Content      ..     16      17      18      19     ..

SANY Crawler Hydraulic Excavator (SY195C9, SY205C9, SY215C9, SY225C9). Shop Manual (2013) - page 18

Testing and Adjusting

6.7 Engine Speed Sensor - Adjust

NOTE: Remove the engine speed sensor (1)

before adjusting. Check for presence of metal

chips and for damaged sensor top. Restore

the sensor.

1

ZXT215-1004001

1. Screw on the sensor (1) until its end con-

tacts with ring gear tip (2) of the flywheel.

1

2

2. Unscrew the sensor some degrees.

Degrees: 1.2~1.4 turns

Adjust the clearance (a) between the

sensor end and the flywheel edge to 2±0.2

mm.

3

3. Tighten the sensor (1) with the nut (3).

a

Nut: 49.0~68.6 N·m {5~7kg·m}

ZX215-1004021

4. Make sure that the engine speed is dis-

played properly on the control panel after

adjustment.

6-19

Testing and Adjusting

6.8 A/C Compressor Belt Tension - Test and Adjust

6.8.1 Testing

Press the intermediate point of the belt be-

Compressor Belt

tween the drive pulley and the compressor pul-

Pulley

ley with a finger force of about 58.8 N(6kgf),

and measure deflection (A) of the belt, which

A

shall be 5~8 mm (0.20 in~0.31in).

Drive Pulley

ZX215-1004022

6.8.2 Adjusting

NOTE: If the belt deflection is abnormal, adjust

it according to the following procedure.

4

1. Loosen the bolts (1) and (2).

1

2. Move the compressor (3) and the bracket

(4) together to adjust belt tension.

3. After positioning the compressor (3), tight-

en the bolts (1) and (2).

2

4. Check belt tension again after adjustment.

3

ZXT215-1004002

6-20

Testing and Adjusting

Reference

Use a tensiometer to check the compressor

belt tension.

New Belt

Used Belt

637±108 N

441±88.2 N

{65±11 kgf}

{45±9 kgf}

NOTE:

Ɣ Check each belt for damage. Check the

V-groove and the V-belt for wear. In addi-

tion, it is especially important to keep the

V-belt free from friction with bottom of the

V-groove.

Ɣ Contact local Sany dealer and replace the

belt in case of the following conditions.

Ɣ The fan belt has been stretched and

little margin is left for adjustment.

Ɣ Cuts or cracks are found in the belt.

Ɣ Abnormal sliding or noise.

Ɣ When a new belt is mounted, readjust the

belt tension after one hour operation.

6-21

Testing and Adjusting

6.9 Swing Bearing Clearance - Measure

Measuring tool

Symbol

Part Number

Part Name

H

60033930

Dial gauge

Ɣ

The following steps are to be followed

when measuring the clearance of swing

bearing.

CAUTION

Ɣ

Park your machine on a level ground.

Lower your work equipment to the

ground.

Ɣ

Do not put your hands or feet under the

undercarriage during measurement.

1.

Fix the dial gauge (H) to the track frame

and apply the probe to the lower end of the

outer race.

2.

Place the work equipment to the maxi-

mum reach position. Raise the bucket to

a height that the bucket tips and the swivel

table bottom are on the same level.

H

At the moment, the front of upper structure

lowers while the rear rises.

ZX215-1004023

3.

Set the dial gauge (H) to zero.

4.

Set the arm almost perpendicular to the

ground and lower the boom until the front

track shoe floats.

At the moment, the front of upper structure

rises while the rear lowers.

5.

Read the dial gauge (H).

6.

Restore the machine to the condition of

ZX215-1004024

6-22

Testing and Adjusting

step 2. Check the dial gauge (H) to see if it

reads zero.

The value indicated by the dial gauge (H)

is the clearance of the bearing.

For more information, see “Swing bearing”

on page 4-13.

ZX215-1004025

Repeat step 3 through step 5 if the dial

gauge (H) reads a value other than zero.

6-23

Testing and Adjusting

6.10 Track Tension - Test and Adjust

6.10.1 Testing

1. Move your machine forward for a distance

that is equal to the length of track on the

3

2

ground. Keep running the engine at low

idle. Park your machine slowly.

a

2. Place a straight bar on the track over idler

(1) and carrier roller (2).

