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

Disassembly and Assembly

8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install

8.24.1 Removal

1. Remove the hydraulic pump assembly (1).

For more information, see “Hydraulic Pump

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

2. Remove the screw (2). Remove the bear-

ing cover (3).

3. Pry the oil seal (4) out with a screwdriver.

NOTE: Be careful not to damage the shaft

while prying the oil seal.

ZX215-1006154

8.24.2 Installation

Ɣ Installation is to be performed in the re-

verse order of removal.

Seal lip:

Grease (No.1 Calcium base grease)

Seal circumference:

Grease (No.1 Calcium base grease)

Ɣ Apply a thin layer of grease to the oil

seal circumference.

ZX215-1006155

8-90

Disassembly and Assembly

8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble

NOTE: This section discusses only the precautions when reassembling the work equipment pilot

valve assembly.

ZX215T-1006156

8.25.1 Assembly

Reassembly of the work equipment pilot

Plug (5) circumference:

valve assembly

Grease (No.1 Calcium base grease)

Install the plate (9) in the valve body (8)

with O-ring seal. Tighten the socket bolt

U-joint moving surface:

(10).

Grease (No.1 Calcium base grease)

Socket bolt:

Threads in valve body:

25~33 N·m {2.55~3.36 kgf·m}

Thread adhesive (Tonsun 1277)

Insert the spring (7) into the spool hole in

the valve body (8). Put the spool (6) in the

spring. Install the plunger (5) on the spool.

Push the plug (5) to the spool hole.

Install the plate (4) on the plunger (5).

Tighten the U-joint (3).

Install the plate (2). Align the position of the

plate (2) and tighten the nut (1).

Nut: 98~133 N·m {10~13.5 kgf·m}

NOTE: Location of each oil port is stamped

on the bottom of valve body.

8-91

Disassembly and Assembly

Ɣ Apply the thread adhesive (Ton-

sun 1277) to two points on the inner

5~7 mm

threads. The amount of application is

approximately 0.02 g.

U-joint (3):

98~133 N·m {10~13.5 kgf·m}

NOTE: Tightening is to be made to the

specified torque.

Contact surface between plung-

ZX215-1006157

er (5) and plate (2):

Grease 0.3~0.8 ml (No.1 Calcium base

grease)

8-92

Disassembly and Assembly

8.26 Pilot Valve AS (Travel) - Disassemble and Assemble

NOTE: This section discusses only the precautions when reassembling the travel pilot valve as-

sembly.

Plunger

ZX215T-1006158

8.26.1 Assembly

Ɣ Reassembly of the pedal pilot valve assembly

1. Install the spring (8) into the spool installation hole in the body assembly (9). Install the spool

(7). Place the cover assembly (6) on the spool and press the cover assembly (6) with a hand.

2. Install the cover (4) after aligning the holes. Tighten the socket bolts (1).

Bolt (socket): 98~114 N·m {10~11.6 kgf·m}

3. Install the dust ring (3) on the plunger. Install the cover (2) and fix the cover (2) with the cam-

shaft (5).

Contact surface between plunger and dust ring (5):

Grease (No.1 Calcium base grease)

8-93

Disassembly and Assembly

8.27 Hydraulic Cylinder AS - Disassemble and Assemble

Special tools

Application

Tool Shape

Necessity

Quantity

Pulling out/pushing

in the bushing

Press fitting the

dust ring

O-ring seal correc-

tion

Inserting tool

Correcting tool

Inserting the cylin-

der head

Inserting the piston

8-94

Disassembly and Assembly

8.27.1 Disassembly

1. Drain the oil and remove the tubing.

2. Fix the cylinder.

Ɣ Fix the cylinder in a vertical or level

manner. A vertically fixed cylinder can

be disassembled and assembled eas-

ily.

Ɣ The pin bore in the head end can be

used for fixing of the cylinder. The pin

roll can prevent the cylinder from turn-

ing.

Ɣ Remove the tubing in case of tubing in-

terference while fixing the cylinder.

Fix the cylinder

ZX215-1006164

3. Removal of cylinder head

Approx 1.5m

Ɣ Unscrew the bolts with Allen Wrench.

Ɣ Using an extension rod, as shown in

the illustration on the right, will make

the work easy.

