SANY Crawler Hydraulic Excavator SY215CLC (CUMMINS QSB6.7 engine). Shop Manual

Shop Manual

SY215C

Crawler Hydraulic Excavator

●

Compiled for experienced technicians, this shop manual aims to provide technical information
required for maintenance and repair of the machine.

●

Work equipment or optional components not available locally may be included in this shop
manual. Consult authorized Sany dealers for information on these parts and components.
Material or technical speci

cation is subject to change without prior notice.

●

SY215C

excavators are equipped with CUMMINS QSB6.7 engine.

Table of Contents

SY215C

Table of Contents

1 Introduction

1.1 Safety Notice ........................................................................................................... 1-3

1.2 How to Read the Shop Manual .............................................................................. 1-13

1.3 Terms for Maintenance Standard ........................................................................... 1-16

1.4 Handling Electrical and Hydraulic Components..................................................... 1-19

1.4.1 Points to remember when handling electric components ............................ 1-19

1.4.2 Points to remember when handling hydraulic equipment ............................ 1-28

1.5 Hose Connector ..................................................................................................... 1-30

1.5.1 Type of hose connector ................................................................................ 1-31

1.5.2 Hose connector tightening torque table ....................................................... 1-31

1.5.3 Connection of O-rings .................................................................................. 1-32

1.6 Table of Standard Tightening Torques .................................................................. 1-33

1.7 Type of Bolts .......................................................................................................... 1-34

1.8 Tightening Sequence ............................................................................................. 1-34

1.9 Maintenance of Half Flanges ................................................................................. 1-35

1.9.1 Table of tightening torques for half

ange bolts ........................................... 1-35

1.10 Conversion Table ................................................................................................. 1-36

1.10.1 Method of using conversion table .............................................................. 1-36

1.10.2 Temperature ............................................................................................... 1-41

2 Shop Safety

2.1 Hazard Alert Information .......................................................................................... 2-3

2.2 General Shop Safety ............................................................................................... 2-6

2.2.1 Rules and shop behavior ............................................................................... 2-7

2.2.2 Housekeeping ................................................................................................ 2-7

2.2.3 Shop Liquids Storage..................................................................................... 2-8

2.2.4 Cleaning Parts ............................................................................................... 2-8

2.2.5 Jacking Up the Machine................................................................................. 2-9

2.2.6 Electrical Dangers .......................................................................................... 2-9

2.2.7 Removing Attachments ................................................................................ 2-10

2.2.8 Cleaning the Machine .................................................................................. 2-10

2.2.9 Using the Correct Tools .................................................................................2-11

2.2.10 Hoisting a Load ...........................................................................................2-11

2.2.11 Appropriate Working Apparel ..................................................................... 2-12

2.2.12 Safety Partners .......................................................................................... 2-12

2.2.13 Two people when engine running .............................................................. 2-13

2.2.14 Driving Pins ................................................................................................ 2-13

2.2.15 Aligning Parts or Components ................................................................... 2-14

2.2.16 Fire Extinguisher and Emergency Exits ..................................................... 2-14

2.2.17 Personal Protective Equipment.................................................................. 2-14

2.2.18 Running the Machine ................................................................................. 2-15

2.2.19 Accumulator ............................................................................................... 2-16

2.2.20 Adding Fluids to a System ......................................................................... 2-16

2.2.21 Track Recoil Springs .................................................................................. 2-17

2.2.22 High-Pressure Fluid Lines.......................................................................... 2-17

2.2.23 Safe Work Preparations ............................................................................. 2-18

2.2.24 Mounting and Dismounting ........................................................................ 2-19

2.2.25 Battery Hazards ......................................................................................... 2-20

2.2.26 Jump-Start Safety ...................................................................................... 2-21

2.2.27 Disconnecting the System Power .............................................................. 2-21

2.2.28 LOCKOUT/TAGOUT .................................................................................. 2-22

2.2.29 Sequence of Procedures ........................................................................... 2-22

2.2.30 CHEMICAL HAZARDS .............................................................................. 2-24

2.2.31 Material Safety Data Sheets (MSDS) ........................................................ 2-24

3 Specifi cations

3.1 Dimensions .............................................................................................................. 3-3

3.2 Working Ranges ...................................................................................................... 3-4

