SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual - page 31

 

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SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual - page 31

 

 

7-120

Troubleshooting

H-22  Large shock is produced when upper structure stops swinging

Trouble

Large shock is produced when upper structure stops swinging.

Related information

Set working mode to (S) and fuel control dial at position (10) to
carry out troubleshooting.

Possible causes and standard value in normal 

state

Cause

Standard value in normal state/Remarks on troubleshooting

1

Malfunction of swing 

pilot valve

Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.

Swing control lever

Pilot valve output pressure

"NEUTRAL"

0 {0}

Left swing

Right swing

3.5MPa {

36 kg/cm²}

2

Malfunction of swing 

reverse prevention 

valve

Reverse prevention valve of swing motor may have malfunction. 
Check it directly.

Replace the valve with a new on in order to determine whether the
valve fails.

3

Malfunction of swing 

relief valve

Swing relief valve may be worn or sluggish. 

H-23  High noise is produced when upper structure stops swinging

Trouble

High noise is produced when upper structure stops swinging.

Related information

Set working mode to (S) and fuel control dial at position (10) to
carry out troubleshooting.

Possible causes and standard value in normal 

state

Cause

Standard value in normal state/Remarks on troubleshooting

1

Malfunction of back 
pressure valve

Back pressure valve may have malfunction. Check it directly.

2

Malfunction of swing 
motor (relief valve)

Relief valve of swing motor may have malfunction. Check it directly.

3

Malfunction of swing 
motor (makeup valve)

Seal of makeup valve in swing motor may have malfunction. Check it 
directly.

Swap the left and right makeup valves and observe the result in
order to determine whether the seal fails.

4

Failure of swing mecha-
nism

The swing mechanism is suspected of an internal failure. Check the 
inside of the machinery itself. 

Internal defect of swing mechanism can be determined with ab-
normal noise, overheat, and metal powder or debris contained in
the oil drained.

7-121

Troubleshooting

H-24  Swing drift excessive

Trouble (1)

Hydraulic drift of swing is large (when swing holding brake is ap-
plied).

Related information

When swing lock switch is turned ON or when swing holding
brake release switch is in normal position, swing holding brake
operates and upper structure is 

fi

 xed with disc brake.

Possible causes and standard value 

in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

1

Failure of swing hold-
ing brake control lines

Swing holding brake control lines and holding brake pilot valve may be 
defective. Check them directly.

2

Malfunction of swing 
motor (parking brake)

Parking brake of swing motor may have malfunction. Check it directly.

Trouble (2)

Hydraulic drift of swing is large (when swing holding brake is re-
leased).

Related information

When swing holding brake release switch is in release position,
swing holding brake is released and upper structure is secured
by only hydraulic pressure.

Possible causes and standard value 

in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

1

Malfunction or defec-
tive seal of swing 
control valve (spool)

Swing control valve spool may have malfunction or defective seal.
Check it directly.

2

Failure of swing motor 
(relief valve)

Seal of relief valve in swing motor may be defective. Check it directly.

3

Failure of swing motor 
(makeup valve)

Seal of makeup valve in swing motor may be defective. Check it di-
rectly.

Disassembly and Assembly

Disassembly and Assembly

8-1

8 Disassembly and Assembly

8.1  How to Read This Manual ....................................................................................... 8-5

8.1.1  Removing and Installing an Assembly ........................................................... 8-5
8.1.2  Disassembling and assembling an assembly ................................................ 8-5
8.1.3 Special tools................................................................................................... 8-5
8.2.1  The symbols used in this section  .................................................................. 8-6

8.2 Operating Precautions ............................................................................................. 8-6
8.3  Start Motor AS - Remove and Install ..................................................................... 8-10

8.3.1 Removal ....................................................................................................... 8-10
8.3.2 Installation .................................................................................................... 8-10

8.4  Injection Pump AS - Remove and Install ................................................................8-11

8.4.1 Removal ........................................................................................................8-11
8.4.2 Installation .................................................................................................... 8-13

8.5  Engine Front Seal - Remove and Install ................................................................ 8-15

8.5.1 Removal ....................................................................................................... 8-15
8.5.2 Installation .................................................................................................... 8-15

8.6  Engine Rear Seal - Remove and Install................................................................. 8-16

8.6.1 Removal ....................................................................................................... 8-16
8.6.2 Installation .................................................................................................... 8-17

8.7  Cylinder Head AS - Remove and Install ................................................................ 8-18

8.7.1 Removal ....................................................................................................... 8-18
8.7.2 Installation .................................................................................................... 8-22

8.8  Radiator AS - Remove and Install.......................................................................... 8-24

8.8.1 Removal ....................................................................................................... 8-24
8.8.2 Installation .................................................................................................... 8-27

