SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual - page 6

 

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SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual - page 6

 

 

Specifi cations

3.6 Capacity Table

●

Machine oil above API CF-4 (no lower than APC CD) is recommended.

●

Gear oil GL-5 is recommended.

●

Obtain genuine oil from Sany Heavy Machine or its authorized dealers.

Engine oil pan

Swing mecha-

nism casing

Final drive 

casing

Hydraulic 

system

Cooling system

Fuel tank

22 {5.81}

4.0 {1.06}

5.5 {1.45}

239 {63.14}

22.5 {5.94}

340 {89.82}

Unit: L {US Gal}

3-11

Specifi cations

3.7  

Engine Performance Curve

Testing condition:

1) Temperature: 298K, one standard atmospheric pressure.  2)  No fan.

ZX215-1001003

240

230

220

210

2000

1800

1600

1400

1200

1000

20

40

60

80

100

120

kW

Engine speed min

Fuel consumption

Fuel consumption

Power output

Power output

600

500

400

300

Torque

N·m

Torque

g/kw·h

-1

Structure and Function

Structure and Function

4-1

4  Structure and Function

4.1  Engine and Cooling System .................................................................................... 4-5

4.1.1 Engine-related parts....................................................................................... 4-5
4.1.2  Radiator and intercooler................................................................................. 4-6

4.2 Power Train.............................................................................................................. 4-7

4.2.1  Power transmission system  .......................................................................... 4-7
4.2.2  Final drive assembly ...................................................................................... 4-8
4.2.3 Swing machinery.......................................................................................... 4-12
4.2.4 Swing bearing .............................................................................................. 4-14

4.3  Undercarriage and Frame...................................................................................... 4-15

4.3.1  Track frame and recoil spring....................................................................... 4-15
4.3.2 Idler .............................................................................................................. 4-17
4.3.3 Carrier roller ................................................................................................. 4-19
4.3.4 Track roller ................................................................................................... 4-20
4.3.5 Track shoe ................................................................................................... 4-21
4.3.6  Triple grouser shoe ...................................................................................... 4-25

4.4  Hydraulic System, Part 1 ....................................................................................... 4-26

4.4.1  Hydraulic equipment layout.......................................................................... 4-26
4.4.2  Hydraulic tank and 

fi

 lter ............................................................................... 4-28

4.4.3 Hydraulic pump

   ................................................................................................... 4-29

4.4.4 Pilot pump .................................................................................................... 4-36
4.4.5 Regulator  .................................................................................................... 4-37

4.4.5.1  Control mechanism makeup ............................................................... 4-39
4.4.5.2  Adjustment of the regulator ................................................................. 4-40
4.4.5.3 Operation ............................................................................................ 4-42

4.5  Hydraulic System, Part 2 ....................................................................................... 4-45

4.5.1 Control valve ................................................................................................ 4-45

4-2

Structure and Function

4.5.2 Operating principle ....................................................................................... 4-48

4.5.2.1  When spool is in neutral position ........................................................ 4-48
4.5.2.2 Travel .................................................................................................. 4-50
4.5.2.3 Arm ...................................................................................................... 4-51
4.5.2.4 Boom ................................................................................................... 4-56
4.5.2.5 Bucket ................................................................................................. 4-59
4.5.2.6 Swing .................................................................................................. 4-61
4.5.2.7 Option ................................................................................................. 4-63
4.5.2.8 Travel straight ..................................................................................... 4-64
4.5.2.9  Lock valve function ............................................................................. 4-65
4.5.2.10  Main relief valve function .................................................................. 4-67
4.5.2.11  Port relief valve function .................................................................... 4-68

4.5.3 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 .................................................................... 4-95

4.6.7  Valve control system .................................................................................. 4-107
4.6.8  Pilot  valve.................................................................................................. 4-109

4.6.8.1  Work equipment and swing pilot valve .............................................. 4-109
4.6.8.2  Travel PPC valve ...............................................................................4-113

4.6.9 Solenoid valve.............................................................................................4-117
4.6.10 Accumulator ..............................................................................................4-118
4.6.11 Pilot oil 

fi

 lter ...............................................................................................4-119

4.6.12  Pump oil pressure sensor ........................................................................ 4-120
4.6.13 Hydraulic cylinder..................................................................................... 4-121
4.6.14 Work equipment ....................................................................................... 4-123

4.7  Air Conditioning System....................................................................................... 4-129

4.7.1  A/C components layout drawing ................................................................ 4-130
4.7.2 Control panel.............................................................................................. 4-131
4.7.3 Circuit diagram ........................................................................................... 4-132
4.7.4 Refrigeration principle ................................................................................ 4-134

4-3

Structure and Function

4.7.4.1  Refrigeration cycle diagram .............................................................. 4-134
4.7.4.2  Heating cycle diagram ...................................................................... 4-134

4.7.5 Compressor ............................................................................................... 4-135
4.7.6 Clutch ......................................................................................................... 4-137
4.7.8 Condenser ................................................................................................. 4-138
4.7.7 Expansion valve ......................................................................................... 4-138
4.7.9 Evaporator ................................................................................................. 4-139
4.7.10 Receiver tank ........................................................................................... 4-139
4.7.11 Pressure switch ........................................................................................ 4-140
4.7.12  Fresh air sensor ....................................................................................... 4-141
4.7.13 Refrigerant ............................................................................................... 4-141
4.7.14 Compressor oil ......................................................................................... 4-160

