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Crawler Hydraulic

Crawler Hydraulic Excavator

Shop Manual SY365(B)H-9
Excavator

SY365H-9

SY365BH-9

SANY HEAVY MACHINERY LIMITED

318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P.R. of China 201413

Tel: (86) 21 5700 8518

Service hotline: (86) 4006 098 318
E-mail: [email protected]

Documentation No.: B06T03ENAN1-SY365(B)H-9

Shop Manual
SY365(B)H-9 Crawler Hydraulic Excavator

SY365(B)H-9
Crawler Hydraulic Excavator
Shop Manual

WARNING

● Read and follow the safety precautions and instructions in this manual and on the ma-
chine decals. Failure to do can cause serious injury, death or property damage. Keep
this manual with the machine for reading and future reference.

Shop Manual - April 2014

 SY365(B)H-9 Crawler Hydraulic Excavator

Sany Group
Sany Heavy Machinery Limited
318A, Lianggang Avenue, Lingang Industrial Park,
Fengxian District, Shanghai, P. R. of China 201413

http://www.sanygroup.com

Tel: 0086-21-57008518 Fax: 0086-21-58596210

Service hotline: 0086-21-58592902
Complaint hotline: 0086-21-58590631
E-mail: [email protected]

© 2012 by Sany Group. All right reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as de-
scribed herein. All information included within this publication was accurate at the time
of publication. Product improvements ,revisions, etc., may result in differences between
your machine and what is presented here. Sany Group assumes no liability. For more in-
formation, Contact Sany Group.
Shop Manual - April 2014
SY365(B)H-9 Crawler Hydraulic Excavator Table of Contents

Table of Contents

1 Introduction
1.1 How to Read the Manual ......................................................................................... 1-3
1.1.1 Shop manual organization ............................................................................. 1-3
1.1.2 Revision and distribution ................................................................................ 1-4
1.1.3 Symbols ......................................................................................................... 1-5
1.1.4 Units ............................................................................................................... 1-5
1.2 Technical Terms ....................................................................................................... 1-6
1.2.1 Standard size and tolerance .......................................................................... 1-6
1.2.2 Standard clearance and value ....................................................................... 1-7
1.2.3 Standard interference .................................................................................... 1-7
1.2.4 Repair limit and allowable value .................................................................... 1-8
1.2.5 Clearance limit ............................................................................................... 1-8
1.2.6 Interference limit ............................................................................................ 1-8
1.3 Handling Electrical and Hydraulic Components....................................................... 1-9
1.3.1 Points to remember when handling electric components .............................. 1-9
1.3.1.1 Handling wiring harnesses and connectors .......................................... 1-9
1.3.1.2 Main failures occurring in wiring harness ............................................ 1-10
1.3.1.3 Removing, installing, and drying connectors and wiring harnesses ... 1-12
1.3.1.4 Handling the integrated control monitor .............................................. 1-16
1.3.1.5 Electric circuits troubleshooting precautions ....................................... 1-17
1.3.2 Points to remember when handling hydraulic equipment ............................ 1-18
1.3.2.1 Be careful of the operating environment ............................................. 1-18
1.3.2.2 Disassembly and maintenance work in the field ................................. 1-18
1.3.2.3 Sealing openings ................................................................................ 1-18
1.3.2.4 Do not let any dirt or dust get in during refilling operations ................. 1-19
1.3.2.5 Change hydraulic oil when the temperature is high ............................ 1-19
1.3.2.6 Flushing operations............................................................................. 1-19
1.3.2.7 Cleaning operations ............................................................................ 1-20
1.4 Hose Connector ..................................................................................................... 1-20
1.4.1 Type of hose connector................................................................................ 1-21
1.4.2 Hose connector tightening torque table ....................................................... 1-21
1.4.3 Connection of O-rings .................................................................................. 1-22
1.5 Table of Standard Tightening Torques .................................................................. 1-23

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1.6 Type of Bolts .......................................................................................................... 1-24

1.7 Tightening Sequence ............................................................................................. 1-24
1.8 Maintenance of Half Flanges ................................................................................. 1-25
1.8.1 Table of tightening torques for half flange bolts ........................................... 1-25
1.8.2 Temperature ................................................................................................. 1-31

2 Shop Safety
2.1 Hazard Alert Information .......................................................................................... 2-3
2.2 General Shop Safety ............................................................................................... 2-5
2.2.1 Rules and shop behavior ............................................................................... 2-6
2.2.2 Housekeeping ................................................................................................ 2-6
2.2.3 Shop Liquids Storage..................................................................................... 2-7
2.2.4 Cleaning the Parts ......................................................................................... 2-7
2.2.5 Cleaning the Machine .................................................................................... 2-8
2.2.6 Appropriate Working Apparel ......................................................................... 2-8
2.2.7 Personal Protective Equipment...................................................................... 2-8
2.2.8 Using the Correct Tools.................................................................................. 2-9
2.2.9 Fire Extinguisher and Emergency Exits ......................................................... 2-9
2.2.10 Electrical Dangers ...................................................................................... 2-10
2.2.11 Hoisting a Load .......................................................................................... 2-10
2.3 Before Repair..........................................................................................................2-11
2.3.1 Safe Work Preparations ................................................................................2-11
2.3.2 Preparing yourself ........................................................................................ 2-12
2.3.3 Lockout/Tagout............................................................................................. 2-13
2.3.4 Two people when engine running ................................................................ 2-15
2.3.5 Safety Partners ............................................................................................ 2-15
2.4 Repair Precautions ................................................................................................ 2-16
2.4.1 Running the Machine ................................................................................... 2-16
2.4.2 Mounting and Dismounting .......................................................................... 2-17
2.4.3 Removing Attachments ................................................................................ 2-18
2.4.4 Jacking Up the Machine............................................................................... 2-18
2.4.5 Adding Fluids to a System ........................................................................... 2-18
2.4.6 Aligning Parts or Components ..................................................................... 2-19
2.4.7 Driving Pins .................................................................................................. 2-19
2.4.8 When compressed air is used...................................................................... 2-19
2.4.9 Welding operation ........................................................................................ 2-20

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2.4.10 Track Recoil Springs .................................................................................. 2-20

2.4.11 High-Pressure Fluid Lines .......................................................................... 2-21
2.4.12 Air-conditioning system maintenance ........................................................ 2-22
2.4.13 High voltage precautions ........................................................................... 2-22
2.4.14 Disconnecting the System Power .............................................................. 2-23
2.4.15 Accumulator ............................................................................................... 2-23
2.4.17 Battery Hazards ......................................................................................... 2-24
2.4.18 Jump-Start Safety ...................................................................................... 2-25
2.4.19 Avoiding fire and explosion ........................................................................ 2-26
2.4.20 Chemical hazard ........................................................................................ 2-27
2.4.21 Material Safety Data Sheets (MSDS) ........................................................ 2-27
2.4.22 Proper disposal of wastes .......................................................................... 2-28
2.5 Other Precautions .................................................................................................. 2-29
2.5.1 Sling work and giving signals ....................................................................... 2-29
2.5.2 Using mobile crane ...................................................................................... 2-31
2.5.3 Using overhead hoist crane ......................................................................... 2-31
2.5.4 Selecting wire ropes..................................................................................... 2-33

3 Specifications
3.1 Specific Dimension .................................................................................................. 1-3
3.1.1 Dimension ...................................................................................................... 1-3
3.1.2 Working ranges .............................................................................................. 1-4
3.2 Technical Specifications........................................................................................... 1-5
3.3 Weight Table ............................................................................................................ 1-7
3.4 Engine oil, Fuel and Coolant.................................................................................... 1-8
3.5 Engine Performance Curves.................................................................................... 1-9

4 Structure and Functions

4.1 Engine and Cooling System ................................................................................... 4-5
4.1.1 Engine-related parts....................................................................................... 4-5
4.1.2 Radiator and intercooler................................................................................. 4-6
4.2 Power Train.............................................................................................................. 4-7
4.2.1 Overview ........................................................................................................ 4-7
4.2.2 Travel reducer AS ......................................................................................... 4-8
4.2.3 Swing reducer mechanism........................................................................... 4-10
4.2.4 Swing bearing .............................................................................................. 4-12

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4.3 Undercarriage Travel System ............................................................................... 4-14

4.3.1 Track frame and tensioning mechanism ...................................................... 4-14
4.3.2 Idler .............................................................................................................. 4-16
4.3.3 Carrier roller ................................................................................................. 4-18
4.3.4 Track roller ................................................................................................... 4-19
4.3.5 Track ........................................................................................................... 4-20
4.3.6 Tri-grouser track shoe .................................................................................. 4-23
4.4 Hydraulic System, Part 1 ....................................................................................... 4-24
4.4.1 Deployment of hydraulic parts ..................................................................... 4-24
4.4.2 Hydraulic tank and filter ............................................................................... 4-26
4.4.3 Hydraulic pump ............................................................................................ 4-28
4.4.3.1 Outline................................................................................................. 4-29
4.4.3.2 Function .............................................................................................. 4-31
4.4.3.3 Structure ............................................................................................. 4-31
4.4.3.4 Operating principle .............................................................................. 4-32
4.4.3.5 Oil delivery control .............................................................................. 4-33
4.4.4 Pilot pump .................................................................................................... 4-34
4.4.5 Regulator .................................................................................................... 4-35
4.5 Hydraulic system, Part 2 ........................................................................................ 4-48
4.5.1 Main control valve ........................................................................................ 4-48
4.5.1.1 Overview ............................................................................................ 4-48
4.5.1.2 Main valve structure ............................................................................ 4-50
4.5.2 Hydraulic circuit (With bucket confluence function) .............................................. 4-56
4.6 Hydraulic System, Part 3 ....................................................................................... 4-79
4.6.1 Swing motor ................................................................................................. 4-79
4.6.2 Swing holding brake..................................................................................... 4-81
4.6.3 Relief valve section ...................................................................................... 4-82
4.6.4 Anti-jerk valve............................................................................................... 4-84
4.6.4.1 Operation diagram .............................................................................. 4-84
4.6.4.2 Effect illustration.................................................................................. 4-84
4.6.5 Central Swivel Joint ..................................................................................... 4-86
4.6.6 Travel motor ................................................................................................. 4-87
4.6.7 Reducer ....................................................................................................... 4-89
4.6.8 Travel motor (Nabtesco) .............................................................................. 4-91
4.6.9 Operating principle of the basic components ............................................... 4-93
4.6.9.1 Double-balanced valve ....................................................................... 4-93