NOTE: A straight angle steel bar is recom-

mended for this purpose as it has good

1

resistance to bending strain.

ZX215-1004026

3. Measure the maximum clearance (a) be-

tween the upper surface of track and the

lower edge of the straight bar.

Ɣ Max. clearance (a): 10~30 mm (0.4~1.2

in)

6-24

Testing and Adjusting

6.10.2 Adjusting

Ɣ

If track tension is incorrect, make adjust-

ment as per the following instruction.

CAUTION

Ɣ

Do not loosen the valve over one turn.

If the valve is loosened too much, the

grease under high pressure may cause

the valve to eject.

1.

Reduce track tension

1) Loosen the valve (1) to discharge

grease. Tighten the valve after dis-

charging.

2) Check the track tension again as per

1

the above method after adjustment.

2.

Increase track tension

2

1) Add grease through the grease fitting

(2) with a grease gun.

ZXT215-1004003

2) Check the track tension again as per

the above method after adjustment.

NOTE: Add grease until the gap (b) be-

tween the idler guide and the track frame

end becomes zero. If the tension is till low,

it indicates that the pins and bushings are

seriously worn. Replace the pins and bush-

ings, or remove a piece of track shoe.

b

ZX215-1004027

6-25

Testing and Adjusting

6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust

Testing and adjusting tools

ID

Part Number

Part Name

60038932

Hydraulic Tester

—

B210770000084

Adaptor

NOTE: The hydraulic pressure in work equip-

ment, swing and travel (hydraulic pump out-

put) circuits can be viewed on the monitor.

6.11.1 Measuring

CAUTION

Ɣ

Lower the work equipment to the

ground and stop the engine. Operate

the control levers for several times to

release the residual pressure in hydrau-

lic circuits.

Ɣ

Open the butterfly nut on the breather

valve and press the relief button to re-

lease pressure in the hydraulic tank.

1.

Preparatory work before measuring

1) Remove the plug (1) and plug (2) for

measuring the hydraulic pressure.

Ɣ Plug (1): For oil circuit of rear pump

2

1

Ɣ Plug (2): For oil circuit of front pump

2) Install the priming adaptor and connect

it to the hydraulic tester.

Ɣ Use an oil pressure gauge with a ca-

pacity of 40 MPa {408 kgf/cm²}.

ZX215-1004028

3) Start the engine and keep it running

until the hydraulic pressure rises to a

point within the operational range.

6-26

Testing and Adjusting

5. Measurement of travel pressure at relief

1) Start the engine and lock the travel

mechanism.

NOTE: Place the pin (1) between the

sprocket and the track frame to lock the

travel mechanism.

2) Measure the hydraulic pressure when

the engine is running at high idle and

1

the travel circuit is in relief condition.

NOTE: The hydraulic pressure indicat-

ed is the pressure when the main relief

ZXT215-1004004

valve is in relief condition. When the

travel circuit is in relief condition, the

pressure indicated is always the pres-

sure at high relief.

6.11.2 Adjusting

NOTE: The boom relief valve cannot be ad-

justed.

1. Adjustment of main relief pressure

NOTE: If the high relief pressure is abnor-

3

mal, adjust the high pressure setting of the

main relief valve (3) as per the following.

1) Disconnect the pilot hose.

2) Loosen the locknut (4). Turn the adjust-

ZXT225-1104002

ment screw (5) to adjust the pressure.

Pressure rises as the screw turns right.

Pressure drops as the screw turns left.

Each turn of the screw equals about:

4

12.5 MPa {128 kgf/cm²}

Locknut:

53.5±4.9 N·m {5.5±0.5 kgf·m}

5

ZX215-1004029

6-28

Testing and Adjusting

3) Check the pressure again after adjust-

ment. Measure the pressure according

to the procedure described above.

Ɣ Connect the pilot hose before measur-

ing the pressure.

Ɣ Adjustment of the high pressure setting

side will affect the low pressure setting

side. The low pressure setting side is,

therefore, to be adjusted too.

2.

Adjustment of swing relief pressure

NOTE: If the swing relief pressure is ab-

normal, adjust the swing motor relief valve

(6) as per the following.

1) Loosen the locknut (7). Turn the adjust-

ment screw (8) to adjust the pressure.

