SANY Crawler Hydraulic Excavator (SY195C9, SY205C9, SY215C9, SY225C9). Shop Manual (2013) - page 27
Disassembly and Assembly
11. Disconnect the cables (17) and (18) as
18
20
well as the tubes (19) and (20) from the
compressor.
17
19
ZX215T-1006040
12. Disconnect the hoses (21), (22), (23) and
(24) between the engine and the radiator
24
21
22
23
ZX215T-1006041
13. Disconnect the air intake hose (25).
25
ZX215T-1006042
8-30
Disassembly and Assembly
14. Disconnect the external cable (26) of the
rpm sensor.
15. Disconnect the external cable (27) of en-
gine oil pressure sensor.
26
27
ZX215T-1006043
16. Disconnect the engine oil inlet tube (28)
and outlet tube (29).
30
17. Disconnect the wiring (30) of the engine oil
pressure switch.
29
28
ZX215T-1006044
18. Disconnect the cables (31) and (32), and
remove the hose clamp (33).
33
32
31
ZX215T-1006045
8-31
Disassembly and Assembly
19. Remove the hose clamp (35).
20. Disconnect the wiring (34) of the water
temperature sensor.
35
34
ZX215T-1006046
21. Disconnect the cables (36) and (37) of the
water temperature switch.
37
36
ZX215T-1006047
22. Disconnect the oil return hose (38).
23. Disconnect the A/C water pipe (39).
38
39
ZX215T-1006048
8-32
Disassembly and Assembly
24. Disconnect the radiator fan guard (40).
40
ZX215T-1006049
25. Remove the fixing bolt (41) on each of the
four mounting plates of the damper. Lift the
engine and main pump assembly.
Engine and hydraulic pump AS:
640 kg
41
41
ZX215T-1006050
8-33
Disassembly and Assembly
8.9.2 Installation
Ɣ
Installation is to be performed in the re-
verse order of removal.
Ɣ
Open the radiator tank cover to add cool-
ant. Also add coolant to the coolant reser-
voir.
Engine coolant: approx. 22.5 L.
Ɣ
Refill the hydraulic tank with hydraulic oil.
Hydraulic tank: approx. 225 L
Ɣ Start the engine to circulate the coolant
in order release the foams, and check
the coolant level again.
Ɣ Start the engine to circulate the hy-
draulic oil in the hydraulic system, and
check the oil level again.
Ɣ
Air bleeding
For more information, see “Air in Each
Component - Bleed” on page 6-46.
8-34
Disassembly and Assembly
8.10 Final Drive AS - Remove and Install
8.10.1 Removal
CAUTION
Ɣ Lower the work equipment to the
ground. Stop the engine. Operate the
breather valve to release internal pres-
sure.
1. Remove the sprocket.
For more information, see “Sprocket -
Remove and Install” on page 8-62.
2. Remove the motor cover plate (1).
1
ZX215-1006051
3. Disconnect the four hoses (2) of the travel
motor and the corresponding hose connec-
2
tors.
ZX215T-1006052
8-35
Disassembly and Assembly
4. Remove the 30 mounting bolts from the
final drive assembly (3), and lift the assem-
bly for disassembling.
3
Final Drive Assembly: 250 kg
NOTICE
Ɣ Be careful not to damage the surface
of mounting seal installed on the hose
base.
ZX215-1006053
Ɣ Never use the threaded holes to lift the
cover when lifting the final drive.
8.10.2 Installation
Ɣ Installation is to be performed in the re-
verse order of removal.
Mounting bolts (final drive assembly):
245~309 N·m {25~31 kgf·m}
Ɣ Hydraulic oil adding
Add hydraulic oil through the filler opening
to the specified level. Start the engine to
circulate oil in the hydraulic system, and
check the oil level again.
Ɣ Air bleeding
For more information, see “Air in Each
Component - Bleed” on page 6-46.
8-36
Disassembly and Assembly
8.11 Final Drive AS - Disassemble and Assemble
8.11.1 Disassembly
1. Oil draining
Open the drain plug to drain the oil from
the final drive tank.
Final drive tank: approx. 4.7 L
2. Cover
Remove the bolts. Use eyebolts to the
cover (1).
æ
1
ZX215-1006054
3. Spacer
2
Remove the spacer (2).
ZX215-1006055
8-37
Disassembly and Assembly
4. No. 1 planetary carrier assembly
3
1) Remove the No.1 planetary carrier as-
sembly (3).
