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

Disassembly and Assembly

2) Adhere rubber seal (6) on the left cab

window as illustrated.

ZXT225-1006248

3) Adhere rubber seal (6) onto the lower

cab door window as illustrated.

ZXT225-1006249

Ɣ Adhere additional rubber seal (6b) onto

the lower cab door window frame as il-

lustrated.

Position of additional rubber seal:

(j): 110 mm

(k): 90 mm

(m): 200 mm

ZXT225-1006250

8-130

Disassembly and Assembly

4) Adhere rubber seal (6) onto the front

window glass as illustrated.

ZX215-1006243

Ɣ Different from the rubber seal (6) on

other window, rubber seal (6c) on the

bottom of the front window shall be

adhered onto the external edge of the

lower part of the front window frame.

(If it is adhered along the inner edge,

the rubber seal will be seen through the

clear part of the glass.)

ZXT225-1006252

5. Positioning of new window glass

1) Check the clearance between the edge

of glass and the cab in 4 directions,

and position the glass. Make sure the

clearance is even.

2) Put a tape [6] across the glass (9) and

cab (8) and draw a line (n) on it for

[6]

alignment.

Ɣ Adhere tape [6] at 3 points as illustrated

for precise alignment of right window

glass, left rear window glass and cab

door lower window glass.

ZXT215-1006245

3) Cut the tapes across the glass (9) and

the cab (8) and remove the glass.

Ɣ Do not remove the tape on the left side

of the glass until the glass is installed.

8-131

Disassembly and Assembly

Ɣ When positioning front window glass

(4), cover it across the width of the win-

dow frame in the horizontal direction.

[6]

Set the clearance (p) between the top

edge of the glass and the upper frame

[6]

at 3 mm when positioning it in the verti-

cal direction.

ZX215-1006246

ZX225-1006255

8-132

Disassembly and Assembly

6. Adhesive

Ɣ Store adhesion agent in dark places

where temperature is blow 25°C.

Ɣ Do not heat the adhesive to above

30°C.

Ɣ Before using adhesive that has been

unsealed, remove the hardened part at

the nozzle.

1) Open the aluminum seal (13) on the

head of the cylinder (12) and install the

nozzle (14).

ZX215-1006247

Adhesive:

Sunrise MSI SR sealant U90 4463876

2) Cut the tip of nozzle (14) as illustrated.

Dimension of the cut:

(q): 10 mm

(r): 5 mm

3) Set the cylinder (12) in the gun [7].

[7]

Ɣ An electrical caulking gun is more ef-

ficient.

ZX215-1006249

8-133

Disassembly and Assembly

4) Remove the waxed paper of the rubber

seal on the surface where adhesive is

to be applied.

5) Apply adhesive (15) along the external

edge of the rubber seal (6).

ZX215-1006250

Ɣ Adhesive (15) for rubber seal (6) on

cab (8) shall be applied as illustrated:

Dimension of (s): 10 mm

Dimension of (t): 15 mm

Ɣ Adhesive (15) shall be thicker that the

rubber seal (6).

Ɣ Apply adhesive of the same thickness

evenly.

ZX215-1006251

8-134

Disassembly and Assembly

Ɣ Apply adhesive (15) onto the additional

rubber seal of the right window (6a) and

additional rubber seal of the cab door

lower window (6b).

ZX215-1006252

ZX215-1006253

7. Install window glass

1) Install window glass (9) and align it with

the mark on the cab. (See step 5)

Ɣ Since the glass can not be remove

once installed, be very careful when

performing this task.

Ɣ Install the glass properly within 5 min-

utes after adhesive has been applied.

2) Press the perimeter of the glass (9)

after is has been put in place until it is

ZXT215-1006254

securely stuck to the rubber seal.

Ɣ Press the corners of the glass hard.

8-135

Disassembly and Assembly

Ɣ After the front window glass has been

installed, fill the clearance between the

glass on area (s) and the center adjust-

ing seal (16) to the dimension of (t) and

(u). Coat primer onto glass (4) on sec-

tion A-A and apply the adhesive as fill-

ers.

Dimension of (t): 2 mm

Dimension of (u): 5 mm

Ɣ Use a rubber spatula to cover the edge

of the glass and trim the adhesive.

A-A

ZX215-1006255

Ɣ Remove surplus adhesive.

Glass primer:

Sunrise MSI Primer 35

Adhesive:

Sunrise MSI SR Sealant U90 4463876

8. Fix the glass

1) After the right window glass (1) has

been adhered to the cab, put position-

ing chips a (1 or 2 pcs) beneath the

glass in order to fix it.

ZXT215-1006256

8-136

Disassembly and Assembly

2) Use foam polystyrene blocks [9] and

rubber band [10] to fix the glass and

[10]

the rubber seal as illustrated.