ZX215-1006165

8-95

Disassembly and Assembly

4. Pulling out the piston rod

Ɣ Be sure to have removed the tubing

cover.

Ɣ Prepare a suitable container to collect

oil coming out of the oil port.

Ɣ After pulling out the piston rod to its

limit, slowly loosen the cylinder head

and pull it out.

Sleeper

Ɣ Remove the piston rod (1) with the

cylinder head (2) and place them on a

ZX215-1006166

wooden sleeper.

5. Fixing the piston rod

Ɣ Use pin bore on the rod end or the flat

part of the ear to prevent turning of the

Fixing

piston rod.

ZX215-1006167

8-96

Disassembly and Assembly

Remove of the piston nut (5)

Drill bit

Remove the fixing screw (3) from the

piston nut (5).

NOTE: Around the fixing screw there

are two points that have been punched

against loosening. After removing the

riveted part with a hand drill, loosen

and remove the fixing screw (3).

Remove the steel ball (4).

ZX215-1006168

Remove the piston nut (5).

NOTE: The piston nut (5) is very tight.

To loosen the piston nut (5), prepare

a hydraulic jack or a spanner powered

by hydraulic cylinder. An extension rod

should be ready when removing the

piston nut (5) manually.

Hydraulic jack

Hydraulic cylinder

ZX215-1006169

7. Removal of piston assembly

Ɣ Remove in turn the piston (7), buffer

sleeve (6) and cylinder head (2).

ZX215-1006170

8-97

Disassembly and Assembly

8. Removal of the buffer sleeve (8) on the

bottom end

Thread

1) Remove first the piston nut (5).

Piston rod

2) Use a tool like rubber hammer to tap

the piston nut (5) slightly for removal

while keeping the piston rod and the

buffer sleeve (8) intact. Remove the

elastic ring (9).

one gap

(2 pcs)

3) Slide the buffer sleeve (8) toward the

ZX215-1006171

piston threads in order to remove the

two-piece stopper ring.

4) Remove the buffer sleeve (8).

5) There is an opening in the buffer seal

(10). Take advantage of this opening to

remove the buffer seal (10).

9. Removal of piston seal

Screwdriver

1) The slide ring (12) and the guard

ring (13) can be simply removed with

Piston

hands.

2) The seal (14) can be removed with a

Bench clamp

hammer and a flat-head screwdriver.

3) Remove the O-ring seal (15) with a pry

bar.

ZX215-1006172

NOTE: The removed seals should not

be reused.

10. Removal of buffer ring (16)

NOTE: The buffer ring (16) is installed

in the inner groove in the cylinder head.

Use a tool with sharp end to pry it out and

remove it with a scraper.

ZX215-1006173

8-98

Disassembly and Assembly

11. Removal of the U-ring (17) and the dust

ring (18)

Press

1) Remove the U-ring (17) with a tool such

as screwdriver.

Cushion

2) Pierce a tool (such as a screwdriver)

into the dust ring (18) and hammer the

screwdriver to remove the dust ring

(18).

NOTE: The removed seals should not

Support

be reused.

ZX215-1006174

12. Removal of bushing (19)

1) Remove the elastic ring (20) from the

cylinder head (2) with a screwdriver.

2) Push the bushing (19) out with the help

of clamps and press.

13. Removal of bushing (21)

1) Remove the dust ring (22) on the side

of cylinder barrel and piston rod with a

tool such as screwdriver.

2) Remove the bushing (21) with the help

of a suitable cushion block.

8-99

Disassembly and Assembly

8.27.2 Assembly

1. Installation of bushing (21)

1) Use a mounting tool to press the bush-

Press

ing (21) into the bushing (lubricated

with hydraulic oil) on the side of piston

Mounting tool

rod and cylinder barrel.

Cushion

Piston rod

2) Install the dust ring (22) with the help of

a suitable cushion block.

ZX215-1006175

2. Assembly of cylinder head (2)

Hydraulic press

1) Use the press to push in the bushing

(19).

Tool

NOTE: Apply hydraulic oil to the inside

of cylinder head in advance. Make

sure that the bushing (19) pushed in is

free from a raised shoulder.

2) Use the press to push in dust ring (18).

Pressure surface

ZX215-1006176

3) Install the guard ring and the U-ring (17)

sequentially in the U-groove.