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4.6.9.2 Operation of parking brake ................................................................. 4-98

4.6.9.3 Operation of braking valve .................................................................. 4-99
4.6.10 Control system ......................................................................................... 4-108
4.6.11 Manual pilot valve .....................................................................................4-110
4.6.12 Travel pilot valve .......................................................................................4-114
4.6.12.1 Operating principle ...........................................................................4-116
4.6.13 Solenoid valve...........................................................................................4-118
4.6.14 PPC accumulator ......................................................................................4-119
4.6.15 Pilot oil filter.............................................................................................. 4-121
4.6.16 Hydraulic cylinders ................................................................................... 4-122
4.6.16.2 Lubrication at every 100 service hours ........................................... 4-123
4.6.16.1 Lubrication at every 500 service hours ........................................... 4-123
4.7 Work Equipment .................................................................................................. 4-124
4.7.1 Component dimensions ............................................................................. 4-124
4.7.2 Arm dimensions ......................................................................................... 4-126
4.7.2.1 Bucket dimensions ............................................................................ 4-128
4.8 Operator Station and Its Attachments .................................................................. 4-130
4.8.1 Air conditioner lines .................................................................................... 4-130
4.8.1.1 Layout of A/C components ................................................................ 4-132
4.8.1.2 A/C control panel............................................................................... 4-133
4.8.1.3 Diagram of electrical circuit ............................................................... 4-134
4.8.1.4 Operating principle ............................................................................ 4-136
4.8.1.5 Compressor ...................................................................................... 4-137
4.8.1.6 Clutch ................................................................................................ 4-139
4.8.1.7 Condenser ........................................................................................ 4-140
4.8.1.8 Expansion valve ................................................................................ 4-141
4.8.1.9 Evaporator ........................................................................................ 4-141
4.8.1.10 Dehydrator ..................................................................................... 4-142
4.8.1.11 Pressure switch .............................................................................. 4-143
4.8.1.12 Fresh air sensor .............................................................................. 4-144
4.8.2 Refrigerant ................................................................................................. 4-145
4.8.2.1 Compressor oil .................................................................................. 4-163
4.9 Engine Control ..................................................................................................... 4-164
4.9.1 System operation ....................................................................................... 4-165
4.9.1.1 Engine starting .................................................................................. 4-165
4.9.1.2 Engine speed control ........................................................................ 4-165

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4.9.1.3 Engine shutdown .............................................................................. 4-165

4.9.2 System components .................................................................................. 4-166
4.9.2.1 Fuel control dial................................................................................. 4-166
4.9.2.2 Controller .......................................................................................... 4-168
4.10 Electrical Control System................................................................................... 4-170
4.10.1 Control function ........................................................................................ 4-170
4.10.2 Diagram of machine control system......................................................... 4-171
4.10.3 Engine-pump combination control ........................................................... 4-173
4.10.4 Pump control function .............................................................................. 4-177
4.10.4.1 Constant power control ................................................................... 4-180
4.10.4.2 ESS control ..................................................................................... 4-180
4.10.5 Valve control function ............................................................................... 4-181
4.10.6 Dual travel speed control ......................................................................... 4-183
4.10.7 Engine preheat/overheat alarm ............................................................... 4-185
4.10.8 Auto deceleration/acceleration control ..................................................... 4-187
4.10.9 Engine speed calibration function ............................................................ 4-188
4.10.10 System parts and components .............................................................. 4-190
4.11 Monitoring System ............................................................................................. 4-195
4.11.1 Monitor ..................................................................................................... 4-196
4.11.2 Monitor panel ........................................................................................... 4-197
4.11.2.1 Alert and signal indicators .............................................................. 4-197
4.11.2.2 Operation keys ................................................................................ 4-199
4.11.3 Monitor display and operation .................................................................. 4-201
4.11.3.1 Default page .................................................................................... 4-201
4.11.3.2 Password entry to system information ............................................ 4-202
4.11.3.3 Main menu ...................................................................................... 4-202
4.11.3.4 Engine & throttle signals ................................................................. 4-203
4.11.3.5 Pilot pressure signals ...................................................................... 4-203
4.11.3.6 Main pump & main valve signals..................................................... 4-204
4.11.3.7 Failure codes................................................................................... 4-204
4.11.3.8 Throttle help information ................................................................. 4-205
4.11.3.9 Language selection ......................................................................... 4-205
4.11.3.10 System clock setup ....................................................................... 4-206
4.11.3.11 GPS information ............................................................................ 4-207
4.11.3.12 System setup ................................................................................ 4-208
4.11.3.13 Machine configuration ................................................................... 4-208

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SY365(B)H-9 Crawler Hydraulic Excavator Table of Contents

4.11.3.14 Service hour setup ....................................................................... 4-209

4.11.3.15 Machine configuration setup ......................................................... 4-210
4.11.3.16 Hydraulic oil temperature ...............................................................4-211
4.11.3.17 Screen brightness setup ................................................................4-211
4.11.3.18 System lockout (level 1) ................................................................ 4-212
4.11.3.19 System lockout (level 2) ................................................................ 4-212

5 Table of Standard Values

5.1 Standard Values for Engine-Related Parts .............................................................. 5-3
5.2 Standard Values for Chassis-Related Parts ............................................................ 5-4

6 Testing and adjusting

6.1 Engine Speed - Test and Adjust............................................................................... 6-3
6.2 Exhaust Gas Color - Test ......................................................................................... 6-5
6.3 Valve Clearance - Adjust.......................................................................................... 6-7
6.3.1 Testing............................................................................................................ 6-8
6.3.2 Adjusting ........................................................................................................ 6-9
6.4 Compression force - Test ....................................................................................... 6-10
6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13
6.5.1 Testing.......................................................................................................... 6-14
6.5.2 Adjusting ...................................................................................................... 6-18
6.6 A/C Compressor Belt Tension - Test and Adjust .................................................... 6-19
6.6.1 Testing ......................................................................................................... 6-19
6.6.2 Adjusting ...................................................................................................... 6-19
6.7 Swing Bearing Clearance - Test ............................................................................ 6-20
6.8 Track Tensioner - Test and Adjust .......................................................................... 6-21
6.8.1 Testing.......................................................................................................... 6-21
6.8.2 Adjusting ...................................................................................................... 6-22
6.9 Oil in Hydraulic Circuits - Test and Adjust .............................................................. 6-23
6.9.1 Testing.......................................................................................................... 6-23
6.9.2 Adjusting ...................................................................................................... 6-25
6.10 Control Oil Circuit Pressure - Test and Adjust...................................................... 6-28
6.10.1 Testing........................................................................................................ 6-28
6.10.2 Adjusting .................................................................................................... 6-28
6.11 Solenoid Valve Output Pressure - Test ................................................................ 6-29
6.12 Pilot Valve Output Pressure - Test ....................................................................... 6-31

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6.13 Work Equipment and Swing Pilot Valves - Adjust ................................................ 6-33
6.14 Hydraulic Drift of Work Equipment - Test ............................................................. 6-34
6.15 Remaining Pressure in Hydraulic Lines - Relieve................................................ 6-36
6.16 Oil Leakage Amount - Test................................................................................... 6-37
6.17 Air in Each Component - Purge ........................................................................... 6-41

7 Troubleshooting
7.1 Checks before Troubleshooting ............................................................................... 7-5
7.2 Failure Symptoms and Troubleshooting Codes ....................................................... 7-6
7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-9
7.3.1 Connector location layout ............................................................................ 7-13
7.3.2 Diagram of system electrical elements ........................................................ 7-18
7.3.3 Diagram of electrical control system ........................................................... 7-20
7.3.4 SWP connectors .......................................................................................... 7-22
7.3.5 A/AMP connectors ....................................................................................... 7-23
7.3.6 DT connectors.............................................................................................. 7-24
7.4 Troubleshooting with an Event Code ..................................................................... 7-25
7.5 Troubleshooting Electrical System (E-Mode)......................................................... 7-49
7.6 Troubleshooting Hydraulic and Mechanical Systems (H-mode) ............................ 7-81

8 Disassembly and Assembly

8.1 How to Read This Manual ....................................................................................... 8-5
8.1.1 Removing and installing an assembly............................................................ 8-5
8.2 Operating Precautions ............................................................................................. 8-6
8.3 Start Motor AS ........................................................................................................ 8-9
8.3.1 Removal ......................................................................................................... 8-9
8.3.2 Installation ...................................................................................................... 8-9
8.4 Fuel Injection Pump AS ........................................................................................ 8-10
8.4.1 Removal ....................................................................................................... 8-10
8.4.2 Installation .................................................................................................... 8-12
8.5 Engine Front Oil Seal ............................................................................................ 8-13
8.5.1 Removal ....................................................................................................... 8-13
8.5.2 Installation .................................................................................................... 8-13
8.6 Engine Rear Oil Seal ............................................................................................ 8-14
8.6.1 Removal ....................................................................................................... 8-14
8.6.2 Installation .................................................................................................... 8-14

