Content .. 18 19 20 21 ..

SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual - page 20

5-4

Standard Values

Categ.

Item

Measurement condition

Unit

Std. value for

new machine

Permis-

sible value

Engine Speed

2 pumps at relief

●

Engine coolant temperature: Within
operational range

●

Hydraulic oil temperature: Within
operational range

●

Engine running at high idle

●

Heavy-load operating mode (H)

●

Arm-in relief condition

rpm

2,030 ± 50

Speed when auto
deceleration is oper-
ated

●

Engine running at high idle

●

Auto idling switch on

●

All control levers neutral

rpm

1,400 ± 50

1,400 ± 100

Spool Stroke

Boom control valve

●

Engine stopped

●

See Control valve.

11.5 ± 0.5

DOWN

9.5 ± 0.5

Arm control valve

11.5 ± 0.5

OUT

9.5 ± 0.5

Bucket control valve

DIG/DUMP

9.5 ± 0.5

Swing control valve

Travel (L&R)

9.5 ± 0.5

Travel control valve

Forward &

Reverse

9.5 ± 0.5

Control Lever stroke

Boom control lever

●

Engine stopped

●

Control lever grip at center

●

Max. reading at stroke end (except
lever play in NEUTRAL position)

85 ± 10

Arm control lever

85 ± 10

Bucket control lever

85 ± 10

Swing control lever

85 ± 10

Travel control lever

115 ± 12

Play of control lever

●

Engine stopped

●

Slightly push the
control lever. Stop
pushing when re-
sistance is felt.

●

Max. reading at

stroke end.

Work Equip-

ment

Max. 15

Max. 20

Stroke

Max. 20

Max. 25

5.2 Standard Values of Chassis-related Parts

5-5

Standard Values

Categ.

Item

Measurement condition

Unit

Std. value for

new machine

Permis-

sible value

Operating Force of Control Lever/

Pedal

Boom control
lever

●

Hydraulic oil temp: Within operational
range

●

Engine running at high idle

●

Control lever grip at center

●

Pedal at tip

●

Max. reading at stroke end

{kgf}

Max. 19.6

{Max. 2.0}

Max. 24.5

{Max. 2.5}

Arm control
lever

Max. 19.6

{Max. 2.0}

Max. 24.5

{Max. 2.5}

Bucket con-
trol lever

Max. 15.6

{Max. 1.6}

Max. 21.6

{Max. 2.2}

Swing control
lever

Max. 15.6

{Max. 1.6}

Max. 21.6

{Max. 2.2}

Travel control
lever

Max. 30.4

{Max. 3.1}

Max. 39.2

{Max. 4.0}

Travel control
pedal

Max. 93.1

{Max. 9.5}

Max. 107.8

{Max. 11}

Hydraulic Pressure

Unloaded
pressure

●

Hydraulic oil temp: Within operational
range

●

Engine running at high idle

●

Working mode: H

●

All control levers in neutral position

●

Hydraulic pump output pressure

MPa

{kg/cm²}

0~1.0

{0~10}

0~2.0

{0~20}

Boom relief

●

Hydraulic oil temp: Within operational
range

●

Operate corresponding control lever
after engine runs at high idling speed.

●

Working mode: H

●

Hydraulic pump output pressure with
all measurement circuits relieved

34.3 ± 1.0

{350 ± 10}

33.3 ~ 35.3

{340 ~ 360}

Arm relief

34.8 ± 1.0

{355 ± 10}

33.3 ~ 36.8

{340 ~ 375}

Bucket relief

34.8 ± 1.0

{355 ± 10}

33.3 ~ 36.8

{340 ~ 375}

Swing relief

●

Hydraulic oil temp: Within operational
range

●

Operate corresponding control lever
after the engine runs at high idling
speed.

●

Working mode: H

●

Hydraulic pump output pressure with
all measurement circuits relieved

25.5 ± 1.0

{261 ± 10}

24.5 ~ 27.5

{250 ~280}

Travel relief

33.4 ± 1.0

{342 ± 10}

32.4 ~ 34.4

{330 ~ 351}

Control circuit
source pres-
sure

●

Hydraulic oil temp: Within operational
range

●

Engine running at high idle

●

Self pressure reducing valve output
pressure with all control levers in
NEUTRAL position

3.9 ± 0.2

{40 ± 2}

3.7 ~ 4.1

{37 ~ 41}

5-6

Standard Values

Categ.

Item

Measurement condition

Unit

Std. value for

new machine

Permis-

sible value

Swing

Swing
brake
angle

●

Hydraulic oil temp: Within operational range

●

Engine running at high idle

●

Working mode: H

●

Swing circle misalignment amount when stopping
after one turn

●

For measuring posture see Swing 1.

