer terminal shall be equipped with rubber
均为AVX-0.85mm 2 的电线，0号线为黑色线。 cap of corresponding size, and other accessories such
4. 护套上有编号的接插件线号排列顺序以编号为准，护 as plug-in terminal, accessory sleeve and waterproof

9-8 Maintenance Manual - 01 - 2021

SY135F Hydraulic Forestry Crane Hydraulic & Electrical Diagram

套上无编号的若无特殊说明全部从端子侧接插件正面看。 plug shall be imported parts unless otherwise specified.

5. 该图纸版本号为C版本。 3. Except for the wire diameter otherwise indicated in
6. 满足《三一重机挖掘机线束制作技术协议》要求。 the drawing, the wire number and diameter without
special description are all AVX-0.85mm2 wires, and No.
0 wire is a black one.
4. The wire number of the connector with number on the
sheath shall be arranged according to the number. If No
special description on the sheath, all the connection
numbers on the terminal side shall be viewed from the
front.
5. The drawing version number is Version C.
6. It shall meet the requirements of Technical
Agreement on Harness Production of Sany Excavator.

9.5 Body harness

SY135C3I2K body harness

原文 译文
线径 Wire diameter
至驾驶室线束 To cab harness
调试口 Testing port
采用布胶带包扎 Wrapped with cloth tape
贴标签处 Location where the label is to be attached
防水插座 Waterproof socket
接插件 Plug-in elements
压力传感器接插件各增加一个透明胶帽 Add a transparent rubber cap for every plug-in part of
pressure sensor

Maintenance Manual - 01 - 2021 9-9

Hydraulic & Electrical Diagram SY135F Hydraulic Forestry Crane

动臂提升压力传感器 Boom lifting pressure sensor

动臂下降压力传感器 Boom lowering pressure sensor
铲斗挖掘压力传感器 Bucket excavation pressure sensor
铲斗卸载压力传感器 Bucket unloading pressure sensor
右行走压力传感器 Right travelling pressure sensor
左行走压力传感器 Left travelling pressure sensor
斗杆挖掘压力传感器 Grab arm excavation pressure sensor
斗杆卸载压力传感器 Grab arm unloading pressure sensor
回转压力传感器 Slewing pressure sensor
先导电磁阀 Leading electromagnetic valve
直线行走比例阀 Proportional valve for linear travel
备用比例阀 Standby proportional valve
回转解锁比例阀 Slewing unlocking proportional valve
二次增压电磁阀 Secondary turbocharging electromagnetic valve
高低速电磁阀 High/low speed electromagnetic valve
于预热保险丝 For preheating fuse
发动机飞轮传感器 Engine flywheel sensor
后泵比例电磁阀 Rear pump proportional electromagnetic valve
前泵给电磁阀 Front pump proportional electromagnetic valve
后主压力传感器 Rear main pressure sensor
前主压力传感器 Front main pressure sensor
增加透明胶帽 Add a transparent rubber cap
至液压油温度传感器 To hydraulic oil temperature sensor
至电位计 To potentiometer
至电产马达 To NIDEC motor
机油压力传感器 Engine oil pressure sensor
本虚线框全部用布胶带包扎到位，不能看见裸露导线 All the dotted line boxes are wrapped in place with cloth
tape, and the exposed wires cannot be seen.
技术要求 Technical Requirements
1.护套上有编号的接插件线号排列顺序以编号为准，护套 1. The wire number of the connector with number on the
上无编号的若无特殊说明全部从端子侧接插件正面看。 sheath shall be arranged according to the number, and
the connector without number on the sheath shall be
2. 所有接插件需配齐相应型号的端子、楔块、防水塞
viewed from the front of the connector on the terminal
等；各接插件端子、附套、防水塞等其它附件除特珠说明 side without special instructions.
均采用进口件，各圆片端子配加相应大小的橡皮帽。 2. All connectors shall be equipped with the
3. 除图中另标注的电线线径外，其余均为耐温为105℃、 corresponding types of terminals, wedges, waterproof
AVS-0.85 mm2的电线，0号线为黑色线。 plugs, etc. Except for special instructions, all connector
4. 线束中所有的波纹管、接插件均需而125℃高温电线、 terminals, accessories, waterproof plugs and other
电览需耐105℃高温，除特珠标明外，其波纹管PVC管与 accessories are imported parts, and rubber caps of
插接件之间留有30mm距离。 corresponding size are added to each round terminal.
3. Except for the wire diameter otherwise indicated in
5. 108、000号线为屏蔽双绞线，A+、A-号线为屏蔽双绞
the drawing, the rest are wires with the temperature
线，B+、B-号线为屏蔽双绞线，屏蔽层和0号线相连。
resistance of 105 ℃ and AVS-0.85 mm2, and No. 0
6. 在线束贴标签处贴上对应的线束标签，标签两端阴影 wire is a black one.
区域为胶带粘贴区域，各厂家选择不同颜色胶带区别利 4. All bellows and connectors in the wiring harness are
电，蓝色大地；绿色虹桥浅绿色条形码区域为选用区域。 equipped with 125℃ high temperature wires. The cable
7. 满足《三一重机挖掘机线束制作技术协议》要求。 should be able to withstand high temperature of 105 ℃.
Except for the special bead, there is a 30 mm distance
between the corrugated PVC pipe and the connector.
5. No. 108 and 000 wires are shielded twisted pair.
Lines A + and A - are shielded twisted pair, Lines B +
and B - are shielded twisted pair, and the shielding layer
is connected with No. 0 line.
6. Paste the corresponding harness label on the label.
The shadow area at both ends of the label is the
adhesive tape pasting area. Manufacturers choose
different colors of adhesive tape to distinguish; Lidian:
blue; Dadi: green, Hongqiao: light green. Bar code areas
are the selection ones.
7. It shall meet the requirements of Technical
Agreement on Harness Production of Sany Excavator.

9-10 Maintenance Manual - 01 - 2021

www.sanygroup.com

SANY Heavy Machinery Co., Ltd.

SANY Industrial Park, Dongcheng Avenue, Kunshan Economic & Technological
Development Zone, Jiangsu Province

Post code: 215300

E-mail: [email protected]
Service Hotline: 4008 28 2318 Complaints hotline: 4008 87 9318