SANY Crawler Hydraulic Excavator (SY195C9, SY205C9, SY215C9, SY225C9). Shop Manual (2013) - page 13
Structure and Function
Replace the fluorine cylinder
When the refrigerant in a cylinder is used up,
replace the cylinder as per the following in-
Handle
struction:
1.
Close the Hi- and Lo-pressure valves of
the manifold pressure gauge.
Air hose connector
2.
Raise the needle and disc plate of the cyl-
Needle valve
inder and remove the empty cylinder.
Gasket
3.
Install a new cylinder onto the cylinder
valve.
Disc plate
Refrigerant
4.
Release the air in the hose as per the fol-
cylinder
lowing instruction:
ZX215-1002164
1) Tighten the valve of the fluorine cylinder,
and then, loosen it a bit.
2) Open the Lo-pressure valve of the mani-
fold pressure gauge a bit.
3) Press the vent valve and allow a little re-
frigerant to come out. Immediately close
the valve of the cylinder and the Lo-
pressure valve of the manifold pressure
gauge.
Valve
CAUTION
Lo
Hi
Loose
OFF
Ɣ
Do not press the valve with naked hand
Close the Lo-pressure valve
to avoid frostbite.
once you hear the hissing sound
5.
Turn the handle of the cylinder valve to
pierce the cylinder and continue charging
Loosen the valve a bit
Lo-pressure
operation.
valve
Green
Blue
R-134a
Red
To compressor
Refrigerant cylinder
ZX215-1002165
4-150
Structure and Function
6. Fault testing with manifold pressure gauge
After the engine has been preheated, read the pressure value on the gauge under the following
conditions:
1) Temperature at air inlet: 30 - 35°C
2) Engine speed: 1500 rpm
3) Fan speed: High
4) Temperature control: Minimum.
5) Air circulation mode: Recirculation
Ɣ Cooling system under normal condition
Gauge reading:
Lo-pressure end: 0.15~0.25 Mpa (1.5~2.5 Kgf/cm²)
Hi-pressure end: 1.37~1.57 Mpa (14~16 Kgf/cm²)
04
15
03
05
2
4
5
15
20
3
1
02
06
2
6
10
25
25
1
7
01
07
5
30
{cmHg kgf/cm2}
05
{cmHg kgf/cm2}
0
8
3
-50
8.5
0
0
-76
08
-76
35
-01
15
085
0
-01
35
MPa
MPa
R134a
ZX215-1002167
4-151
Structure and Function
Ɣ Moisture in the refrigerating system
Symptom: Intermittent refrigeration to non-refrigeration
04
15
2
03
05
4
15
20
3
5
1
02
06
6
10
25
25
2
1
7
01
07
5
30
{cmHg kgf/cm2}
05
{cmHg kgf/cm2}
0
8
3
-50
8.5
0
0
08
-76
-76
35
085
0
-01
15
-01
35
MPa
MPa
ZX215-1002168
Symptom
Cause
Analysis
Remedy
Ɣ When the system is
Ɣ Moisture in the system
Ɣ Over-saturation of de-
Ɣ Replace receiver/
operating, pressure
ices up at the expan-
hydrator.
dehydrator
at the Lo-pressure
sion valve causing
Ɣ Moisture in the system
Ɣ Remove the mois-
end unstable (some-
circular temporary
ices up at the expan-
ture in the system
times vacuum,
stop. When ice melts,
sion valve and hinders
through constant
sometimes normal)
the system becomes
the circulation of the
pumping.
normal again.
refrigerating system.
Ɣ Add proper volume
of new refrigerant.
4-152
Structure and Function
Ɣ Insufficient refrigeration
Symptom: Insufficient refrigeration
04
15
2
03
05
4
15
20
3
5
1
02
06
6
10
25
2
25
7
1
01
07
5
30
{cmHg kgf/cm2}
05
{cmHg kgf/cm2}
0
8
3
-50
8.5
0
0
-76
08
-76
35
085
0
-01
15
-01
35
MPa
MPa
ZX215-1002169
Symptom
Cause
Analysis
Remedy
Ɣ
Pressure at both Hi- and
Ɣ Air leaks
Ɣ
Insufficient
Ɣ
Check for air leakage with a leak
Ho-pressure ends very
somewhere
refrigerant in the
detector. Make necessary re-
low
in the refrig-
system
pairs.
erating sys-
Ɣ
Foam is continuously ob-
Ɣ
Leak of refriger-
Ɣ
Add proper amount of refriger-
tem
served via the sight glass
ant
ant.