ZX215-1006056
2) Disassembly of No.1 planetary carrier
assembly.
9
7
4
5
10
8
3) Remove the screws (4). Remove the
coverplate (5) from the planetary carrier
assembly (6).
4) Remove the thrust washer (7), gear (8),
bearing (9), bearing inner race (10) and
11
a second thrust washer (11).
6
ZX215-1006057
5. No.1 sun gear shaft
12
Remove No.1 sun gear shaft (12).
ZX215-1006058
8-38
Disassembly and Assembly
6. Thrust washer
13
14
Remove the thrust washer (13).
7. No.2 sun gear
Remove No.2 sun gear (14).
ZX215-1006059
8. Disassembly of No.2 planetary carrier
18
19
15
assembly
1) Remove the screws (15). Remove the
16
plate (16) and the planetary gear (17)
17
from the carrier assembly (22).
20
23
2) Remove the bearing inner race (19)
21
and outer race (18). Remove the plate
(20).
22
3) Remove the screw (21) to take the
planetary carrier assembly (22) and the
ZX215-1006060
shim (23) from the body.
9. Hub assembly
ç
1) Use eyebolts to remove the hub as-
sembly (24) from the travel motor.
24
ZX215-1006061
8-39
Disassembly and Assembly
2) Disassemble the hub assembly as the
following.
26
27
3) Remove the float seal (25).
4) Remove the bearing (26) and bearing
(27) from the hub (28).
NOTE: Do not damage the bearing retainer
when removing the bearing (26).
25
28
ZX215-1006062
5) Remove the float seal (29) from the
travel motor.
29
30
ZX215-1006063
8-40
Disassembly and Assembly
8.11.2 Assembly
NOTE: Clean all the parts. Check that these
parts are free from any contamination or dam-
age. Apply some engine oil to the sliding sur-
face prior to installation.
1. Hub assembly
1) Install the bearing 26 and bearing (27)
by pressing them onto the hub (28).
26
27
2) Install the float seal (25).
25
28
ZX215-1006062
Ɣ Remove any oil or dust from the O-ring
or O-ring contact surface. Dry the parts
before installing the float seal.
Ɣ After installing the float seal, check that
the angle of the floating seal is within 1
mm.
Ɣ Apply a thin layer of engine oil to the
sliding surface after the float seal has
been installed.
ZX215-1006064
3) Install the float seal (29) to the travel
motor (30).
Ɣ See the above step 2 for the installation
29
procedure.
30
ZX215-1006063
8-41
Disassembly and Assembly
4) Use eyebolts to carefully place the
ç
hub assembly (24) onto the travel mo-
tor. Tap to press fit the bearing.
24
ZX215-1006061
2. Calculation of shim thickness
1) Measure the thickness (H) of the raised
part of No.2 carrier assembly (22).
22
H
ZX215-1006065
2) Measurement of raised thickness
Apply 3000 Kg load to the bearing and
measure the value (H) of the raised
part of the bearing.
Ɣ Turn the hub 2-3 times before applying
Load 3000Kg
a pushing force.
Ɣ Do not use a spray gun to cushion the
bearing.
Ɣ Do not push or strike the resin retainer.
ZX215-1006066
3) Shim thickness calculation: C=H-h.
8-42
Disassembly and Assembly
4) Place the shims on the body and insert
the dowel pin. Press the carrier assem-
bly onto the dowel pin and tighten it
with screw (21). Apply locking adhesive
Tensiometer
to the threads.
Screw-locking adhesive:
(Tonsan 1277)
Screw (21):
ZX215-1006067
539±28 N·m {55±2.9 kgf·m}
Ɣ Use a tensiometer to measure the tan-
gential force of hub to motor rotation.
Tangential force: Max.294 N {30 kg}
Maximum tangential force occurs when
the rotating direction begins to change.
3.
Assembly of No.2 planetary carrier as-
sembly
18
19
15
1)
Assemble the No.2 planetary carrier
16
assembly according to the following
17
procedure.
20
23
NOTE: Replace the plates (20) and (16)
21
with new parts.
22
2)
Assemble the bearing (18) and bearing
(19) to the gear (17). Assemble the top
ZX215-1006060
and bottom plates (16) and (20), and
place the gear assembly into the carrier
assembly (22).
3)
Tighten the screw (15).
Screw (15):
539±28 N·m {55±2.9 kgf·m}
Ɣ
Check the flexibility of gear (17) after
assembling the planetary carrier as-
sembly.
