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

Disassembly and Assembly

6. No. 2 sun gear

Remove No. 2 sun gear (11).

ZX215-1006076

7. No.2 planetary carrier assembly

1) Remove No.2 carrier assembly (12).

2) Disassemble No. 2 carrier assembly as

per the following procedure.

ZX215-1006077

8-50

Disassembly and Assembly

3) Insert pin (13) and push the shaft (14)

out of the carrier assembly (19).

NOTE: Pull out the pin (13) after re-

moval of the shaft.

4) Remove the thrust washer (16), gear

(17) and a second thrust washer (19).

5) Insert the pin (15) to remove the bear-

ing (18) from the shaft. Remove the pin

(15).

ZX215-1006078

8. Snap ring

Remove the snap ring (20).

ZX215-1006079

9. Disassembly of main shaft

Press

1) Place the shaft housing assembly on a

press and push the shaft assembly (21)

out of the shaft housing assembly (22).

ZX215-1006080

8-51

Disassembly and Assembly

2) Disassemble the shaft assembly in the

Press

following procedure.

Remove the bearing (23) from the shaft

(24).

ZX215-1006081

10. Bearing

Remove the bearing (25) and the oil seal

(26) from the housing (27).

ZX215-1006082

8-52

Disassembly and Assembly

8.13.2 Assembly

NOTE: Clean all the parts and check for any

contamination or damage. Apply engine oil to

the sliding surface of the parts.

1. Bearing

Press the bearing (23) into the housing

(27).

ZX215-1006083

2. Oil seal

Press the oil seal (26) into the housing (27).

Oil seal installation surface:

Gasket sealant (Loctite 515)

ZX215-1006084

3. Housing assembly

1) Position the plate (28) on the shaft (24).

2) Position the housing assembly (22) on

the shaft (24). Press in the bearing.

ZX215-1006085

8-53

Disassembly and Assembly

4. Bearing

Press in the bearing (25).

Ɣ When press fitting the bearing, press

the bearing inner race and outer race

simultaneously. Never press only the

inner race.

Ɣ After assembling the bearing, check if

the housing rotates freely.

ZX215-1006086

No. 2 Planetary carrier assembly

1) Reassemble No. 2 carrier assembly ac-

cording to the following procedure.

2) Assemble the plate (16) in the carrier

assembly (19).

3) Assemble the gear (17) in the carrier

assembly (19). Put the bearing (18)

on the shaft (14). Slightly tap the pin

(15) into the bore after alignment. Use

ZX215-1006078

a rubber hammer to tap the pin. Make

sure that the pin (15) must not higher

than the bearing (18).

4) Push the shaft assembly into the car-

rier assembly (19). Be careful not to

damage the gear and the plate. Align

the pin bore of the shaft with that of

the carrier assembly, and install the pin

(13). Carefully tap the pin with a rubber

hammer during installation.

NOTE: Installation of the shaft requires

rotating the planetary gear. Be careful not

to damage the thrust washer.

8-54

Disassembly and Assembly

6. Assemble in turn the snap ring (20),

No.2 carrier assembly and No.2 sun

No.2 planetary carrier

gear (11).

ZX215-1006087

7. Installation of ring gear

Apply sealant on the mating surface

indicated by (C) and tighten it with screws.

Never get the sealant onto the ring gear

(10).

Mating surface:

Sealant (Loctite 515)

ZX215-1006088

8. No. 1 planetary carrier assembly

1) No. 1 carrier assembly is assembled as

per the following procedure.

2) Install the plate (7) into the carrier as-

sembly (5).

3) Install the gear (6) onto the plate after

installing the bearing (9) into the gear.

4) Press the shaft (8) into the gear (6) and

the carrier assembly (5). Rivet one end

of the shaft.

ZX215-1006074

Ɣ Check if the gear rotates freely.

8-55

Disassembly and Assembly

10. Installation of swing motor assembly

Apply sealant to the contact surfaces of the

ring gear and the motor cover, and install

the swing motor assembly.

Contact surface:

Sealant (Loctite 515)

Swing motor assembly: 55 kg

Mounting bolts (swing motor):

156±5 N·m {16±0.5 kg}

NOTE: The 14 bolt holes of the swing

motor and swing drive assembly are

distributed nonuniformly. The mating direc-

tion of each hole is fixed, as shown in the

illustration on the right. The installation of

swing motor requires proper alignment of

the bolt holes in order to ensure the instal-

lation orientation.