3.3 Technical Speci

cations ........................................................................................... 3-5

3.4 Weight Table ............................................................................................................ 3-6

3.5 Fuel and Coolant ..................................................................................................... 3-7

III

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

4 Structure and Function

4.1 Engine and Cooling System .................................................................................... 4-3

4.1.1 Engine-related parts....................................................................................... 4-3

4.1.2 Radiator and intercooler................................................................................. 4-4

4.2 Power Train.............................................................................................................. 4-5

4.2.1 Power transmission system .......................................................................... 4-5

4.2.2 Final drive AS (KYB) ...................................................................................... 4-6

4.2.3 Final drive AS (Nabtesco) .............................................................................. 4-8

4.2.4 Swing machinery.......................................................................................... 4-10

4.2.5 Swing bearing .............................................................................................. 4-12

4.3 Undercarriage and Frame...................................................................................... 4-13

4.3.1 Track frame and recoil spring....................................................................... 4-13

4.3.2 Idler .............................................................................................................. 4-15

4.3.3 Carrier roller ................................................................................................. 4-17

4.3.4 Track roller ................................................................................................... 4-18

4.3.5 Track shoe ................................................................................................... 4-20

4.3.6 Triple grouser shoe ...................................................................................... 4-23

4.4 Hydraulic System, Part 1 ....................................................................................... 4-24

4.4.1 Hydraulic equipment layout drawing ............................................................ 4-24

4.4.2 Hydraulic tank and

lter ............................................................................... 4-26

4.4.3 Hydraulic pump ............................................................................................ 4-28

4.4.4 Pilot pump .................................................................................................... 4-35

4.4.5 Regulator (KR3G-0E11-AV) ......................................................................... 4-36

4.4.5.1 Control mechanism makeup ............................................................... 4-38

4.4.5.2 Adjustment of the regulator ................................................................. 4-39

4.4.5.3 Operation ............................................................................................ 4-41

4.5 Hydraulic System, Part 2 ....................................................................................... 4-44

4.5.1 Control valve ................................................................................................ 4-44

4.5.2 Hydraulic circuit diagram (with bucket con

uence function) ........................ 4-47

4.5.3 Operating principle ....................................................................................... 4-48

4.5.3.1 When spool is in neutral position ........................................................ 4-48

4.5.3.2 Travel .................................................................................................. 4-50

4.5.3.3 Arm ...................................................................................................... 4-51

4.5.3.4 Boom ................................................................................................... 4-56

4.5.3.5 Bucket ................................................................................................. 4-59

4.5.3.6 Swing .................................................................................................. 4-61

4.5.3.7 Option ................................................................................................. 4-63

4.5.3.8 Travel straight ..................................................................................... 4-64

4.5.3.9 Lock valve function ............................................................................. 4-65

4.5.3.10 Main relief valve function .................................................................. 4-67

4.5.3.11 Port relief valve function .................................................................... 4-68

4.5.4 Section view ................................................................................................. 4-72

4.6 Hydraulic System, Part 3 ....................................................................................... 4-83

4.6.1 Swing motor ................................................................................................. 4-83

4.6.2 Swing holding brake..................................................................................... 4-85

4.6.3 Relief valve portion ...................................................................................... 4-86

4.6.4 Reverse prevention valve ............................................................................ 4-88

4.6.4.1 Operation drawing ............................................................................... 4-88

4.6.4.2 Explanatory drawing of effects ............................................................ 4-89

4.6.5 Center swivel joint ........................................................................................ 4-91

4.6.6 Travel motor ................................................................................................. 4-93

4.6.6.1 Operation of components .................................................................... 4-96

4.6.6.2 Operation of parking brake ............................................................... 4-102

4.6.6.3 Brake valve operation ....................................................................... 4-103

4.6.7 Valve control system ...................................................................................4-112

4.6.8 Pilot valve...................................................................................................4-114

4.6.8.1 Work equipment and swing pilot valve ...............................................4-114

4.6.8.2 Travel PPC valve ...............................................................................4-118

4.6.9 Solenoid valve............................................................................................ 4-122

4.6.10 Accumulator ............................................................................................. 4-123

4.6.11 Pilot oil

lter .............................................................................................. 4-124

