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

Disassembly and Assembly

8.3 Start Motor AS - Remove and Install

8.3.1 Removal

CAUTION

Ɣ Before removing the start motor assem-

bly, disconnect the cable from the nega-

tive (-) post of the battery, and insulate

between the cable and the negative post

with insulation tape.

1. Open the engine hood.

2. Disconnect the cables (1), (2), (3), (4) and

(5).

3. Unscrew the bolts (6) and (7) used to fix

Starter

the start motor. Remove the start motor as-

Terminal B

sembly.

Terminal S

Starter relay

ZX215-1006001

8.3.2 Installation

Ɣ Installation is to be performed in the re-

verse order of removal.

Terminal B locknut (start motor):

18 ~ 25 N·m {1.8 ~ 2.6 kgf·m}

Fixing bolts (start motor):

43±6 N·m {4.4±0.6 kgf·m}

ZX215T-1006002

8-10

Disassembly and Assembly

8.4 Injection Pump AS - Remove and Install

8.4.1 Removal

CAUTION

Ɣ Disconnect the negative (-) post of the

battery.

1. Open the engine hood.

ZX215T-1006003

2. Disconnect the air intake hose (1).

ZX215T-1006004

3. Disconnect fuel supply tube (2), fuel deliv-

ery hose (4), fuel return hose (3) and fuel

supply tube (5).

Ɣ Block the hose with a cork in order to

prevent flow of fuel from the hose.

ZX215T-1006005

8-11

Disassembly and Assembly

4. Disconnect the lubrication tube (6).

ZX215T-1006006

5. Disconnect six fuel delivery tubes (7).

ZX215T-1006007

6. Disconnect the air hose (8).

7. Remove the bolt (9) fixing the electronic

choke. Disconnect the bolt (10) fixing the

governor motor.

ZX215T-1006008

8-12

Disassembly and Assembly

8. Adjust the injection timing of the timing

gear. For more information, see “Fuel In-

jection Timing - Test and Adjust” on page 6-13.

9. Remove the injection pump mounting nuts

in order to disassemble the injection pump

assembly.

A: 4 nuts on the flange

B: 1 nut

ZX215-1006009

8.4.2 Installation

Installation is to be performed in the re-

verse order of removal.

Bolts for installation of fuel supply

tube:

20~29 N·m {2.1~3.0 kgf·m}

Relief valve:

20~29 N·m {2.1~3.0 kgf·m}

Bolts for installation of engine oil line:

10~13 N·m {1.0~1.3 kgf·m}

Fuel injection tube:

24 N·m {2.5 kgf·m}

Bolts for installation air hose:

12~15 N·m {1.2~1.5 kgf·m}

Ɣ Adjust the engine speed. For more in-

formation, see “Engine Speed - Test

and Calibrate” on page 6-3.

8-13

Disassembly and Assembly

Ɣ Installation of the fuel injection pump is to

be performed as the following:

1) Check the fuel injection timing to see if it

has been adjusted properly.

Ɣ For more information, see “Fuel Injec-

tion Timing - Test and Adjust” on page 6-13.

2) Assemble the fuel injection pump assem-

bly and tighten the 4 nuts at position A and

1 nut at position B.

Nut: 9.8±2 N·m {10±0.2 kgf·m}

Ɣ Air bleeding

ZX215-1006009

Bleed the air from the fuel injection system.

8-14

Disassembly and Assembly

8.5 Engine Front Seal - Remove and Install

8.5.1 Removal

1. Remove the radiator assembly.

For more information, see “Radiator AS -

Remove and Install” on page 8-24.

Water pump

2. Remove the engine fan (1), the belt (2) and

the pulley (3).

ZX215-1006010

3. Remove the mounting nut (4) and replace

the cone (5) and the O-ring (6). Remove

the crankshaft belt pulley (7).

Ta 4

ZX215-1006011

4. Disassemble the front oil seal (8).

8.5.2 Installation

Ɣ Installation is to be performed in the re-

verse order of removal.

