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SANY Crawler Hydraulic Excavator (SY195C9, SY205C9, SY215C9, SY225C9). Shop Manual (2013) - page 33

Disassembly and Assembly

8.36.3 Installation

Ɣ Installation is to be performed in the re-

verse order of removal.

8.36.4 Connector model and wiring

1

2

3

1

2

3

20b

R+

L+

0

28

R-

L-

4

5

6

7

4

5

6

7

Harness socket terminals

Raido wiring terminals

Type: Yasaki 7119-3070

ZX215-1006289

8-150

Disassembly and Assembly

8.37 Battery

8.37.1 Structure

A

2

B

10

J

C

11

6

E

D

I

G

H

F

8

7

5

9

4

3

1

ZX215-1006290

1) Spinning post

7) Paste (active material)

2) Charge densiometer

8) "Bag-type" screen

3) Heat-sealing cover

9) Polar group

4) PP casing

10) Liquid-gas separator

5) Central polar ear

11) Central busbar

6) Forged grid

8-151

Disassembly and Assembly

8.37.2 Removal

NOTICE

Ɣ Turn the start switch to the OFF posi-

tion before removal.

Ɣ Do not remove the charge densimeter.

Tighten the densimeter clockwise, if it

Bolt

Terminal

Grounding cable

is loosened, with a suitable tool.

1. Removal of battery grounding wire

Ɣ Open the tarpaulin, unscrew the bolt, and

remove the terminal from the battery wiring

post.

Battery

CAUTION

ZX215-1006291

Ɣ Battery gas can cause explosion. No

sparks or flames are allowed near the

battery.

Battery cable

2. Disconnect the battery wiring cable and the

battery breaker cable.

VARTA

Battery

Breaker cable

ZX215-1006292

3. Remove the four bolts and washers. Re-

Battery

move the battery assembly from the bot-

tom plate. Remove the battery.

Battery box

Bolt

Wahser

ZX215-1006293

8-152

Disassembly and Assembly

8.38 Start Switch

8.38.1 Structure

23

22

20

18

17

15

13

12,11

28

6

10,9,8,7

25,24

21

1

14

19

16

26

5

4,3,2

27

ZX215-1006294

1) Housing

8) Shield

15) Cover

22) Contact SPR-A

2) Key

9) Pin

16) Spring

23) Contact B

3) Ring

10) Spring

17) Ball

24) Terminal

4) Knob

11) Disc

18) Spring

25) Bolt

5) Nut

12) Spring

19) Contact SPR-B

26) O-ring seal

6) Cylinder

13) Plug

20) Contact A

27) Harness AS

7) Cap

14) Rotor

21) Seat

28) Washer

8-154

Disassembly and Assembly

8.38.2 Removal

NOTICE

Ɣ Disconnect the power supply of the

start switch before removal.

1. Remove the setscrew to remove the con-

sole cover.

Start swich

Console cover

Set screw

ZX215-1006295

2. Remove both setscrews in order to remove

Set screw Console cover

the mounting plate and the start switch

from the console cover.

Mounting plate Start switch

ZX215-1006296

3. Remove the nut so as to remove the start

switch from its mounting plate.

Start switch

Mounting plate

Nut

ZX215-1006297

8-155

Disassembly and Assembly

Working principle and wiring of start switch

1. Working principle

ON/OFF

Key Position

Preheat Plug

Battery (B)

Battery Relay (BR)

Accessory

Start Relay (C)

(R1)

(R2)

HEAT

OFF

ON

START

2. Wiring

1

B

BR

ACC

3

1

22

13

3

4

R1

R2

C

6

4

16

11

6

HARNESS PLUG TERMINALS

JACKET MODEL˖YAZAKI 7123-7464-30

KEY SWITCH WIRING TERMINALS

JACKET MODEL˖YAZAKI 7222-7464-30

ZX215-1006299

8-156

Disassembly and Assembly

8.39 Fuse Box

8.39.1 Removal

Cover

1. Remove the cover.

ZX215-1006300

2. Remove the bolts and take off the back

cover along with the fuse box.

Back cover Fuse box cover

Bolt

ZX215-1006301

3. Remove the bolts so as to separate the

Fuse box harness

fuse box and harness assembly from the

back cover.

Bolt

Back cover

ZX215-1006302

8-157

Disassembly and Assembly

8.40 Wiper

8.40.1 Structure

Blade

Rotating mechanism

Arm

Wiper motor

Connector

Mounting bracket

ZX215-1006303

8.40.2 Working principle

GREEN (LOW SPEED)

YELLOW (RESET)

M

BLUE (HIGH SPEED)

RED (POWER+)

BLACK (POWER-)

ZX215-1006304

8-158

Disassembly and Assembly

8.40.3 Removal

1. Remove the decorative button in order to

remove the interior decoration.

Decoration

button

Inner decor

ZX215-1006305

2. Remove the moving mechanism and the

motor.

Bolt

Ɣ Unscrew the bolts to remove the wiper

motor and moving mechanism from the

Moving

cab.

mechanism

Wiper motor

Bolt

ZX215-1006306

3. Remove the arm and the blade.

Ɣ Unscrew the nut to remove the wiper

arm and blade from the cab.

Arm bracket

Cap

Locknut

Cab

ZX215-1006307

8-159

Disassembly and Assembly

8.40.5 Installation

Ɣ Installation is to be performed in the re-

verse order of removal.

8.40.4 Angle adjustment of wiper arm

Ɣ The arm should stops moving when the

Stopper

blade reaches the stopper.

