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SANY Crawler Hydraulic Excavator (SY195C9, SY205C9, SY215C9, SY225C9). Shop Manual (2013) - page 17

Standard Values

Travel 4: Hydraulic drift of Travel

Work equipment 3: Arm speed

12°

ZX215-1003008

ZX215-1003011

Work equipment 1: Hydraulic drift of work

Work equipment 4: Bucket speed

equipment

ZX215-1003009

ZX215-1003012

Work equipment 2: Boom speed

Work equipment 5: Boom delay

ZX215-1003010

ZX215-1003013

5-11

Standard Values

Work equipment 6: Arm delay

Work equipment 7: Bucket delay

ZX215-1003014

ZX215-1003015

5-12

Testing and Adjusting

6 TESTING AND ADJUSTING

6.1 Engine Speed - Test and Calibrate

Engine speed calibrator

ID

Part Number

Part Name

1

B249900001206

Engine Speed Calibrator

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

ENG.

harness.

Shaft bracket

2. Push the memory switch of the calibrator

Tighten Lock nut

down to the OFF position.

Loosen

3. Turn the start switch of the machine to the

ON position.

Min. throttle

Max. throttle

Flexible shaft

4. Start the engine. Check if engine speed is

within 1100±50 rpm range. (Throttle volt-

WX215-1304008

age at speed level 1 is 1.3±0.03V)

6-3

Testing and Adjusting

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

Memory s/w

switch of the machine to the ON position.

MEMORY

ON

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

H

S

L

A/I

DOWN

UP

be displayed on the screen display of the

RPM

calibrator. Press the H button and hold it,

the screen will display “E. XXXX”.

H

S

L

A/I

Analog output

4. When automatic speed calibration is com-

A/I button

H button

pleted, the screen display of the calibrator

will change from “E. XXXX” to “XXXX”.

WX215-1304009

5. Shut off the engine.

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.

6-4

Testing and Adjusting

Engine speed reference (SY215C9)

Level

Speed (rmp)

Level

Speed (rmp)

S1

1100

H1

1100

S2

1200

H2

1200

S3

1300

H3

1300

S4

1500

H4

1500

S5

1600

H5

1600

S6

1650

H6

1700

S7

1750

H7

1800

S8

1850

H8

1900

S9

1950

H9

2000

S10

2050

H10

2100

S11

2150

H11

2200

6-5

Testing and Adjusting

6.2 Exhaust Gas Color - Test

Testing tools

ID

Model

Part Name

1

YDJ-2006

Smoke meter

2

SV-2TY

Opacimeter

CAUTION

Ɣ

Do not touch any hot parts when mount-

ing or dismounting the testing tools.

1.

Measure with a smoke meter

1) Put the filter 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

ZX215-1004002

gas through smoke meter to the filter

paper.

5) Remove the filter 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.

6-6

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

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.

ZX215-1004004

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.

6-7

Testing and Adjusting

6.3 Valve Clearance - Adjust

Service Standard (Unit: mm)

Location

Service Item

Standard Value

Limits

Remedy

—

Valve clearance (engine cold)

0.4

—

Adjust

Special Tools

Symbol

Tool Name and Shape

Part Number

Application

Flat head screwdriver

Valve clearance adjustment

MH060008

(Carried on vehicle)

Check and adjust valve clearance in cold state

as per the following procedure:

Sight Glass

6.3.1 Testing

1. Remove the rocker arm cover.

2. Turn the No.1 piston or the No.6 piston to

the top dead center of compression stroke

by following the procedure below.

Ɣ Turn the engine until the mark 16 on

the flywheel aligns with the pointer on

sight glass of the flywheel shell.

Sight Glass

Ɣ Turn the No.1 piston or the No.6 piston

to the top dead center of compression

stroke.

Pointer

ZX215-1004009

6-8

Testing and Adjusting

NOTE:

When the rocker arm at the intake side and

rocker arm at the exhaust side cannot be

turned with hands, it is indicated that the pis-

ton has reached the top dead center of com-

pression stroke. Turning the engine by one

more turn, the top dead center of compression

stroke of No.1 piston and No.6 piston inter-

changes.