8.9  Engine and Hydraulic Pump AS - Remove and Install .......................................... 8-28

8.9.1 Removal ....................................................................................................... 8-28

8-2

Disassembly and Assembly

8.9.2 Installation .................................................................................................... 8-34

8.10  Final Drive AS - Remove and Install .................................................................... 8-35

8.10.1 Removal ..................................................................................................... 8-35
8.10.2 Installation .................................................................................................. 8-36

8.11  Final Drive AS - Disassemble and Assemble ....................................................... 8-37

8.11.1 Disassembly ............................................................................................... 8-37
8.11.2 Assembly .................................................................................................... 8-41

8.12  Swing Motor and Swing Drive AS - Remove and Install ...................................... 8-46

8.12.1 Removal ..................................................................................................... 8-46
8.12.2 Installation .................................................................................................. 8-47

8.13  Swing Motor and Swing Drive AS - Disassemble and Assemble......................... 8-48

8.13.1 Disassembly............................................................................................... 8-48
8.13.2 Assembly.................................................................................................... 8-53

8.14  Idler AS - Disassemble and Assemble ................................................................. 8-58

8.14.1 Disassembly............................................................................................... 8-58
8.14.2 Assembly.................................................................................................... 8-59

8.15  Sprocket - Remove and Install............................................................................. 8-62

8.15.1 Removal ..................................................................................................... 8-62
8.15.2 Installation .................................................................................................. 8-62

8.16  Track AS - Remove and Install ............................................................................ 8-63

8.16.1 Removal ..................................................................................................... 8-63
8.16.2 Installation .................................................................................................. 8-65

8.17  Swing Bearing AS - Remove and Install .............................................................. 8-66

8.17.1 Removal ..................................................................................................... 8-66
8.17.2 Installation .................................................................................................. 8-67

8.18  Swing Platform AS - Remove and Install ............................................................. 8-68

8.18.1 Removal ..................................................................................................... 8-68
8.18.2 Installation .................................................................................................. 8-71

8.19  Swivel Joint AS - Remove and Install .................................................................. 8-72

8.19.1 Removal ..................................................................................................... 8-72
8.19.2 Installation .................................................................................................. 8-74

8.20  Swivel Joint AS - Disassemble and Assemble ..................................................... 8-75

8.20.1 Disassembly............................................................................................... 8-75
8.20.2 Assembly.................................................................................................... 8-76

8.21  Hydraulic Tank AS - Remove and Install .............................................................. 8-77

8.21.1 Removal ..................................................................................................... 8-77
8.21.2 Installation .................................................................................................. 8-79

8.22  Control Valve AS - Remove and Install ................................................................ 8-80

8-3

Disassembly and Assembly

8.22.1 Removal ..................................................................................................... 8-80
8.22.2 Installation .................................................................................................. 8-84

8.23  Hydraulic Pump AS - Remove and Install ............................................................ 8-85

8.23.1 Removal ..................................................................................................... 8-85
8.23.2 Installation .................................................................................................. 8-89

8.24  Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install .................... 8-90

8.24.1 Removal ..................................................................................................... 8-90
8.24.2 Installation .................................................................................................. 8-90

8.25  Pilot Valve AS (Work Equipment) - Disassemble and Assemble ......................... 8-91

8.25.1 Assembly.................................................................................................... 8-91

8.26  Pilot Valve AS (Travel) - Disassemble and Assemble .......................................... 8-93

8.26.1 Assembly.................................................................................................... 8-93

8.27  Hydraulic Cylinder AS - Disassemble and Assemble........................................... 8-94

8.27.1 Disassembly............................................................................................... 8-95
8.27.2 Assembly.................................................................................................. 8-100

8.28  Work Equipment AS - Remove and Install ......................................................... 8-105

8.28.1 Removal ................................................................................................... 8-105
8.28.2 Installation ................................................................................................ 8-107

8.29  Air Conditioner AS - Remove and Install............................................................ 8-108

8.29.1 Removal ................................................................................................... 8-108
8.29.2 Installation .................................................................................................8-112

8.30  Counterweight AS - Remove and Install .............................................................8-113

8.30.1 Removal ....................................................................................................8-113
8.30.2 Installation .................................................................................................8-114

8.31  Cab AS - Remove and Install..............................................................................8-115

8.31.1 Removal ....................................................................................................8-115
8.31.2 Installation .................................................................................................8-119

8.32  Cab Window Glass – Disassemble and Assemble ............................................ 8-120

8.32.1 Removal ................................................................................................... 8-121
8.32.2 Installation ................................................................................................ 8-125