Ɣ If the arm is still working when the blade

Blade

reaches the stopper or the arm already

stops working before the blade reaches the

stopper, the moving angle of wiper should

be adjusted to prevent breakdown of the

wiper.

Arm

Ɣ Adjust the wiper in such a way. Loosen the

locknut; adjust the arm working angle ac-

cording to actual condition. Make sure that

the wiper motor stops working at the mo-

Locknut

ment that the blade reaches the mechani-

cal stopper.

ZX215-1006308

8-160

Disassembly and Assembly

8.41 Relay

8.41.1 Engine relays

1. Starter relay - check

S

Ɣ Check the conduction and action. Replace

the relay in case of any failure.

B

S

SW

L

B

1

SW(-)

2

L(-)

ZX215-1006309

2. Mains relay - check

1(+)

2(-)

Ɣ Check the conduction and action. Replace

the relay in case of any failure.

3

4

Battery (+) terminal

3

4

1(+)

2(-)

ZX215-1006310

3. Heater relay

5(-)

Ɣ Check the conduction and action. Replace

the relay in case of any failure.

1

5

1

2

3

4

(-)

(+)

2

4(+)

Fuse

3

ZX215-1006311

8-161

Disassembly and Assembly

4. Safety relay

Measure the resistance between terminal

2 and terminal 3.

Standard Value

Approx. 200ȍ

Ɣ Check the conduction and action. Replace

(P)6

the relay in case of any failure.

3(R)

5

2(L)

(E)4

1(S)

8.41.2 Other relays

ZX215-1006312

1. Function and location

Starter control relay

Work lamp relay

Relay harness

Shutdown delay relay

Head lamp relay

Parking relay

Pilot control relay

Horn relay

Mounting plate

ZX215-1006313

8-162

Disassembly and Assembly

2. Removal

1) Remove relay from its seat.

Relay harness Mounting plate

2) Remove the screw in order to remove the

relay seat and harness from the mounting

plate.

3. Installation

Ɣ Installation is to be performed in the re-

verse order of removal.

Relay seat Screw

Relay

ZX215-1006314

8-163

Disassembly and Assembly

4. Relay connector and wiring

5

1

4

2

3

Relay wiring terminals

Relay model: HELLA 4RD 007 903-027

Horn relay

Work lamp relay

Pilot control relay

Starter control relay

Parking relay

Head lamp relay Shutdown delay relay

K5

K6

K10

K3

K7

K8

K9

32

34

27

11

64

70

21

31

0

33

0

105

0

105

0

13

0

72

0

0

13

606

65

23

24

12

63

71

15

Harness socket terminals

Socket model: Jacket 8JA003526-00

ZX215-1006315

8-164

Disassembly and Assembly

8.42 Sensor

1. Water temperature sensor - check

Ɣ Put the sensor into a vessel containing en-

gine oil.

1

Ɣ Heat the oil to the specified temperature.

Stir the oil at the same time.

Sensor body

Ɣ Measure the resistance value between the

terminal 1 and the sensor body at different

temperatures.

50±0.2°C

80±10ȍ

60°C

56.3ȍ(ref.)

ZX215-1006316

Standard

80°C

29.5ȍ(ref.)

Value

100°C

16.5ȍ(ref.)

106±0.3°C

14.3±1.0ȍ

120°C

10ȍ(ref.)

Ɣ Replace the sensor if the measured value

exceeds the standard one.

2. Engine speed sensor - check

Ɣ Measure the resistance between terminal

1 and terminal 2.

Std. Value(25°C)

2.3±0.2kȍ

Ɣ Replace the sensor if the measured value

exceeds the standard one.

2

1

ZX215-1006317

NOTICE

Ɣ Insufficient tightening of the engine

speed sensor may cause signal output

failure. Tighten the sensor to specified

torque.

8-165

Disassembly and Assembly

3. Pressure sensor - check

Ɣ Input volt: 4.75~5.25VDC

Ɣ Output volt: 0.5~4.5V

Ɣ Pressure range: 0~50BAR

4. Fuel level sensor - check

Ɣ Swing the float up and down in order

to measure the effective angle of radial

swing, i.e. the line through the float and the

Float

turning point will swing 105°.

Ɣ Swing the float up and down. The vertical

distance between the upper limit and the

Lever

lower limit of the float should be 500 mm.

Ɣ Move the float to its upper limit. Measure

the resistance between the sensor terminal

R and ground with a multimeter. The mea-

Ternimal R

sured resistance should be Ru

9.6ȍ.

Casing

Ɣ Move the float to its lower limit. Measure

Connector

the resistance between the sensor terminal

R and ground with a multimeter. The mea-

ZX215-1006319

sured resistance should be Rd

86ȍ.

8-166

Disassembly and Assembly

8.43 Connector Terminals - Insert and Remove

8.43.1 Insertion

1. Hold tightly a wire terminal at a distance of

about 25 mm from its end.

ZX215-1006320

2. Hold the connector. Let the rear seal face

you.

ZX215-1006321

3. Align the terminal with a hole on the seal

and push it perpendicularly to the bottom.

Slightly pull back the wire in order to en-

sure that the terminal is locked in place.

ZX215-1006322

8-167

Disassembly and Assembly

8.43.2 Removal

1. Hold the connector, with its back end fac-

ing you. Select a suitable tool and clip on

the wire.

ZX215-1006323

2. Push the tool along the wire into the con-

nector so that the tool can expand the ter-

minal lock shoulder and reach its flanged

part.

ZX215-1006324

3. Pull out the tool to remove the wire with

terminal.

ZX215-1006325

8-168

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