4.6.12 Pump oil pressure sensor ........................................................................ 4-125

4.6.13 Hydraulic cylinder..................................................................................... 4-126

4.6.14 Work equipment ....................................................................................... 4-128

4.7 Air Conditioning System....................................................................................... 4-132

4.7.1 A/C components layout drawing ................................................................ 4-133

4.7.2 Control panel.............................................................................................. 4-134

4.7.3 Circuit diagram ........................................................................................... 4-135

4.7.4 Refrigeration principle ................................................................................ 4-137

4.7.4.1 Refrigeration cycle diagram .............................................................. 4-137

4.7.4.2 Heating cycle diagram ...................................................................... 4-137

4.7.5 Compressor ............................................................................................... 4-138

4.7.6 Clutch ......................................................................................................... 4-140

4.7.7 Condenser ................................................................................................. 4-141

4.7.8 Expansion valve ......................................................................................... 4-142

4.7.9 Evaporator ................................................................................................. 4-142

4.7.10 Dehydrator ............................................................................................... 4-143

4.7.11 Pressure switch ........................................................................................ 4-144

4.7.12 Fresh air sensor ....................................................................................... 4-145

4.7.13 Refrigerant ............................................................................................... 4-146

4.7.14 Compressor oil ......................................................................................... 4-165

4.8 Engine Control ..................................................................................................... 4-166

4.8.1 System operation ...................................................................................... 4-167

4.8.1.1 Engine startup ................................................................................... 4-167

4.8.1.2 Engine speed control ........................................................................ 4-167

4.8.1.3 Engine shutdown .............................................................................. 4-167

4.8.2 Components............................................................................................... 4-168

4.8.2.1 Fuel control dial ................................................................................. 4-168

4.8.2.2 Controller .......................................................................................... 4-170

4.9 Electrical Control System..................................................................................... 4-172

4.9.1 Control function .......................................................................................... 4-172

4.9.2 Machine control system diagram ............................................................... 4-173

4.9.3 Engine and pump composite control function ............................................ 4-175

4.9.4 Pump control function ................................................................................ 4-179

4.9.4.1 Electrical positive

ow control ........................................................... 4-180

4.9.4.2 Constant power control ..................................................................... 4-183

4.9.4.3 ESS control ....................................................................................... 4-184

4.9.5 Valve control function ................................................................................. 4-185

4.9.5.1 Bucket

ow control ............................................................................ 4-186

4.9.5.2 Swing priority control ......................................................................... 4-187

4.9.6 Duo travel speed control ............................................................................ 4-188

4.9.7 Engine preheating/overheating alarm ....................................................... 4-190

4.9.7.1 Engine preheating ............................................................................. 4-191

4.9.7.2 Engine overheating alarm ................................................................. 4-192

4.9.8 Engine oil under–pressure alarm ............................................................... 4-192

4.9.9 Auto deceleration/acceleration control ....................................................... 4-193

4.9.10 Engine speed calibration function ............................................................ 4-195

4.9.11 System Components ................................................................................ 4-197

4.9.11.1 Pump pressure sensor .................................................................... 4-197

4.9.11.2 Pilot pressure sensor ...................................................................... 4-198

4.9.11.3 Engine speed sensor ...................................................................... 4-199

4.9.11.4 Coolant temperature sensor ............................................................ 4-200

4.9.11.5 Fuel sensor ..................................................................................... 4-201

4.9.11.6 Oil pressure switch .......................................................................... 4-202

4.10 Monitoring System ............................................................................................. 4-203