Deg.

Max. 100

(—)

Max. 130

(—)

Time
taken
to start
swing

●

Hydraulic oil temp: Within operational range

●

Engine running at high idle

●

Working mode: H

●

Time required for passing points 90°and
180° from starting point

●

For measuring posture see Swing 1.

90° sec.

3.1 ± 0.3

Max. 3.7

180° sec.

4.4 ± 0.4

Max. 5.5

Time
taken to
swing

●

Hydraulic oil temp: Within operational range

●

Engine running at high idle

●

Working mode: H

●

Time required for 5 turns after making initial 1
turn

●

For measuring posture see Swing 1.

sec.

27 ± 3.5

Max. 30

Hydraulic
drift

●

Hydraulic oil temp: Within operational range

●

Engine stopped

●

Keeping the upper structure transverse on a
grade of 15°. For more information see Swing 2.

●

Notching a mating mark on inner and outer races
of the swing circle

●

Mating mark misalignment amount during 5 min.

Motor
leakage

●

Hydraulic oil temp: Within operational range

●

Engine running at high idle

●

Swing lockout switch: ON

●

Leakage amount for 1 minute during swing relief

ml/

min

Max. 5

Max. 10

ravel

Travel
speed
(unload-
ed)

●

Hydraulic oil temp: Within operational range

●

Engine running at high idle

●

Working mode: H

●

Time required for track shoes to make 5
turns after making one initial idle turn

●

For more information on measuring posture
see Travel 1.

sec.

51.3 ± 5.1

46.2 - 60.4

28.0 ± 1.4

26.6 - 31.4

5-7

Standard Values

Cat.

Item

Measurement Condition

Unit

Std. value for

new machine

Permis-

sible value

ravel

ravel speed

(Actual run)

●

Hydraulic oil temp: Within operational range

●

Engine running at high idle

●

Working mode: H

●

Level ground

●

Time required for traveling 10m after 10m trial run

●

For measuring posture see Swing 2.

sec.

20 ± 2.5

17.5~22.5

13 ± 2.5

11.5~15.5

Deviation

●

Hydraulic oil temp: Within operational range

●

Engine running at high idle

●

Working mode: H

●

Travel Speed: Low

●

Hard level ground

●

Amount of deviation (

) while traveling 20m after initial

10m trial run

●

For measuring posture see Travel 2/3.

Max. 800

Max. 900

Hydraulic drift

●

Hydraulic oil temp: Within operational range

●

Engine stopped

●

Park the machine on a grade of 12°, with the sprocket
in the downhill direction

●

Measure the sliding distance for 5 minutes

●

For measuring posture see Travel 4.

Leakage of

travel motor

●

Hydraulic oil temp: Within operational range

●

Engine running at high idle

●

Traveling with the sprocket locked

●

Oil leakage amount for one minute with traveling in re-
lief condition

13.6

27.2

ork Equipment

Hydraulic drift

Bucket

tips

●

Hydraulic oil temp: Within operational range

●

Flat and level ground

●

Bucket full of earth or with rated load (0.8m

: 1,440 kg)

●

Boom horizontal, arm fully retracted and bucket cylin-
der fully extended

●

Engine stopped

●

Work equipment control lever in neutral position

●

Measure total amount of falling for 15 min. by measur-
ing the falling every 5 min. immediately after initial set-
ting

●

Buck

et tip lower distance

●

Boom cylinder: Cylinder retracting distance

●

Arm cylinder: Cylinder extending distance

●

Bucket cylinder: Cylinder retracting distance

●

For measuring posture see Work Equipment 1

Max. 600

Max. 900

Boom

cylinder

Max. 20

Max. 27

Arm cylin-

der

Max. 20

Bucket cylinder

Max. 45

5-8

Standard Values

Categ.

Item

Measurement condition

Unit

Std. value for

new machine

Permis-

sible value

ork Equipment

ork Equipment Speed

Boom

●

Hydraulic oil temp: Within operation-
al range

●

Engine running at high idle

●

Working mode: H

●

Time required for the bucket to raise
from the ground to its stroke end

●

For measuring posture see Work
Equipment 2.

sec.

3.4 ± 0.4

Max. 4.8

Arm

●

Hydraulic oil temp: Within operation-
al range

●

Engine running at high idle

●

Working mode: H

●

Time required from dumping stroke
end to digging stroke end

●

For measuring posture see Work
Equipment 3.

sec.

2.8 ± 0.4

Max. 4.5

OUT

sec.

2.3± 0.3

Max. 3.5

Bucket

●

Hydraulic oil temp: Within operation-
al range

●

Engine running at high idle

●

Working mode: H

●

Time required from dumping stroke
end to digging stroke end

●

For measuring posture see Work
Equipment 4.