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8.7 Cylinder Head AS .................................................................................................. 8-15

8.7.1 Removal ....................................................................................................... 8-15
8.7.2 Installation .................................................................................................... 8-19
8.8 Radiator AS ........................................................................................................... 8-20
8.8.1 Removal ....................................................................................................... 8-20
8.8.2 Installation .................................................................................................... 8-23
8.9 Engine and Hydraulic Pump AS ............................................................................ 8-24
8.9.1 Removal ....................................................................................................... 8-24
8.9.2 Installation .................................................................................................... 8-30
8.10 Final Drive AS ..................................................................................................... 8-31
8.10.1 Removal ..................................................................................................... 8-31
8.10.2 Installation .................................................................................................. 8-32
8.11 Final Drive AS ...................................................................................................... 8-33
8.11.1 Disassembly ............................................................................................... 8-33
8.11.2 Assembly .................................................................................................... 8-36
8.12 Swing Motor and Swing Drive AS ....................................................................... 8-42
8.12.1 Removal ..................................................................................................... 8-42
8.12.2 Installation .................................................................................................. 8-43
8.13 Swing Motor and Swing Drive AS ....................................................................... 8-44
8.13.1 Disassembly............................................................................................... 8-44
8.13.2 Assembly.................................................................................................... 8-49
8.14 Idler AS ............................................................................................................... 8-54
8.14.1 Disassembly............................................................................................... 8-54
8.14.2 Assembly.................................................................................................... 8-55
8.15 Sprocket .............................................................................................................. 8-58
8.15.1 Removal ..................................................................................................... 8-58
8.15.2 Installation .................................................................................................. 8-58
8.16 Track AS ............................................................................................................. 8-59
8.16.1 Removal ..................................................................................................... 8-59
8.16.2 Installation .................................................................................................. 8-60
8.17 Swing Bearing AS ............................................................................................... 8-62
8.17.1 Removal ..................................................................................................... 8-62
8.17.2 Installation .................................................................................................. 8-63
8.18 Swing frame AS .................................................................................................. 8-64
8.18.1 Removal ..................................................................................................... 8-64
8.18.2 Installation .................................................................................................. 8-66

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8.19 Swivel Joint AS .................................................................................................... 8-67

8.19.1 Removal ..................................................................................................... 8-67
8.19.2 Installation .................................................................................................. 8-69
8.20 Central Swivel Joint AS ....................................................................................... 8-70
8.20.1 Disassembly............................................................................................... 8-70
8.20.2 Assembly.................................................................................................... 8-70
8.21 Hydraulic Tank AS ............................................................................................... 8-71
8.21.1 Removal ..................................................................................................... 8-71
8.21.2 Installation .................................................................................................. 8-73
8.22 Control Valve AS .................................................................................................. 8-74
8.22.1 Removal ..................................................................................................... 8-74
8.22.2 Installation .................................................................................................. 8-79
8.23 Hydraulic Pump AS ............................................................................................. 8-80
8.23.1 Removal ..................................................................................................... 8-80
8.23.2 Installation .................................................................................................. 8-83
8.24 Middle Oil Seal (Hydraulic Pump Input Shaft) ..................................................... 8-84
8.24.1 Removal ..................................................................................................... 8-84
8.24.2 Installation .................................................................................................. 8-84
8.25 Pilot Valve AS (Work Equipment) ....................................................................... 8-85
8.26 Travel Pilot Valve AS ........................................................................................... 8-86
8.27 Hydraulic Cylinder AS ......................................................................................... 8-87
8.27.1 Disassembly............................................................................................... 8-88
8.27.2 Assembly.................................................................................................... 8-92
8.28 Work Equipment AS ............................................................................................ 8-97
8.28.1 Removal ..................................................................................................... 8-97
8.28.2 Installation .................................................................................................. 8-99
8.29 Air Conditioner AS ............................................................................................. 8-100
8.29.1 Removal ................................................................................................... 8-100
8.29.2 Installation ................................................................................................ 8-103
8.30 Counterweight AS ............................................................................................. 8-104
8.30.1 Removal ................................................................................................... 8-104
8.30.2 Installation ................................................................................................ 8-105
8.31 Cab AS .............................................................................................................. 8-106
8.31.1 Removal ................................................................................................... 8-106
8.31.2 Installation ................................................................................................ 8-109
8.32 Cab Window Glass ............................................................................................8-110

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8.32.1 Removal ....................................................................................................8-111

8.32.2 Installation .................................................................................................8-114
8.33 Front Window AS ............................................................................................... 8-126
8.33.1 Disassembly............................................................................................. 8-126
8.33.2 Assembly.................................................................................................. 8-129
8.34 Monitor - Remove and Install ............................................................................. 8-135
8.34.1 Removal ................................................................................................... 8-135
8.34.2 Installation ................................................................................................ 8-135
8.35 Controller AS ..................................................................................................... 8-136
8.35.1 Removal ................................................................................................... 8-136
8.35.2 Installation ................................................................................................ 8-136
8.36 Radio ................................................................................................................. 8-137
8.36.1 Structure .................................................................................................. 8-137
8.36.2 Removal and installation .......................................................................... 8-139
8.36.3 Connector model and wiring .................................................................... 8-140
8.37 Battery ............................................................................................................... 8-141
8.37.1 Structure .................................................................................................. 8-141
8.37.2 Removal and installation .......................................................................... 8-142
8.37.3 Replacement ............................................................................................ 8-143
8.38 Start Switch........................................................................................................ 8-144
8.38.1 Structure ................................................................................................. 8-144
8.38.2 Removal ................................................................................................... 8-145
8.38.3 Working principle ..................................................................................... 8-146
8.38.4 Wiring ....................................................................................................... 8-146
8.39 Fuse Box............................................................................................................ 8-147
8.40 Wiper ................................................................................................................. 8-148
8.40.1 Structure .................................................................................................. 8-148
8.40.2 Working principle ..................................................................................... 8-149
8.40.3 Removal ................................................................................................... 8-150
8.40.4 Installation ................................................................................................ 8-150
8.40.5 Angle adjustment of wiper arm................................................................. 8-151
8.41 Relays ................................................................................................................ 8-152
8.41.1 Engine relays ........................................................................................... 8-152
8.41.2 Other relays ............................................................................................. 8-153
8.41.3 Removal and installation .......................................................................... 8-154
8.41.4 Relay connector and wiring...................................................................... 8-154

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8.42 Sensors.............................................................................................................. 8-155

8.43 Connector Terminals ......................................................................................... 8-157
8.43.1 Insertion ................................................................................................... 8-157
8.43.2 Removal ................................................................................................... 8-158

9 System Schematics
9.1 Diagram of Hydraulic Lines...................................................................................... 9-3
9.2 Electrical diagram of chassis ................................................................................... 9-4
9.3 Electrical diagram of control switches...................................................................... 9-5
9.4 Electrical diagram of operator station ...................................................................... 9-6
9.5 Electrical diagram of air conditioner......................................................................... 9-7
9.6 Electrical diagram of monitor ................................................................................... 9-8

XII Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

Introduction

.
1 Introduction

De al
pt
1.1 How to Read the Manual ......................................................................................... 1-3
1.1.1 Shop manual organization ............................................................................. 1-3
g n
1.1.2 Revision and distribution ................................................................................ 1-4
o
1.1.3 Symbols ......................................................................................................... 1-5
in ti

1.1.4 Units ............................................................................................................... 1-5

1.2 Technical Terms ....................................................................................................... 1-6
营
销
公
司

1.2.1 Standard size and tolerance .......................................................................... 1-6

et a

1.2.2 Standard clearance and value ....................................................................... 1-7

n

1.2.3 Standard interference .................................................................................... 1-7

rk er

1.2.4 Repair limit and allowable value .................................................................... 1-8

1.2.5 Clearance limit ............................................................................................... 1-8
Ma t

1.2.6 Interference limit ............................................................................................ 1-8

In

1.3 Handling Electrical and Hydraulic Components....................................................... 1-9

1.3.1 Points to remember when handling electric components .............................. 1-9
1.3.1.1 Handling wiring harnesses and connectors .......................................... 1-9
1.3.1.2 Main failures occurring in wiring harness ............................................ 1-10
1.3.1.3 Removing, installing, and drying connectors and wiring harnesses ... 1-12
1.3.1.4 Handling the integrated control monitor .............................................. 1-16
1.3.1.5 Electric circuits troubleshooting precautions ....................................... 1-17
1.3.2 Points to remember when handling hydraulic equipment ............................ 1-18
1.3.2.1 Be careful of the operating environment ............................................. 1-18
1.3.2.2 Disassembly and maintenance work in the field ................................. 1-18
1.3.2.3 Sealing openings ................................................................................ 1-18
1.3.2.4 Do not let any dirt or dust get in during refilling operations ................. 1-19
1.3.2.5 Change hydraulic oil when the temperature is high ............................ 1-19
Shop Manual - April 2014 1-1
Introduction SY365(B)H-9 Crawler Hydraulic Excavator

1.3.2.6 Flushing operations............................................................................. 1-19

1.3.2.7 Cleaning operations ............................................................................ 1-20
1.4 Hose Connector ..................................................................................................... 1-20
1.4.1 Type of hose connector................................................................................ 1-21
1.4.2 Hose connector tightening torque table ....................................................... 1-21
1.4.3 Connection of O-rings .................................................................................. 1-22
1.5 Table of Standard Tightening Torques .................................................................. 1-23
1.6 Type of Bolts .......................................................................................................... 1-24
1.7 Tightening Sequence ............................................................................................. 1-24
1.8 Maintenance of Half Flanges ................................................................................. 1-25
1.8.1 Table of tightening torques for half flange bolts ........................................... 1-25

.
De al
1.8.2 Temperature ................................................................................................. 1-31

pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

1-2 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

1 INTRODUCTION
1.1 How to Read the Manual
● Some attachments and optional parts in
this shop manual may not be delivered to
certain areas. If one of them is required,
consult Sany distributors.
● Materials and specifications are subject to
change without notice.

