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

8-63

Disassembly and Assembly

8.16

Track AS - Remove and Install

8.16.1 Removal

1. Choose a place that has enough space to

spread the track. Park the machine when
the master pin is between the idler and the
carrier roller.

2. Lower the work equipment. Loosen the

grease

tting (1) and release the track ten-

sion.

Special tools

Mark

Part Name

Necessity

Qty

Manual/electric hydraulic
track removing/installing
machine

●

3. Pull out the master pin (2) with the tool (M).

ZX215T-1006100

ZX215-1006101

WARNING

●

The adjustment cylinder is under ex-
tremely high pressure. Never loosen the
grease fi tting by more than one turn.

8-64

Disassembly and Assembly

4. Remove the tool (M). Move the machine

forward so that the temporary pin is in
front of the idler. Place the block .

5. Remove the temporary pin and the dust

seal. Move the machine backward to
spread the track (3).

ZX215-1006102

8-65

Disassembly and Assembly

●

Use the tool (M) to press the master pin.
Make sure that the protrusion of master pin
meets the size (a).

Master pin protrusion (a): 2.5±1 mm

●

Before installing the dust seal, apply
grease (No.2 lithium base) to its contact
surface with the bushing.

8.16.2 Installation

●

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

For more information, see “Track Tension -
Test and Adjust” on page 6-24.

●

Installation procedure of track shoe bolts
and nuts

1. Bring the R side of the track shoe nut (1)

to the link seat surface. Both seat surfaces
should be in close contact when assem-
bling the track shoe.

NOTE: If the track shoe bolts are installed
from the other side, the corner of nut will
interfere with the link seat surface, causing
the nut to raise and the bolt to loosen.

2. Tighten the bolts of track shoe to the

torque below.

Track shoe bolts:

750±30 N·m {77±3 kgf·m}

ZX215-1006103

Corner

Track shoe nut
(Square)

Seat surface
in close contact

ZX215-1006104

8-66

Disassembly and Assembly

8.17 Swing Bearing AS - Remove and Install

8.17.1 Removal

1. Remove the swing platform assembly.

For more information, see “Swing Platform
AS - Remove and Install” on page 8-68.

2. Dismount the 36 bolts (1) to remove the

swing bearing assembly.

Hoist the swing bearing assembly (2).

Swing bearing assembly: 314 kg

ZX215T-1006105

ZX215T-1006106

8-67

Disassembly and Assembly

8.17.2 Installation

●

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

Threads (bolt - swing bearing):

Thread adhesive (Tonsun 1277)

Mounting bolts (swing bearing):

Step 1:

Use a pneumatic spanner to tighten the
bolts.

Step 2:

Torque to: 549±59 N·m {56±6kgf·m}

1) When a torque spanner is used to tighten

the bolts, tighten

rst the four corners and

mark them.

2) Other bolts will be tightened clockwise or

counterclockwise. After one bolt is tight-
ened, tighten the next one on the diagonal
position and make a mark.

3) Tighten the rest bolts in this way.

●

Let the S mark in the soft zone of the
inner race of the inner ring face the
right side, as shown in the photo, and
install the swing bearing to the track
frame.

●

Apply grease to the inside of the gear
ring of the swing bearing.

NOTE: All gear teeth must be covered
by grease .

Swing bearing:

Grease(supramoly lithium base):15 L

ZX215T-1006107

Inner race soft zone

8-68

Disassembly and Assembly

8.18

Swing Platform AS - Remove and Install

1. Disassemble the work equipment assem-

bly.

F o r m o r e i n f o r m a t i o n , s e e “ W o r k
Equipment AS - Remove and Install” on
page 8-105.

2. Remove the counterweight assembly.

For more information, see “Counterweight
AS - Remove and Install” on page 8-113

3. Remove the four hoses (1) of boom cylin-

der.

NOTE: Plug the hoses to prevent flow of
oil.