ZX215-1006012

Nut: 490 N·m {50 kgf·m}

8-15

Disassembly and Assembly

8.6 Engine Rear Seal - Remove and Install

8.6.1 Removal

1. Remove the hydraulic pump assembly.

For more information, see “Hydraulic Pump

AS - Remove and Install” on page 8-85.

2. Remove the bolt (1), the latch piece (2)

and the bearing (3).

3. Remove the flywheel (4).

4. Remove the engine speed sensor (5) and

Ta 1

the flywheel shell (6).

ZX215-1006013

5. Remove the rear seal (7).

Lip

ZX215-1006014

8-16

Disassembly and Assembly

8.6.2 Installation

Ɣ The installation is to be performed in the

reverse order of removal.

Bolt:

39 N·m {4.0 kgf·m} + 47°

Sealant

Ɣ The rear oil seal is to be installed accord-

ing to the following procedure:

ø2mm

1. Apply engine oil to the lips of the rear seal.

2. Clean the oil-sealing surface.

3. Apply the sealant evenly and continuously

Line

align the line of the rear seal.

ZX215-1006015

Sealant (Tonsun 1596)

4. The installation is to be performed 3 min-

utes after application of the sealant. Be

careful not to deviate the line while apply-

ing the sealant.

8-17

Disassembly and Assembly

8.7 Cylinder Head AS - Remove and Install

8.7.1 Removal

CAUTION

Ɣ Disconnect the negative (-) post of the

battery.

1. Drain the engine of coolant.

Coolant: 18 L

2. Open the engine hood.

ZX215T-1006016

3. Disconnect the air intake hose (1).

ZX215T-1006017

4. Remove piping (2) and piping (3) between

the fuel filter and the injection pump.

ZX215T-1006018

8-18

Disassembly and Assembly

5. Remove the fuel filter bracket (4) and the

fuel filter assembly (5).

6. Remove the six delivery hoses (6).

ZX215T-1006019

7. Remove the exhaust muffler connector

cover (7).

ZX215T-1006020

8. Remove the air cleaner suction hose (8).

9. Remove the air intake tube (9) and its

clamps (10) between the turbocharger and

the intercooler.

10. Remove the engine oil delivery tube (11)

and the oil return tube (12).

ZX215T-1006021

8-19

Disassembly and Assembly

11. Remove the turbocharger assembly.

ZX215-1006022

12. Remove the exhaust manifold (13).

ZX215-1006023

13. Remove the radiator inlet hose (14) and

outlet hose (15).

ZX215T-1006024

8-20

Disassembly and Assembly

14. Remove the six nozzle seats (16).

ZX215T-1006025

15. Remove the rocker arm housing (17).

16. Remove the rocker arm assembly (18).

17. Remove the pushrod (19).

18. Remove the 25 mounting bolts from the

cylinder head assembly. Lift the cylinder

head assembly in order to disassemble it.

19. Remove the cylinder head gasket (21).

ZX215-1006026

8-21

Disassembly and Assembly

8.7.2 Installation

Ɣ The installation is to be performed in the

reverse order of removal.

Installation of cylinder head gasket

Choose a cylinder head gasket as per the

following.

1. Measure the amount of piston projection of

each cylinder.

2. Select from the following table a gasket

with a thickness suitable for the maximum

piston projection after measurement. In ad-

dition, even if one cylinder's piston projec-

tion is 0.05 mm greater than the average,

the gasket with a thickness one grader

higher (AĺB, BĺC) is to be used.

Unit: mm

Piston Projection

Cylinder Head Gasket

Size mark

Thickness

Average

Size

Tightened

0.546~0.610

1.3

0.610~0.674

1.35

0.674~0.738

1.4

oUPp

3. The size of cylinder head gasket is deter-

mined according the notch.

4. Install the cylinder head gasket to the

crankshaft case as indicated by the arrow.

Notch

NOTICE

ZX215-1006027

The amount of piston projection must be

measured as the amount of piston projec-

tion may vary when replacing a piston or

connecting rod.

8-22

Disassembly and Assembly

Bolt (rocker cover installation):

4.9~6.9 N·m {0.5~0.7 kgf·m}

Bolt (cylinder head):

147 N·m {15 kgf·m}+90°

Bolt threads (cylinder head):

Engine oil

Tappet circumference:

Engine oil

Tappet ends:

Engine oil

Adjustment of valve clearance

For more information, see

“Valve

Clearance - Adjust” on page 6-8.