8-43
Disassembly and Assembly
4. Thrust washer
13
14
Install the thrust washer (13).
5. No.2 sun gear
Install No.2 sun gear (14).
ZX215-1006059
6. No. 1 sun gear shaft
12
Install No.1 sun gear shaft (12).
ZX215-1006058
7. No.1 planetary carrier assembly
1) No. 1 planetary carrier assembly is as-
9
7
4
5
10
8
sembled as the following.
NOTE: Replace the thrust washers (7)
and (11) with new parts.
2) Assemble the bearings (9) and (10)
onto the gear (8). Assemble the top
11
and bottom thrust washers (7) and (11).
6
Place the gear assembly into the car-
ZX215-1006057
rier assembly (6).
3) Fix the coverplate (5) to the carrier as-
sembly (6) with screw (4).
8-44
Disassembly and Assembly
4) Install No.1 planetary carrier assembly
(3).
3
ZX215-1006056
8. Spacer
2
Install the spacer (2).
ZX215-1006055
9. Cover
Use eyebolts to assemble the cover (1).
Use a torque spanner to tighten the bolts.
Bolts:
73.4±3.63 N·m {7.5±0.4 kgf·m}
Torque wrench
10. Oil adding
Tighten the drain plug and add engine oil
through the filler.
ZX215-1006068
Final drive case: approx. 4.7 L
Ɣ Check the oil level after the final drive
has been successfully installed to the
chassis.
8-45
Disassembly and Assembly
8.12 Swing Motor and Swing Drive AS - Remove and Install
8.12.1 Removal
CAUTION
Ɣ
Lower the work equipment to the
ground. Stop the engine. Press the re-
lease button of the breather valve to re-
lease residual pressure in the hydraulic
tank. Place the hydraulic lockout con-
trol in the LOCK position.
Release the residual pressure in the hy-
draulic circuit. Refer to “Residual Pressure
in Hydraulic Circuit - Release” on page 6-40.
1.
Disconnect the hoses (1) to (7).
Ɣ
Between hydraulic tank and swing motor
3
(port DR)
Ɣ
Between central swivel joint and swing mo-
tor (port DR)
Ɣ
Between swing motor and main valve (port
M)
5
7
Ɣ
Between swing motor and main valve (port
4
1
6
2
HA)
ZXT225-1106002
Ɣ
Between swing motor and main valve (port
HB)
Ɣ
Between swing motor and main valve Px
port (port SH)
8
Ɣ
Between swing motor and solenoid valve
block (port PG)
9
2.
Remove the 11 fixing bolts (8).
3.
Lift the swing motor and swing drive as-
sembly (9) for disassembling.
NOTE: Slowly lift the swing motor and
swing drive assembly in order to avoid
ZXT225-1106003
damaging the hoses and other parts.
Swing motor and swing drive as-
sembly: 260 kg
8-46
Disassembly and Assembly
8.12.2 Installation
Ɣ Installation is performed in the reverse or-
der of removal.
Mounting bolts (swing motor and
swing drive assembly):
490~608 N·m {50~62 kgf·m}
Ɣ Hydraulic oil adding
Add hydraulic oil through the filler opening
to the specified level. Start the engine to
circulate oil in the hydraulic system, and
check the oil level again.
Ɣ Air bleeding
For more information, see “Air in Each
Component - Bleed” on page 6-46.
8-47
Disassembly and Assembly
8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble
8.13.1 Disassembly
1. Draining of oil
Open the drain plug to drain the oil from
the swing drive.
Swing drive: approx. 4.4 L
2. Swing motor assembly
1) Place the swing motor and swing drive
1
assembly on a suitable cribbing. Be
careful not to damage the drive gear or
let it contact the ground.
2) Unscrew the 14 bolts in order to re-
move the swing motor assembly (1).
Swing motor assembly: 70 kg
ZX225-1006077
3. No.1 sun gear
2
1) Remove No.1 sun gear (2).
ZX215-1006072
8-48
Disassembly and Assembly
4. No.1 planetary carrier assembly
3
4
1) Remove No.1 carrier assembly (3) and
the plate (4).
ZX215-1006073
2) Disassemble the carrier assembly.
Cut the rivets on the shaft (8) to re-
move the shaft (8), and remove in turn
8
9
6
7
the gear (6), bearing (9) and plate (7).
5
ZX215-1006074
5. Ring gear
10
Unscrew the mounting bolts to remove the
ring gear (10).
ZX215-1006075
8-49