SANY Crawler Hydraulic Excavator SY365H-9, SY365BH-9. Shop Manual (2014)

8-93

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZX335-1006176

Tool

Piston

O-ring

Tool for
correction

Block

Press in

ZX335-1006177

Assembling tool

3. Assembling the piston assembly

A. Installation of seal (14).

●

Install first the O-ring seal and the
one-side guard ring (13) on the pis-
ton. Place the piston on the press. As
shown in the illustration on the right,
the seal (14) is installed with the tools
indicated.

B. Correction of seal (14)

●

Install the seal (14) and the guard ring
(13) on the other side. In order to pre-
vent the expansion of the seal (14), a
corrector must be used to correct the
seal (14) which has been stretched
during installation. The piston rod
may not be able to go in the cylinder
barrel if the seal (14) is not corrected
timely.

C. Installation of slide ring (12)

●

Slightly open the slide ring (12) and
install it axially. Excessive opening of
the slide ring (12) can fail installation.

4. Assembling the piston rod assembly

A. Fix the piston rod (1).

B. Install the cylinder (2) on the piston rod.

●

Make sure that the dust ring lip or
the U-ring lip is not stopped by the
shoulder of any part. Install the cyl-
inder head and the piston rod with
the tools.

Fig. 8-187

Fig. 8-188

8-94

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZX335-1006179

The opening faces the piston side.

Rod end buffer

C. If the bottom side of cylinder contains

a buffer (not for bucket cylinder), install
the buffer bearing and the buffer seal in
the following order.

a. Let the notched side of the buffer

seal (10) face the piston while
installing the buffer seal (10) in the
groove.

b. Install the buffer sleeve (8) accord-

ing to the indication in the illustration
on the right.

c. Install the stopper ring (11) in the

groove. Install the elastic ring after
the buffer sleeve (8) is pushed
to the bottom. A rubber hammer
should be used for the tapping job
in order to avoid damaging the
piston rod and the buffer bearing.

D. If the head side of cylinder contains a

buffer, install the buffer sleeve (6) and
the buffer seal (23) according to the
following order.

a. The piston nut must be installed

after installation of the buffer bear-
ing.

b. The buffer seal (23) must be

installed in the groove, with its
notches facing the piston.

c. The buffer sleeve (6) must be

installed according to the illustration
on the right.

E. Tighten the piston nut (5).

Piston nut (arm):

9600 Nm {979.6 kgm}

Piston nut (boom and bucket):

6200 Nm {632.6 kgm}

●

Insufficient tightening can cause oil
leakage, loose nut and thread break-
age. In addition, excessive tightening
can cause expansion of the buffer shaft
on the extending side or deformation of

ZX335-1006178

Head end buffering

With one opening

(Two piece type)

Piston rod

Threads

The opening faces the threads.

Fig. 8-189

Fig. 8-190

8-95

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZX335-1006180

Rivet

Punch

piston on the contact side.

●

Thoroughly clean and grease (with ba-
nana oil) the threaded portions of the
piston, nuts and piston rod before tight-
ening the nuts.

F. Treatment of the piston against loosen-

ing

●

After the piston nut (5) is tightened, put
in the steel ball (4), tighten the setscrew
(3) and punch to rivet the two periph-
eral points.

Setscrew (3):

66.9 Nm {6.8 kgm}

5. Install the piston into the cylinder barrel.

A. Fix the barrel in a vertical or level man-

ner.

B. Install the piston rod into the cylinder

barrel.

●

xed in a vertical manner, the pis-

ton rod falls into the barrel under its
gravity.

●

Make sure that the slide ring does
not fall while the piston is inserted
into the barrel.

ZX335-1006181

Tool
Nylon sleeve
(two pieces)

(Move the notch
180 degrees away.)

Fig. 8-191

Fig. 8-192

8-96

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

Bolt tightening sequence

ZX335-1006182

6. Tightening of cylinder head

Tighten the bolts following the sequence
shown in the illustration on the right.