1.1.1 Shop manual organization

This shop manual contains the necessary

.
De al
technical information for services performed

pt
in a workshop. For ease of understanding, the
manual is divided into the following sections.
g n
Introduction
o
This section provides an overview of what is
in ti

covered in the rest of this manual and how to

use this manual,. 营
销
公
司
et a

Shop Safety
n

This section covers basic shop safety infor-

rk er

mation relating to this equipment. It also de-

scribes what the hazard alerts mean that are
used throughout the manual.
Ma t

Specifications
In

Technical specification of work equipment and

optional parts are given in this section.

Structure and functions

This section explains the structure and func-
tion of each component. It helps the reader
to get a better understanding of the machine
structure, and also serves as a reference for
troubleshooting.

Shop Manual - April 2014 1-3

Introduction SY365(B)H-9 Crawler Hydraulic Excavator

Standard Values
This section explains the standard values for
a new machine and judgement criteria for test-
ing, adjusting, and troubleshooting. This stan-
dard value table is used to check the standard
values in testing and adjusting and to judge
parts in troubleshooting.

Testing and adjusting

This section details the inspection before and
after repair work as well as the adjustment
during inspection and repair work. Trouble-
shooting table that involves “Fault”and

.
De al
“Cause”are also included in this section.

pt
Troubleshooting
g n
This section explains the way to detect faulty
o
parts and the method to repair them. This sec-
tion is divided into the following parts: Electri-
in ti

cal system, Engine, Hydraulic and mechanical

system and Monitoring system. 营
销
公
司
et a

Disassembly and assembly

n

This section explains the procedures as well

rk er

as precautions for removing, installing, disas-

sembling and assembling of each component.
Engine
Ma t

This section provides information the cooling

In

system, lubricating system, electrical system

and alternator in addition to disassembly and
reassembly of the engine.

System Schematics
This section provides hydraulic circuit dia-
grams and electrical circuit diagrams.

1.1.2 Revision and distribution

Any complements, revisions, or other change
of notices will be sent to Sany distributors. Get
the most up-to-date information before you
start any work.

1-4 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

1.1.3 Symbols
Important safety and quality portions are marked with the following symbols so that the shop
manual will be used practically.

Symbol Item Remarks

Special safety precautions are necessary when performing

Safety
work.

Special technical precautions or other precautions for pre-

★ Caution
serving standards are necessary when performing work.
Weight of parts of component or parts. Caution necessary

.
Weight when selecting hoisting wire, or when working posture is

De al
important, etc.

pt
Tightening Places that require special attention for tightening torque
torque during assembly.
g no
Coat Places to be coated with adhesives, etc. during assembly.
in ti

Oil, Coolant Places where oil, etc. must be added, and capacity.
司
公
销
营
et a

Places where oil, etc. must be drained, and quantity to be

Drain
drained.
n
rk er

1.1.4 Units
In this shop manual, the units are indicated with International System of units (SI). For reference,
Ma t

conventionally used Gravitational System of units is indicated in parentheses { }.

In

Shop Manual - April 2014 1-5

Introduction SY365(B)H-9 Crawler Hydraulic Excavator

1.2 Technical Terms

The maintenance standard values necessary
for judgment of products and parts are de-
scribed by the following terms.

1.2.1 Standard size and tolerance

● To be accurate, the finishing size of parts
is a little different from one to another.
● To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.

.
● The above size set temporarily is called

De al
the "standard size" and the range of differ-

pt
ence from the standard size is called the
"tolerance".
g n
● The tolerance with the symbols of + or – is
o
indicated on the right side of the standard
in ti

size.
司
公
销
营

Example
et a
n

Standard size Tolerance

–0.022
rk er

120
–0.126
Ma t

Std.size F 60
★ The tolerance may be indicated in the text
In

Tolerance of hole
and a table as [standard size (upper limit (upper):+0.046
of tolerance/lower limit of tolerance)]. Ex- Std.clearance (max.):0.122

ample) 120 (–0.022/–0.126) Std.clearance (min.):0.030

Tolerance of shaft
● Usually, the size of a hole and the size (lower):-0.076
of the shaft to be fitted to that hole are Tolerance of shaft
(upper):-0.030
indicated by the same standard size
and different tolerances of the hole and
shaft. The tightness of fit is decided by
the tolerance.
● Indication of size of rotating shaft and
ZX215-1000003
hole and relationship drawing of them.
Fig. 1-1

1-6 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

Example

Tolerance
Standard size
Shaft Hole
-0.030 +0.046
φ60
-0.076 0

1.2.2 Standard clearance and value

● The clearance made when new parts are

assembled is called the "standard clear-
ance", which is indicated by the range from
the minimum clearance to the maximum

.
De al
clearance.

pt
● When some parts are repaired, the clear-
g n
ance is generally adjusted to the standard
clearance.
o
● A value of performance and function of
in ti

new products or equivalent is called the

"standard value", which is indicated by a 营
销
公
司

range or a target value.

et a
n

● When some parts are repaired, the value

of performance/function is set to the stan-
rk er

dard value.
Ma t

1.2.3 Standard interference

In

● When the size of a hole is smaller than the

size of a shaft because of the standard
size and tolerance, the difference between
these sizes is called the "interference".

● The range (A – B) from the difference (A)

between the minimum size of the shaft and
the maximum size of the shaft to the differ-
ence (B) between the maximum size of the
shaft and the minimum size of the hole is
the "standard interference".

● After repairing or replacing some parts,

measure the size of their hole and shaft
and check that the interference is in the
standard range.

Shop Manual - April 2014 1-7

Introduction SY365(B)H-9 Crawler Hydraulic Excavator

1.2.4 Repair limit and allowable value

● The size of a part changes due to wear

and deformation while it is used. The limit
of changed size is called the "repair limit".

● If a part is worn to the repair limit must be

replaced or repaired.

● The performance and function of a product

lowers while it is used. A value below which
the product can be used without causing a
problem is called the "allowable value".

.
● If a product is worn to the allowable value,

De al
it must be checked or repaired. Since the

pt
permissible value is estimated from vari-
ous tests or experiences in most cases,
g n
however, it must be judged after consider-
o
ing the operating condition and customer's
requirement.
in ti

1.2.5 Clearance limit

司
公
销
营
et a

● Parts can be used until the clearance be-

n

tween them is increased to a certain limit.

The limit at which those parts cannot be
rk er

used is called the "clearance limit".

● If the clearance between the parts exceeds

Ma t

the clearance limit, they must be replaced

In

or repaired.

1.2.6 Interference limit

● The allowable maximum interference be-

tween the hole of a part and the shaft of
another part to be assembled is called the
"interference limit".

● The interference limit shows the repair limit

of the part of smaller tolerance.

● If the interference between the parts ex-

ceeds the interference limit, they must be
replaced or repaired.

1-8 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

1.3 Handling Electrical and Hy-

draulic Components
To maintain the performance of the machine
over a long period, and to prevent failures or
other troubles before they occur, correct "oper-
ation", "maintenance and inspection", "trouble-
shooting", and "repairs" must be carried out.
This section deals particularly with correct re-
pair procedures for mechatronics and is aimed
at improving the quality of repairs. For this
purpose, it gives sections on "Handling electric
components" and "Handling hydraulic equip-

.
ment" (particularly gear oil and hydraulic oil).

De al
pt
1.3.1 Points to remember when han-
g n
dling electric components
o
in ti

1.3.1.1 Handling wiring harnesses and

connectors 营
销
公
司

Wiring harnesses consist of wiring con-

et a

necting one component to another compo-

n

nent, connectors used for connecting and

disconnecting one wire from another wire,
rk er

and protectors or tubes used for protecting

the wiring.
Ma t

Compared with other electrical compo-

nents fitted in boxes or cases, wiring har-
In

nesses are more likely to be affected by

the direct effects of rain, water, heat, or
vibration. Furthermore, during inspection ZX215-1000004
and repair operations, they are frequently Fig. 1-2
removed and installed again, so they are
likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.

Shop Manual - April 2014 1-9

Introduction SY365(B)H-9 Crawler Hydraulic Excavator

1.3.1.2 Main failures occurring in wiring

harness
1. Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely Improper insertion
to occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors
is deformed or the position is not correctly
aligned, or because there is corrosion or
oxidation of the contact surfaces.

.
ZX215-1000005

De al
Fig. 1-3

pt
g n
2. Defective crimping or soldering of connec-
tors
o
The pins of the male and female connec- Crimped portion
in ti

tors are in contact at the crimped terminal

or soldered portion, but if there is exces- 营
销
公
司

sive force brought to bear on the wiring,

et a

the plating at the joint will peel and cause

improper connection or breakage.
n
rk er

ZX215-1000006

Fig. 1-4
Ma t
In

3. Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.