NOTE:

Tool

U-groove

Ɣ Install the U-ring (17) in correct direc-

tion. Make sure that the U-ring is intact

Press in

before installation.

Ɣ Inverse installation will cause leak of

oil.

Ɣ Make sure that the U-ring is free from

ZX215-1006177

any corrugation or permanent deforma-

tion after installation.

8-100

Disassembly and Assembly

4) Installation of buffer ring (16)

NOTE: Make sure that the seal is in-

stalled in correct direction. Inverse in-

stallation can cause high pressure be-

tween the buffer ring (16) and the U-ring

(17), which may lead to deformation or

breakage of oil cylinder.

5) Install the elastic ring (20) to prevent

the fall of the bushing (19).

Assembling the piston assembly

Installation of seal (14).

NOTE: Install first the O-ring seal and

the one-side guard ring (13) on the pis-

ton. Place the piston on the press. As

shown in the illustration on the right,

the seal (14) is installed with the tools

indicated.

Correction of seal (14)

ZX215-1006173

NOTE: Install the seal (14) and the

guard ring (13) on the other side. In

order to prevent the expansion of the

seal (14), a corrector must be used to

Press

correct the seal (14) which has been

Block

Press

stretched during installation. The piston

Tool

rod may not be able to go in the cyl-

inder barrel if the seal (14) is not cor-

rected timely.

Tool

Corrector

Installation of slide ring (12)

Piston

NOTE: Slightly open the slide ring (12)

O-ring

and install it axially. Excessive opening

of the slide ring (12) can fail installation.

ZX215-1006179

8-101

Disassembly and Assembly

4. Assembling the piston rod assembly

1) Fix the piston rod (1).

Assembly tool

2) Install the cylinder (2) on the piston rod.

NOTE: Make sure that the dust ring lip

or the U-ring lip is not stopped by the

shoulder of any part. Install the cylinder

head and the piston rod with the tools.

3) If the bottom side of cylinder contains

ZX215-1006180

a buffer (not for bucket cylinder), install

the buffer bearing and the buffer seal in

the following order.

Let the notched side of the buffer seal

(10) face the piston while installing the

buffer seal (10) in the groove.

Install the buffer sleeve (8) according to

the indication in the illustration on the

Gap facing thread direction

right.

Thread

Install the stopper ring in the groove.

Install the elastic ring after the buffer

Piston rod

sleeve (8) is pushed to the bottom. A

rubber hammer should be used for the

tapping job in order to avoid damaging

the piston rod and the buffer bearing.

If the head side of cylinder contains a

One gap

(2 pcs)

buffer, install the buffer sleeve (6) and

Head end buffer

ZX215-1006181

the buffer seal (23) according to the fol-

lowing order.

The piston nut must be installed after

installation of the buffer bearing.

The buffer seal (23) must be installed in

the groove, with its notches facing the

piston.

8-102

Disassembly and Assembly

10) The buffer sleeve (6) must be installed

according to the illustration on the right.

11) Tighten the piston nut (5).

Piston nut (arm):

9600 N·m {979.6 kgf·m}

Piston nut (boom and bucket):

6200 N·m {632.6 kgf·m}

Gap facing piston side

NOTE:

Rod end buffer

ZX215-1006182

Ɣ Insufficient tightening can cause oil

leakage, loose nut and thread break-

age. In addition, excessive tightening

can cause expansion of the buffer shaft

on the extending side or deformation of

piston on the contact side.

Ɣ Thoroughly clean and grease (with ba-

nana oil) the threaded portions of the

piston, nuts and piston rod before tight-

ening the nuts.

12) Treatment of the piston against loosen-

ing

NOTE: After the piston nut (5) is tight-

ened, put in the steel ball (4), tighten

Punch

Rivet

the setscrew (3) and punch to rivet the

two peripheral points.

Setscrew (3):

66.9 N·m {6.8 kgf·m}

ZX215-1006183

8-103

Disassembly and Assembly

5. Install the piston into the cylinder barrel

Tool

Nylon sleeve

1) Fix the barrel in a vertical or level man-

(2 pcs type)

ner.

2) Install the piston rod into the cylinder

(Spread the

gaps by 180°)

barrel.

