Content .. 3 4 5 6 ..

SANY Crawler Hydraulic Excavator (SY195C9, SY205C9, SY215C9, SY225C9). Shop Manual (2013) - page 5

Specifications

3 Specifications

3.1 Dimensions

3-3

3.2 Working Ranges

3-4

3.3 Technical Specifications

3-5

3.4 Weight Table

3-8

3.5 Recommended Oil, Fuel and Coolant

3-9

3.6 Capacity Table

3-10

3.7 Engine Performance Curve

3-11

3-1

Specifications

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.

3-2

Specifications

3 SPECIFICATIONS

3.1 Dimensions

CJ13032601-1

Unit: mm (ft, in)

Item

SY195C-9

SY205C-9

SY215C-9

SY225C-9

Overall length (shipping)

9560 {31'4''}

9680 {31'9''}

Overall width

2800 {9'2''}

2980 {9'9''}

Overall height (Shipping)

3250 {10'8''}

3440 {11'3''}

Width (top)

2710 {8'11''}

Overall height (to cab roof)

2990 {9'10''}

Std. track shoe width

600 {1'12''}

Track gauge

2200 {7'3''}

2380 {7'10''}

Min. ground clearance

440 {1'5''}

Tail swing radius

2890 {9'6''}

Length of track on ground

3260 {10'8''}

3355 {11'0''}

3445 {11'4''}

3640 {11'11''}

Track length

4060 {13'4''}

4160 {13'8''}

4250 {13'11''}

4445 {14'7''}

3-3

Specifications

3.2 Working Ranges

c d

CJ13032602-1

Unit: mm (ft, in)

Item

SY195C-9

SY205C-9

SY215C-9

SY225C-9

Max. cutting height

9410 {30'10''}

9570 {31'5''}

Max. dumping height

6490 {21'4''}

6700 {21'12''}

Max. digging depth

6410 {21'0''}

6600 {21'8''}

Max. vertical digging depth

5790 {18'12''}

5800 {19'0''}

Max. digging reach

9740 {31'11''}

9950 {32'8''}

Min. swing radius

3755 {12'4''}

3595 {12'12''}

Max. height at min. swing radius

7700 {25'3''}

7665 {25'2''}

3-4

Specifications

3.3 Technical Specifications

Machine model

SY195C-9

SY205C-9

SY215C-9

SY225C-9

Bucket capacity

m³

0.8

0.9

1.0

Operating weight

21000

21200

21800

22600

Max. bucket digging force

135

138

Max. arm digging force

109

103

Swing speed

rpm

Travel speed (Hi/Lo)

km/h

5.4/3.3

Gradeability

Deg.

Ground pressure

kPa

Model

MITSUBISHI 6D34-TL

Type

6-cylinder, 4-cycle, water-cooled, in-line, direct injection

No. of cylinders-bore x stroke

6-ĭ104mm×115mm

Piston displacement

5.86

Rated power

KW/rpm

114 / 2050

Max. torque

N·m/rpm

590 / 1400

Max. speed at no load

rpm

2200±50

Min. speed at no load

rpm

1000±10

Min. fuel consumption

g/KWh

210

Starting motor

24V/5.0 KW

Alternator

24V/50A

Carrier roller (each side)

Track roller (each side)

Track shoe (each side)

Type

KAWASAKI (Variable displacement piston type)

L/min

Max. delivery

2×210

Mpa

Safety valve pressure

34.3

Type x No.