ZX215-1006089

11. Lubricant adding

Screw on the drain plug and add lubricant

through the filler to the specified level (the

upper mark of oil stick).

Swing drive: approx. 4 L

8-57

Disassembly and Assembly

8.14 Idler AS - Disassemble and Assemble

8.14.1 Disassembly

1. Remove the dowel pin (1) and the support

(2).

2. Remove the float seals (3) from the sup-

12 10

port (2) and the idler (4).

3. Remove the O-ring (11). Remove the idler

(4) from the shaft (5) and the support as-

sembly (7).

NOTE: The idler contains 80 ml oil, which

should be drained completely before disas-

sembling. Spread a cloth on the floor to

prevent smearing the floor with oil.

ZX215-1006090

4. Remove the float seals (6) on the other

side from the idler (4), shaft (5) and sup-

port assembly (7).

ZX215-1006091

5. Remove the dowel pin (8) in order to re-

move the support (7) from the shaft (5).

9̹10

6. Remove the bushings (9) and (10) from the

idler (4).

ZX215-1006092

8-58

Disassembly and Assembly

8.14.2 Assembly

1. Install the bushings (9) and (10) in the idler

(4).

ZX215-1006093

2. Assemble the O-ring. Install the support (7)

to the shaft (5) with the dowel pin (8).

9̹10

ZX215-1006092

3. Install the float seals (6) to the idler (4),

shaft (5) and support (7) assembly.

Ɣ Float seals

Completely remove the grease from the

contact surfaces (hatched area in the

illustration on the right) of O-ring and

float seal before installing the float seal.

In addition, care must be taken to keep

the contact surface of float seal free

ZX215-1006094

from dust.

8-59

Disassembly and Assembly

Ɣ After installation of the float seals,

check that the sealing inclination should

be less than 1 mm and the seal protru-

sion between 5 and 7 mm.

ZX215-1006095

4. Install the shaft (5) and support (7) assem-

bly to the idler (4).

ZX215-1006096

8-60

Disassembly and Assembly

5. Install the float seal (3) to the idler (4) and

support (2).

NOTE: Apply oil to the sliding surface of

float seal. Care must be taken to keep the

sliding surface from any contaminants or

dust.

NOTE: Remove the oil and dust from the

contact surfaces of the O-ring and float

seal.

ZX215-1006097

ZX215-1006098

6. Install the O-ring. Install the support (2)

with the dowel pin (1).

7. Add oil and screw on the plug.

12 10

Oil: approx.

80 ml (No.18 hyperbola gear oil)

Plug:

205.8±49 N·m {21±5 kgf·m}

ZX215-1006090

8-61

Disassembly and Assembly

8.15 Sprocket - Remove and Install

8.15.1 Removal

1. Remove the track assembly.

Refer to “Track AS - Remove and Install”

on page 8-63.

2. Swing the work equipment 90°and lift the

chassis with the work equipment. Place a

block between the track frame and the

track shoe.

3. Remove the sprocket (1).

Sprocket: 58 kg

ZX215-1006099

8.15.2 Installation

Ɣ Installation is to be performed in the re-

verse order of removal.

Threads (bolt - sprocket):

Thread sealant (Tonsan 1277)

Bolts (sprocket):

339±20 N·m {35±2 kgf·m}

8-62

Disassembly and Assembly

8.16 Track AS - Remove and Install

Special tools

Mark

Part Name

Necessity

Qty

Manual/electric hydraulic

track removing/installing

machine

8.16.1 Removal

1. Choose a place that has enough space to

spread the track. Park the machine when

the master pin is between the idler and the

carrier roller.

2. Lower the work equipment. Loosen the

grease fitting (1) and release the track ten-

sion.

WARNING

Ɣ The adjustment cylinder is under ex-

ZX215T-1006100

tremely high pressure. Never loosen the

grease fitting by more than one turn.

3. Pull out the master pin (2) with the tool (M).

ZX215-1006101

8-63

Disassembly and Assembly

4. Remove the tool (M). Move the machine

forward so that the temporary pin is in

front of the idler. Place the block

5. Remove the temporary pin and the dust

seal. Move the machine backward to

spread the track (3).

ZX215-1006102

8-64

Disassembly and Assembly

8.16.2 Installation

Ɣ Installation is to be performed in the re-

Track shoe nut

Corner

(Square)

verse order of removal.