ZX215-1000007

Fig. 1-5

1-10 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

4. High-pressure water entering connector

The connector is designed to make it dif-
ficult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
splash water over the connector. The con-
nector is designed to prevent water from
entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the con- ZX215-1000008
nector, the pins will be short-circuited by

.
Fig. 1-6

De al
the water, so if any water gets in, immedi-

pt
ately dry the connector or take other ap-
propriate action before passing electricity
g n
through it.
5. Oil or dirt stuck to connector
o
If oil or grease are stuck to the connec-
in ti

tor and an oil film is formed on the mating

surface between the male and female pins, 营
销
公
司

the oil will not let the electricity pass, so

et a

there will be defective contact. If there is

n

oil or grease stuck to the connector, wipe

it off with a dry cloth or blow it dry with
rk er

compressed air and spray it with a contact

restorer.
Ma t

★ When wiping the mating portion of the

connector, be careful not to use exces- ZX215-1000009
In

sive force or deform the pins. Fig. 1-7

★ If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and wa-
ter from the compressed air completely
before cleaning with compressed air.

Shop Manual - April 2014 1-11

Introduction SY365(B)H-9 Crawler Hydraulic Excavator

1.3.1.3 Removing, installing, and drying

connectors and wiring harnesses
1. Disconnecting connectors
A. Hold the connectors when disconnect-
ing.
Press lightly
When disconnecting the connectors, when removing
hold the connectors. For connectors Lock stopper
held by a screw, loosen the screw fully,
then hold the male and female connec-
tors in each hand and pull apart. For
connectors which have a lock stop-
per, press down the stopper with your

.
ZX215-1000010
thumb and pull the connectors apart.

De al
Fig. 1-8

pt
★ Never pull with one hand.
B. When removing from clips
g n
● Both of the connector and clip have
o
stoppers, which are engaged with each Both stoppers
in ti

other when the connector is installed.

司
公
销
营
et a
n
rk er

ZX215-1000011

Fig. 1-9
Ma t
In

● When removing a connector from a clip,

pull the connector in a parallel direction
to the clip for removing stoppers.
★ If the connector is twisted up and
down or to the left or right, the hous-
ing may break.

ZX215-1000012

Fig. 1-10

1-12 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

C. Action to take after removing connec-

tors
After removing any connector, cover
it with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
★ If the machine is left disassembled
for a long time, it is particularly easy
for improper contact to occur, so al-
ways cover the connector. ZX215-1000013

Fig. 1-11

.
De al
2. Connecting connectors

pt
A. Check the connector visually
g n
Check that there is no oil, dirt, or water
Clicks into position
o
stuck to the connector pins (mating por-
tion).
in ti

Check that there is no deformation, de-

fective contact, corrosion, or damage to 营
销
公
司

the connector pins.

et a

Check that there is no damage or

n

ZX215-1000022
breakage to the outside of the connec-
rk er

tor. Fig. 1-12

★ If there is any oil, water, or dirt stuck

to the connector, wipe it off with a
Ma t

dry cloth. If any water has got inside

In

the connector, warm the inside of

the wiring with a dryer, but be care-
ful not to make it too hot as this will
cause short circuits.
★ If there is any damage or breakage,
replace the connector.
B. Fix the connector securely.
Align the position of the connector cor-

Shop Manual - April 2014 1-13

Introduction SY365(B)H-9 Crawler Hydraulic Excavator

rectly, and then insert it securely. For

connectors with lock stopper, push in
the connector until the stopper clicks
into position.
C. Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct
any protrusion of the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its ZX215-1000014
correct position.
Fig. 1-13
★ If the connector cannot be corrected

.
easily, remove the clamp and adjust

De al
the position.

pt
● If the connector clamp has been
g n
removed, be sure to return it to its
original position. Check also that
o
there are no loose clamps.
in ti

3. Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty 营
销
公
司

wire connectors have 2 latches respective-

et a

ly, push them in until they click 2 times. ZX215-1000015

n

● Male connector: 1 Fig. 1-14

rk er

● Female connector: 2
● Normal locking state (Horizontal): a, b,
Ma t

d 2 a 1 c
In

● Incomplete locking state (Diagonal): c

d
b

ZX215-1000016

Fig. 1-15

1-14 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

4. Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do not
use high-pressure water or steam directly
on the wiring harness. If water gets directly
on the connector, do as follows.
A. Disconnect the connector and wipe off
the water with a dry cloth. ZX215-1000009

★ If the connector is blown dry with Fig. 1-16

compressed air, there is the risk that

.
oil in the air may cause defective

De al
contact, so remove all oil and wa-

pt
ter from the compressed air before
blowing with air.
g n
B. Dry the connector with a dryer.
o
If water gets inside the connector, use
in ti

a dryer to dry the connector.

★ Hot air from the dryer can be used, 营
销
公
司

but regulate the time that the hot air

et a

is used in order not to make the con-

n

ZX215-1000017
nector or related parts too hot, as
this will cause deformation or dam- Fig. 1-17
rk er

age to the connector.

C. Carry out a continuity test on the con-
Ma t

nector.
In

After drying, leave the wiring harness

disconnected and carry out a continuity
test to check for any short circuits be-
tween pins caused by water.
★ After completely drying the connec- T adapter
tor, blow it with contact restorer and
reassemble.

ZX215-1000018

Fig. 1-18

Shop Manual - April 2014 1-15

Introduction SY365(B)H-9 Crawler Hydraulic Excavator

1.3.1.4 Handling the integrated control

monitor
1. The integrated control monitor contains
a microcomputer, an electronic control
circuits, an LCD monitor and GPS position-
ing circuit. They control all of the electronic
circuits on the machine, so be extremely
careful when handling the integrated
control monitor.
2. Do not place objects on the integrated
control monitor. ZX135-1000001

3. Cover the control connectors with tape or Fig. 1-19

.
a vinyl bag. Never touch the connector

De al
contacts with your hand.

pt
4. Do not leave it where it may be exposed to
g n
rain.
Tool
o
5. Do not place the integrated control monitor Box

on oil, water, or soil, or in any hot place,

in ti

even for a short time.

6. Precautions for arc welding
司
公
销
营
et a

When welding on the controller, disconnect

n

all wiring harness connectors connected

to the controller. Fit an arc welding ground ZX215-1000020
rk er

close to the welding point.

Fig. 1-20
Ma t
In

ZX215-1000021

Fig. 1-21

1-16 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

1.3.1.5 Electric circuits troubleshooting

precautions
1. Always turn the power OFF before discon-
necting or connecting connectors.
2. Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
★ Disconnect and connect the related
connectors several times to check.
3. Always connect any disconnected connec-
tors before going on to the next step.

.
★ If the power is turned ON with the con-

De al
nectors still disconnected, unnecessary

pt
abnormality displays will be generated.
g n
4. When carrying out troubleshooting of
circuits (measuring the voltage, resistance,
o
continuity, or current), move the related
in ti

wiring and connectors several times and

check that there is no change in the read-
ing of the tester.
司
公
销
营
et a

★ If there is any change, there is probably

n

defective contact in that circuit.

rk er
Ma t
In

Shop Manual - April 2014 1-17

Introduction SY365(B)H-9 Crawler Hydraulic Excavator

1.3.2 Points to remember when handling hydraulic equipment

With the increase in pressure and precision

of hydraulic equipment, the most common
cause of failure is dirt (foreign material) in the
hydraulic circuit. When adding hydraulic oil, or
when disassembling or assembling hydraulic
equipment, it is necessary to be particularly
careful.

1.3.2.1 Be careful of the operating environ-

ment

.
Avoid adding hydraulic oil, replacing filters,

De al
or repairing the machine in rain or high

pt
winds, or places where there is a lot of
dust.
g no
1.3.2.2 Disassembly and maintenance work
in the field
in ti

If disassembly or maintenance work is 司

ZX215-1000023

carried out on hydraulic equipment in the

公
销
营

Fig. 1-22
et a

field, there is danger of dust entering the

equipment. It is also difficult to check the
n

performance after repairs, so it is desir-

rk er

able to use unit exchange. Disassembly

and maintenance of hydraulic equipment
should be carried out in a specially pre-
Ma t

pared dust-proof workshop, and the perfor-

mance should be checked with special test
In

equipment.

1.3.2.3 Sealing openings

After any piping or equipment is removed,
the openings should be sealed with caps,
tapes, or vinyl bags to prevent any dirt or
dust from entering. If the opening is left
open or is blocked with a rag, there is
danger of dirt entering or of the surround-
ing area being made dirty by leaking oil so
never do this. Do not simply drain oil out
onto the ground, but collect it and ask the
customer to dispose of it, or take it back
with you for disposal. ZX215-1000024

Fig. 1-23

1-18 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

1.3.2.4 Do not let any dirt or dust get in

during refilling operations
Be careful not to let any dirt or dust get
in when refilling with hydraulic oil. Always
keep the oil filler and the area around it
clean, and also use clean pumps and oil
containers. If an oil cleaning device is
used, it is possible to filter out the dirt that
has collected during storage, so this is an
even more effective method.
ZX215-1000025

Fig. 1-24

.
1.3.2.5 Change hydraulic oil when the

De al
temperature is high

pt
When hydraulic oil or other oil is warm, it
g n
flows easily. In addition, the sludge can
also be drained out easily from the circuit
o
together with the oil, so it is best to change
in ti
the oil when it is still warm. When changing
the oil, as much as possible of the old hy-
draulic oil must be drained out. (Drain the
司
公
销
营
et a

oil from the hydraulic tank; also drain the

oil from the filter and from the drain plug in
n

the circuit.) If any old oil is left, the contam-

inants and sludge in it will mix with the new
rk er

oil and will shorten the life of the hydraulic

oil.
Ma t

1.3.2.6 Flushing operations

In

After disassembling and assembling the

equipment, or changing the oil, use flush-
ing oil to remove the contaminants, sludge,
and old oil from the hydraulic circuit. Nor- Flushing oil
mally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and
secondary flushing is carried out with the
specified hydraulic oil.

