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

Disassembly and Assembly

SY215C

8-68

5. Disconnect the pilot hoses (10) to (18)

and tag them properly.

(10): XBtr Travel RIGHT

(11): XAs Swing LEFT

(12): PSP Swing priority

(13): XAa1 Arm OUT

(14): XBp2 Bucket con

uence

(15): XBtL Travel LEFT

(16): XAb1 Boom UP

(17): XBK Bucket DIG

(18): XAa2 Arm OUT

6. Remove the port (19) (accumulator to

solenoid valve), port (10) (pilot

lter to ac-

cumulator). Remove hose clip (21) of the
central swivel joint.

7. Remove bucket hoses (22) and (23) and

seal the ports.

8. Remove arm hoses (24) and (25) and

seal the ports.

9. Remove boom hoses (26) and (27) and

seal the ports.

ZXT225-1106012

ZXT225-1106013

ZXT225-1106014

Disassembly and Assembly

SY215C

8-69

10. Remove central swivel joint hoses (28),

(29), (30) and (31). Remove travel speed
switching hose (32) and seal the ports.

11. Remove swing motor hoses (33) and

(34). Remove swing motor oil complement
hose (35). Seal the ports properly.

12. Remove pipe (36) (main valve to radia-

tor).

ZXT225-1106015

ZXT225-1106016

ZXT225-1106017

Disassembly and Assembly

SY215C

8-70

13. Remove pipe (37) (main valve to return

oil tank). Seal the ports properly.

14. Remove hydraulic pump hoses (38) and

(39).

15. Remove hoses (40) to (44) on the sole-

noid valve and tag them properly.

(40): PPC lockout valve

(41): Main valve PnA2

(42): Main valve XBP2

(43): Main valve PSP

(44): Travel PT port

ZXT225-1106018

ZXT225-1106019

ZXT225-1106020

44 43 42 41 40

Disassembly and Assembly

SY215C

8-71

16. Remove the fixing bolts (45). Lift the

control valve assembly (46) for disassem-
bling.

Control valve assembly: 220 kg

8.17.2 Installation

●

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

●

Oil adding (hydraulic tank)

Add hydraulic oil through the

ller opening

to the specified level. Start the engine to
circulate oil in the hydraulic system, and
check the oil level again.

●

Air bleeding

Bleed the air from the circuit between the
valve and the hydraulic cylinder. For more
information, see “Air in Each Component -
Bleed” on page 6-35.

ZXT225-1106021

Disassembly and Assembly

SY215C

8-72

8.18

Hydraulic Pump AS - Remove and Install

8.18.1 Removal

Lower the work equipment to the ground

and stop the engine. Press the release
button of the breather valve to release re-
sidual pressure in the hydraulic tank.

Disconnect the cable from the negative (-)

post of the battery before performing the
job.

★

Tag each line so as to ensure correction
installation.

1. Remove the oil inlet

lter element from the

hydraulic tank and stop oil out

ow with an

oil stopper.

★

If no oil stopper is used, remove the
drain plug and drain the oil from the
hydraulic tank and from circuits.

Hydraulic tank: Approx. 225 L

2. Lift the hood (1).

Oil stopper

ZX215-1006144

ZX215T-1006145

Disassembly and Assembly

SY215C

8-73

3. Remove the pin (2) and the bolts (3). Lift

the engine hood in order to remove it.

4. Remove the right upper cover (4).

5. Disconnect the hose (5) supplying oil to

the lower proportional valve and the hose
(6) delivering oil from the pilot pump.

ZX215T-1006146

ZX215T-1006147

ZX215T-1006148

Disassembly and Assembly

SY215C

8-74

6. Disconnect the shutdown wire (7).

7. Remove the right door (8).

8. Remove the hydraulic pump cover (9).

9. Disconnect the oil drain hose (10) and

seal the openings properly.

10. Disconnect the high-pressure hoses (11)

and (12) connecting to the control valve,
and seal the openings properly.

11. Disconnect the harness (13) of the pres-

sure transducer.

12. Disconnect the pilot pump oil inlet hose

(14) and seal the openings properly.

13. Disconnect the pilot pump oil inlet tube

(15) and seal the openings properly.

ZX215T-1006149

ZX215T-1006150

ZX215T-1006151

Disassembly and Assembly

SY215C

8-75

14. Disconnect the solenoid valve harnesses

(16) and (17). Remove the cable straps (18)
and (19).

15. Remove the four bolts (20) of the hydrau-

lic pump. Lift the hydraulic pump assembly
(21) to remove it.

