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SANY Crawler Hydraulic Excavator (SY195C9, SY205C9, SY215C9, SY225C9). Shop Manual (2013) - page 31

Disassembly and Assembly

12. Remove the cover (11).

13. Remove the cab's center connector (12).

14. Remove the radio antenna(13).

13

12

11

ZXT225-1006206

15. Remove the connector (14), connector (15)

18

and air conditioner wiring connection (16).

17

Remove the two air conditioner relays (17),

three mounting bolts (18). Remove the

16

electrical mounting plate (19).

14

15

19

ZXT215-1308207

16. Remove the air conditioner water pipes (20)

and (21) as well as the dripping tube (22).

22

20

21

ZX215T-1006200

8-110

Disassembly and Assembly

17. Remove the air conditioner unit (23).

NOTE: Also disconnect the two hoses con-

necting to the bottom of the air conditioner

23

when removing the air conditioner unit.

ZX215T-1006201

8-111

Disassembly and Assembly

8.30 Counterweight AS - Remove and Install

8.30.1 Removal

1. Remove the cover (1) from the counter-

weight. Install eyebolts to the counter-

1

weight. Hold the counterweight.

ZX225-1106004

2. Remove the four bolts (2).

Wire rope

2

ZX225-1106005

3. Lift the counterweight levelly with wire rope

or chain hoist.

NOTE: Be careful not to damage the

engine, radiator or cooler.

Counterweight assembly:

3901 kg

3

ZX225-1106006

8-113

Disassembly and Assembly

8.30.2 Installation

Ɣ Installation is to be performed in the re-

verse order of removal.

Threads (mounting bolt - counter-

weight):

Thread adhesive (Tonsun 1277)

Mounting bolt (counterweight):

1,180~1,470 N·m {120~150 kgf·m}

Counterweight adjustment

1.

Move the counterweight with a crane to a

suitable position on the frame.

2.

Push the counterweight and install the

Door

bolts. Adjust the position of the counter-

weight in such a manner that the following

Counterweight

dimensions can be obtained.

a=10±4mm

Ɣ Clearance with swivel:

10±5 mm(L&R)

b=0±5mm

Ɣ Clearance with bodywork door:

Swivel

10±5 mm(L&R)

ZX215-1006205

Ɣ Step from swivel in left to right direction

b: max. 5 mm

Ɣ Step from bodywork door in left to right

direction

a: 10±4

Ɣ Step from bodywork top cover in upper

to lower direction

c: max. 5 mm

8-114

Disassembly and Assembly

8.31 Cab AS - Remove and Install

8.31.1 Removal

CAUTION

Ɣ Disconnect first the cable connecting to

the negative (-) post of the battery.

1. Remove the floor mat (1).

1

ZX215T-1006193

2. Remove the fuse box (2) and storage box

(3).

3. Remove outer covering (4).

4. Remove the air conditioner cover (5).

4

3

2

5

ZX215T-1006001

5. Disconnect the left wire harness (6), moni-

tor harness connector (7) and window

washer harness (8).

6

7]’

6. Remove the right side air duct (9).

8

9

ZXT225-1006216

8-115

Disassembly and Assembly

7. Remove external air filter (10).

10

ZXT225-1006217

8. Disconnect the external air duct (11).

11

ZX215T-1006210

9. Remove the storage box on the armrest

(12).

12

ZX215T-1006211

8-116

Disassembly and Assembly

10. Remove the radio connector (13).

11. Remove the radio wire harness (14).

13

14

ZX215T-1006212

12. Remove the window washer reservoir (15).

15

ZX215T-1006213

13. Remove the window washer pipe (16).

16

ZX215T-1006214

8-117

Disassembly and Assembly

14. Remove the decor cover (17).

17

ZX215T-1006215

15. Remove the four mounting nuts (18) and

the five mounting bolts (19).

19

18

ZXT225-1006224

16. Lift the cab assembly (20) for removal.

Cab assembly: 450 kg

20

ZX215T-1006217

8-118

Disassembly and Assembly

8.31.2 Installation

Ɣ Installation is to be performed in the re-

verse order of removal.