ZX215-1000026

Fig. 1-25

Shop Manual - April 2014 1-19

Introduction SY365(B)H-9 Crawler Hydraulic Excavator

1.3.2.7 Cleaning operations

After repairing the hydraulic equipment
(pump, control valve, etc.) or when run-
ning the machine, carry out oil cleaning to
remove the sludge or contaminants in the
hydraulic oil circuit. The oil cleaning equip-
ment is used to remove the ultra fine (about
3 μ) particles that the filter built in the hy-
draulic equipment cannot remove, so it is
an extremely effective device.
ZX215-1000027

Fig. 1-26

.
1.4 Hose Connector

De al
pt
Hose connector is used to connect hoses with
a small diameter. The metal sealing surface (4)
g n
of the joint (1) must be in close contact with 1 4 3 5 2
the metal sealing surface (5) of the hose (2) to
o
seal pressurized oil.
in ti

NOTICE 营
销
公
司
et a

● Do not over-tighten the nut (3). Exces- Connector

n

sive force applied on the metal sealing

ZX215-1000028
surface (4) and (5) may cause the joint
rk er

(1) to break. Be sure to tighten nut (3) Fig. 1-27

according to technical specifications.
Ma t

● Scratches or other damages on seal-

ing surface (4) and (5) may cause leaks
In

at the joint. Be extremely careful not

to damage the sealing surfaces during
connecting and disconnecting work.

1-20 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

1.4.1 Type of hose connector

24°

24°

Male Female

ZX215-1000029

Fig. 1-28

.
1.4.2 Hose connector tightening torque table

De al
pt
Wrench size mm Wrench size mm Tightening torque
Type
g no
Connecting nut Hose joint N·m(kgf·m,Ibf·ft)
19 19 59(6,44)
in ti
22 22 98(10,72)
27 27 118(12,87)
司
公
销
营

36 36 235(24,173)
et a

24° Male
41 41 295(30,218)
n

50 50 490(50,361)
rk er

60 60 670(68,494)
70 70 980(100,723)
19 17 44(4.5,32)
Ma t

22 19 59(6,44)
In

27 22 118(12,87)
24° Female
36 30, 32 235(24,173)
41 36 295(30,218)
50 46 490(50,361)

NOTICE

● The torque values listed in the table are

intended for general application.
● Do not use torque values listed in this
table when different torque values are
specified for a special purpose.

Shop Manual - April 2014 1-21

Introduction SY365(B)H-9 Crawler Hydraulic Excavator

1.4.3 Connection of O-rings

Place O-ring (6) in contact with the contact

surface of the joint (7) to seal the pressurized
7 6 9
oil.

NOTICE

● Replace o-rings (6) with new ones

Hose connector
when re-connecting hoses. 8 10

● Before tightening nut (9), make sure the

o-ring (6) has been placed into the o- ZX215-1000030

.
ring seat (8).Displacement of the o-ring Fig. 1-29

De al
may have it damaged and cause leaks.

pt
● Be careful not to damage the o-ring
g n
seat (8) or the sealing surface (10).
Damaged o-ring (6) may cause oil leak-
o
age.
in ti

● If oil leakage due to loosened nut (9) is

detected, do not try to stop the leakage 营
销
公
司

by tightening nut (9). Instead, replace

et a

o-ring (6) with a new one and make

n

sure it is well positioned, and tighten

nut (9).
rk er
Ma t
In

Wrench size mm Wrench size mm Tightening torque

Connecting nut Hose joint N·m (kgf·m,Ibf·ft)
19 17 44(4.5,32)
22 19 59(6,44)
27 22 118(12,87)
36 30, 32 235(24,173)
41 36 295(30,218)
50 46 490(50,361)

1-22 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

1.5 Table of Standard Tightening Torques

Table of tightening torques for bolts and nuts

★ Unless specified otherwise, tighten metric nuts and bolts to the torque below. (When using
torque wrench)

Bolt di- Bolt Wrench Hex wrench Hexagonal bolt Hexagonal socket head bolt
ameter grade size size N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M6 10.9 10 4 13.2 1.37 9.74 13.2 1.37 9.74
M8 10.9 13 6 31 3.16 22.87 31 3.16 22.87
M10 10.9 17 8 66 6.73 48.7 66 6.73 48.7

.
De al
M12 10.9 19 10 113 11.53 83.39 113 11.53 83.39

pt
M14 10.9 22 12 177 18.06 130.6 177 18.06 130.6
M16 10.9 24 14 279 28.47 205.9 279 28.47 205.9
M18
g n
10.9
o
27 14 382 38.98 281.9 382 38.98 281.9
M20 10.9 30 17 549 56.02 405.16 549 56.02 405.16
in ti

M27 10.9 41 19 1320 134.7 974.16 1320 134.7 974.16

M10 12.9 17 6 78销
公
司
7.96 57.76 78 7.96 57.76
营

M12 12.9 19 8 137 13.98 101.1 137 13.98 101.1

et a

M16 12.9 24 14 339 34.6 250.18 339 34.6 250.18

n

M20 12.9 30 17 664 67.75 490 664 67.75 490

rk er

NOTICE
Ma t

The following items apply to fine thread and coarse thread.

In

● Apply grease (zinc white B dissolved in spindle oil) onto the nuts and bolts to reduce
the friction coefficient. Thrust bolts do not require greasing.
● Torque tolerance is ±10%.
● Always use bolts of correct length. The tip of bolts with excessive length may contact
the bottom of the bolt hole, resulting in under-tightening. Bolts with inadequate length
may result in insufficient fastening.
● The torque values listed in the table are intended for general application. If different
torque values are specified for a special purpose, the torque values in this table are
not applicable any more.
● Make sure the threads are free of dirt or rusts before installation of nuts and bolts.

Shop Manual - April 2014 1-23

Introduction SY365(B)H-9 Crawler Hydraulic Excavator

1.6 Type of Bolts

Tighten nuts and bolts properly to specified

Hex bolt Socket head hex bolt
torque values. The type and grade of bolts are
illustrated on the right.
8.8 10.9 12.9
Use correct bolts and tighten them properly
when assembling machines or components.

ZX215-1000031

Fig. 1-30

.
1.7 Tightening Sequence

De al
pt
When two or more bolts are being tightened, Cross tightening Diagonal tightening
follow the tightening sequence shown on the
g n 1 1
right to ensure even tightening. 6 3
o
3 4
4 5
in ti
CAUTION 2 2

Central and diagonal tightening

● Always use suitable tools for specific 营
销
公
司

work. Use of improper tools and meth-

et a

12 9 4 1 6 7 14
ods may cause a hazardous situation.
n

● Use tools of correct sizes when loosen- 13 8 5 2 3 10 11

rk er

ing or tightening the nuts or bolts. Oth-

ZX215-1000032
erwise, the tools may slide and cause
personal injury. Fig. 1-31
Ma t
In

ZX215-1000033

Fig. 1-32

1-24 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

1.8 Maintenance of Half Flanges

1. Clean the sealing surface of the flange and

check it carefully. Scratches and coarse-
ness cause leaks or abrasion of seals.
Uneven surface may squeeze the seal out.
If these faults are not corrected properly,
parts may have to be replaced.

2. Always use specified O-rings. Check that ZX215-1000034

the O-rings are not damaged. Do not file
Fig. 1-33
the surface of the O-ring. Apply grease
onto the O-ring to locate it.

.
De al
pt
3. Tighten the half flanges carefully. Locate
g n
the opening at the center so that it is
perpendicular to the oil opening. Tighten Improper
o
the bolt manually to maintain the location
in ti
of the components.

司
公
销
营
et a
n
rk er

ZX215-1000035

Fig. 1-34
Ma t

1.8.1 Table of tightening torques for half flange bolts

In

★ Unless specified otherwise, tighten the half flange bolts to the torques below.

Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
10 14 59~74 6.0~7.5
12 17 98~123 10.0~12.5
16 22 235~285 23.5~29.5

Shop Manual - April 2014 1-25

Introduction SY365(B)H-9 Crawler Hydraulic Excavator

Conversion Table
Method of using conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details
of the method of using the conversion table, see the example given below.
Example:
Method of using the conversion table to convert from millimeters to inches
Convert 55 mm into inches
Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a
horizontal line from (A).
Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line
down from (B).

.
De al
Take the point where the two lines cross as (C). This point (C) gives the value when converting

pt
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
g n
Convert 550 mm into inches
o
The number 550 does not appear in the table, so divide it by 10 (move the decimal point one
place to the left) to convert it to 55 mm.
in ti

Carry out the same procedure as above to convert 55 mm to 2.165 inches.