8.33  Front Window AS - Disassemble and Assemble................................................ 8-138

8.33.1 Disassemble ............................................................................................ 8-138
8.33.2 Assemble ................................................................................................. 8-141

8.34  Monitor - Remove and Install ............................................................................. 8-146

8.34.1 Removal ................................................................................................... 8-146
8.34.2 Installation ................................................................................................ 8-146

8.35  Controller AS - Remove and Install.................................................................... 8-147

8.35.1 Removal ................................................................................................... 8-147

8-4

Disassembly and Assembly

8.35.2 Installation ................................................................................................ 8-147

8.36 Radio ................................................................................................................. 8-148

8.36.1 Structure .................................................................................................. 8-148
8.36.2 Removal ................................................................................................... 8-149
8.36.3 Installation ................................................................................................ 8-150
8.36.4  Connector model and wiring .................................................................... 8-150

8.37 Battery ............................................................................................................... 8-151

8.37.1 Structure .................................................................................................. 8-151
8.37.2 Removal ................................................................................................... 8-152
8.37.3 Installation ................................................................................................ 8-153
8.37.4 Replacement ............................................................................................ 8-153

8.38 Start Switch........................................................................................................ 8-154

8.38.1 Structure  ................................................................................................. 8-154
8.38.2 Removal ................................................................................................... 8-155

8.39 Fuse Box............................................................................................................ 8-157

8.39.1 Removal ................................................................................................... 8-157

8.40 Wiper ................................................................................................................. 8-158

8.40.1 Structure .................................................................................................. 8-158
8.40.2 Working principle ..................................................................................... 8-158
8.40.3 Removal ................................................................................................... 8-159
8.40.5 Installation ................................................................................................ 8-160
8.40.4  Angle adjustment of wiper arm................................................................. 8-160

8.41 Relay.................................................................................................................. 8-161

8.41.1 Engine relays ........................................................................................... 8-161
8.41.2 Other relays ............................................................................................. 8-162

8.42 Sensor ............................................................................................................... 8-165
8.43  Connector Terminals - Insert and Remove ........................................................ 8-167

8.43.1 Insertion ................................................................................................... 8-167
8.43.2 Removal ................................................................................................... 8-168

8-5

Disassembly and Assembly

8  

DISASSEMBLY AND ASSEMBLY

8.1  How to Read This Manual

8.1.1  Removing and Installing an Assembly

Removal

The "Removal" section contains procedure, precautions and the amount of oil or water to be
discharged.

Installation

Unless speci

fi

 ed otherwise, installation of a part is a reverse procedure of removing the part.

8.1.2  Disassembling and assembling an assembly

Disassembly

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

Assembly

The "Assembly " section contains operating procedure, precautions, technical specification
and the amount of oil or water to be added.

8.1.3 Special tools

Special tools for parts disassembly and assembly 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 replaced with commercially available ones.

8-6

Disassembly and Assembly

8.2 Operating Precautions

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

1. Precautions to be observed prior to removal operation

Dispose the engine coolant properly if antifreeze 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. To avoid excessive force imposing on
the wire, hold the connector 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 reinstallation.

Count and check the number and thickness of the shims, and keep them in a safe place.

When raising or lifting components, be sure to use proper lifting equipment of ample
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 remov-
al in order to prevent invasion of dirt or dust.

8.1.4  The symbols used in this section 

This section uses some symbols and icons that are not used elsewhere in this manual. They in-
clude: 

 This symbol indicates the amount of oil or water to be discharged.

 This symbol indicates that speci

fi

 c coating agent must be used. 

    This symbol indicates the lubricant required. 

 This symbol indicates a torque speci

fi

 ed. 

  This symbol indicates the amount of oil or water to be added. 

 This symbols indicates the weight of a component or an assembly.

8-7

Disassembly and Assembly

Precautions to be observed when disassembling the lines

The lines disassembled must be blinded with plugs.

A: Thread-connected hoses

I.D. (mm)

Code

Description

Light Thread Connection

6

B210780001189

Plug

8

B210780001190

Plug

10

B210780000077

Plug

12

B210780000078

Plug

15

B210780000883

Plug

20

B210780000079

Plug

22

60056667

Plug

Heavy Thread Connection

12

B210780001142

Plug

16

60002397

Plug

20

B210780000080

Plug

25

B210780000081

Plug

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

I.D. (mm)

Code

Description

Code

Description

Light Thread Connection

6

B210780000903

Taper bore plug

23002925

Nut

8

B210780001146

Plug

B210770000011

Nut

10

B210780000088

Plug

B210334000011

Nut

12

B210780000089

Plug

B210334000012

Nut

15

B210780000882

Plug

B210334000004

Nut

20

B210780000090

Plug

B210334000010

Nut

22

B210780000091

Plug

B210780000112

Nut

Heavy Thread Connection

12

B210780001143

Plug

B210780000406

Nut

16

A820205001523

Plug

B210780000405

Nut

20

B210780000902

Plug

B210780000904

Nut

25

B210780001172

Plug

B210334000006

Nut

8-8

Disassembly and Assembly

2. Precautions prior to installation operation

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

fi

 ed torques.