Bolt: 267 Nm {27.2 kgm}

7. Install the tubing.

Fig. 8-193

8-97

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZXT335-1006183

ZXT335-1006184

8.28 Work Equipment AS

8.28.1 Removal

Fully extend the arm and the bucket. Lower
the work equipment to the ground. Move the
hydraulic lockout control to the LOCK position.

Release remaining pressure in the hydraulic
circuit. See

“Remaining Pressure in Hydrau-

lic Lines - Relieve” on page 6-36

1. Disconnect the grease hose (1).

2. Lift the boom cylinder assembly (2).

Remove the lockbolt (3).

3. Remove the plate (4) and then the pin roll (5

●

There are shims installed. Count the
shims and check the thickness. Place
the shims in a safe place.

4. Start the engine and retract the piston rod.

●

Secure the piston rod with a wire rope
in order to prevent the piston from slip-
ping out. Place the cylinder on a bench
or support. The grease fitting on the
bottom side must be removed in the
later case.

●

Remove the other boom cylinder in the
same way.

5. Remove the two hoses (6) of bucket

cylinder and the two hoses (7) of the arm
cylinder.

●

Cork the hoses to prevent out

ow of oil.

Tie the hoses to the valve side

6. Remove the mid-connector (8) used for

work lamp.

Fig. 8-194

Fig. 8-195

8-98

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZXT335-1006185

ZXT335-1006186

7. Lift the work equipment and remove the

plate (9). Remove the bottom pin roll (10).

There are shims installed. Count the shims
and mark their locations.

8. Lift the work equipment assembly (11) in

order to disassemble it.

Work equipment assembly:

Model

Weight

SY365H-9

5,652 kg

SY365BH-9

7,102 kg

Fig. 8-196

Fig. 8-197

8-99

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZX335-1006188

8.28.2 Installation

●

Installation is performed in the reverse pro-
cedure of removal.

A clearance (a: 0.5 - 1.5 mm) should be
left between the plate and the nut when
tightening the locknut.

Greasing after assembling the pin:

Grease (MoS

G2-L1)

ZX335-1006187

●

Adjust the shim thickness in order to
have a desired clearance (a: 0.5

＜

1 mm) between the piston end (12)

and the plate (4).

●

Standard shim thickness: 1.0 mm and
2.0 mm.

Greasing after assembling the pin:

Grease (MoS

G2-LI)

WARNING

●

Never use your finger to align the pin
holes.

WARNING

●

Never use your finger to align the pin
holes.

●

lling the hydraulic oil

Refill hydraulic oil to the specified level.
Start the engine to circulate the oil in the
hydraulic system, and check the oil level
again. Add more hydraulic oil if necessary.

●

Purging the air

Purge the air from travel motor. See

“Air

in Each Component - Purge” on page 6-41.

Fig. 8-198

Fig. 8-199

8-100

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZXT335-1006189

ZXT335-1006190

8.29 Air Conditioner AS

Special tools

Part Name

Model

Necessity Qty

Refrigerant

ller

●

8.29.1 Removal

1. Drain the coolant.

Coolant: Approx 22.5 L

2. Recover refrigerant from the air-condition-

ing system with the tool (S).

3. Remove the pad on the bottom cover (1).

Fig. 8-200

Fig. 8-201

Fig. 8-202

NOTICE

●

Always disconnect the cable from nega-
tive post of the battery before you pro-
ceed.

Cover

ZXT335-1006191

4. Use the start key to open the left rear cover

of the cab. Remove the external air filter
element (2).

8-101

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZXT335-1006192

ZXT335-1006193

5. Remove the monitor lower covers (3) and

(4).

Disconnect the wire (M19) of the cigar
lighter before removing the cover (3).

6. Remove the air duct (5) on the right side.

7. Remove the back cover (6).

8. Remove the back air duct (7).

9. Remove the left air duct (8).

10. Remove the baf

e (9).

11. Remove the right air duct (10).

Fig. 8-203

Fig. 8-204

Fig. 8-205

ZXT365-1308197

8-102

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZXT335-1006195

ZXT335-1006196

12. Remove the cover (11).

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

14. Remove the radio antenna(13).

15. Remove the air duct (14) and the control-

ler wiring connector (15). Disconnect the
wiring connector (16). Remove the air
conditioner relay (17). Remove the three
(3) mounting bolts (18) and then the board
(19).