3. When the No.1 piston is at the top dead

center, adjust the valve clearance in a se-

quence marked by the black dot.

Cylinder

1

2

3

4

5

6

INT

Ɣ

ż

Ɣ

ż

Ɣ

ż

EXH

Ɣ

Ɣ

ż

Ɣ

ż

ż

1) When a feeler gauge is used for such

measurement, resistance to a moving

Valve clearance

feeler gauge in the clearance should be

felt.

2) If the feeler gauge moves easily in the

clearance, it is impossible to obtain ac-

curate result.

4. If the measured value is out of specifica-

tion, readjustment shall be performed ac-

cording to the following method.

ZX215-1004007

6-9

Testing and Adjusting

6.3.2 Adjusting

1. To adjust valve clearance, loosen the lock-

Adjustment Screw

nut before adjusting the adjustment screw.

Standard clearance is achieved when re-

sistance to the feeler gauge is felt when

Locknut

pulling it out from the clearance.

2. After adjustment, stop the turning motion

of the adjustment screw with a screwdriver,

and tighten the locknut.

Locknut: 16-24 N·m {1.7±2.5 kgf·m}

3. Go on with the next step until all valve

Valve Clearance

ZX215-1004006

clearances marked with a black dot have

been adjusted.

4. Check the clearances again with the feeler

gauge. Readjustment should be made if

the value is out of specification.

5. When the engine is carried in vehicle, us-

Adjustment

ing

to turn the adjustment screw will

Screw

make your work easy.

ZX215-1004008

6-10

Testing and Adjusting

6.4 Compression Pressure - Measure

Service Standard

Location

Service Item

Standard Value

Limits

Remedy

Each cylinder (at 200

2550kPa {26kgf/cm²}

1960 kPa {20kgf/cm²}

Test

Compression

rpm)

—

pressure

Differential pressure

—

Below 390 kPa {4kgf/cm²}

Test

between cylinders

Special Tool

Symbol

Tool Name and Shape

Part Number

Application

Compression

pressure gauge

connector

Measuring compression

MH061460

A

pressure

M14×1.5

A

1.

Reduction of compression pressure can be

an indication for engine overhaul.

2.

Check the compression pressure regularly

and pay attention to its variation from time

to time. In addition, in a new vehicle or

when new parts are installed for replace-

ment, the pressure may be higher due to

running-in of the piston ring, valve seat,

etc. The pressure will become normal as

the parts wear.

3.

Before testing, make sure engine oil, start

motor and battery are in normal condition.

4.

Set the machine as per the following:

1) Preheat the engine until engine coolant

temperature reaches 75~85°C.

2) Switch off all lamps and auxiliary de-

vices.

3) Place the gear lever in a neutral posi-

tion.

5.

Remove the entire fuel injector.

6-11

Testing and Adjusting

6. Cover the fuel injector mounting opening

with cloth.

Rags

7. Activate the start motor in order to run the

Injector

engine. Check if the cloth is stained by for-

mounting hole

eign substances.

8. Determine the problem with the engine ac-

cording to the substances (engine oil and/

or coolant) on the cloth.

1) When engine oil is found, it might be

improper sealing caused by piston ring.

ZX215-1004005

Check the piston ring.

2) When engine oil and coolant are found,

it might be cracking of cylinder. Replace

the crankcase.

9. Mount the gasket and tool

to the fuel

CAUTION

injector mounting hole and fix them with

the injector cap. Install the compression

When coolant and/or engine oil is found

pressure gauge.

attached to the cloth, running the engine

may cause the hot coolant and engine oil

10. Start the engine and measure the com-

to squirt out through the mounting hole of

pression pressure of each cylinder. Calcu-

the fuel injector. This is very dangerous.

late the differential pressure between the

Never touch or look into the fuel injector

cylinders.

mounting hole when the engine is running.

11. When the compression pressure and the

differential pressure between cylinders de-

viate from their limits, inject a small amount

of engine oil through the fuel injector

mounting hole, and measure the compres-

sion pressure again.

Ɣ If the compression pressure is higher,

it is probably due to worn or damaged

piston ring or cylinder inner surface.