Install the hoses without twisting or interference.

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 adhe-
sive 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 cir-
cular groove.

Before connecting the wiring connector, clean the wiring connector of oil, dirt or water.
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 

fl

 ange, tighten it evenly in turn in order to prevent over tighten-

ing on one side.

NOTE: 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 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.

NOTE: This procedure is to be performed before using your machine for the 

fi

 rst time after 

repair or long storage. 

8-9

Disassembly and Assembly

3. Precautions to be observed upon completion of the operations

Completely discharge the engine coolant, 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 speci

fi

 ed level after disassembly and reinstallation of a hydraulic

unit. Run the engine to circulate the hydraulic oil through the system. Check the oil level
again.

Bleed the air from the system after removing and repairing the lines or hydraulic unit and
reassembling the parts.

For more information, see “Air in Each Component - Bleed” on page 6-46.

Add the speci

fi

 ed amount of grease (molybdenum disulphide) to the work equipment re-

lated parts.

8-10

Disassembly and Assembly

8.3  Start Motor AS - Remove and Install

8.3.1 Removal

8.3.2 Installation

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

 Terminal B locknut (start motor): 

18 ~ 25 N·m {1.8 ~ 2.6 kgf·m}

 Fixing bolts (start motor):

43±6 N·m {4.4±0.6 kgf·m}

ZX215-1006001

Starter

Starter relay

Terminal B

Terminal S

1 2

3

4

5

6

7

ZX215T-1006002

1. Open the engine hood.

2. Disconnect the cables (1), (2), (3), (4) and

(5).

3. Unscrew the bolts (6) and (7) used to fix

the start motor. Remove the start motor as-
sembly.

 

CAUTION

Before removing the start motor assem-
bly, disconnect the cable from the nega-
tive (-) post of the battery, and insulate
between the cable and the negative post
with insulation tape.

8-11

Disassembly and Assembly

8.4  Injection Pump AS - Remove and Install

1. Open the engine hood.

2. Disconnect the air intake hose (1).

3. Disconnect fuel supply tube (2), fuel deliv-

ery hose (4), fuel return hose (3) and fuel
supply tube (5).

Block the hose with a cork in order to
prevent 

fl

 ow of fuel from the hose.

ZX215T-1006003

1

ZX215T-1006004

3

4

2

5

ZX215T-1006005

8.4.1 Removal

 

CAUTION

Disconnect the negative (-) post of the
battery.

8-12

Disassembly and Assembly

4. Disconnect the lubrication tube (6).

5. Disconnect six fuel delivery tubes (7).

6. Disconnect the air hose (8).

7. Remove the bolt (9) fixing the electronic

choke. Disconnect the bolt (10) fixing the
governor motor.

6

ZX215T-1006006

7

ZX215T-1006007

9

10

8

ZX215T-1006008

8-13

Disassembly and Assembly

8. Adjust the injection timing of the timing

gear. For more information, see “Fuel In-
jection Timing - Test and Adjust” on page 6-13.

9. Remove the injection pump mounting nuts

in order to disassemble the injection pump
assembly.

A: 4 nuts on the 

fl

 ange

B: 1 nut

8.4.2 Installation

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

 Bolts for installation of fuel supply 

tube: 

20~29 N·m {2.1~3.0 kgf·m}

 Relief valve: 

20~29 N·m {2.1~3.0 kgf·m}

 Bolts for installation of engine oil line: 

10~13 N·m {1.0~1.3 kgf·m}

 Fuel injection tube:  

24 N·m {2.5 kgf·m}

 Bolts for installation air hose: 

12~15 N·m {1.2~1.5 kgf·m}

Adjust the engine speed. For more in-
formation, see “Engine Speed - Test
and Calibrate” on page 6-3.

A

B

ZX215-1006009

8-14

Disassembly and Assembly

A

B

ZX215-1006009

Installation of the fuel injection pump is to
be performed as the following:

1) Check the fuel injection timing to see if it

has been adjusted properly.

For more information, see “Fuel Injec-
tion Timing - Test and Adjust” on page 6-13.

2) Assemble the fuel injection pump assem-

bly and tighten the 4 nuts at position A and
1 nut at position B.

 Nut: 9.8±2 N·m {10±0.2 kgf·m}

Air bleeding

Bleed the air from the fuel injection system.

 

 

 

 

 

 

 

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