司
公
销
营

The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
et a

point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
n
rk er
Ma t
In

1-26 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

Millimeters to Inches

(B) 1mm=0.03937in

0 1 2 3 4 5 6 7 8 9
0 0.000 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.535
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

.
(A) 60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

De al
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.031 3.071 3.110

pt
80 3.150
g n 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
o
in ti

Millimeters to Inches
司
公
销
营

1mm=0.03937in
et a

0 1 2 3 4 5 6 7 8 9
n

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

rk er

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
Ma t

30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.535
In

40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.031 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Shop Manual - April 2014 1-27

Introduction SY365(B)H-9 Crawler Hydraulic Excavator

Kilogram to Pound
1kg=2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 90.39 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 112.43 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 134.48 55.12 57.32 59.52 61.73 63.93
30 66.14 68.34 70.55 72.75 156.53 77.16 79.37 81.57 83.77 85.98
40 88.18 90.39 92.59 94.80 178.57 99.21 101.41 103.62 105.82 108.03

50 110.23 112.43 114.64 116.84 200.62 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 222.66 143.30 145.50 147.71 149.91 152.12

.
De al
70 154.32 156.53 158.73 160.94 244.71 165.35 167.55 169.75 171.96 174.16

pt
80 176.37 178.57 180.78 182.98 266.76 187.39 189.60 191.80 194.00 196.21
90 198.41 200.62 202.82 205.03 288.80 209.44 211.64 213.85 216.05 218.26
g no
in ti

Liters to U.S. Gallons 营

销
公
司

1 L=0.2642 U.S.Gal
et a

0 1 2 3 4 5 6 7 8 9
n

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.114 2.378

rk er

10 2.642 2.906 3.170 3.435 3.699 3.963 4.227 4.491 4.756 5.020
20 5.284 5.548 5.812 6.077 6.341 6.605 6.869 7.133 7.398 7.662
Ma t

30 7.926 8.190 8.454 8.719 8.983 9.247 9.511 9.775 10.040 10.304
In

40 10.568 10.832 11.096 11.361 11.625 11.889 12.153 12.417 12.682 12.946

50 13.210 13.474 13.738 14.003 14.267 14.531 14.795 15.059 15.324 15.588
60 15.852 16.116 16.380 16.645 16.909 17.173 17.437 17.701 17.966 18.230
70 18.494 18.758 19.022 19.287 19.551 19.815 20.079 20.343 20.608 20.872
80 21.136 21.400 21.664 21.929 22.193 22.457 22.721 22.985 23.250 23.514
90 23.778 24.042 24.306 24.571 24.835 25.099 25.363 25.627 25.892 26.156

1-28 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

Liters to U.K. Gallons

1 L=0.21997 U.K.Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.739 3.959 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.779

50 10.999 11.218 11.438 11.658 11.878 12.098 12.318 12.538 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178

.
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378

De al
pt
80 17.598 17.818 18.038 18.258 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017
g n 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
o
kgm to ft.lb
1 kgm=7.233 ft.lb
in ti

0 1 2 3 4 5 6 7 8 9
司
公
销
营

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

et a

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
n

30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
rk er

40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.3 390.6 397.8 405.0 412.3 419.5 426.7
Ma t

60 434.0 441.2 448.4 455.7 462.9 470.1 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
In

80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.6 1048.8 1056.0 1063.3 1070.5 1077.7

150 1085.0 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1229.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.2 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

Shop Manual - April 2014 1-29

Introduction SY365(B)H-9 Crawler Hydraulic Excavator

kg/cm2 to lb/in2
1 kg/cm2=14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.3 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.0 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4

.
De al
70 996 1010 1024 1038 1053 1067 1081 1095 1109 1124

pt
80 1138 1152
g n 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
o
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
in ti

110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 营
销
公
司
1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
et a

140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
n
rk er

150 2133 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2390 2404
170 2418 2432 2446 2461 2475 2489 2503 2518 2532 2546
Ma t

180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
In

190 2702 2717 2731 2745 2759 2774 2788 2802 2816 2830

200 2845 2859 2873 2887 2902 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3342 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

1-30 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction

1.8.2 Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading
into a Centigrade temperature reading or vice versa is to enter the accompanying table in the
center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or
Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to
be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column to
be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

.
De al
℃ ℉ ℃ ℉ ℃ ℉ ℃ ℉

pt
-40.0 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0
g n -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
o
-28.9 -20
-2 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
in ti
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 营
销
公
司

11.7 53 127.4 31.1 88 190.4

-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
et a

-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

n

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
rk er

-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4

-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
Ma t

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
In

-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4

-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0.0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.8 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
Shop Manual - April 2014 1-31
Introduction SY365(B)H-9 Crawler Hydraulic Excavator

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1-32 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

Shop Safety

.
2 Shop Safety

De al
pt
2.1 Hazard Alert Information .......................................................................................... 2-3
2.2 General Shop Safety ............................................................................................... 2-5
g n
2.2.1 Rules and shop behavior ............................................................................... 2-6
o
2.2.2 Housekeeping ................................................................................................ 2-6
in ti

2.2.3 Shop Liquids Storage..................................................................................... 2-7

2.2.4 Cleaning the Parts ......................................................................................... 2-7
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2.2.5 Cleaning the Machine .................................................................................... 2-8

et a

2.2.6 Appropriate Working Apparel ......................................................................... 2-8

n

2.2.7 Personal Protective Equipment...................................................................... 2-8

rk er

2.2.8 Using the Correct Tools.................................................................................. 2-9

2.2.9 Fire Extinguisher and Emergency Exits ......................................................... 2-9
Ma t

2.2.10 Electrical Dangers ...................................................................................... 2-10

In

2.2.11 Hoisting a Load .......................................................................................... 2-10

2.3 Before Repair..........................................................................................................2-11
2.3.1 Safe Work Preparations ................................................................................2-11
2.3.2 Preparing yourself ........................................................................................ 2-12
2.3.3 Lockout/Tagout............................................................................................. 2-13
2.3.4 Two people when engine running ................................................................ 2-15
2.3.5 Safety Partners ............................................................................................ 2-15
2.4 Repair Precautions ................................................................................................ 2-16
2.4.1 Running the Machine ................................................................................... 2-16
2.4.2 Mounting and Dismounting .......................................................................... 2-17
2.4.3 Removing Attachments ................................................................................ 2-18
2.4.4 Jacking Up the Machine............................................................................... 2-18
2.4.5 Adding Fluids to a System ........................................................................... 2-18
Shop Manual - April 2014 2-1
Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

2.4.6 Aligning Parts or Components ..................................................................... 2-19

2.4.7 Driving Pins .................................................................................................. 2-19
2.4.8 When compressed air is used...................................................................... 2-19
2.4.9 Welding operation ........................................................................................ 2-20
2.4.10 Track Recoil Springs .................................................................................. 2-20
2.4.11 High-Pressure Fluid Lines .......................................................................... 2-21
2.4.12 Air-conditioning system maintenance ........................................................ 2-22
2.4.13 High voltage precautions ........................................................................... 2-22
2.4.14 Disconnecting the System Power .............................................................. 2-23
2.4.15 Accumulator ............................................................................................... 2-23
2.4.17 Battery Hazards ......................................................................................... 2-24

.
De al
2.4.18 Jump-Start Safety ...................................................................................... 2-25

pt
2.4.19 Avoiding fire and explosion ........................................................................ 2-26
g n
2.4.20 Chemical hazard ........................................................................................ 2-27
2.4.21 Material Safety Data Sheets (MSDS) ........................................................ 2-27
o
2.4.22 Proper disposal of wastes .......................................................................... 2-28
in ti

2.5 Other Precautions .................................................................................................. 2-29

2.5.1 Sling work and giving signals ....................................................................... 2-29
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2.5.2 Using mobile crane ...................................................................................... 2-31

n

2.5.3 Using overhead hoist crane ......................................................................... 2-31

2.5.4 Selecting wire ropes..................................................................................... 2-33
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Ma t
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2-2 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2 SHOP SAFETY
2.1 Hazard Alert Information
Most accidents are usually caused by the failure to follow fundamental repair procedures and
safety rules for the system under repair. To avoid accidents it is important to read and understand
all information outlined in this manual before performing repairs on the machine system.
The following (ANSI/ISO) signal words are used to inform you that there is a potentially hazard-
ous situation that may lead to damage, personal injury or even death. In this manual, on the ma-
chine, part or component decals and different signal words are used to express the potential level
of a hazard.

.
De al
DANGER WARNING

pt
● Indicates an imminent hazard which ● Indicates a potentially hazardous situa-
WILL result in serious injury or death if tion which COULD result in serious in-
g n
message is ignored. jury or death if message is ignored.
o
in ti

CAUTION 营
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司

NOTICE
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● Indicates a potentially hazardous situ- ● Indicates THE MACHINE MAY BE DAM-

n

ation which COULD RESULT IN MINOR AGED if improperly operated or main-

OR MAJOR INJURY if message is ig- tained.
rk er

nored.
Ma t

This is to alert the user of a hazard. It is This symbol is used in a graphic to alert
In

usually used in a graphic. the user to not do something.

Besides the above signals words, the following words are also used to remind you of rules to be
followed or to provide you with very useful information.
Note: It is followed by measures that must be taken to prevent reduction of machine service life.
Remark: It is followed by very useful information.

Shop Manual - April 2014 2-3

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

WARNING

● Improper repair procedures on this machine can be hazardous and could result in serious in-
jury or even death.
● All personnel involved with the repair of this machine must read this manual thoroughly before
performing any procedures on this equipment.
● Some actions involved in the operation or repair of this machine could cause a serious acci-
dent if they are not performed in the manner described in this manual.
● All precautions outlined in this manual apply only to intended repair procedures of the ma-
chine or system. If you perform any repairs not specifically prohibited, you must be sure that it
is safe for you and others. In no event should you or others engage in prohibited uses or ac-
tions as described in this manual.

.
De al
● SANY delivers machines that comply with all applicable regulations and standards of

pt
the country to which the machines have been shipped. If this machine has been pur-
chased in another country or purchased from someone in another country, it may lack
g n
certain safety features and specifications that are necessary for use in your country. If
o
there is any question about whether your product complies with the applicable stan-
dards and regulations of your country, contact your SANY representative before per-
in ti

forming repairs on this machine.