Hydraulic pump assembly: 112 kg

ZX215T-1006152

ZX215T-1006153

Disassembly and Assembly

SY215C

8-76

Mating surface (hydraulic pump

housing):

Gasket sealant: (Loctite 515)

●

Oil adding (hydraulic tank)

Add hydraulic oil through the

ller opening

to the specified level. Start the engine to
circulate oil in the hydraulic system, and
check the oil level again.

Hydraulic tank: approx. 225 L

●

Air bleeding

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

8.18.2 Installation

●

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

★

After tightening the hose clamping
screw, check that the screw should be
in the range indicated in the illustration.

Screw (hose clamp):

8.8±0.5 N·m {0.9±0.05 kgf·m}

★

Install the hose clamp and tighten the
screw according to the illustration on
the right.

Screw

Up
Down

ZX215-1006128

Pipe

Clamp

Hose

Bulge

ZX215-1006129

Disassembly and Assembly

SY215C

8-77

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

8.19.1 Removal

1. Remove the hydraulic pump assembly (1).

Refer to “Hydraulic Pump AS - Remove
and Install” on page 8-72.

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

ing cover (3).

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

★

Be careful not to damage the shaft
while prying the oil seal.

8.19.2 Installation

●

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)

★

Apply a thin layer of grease to the oil
seal circumference.

3
4

ZX215-1006154

ZX215-1006155

Disassembly and Assembly

SY215C

8-78

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

★

This section discusses only the precautions
when reassembling the work equipment
pilot valve assembly.

8.20.1 Assembly

●

Reassembly of the work equipment pilot
valve assembly

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

with O-ring seal. Tighten the socket bolt
(10).

Socket bolt:

25~33 N·m {2.55~3.36 kgf·m}

2. Insert the spring (7) into the spool hole

in the valve body (8). Put the spool (6) in
the spring. Install the plug (5) on the spool.
Push the plug (5) to the spool hole.

3. Install the plate (4) on the plug (5).

Tighten the U-joint (3).

4. 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}

★

Location of each oil port is stamped on
the bottom of valve body.

ZX215T-1006156

Disassembly and Assembly

SY215C

8-79

★

Apply the thread adhesive (Tonson
1277) to two points on the inner
threads, as indicated in the illustration
below. The amount of application is
approximately 0.02 g.

U-joint (3):

98~133 N·m {10~13.5 kgf·m}

★

Tightening is to be made to the speci-

ed torque.

Contact surface between plug (5)

and plate (2):

Grease 0.3~0.8cc (No.1 Calcium base
grease)

★

See also “Pilot Valves (Work Equipment
and Swing) - Adjust” on page 6-25.

Plug (5) circumference:

Grease (No.1 Calcium base grease)

U-joint moving surface:

Grease (No.1 Calcium base grease)

Threads in valve body:

Thread adhesive (Tonson 1277)

5~7 mm

ZX215-1006157

Disassembly and Assembly

SY215C

8-80

8.21 Pilot Valve AS (Travel) - Disassemble and Assemble

★

This section discusses only the precau-
tions when reassembling the travel pilot
valve assembly.

Plunger

ZX215T-1006158

Disassembly and Assembly

SY215C

8-81

8.21.1 Assembly

●

Reassembly of the pedal pilot valve as-
sembly

1. Install the spring (8) into the spool installa-

tion 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 plug.

Install the cover (2) and fix the cover (2)
with the camshaft (5).

Contact surface between the plug

and the dust ring (5):

Grease (No.1 Calcium base grease)

Disassembly and Assembly

SY215C

8-82

8.22 Hydraulic Cylinder AS - Disassemble and Assemble

Special tools

Application

Tool Shape

Necessity

Quantity

Pulling out/pushing
in the bushing

ZX215-1006159

■

Press

tting the

dust ring

ZX215-1006160

■

O-ring seal correc-
tion

Inserting tool

Correcting tool

ZX215-1006161

■

Inserting the cylin-
der head

ZX215-1006162

■

Inserting the piston

ZX215-1006163

■

Disassembly and Assembly

SY215C

8-83

8.22.1 Disassembly

1. Drain the oil and remove the tubing.

2. Fix the cylinder.

★

Fix the cylinder in a vertical or level
manner. A vertically fixed cylinder can
be disassembled and assembled easily.

★

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.

★

Remove the tubing in case of tubing
interference while

xing the cylinder.

3. Removal of cylinder head

★

Unscrew the bolts with Allen Wrench.

★

Using an extension rod, as shown in
the illustration on the right, will make
the work easy.

Fix the cylinder

ZX215-1006164

Approx 1.5m

ZX215-1006165

SANY Crawler Hydraulic Excavator SY215CLC (CUMMINS QSB6.7 engine). Shop Manual - page 35