Bolt: 200 N·m {20.4 kgf·m}

Nut: 210 N·m {21.4 kgf·m}

8-119

Disassembly and Assembly

8.32 Cab Window Glass - Disassemble and Assemble

10

10

9

8

1

10

2

7

6

10

11

4

5

12

10

3

ZX215-1006218

1) Right window glass

7) Left side rear window glass

2) Front window glass

8) Rear window glass

3) Lower front glass

9) Roof window glass

4) Cab door window glass (upper)

10) Rubber sealing strip

5) Cab door window glass (lower)

11) Center adjusting seal

6) Cab door window glass (upper)

12) Front window AS (Glass and frame)

Ɣ

Cab window glasses (1), (2), (5), (7) and (9) are adhered to the window frame.

Ɣ

When replacing front window glass (2), disassemble front window assembly (12). (If the cab

is install with a front window assembly, do not only replace the front window glass.) For more

information about front window replacement, see “Front Window AS - Disassemble and As-

semble” on page 8-134.

8-120

Disassembly and Assembly

8.32.1 Removal

CAUTION

Ɣ Removing shattered or cracked window

glass may cause finger cuts.

Ɣ Wear proper PPEs when removing shat-

tered cab window glasses.

NOTE: To avoid finger cut during when remov-

ing a shattered or cracked glass, cover it with

a piece of adhesive film or tapes.

1. Removal of glass (3)

Glass (3) is hold in place by sealing strips.

Pull it upward carefully to remove it.

3

ZX215-1006219

2. Removal of glass (4) and (6)

1) Remove the sealing strip from the

frame of the cab door.

2) Push the glass outward carefully from

inside of the cab and remove glass (4)

and (6) together with the frame.

6

4

ZX215-1006220

8-121

Disassembly and Assembly

3) Remove glass (4) and (6) from the

frame with a screw driver.

Frame

Seal

6

4

ZX215-1006221

3. Removal of glass (8)

1) Remove the retainer from the groove

8

on the rubber with an ordinary screw

driver.

2) Put a thin bamboo chip inside part A of

the retaining rubber and detach the re-

tainer along the edge.

3) Pat the glass from inside of the cab

and remove it. This job may require two

people.

ZX215-1006222

Rubber retainer side

Rubber retainer

Glass

Cab side

Retainer

A

A

Cab

ZX225-1006231

8-122

Disassembly and Assembly

4. Removal of glass (1), (2), (5), (7) and (9).

9

1

7

2

5

ZX215-1006223

1) Remove the resin board, decor strip

and retainer along the edge of the

Cab

glass.

Glass

Drill

2) Punch a hole through the adhesive with

a drill (or a cutter) as illustrated.

Adhesive

ZX215-1006224

3) Pull a piece of piano string (or steel

wire) through the hole as illustrated.

Piano string

(or steel wire)

ZX215-1006225

8-123

Disassembly and Assembly

4) Fix both ends of the piano string onto

two screw drivers. Pull the wire back

Cab

(Outside)

and forth in order to cut the adhesive

Glass

and detach the glass from the cab. This

job may require 2-3 people.

Ɣ Run the string along the center of the

adhesive. The string may break when

it becomes very hot. Use different sec-

tions of the string while cutting the ad-

Adhesive

hesive.

(Inside)

ZX215-1006226

8-124

Disassembly and Assembly

8.32.2 Installation

Ɣ Reverse the disassembling sequence

when installing glasses (3), (4), (6) and

(8). Follow the procedures below to install

glasses (1), (2), (5), (7) and (9).

1. Clean the remaining adhesive and rubber

on cab frame (contact surface) with a knife

or scraper [5].

Ɣ Remove the remaining adhesive and

rubber so that they will not affect the

[5]

application of new adhesive. Do not

scrape the original paint on the surface.

ZXT215-1006227

(Scraping of paint reduces the perfor-

mance of the adhesive.)

2. Clean the grease, dust and dirt on the cab

(8) and the glass (9) with unleaded gaso-

line.