16. Remove the air conditioner water pipes

(20) and (21) as well as the dripping tube
(22) under the bottom cover.

Fig. 8-206

Fig. 8-207

Fig. 8-208

ZXT335-1006197

8-103

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZXT335-1006198

17. Remove the air conditioner unit (23).

Also disconnect the two hoses connecting
to the bottom of the air conditioner when
removing the air conditioner unit.

8.29.2 Installation

●

Installation is performed in the reverse pro-
cedure of removal.

Keep the hoses free from contamination by
dirt, dust or water while installing the return
hose of the air conditioner.

Make sure that the O-ring seal is present
in the connection before connecting a hose
of the air conditioner.

Make sure that the O-ring seals are free
from any damage or deformation.

●

Apply compressor oil (ND8#) to the
threads of the parts connected with the
refrigerant lines. Tighten the line connec-
tions with a double-end spanner.

Screw (hose clamp):

8.83~14.7 Nm {0.9~1.5 kgm}

Bolt (pressure plate):

13.5

1.2 Nm {1.38

0.12 kgm}

●

lling refrigerant

Refill refrigerant (HFC-134a) into the air
conditioner circuit with the tool (S).

Fig. 8-209

8-104

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

8.30 Counterweight AS

8.30.1 Removal

1. Install lift pin (1) in lift eye of counterweight.

Slowly tighten the wire rope (2) with lifting
equipment to hold the counterweight.

2. Remove the four mounting bolts (2 ) and

washers.

3. Lift the counterweight with lifting equip-

ment.

Take care not to damage the engine, radia-
tor and cooler.

Counterweight AS: 6800 kg

ZX365-1308163

Fig. 8-210

ZX365-1308164

8-105

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

b=0±5

a=10±4

c=0±5

ZX335-1006202

Unit: mm

Counterweight

Swing frame

8.30.2 Installation

●

Installation is performed in the reverse pro-
cedure of removal.

Threads (mounting bolt - counter-

weight):

Thread adhesive (Tianshan 1277)

Mounting bolt (counterweight):

2,295

200 N·m {214~255 kgf·m}

●

Counterweight Installation and adjustment

A. Lift the counterweight with a crane to a

suitable position over the frame.

B. Push the counterweight and install the

bolts. Adjustment is to be made accord-
ing to the following speci

cation.

●

Clearance with swivel:

5 mm(L&R)

●

Clearance with bodywork door:

5 mm(L&R)

●

Step difference from swing frame in left
to right direction

b: max. 5 mm

●

Step difference from bodywork door in
left to right direction

a: 10

●

Step difference from bodywork top cov-
er in upper to lower direction

c: max. 5 mm

Fig. 8-211

8-106

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZXT335-1006203

ZXT335-1006204

ZXT335-1006205

8.31 Cab AS

8.31.1 Removal

1. Remove the

oor mat (1).

2. Remove the back covers (2) and (3).

NOTICE

●

Always disconnect the cable from nega-
tive post of the battery before you pro-
ceed.

3. Disconnect the left harness (4), the monitor

harness connector (5) and the window
washer harness (6).

4. Remove the right air duct (7).

Fig. 8-212

Fig. 8-213

Fig. 8-214

8-107

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZXT335-1006206

ZXT335-1006207

ZXT335-1006208

5. Remove the fresh air

lter element (8).

6. Remove the fresh air duct (9).

7. Remove the storage box (10) of console.

Fig. 8-215

Fig. 8-216

Fig. 8-217

8-108

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZXT335-1006209

ZXT335-1006210

ZXT335-1006211

8. Disconnect the radio connector (11).

9. Disconnect the radio harness (12).

10. Remove the window washer

uid reservoir

(13).

11. Remove the window washer hose (14).

Fig. 8-218

Fig. 8-219

Fig. 8-220

SANY Crawler Hydraulic Excavator SY365H-9, SY365BH-9. Shop Manual (2014) - page 35