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SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual - page 32

8-15

Disassembly and Assembly

8.5 Engine Front Seal - Remove and Install

8.5.1 Removal

1. Remove the radiator assembly

For more information, see “Radiator AS -
Remove and Install” on page 8-24.

2. Remove the engine fan (1), the belt (2) and

the pulley (3).

3. Remove the mounting nut (4) and replace

the cone (5) and the O-ring (6). Remove
the crankshaft belt pulley (7).

8.5.2 Installation

●

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

Nut: 490 N·m {50 kgf·m}

ZX215-1006010

Water pump

ZX215-1006011

ZX215-1006012

4. Disassemble the front oil seal (8).

8-16

Disassembly and Assembly

8.6 Engine Rear Seal - Remove and Install

8.6.1 Removal

1. Remove the hydraulic pump assembly.

For more information, see “Hydraulic Pump
AS - Remove and Install” on page 8-85.

2. Remove the bolt (1), the latch piece (2)

and the bearing (3).

3. Remove the

ywheel (4).

4. Remove the engine speed sensor (5) and

the

ywheel shell (6).

5. Remove the rear seal (7).

ZX215-1006013

ZX215-1006014

Lip

Disassembly and Assembly

8.6.2 Installation

●

The installation is to be performed in the
reverse order of removal.

Bolt:

39 N·m {4.0 kgf·m} + 47°

●

The rear oil seal is to be installed accord-
ing to the following procedure:

1. Apply engine oil to the lips of the rear seal.

2. Clean the oil-sealing surface.

3. Apply the sealant evenly and continuously

align the line of the rear seal.

Sealant (Tonsun 1596)

4. The installation is to be performed 3 min-

utes after application of the sealant. Be
careful not to deviate the line while apply-
ing the sealant.

ø2mm

ZX215-1006015

Sealant

Line

8-18

Disassembly and Assembly

8.7 Cylinder Head AS - Remove and Install

1. Drain the engine of coolant.

Coolant: 18 L

2. Open the engine hood.

3. Disconnect the air intake hose (1).

4. Remove piping (2) and piping (3) between

the fuel

lter and the injection pump.

ZX215T-1006016

ZX215T-1006017

ZX215T-1006018

8.7.1 Removal

CAUTION

●

Disconnect the negative (-) post of the
battery.

8-19

Disassembly and Assembly

5. Remove the fuel filter bracket (4) and the

fuel

lter assembly (5).

6. Remove the six delivery hoses (6).

7. Remove the exhaust muffler connector

cover (7).

8. Remove the air cleaner suction hose (8).

9. Remove the air intake tube (9) and its

clamps (10) between the turbocharger and
the intercooler.

10. Remove the engine oil delivery tube (11)

and the oil return tube (12).

ZX215T-1006019

ZX215T-1006020

ZX215T-1006021

8-20

Disassembly and Assembly

11. Remove the turbocharger assembly.

12. Remove the exhaust manifold (13).

13. Remove the radiator inlet hose (14) and

outlet hose (15).

ZX215-1006022

ZX215-1006023

ZX215T-1006024

8-21

Disassembly and Assembly

14. Remove the six nozzle seats (16).

15. Remove the rocker arm housing (17).

16. Remove the rocker arm assembly (18).

17. Remove the pushrod (19).

18. Remove the 25 mounting bolts from the

cylinder head assembly. Lift the cylinder
head assembly in order to disassemble it.

19. Remove the cylinder head gasket (21).

ZX215T-1006025

ZX215-1006026

8-22

Disassembly and Assembly

8.7.2 Installation

●

The installation is to be performed in the
reverse order of removal.

ZX215-1006027

Size mark

Notch

Installation of cylinder head gasket

Choose a cylinder head gasket as per the
following.

1. Measure the amount of piston projection of

each cylinder.

2. Select from the following table a gasket

with a thickness suitable for the maximum
piston projection after measurement. In ad-
dition, even if one cylinder's piston projec-
tion is 0.05 mm greater than the average,
the gasket with a thickness one grader
higher (A

→

B, B

→

C) is to be used.

Unit: mm

Piston Projection

Cylinder Head Gasket

Average

Size

Thickness

Tightened

0.546~0.610

1.3

0.610~0.674

1.35

0.674~0.738

1.4

3. The size of cylinder head gasket is deter-

mined according the notch.

4. Install the cylinder head gasket to the

crankshaft case as indicated by the arrow.

NOTICE

The amount of piston projection must be
measured as the amount of piston projec-
tion may vary when replacing a piston or
connecting rod.

8-23

Disassembly and Assembly

Bolt (rocker cover installation):

4.9~6.9 N·m {0.5~0.7 kgf·m}

Bolt (cylinder head):

147 N·m {15 kgf·m}+90°

Bolt threads (cylinder head):

Engine oil

Tappet circumference:

Engine oil

Tappet ends:

Engine oil

●

Adjustment of valve clearance

F o r m o r e i n f o r m a t i o n , s e e “ Va l v e
Clearance - Adjust” on page 6-8.

●

Adding coolant

Add engine coolant to the specified level.
Start the engine to circulate the coolant in
order to release all foams. Check the cool-
ant level again.

8-24

Disassembly and Assembly

8.8

Radiator AS - Remove and Install

8.8.1 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. 18 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).

8. Disconnect the cooler inlet hose (6) and

outlet hose (7).

ZX215T-1006029

ZX215T-1006030

ZX215T-1006028

1 Cover plate

8-25

Disassembly and Assembly

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).

9. Disconnect the intercooler air inlet tube (8)

and outlet tube (9).

ZX215T-1006031

ZX215T-1006032

ZX215T-1006033

8-26

Disassembly and Assembly

13. Mount the hoisting bolts (14) to both sides

of the radiator in order to hoist the radiator
assembly.

NOTE: Before the radiator assembly is
hoisted, move the radiator assembly axially
until the fan avoids its guard.

12. Remove the four mounting bolts (12) from

the radiator bottom and the two mounting
bolts (13) from the left and right brackets.

ZX215T-1006034

ZXT335-1006029

Disassembly and Assembly

8.8.2 Installation

●

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

NOTE:

●

Adjust the clearance (a) between the fan
and the fan guard in order to have a uni-
form 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. 18 L

Hydraulic oil radiator: approx. 12 L

8-28

Disassembly and Assembly

8.9 Engine and Hydraulic Pump AS - Remove and Install

NOTE:

Mark the lines to avoid mistakes during

reinstallation.

1. Remove the hydraulic tank suction

lter el-

ement and block the opening.

2. Drain the engine of coolant.

Coolant: approx. 18 L

3. Open the engine hood.

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

ZX215T-1006036

ZX215T-1006028

8.9.1 Removal

CAUTION

●

L o w e r t h e w o r k e q u i p m e n t t o t h e
ground. Stop the engine. Disconnect
the cable from the battery negative (-)
post.

●

Loosen the butterfl y nut on the breather
valve and press the relief button to re-
lieve internal pressure.

8-29

Disassembly and Assembly

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

8-30

Disassembly and Assembly

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

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