SANY Crawler Hydraulic Excavator SY215CLC (CUMMINS QSB6.7 engine). Shop Manual

Disassembly and Assembly

SY215C

8-4

8.1.1.3 Installation

●

Unless speci

ed otherwise, installation of a

part is a reverse procedure of removing the
part.

●

The mark

used in the "Installation"

section indicates the rules and precautions
related to parts installation.

●

Symbols used in the "Installation" sections
are shown below:

This symbol indicates that safety-

related precautions must be ob-
served when doing the job.

★

This symbol is followed by instruc-

tions or precautions when perform-
ing a procedure.

This symbol indicates that specific

coating agent must be used.

This symbol indicates the lubricant

required.

This symbol indicates a torque

speci

ed.

This symbol indicates the amount of

oil or water to be added.

Disassembly and Assembly

SY215C

8-5

8.1.2 Disassembling and assembling an assembly

8.1.2.1 Special tools

●

Special tools for parts disassembly and as-
sembly are listed.

●

Necessary characteristics of the tools are
noted in the list of special tools.

■

: Special tools that cannot be replaced

and must be used.

●

: Very useful tools, which can be re-

placed with commercially available
ones.

8.1.2.2 Disassembly

●

The "Disassembly" section contains proce-
dure, precautions and the amount of oil or
water to be discharged.

●

The symbols used the in the "Disassem-
bly" section are described below:

This symbol indicates that safety-

related precautions must be ob-
served when doing the job.

★

This symbol is followed by instruc-

tions or precautions when perform-
ing a procedure.

This symbol indicates related rules

and precautions that must be
obeyed when installing the pats.

This symbol indicates the amount of

oil or water to be discharged.

Disassembly and Assembly

SY215C

8-6

8.1.2.3 Assembly

●

The "Assembly " section contains oper-
ating procedure, precautions, technical
speci

cation and the amount of oil or water

to be added.

●

The symbols used the in the "Assembly"
section are described below:

This symbol indicates that safety-

related precautions must be ob-
served when doing the job.

★

This symbol is followed by instruc-

tions or precautions when perform-
ing a procedure.

This symbol indicates that specific

coating agent must be used.

This symbol indicates the lubricant

required.

This symbol indicates a torque

speci

ed.

This symbol indicates the amount of

oil or water to be added.

Disassembly and Assembly

SY215C

8-7

8.2 Operating Precautions

The following precautions must be observed
before removing or installing (disassembling
or assembling) a component.

1. Precautions to be observed prior to removal

operation

●

Dispose the engine coolant properly if anti-
freeze is contained in the engine coolant.

●

After disconnecting a hose or tube, cover
or plug must be used to prevent invasion
of dirt or dust.

●

A suitable container must be prepared to
collect oil when draining the oil.

●

Matching mark must be made at where
is necessary before removing in order to
avoid mistake during reinstallation.

●

Do not pull the wire and avoid the wire
coming off its contact. To avoid excessive
force imposing on the wire, hold the con-
nector when disconnecting a wire.

●

Tag the wires and the hoses in order to
ensure their connecting positions. By doing
so, mistakes can be avoided during rein-
stallation.

●

Count and check the number and thick-
ness of the shims, and keep them in a safe
place.

●

When raising or lifting components, be
sure to use proper lifting equipment of am-
ple strength and safety.

●

When forcing screws are used to remove
any components, tighten the screws evenly
in turn.

●

The surrounding area must be cleaned
before removing a unit. Cover the unit after
removal in order to prevent invasion of dirt
or dust.