KMX15RB/B45201B ×1

Control method

Hydraulic

2 x KYB variable displacement piston type

Travel motor

(with brake valve and parking brake)

1 x KAWASAKI angle type, piston type

Swing motor

(swing brake controller)

Type

Double acting piston

Bore

120 (Boom), 135 (Arm), 115 (Bucket)

Rod diameter

85 (Boom), 95 (Arm), 80 (Bucket)

Stroke

1285 (Boom), 1490 (Arm), 1120 (Bucket)

Hydraulic tank

Closed type

Hydraulic oil filter element

Tank return side

Hydraulic oil cooler

Air-cooling type

3-5

Specifications

Engine

Item

Specification

Engine model

6D34TLE2A

Type

In-line 6-cylinder; water-cooled, 4-cycle diesel engine

Combustion chamber type

Direct injection

Valve mechanism

OHV

Max. output power

kW{PS}/rpm

114{155}/2050

Max. torque

N·m{kgf·m}/rpm

590{60}/1400

Bore×Stroke

ĳ104×115

Total displacement

cm³{L}

5860{5.860}

Compression ratio

18.2

Swing motor

Producer

KAWASAKI

Model

M5×180CHB-12A-51A/260

angle type, piston type

Type

(swing brake controller)

Theoretical displacement

cm³/rev

129.2

Safety valve set pressure

MPa {Kg/cm³}

25.5 {260}

Rated engine speed

rpm

2050

Brake release pressure

MPa {Kg/cm³}

3.4 {34}

Control valve

Item

Specification

Model

KMX15RB

Standard flow rate (equivalent to one pump)

300 L/min

When main relief valve is normal

34.3 MPa

Maximum pressure

When main relief valve is boosting

37.3 MPa

Maximum pressure

When port relief valve is normal

39.2 MPa

Working oil temperature

-20~90°C

Drained oil maximum pressure

0.3 MPa

3-6

Specifications

Travel motor

Maker

KYB

Model

MAG-170VP-3400E

Variable displacement piston type

Type

(w/ brake valve and parking brake)

Weight

275

Equivalent displacement

cm³/rev

q x i

Large displacement q1

cm³/rev

130.4

Motor displacement q

Small displacement q2

cm³/rev

74.9

Speed reduction rate i

2-speed switching

Lo-Hi

Mpa

> 6.86

Pilot pressure

Hi-Lo

Mpa

> 1.96

Braking torque

N·m

398

Operating displacement

L/min

228

Operating pressure

Mpa

33.34

Peak pressure

Mpa

within 44.1

Acting times (above 34.3Mpa and below 44.1Mpa)

times

< 1,200,000

Large flow

rpm

1679

Motor shaft

Small flow

rpm

2861

Swing speed

Large flow

rpm

Reducer

Small flow

rpm

47.7

Output torque

KN·m

within 37

Normal

Input power

Maximum

within 210 (within 30 consecutive sec.)

Normal

Mpa

within 0.2

Drain pressure

Momentary maximum

Mpa

within 0.5 (below 0.3 MHz)

3-7

Specifications

3.4 Weight Table

Unit: kg

Machine Model

SY195C-9

SY205C-9

SY215C-9

SY225C-9

Engine

520

Radiator assembly

Hydraulic tank assembly (w/o hydraulic oil)

148

Fuel tank assembly (w/o fuel)

126

Revolving frame

1770

Operator cab

360

Operator seat & control console

Counterweight

3900

Hydraulic pump

120

Control valve

185

Swing reducer assembly

200

Final drive assembly

300×2

Center swivel joint

Track frame

2280

2432

2746

Swing bearing

286

Idler

116×2

Tensioning device

135×2

Carrier roller

25.5×4

Track roller

40×14

40×16

40×18

Boom assembly

1568

1590

Arm assembly

706

709

Bucket assembly

769

781

Boom cylinder assembly

206×2

Arm cylinder assembly

262

Bucket cylinder assembly

188

Linkage

Rocker

22×2

3-8

Specifications

3.5 Recommended Oil, Fuel and Coolant

Ambient temperature

Fluid

Reservoir

-22

-4

104

122°F

type

-30

-20

-10

50°C

SAE 30

SAE 10W

Engine oil pan

SAE 10W-30

SAE 15W-40

Swing machinery

case

Engine oil

Idler

SAE 30

Track roller

Carrier roller

SAE 10W

SAE 10W-30

SAE 15W-40

Hydraulic system

L-HV32 Low-temp, wear-resistant

hydraulic oil

Hydraulic

L-HM46 Wear-resistant hydraulic oil

oil

L-HM68 Wear-resistant hydra. oil

ASTM D 975 No.2

Diesel

Fuel tank

GB252 Super-20 Diesel fuel

fuel

GB252 Super-35 Diesel fuel

Grease fitting

Grease

NLGI No.2

Cooling system

Coolant

TEEC L35

3-9

Specifications

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

Ɣ Gear oil GL-5 is recommended.