4.10.1 Machine monitor ...................................................................................... 4-204

4.10.2 Monitor functions...................................................................................... 4-205

4.10.3 Screen display and operation .................................................................. 4-209

4.10.3.1 Initializing page ............................................................................... 4-209

4.10.3.2 Home page ..................................................................................... 4-209

4.10.3.3 System Information ......................................................................... 4-210

4.10.3.4 Main Menu .......................................................................................4-211

4.10.3.5 Engine Signals ................................................................................ 4-212

VII

4.10.3.6 Throttle Signals ............................................................................... 4-212

4.10.3.7 Pilot Pressure Signal - 1 ................................................................. 4-213

4.10.3.8 Pilot Pressure Signal - 2 ................................................................. 4-213

4.10.3.9 Main Pump Signals ......................................................................... 4-214

4.10.3.10 Main Valve Signals ........................................................................ 4-214

4.10.3.11 Fault Information ........................................................................... 4-215

4.10.3.12 Throttle Help Information .............................................................. 4-215

4.10.3.13 Language Selection ...................................................................... 4-216

4.10.3.14 System Clock Calibration .............................................................. 4-216

4.10.3.15 Unit Display Setup ........................................................................ 4-217

4.10.3.16 Working Mode Selection ............................................................... 4-217

4.10.3.17 System Setup Password Entry ..................................................... 4-218

4.10.3.18 System Setup Menu ...................................................................... 4-219

4.10.3.19 Machine Con

guration Password ................................................. 4-220

4.10.3.20 Machine Con

guration .................................................................. 4-221

4.10.3.21 Service Hour Calibration Password .............................................. 4-222

4.10.3.22 Service Hour Calibration ............................................................... 4-223

4.10.3.23 Machine Con

guration Calibration Password ............................... 4-224

4.10.3.24 Machine Con

guration Calibration ................................................ 4-225

4.10.3.25 Hydraulic Oil Temperature ............................................................ 4-227

4.10.3.26 System Lockout Level 1 ................................................................ 4-228

4.10.3.27 System Lockout Level 2 ................................................................ 4-228

5 Standard Values

5.1 Standard Values for Chassis-related Parts .............................................................. 5-3

6 Testing and Adjusting

6.1 Engine Speed - Test and Calibrate .......................................................................... 6-3

6.1.2 Testing ........................................................................................................... 6-3

6.1.1 Adjusting ........................................................................................................ 6-3

6.2 Exhaust Gas Color - Test ......................................................................................... 6-5

6.3 Engine Speed Sensor - Adjust ................................................................................. 6-7

VIII

6.4 A/C Compressor Belt Tension - Test and Adjust ..................................................... 6-8

6.4.1 Testing ........................................................................................................... 6-8

6.4.2 Adjusting ........................................................................................................ 6-8

6.5 Swing Bearing Clearance - Measure ..................................................................... 6-10

6.6 Track Tension - Test and Adjust ............................................................................. 6-12

6.6.1 Testing .......................................................................................................... 6-12

6.6.2 Adjusting ...................................................................................................... 6-13

6.7 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust .................................... 6-14

6.7.1 Measuring .................................................................................................... 6-14

6.7.2 Adjusting ...................................................................................................... 6-16

6.8 Control Circuit Oil Pressure - Test and Adjust ........................................................ 6-19

6.8.1 Testing .......................................................................................................... 6-19

6.8.2 Adjusting ...................................................................................................... 6-20

6.9 Solenoid Valve Output Pressure - Measure ........................................................... 6-21

6.10 Pilot Valve Output Pressure - Measure ................................................................ 6-23

6.11 Pilot Valves (Work Equipment and Swing) - Adjust .............................................. 6-25

6.12 Work Equipment Hydraulic Drift - Test ................................................................. 6-26

6.13 Residual Pressure in Hydraulic Circuit - Release ................................................ 6-29

6.14 Oil Leakage - Measure ........................................................................................ 6-30

6.15 Air in Each Component - Bleed............................................................................ 6-35

7 Troubleshooting

7.1 Points to Remember When Troubleshooting ........................................................... 7-3

7.2 Sequence of Events in Troubleshooting .................................................................. 7-6

7.3 Troubleshooting Procedures .................................................................................... 7-7

7.4 Connectors ............................................................................................................ 7-10

7.4.1 Table of connectors ...................................................................................... 7-10

7.4.2 Connector layout .......................................................................................... 7-14

7.4.3 Electrical element circuit diagram (cab circuit)............................................. 7-20

7.4.4 Electrical control circuit diagram (engine circuit).......................................... 7-22

7.4.5 Electrical control circuit diagram (sensor and solenoid valve circuit) ........... 7-24

7.4.6 SWP type connector .................................................................................... 7-25

7.4.7 A/AMP type connector ................................................................................. 7-26

7.4.8 DT type connector ....................................................................................... 7-27

7.5 Failure Symptoms and Service Codes .................................................................. 7-28

7.5.1 Troubleshooting with an failure code ........................................................... 7-30

7.5.2 Troubleshooting of Electrical System (E - Code) ......................................... 7-61

7.5.3 Troubleshooting of Hydraulic and Mechanical Systems (H - Code) ............ 7-90

8 Disassembly and Assembly

8.1 Reading Guide ......................................................................................................... 8-3

