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

Disassembly and Assembly

8.21.2 Installation

●

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

Drain plug (hydraulic tank):

58.8~78.5 N·m {6.0~8.0 kgf·m}

NOTE: 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.

Bolt:

245.2~308.9 N·m {25~31.5 kgf·m}

ZX215-1006128

Screw

Up
Down

ZX215-1006129

Pipe

Clamp

Hose

Bulge

●

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

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

8-80

Disassembly and Assembly

8.22 Control Valve AS - Remove and Install

1. Lift the hood (1).

2. Remove the cover (2) above the control

valve.

3. Remove the engine silencing hood (3).

4. Remove the baffle (4) to (9) of the pres-

sure transducer and tag them.

(4): XAK Bucket DIG

(5): XBb1 Boom DOWN

(6): XAtL Travel LEFT

(7): XBa1 Arm IN

(8): XBs Swing RIGHT

(9): XAtr Travel RIGHT

ZXT225-1106011

ZXT225-1106009

ZXT225-1106010

8.22.1 Removal

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

WARNING

●

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. Press the re-
lease button of the breather valve to re-
lease residual pressure in the hydraulic
tank. Place the hydraulic lockout con-
trol in the LOCK position.

8-81

Disassembly and Assembly

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

8-82

Disassembly and Assembly

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.

ZXT225-1106015

ZXT225-1106016

ZXT225-1106017

12. Remove pipe (36) (main valve to radiator).

8-83

Disassembly and Assembly

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 solenoid

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

WXT215-1208001G

40 41

8-84

Disassembly and Assembly

8.22.2 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 6-46.

ZXT225-1106021

16. Remove the

xing bolts (45). Lift the con-

trol valve assembly (46) for disassembling.

Control valve assembly: 220 kg

8-85

Disassembly and Assembly

8.23

Hydraulic Pump AS - Remove and Install

1. Remove the oil inlet

lter element from the

hydraulic tank and stop oil out

ow with an

oil stopper.

NOTE: 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).

ZX215-1006144

Oil stopper

ZX215T-1006145

8.23.1 Removal

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

WARNING

●

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 stop the engine. Press the
release button of the breather valve to
release residual pressure in the hydrau-
lic tank.

●

Disconnect the cable from the negative
(-) post of the battery before performing
the job.

8-86

Disassembly and Assembly

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).

ZX215T-1006146

ZX215T-1006147

ZX215T-1006148

5. Disconnect the hose (5) supplying oil to the

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

8-87

Disassembly and Assembly

6. Disconnect the shutdown wire (7).

7. Remove the right door (8).

8. Remove the hydraulic pump cover (9).

ZX215T-1006149

ZX215T-1006150

ZX215T-1006151

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.

8-88

Disassembly and Assembly

ZX215T-1006152

ZX215T-1006153

14. Disconnect the solenoid valve harnesses

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

15. Remove the four bolts (20) of the hydraulic

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

Hydraulic pump assembly: 112 kg

8-89

Disassembly and Assembly

8.23.2 Installation

●

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

NOTE: 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.

Mating surface (hydraulic pump

housing):

Gasket sealant: (Loctite 515)

ZX215-1006128

Screw

Up
Down

ZX215-1006129

Pipe

Clamp

Hose

Bulge

●

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 6-46.

8-90

Disassembly and Assembly

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

8.24.1 Removal

1. Remove the hydraulic pump assembly (1).

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

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

ing cover (3).

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

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

8.24.2 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.

2
3
4

ZX215-1006154

ZX215-1006155

8-91

Disassembly and Assembly

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

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

8.25.1 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 plunger (5) on the spool.
Push the plug (5) to the spool hole.

3. Install the plate (4) on the plunger (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}

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

ZX215T-1006156

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 (Tonsun 1277)

Disassembly and Assembly

●

Apply the thread adhesive (Ton-
sun 1277) to two points on the inner
threads. The amount of application is
approximately 0.02 g.

U-joint (3):

98~133 N·m {10~13.5 kgf·m}

NOTE: Tightening is to be made to the
speci

ed torque.

Contact surface between plung-

er (5) and plate (2):

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

5~7 mm

ZX215-1006157

8-93

Disassembly and Assembly

8.26 Pilot Valve AS (Travel) - Disassemble and Assemble

NOTE: This section discusses only the precautions when reassembling the travel pilot valve as-
sembly.

8.26.1 Assembly

●

Reassembly of the pedal pilot valve assembly

1. Install the spring (8) into the spool installation 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 plunger. Install the cover (2) and

x the cover (2) with the cam-

shaft (5).

Contact surface between plunger and dust ring (5):

Grease (No.1 Calcium base grease)

ZX215T-1006158

Plunger

8-94

Disassembly and Assembly

8.27 Hydraulic Cylinder AS - Disassemble and Assemble

Special tools

Application

Tool Shape

Necessity

Quantity

Pulling out/pushing
in the bushing

■

Press

tting the

dust ring

■

O-ring seal correc-
tion

Inserting tool

Correcting tool

■

Inserting the cylin-
der head

■

Inserting the piston

■

SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual - page 36