4.8 Engine Control ..................................................................................................... 4-161

4.8.1  System operation  ...................................................................................... 4-162
4.8.2 Components............................................................................................... 4-163

4.8.2.1  Fuel control dial ................................................................................. 4-163
4.8.2.2 Controller .......................................................................................... 4-165

4.9  Electrical Control System..................................................................................... 4-167

4.9.1 Control function .......................................................................................... 4-167
4.9.2  Machine control system diagram ............................................................... 4-168
4.9.3  Engine and pump composite control function ............................................ 4-170
4.9.4  Pump control function ................................................................................ 4-174

4.9.4.1 Electrical positive 

fl

 ow control ........................................................... 4-175

4.9.4.2  Constant power control ..................................................................... 4-178

4.9.5  Valve control function ................................................................................. 4-180

4.9.5.1 Bucket 

fl

 ow control ............................................................................ 4-181

4.9.5.2  Swing priority control ......................................................................... 4-182

4.9.6  Duo travel speed control ............................................................................ 4-183
4.9.7  Engine preheating/overheating alarm  ....................................................... 4-185

4.9.7.1 Engine preheating ............................................................................. 4-186
4.9.7.2  Engine overheating alarm ................................................................. 4-187

4.9.8  Engine oil under–pressure alarm ............................................................... 4-187
4.9.9  Auto deceleration/acceleration control ....................................................... 4-188
4.9.10  Engine speed calibration function ............................................................ 4-190
4.9.11 Electrical Components ............................................................................. 4-192

4.9.11.1  Pump pressure sensor .................................................................... 4-192
4.9.11.2  Pilot pressure sensor ...................................................................... 4-193
4.9.11.3  Engine speed sensor ...................................................................... 4-194

Structure and Function

4-4

 

WARNING

Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided 
with this machine and before operating or 
servicing the machine. Also read the safety 
information on machine decals before per-
forming any operations. Failure to do so 
can cause machine damage, personal in-
jury or death.

4.9.11.4  Coolant temperature sensor ............................................................ 4-195
4.9.11.5  Fuel level sensor ............................................................................. 4-196
4.9.11.6  Oil pressure switch .......................................................................... 4-197

4.10 Monitoring System ............................................................................................. 4-198

4.10.1 Machine monitor ...................................................................................... 4-199
4.10.2 Monitor functions...................................................................................... 4-200
4.10.3 Monitor operation ..................................................................................... 4-203

4-5

Structure and Function

4.1  Engine and Cooling System

4 STRUCTURE AND FUNCTION

4.1.1 Engine-related parts

Specifi cation

Oil capacity: 22 L

ZX215-1002001

6

7

1

3

5

4

2

1)

Fan

2)

Front engine mount

3)

Fuel 

fi

 lter

4)

Start 

motor

5)

Rubber damper assembly

6)

Rear engine mount

7)

Muf

fl

 er

4-6

Structure and Function

4.1.2  Radiator and intercooler

1)

Radiator outlet hose

2)

Radiator inlet hose

3)

Radiator

4)

Intercooler air intake

5)

Reserve 

tank

6)

Intercooler

7)

Intercooler air outlet

8)

Fan 

guard

9)

Radiator 

cap

Specifi cations

Radiator assembly: 

ZH860×385×1050-S70Y75Z20Q/SY015

Aluminum pipe, belt-type radiator

Radiator and oil cooler in parallel connection; 
intercooler in series connection with radiator 
and oil cooler.

Reservoir capacity: 8.9 L (2.35 US gal)

Engine coolant capacity: 9.5L (2.51 US gal)

6

4

7

9

1

2

8

5

3

WX215-1204009G

4-7

Structure and Function

4.2 Power Train

4.2.1  Power transmission system 

ZX215-1002003

2

1

3

4

5

6

7

8

9

10

1)

Swing 

motor

2)

Swing 

reducer

3)

Swing 

bearing

4)

Idler

5)

Central swivel joint

6)

Accumulator

7)

Control 

valve

8)

Final 

drive 

AS

9)

Hydraulic 

pump

10) Engine

Structure and Function

ZX215-1002005

13

14

15

Final drive AS (KYB)

4.2.2  

Final drive assembly

ZX215-1002004-1

205±10 N·m

73±3.6 N·m

59±4.9 N·m

157±8 N·m

1

2

3

4

5

6

7

8

9

10

11

12

16

19

17

20

18

Structure and Function

1)

Cylinder 

GP

2)

Shaft

3)

Gear hub (No. of teeth: 85)

4)

No. 2 planetary carrier

5)

No. 1 planetary carrier

6)

No. 1 planetary gear (No. of teeth: 36)

7)

No. 1 sun gear (No. of teeth: 12)

8)

End 

cover

9)

No. 2 sun gear (No. of teeth: 19)

10) No. 2 planetary gear (No. of teeth: 36)
11) Seal ring
12) Travel motor
13) Fill port
14) Level port
15) Drain port

Specifi cations

Reduction ratio:

( (12+85) /12) × ( (19+85) /19) ) -1= 43.246

No.