DIG

sec.

2.3 ± 0.4

Max. 3.4

DUMP

sec.

1.6 ± 0.3

Max. 2.3

5-9

Standard Values

Cat.

Item

Measurement condition

Unit

Std. value for

new machine

Judgement

criteria

ork Equipment

ime Delay

Boom

●

Hydraulic oil temp: Within operational range

●

Engine running at low idle

●

Working mode: H

●

Time required from maneuvering the joystick
to the moment that the bucket reaches the
ground and begins to push the machine up-
ward, within 50mm off the ground

●

For measuring posture see Work Equipment
5.

sec.

Max. 1.0

Max. 1.2

Arm

●

Hydraulic oil temp: Within operational range

●

Engine running at low idle

●

Working mode: H

●

Average time required for operating the con-
trol lever back and forth till the arm starts to
move

●

For measuring posture see Work Equipment
6.

sec.

Max. 2.0

Max. 2.8

Bucket

●

Hydraulic oil temp: Within operational range

●

Engine running at low idle

●

Working mode: H

●

Average time required for operating the con-
trol lever back and forth till the arm starts to
move

●

For measuring posture see Work Equipment
7.

sec.

Max. 1.0

Max. 3.6

Internal Leakage

Cylinders

●

Hydraulic oil temp: Within operational range

●

Engine running at high idle

●

Leakage amount for one minute with cylinder
or travel measured at relief condition

ml/

min

Central Swivel

Joint

Performance in Combined

Operations

Amount of deviation in

simultaneous operation of

work equipment and travel

●

Hydraulic oil temp: Within operational range

●

Engine running at high idle

●

Working mode: H

●

Travel Speed: Low

●

Amount of deviation measured for 20 m after
traveling about 10 m on a hard level ground

●

For measuring posture see Travel 2.

Max. 200

Max. 220

5-10

Standard Values

Machine postures for measuring (For all models)

Control value: Spool stroke

Travel 1: Travel speed (without load)

Travel 2: Travel speed (actual run), Travel de-
viation

ZX215-1003002

ZX215-1003005

ZX215-1003006

45°

Swing 1: Swing brake angle, time taken to
start swing, time taken to swing

Travel 3: Travel deviation

ZX215-1003007

10m

ZX215-1003003

Swing 2: Hydraulic drift of swing

ZX215-1003004

15°

Sprocket

5-11

Standard Values

Travel 4: Hydraulic drift of Travel

ZX215-1003008

12°

Work equipment 1: Hydraulic drift of work
equipment

ZX215-1003009

Work equipment 2: Boom speed

ZX215-1003010

Work equipment 3: Arm speed

ZX215-1003011

Work equipment 4: Bucket speed

Work equipment 5: Boom delay

ZX215-1003012

ZX215-1003013

5-12

Standard Values

Work equipment 6: Arm delay

Work equipment 7: Bucket delay

ZX215-1003014

ZX215-1003015

Testing and Adjusting

6-1

6 Testing and Adjusting

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

6.1.1 Testing ........................................................................................................... 6-3
6.1.2 Adjusting ........................................................................................................ 6-3

6.2 Exhaust Gas Color - Test ......................................................................................... 6-6
6.3 Valve Clearance - Adjust .......................................................................................... 6-8

6.3.1 Testing ............................................................................................................ 6-8
6.3.2 Adjusting ...................................................................................................... 6-10

6.4 Compression Pressure - Measure ..........................................................................6-11
6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13

6.5.1 Testing .......................................................................................................... 6-13
6.5.2 Adjusting ...................................................................................................... 6-15

6.6  Engine Oil Pressure - Measure.............................................................................. 6-17
6.7  Engine Speed Sensor - Adjust ............................................................................... 6-19
6.8  A/C Compressor Belt Tension - Test and Adjust ................................................... 6-20

6.8.1 Testing ......................................................................................................... 6-20
6.8.2 Adjusting ...................................................................................................... 6-20

6.9 Swing Bearing Clearance - Measure ..................................................................... 6-22
6.10 Track Tension - Test and Adjust ........................................................................... 6-24

6.10.1 Testing ........................................................................................................ 6-24
6.10.2 Adjusting .................................................................................................... 6-25

6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust .................................. 6-26

6.11.1 Measuring .................................................................................................. 6-26
6.11.2 Adjusting ..................................................................................................... 6-28

6.12 Control Circuit Oil Pressure - Test and Adjust ...................................................... 6-30

6.12.1 Testing ........................................................................................................ 6-30
6.12.2 Adjusting .................................................................................................... 6-31

Testing and Adjusting

6-2

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.