8.1.1 Removing and Installing an Assembly ........................................................... 8-3

8.1.1.1 Special tools .......................................................................................... 8-3

8.1.1.2 Removal ................................................................................................ 8-3

8.1.1.3 Installation ............................................................................................. 8-4

8.1.2 Disassembling and assembling an assembly ................................................ 8-5

8.1.2.1 Special tools .......................................................................................... 8-5

8.1.2.2 Disassembly .......................................................................................... 8-5

8.1.2.3 Assembly ............................................................................................... 8-6

8.2 Operating Precautions ............................................................................................. 8-7

8.3 Radiator AS - Remove and Install...........................................................................8-11

8.3.1 Removal ........................................................................................................8-11

8.3.2 Installation .................................................................................................... 8-14

8.4 Engine and Hydraulic Pump AS - Remove and Install .......................................... 8-15

8.4.1 Removal ....................................................................................................... 8-15

8.4.2 Installation .................................................................................................... 8-21

8.5 Final Drive AS - Remove and Install ...................................................................... 8-22

8.5.1 Removal ....................................................................................................... 8-22

8.5.2 Installation .................................................................................................... 8-23

8.6 Final Drive AS - Disassemble and Assemble......................................................... 8-24

8.6.1 Disassembly................................................................................................. 8-24

8.6.2 Assembly...................................................................................................... 8-28

8.7 Swing Motor and Swing Drive AS - Remove and Install ........................................ 8-33

8.7.1 Removal ....................................................................................................... 8-33

8.7.2 Installation .................................................................................................... 8-34

8.8 Swing Motor and Swing Drive AS - Disassemble and Assemble........................... 8-35

8.8.1 Disassembly................................................................................................. 8-35

8.8.2 Assembly...................................................................................................... 8-40

8.9 Idler AS - Disassemble and Assemble ................................................................... 8-45

8.9.1 Disassembly................................................................................................. 8-45

8.9.2 Assembly...................................................................................................... 8-46

8.10 Sprocket - Remove and Install............................................................................. 8-49

8.10.1 Removal ..................................................................................................... 8-49

8.10.2 Installation .................................................................................................. 8-49

8.11 Track AS - Remove and Install ............................................................................. 8-50

8.11.1 Removal ..................................................................................................... 8-50

8.11.2 Installation .................................................................................................. 8-52

8.12 Swing Bearing AS - Remove and Install .............................................................. 8-53

8.12.1 Removal ..................................................................................................... 8-53

8.12.2 Installation .................................................................................................. 8-54

8.13 Swing Platform AS - Remove and Install ............................................................. 8-55

8.13.1 Removal ..................................................................................................... 8-55

8.13.2 Installation .................................................................................................. 8-58

8.14 Swivel Joint AS - Remove and Install .................................................................. 8-59

8.14.1 Removal ..................................................................................................... 8-59

8.14.2 Installation .................................................................................................. 8-61

8.15 Swivel Joint AS - Disassemble and Assemble ..................................................... 8-62

8.15.1 Disassembly............................................................................................... 8-62

8.15.2 Assembly.................................................................................................... 8-63

8.16 Hydraulic Tank AS - Remove and Install .............................................................. 8-64

8.16.1 Removal ..................................................................................................... 8-64

8.16.2 Installation .................................................................................................. 8-66

8.17 Control Valve AS - Remove and Install ................................................................ 8-67

8.17.1 Removal ..................................................................................................... 8-67

8.17.2 Installation .................................................................................................. 8-71

8.18 Hydraulic Pump AS - Remove and Install ............................................................ 8-72

8.18.1 Removal ..................................................................................................... 8-72

8.18.2 Installation .................................................................................................. 8-76

8.19 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install .................... 8-77

8.19.1 Removal ..................................................................................................... 8-77

8.19.2 Installation .................................................................................................. 8-77