Ɣ
Insufficient refrigeration.
Ɣ
When connected with the gauge,
if the reading is near zero, set
the system under vacuum state
after inspection and repair.
4-153
Structure and Function
Ɣ Defective refrigerant circulation
Symptom: insufficient refrigeration
04
15
2
03
05
4
15
20
3
5
1
02
06
6
10
25
25
2
1
7
01
07
5
30
{cmHg kgf/cm2}
05
{cmHg kgf/cm2}
0
8
3
-50
8.5
0
0
08
-76
-76
35
085
0
-01
15
-01
35
MPa
MPa
ZX215-1002170
Symptom
Cause
Analysis
Remedy
Ɣ Pressure at both
Ɣ Contaminant in the
Ɣ Blocked reservoir
Ɣ Replace reservoir
Hi- and Lo-pressure
reservoir hinders the
sides very low
flow of refrigerant.
Ɣ Frosting on the pip-
ing between parts
and reservoir
4-154
Structure and Function
Ɣ Refrigerant not circulating
Symptom: Non-refrigeration (intermittent refrigeration)
04
15
2
03
05
4
15
20
3
5
1
02
06
25
2
6
10
25
7
01
1
07
5
30
{cmHg kgf/cm2}
05
{cmHg kgf/cm2}
0
8
3
-50
8.5
0
0
08
-76
-76
35
085
0
-01
15
-01
35
MPa
MPa
ZX215-1002171
Symptom
Cause
Analysis
Remedy
Ɣ
Vacuum at Lo-pres-
Ɣ
Moisture or contami-
Ɣ
Refrigerant not
Ɣ
Check the expansion valve
sure side; pressure
nant in the refrigerant
circulating
and ERP.
at Hi-pressure side
hinders the flow of
Ɣ
Blow the contaminant in the
extremely low
refrigerant.
expansion valve or replace
Ɣ
Frosting or conden-
Ɣ
Air leak at the thermal
the expansion valve if nec-
sation on the pipes
pipe of the expansion
essary.
around the expan-
valve hinders the flow
Ɣ
Replace the receiver
sion valve or receiv-
of refrigerant.
er/dehydrator
Ɣ
Release internal air and
add refrigerant. If air leaks
from thermal pipe, replace
expansion valve.
4-155
Structure and Function
Ɣ Over-charging of refrigerant or insufficient refrigeration of condenser
Symptom: Insufficient refrigeration
04
15
2
03
05
4
15
20
3
5
1
02
06
6
10
25
25
2
1
7
01
07
5
30
{cmHg kgf/cm2}
05
{cmHg kgf/cm2}
0
8
3
-50
8.5
0
0
08
-76
-76
35
085
0
-01
15
-01
35
MPa
MPa
ZX215-1002172
Symptom
Cause
Analysis
Remedy
Ɣ
Pressure at both Hi-
Ɣ
Over-filling of refriger-
Ɣ Over-filling of refriger-
Ɣ
Clean the condenser
and Lo-pressure
ant in the system. Re-
ant
Ɣ
Check the working
sides very high
frigerating performance
Ɣ Condenser fins clogged
condition of fan mo-
inadequate.
Ɣ
No foam can be ob-
or fan motor error.
tor
served via the sight
Ɣ
Insufficient refrigera-
Ɣ
If the two above
glass even when
tion of condenser
items are normal,
engine speed drops.
check the volume
of refrigerant. Add
refrigerant.