Pressure rises as the screw turns right.

Pressure drops as the screw turns left.

Each turn of the screw equals about:

6.71 MPa { 68.4 kgf/cm²}

Locknut:

8

6

7

78-103 N·m{8.0-10.5 kgf·m}

ZXT225-1104003

2) Check the pressure again after adjust-

ment. Measure the pressure according

to the procedure described above.

7

8

ZX215-1004030

6-29

Testing and Adjusting

6.12 Control Circuit Oil Pressure - Test and Adjust

Testing and adjusting tools

ID

Part Number

Part Name

21008760

Hydraulic Tester

—

B210770000084

Adaptor

6.12.1 Testing

CAUTION

Ɣ

Lower the work equipment to the

ground and stop the engine. Operate

the control levers for several times to

release the residual pressure in hydrau-

lic circuits.

Ɣ

Open the butterfly nut on the breather

valve and press the relief button to re-

lease pressure in the hydraulic tank.

1.

Remove the plug (1) for measuring the hy-

draulic pressure.

2.

Install the priming adaptor and connect it

to the hydraulic tester.

Use an oil pressure gauge with a capacity

of 6 MPa{61 kgf/cm²}

3.

Start the engine and keep it running until

1

the hydraulic pressure rises to a point with-

in the operational range.

4.

Measure oil pressure when the engine is

2

running at high idle and all control levers

ZXT215-1004007

are in a neutral position.

6-30

Testing and Adjusting

6.12.2 Adjusting

1. If the measurement is less than 3.5 kgf/

cm², loosen the retaining nut (2) and screw

in adjusting stud (3). Watch the change

3

2

of readings on the pressure gauge at the

same time. Tighten the retaining nut (2)

when proper pressure value is achieved.

2. Remove all the tools after measurement

and make sure the machine returns to its

normal condition.

ZX215-1004031

6-31

Testing and Adjusting

6.13 Solenoid Valve Output Pressure - Measure

Measuring tools

ID

Part Number

Part Name

21008760

Hydraulic Tester

—

B210770000084

Adaptor

NOTE: Make sure that the initial pressure of

control oil circuit is normal before measuring

the output pressure of solenoid valve.

CAUTION

Ɣ Lower the work equipment to the

ground and stop the engine. Operate

the control levers for several times to

release the residual pressure in hydrau-

lic circuits.

Ɣ Open the butterfly nut on the breather

valve and press the relief button to re-

lease pressure in the hydraulic tank.

1. Disconnect the hose of solenoid valve to

measure the pressure at the outlet.

No.

Solenoid Valves to be Measured

5

4

3

2

1

1

Solenoid valve - high/low travel speed

2

Solenoid valve - swing priority

Solenoid valve - bucket confluence/difflu-

3

ence

4

Solenoid valve - boom priority

A

5

Solenoid valve - pilot lockout

2. Install a tee to location (A) on each sole-

noid valve and connect the hose.

WXT215-1206001G

3. Mount the adaptor onto the tee and con-

nect it to the hydraulic tester.

Use a hydraulic tester with a capacity of 6

MPa{61 kgf/cm²} .

6-32

Testing and Adjusting

4. Start the engine and keep it running un-

til the hydraulic oil temperature rises to a

point within the operational range.

5. Run the engine at full speed. Operate the

control levers to open or close each sole-

noid valve, and measure the pressure.

Ɣ The function of each solenoid valve

can be checked through the monitor's

monitoring function. (This is a special

function of the monitor.)

Ɣ When each output pressure reads the

following values, the solenoid valve is

normal.

High speed travel

Solenoid Valve

Output Pressure

OFF (de-energize)

0 {0}

ON (energize)

3.9~4.1 MPa{39~41 kgf/cm²}

Swing priority

Solenoid Valve

Output Pressure

OFF (de-energize)

0 {0}

ON (energize)

3.0~3.9 MPa{30~39 kgf/cm²}

6. Remove all measuring tools after measure-

ment. Make sure that the machine returns

to its normal condition.

Table of functioning state - pilot lock solenoid

valve

Functioning State

Function

Lock

OFF

Lockout control

Free

ON

6-33

Testing and Adjusting

6.14 Pilot Valve Output Pressure - Measure

Measuring tools

ID

Part Number

Part Name

21008760

Hydraulic Tester

—

B210770000084

Adaptor

NOTE: Make sure that the initial pressure of

control oil circuit is normal before measuring

the output pressure of pilot valve.

