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

1-3

1 INTRODUCTION

1.1

Safety Notice

Proper servicing and repair are extremely im-
portant for safe machine operation. The ser-
vicing and repair techniques recommended by
Sany and described in this manual are both
effective and safe. Some of the techniques
require the use of tools specially designed by
Sany for the speci

c purpose.

To prevent injury to workers, the symbol is
used to mark safety precautions in this manu-
al. The cautions accompanying these symbols
should always be followed carefully. If any
dangerous situation arises or may possibly
arise,

rst consider safety, and take necessary

actions to deal with the situation.

1. General precautions

Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine.

1) Before carrying out any greasing or re-

pairs, read all the safety messages on the
machine. For the locations of the safety
messages and detailed explanation of pre-
cautions, see the Operation and Mainte-
nance Manual.

2) Choose a place in the repair workshop

to keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the working area
clean and make sure that there is no dirt,
water, or oil on the

oor. Smoke only in the

areas provided for smoking. Never smoke
while working.

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1-4

3) When carrying out any operation, always

wear safety shoes and hard hat. Do not
wear loose work clothes, or clothes with
buttons missing.

●

Always wear goggles while striking any
parts with a hammer.

●

Always wear goggles while grinding
parts with a grinder, etc.

4) When carrying out any operation with two

or more workers, always agree on the op-
erating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
the work, hang UNDER REPAIR tags in
the operator’s cab.

5) Only quali

ed workers are allowed to carry

out work and operation which require li-
cense or quali

cation.

6) Keep all tools in good condition, learn

the correct way to use them, and use the
proper ones of them. Before starting the
work, thoroughly check the tools, machine,
forklift, service car, etc.

7) If welding repairs are needed, always have

a trained and experienced welder carry out
the work. When carrying out welding work,
always wear welding gloves, apron, shield-
ing goggles, cap and other clothes suited
for welding operation.

8) Before starting the work, warm up thor-

oughly to start work under good condition.

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2. Preparations for work

1) Before adding oil or making any repairs,

park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.

2) Before starting work, lower the work equip-

ment (blade, ripper, bucket, etc.) to the
ground. If this is not possible, insert the
lock pin or use blocks to prevent the work
equipment from falling. In addition, be
sure to lock all the control levers and hang
warning signs on them.

3) When disassembling or assembling, sup-

port the machine with blocks, jacks, or
stands before starting work.

4) Remove all mud and oil from the steps or

other places used to get on and off the ma-
chine. Always use the handrails, ladders or
steps when getting on or off the machine.
Never jump on or off the machine. If it is
impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.

Safety points

Good arrangement

Correct work clothes

Following work standard

Making and checking signs

Prohibition of operation and handling by
unlicensed workers

Safety check before starting work

Wearing protective goggles (for cleaning or
grinding operation)

Wearing shielding goggles and protectors
(for welding operation)

Good physical condition and preparation

Precautions against work which you are
not used to or you are used to too much

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3. Precautions during work

1) Before disconnecting or removing compo-

nents of the oil, water, or air circuits, first
relieve the pressure completely from the
circuit. When removing the oil

ller cap, a

drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
squirting out.

2) The coolant and oil in the circuits are hot

when the engine is stopped, so be care-
ful not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.

3) Before starting work, stop the engine.

When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping the
engine (measuring oil pressure, revolving
speed, temperature, etc.), take extreme
care not to get rolled or caught in rotating
parts or moving parts.

4) Before starting work, remove the leads

from the battery. Always remove the lead
from the negative (–) terminal

rst.

5) When raising a heavy component (more

than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.

6) When removing a cover which is under

internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal po-
sitions. Loosen those bolts gradually and
alternately to release the pressure, and
then remove the cover.

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7) When removing components, be careful

not to break or damage electrical wiring.
Damaged wiring may cause electrical

res.

8) When removing piping, stop fuel or oil from

spilling out. If any fuel or oil drips onto the
floor, wipe it up immediately. Fuel or oil
on the

oor can cause you to slip and can

even start

res.