4. Lift the boom cylinder assembly (2).

ZX215T-1006108

ZX215T-1006109

8.18.1 Removal

CAUTION

●

Fully extend the arm and the bucket.
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 and move the hydraulic lockout
control lever to the LOCK position.

8-69

Disassembly and Assembly

5. Remove the plate (3) and the pin (4). Lift

the boom cylinder assembly (2) in order to
remove it.

●

Remove the boom cylinder assembly
on the other side in the same way.

Boom cylinder AS: 230 kg

6. Remove the plate (5), air intake hose (6)

and fan guard (7).

NOTE: Removal of the swing platform
requires removing other parts that interfere
with the lifting of swing platform.

7. Disconnect the six hoses above the swivel

joint assembly.

●

Central swivel joint (port A) - Left travel
control valve (port BTL)

●

Central swivel joint (port C) - Left travel
control valve (port ATL)

●

Central swivel joint (port F) - Solenoid
valve

●

Central swivel joint (port G) - Swing
motor (port T)

●

Central swivel joint (port D) - Right trav-
el control valve (port ATR)

●

Central swivel joint (port B) - Right trav-
el control valve (port BTR)

8. Remove the bolt (14).

ZX215T-1006110

ZX215T-1006111

ZX215T-1006112

8-70

Disassembly and Assembly

ZX215T-1006113

9. Unscrew the 32 swing platform mounting

bolts in order to remove the swing platform
assembly (15). Lift the swing platform as-
sembly off the machine.

NOTE: Remove the front and rear mount-
ing bolts of the platform. Use a lever block
to adjust the swing platform so that the
platform can reach a balance both longi-
tudinally and laterally. Remove the last two
bolts

nally.

Swing platform assembly:

Assembly

Swing Platform

Only (Ref.)

8,427 kg

1,689 kg

NOTICE

●

Be careful not to impact the central
swivel joint while removing the swing
platform assembly.

Disassembly and Assembly

8.18.2 Installation

●

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

Clamping screws (air intake hose):

5.4~6.4 N·m {0.55~0.65 kgf·m}

Mating surface (swing bearing):

Flat surface sealant (Tonsun 1596)

Threads (bolt - swing platform):

Thread adhesive: (Tonsun 1277)

Mounting bolts (swing platform):

Step 1: Tighten the bolts with a pneumatic

spanner.

Step 2: tighten them again.

490~608 N·m {50~62 kgf·m}

●

Hydraulic oil adding

Add through the

ller opening the hydraulic

oil 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 travel motor.

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

8-72

Disassembly and Assembly

8.19 Swivel Joint AS - Remove and Install

1. Disconnect the six hoses from (1) to (6) on

the central swivel joint of the travel motor.

1) Central swivel joint (port T) - Left travel

motor (port T)

2) Central swivel joint (port T) - Right trav-

el motor (port T)

3) Central swivel joint (port B) - Left travel

motor (port PA)

4) Central swivel joint (port D) - Right trav-

el motor (port PB)

5) Central swivel joint (port A) - Left travel

motor (port PB)

6) Central swivel joint (port C) - Right trav-

el motor (port PA)

ZX215T-1006114

8.19.1 Removal

Refer to “Residual Pressure in Hydraulic Cir-
cuit - Release” on page 6-40.

NOTE: Tag each line so as to ensure correc-
tion installation.

WARNING

●

Release residual pressure in the hy-
draulic circuit before disconnecting the
hydraulic hoses.

8-73

Disassembly and Assembly

2. Disconnect the eight hoses from (7) to (14).

7) Central swivel joint (port F) - Left travel

motor (port P)

8) Central swivel joint (port F) - Right trav-

el motor (port P)

9) Central swivel joint (port G) - Swing

motor (port T)

10) Central swivel joint (port F) - Solenoid

valve

11) Central swivel joint (port C) - Left travel

control valve (port ATL)

12) Central swivel joint (port A) - Left travel

control valve (port BTL)

13) Central swivel joint (port D) - Right trav-

el control valve (port ATR)

14) Central swivel joint (port B) - Right trav-

el control valve (port BTR)

3. Remove the

xing bolt (15).