8.20 Pilot Valve AS (Work Equipment) - Disassemble and Assemble ......................... 8-78

8.20.1 Assembly.................................................................................................... 8-78

8.21 Pilot Valve AS (Travel) - Disassemble and Assemble .......................................... 8-80

8.21.1 Assembly.................................................................................................... 8-81

8.22 Hydraulic Cylinder AS - Disassemble and Assemble........................................... 8-82

8.22.1 Disassembly............................................................................................... 8-83

8.22.2 Assembly.................................................................................................... 8-88

8.23 Work Equipment AS - Remove and Install ........................................................... 8-94

8.23.1 Removal ..................................................................................................... 8-94

8.23.2 Installation .................................................................................................. 8-96

8.24 Air Conditioner AS - Remove and Install.............................................................. 8-97

8.24.1 Removal ..................................................................................................... 8-97

8.24.2 Installation ................................................................................................ 8-100

8.25 Counterweight AS - Remove and Install ............................................................ 8-101

8.25.1 Removal ................................................................................................... 8-101

8.25.2 Installation ................................................................................................ 8-102

8.26 Cab AS - Remove and Install............................................................................. 8-103

8.26.1 Removal ................................................................................................... 8-103

8.26.2 Installation ................................................................................................ 8-107

8.27 Cab Window Glass – Disassemble and Assemble ............................................ 8-108

8.27.1 Removal ................................................................................................... 8-109

8.27.2 Installation .................................................................................................8-112

8.28 Front Window AS - Disassemble and Assemble................................................ 8-124

8.28.1 Disassemble ............................................................................................ 8-124

8.28.2 Assemble ................................................................................................. 8-127

XII

8.29 Monitor - Remove and Install ............................................................................. 8-133

8.29.1 Removal ................................................................................................... 8-133

8.29.2 Installation ................................................................................................ 8-133

8.30 Controller AS - Remove and Install.................................................................... 8-134

8.30.1 Removal ................................................................................................... 8-134

8.30.2 Installation ................................................................................................ 8-134

8.31 Radio ................................................................................................................. 8-135

8.31.1 Structure .................................................................................................. 8-135

8.31.2 Removal and installation .......................................................................... 8-137

8.31.2.1 Removal .......................................................................................... 8-137

8.31.2.2 Installation ....................................................................................... 8-137

8.31.3 Connector model and wiring .................................................................... 8-138

8.32 Battery ............................................................................................................... 8-139

8.32.1 Structure .................................................................................................. 8-139

8.32.2 Removal and installation .......................................................................... 8-140

8.32.2.1 Removal .......................................................................................... 8-140

8.32.2.2 Installation ....................................................................................... 8-141

8.32.3 Replacement ............................................................................................ 8-141

8.33 Start Switch........................................................................................................ 8-142

8.33.1 Structure ................................................................................................. 8-142

8.33.2 Removal and installation .......................................................................... 8-143

8.33.2.1 Removal .......................................................................................... 8-143

8.33.3 Working principle and wiring of start switch ............................................. 8-144

8.34 Fuse Box............................................................................................................ 8-145

8.34.1 Removal and installation .......................................................................... 8-145

8.35 Wiper ................................................................................................................. 8-146

8.35.1 Structure and working principle................................................................ 8-146

8.35.2 Removal and Installation.......................................................................... 8-148

8.35.3 Angle adjustment of wiper arm................................................................. 8-150

8.36 Relay.................................................................................................................. 8-151

8.36.1 Engine relays ........................................................................................... 8-151

XIII

8.36.2 Other relays ............................................................................................. 8-152

8.36.2.1 Function and location ...................................................................... 8-152

8.36.2.2 Removal and Installation ................................................................. 8-153

8.36.2.3 Relay connector and wiring ............................................................. 8-154

8.37 Sensor ............................................................................................................... 8-155

8.38 Connector Terminals - Insert and Remove ........................................................ 8-157

8.38.1 Insertion ................................................................................................... 8-157

8.38.2 Removal ................................................................................................... 8-158

9 System Schematics

9.1 Hydraulic System Diagram ...................................................................................... 9-3

9.2 Air-Conditioning Electrical Diagram ......................................................................... 9-4

9.3 Fuse Box Relay ....................................................................................................... 9-5

9.4 Control Switches and Monitor Electrical Diagram ................................................... 9-6

9.5 Operator Cab Electrical Diagram ............................................................................. 9-7

9.6 Chassis Electrical Diagram ...................................................................................... 9-8

Introduction

1-1