9) As a general rule, do not use gasoline to

wash parts. Do not use it to clean electrical
parts, in particular.

10) Be sure to assemble all parts again in their

original places. Replace any damaged
parts and non-reusable part. When install-
ing hoses and wires, be sure that they will
not be damaged by contact with other parts
when the machine is operated.

11) When installing high pressure hoses, make

sure they are not twisted. Damaged hoses
are dangerous, so be extremely careful
when installing hoses for high pressure cir-
cuits. Make sure connecting parts are cor-
rectly installed.

12) When assembling or installing parts, al-

ways tighten them to the speci

ed torques.

When installing protective parts such as
guards, or parts which vibrate violently or
rotate at high speed, be particularly careful
to check that they are installed correctly.

13) When aligning 2 holes, never insert your

ngers or hand. Be careful not to get your

ngers caught in a hole.

14) When measuring hydraulic pressure,

check if the measuring tools are correctly
assembled.

15) Take care when removing or installing the

tracks of track-type machines. When re-
moving the track, the track separates sud-
denly, so never let anyone stand at either
end of the track.

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4. Precautions for sling work and giving

signals

1) Only one appointed worker is allowed to

give signals and co-workers must commu-
nicate with each other frequently. The ap-
pointed signal person must give specified
signals clearly at a place where he is seen
well from the operator's seat and where he
can see the working condition easily. The
signal person must always stand in front of
the load and guide the operator safely.

●

Do not stand under the load.

●

Do not step on the load.

2) Check the slings before starting sling work.

3) Always wear gloves during sling work.

(Wear leather gloves, if available.)

4) Measure the weight of the load by the eye

and check its center of gravity.

5) Use proper sling according to the weight of

the load and method of slinging. If too thick
wire ropes are used to sling a light load,
the load may slip and fall.

6) Do not sling a load with 1 wire rope alone.

If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire ropes
symmetrically.

Slinging with one rope may cause turn-
ing of the load during hoisting, untwisting
of the rope, or slipping of the rope from
its original winding position on the load,
which can result in a dangerous accident.

16) If the engine is operated for a long time

in a poor ventilated place, you may suffer
from gas poisoning. Keep windows and
doors open to provide enough ventilation.

CAUTION

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7) Limit the hanging angle to 60°, as a rule.

Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more ropes,
the force subjected to each rope will in-
crease with the hanging angle. The table
below shows the variation of allowable
load in kN {kg} when hoisting is made with
2 ropes, each of which is allowed to sling
up to 9.8 kN {1,000 kg} vertically, at various
hanging angles. When the 2 ropes sling a
load vertically, up to 19.6 kN {2,000 kg} of
total weight can be suspended. This weight
is reduced to 9.8 kN {1,000 kg} when the 2
ropes make a hanging angle of 120°. If the
2 ropes sling a 19.6 kN {2,000 kg} load at
a lifting angle of 150°, each of them is sub-
jected to a force as large as 39.2 kN {4,000
kg}.

8) When installing wire ropes to an angular

load, apply softeners to protect the wire
ropes. If the load is slippery, apply proper
material to prevent the wire rope from slip-
ping.

9) Use the specified eyebolts and fix wire

ropes, chains, etc. to them with shackles,
etc.

10) Apply wire ropes to the middle portion of

the hook.

●

Slinging near the tip of the hook may
cause the rope to slip off the hook dur-
ing hoisting. The hook has the maxi-
mum strength at the middle portion.

11) Do not use twisted or kinked wire ropes.

12) When lifting up a load, observe the follow-

ing.

●

Wind in the crane slowly until wire
ropes are stretched. When settling the
wire ropes with the hand, do not grasp
them but press them from above. If

Hanging angle (Deg.)