NOTE:

Ɣ If fixed in a vertical manner, the piston

rod falls into the barrel under its gravity.

Ɣ Make sure that the slide ring does not

fall while the piston is inserted into the

barrel.

ZX215-1006184

6. Tightening of cylinder head

Tighten the cylinder head according to the

sequence shown in the illustration on the

right.

Bolt: 267 N·m {27.2 kgf·m}

7. Install the tubing.

Tightening sequence

ZX215-1006185

8-104

Disassembly and Assembly

8.28 Work Equipment AS - Remove and Install

8.28.1 Removal

WARNING

Ɣ Fully extend the arm and the bucket.

Lower the work equipment to the

ground. Move the hydraulic lockout

control to the LOCK position.

Ɣ Release residual pressure in the hy-

draulic circuit.

See “Residual Pressure in Hydraulic Circuit -

Release” on page 6-40.

1. Disconnect the grease hose (1).

2. Lift the boom cylinder assembly (2). Re-

move the lock bolt (3).

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

NOTE: There are shims installed. Count

the shims and check the thickness. Place

ZX215T-1006186

the shims in a safe place.

4. Start the engine and retract the piston rod.

NOTE: Secure the piston rod with a wire

rope in order to prevent the piston from

slipping out. Put the cylinder on a bench or

support. Remove the grease fitting on the

bottom side in the later case. Remove the

other boom cylinder in the same way.

5. Remove the two hoses (6) of bucket cylin-

der and the those (7) of the arm cylinder.

NOTE: Cork the hoses to prevent outflow

ZXT225-1106028

of oil. Secure the hoses to the valve side.

6. Remove the inter-connector (8) used for

work lamp.

8-105

Disassembly and Assembly

7. Lift the work equipment and remove the

plate (9). Remove the pin (10) from the

bottom.

NOTE: There are shims installed. Count

the shims and mark their locations.

ZX215T-1006188

8. Lift and disassemble the work equipment

assembly.

Work equipment assembly: 3451 kg

ZX215T-1006189

8-106

Disassembly and Assembly

8.28.2 Installation

CAUTION

Ɣ Do not put your finger in the pin bore

while aligning the pin bore.

Ɣ Installation is to be performed in the re-

verse order of removal.

NOTE: A clearance (a: 0.5~1.5 mm) shall

be left between the plate and the nut when

tightening the locknut.

Greasing after assembling the pin:

Grease (supramoly lithium base)

ZX215-1006190

NOTE: Adjust the shim thickness in order

to have a desired clearance (a: 0.5<a<1

mm) between the piston end (12) and the

plate (4).

Standard shim thickness: 1.0 mm and 2.0

mm.

Greasing after assembling the pin:

Grease (supramoly lithium base)

ZX215-1006191

Hydraulic oil adding

Add hydraulic oil to the specified level.

Start the engine to circulate the oil in the

hydraulic system, and check the oil level

again. Add more hydraulic oil if necessary.

Air bleeding

Bleed the air from travel motor.

For more information, see “Air in Each

Component - Bleed” on page 6-46.

8-107

Disassembly and Assembly

8.29 Air Conditioner AS - Remove and Install

Special tools

Part Name

Model

Necessity

Qty

Refrigerant

Robinair

charger

34711-2K

Refrigerant

Inoue Qing-

charger

Hua

8.29.1 Removal

CAUTION

Ɣ Disconnect the cable from the negative

(-) post of the battery.

1. Drain the coolant.

Coolant: approx. 22.5 L

2. Recover refrigerant from the air-condition-

ing system with the tool (S).

ZX215T-1006192

3. Remove the pad (1) on the cab floor.

ZX215T-1006193

8-108

Disassembly and Assembly

4. Open the left rear cover of the cab with the

ignition key. Remove the outer filter ele-

ment (2).

Cover

W13092904

5. Remove the fuse box (3) and storage box

(4).

6. Remove outer covering (5).

7. Remove the air conditioner cover (6).

ZX215T-1006196

8. Remove the back air duct (7).

9. Remove the left air duct (8).

10. Remove the baffle (9).

11. Remove the right air duct (10).

ZXT225-1006205

8-109

SANY Crawler Hydraulic Excavator (SY195C9, SY205C9, SY215C9, SY225C9). Shop Manual (2013) - page 30