4-156
Structure and Function
Ɣ Air is observed in the refrigerating system
Symptom: Poor refrigeration
NOTE: If refrigerant is added with no evacuation operation performed, the following gauge read-
ing will appear:
04
15
2
03
05
4
15
20
3
5
1
02
06
6
10
25
2
25
7
01
1
07
5
{cmHg kgf/cm2}
05
{cmHg kgf/cm2}
30
0
8
3
-50
8.5
0
0
08
-76
-76
35
085
0
-01
15
-01
35
MPa
MPa
ZX215-1002173
Symptom
Cause
Analysis
Remedy
Ɣ Pressure at both Hi- and
Ɣ Air enters the re-
Ɣ Air enters the refriger-
Ɣ Check if compressor
Lo-pressure ends very
frigerating system
ant system
oil is contaminated
high
or inadequate.
Ɣ Insufficient evacuation
Ɣ Lo-pressure piping feel-
Ɣ Evacuate and add
ing hot
new refrigerant.
Ɣ Foam is observed
through the sight glass
4-157
Structure and Function
Ɣ Improper installation of expansion valve/thermal pipe defect (wide opening)
Symptom: insufficient refrigeration
04
15
2
03
05
4
15
20
3
5
1
02
06
6
10
25
2
25
7
1
01
07
5
30
{cmHg kgf/cm2}
05
{cmHg kgf/cm2}
0
8
3
-50
8.5
0
0
08
-76
-76
35
085
0
-01
15
-01
35
MPa
MPa
ZX215-1002174
Symptom
Cause
Analysis
Remedy
Ɣ Pressure at both
Ɣ Expansion valve de-
Ɣ Over-filling of
Ɣ Check the installation of
Hi- and Lo-pressure
fect, or improper instal-
refrigerant in
thermal piping
ends very high
lation of thermal pipe
Lo-pressure
Ɣ If thermal piping is normal,
piping
Ɣ Frosting or conden-
check the expansion valve.
sation on Lo-pres-
Ɣ Expansion
Replace defective expan-
sure piping
valve opening
sion valve if observed.
very wide
4-158
Structure and Function
Ɣ Compressing error
Symptom: No refrigeration
04
15
2
03
05
4
15
20
3
5
1
02
06
6
25
2
10
25
7
01
1
07
5
30
{cmHg kgf/cm2}
05
{cmHg kgf/cm2}
0
8
3
-50
8.5
0
0
-76
08
-76
35
085
0
-01
15
- 01
35
MPa
MPa
ZX215-1002175
Symptom
Cause
Analysis
Remedy
Ɣ Pressure at Lo-pressure
Ɣ Compressor internal
Ɣ Compressing fault;
Ɣ Repair or replace
side very high
leakage
compressor
Ɣ Leaking or damaged
Ɣ Pressure at Hi-pressure
valve, loosened parts
side very low
4-159
Structure and Function
4.7.14 Compressor oil
Oil shall be added into the A/C system for lubrication. Compressor oil is solved in the refrigerant
and circulates in the system. When the air conditioning system is shut down, compressor oil will
stay inside the components. If no compressor oil is added into the system when replacing compo-
nents, inadequate lubrication will result. Add compressor oil according to the chart below:
Replaced component
Compressor
Condenser
Evaporator
Volume (ml)
See "CAUTION" below
40
40
ND8# (10P, 10PA, 10S series compressor)
Compressor oil grade
ND9#(TV series compressor)
CAUTION
Ɣ Add oil into a new compressor according to the required volume of the system. When
the compressor is to be replaced, discharge the surplus oil in it.
Ɣ Over-filling of compressor oil will reduce the refrigerating capacity. Short of compres-
sor oil in the system will cause compressor abnormality.
Ɣ Protect pipe joints and O-rings from contamination when disassembling the compres-
sor.
4-160
Structure and Function
4.8 Engine Control
4
5
3
2
9
6
7
8
1
Z
ZX215-1002176
1) Battery relay
Outline
2) Battery
Ɣ Start and stop the engine only with the en-
3) Engine start switch
gine start switch (3).
4) Fuel control dial
Ɣ The controller (6) receives the signal from
5) Start motor
the fuel control dial (4) and transmits the
6) Engine controller
drive signal to the throttle motor (8) to
7) Fuel injection pump
control the governor lever angle of fuel
injection pump (7) and control the engine
8) Throttle motor
speed.
9) Shutdown device
Ɣ When engine start switch (3) is turned to
the OFF position, the shutdown device (9)
pulls the flame-out arm on the injection
pump to the “parking” position and cuts the
engine fuel supply. Then, the engine stops.