Adding coolant

Add engine coolant to the specified level.

Start the engine to circulate the coolant in

order to release all foams. Check the cool-

ant level again.

8-23

Disassembly and Assembly

8.8 Radiator AS - Remove and Install

8.8.1 Removal

1. Open the engine hood.

2. Open the pressure cap (1). Open the drain

valve to discharge engine coolant from the

coolant tank.

Coolant: approx. 18 L

Cover plate

3. Remove the coverplate.

ZX215T-1006028

4. Remove the two U-bolts (2).

5. Disconnect the hydraulic oil cooler inlet

connector (3) and outlet connector (4).

Block the openings to prevent leakage of

hydraulic oil.

6. Discharge hydraulic oil from the hydraulic

cooler.

Hydraulic oil radiator: approx. 5.6 L

7. Disconnect the coolant tank hose (5).

ZX215T-1006029

8. Disconnect the cooler inlet hose (6) and

outlet hose (7).

ZX215T-1006030

8-24

Disassembly and Assembly

9. Disconnect the intercooler air inlet tube (8)

and outlet tube (9).

ZX215T-1006031

10. Remove the four bolts (10) from the air

conditioner radiator. Remove the air condi-

tioner radiator and store it properly.

ZX215T-1006032

11. Remove the radiator fan guard (11).

ZX215T-1006033

8-25

Disassembly and Assembly

12. Remove the four mounting bolts (12) from

the radiator bottom and the two mounting

bolts (13) from the left and right brackets.

ZX215T-1006034

13. Mount the hoisting bolts (14) to both sides

of the radiator in order to hoist the radiator

assembly.

NOTE: Before the radiator assembly is

hoisted, move the radiator assembly axially

until the fan avoids its guard.

ZXT335-1006029

8-26

Disassembly and Assembly

8.8.2 Installation

Ɣ Installation is to be performed in the re-

verse order of removal.

NOTE:

Ɣ Adjust the clearance (a) between the fan

and the fan guard in order to have a uni-

form clearance surrounding the fan.

Ɣ Check the values (a) at the four measuring

points in the left, right, top and bottom di-

rections, which should be as the following:

Standard clearance (a) in all directions:

15±1.5 mm

Fan diameter (b): ø620 mm

Fan guard inner diameter (c): ø650 mm

Ɣ Engine coolant and hydraulic oil adding

Add a specific amount of coolant and

hydraulic oil. Start the engine to circulate

the coolant and hydraulic oil. Check the

coolant level and the oil level.

Engine coolant: approx. 18 L

Hydraulic oil radiator: approx.

12 L

8-27

Disassembly and Assembly

8.9 Engine and Hydraulic Pump AS - Remove and Install

8.9.1 Removal

CAUTION

Ɣ Lower the work equipment to the

ground. Stop the engine. Disconnect

the cable from the battery negative (-)

post.

Ɣ Loosen the butterfly nut on the breather

valve and press the relief button to re-

lieve internal pressure.

NOTE: Mark the lines to avoid mistakes during

reinstallation.

1. Remove the hydraulic tank suction filter el-

ement and block the opening.

2. Drain the engine of coolant.

Coolant: approx. 18 L

3. Open the engine hood.

ZX215T-1006028

4. Disconnect piping (1), (2) and (3).

ZX215T-1006036

8-28

Disassembly and Assembly

5. Disconnect piping (4), (5) and (6).

6. Remove the sensors (7) and (8).

ZX215T-1006037

7. Remove the clamps (9) and (10). Remove

the line (11) and the cable (12).

ZX215T-1006038

8. Unscrew the connection bolt (13) of the

governor motor and the connection bolt (14)

of the engine stopper.

9. Disconnect the external cable from the

starter (15).

10. Remove the mounting bolt (16) from the

hose clamp.

ZX215T-1006039

8-29

SANY Crawler Hydraulic Excavator (SY195C9, SY205C9, SY215C9, SY225C9). Shop Manual (2013) - page 26