Disassembly and Assembly

SY215C

8-8

B: Thread-connected adaptors (plug and nut used in combination)

I.D. (mm)

Code

Description

Code

Description

Light Thread Connection

B210780000903

Taper bore plug

23002925

Nut

B210780001146

Plug

B210770000011

Nut

B210780000088

Plug

B210334000011

Nut

B210780000089

Plug

B210334000012

Nut

B210780000882

Plug

B210334000004

Nut

B210780000090

Plug

B210334000010

Nut

B210780000091

Plug

B210780000112

Nut

Heavy Thread Connection

B210780001143

Plug

B210780000406

Nut

A820205001523

Plug

B210780000405

Nut

B210780000902

Plug

B210780000904

Nut

B210780001172

Plug

B210334000006

Nut

A: Thread-connected hoses

I.D. (mm)

Code

Description

Light Thread Connection

B210780001189

Plug

B210780001190

Plug

B210780000077

Plug

B210780000078

Plug

B210780000883

Plug

B210780000079

Plug

60056667

Plug

Heavy Thread Connection

B210780001142

Plug

60002397

Plug

B210780000080

Plug

B210780000081

Plug

★

Precautions to be observed when disassembling the lines

The lines disassembled must be blinded with plugs.

Disassembly and Assembly

SY215C

8-9

2. Precautions to be observed prior to instal-

lation operation

●

Tighten all the screws and nuts (sleeve
nuts) to speci

ed torques.

●

Install the hoses without twisting or inter-
ference.

●

Replace the gaskets, O-rings, cotter pins
and lock plates with new parts.

●

Bend the cotter pin or lock plate securely.

●

Before applying the adhesive, clean the
parts of oil and dust. Apply 2 or 3 drops of
adhesive to the threaded portion.

●

Before applying the sealant to the gasket,
clean the gasket surface of oil and dust.
Check the gasket for contamination or
damage. Apply the gasket sealant evenly.

●

Clean all parts, and correct any damage,
dents, burrs, or rust.

●

Apply engine oil to the moving parts.

●

Before installing a snap ring, make sure
that the snap ring is mounted properly in
the circular groove.

●

Before connecting the wiring connector,
clean the wiring connector of oil, dirt or wa-
ter. Make sure that the wiring connector is
connected securely.

●

Before using an eyebolt, check the eyebolt
for deformation or deterioration. Screw on
the eyebolt as far as possible and align it
to the direction of the hook.

●

Before tightening the split

ange, tighten it

evenly in turn in order to prevent over tight-
ening on one side.

★

After reassembling the hydraulic cylinder,
main pump or other hydraulic equipment
that has been disassembled and repaired,
it is necessary to bleed the air from the
hydraulic cylinder prior to initial operation

Disassembly and Assembly

SY215C

8-10

3. Precautions to be observed upon comple-

tion of the operations

●

Completely discharge the engine cool-
ant, tighten the drain valve, and add
coolant to the specified level. Run the
engine to circulate the coolant through
the system. Check the coolant level
again.

●

Add hydraulic oil to the specified level
after disassembly and reinstallation of
a hydraulic unit. Run the engine to cir-
culate the hydraulic oil through the sys-
tem. Check the oil level again.

●

Bleed the air from the system after
removing and repairing the lines or hy-
draulic unit and reassembling the parts.

★

Bleed the air. For more information, see “Air
in Each Component - Bleed” on page 6-35.

●

Add the specified amount of grease
(molybdenum disulphide) to the work
equipment related parts.

of the cylinder. The purging procedure is
performed as the following:

1) Start the engine and run the engine at

low idle.

2) Operate the work equipment control

lever in order to cycle the movement of
the hydraulic cylinder 4 or 5 times. Hold
the cylinder at where it is 100 mm from
its stroke end.

3) Go on operating the hydraulic cylinder

3 or 4 times to its stroke end.

4) You can run the engine at normal

speed after this operation.

★

This procedure is to be performed before
using your machine for the first time after
repair or long storage.

Disassembly and Assembly

SY215C

8-11

8.3

Radiator AS - Remove and Install

8.3.1 Removal

1. Open the engine hood.

2. Open the pressure cap (1). Open the drain

valve to discharge engine coolant from the
coolant tank.

Coolant: approx. 22.5 L

3. Remove the coverplate.

4. Remove the two U-bolts (2).

5. Disconnect the hydraulic oil cooler inlet

connector (3) and outlet connector (4).
Block the openings to prevent leakage of
hydraulic oil.