4-161
Structure and Function
4.8.1 System operation
Engine startup
Ɣ When the start switch is turned to the
START position, the starting signal is trans-
(Power)
mitted to the start motor. Then, the start
Engine
Start S/W
Start motor
Starting relay
Fuel ctrl dial
S
SW
Lo
s
(Starting signal)
L
B
motor rotates to start the engine.
Hi
Hi
Governor
E
motor
Safety
s
relay
P
E
P
B
BR
C
Lo
M
B
E
Throttle On
P
Alternator
Lock
When it happens, the controller checks the
relay
signal voltage from the fuel control dial and
Shutdown
Bat. relay
device
Pilot S/W
sets the engine speed to the speed set by
Shutdown
relay
the fuel control dial.
Controller
(Regulating signal
(Start switch ON signal)
ZX215-1002177
Engine speed control
Ɣ The fuel control dial sends a signal voltage
corresponding to the rotation angle to con-
(Power)
Engine
Start S/W
troller.
Start
motor
Starting relay
Fuel ctrl dial
S
SW
Lo
s
(Starting signal)
B
Hi
Hi
Governor
E
L
motor
Safety
s
relay
P
E
P
B
BR
Lo
M
B E
C
The controller sends a driving signal to the
Throttle On
P
Alternator
Lock
relay
throttle motor according to the signal volt-
Shutdown
Bat. relay
Pilot S/W
age to control the fuel injection pump, and
device
Shutdown
eventually controls the engine speed.
relay
Controller
(Regulating signal
(Start switch ON signal)
ZX215-1002178
Engine shutdown
Ɣ When the start switch is turned to the OFF
position, the shutdown device cuts off the
(Power)
fuel supply and stops the engine.
Engine
Starting relay
Start S/W
Fuel ctrl dial
Start
motor
Lo
Governor
s
(Starting signal)
S
SW
Hi
Hi
motor
E
L
B
Safety s
P
relay
P
E
B
BR
C
Lo
B
E
Throttle On
Alternator
Lock
relay
Shutdown
Bat. relay
device
Pilot S/W
Shutdown
relay
Controller
(Regulating signal
(Start switch ON signal)
ZX215-1002179
4-162
Structure and Function
4.8.2 Components
4.8.2.1 Fuel control dial
140°
9×10°
1
Level 1
Level 10
25°
2
Left limit
Right limit
3
4
5
6
Yellow
a
5V
b
Blue
VR
b
a
c
Red
c
0V
ZX215-1002180
1) Knob
4) Ball
2) Dial
5) Potentiometer
3) Spring
6) Connector
4-163
Structure and Function
Function
Ɣ Turning of the fuel control dial changes the
resistance of the sliding rheostat inside the
č%Ď
dial and the voltage signal collected by the
100
controller. The controller calculates the col-
lected signals and drives the throttle motor
via signal output and controls the volume
of the injection pump so that the engine
can run at an optimal speed.
Ɣ When throttle voltage is beyond the area,
0
0.25
1.72
4.49
4.75
5
čVĎ
the controller sends out alarm code and
Voltage˄V˅
the engine runs at low idle. The area under
ZX215-1002181
the sloping line is the abnormality detection
area.
Remark:
The left limit is 0%; and the right limit is 100%.
4-164
Structure and Function
4.8.2.2 Controller
Controller
A
TYPE
USE FOR
NO
ZX215-1002182
Controller port layout
A2
A1
ZX215-1002183
4-165
Structure and Function
Input and output signals
A1
A1
Pin
Input/
Pin
Input/
Signal name
Signal name
No.
output
No.