9. After the glass has been fixed, remove all

the remaining primer and adhesive on the

cab and on the glass.

Ɣ Clean the adhesive with unleaded gas-

oline before it is hardened.

[9]

Ɣ Do not apply impacting force onto the

glass when cleaning it.

ZX215-1006257

10. Protection of fixed window glass

1) Remove the positioning chips, foam

polystyrene blocks and the rubber band

after 10 hours.

(Condition: Temperature: 20; humidity:

60%)

2) Wait for another 14 hours after the re-

moval of positioning chips, foam poly-

styrene blocks and rubber band before

operating the machine.

8-137

Disassembly and Assembly

8.33 Front Window AS - Disassemble and Assemble

NOTICE

Ɣ Before removing the front window as-

sembly, lower the work equipment onto

the ground and shut down the engine.

The front window assembly must be removed

from the cab in order to replace the front win-

dow glass.

8.33.1 Disassemble

1. Raise the front window assembly to the

roof and secure it with the rear locks (at

both sides).

2. Remove left corner plate (1) and right cor-

ner plate (2).

Ɣ Mounting bolt (4) and washer (3) of the

left corner plate will be used in Step 6

to hang the pull rod.

ZX215-1006258

3. Release the rear lock of the cab.

4. Lower the front window assembly carefully

a bit. Take out and hold the rollers (5) and

(6) at the bottom of the front window from

the removed parts in Step 2.

5. Remove roller (5) and (6) from both sides

of the bottom of the front window.

ZX215-1006259

8-138

Disassembly and Assembly

6. Remove pin (7) at the lower left side.

Ɣ Plate (8) at the end of the pull rod (9)

will come out by removing of pin (7).

Ɣ Hang plate (8) onto the mounting bolt

of left corner plate (using the washer)

and fix it.

NOTICE

Ɣ A return load of 58.8 N {6 kg} is applied

ZX215-1006260

onto the rear of the cab. Be very care-

ful when removing pin (7) to disconnect

pull rod (9).

ZX215-1006261

7. Pull out the front window assembly (10)

from the opened part of the guide rail and

lower the assembly gradually.

ZX215-1006262

8-139

Disassembly and Assembly

8. Lower the front window assembly (10)

completely.

Ɣ Be careful not to allow the front window

assembly to damage the machine mon-

itor.

ZX215-1006263

9. Move the front window assembly (10) to

the right and the left and remove the two

upper rollers (11) and (12) from the guide

rail. Then, remove the front window as-

sembly (10).

ZX215-1006265

8-140

Disassembly and Assembly

8.33.2 Assemble

Ɣ Reverse the disassembling sequence.

Ɣ Adjust the opening and closing of the front

window assembly as per the following in-

struction.

1. Open and close the front window assembly

and check if it interferes with the guide rail.

Check if the roller is jammed.

2. If the front window can not be opened or

closed properly, loosen the mounting bolt

of the roller adjusting bracket (13) and

adjust the condition of the front window.

Tighten the mounting bolt after adjusting.

Mounting bolt:

34.3 N·m {3.5 kgf·m}

ZX215-1006266

3. Raise the front window assemble and fix it

with rear locks (at both sides).

Ɣ Check if the locks at the rear of the cab

are securely fixed.

4. Install the right corner plate (2).

Ɣ After the "locked" position is adjusted in

Step 6, tighten the corner plate.

Ɣ Install the right corner plate. Clearance

ZX215-1006267

(a) between the guide rail and the right

corner plate (2) is 0 - 2.0 mm.

Ɣ Install the right corner plate. Keep the

surface (R) of the roller without a level

error.

ZX215-1006268

8-141

Disassembly and Assembly

5. Install left corner plate (1)

Ɣ After the "locked" position is adjusted in

Step 6, tighten the corner plate.

Ɣ Install left corner plate. Clearance (b)

between the guide rail and the left cor-

ner plate (1) is 0 - 2.0 mm.

Ɣ Install left corner plate and keep the

surface (R) of the roller without a level

error. (See previous illustration).

ZX215-1006269

Adjust the "locked" position of the lock of

front window assembly as per the following

instruction.

Tighten the left corner plate (1) and the

right corner plate (2) in a nearly correct

position so that front window glass (14)

is pressed closely against the adjusting

seal (15) on the cab.

ZX215-1006270

Open and close the front window as-

sembly and check the working condi-

tion of left lock (16) and right lock (17).

If left lock (16) and right lock (17) do

not work properly, Loosen the mounting

bolt (19) of the lock and move the lock

(16) forward. Tighten the bolt after that.

Adjust the right lock with the same

method.