6. Discharge hydraulic oil from the hydraulic

cooler.

Hydraulic oil radiator:

approx. 5.6 L

7. Disconnect the coolant tank hose (5).

ZX215T-1006029

ZX215T-1006030

Cover

Disassembly and Assembly

SY215C

8-12

10. Remove the four bolts (10) from the air

conditioner radiator. Remove the air condi-
tioner radiator and store it properly.

11. Remove the radiator fan guard (11).

8. Disconnect the cooler inlet hose (6) and

outlet hose (7).

9. Disconnect the intercooler air inlet tube (8)

and outlet tube (9).

ZX215T-1006031

ZX215T-1006032

ZX215T-1006033

Disassembly and Assembly

SY215C

8-14

8.3.2 Installation

●

Installation is to be performed in the re-
verse order of removal.

★

Adjust the clearance (a) between the
fan and the fan guard in order to have a
uniform clearance surrounding the fan.

★

Check the values (a) at the four measuring
points in the left, right, top and bottom di-
rections, which should be as the following:

●

Standard clearance (a) in all directions:
15±1.5 mm

●

Fan diameter (b): ø620 mm

●

Fan guard inner diameter (c): ø650 mm

●

Engine coolant and hydraulic oil adding

Add a specific amount of coolant and
hydraulic oil. Start the engine to circulate
the coolant and hydraulic oil. Check the
coolant level and the oil level.

Engine coolant: approx. 22.5 L

Hydraulic oil radiator: approx. 5.6 L

Disassembly and Assembly

SY215C

8-15

8.4 Engine and Hydraulic Pump AS - Remove and Install

8.4.1 Removal

Lower the work equipment to the ground.

Stop the engine. Disconnect the cable
from the battery negative (-) post.

Loosen the butter

y nut on the breather

valve and press the relief button to re-
lieve internal pressure.

★

Mark the lines to avoid mistakes during
reinstallation.

1. Remove the hydraulic tank suction filter

element and block the opening.

2. Drain the engine of coolant.

Coolant: approx. 22.5 L

3. Open the engine hood.

4. Disconnect piping (1), (2) and (3).

ZX215T-1006036

Disassembly and Assembly

SY215C

8-16

5. Disconnect piping (4), (5) and (6).

6. Remove the sensors (7) and (8).

7. Remove the clamps (9) and (10). Remove

the line (11) and the cable (12).

8. Unscrew the connection bolt (13) of the

governor motor and the connection bolt (14)
of the engine stopper.

9. Disconnect the external cable from the

starter (15).

10. Remove the mounting bolt (16) from the

hose clamp.

ZX215T-1006037

ZX215T-1006038

ZX215T-1006039

Disassembly and Assembly

SY215C

8-17

11. Disconnect the cables (17) and (18) as

well as the tubes (19) and (20) from the
compressor.

12. Disconnect the hoses (21), (22), (23) and

(24) between the engine and the radiator

13. Disconnect the air intake hose (25).

ZX215T-1006040

ZX215T-1006041

ZX215T-1006042

Disassembly and Assembly

SY215C

8-18

14. Disconnect the external cable (26) of the

rpm sensor.

15. Disconnect the external cable (27) of

engine oil pressure sensor.

16. Disconnect the engine oil inlet tube (28)

and outlet tube (29).

17. Disconnect the wiring (30) of the engine

oil pressure switch.

18. Disconnect the cables (31) and (32), and

remove the hose clamp (33).

ZX215T-1006043

ZX215T-1006044

ZX215T-1006045

Disassembly and Assembly

SY215C

8-19

19. Remove the hose clamp (35).

20. Disconnect the wiring (34) of the water

temperature sensor.

21. Disconnect the cables (36) and (37) of the

water temperature switch.

22. Disconnect the oil return hose (38).

23. Disconnect the A/C water pipe (39).

ZX215T-1006046

ZX215T-1006047

ZX215T-1006048

SANY Crawler Hydraulic Excavator SY215CLC (CUMMINS QSB6.7 engine). Shop Manual - page 31