output
1
Power ground
53
Rear pump pressure sensor
Input
2
Power ground
54
Sensor power ground
Input
3
Power ground
55
Sensor power ground
Input
4
Power supply(24V constant)
Input
56
Sensor power
Output
5
Power supply(24V constant)
Input
60
Monitor CAN Low
11
Fuel level sensor
Input
61
Calibrator CAN High
15
Throttle position signal
Input
62
Calibrator CAN Low
19
Engine speed signal
Input
66
Coolant temp very high
Input
22
RS232 ground
67
R. travel pressure sensor
Input
23
RS232 receive
68
Swing pressure sensor
Input
24
Enable
69
Bucket CURL pressure sensor
Input
30
Coolant temperature sensor signal
Input
70
Boom RAISE pressure sensor
Input
31
Oil temperature sensor signal
Input
71
Arm IN pressure sensor
Input
33
Backup pilot pressure signal
Input
72
Front pump pressure sensor
Input
34
Fuel dial signal
Input
73
Sensor PWR ground
38
Engine speed signal ground
74
Sensor PWR
Output
41
RS232 send
75
Sensor PWR
Output
42
CPU mode
76
State indicator
43
Enable
77
Monitor CAN High
48
Engine oil pressure switch
Input
78
Monitor CAN Low
49
L. travel pressure sensor
Input
79
Calibrator CAN Low
50
Bucket DUMP pressure sensor
Input
80
Calibrator CAN shield wire
51
Boom LOWER pressure sensor
Input
81
Calibrator CAN High
52
Arm OUT pressure sensor
Input
A2
Pin
Input/
Signal name
No.
output
82
Travel speed switching solenoid
88
Front pump solenoid valve
89
Rear pump solenoid valve
97
Swing priority solenoid valve
98
Bucket confluence solenoid valve
99
Boom priority 1
100
Boom priority 2
104
Motor drive signal +
113
Motor drive signal -
114
Power ground
115
Power ground
116
Power ground
117
Power ground
118
Power supply(24V constant)
119
Power supply(24V constant)
120
Power supply(24V constant)
121
Power supply(24V constant)
4-166
Structure and Function
4.9 Electrical Control System
4.9.1 Control function
Engine-Pump composite control function
Pump control function
Valve control function
Dual travel speed control
Electronic control system
Engine preheating/overheating alarm
Engine oil under-pressure alarm
Auto-deceleration/acceleration control
Engine speed calibration function
Self-diagnosis function
NOTE: For detailed information about self-diagnosis function, see "Troubleshooting"
4-167
Structure and Function
4.9.2 Machine control system diagram
Battery
Battery relay
Fuel control dial
Fuse
Power ON signal
Start switch
Swing priority signal
1
Monitor panel
R. travel signal
Network signal
2
Working mode signal
L. travel signal
Signal monitor info
Travel spd select signal
3
Auto-deceleration signal
Boom UP signal
4
Signal monitor info
Boom DOWN signal
5
Arm IN signal
6
Arm OUT signal
Fuel level signal
7
Fuel level sensor
Bucket CURL signal
Hydraulic oil temperature signal
8
Hydraulic oil temp sensor
Bucket DUMP signal
9
Swing signal
Controller
10
Travel spd select signal
11
Bucket confluence signal
17
R.Pump EX press. signal
12
F. Pump EX press. signal
13
F. Pump control signal
14
R. Pump control signal
15
Relay
16
PPCḤlock signal
Engine speed sensor
Motor
Potentiometer
Engine oil pressure
Oil pressure switch
Safety relay
Coolant temp sensor
Coolant temp sensor
Charging indicator
Alternator
Engine
Starting signal
Starting motor
Heater relay
Elct. intake air heater
Preheating signal
ZX215-1002184
4-168
Structure and Function
1
2
R. travel pressure sensor
3
L. travel pressure sensor
4
Boom UP pressure sensor
5
Boom DOWN pressure sensor
PPC
6
Arm IN pressure sensor
Valve
7
Arm OUT pressure sensor
8
Bucket CURL pressure sensor
9
Bucket DUMP pressure sensor
10
Swing pressure sensor
11
17
PPC Basic pressure
13
12
PPC Lock
Bucket
Swing
Travel
solenoid
confluence
priority
speed
16
solenoid
solenoid
solenoid
valve
valve
valve
valve
15
14
Control valve
ports
PnA2
XBp2
PsP
Main valve
Servo
Servo
F
R
Travel motor
Main pump
R. Pump oil-feed device
Swing motor
Work equipment actuator
Travel motor
ZX225-1102049
Remark:
The diagram above illustrates the electrical control system. For hydraulic circuit diagram, see Hy-
draulic System section.
4-169