Ɣ If the compression pressure is still low,

it is probably due to stuck valve or im-

proper seating, or improperly mounted

gasket of cylinder head.

6-12

Testing and Adjusting

6.5 Fuel Injection Timing - Test and Adjust

Service Standard

Location

Service Item

Standard Value

Limits

Remedy

—

Fuel injection timing (BTDC)

14°

—

Adjust

Tightening Torque (Unit: N·m)

Symbol

Parts Tightened

Tightening Torque

Remark

—

Union nut

24

—

—

Lock plate

3.4~4.9

—

—

Lock seat - delivery valve

39~44

—

—

Nut (used for mounting fuel injection pump)

29~39

—

Special Tool

Symbol

Tool Name and Shape

Part Number

Application

Universal Exten-

sion Rod

Testing and adjusting the

A

MH061099

fuel injection timing

14

A

6.5.1 Testing

1. Remove the injection pipe, lock plate, lock

Injection pipe

seat, retainer ring and delivery valve from

the No.1 cylinder of the fuel injection pump.

Lock Seat

Retainer Ring

2. After removal of all the parts, install the

Spring

lock seat.

Lockplate

Delivery Valve

NOTE: The removed parts should be put

into light oil in order to keep them free from

dust.

ZX215-1004011

6-13

Testing and Adjusting

3. Install the prepared injection pipe onto

Injection pipe

No.1 cylinder. Keep the other end of the in-

jection pipe downward so that fuel flowing

out can be observed.

4. Turn the crankshaft manually over 180° in

the forward direction to locate No.1 cylin-

der in a position that is about 30° from the

top dead center of compression stroke.

ZX215-1004012

5. The main pump is used to transfer fuel. As

the fuel flows out of the injection pipe, turn

Injection pipe

the engine manually in the forward direc-

tion.

NOTE: The engine positioning lever on the

governor must be placed in the starting

position.

6. When the fuel coming out of the injection

pipe is about to stop, continue to turn the

engine slowly until the fuel stops coming

Positioning Lever

Priming pump

out.

ZX215-1004013

7. Make sure that the flywheel mark and

pointer are one degree before the fuel in-

jection timing.

Pointer

ZX215-1004014

6-14

Testing and Adjusting

NOTE: When the fuel injection timing deviates

from its standard value, the following steps

must be followed for adjustment.

6.5.2 Adjusting

1. Loosen the mounting nuts of fuel injection

pump.

A: 4 nuts (on the flange)

B: 1 nut

B

A

ZX215-1004015

2. Targeted at the pointer, activate the injec-

tion pump in order to adjust injection tim-

Injection Pump

ing.

3. Tighten the nuts to specific torque. Mea-

sure the injection timing again.

Pointer

ZX215-1004016

6-15

Testing and Adjusting

4. When the injection timing is slow, move the

injection pump toward the crankcase (di-

rection C).

C

D

5. When the injection timing is fast, move the

injection pump away from the crankcase

Injection Pump

(direction D).

ZX215-1004017

6. When injection timing meets the standard

value, install the delivery valve, spring, re-

Lock Seat

tainer ring, lock seat, lock plate and injec-

Injection pipe

tion pipe.

7. Tighten all the parts to specific torques.

Lockplate

ZX215-1004018

6-16

Testing and Adjusting

6.6 Engine Oil Pressure - Measure

Service Standard

Location

Service Item

Standard Value

Limits

—

Engine oil pressure at

Min. speed, unloaded

145 KPa

49 KPa

—

70~90°C

Max. speed, unloaded

295 KPa~490 KPa

195 KPa

Tightening Torque (Unit: N·m)

Symbol

Part Tightened

Tightening Torque

Remark

—

Engine oil pressure switch

7.8~12

Engine cold

Lubricant/Sealant

Symbol

Location

Part Number

Amount

—

Threads of pressure switch

A420300000032

As necessary

1. Remove the engine oil pressure switch.

Engine Oil

Pressure Switch

ZX215-1004019

2. Mount the adaptor to where the engine oil

pressure switch has been removed. Mount

Pressure Gauge

the engine oil pressure gauge to the adap-

tor.

Adaptor

ZX215-1004020

6-17

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