Check 

item

Criteria

Remedy

Standard clearance

Clearance limit

16

Backlash between No. 2 sun gear 
and No.2 planetary gear

0.13 – 0.47

1.00

Replace

17

Backlash between No. 1 planetary 
gear and gear hub

0.17 – 0.57

1.10

Replace

18

Backlash between No. 1 sun gear 
and No.1 planetary gear

0.14 – 0.46

1.00

19

Backlash between No. 2 planetary 
gear and gear hub

0.16 – 0.56

1.10

20

Backlash between No. 1 planetary 
carrier and No. 2 sun gear

0.38 – 0.66

1.00

4-10

Structure and Function

Final drive AS (Daewoo)

2

3

5

6

7

8

9

11

12

13

14 15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

22

1

3

9

4 10

27

WX215-1204010G

1)

O-ring

2)

Mandrel

3)

Float 

seal

4)

Gear 

carrier

5)

Hub

6)

Spacer

7)

Planetary gear shaft

8)

Planetary 

gear

9)

Thrust 

washer

10) Spring pin
11) Needle bearing
12) Floating bush

13) Planetary gear shaft
14) Sun gear
15) Snap ring
16) Planetary gear
17) Needle bearing
18) Drive gear
19) Spring pin
20) End cover
21) Socket head bolt
22) Radial thrust ball bearing
23) O-ring
24) Plug

25) Seal ring
26) O-ring
27) Thrust washer
28) Thrust washer
29) Thrust plate
30) Gear carrier
31) Gasket
32) O-ring
33) O-ring
34) Fill port
35) Level port
36) Drain port

4-11

Structure and Function

ZX215-1002007

1

2

3

4

5

6

7

59~74 Nm

8

9

21

22

10

23
24

11

12

26

25

13

27

14

15

16

17

18

28

19

20

4.2.3  

Swing machinery

4-12

Structure and Function

Specifi cations

Reduction ratio: 

(14+25) /14× (16+25) /14= 20.04

1)

Plug

2)

Oil 

seal

3)

Self-aligning 

bearing

4)

Ring gear (No. of teeth:52)

5)

No. 2 planetary carrier

6)

No. 1 planetary carrier

7)

No. 2 sun gear (No. of teeth: 16)

8)

No. 1 sun gear (No. of teeth:14)

9)

Swing 

motor

10) No. 1 planetary gear (No. of teeth:18)

11) No. 2 planetary gear GP
12) No. 2 planetary gear (No. of teeth:17)
13) Spring pin
14) Swing reducer screw plug
15) Grease 

fi

 tting

16) Self-aligning bearing
17) Bearing sealing
18) Swing pinion
19) Dipstick
20) Oil 

fi

 lling pipe

No.

Check 

item

Criteria

Remedy

Standard clearance

Clearance limit

21

Backlash between swing motor shaft 
and No. 1 sun gear

0.18 – 0.28

—

Replace

22

Backlash between No. 1 sun gear 
and No.1 planetary gear

0.16 – 0.50

1.00

Replace

23

Backlash between No. 1 planetary 
gear and ring gear 

0.18 – 0.59

1.10

24

Backlash between No. 1 planetary 
carrier and No. 2 sun gear

0.39 – 0.71

1.20

25

Backlash between No. 2 sun gear 
and No.2 planetary gear

0.16 – 0.50

0.90

26

Backlash between No. 2 planetary 
gear and ring gear 

0.18 – 0.59

1.00

27

Backlash between No. 2 planetary 
carrier and swing pinion

0.07 – 0.23

—

28

Backlash between swing pinion and 
swing bearing

0.22 – 1.32

2.00

Unit: mm

Structure and Function

4.2.4  

Swing bearing

1)

Swing bearing inner race (Teeth: 91)

2)

Ball

3)

Swing bearing outer race

Specifi cations

Reduction ratio: 91/13= 7
Amount of 

fi

 lled grease: 13±1 Kg

a. Inner race soft zone S position

b. Outer race soft zone S position

Check item

Criteria

Remedy

Axial clearance of bearing

(when mounted on chassis)

Standard clearance

Clearance limit

Replace

0.5~1.6

3.2

ZX215-1002008

a

1

2

3

549±50 Nm

549±50 Nm

b

A-A

A

A

Unit: mm

4-14

Structure and Function

ZX215-1002009

1

2

3

4

5

10

9

7

8

11

X

X

6

1)

Idler

2)

Track 

frame

3)

Carrier 

roller

4)

Sprocket

5)

Track 

roller

6)

Track 

shoe

7)

Center 

guard

8)

Front 

guard

●

Dimension and number of track rollers may
vary depending on the machine model, but
the basic structure is the same.

Model

Q'ty (One side)

SY195C9

7

SY205C9

7

SY215C9

8

SY225C9

9

4.3.1  

Track frame and recoil spring

4.3  

 Undercarriage and Frame

 

 

 

 

 

 

 

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