Load capacity kN(kg)

(

)

19.6

(

2000

)

18.6

(

1900

)

16.7

(

1700

)

13.7

(

1400

)

9.8

(

1000

)

4.9

(

500

)

19.6

(

2000

)

9.8

(

1000

)

120

150

ZX215-1000001

ZX215-1000002

100% 88% 79% 71% 41%

Introduction

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you grasp them, your fingers may be
caught.

●

After the wire ropes are stretched, stop
the crane and check the condition of
the slung load, wire ropes, and soft-
ener.

●

If the load is unstable or the wire rope
or chains are twisted, lower the load
and lift it up again.

●

Do not lift up the load slantingly.

13) When lifting down a load, observe the fol-

lowing.

●

When lifting down a load, stop it tempo-
rarily at 30 cm above the

oor, and then

lower it slowly.

●

Check that the load is stable, and then
remove the sling.

●

Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.

5. Precautions for using mobile crane

6. Precautions for using overhead hoist

crane

Read the Operation and Maintenance Man-
ual of the crane carefully in advance and
operate the crane safely.

When raising a heavy part (heavier than 25
kg), use a hoist, etc. In disassembly and
assembly, the weight of a part heavier than

25 kg is indicated after the mark of

CAUTION

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1-11

1) Before starting work, inspect the wire

ropes, brake, clutch, controller, rails, over
wind stop device, electric shock preven-
tion earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.

2) Observe the signals for sling work.

3) Operate the hoist at a safe place.

4) Check the direction indicator plates (east,

west, south, and north) and the directions
of the control buttons without fail

5) Do not sling a load slantingly. Do not move

the crane while the slung load is swinging.

6) Do not raise or lower a load while the

crane is moving longitudinally or laterally.

7) Do not drag a sling.

8) When lifting up a load, stop it just after it

leaves the ground and check safety, and
then lift it up.

9) Consider the travel route in advance and

lift up a load to a safe height.

10) Place the control switch on a position

where it will not be an obstacle to work and
passage.

11) After operating the hoist, do not swing the

control switch.

12) Remember the position of the main switch

so that you can turn off the power immedi-
ately in an emergency.

13) If the hoist stops because of a power fail-

ure, turn the power switch OFF. When turn-
ing on a switch which was turned OFF by
the electric shock prevention earth leakage
breaker, check that the devices related to
that switch are not in operation state.

14) If you find an obstacle around the hoist,

stop the operation.

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7. Selecting wire ropes

Select adequate ropes as per the weight
of parts to be hoisted, referring to the table
below.

Wire ropes

(Standard “Z” twist ropes without galvanizing)

(JIS G3525, No. 6, Type 6X37-A))

Nominal Diam-

eter of Rope

Allowable Load

Ton

8.8

0.9

12.7

1.3

17.3

1.7

22.6

2.3

28.6

2.9

35.3

3.6

55.3

5.6

79.6

8.1

141.6

14.4

221.6

22.6

318.3

32.4

The allowable load is one-sixth of the
breaking strength of the rope used (Safety
coeffi cient: 6).

15) After finishing the work, stop the hoist at

the speci

ed position and raise the hook to

at least 2 m above the

oor. Do not leave

the sling installed to the hook.

CAUTION

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1-13

1.2

How to Read the Shop Manual

●

Some attachments and optional parts in
this shop manual may not be delivered to
certain areas. If one of them is required,
consult Sany distributors.

●

Materials and speci

cations are subject to

change without notice.

1. Composition of shop manual

This shop manual contains the necessary
technical information for services performed
in a workshop. For ease of understanding, the
manual is divided into the following sections.

Introduction

This section provides an overview of what is
covered in the rest of this manual and how to
use this manual,.

Shop Safety

This section covers basic shop safety infor-
mation relating to this equipment. It also de-
scribes what the hazard alerts mean that are
used throughout the manual.

Specifi cations

Technical speci

cation of work equipment and

optional parts are given in this section.

Structure and function

This section explains the structure and func-
tion of each component. It helps the reader
to get a better understanding of the machine
structure, and also serves as a reference for
troubleshooting.