For more information, see “Track Tension -

Test and Adjust” on page 6-24.

Corner

Ɣ Installation procedure of track shoe bolts

and nuts

1. Bring the R side of the track shoe nut (1)

Seat surface

in close contact

to the link seat surface. Both seat surfaces

should be in close contact when assem-

bling the track shoe.

NOTE: If the track shoe bolts are installed

from the other side, the corner of nut will

interfere with the link seat surface, causing

ZX215-1006103

the nut to raise and the bolt to loosen.

2. Tighten the bolts of track shoe to the

torque below.

Track shoe bolts:

750±30 N·m {77±3 kgf·m}

Ɣ Use the tool (M) to press the master pin.

Make sure that the protrusion of master pin

meets the size (a).

Master pin protrusion (a): 2.5±1 mm

Ɣ Before installing the dust seal, apply

grease (No.2 lithium base) to its contact

surface with the bushing.

ZX215-1006104

8-65

Disassembly and Assembly

8.17 Swing Bearing AS - Remove and Install

8.17.1 Removal

1. Remove the swing platform assembly.

For more information, see “Swing Platform

AS - Remove and Install” on page 8-68.

2. Dismount the 36 bolts (1) to remove the

swing bearing assembly.

ZX215T-1006105

Hoist the swing bearing assembly (2).

Swing bearing assembly: 314 kg

ZX215T-1006106

8-66

Disassembly and Assembly

8.17.2 Installation

Installation is to be performed in the re-

verse order of removal.

Threads (bolt - swing bearing):

Thread adhesive (Tonsun 1277)

Mounting bolts (swing bearing):

Step 1:

Use a pneumatic spanner to tighten the

bolts.

Step 2:

Torque to: 549±59 N·m {56±6kgf·m}

1) When a torque spanner is used to tighten

the bolts, tighten first the four corners and

mark them.

2) Other bolts will be tightened clockwise or

counterclockwise. After one bolt is tight-

ened, tighten the next one on the diagonal

position and make a mark.

3) Tighten the rest bolts in this way.

Ɣ Let the S mark in the soft zone of the

inner race of the inner ring face the

right side, as shown in the photo, and

install the swing bearing to the track

frame.

Ɣ Apply grease to the inside of the gear

ring of the swing bearing.

NOTE: All gear teeth must be covered

by grease .

Inner race soft zone

Swing bearing:

Grease(supramoly lithium base):15 L

ZX215T-1006107

8-67

Disassembly and Assembly

8.18 Swing Platform AS - Remove and Install

8.18.1 Removal

CAUTION

Ɣ Fully extend the arm and the bucket.

Lower the work equipment to the

ground and move the hydraulic lockout

control lever to the LOCK position.

1. Disassemble the work equipment assem-

bly.

For more information, see

“Work

Equipment AS - Remove and Install” on

page 8-105.

2. Remove the counterweight assembly.

For more information, see “Counterweight

AS - Remove and Install” on page 8-113.

3. Remove the four hoses (1) of boom cylin-

ZX215T-1006108

der.

NOTE: Plug the hoses to prevent flow of

oil.

4. Lift the boom cylinder assembly (2).

ZX215T-1006109

8-68

Disassembly and Assembly

5. Remove the plate (3) and the pin (4). Lift

the boom cylinder assembly (2) in order to

remove it.

Ɣ Remove the boom cylinder assembly

on the other side in the same way.

Boom cylinder AS: 230 kg

ZX215T-1006110

6. Remove the plate (5), air intake hose (6)

and fan guard (7).

NOTE: Removal of the swing platform

requires removing other parts that interfere

with the lifting of swing platform.

ZX215T-1006111

7. Disconnect the six hoses above the swivel

joint assembly.

Ɣ Central swivel joint (port A) - Left travel

control valve (port BTL)

Ɣ Central swivel joint (port C) - Left travel

control valve (port ATL)

Ɣ Central swivel joint (port F) - Solenoid

valve

Ɣ Central swivel joint (port G) - Swing

motor (port T)

Ɣ Central swivel joint (port D) - Right trav-

el control valve (port ATR)

ZX215T-1006112

Ɣ Central swivel joint (port B) - Right trav-

el control valve (port BTR)

8. Remove the bolt (14).

8-69

SANY Crawler Hydraulic Excavator (SY195C9, SY205C9, SY215C9, SY225C9). Shop Manual (2013) - page 28