4. Remove the four mounting bolts (16).

ZX215T-1006116

ZX215-1006117

Transition plate

5. Remove the six mounting bolts (17) from

the transition plate. Remove the swivel
joint assembly (18).

Central swivel joint: 56 kg

11 12

ZX215T-1006115

Disassembly and Assembly

8.19.2 Installation

●

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

NOTE: Install the central swivel joint facing
the direction indicated in the illustration.

B D

A C

ZX215-1006118

Sprocket

Central swivel joint

●

Oil adding (hydraulic tank)

Add through the

ller opening the hydraulic

oil 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 travel motor.

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

8-75

Disassembly and Assembly

8.20 Swivel Joint AS - Disassemble and Assemble

8.20.1 Disassembly

1. Remove the bolt (1) and the spring washer

(2).

2. Remove the cover (3).

3. Remove the gasket (4), O-ring (5) and

snap ring (6).

4. Remove the rotor (13) from the housing (9).

NOTE: Be careful not to damage the slid-
ing surface of the seal of the rotor (13).

5. Remove the spacer (7) and the gasket (8)

from the housing (9).

6. Remove the dust seal (12) from the swing

shaft (13).

7. Remove the O-ring seal (11) and the seals

(10) from the housing (9).

2
3

ZX215-1006119

ZX215-1006120

Disassembly and Assembly

8.20.2 Assembly

1. Install the dust seal (12) on the rotor (13).

NOTE: Let the lip face the housing while
installing the dust seal.

2. Install the six seals (10) in the housing (9).

3. Fix the rotor (13) on a work bench. Install

the housing (9) on the rotor (13).

NOTE: Since the clearance between
the housing (9) and the rotor (13) is ap-
proximately 0.1 mm, install the housing (9)
on the rotor (13) slowly and vertically. Be
careful not to damage the seals (10) and
the O-ring seal (11).

4. Use a rubber hammer to tap the housing (9)

in order to match the rotor (13) properly.

5. Install the spacer (7) and gasket (8) in the

housing (9).

6. Install the gasket (4), O-ring seal (5) and

snap ring (6) on the rotor (13).

7. Install the cover (3). Tighten the bolts (1)

and the spring washer (2).

Fixing bolts: 49 N·m{5 kgf·m}

ZX215-1006121

Dust seal

Lip

Body

8-77

Disassembly and Assembly

8.21 Hydraulic Tank AS - Remove and Install

8.21.1 Removal

1. Drain the hydraulic oil into a suitable

container for storage or disposal.

Hydraulic oil: approx. 225 L

2. Open the engine hood.

3. Remove the engine hood (1), cover (2) and

control valve cover (3).

4. Remove the cover mounting frame (4) and

the screen (5).

5. Remove the screen (6) and the partition

frame mounting bolt (7) on the hydraulic
tank side.

6. Remove the screw (8) and the fuel control

motor (9).

7. Remove the two oil return hoses (10) from

the hydraulic tank.

ZX215T-1006122

ZX215T-1006123

ZX215T-1006124

8-78

Disassembly and Assembly

8. Disconnect the seven hoses.

●

(11): Oil return - pilot T block

●

(12): Oil return - main pump

●

(13): Oil return D2 - main valve

●

(14): Sensor - temperature

●

(15): Oil return - solenoid valve

●

(16): Oil return D1/D3 - main valve

●

(17): Oil return - swing motor

NOTE:

●

Disconnect the oil inlet hose (18) from the
hydraulic tank after disconnection of the oil
inlet tube from the pump.

●

Attach each hose with an identi

cation tag.

●

Use a sleeve nut to prevent the

tting and

the cone seal from damage.

9. Remove the hose clamp (19).

10. Lift the hydraulic tank assembly and re-

move the six bolts (20).

11. Lift off the hydraulic tank assembly for dis-

assembling.

Hydraulic tank assembly: 130 kg

ZX215T-1006125

ZX215T-1006127

ZXT225-1106008

SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual - page 35