6.13  Solenoid Valve Output Pressure - Measure ......................................................... 6-32
6.14  Pilot Valve Output Pressure - Measure ................................................................ 6-34
6.15  Pilot Valves (Work Equipment and Swing) - Adjust ............................................. 6-36
6.16  Work Equipment Hydraulic Drift - Test ................................................................. 6-37
6.17  Residual Pressure in Hydraulic Circuit - Release ................................................ 6-40
6.18  Oil Leakage - Measure ........................................................................................ 6-41
6.19  Air in Each Component - Bleed............................................................................ 6-46

6-3

Testing and Adjusting

Engine speed calibrator

Part Number

Part Name

B249900001206 Engine Speed Calibrator

6 TESTING AND ADJUSTING

6.1

Engine Speed - Test and Calibrate

6.1.1 Testing

Start the engine and keep the engine running
until engine coolant temperature rises within
the operational range. Key in the code on the
monitor and check if the engine speed is nor-
mal in each throttle position.

Testing Items:

1. Engine speed at low idle

2. Engine speed at fuel control dial position

11 (H and S modes)

3. Engine speed at relief, with fuel control dial

placed at position 11 (H and S modes)

4. Engine speed at auto idle

6.1.2 Adjusting

Adjust the fixing point of the flexible shaft of
the throttle motor.

1. Connect the calibrator with the chassis

harness.

2. Push the memory switch of the calibrator

down to the OFF position.

3. Turn the start switch of the machine to the

ON position.

4. Start the engine. Check if engine speed is

within 1100±50 rpm range. (Throttle volt-
age at speed level 1 is 1.3±0.03V)

ENG.

WX215-1304008

Min. throttle

Max. throttle

Flexible shaft

Shaft bracket

Lock nut

Tighten

Loosen

Testing and Adjusting

NOTE:

In order to make sure speed calibration is suc-
cessful, deactivate auto-idle mode after the
calibration process and check the idling speed
at each speed level. If excessive variation is
found between the real speed and the target
speed, try automatic speed calibration once
again.

5. Tighten the fixing position of the flexible

shaft when engine speed is lower than
1050 rpm; loosen the fixing position of the
flexible shaft when engine speed is higher
than 1150 rpm.

6. Shutdown the engine.

Speed calibration steps:

1. Connect the calibrator with the chassis

harness.

2. Push the memory switch of the calibrator

down to the OFF position. Turn the start
switch of the machine to the ON position.

3. Start the engine. Engine speed “XXXX” will

be displayed on the screen display of the
calibrator. Press the H button and hold it,
the screen will display “E. XXXX”.

4. When automatic speed calibration is com-

pleted, the screen display of the calibrator
will change from “E. XXXX” to “XXXX”.

5. Shut off the engine.

WX215-1304009

MEMORY

DOWN

RPM

A/I

Memory s/w

H button

A/I button

Analog output

6-5

Testing and Adjusting

Engine speed reference (SY215C9)

Level

Speed (rmp)

Level

Speed (rmp)

1100

1200

1300

1500

1600

1650

1700

1750

1800

1850

1900

1950

2000

S10

2050

H10

2100

S11

2150

H11

2200

6-6

Testing and Adjusting

6.2 Exhaust Gas Color - Test

Testing tools

Model

Part Name

YDJ-2006

Smoke meter

SV-2TY

Opacimeter

1. Measure with a smoke meter

1) Put the

lter paper into the smoke me-

ter.

2) Insert the waste gas intake pipe into

the exhaust pipe.

3) Start the engine and keep the engine

running until engine coolant tempera-
ture is within the operational range.

4) When engine speed increases sudden-

ly or is kept at high idle, direct exhaust
gas through smoke meter to the filter
paper.

5) Remove the

lter paper from the smoke

meter. Read the smoke value through
the apparatus provided.

6) Remove the testing tools after measur-

ing. Make sure the machine goes back
to its normal state.

ZX215-1004002

CAUTION

●

Do not touch any hot parts when mount-
ing or dismounting the testing tools.

6-7

Testing and Adjusting

2. Measure with an opacimeter

1) Mount the opacimeter onto the exhaust

pipe by clamping it to the pipe outlet.

ZX215-1004003

ZX215-1004004

2) Open the opacimeter and preheat it for

about 15 minutes.

3) Start the engine and keep the engine

running until engine coolant tempera-
ture is within the operational range.

4) When engine speed increases sud-

denly or is kept at high idle, use the
opacimeter to read the smoke value of
exhaust gas.

5) Remove the testing tools after measur-

ing. Make sure the machine goes back
to its normal state.

Content .. 18 19 20 21 ..