Ɣ Contaminant on the contact surface re-

duces the performance of adhesive.

Ɣ Clean the black part on the back of the

8

glass.

Ɣ After cleaning, dry the glass for at least

5 minutes.

ZXT215-1006228

9

ZXT215-1006229

8-125

Disassembly and Assembly

3.

Priming coat (10)

Ɣ

Priming paint expires 4 months after

production. Do not use expired paint.

Ɣ

Use the paint within 2 hours after it is

Cab

unsealed.

11

Ɣ

Use the paint within 24 hours even if it

10

is sealed again immediately after un-

Old adhesive edge

sealing. (Dispose the paint 24 hours

on cab side

after it is unsealed)

1)

Make sure the adhesive paint and glass

ZX215-1006230

priming paint are well agitated before

application.

Ɣ

If the priming paint is stored in a refrig-

erator, keep it under ambient tempera-

ture for at least half a day before agita-

tion.

Ɣ

(If the paint is unsealed immediately af-

ter it is taken out of a refrigerator, water

will condense on it.)

2)

Always wash a used brush (11) with

unleaded gasoline before using it.

Ɣ

Check the brush for contaminants after

it has been washed.

Ɣ

Prepare two brushes for priming paint,

one for painted surface and the other

for glass surface.

8-126

Disassembly and Assembly

3) Apply priming paint (for painted sur-

face) evenly onto the surface where

sealing rubber is to be adhered and

8

where adhesive agent is to be applied

(on the cab (8)).

Priming paint (for painted sur-

face): Sunrise MSI Primer 24

Ɣ Do not apply primer more than twice;

otherwise, the performance of the prim-

er will be reduced.

ZXT215-1006231

Ɣ Applying location: Cover the whole area

of (a). Dimension of (a): 25mm

8

6

a

ZX215-1006232

Ɣ Besides the above locations, apply

primer also onto the right window glass

and the cab door lower window glass.

Ɣ Additional priming area on the right

b

window glass: (b)

Ɣ Additional priming area on the cab

door lower window glass: (c)

ZX215-1006233

8-127

Disassembly and Assembly

Ɣ Dry the primer for at least 5 minutes

(within 8 hours).

Ɣ Do not use wrong priming paint.

If, for example, glass primer is mistak-

enly used, wash it with unleaded gaso-

line.

c

ZX215-1006234

4) Apply priming paint (for glass surface)

onto the contact surface of window

9

glass (9).

Glass primer:

Sunrise MSI Primer 35

Ɣ Do not apply the primer more than

twice; otherwise, the performance of

the primer will be reduced.

ZX215-1006235

Ɣ Priming area: Apply the priming paint

on the contact surface of glass (9)

8

(rubber seal (6)adhering location) and

along cab frame (8).

Ɣ Leave a 5 mm margin uncoated along

6

the black strip adjacent to the clear

area of the glass.

d

Ɣ When priming paint has been coated,

9

dry it for at least 5 minutes (within 8

hours).

ZX215-1006236

Ɣ Do not use wrong primer.

If wrong glass primer is used, wash it

with unleaded gasoline.

8-128

Disassembly and Assembly

4. Adhere rubber seal (6) (with adhesive tape

on both sides) along the inner edge of the

contact surface of the glass.

Ɣ Do not detach the waxed paper on the

rubber seal before the window glass is

installed.

Ɣ Do not touch the cleaned area on the

glass before rubber seal is adhered.

6

Ɣ Be careful not to allow the rubber seal

ZXT225-1006245

on the corners to peel off.

Ɣ When sticking rubber seal (6) along the

window frame, do not overlap the two

ends of the seal. A 5 mm gap between

the two ends of the seal is recommend-

ed.

e

6

1) Stick rubber seal (6) onto the right cab

window frame as illustrated.

ZXT225-1006246

Ɣ Adhere additional rubber seal (6a) onto

f

the right cab window

6a

Position of the additional rubber seal:

(f): 50 mm

h

(g): 90 mm

(h): 250 mm

g

ZXT225-1006247

8-129

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