Standard Values

This section explains the standard values for
a new machine and judgement criteria for test-
ing, adjusting, and troubleshooting. This stan-
dard value table is used to check the standard
values in testing and adjusting and to judge
parts in troubleshooting.

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2. Revision and distribution

Any additions, revisions, or other change of
notices will be sent to Sany distributors. Get
the most up-to-date information before you
start any work.

Testing and adjusting

This section details the inspection before and
after repair work as well as the adjustment dur-
ing inspection and repair work. Troubleshoot-
ing table that involves “Fault”and “Cause”are
also included in this section.

Troubleshooting

This section explains the way to detect faulty
parts and the method to repair them. This sec-
tion is divided into the following parts: Electri-
cal system, Engine, Hydraulic and mechanical
system and Monitoring system.

Disassembly and assembly

This section explains the procedures as well
as precautions for removing, installing, disas-
sembling and assembling of each component.

System Schematics

This section provides hydraulic circuit dia-
grams and electrical circuit diagrams.

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Symbol

Item

Remarks

Safety

Special safety precautions are necessary when performing
work.

★

Caution

Special technical precautions or other precautions for pre-
serving standards are necessary when performing work.

Weight

Weight of parts of component or parts. Caution necessary
when selecting hoisting wire, or when working posture is
important, etc.

Tightening

torque

Places that require special attention for tightening torque
during assembly.

Coat

Places to be coated with adhesives, etc. during assembly.

Oil, Coolant

Places where oil, etc. must be added, and capacity.

Drain

Places where oil, etc. must be drained, and quantity to be
drained.

3. Symbols

Important safety and quality portions are
marked with the following symbols so that the
shop manual will be used practically.

4. Units

In this shop manual, the units are indicated
with International System of units (SI). For
reference, conventionally used Gravitational
System of units is indicated in parentheses { }.

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1.3 Terms for Maintenance Standard

1. Standard size and tolerance

●

To be accurate, the finishing size of parts
is a little different from one to another.

●

To specify a

nishing size of a part, a tem-

porary standard size is set and an allow-
able difference from that size is indicated.

●

The above size set temporarily is called
the "standard size" and the range of differ-
ence from the standard size is called the
"tolerance".

●

The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.

★

The tolerance may be indicated in the
text and a table as [standard size (upper
limit of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)

●

Usually, the size of a hole and the size
of the shaft to be

tted to that hole are

indicated by the same standard size
and different tolerances of the hole and
shaft. The tightness of

t is decided by

the tolerance.

●

Indication of size of rotating shaft and
hole and relationship drawing of them.

Example

Standard size

Tolerance

120

–0.022
–0.126

ZX215-1000003

Tolerance of hole
(upper):+0.046

Std.clearance (max.):0.122

Std.clearance (min.):0.030

Tolerance of shaft
(lower):-0.076
Tolerance of shaft
(upper):-0.030

Std.size

The maintenance standard values necessary
for judgment of products and parts are de-
scribed by the following terms.

Introduction

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Example

Standard size

Tolerance

Shaft

Hole

-0.030
-0.076

+0.046

2. Standard clearance and standard value

●

The clearance made when new parts are
assembled is called the "standard clear-
ance", which is indicated by the range from
the minimum clearance to the maximum
clearance.

●

When some parts are repaired, the clear-
ance is generally adjusted to the standard
clearance.

●

A value of performance and function of
new products or equivalent is called the
"standard value", which is indicated by a
range or a target value.

●

When some parts are repaired, the value
of performance/function is set to the stan-
dard value.

3. Standard interference

●

When the size of a hole is smaller than the
size of a shaft because of the standard
size and tolerance, the difference between
these sizes is called the "interference".

●

The range (A – B) from the difference (A)
between the minimum size of the shaft and
the maximum size of the shaft to the differ-
ence (B) between the maximum size of the
shaft and the minimum size of the hole is
the "standard interference".

●

After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.

SANY Crawler Hydraulic Excavator SY215CLC (CUMMINS QSB6.7 engine). Shop Manual - page 2