Check again the adaptability between

the front window assembly (14) and

the adjusting seal (15) on the cab.

(Checked in Step 1)

ZX215-1006271

Tighten the mounting bolts of the left

and right corner plates when the left

and right locks (16, 17) are properly in

place.

8-142

Disassembly and Assembly

7. After adjustment is finished, flush the front

window glass and check if any water leaks

into the cab.

ZX215-1006272

Adjust the "locked" position of the lock of

front window assembly

1) After the "locked" position of the lock of

front window assembly is adjusted in

Step 6 and Step 7, raise the assembly

to the roof.

2) Set the locks of the front window as-

sembly at the rear of the cab at the

"locked" position, and check the follow-

ing items:

Ɣ Check the conditions of left lock (16)

ZX215-1006273

and right lock (17).

Ɣ The front window assembly must con-

tact the left and right rubber stopper

(18), and the rubber stoppers must be

pushed backward by 1.5 - 3.0 mm.

Ɣ The front window assembly shall push

the limit switch 4 - 7mm backward.

ZX215-1006274

8-143

Disassembly and Assembly

3) Close the front window assembly (10).

4) Loosen the retaining nut (20) at the left

and right side of rubber stopper (18),

and pull the two rubber stoppers (18)

inward so that they can not contact the

"unlocked" front window assembly.

5) Adjust the position of latch bolt (21).

Ɣ Latch bolt(21): M10, Inner diameter of

plate (23): ø14.5 mm

ZX215-1006275

6) Adjustment of left and right rubber stop-

per (18)

Ɣ Allow front window assembly (10) to

contact the left and right rubber stopper

(18). (when the lock is "unlocked")

7) Lock front window assembly (10).

ZX215-1006277

8) Turn the left/right rubber stopper (18) to

the left by one and a half round.

Ɣ Turning the rubber stopper (18) leftward

for one round is equivalent to pressing

it by 1.5 mm.

Ɣ When front window assembly is "un-

locked", it must move the left/right rub-

ber stopper (18) by 1.5 - 3.0 mm.

9) Tighten the retaining nuts (20) at both

sides of the rubber stopper (18).

ZX215-1006278

8-144

Disassembly and Assembly

9. Adjust the front window assembly retainer

(24).

Ɣ Adjust and lock both sides of the retain-

er (24) so that surface (d) of stopper

(D) of front window assembly contacts

surface (c) of retainer (24) when front

window assembly is raised.

ZX215-1006279

10. Check the locking ability of front window

assembly.

Ɣ After the adjustment from Step 6 to

Step 9 is finished, check the locking

force of left lock (16) and right lock (17).

Ɣ Check the locking force at the "locked"

side (front of cab) and the "unlocked"

side (rear of cab).

Left lower pin:

27 - 34 N·m {2.75 - 3.47 kgf·m}

Mounting bolt:

Adhesive(LT-2)

ZX215-1006271

8-145

Disassembly and Assembly

8.34 Monitor - Remove and Install

8.34.1 Removal

CAUTION

Ɣ Disconnect first the cable connecting to

the negative (-) post of the battery.

1. Unscrew the three bolts (4). Remove the

mounting plate and the monitor assembly

from the bracket (3).

2. Remove the nut (1) and the gasket (2) to

separate the monitor (5) from the mounting

plate.

ZX215-1006281

8.34.2 Installation

Ɣ Installation is to be performed in the re-

verse order of removal.

8-146

Disassembly and Assembly

8.35 Controller AS - Remove and Install

8.35.1 Removal

CAUTION

Ɣ Disconnect first the cable connecting to

the negative (-) post of the battery.

1. Remove the fuse box (1) and storage box

(2).

2. Remove rear covering (3).

3. Remove air conditioner cover (4).

ZXT335-1006800

4. Remove the controller wiring connectors

A1(5) and A2(6).

5. Remove the four bolts. Remove the con-

troller assembly (7).

ZX215-1308283

8.35.2 Installation

Ɣ Installation is to be performed in the re-

verse order of removal.

8-147

Disassembly and Assembly

8.36.2 Removal

NOTICE

Ɣ Disconnect the power supply prior to

removal.

1. Remove the console cover.

Arm rest cover

Radio

ZX215-1006286

2. Remove the radio connector CN-003F.

Connector CN-003F Cab harness

ZX215-1006287

3. Remove the four screws and the washers

in order to remove the radio and the radio

mounting brackets from the console cover.

Arm rest

4. Remove the four screws and the washers

in order to remove the radio from the radio

mounting brackets.

Radio

Mounting bracket

Washer

Screw

ZX215-1006288

8-149

SANY Crawler Hydraulic Excavator (SY195C9, SY205C9, SY215C9, SY225C9). Shop Manual (2013) - page 32