1. Remove the pilot pressure switch.

Oil Circuit

Oil Circuit

No.

No.

Measured

Measured

1

Travel left

7

Bucket DUMP

2

Travel right

8

Arm IN

3

Arm OUT

9

Swing

4

Bucket DIG

5

Boom DOWN

6

Boom UP

2

1

3

4

5

6

7

2. Install the adaptor and connect it to the hy-

8

9

draulic tester.

ZXT225-1104005

Use a hydraulic tester with a capacity of 6

MPa {61kgf/cm²}

3. Start the engine and keep it running un-

til the hydraulic oil temperature rises to a

point within the operational range.

4. Measure the output pressure when the en-

gine is running at high idle and all control

levers of the tested circuit are in neutral

position or at full stroke.

6-34

Testing and Adjusting

NOTE: When the measured output pres-

sure reads the following values, the pilot

valve is normal.

Control Lever

Hydraulic Pressure

Neutral

0{0}

Close to the average initial pres-

Full stroke

sure of oil control circuit

(See Table of Standard Values)

5. Remove all measuring tools after measure-

ment. Make sure that the machine returns

to its normal condition.

6-35

Testing and Adjusting

6.15 Pilot Valves (Work Equipment and Swing) - Adjust

Ɣ

If the play of work equipment or swing con-

trol lever is excessive, make adjustment as

per the following procedure.

1.

Remove the work equipment and swing pi-

lot valve assembly.

2.

Remove the rubber sleeve (1).

2

3.

Loosen the locknut (2). Screw on the disc

3

(3) until it contacts with the four heads of

plunger (4).

1

NOTE: Do not move the plunger.

4

4.

When the disc (3) is fixed, tighten the lock-

nut (2) to specified torque.

Locknut:

98~127 N·m {10~13 kgf·m}

ZX215-1004032

5.

Install the rubber sleeve (1).

6.

Install the work equipment and swing pilot

valve assembly.

6-36

Testing and Adjusting

6.16 Work Equipment Hydraulic Drift - Test

NOTE: If hydraulic drift exists in the work

equipment cylinder, check it according to the

following procedure and determine whether

the failure lies in the cylinder seal or in the

control valve.

1. Boom and bucket cylinders

1) Park your machine in an attitude as

shown and stop the engine.

NOTE: Load the bucket fully with earth

or impose rated load on the bucket.

2) Operate the control levers so that the

boom is in the raising position and the

ZX215-1004033

bucket in the digging position.

Ɣ If the lowering speed rises, the prob-

lem lies in the cylinder seal. If nothing

changes, the problem lies in the control

valve.

Ɣ Operate the control levers with engine

start switch in the ON position.

Ɣ If the pressure in accumulator drops,

charge the accumulator again by run-

ning the engine for about 10 seconds.

2. Arm cylinder

6-37

Testing and Adjusting

1) Park your machine in an attitude as

shown. The distance between the arm

cylinder and the digging stroke end is

100 mm. Stop the engine.

2) Operate the control levers in order to

place the arm in the digging position.

Ɣ If the lowering speed rises, it is failure

of the cylinder seal. If nothing changes,

it is failure of the control valve.

ZX215-1004034

Ɣ Operate the control levers with engine

start switch in the ON position.

Ɣ If the pressure in accumulator drops,

charge the accumulator again by run-

ning the engine for about 10 seconds.

[Reference]

If hydraulic drift is caused by failure of the

cylinder seal, the reason for lowering speed

increase during the above operation is de-

scribed below:

1) If the machine is set in the above position

(where the holding pressure is applied to

the bottom side), the oil leaks from the bot-

tom side to the head side. The pressure in

the head side is increased.

2) As the pressure in the head side de-

creases, the pressure in the bottom side

increases in order to keep it balanced.

This process is repeated until balance is

reached at a certain level depending on

the amount of leakage.

3) When the pressure is balanced, the lower-

ing speed decreases. If the control levers

are operated according to the above proce-

dure, the oil circuit in the head side opens

to the drain circuit (while the bottom side is

6-38

Content      ..     16      17      18      19     ..