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

3.6 Capacity Table

Unit: L {US Gal}

Swing mecha-

Final drive

Hydraulic

Engine oil pan

Cooling system

Fuel tank

nism casing

casing

system

22 {5.81}

4.0 {1.06}

5.5 {1.45}

239 {63.14}

22.5 {5.94}

340 {89.82}

3-10

Specifications

3.7 Engine Performance Curve

Testing condition:

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

N·m

Torque

600

500

400

300

120

Power output

100

g/kw·h

240

Fuel consumption

230

220

210

1000

1200

1400

1600

1800

2000

Engine speed min^-1

ZX215-1001003

3-11

Structure and Function

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 filter

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

4-1

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 filter

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

4-2

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 flow 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 flow 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

4-3

Structure and Function

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

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.

4-4

Structure and Function

4 STRUCTURE AND FUNCTION

4.1 Engine and Cooling System

4.1.1 Engine-related parts

ZX215-1002001

1) Fan

Specification

2) Front engine mount

Oil capacity: 22 L

3) Fuel filter

4) Start motor

5) Rubber damper assembly

6) Rear engine mount

7) Muffler

4-5

Structure and Function

4.1.2 Radiator and intercooler

WX215-1204009G

1) Radiator outlet hose

Specifications

2) Radiator inlet hose

Radiator assembly:

3) Radiator

ZH860×385×1050-S70Y75Z20Q/SY015

4) Intercooler air intake

Aluminum pipe, belt-type radiator

5) Reserve tank

Radiator and oil cooler in parallel connection;

6) Intercooler

intercooler in series connection with radiator

7) Intercooler air outlet

and oil cooler.

8) Fan guard

Reservoir capacity: 8.9 L (2.35 US gal)

9) Radiator cap

Engine coolant capacity: 9.5L (2.51 US gal)

4-6

Structure and Function

4.2 Power Train

4.2.1 Power transmission system

ZX215-1002003

1) Swing motor

6) Accumulator

2) Swing reducer

7) Control valve

3) Swing bearing

8) Final drive AS

4) Idler

9) Hydraulic pump

5) Central swivel joint

10) Engine

4-7

Structure and Function

4.2.2 Final drive assembly

Final drive AS (KYB)

73±3.6 N·m

205±10 N·m

59±4.9 N·m

157±8 N·m

ZX215-1002004-1

ZX215-1002005

4-8

Structure and Function

1) Cylinder GP

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

2) Shaft

10) No. 2 planetary gear (No. of teeth: 36)

3) Gear hub (No. of teeth: 85)

11) Seal ring

4) No. 2 planetary carrier

12) Travel motor

5) No. 1 planetary carrier

13) Fill port

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

14) Level port

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

15) Drain port

8) End cover

Specifications

Reduction ratio:

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

Criteria

No.

Check item

Remedy

Standard clearance

Clearance limit

Backlash between No. 2 sun gear

0.13

- 0.47

1.00

Replace

and No.2 planetary gear

Backlash between No. 1 planetary

0.17

- 0.57

1.10

gear and gear hub

Backlash between No. 1 sun gear

0.14

- 0.46

1.00

and No.1 planetary gear

Replace

Backlash between No. 2 planetary

0.16

- 0.56

1.10

gear and gear hub

Backlash between No. 1 planetary

0.38

- 0.66

1.00

carrier and No. 2 sun gear

4-9

Content .. 3 4 5 6 ..