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2-4 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2.2 General Shop Safety

It's important to establish good shop safety
rules for everyone who enters or uses the
shop area. Implementing shop safety rules
will keep employees safe and provide the
most productive environment for working or
learning. Post rules where they can clearly be
viewed at all times. If necessary, provide shop
personnel with a written copy of the rules and
discuss any questions or confusion with them.
Always keep in mind, shop safety is NOT
something to be studied at the start of a proj-

.
ect and then forgotten; most accidents are

De al
caused by carelessness, being in a hurry or by

pt
simply disregarding safety rules. Remember
this, if you are DILIGENT and follow instruc-
g n
tions outlined in this shop manual with care,
repair operations can be safe and enjoyable.
o
Safe work practices, should become a force of
in ti

habit.
司
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WARNING
n

● Mistakes in operation are extremely

rk er

hazardous. Read the Safety, Operation

& Maintenance Manual that came with
the machine carefully before operating
Ma t

the machine. Failure to follow this alert

In

could result in serious injury or death.

Shop Manual - April 2014 2-5

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

2.2.1 Rules and shop behavior

● Study all shop rules relating to the proce-
dure carefully and constantly apply them.
When in doubt about any task, get help!
DO NOT take chances.
● Know your job. It is foolish, and often di-
sastrous, to make repairs to a machine
without first receiving proper instructions.
Always use the shop manual when per-
forming any repair tasks. Get additional
help if you are NOT sure what must be
done or how a task should be performed.

.
● The shop is a place to work, not play. It is

De al
NOT a place for “horseplay”. A “joker”

pt
in a repair shop is a “walking hazard” to
everyone. Daydreaming or socializing on
g n
the job also increases your chances of in-
o
jury. Fig. 2-2
in ti

● If you must smoke, smoke only in the area

provided for smoking. Never smoke while
on the shop floor or work area.
司
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2.2.2 Housekeeping
n

● Oils, grease, fuel, antifreeze or any fluid

rk er

spills should be mopped up immediately.

These items pose a serious slip hazard.
Regardless of who was responsible for the
Ma t

spill, it is your job as a shop employee to

In

secure and clean up the spill area.

● Keep the shop clean. Scrap or old parts
should be disposed of properly. Never al-
low them to remain on the bench or shop
floor.
● All equipment and tools must be put back WX235R-1200001
in their proper storage areas after each
Fig. 2-1
use. It's imperative that you do not let a
shop become cluttered and disorganized in
order to prevent accidents.
● Always keep in mind, proper house clean-
ing is vital for a safe and pleasant work en-
vironment.

2-6 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2.2.3 Shop Liquids Storage

● Liquids, cleaning solvents or machine flu-
ids should be properly stored in an area
away from work locations. These storage
areas should be ventilated to an outdoor
location to avoid any vapor accumulation
in a confined shop area. Follow all OSHA
regulations regarding fluid storage.
● Never leave open containers of liquids sit-
ting around. These could spill or catch fire.
Always read the container label for infor-
mation on storage and handling of the liq-

.
WX235R-1200002
uids.

De al
● Never store liquids in containers that are Fig. 2-3

pt
not properly labeled for that liquid. Confu-
sion could result in equipment damage, fire
g n
or an unexpected explosion.
o
● Never smoke or bring open flames around
in ti

liquids, doing so could result in an unex-

pected fire or explosion. 司
公
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● Never handle liquids without using person-

et a

al protective equipment. Treat all liquids

n

with caution.
rk er

2.2.4 Cleaning the Parts

Never use gasoline, diesel fuel or similar flam-
Ma t

mable liquids to clean parts. Always use ap-

In

proved non-flammable solvents to clean parts.

Failure to do so could result in explosion or
fire.

WX235R-1200003

Fig. 2-4

Shop Manual - April 2014 2-7

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

2.2.5 Cleaning the Machine

● Always use high-pressure hot water and
mild, nonflammable grease-cutting soaps
or cleaning agents to clean the machine
parts. Never use flammable or caustic
cleaning agents.
● Never use high-pressure steam cleaners
to clean the machine. Steam cleaners will
damage the paint, hoses or electrical sys-
tem.
● Never pressure-wash or flood the inside of
an operator cab. This will damage sensi- WX235R-1200007

.
tive electrical components.

De al
Fig. 2-5

pt
g n
2.2.6 Appropriate Working Apparel
o
Improper or loose clothing, casual dress cloth-
ing, jewelry, incorrect shoes or long hair can
in ti

result in possible injury.

Make a list of the types of clothing that are not 营
销
公
司

allowed in the shop area. Go over the list with

et a

personnel before they start a job.

n
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Ma t

WX235R-1200005
In

Fig. 2-6

2.2.7 Personal Protective Equipment

If your shop specifies the use of safety equip-
ment, OSHA requires this equipment to be
used when on the shop floor or in the area
where this equipment is required.
Never allow personnel in the shop area with-
out the proper personnel protective equipment
even for a moment.
Always keep personnel protective equipment
in good condition and replace them as re-
quired. CZ335-1102002

Fig. 2-7

2-8 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2.2.8 Using the Correct Tools

● Always use the proper authorized tools for
the job. Using tools that are not authorized,
incorrect for the job, defective or damaged
could cause serious injury.
● Keep all tools in good condition, learn the
correct way to use them.
● Before starting the work, thoroughly check
the tools, machine, forklift, crane, service
car, etc.
● Keep your tools clean, and when the job is ZX215-1000033

complete, take inventory of the tools you

.
Fig. 2-8

De al
were using to be sure no tools were left in

pt
the machine.
● Always put shop tools back in there proper
g n
storage location when finished.
o
● If welding repairs are needed, always have
in ti
a trained, experienced or certified welder
carry out the work.
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2.2.9 Fire Extinguisher and Emergency

n

Exits
rk er

● It is important to know where all emergen-

cy exits and fire extinguishing equipment
are located if a fire should occur in the
Ma t

shop.
In

● Before preparing for work, take time and

walk around the shop to make a mental
note of where all exits and fire equipment
are located. If you are performing repairs
in the field, always have a fire extinguisher
handy and within reach.
● If you do not know how to use a fire extin-
WX235R-1200006
guisher contact someone who can instruct
you in the proper use of this equipment. Fig. 2-9

Shop Manual - April 2014 2-9

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

2.2.10 Electrical Dangers

● When testing electrical circuits, always be
aware of what you will be checking in these
systems. High voltage or high amp circuits
could damage your equipment or cause a
spark, explosion or possible fire.
● Before performing any repairs or testing on
an electrical system be sure of the system
voltage dangers. Always check the circuit
to be sure it is off before performing any
repairs.
● When working around flammable liquids or

.
explosive systems, use only approved anti-

De al
explosion proof work lamps. Non-approved

pt
work lamps can cause an explosion or fire.
g no
Fig. 2-10
in ti

2.2.11 Hoisting a Load 销

公
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营

If you will be lifting parts or components that

et a

weigh more than 35 lbs (16 kg), it is important

n

to follow some basic rules.

rk er

● Always use the appropriate lifting equip-

ment such as hoist, crane, forklift etc. to
handle a loads if possible.
Ma t

● Be sure the lifting equipment is in good

condition and rated for the load you are
In

about to lift.
● If straps are to be used, ensure they are in
good condition and rated for the load to be
lifted with them.
● If you must lift the load by hand, keep your
Fig. 2-11
back straight and parallel with the load,
and lift the load using your leg muscles to
avoid back injuries. Always ask for a lifting
assistant.

2-10 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2.3 Before Repair

2.3.1 Safe Work Preparations
Before starting any repairs, be sure the ma-
chine is sitting on a level stable surface.
Lower all the work equipment to a safe and
stable position on the ground. Turn the engine
OFF and neutralize the work equipment con-
trols by rotating them to the left and right (joy-
stick control) or moving them back and forth
(lever control). This function will relieve system
pressure.

.
De al
Block the tracks (if equipped) or wheels (if

pt
equipped) with chocks to prevent the machine
from moving. g n
If equipped, set the hydraulic lock lever in the
LOCKED position. If equipped, set the parking
o
brake in the PARK position.
in ti

Fig. 2-12
Be sure all personnel and equipment is clear
of your work area and you can be seen by all 营
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公
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working personnel especially if performing re-

et a

pairs in the field.

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Ma t
In

Shop Manual - April 2014 2-11

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

2.3.2 Preparing yourself

Only approved personnel can maintain or
repair the machine. An observer may be as-
signed if necessary.
● Wear protective clothing and shoes neces-
sary for the job.
● Wear rubber apron and rubber gloves
when handling corrosive materials. Wear
heavy gloves when handling wooden ma-
terials, wire ropes or sharp-edged metals. CZ335-1102069

Fig. 2-13
● Wear a face shield when removing spring
or elastic parts, or adding acid to battery.

.
De al
Wear safety hat and goggles when you

pt
weld or cut with a torch.
● Never carry out grinding, flame cutting or
g n
welding without an aspirator and ventilation
o
equipment. If you have to weld on the ma-
chine, refer to related instructions and un-
in ti

derstand the correct operating procedure.

司
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CZ335-1102070

Fig. 2-14
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Ma t
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2-12 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2.3.3 Lockout/Tagout
Due to the size and complexity of this ma-
chine, Lockout and Tagout procedures may
be required by your company to ensure the
safety of yourself and others involved in the
repair process of the machine. While work
is in progress, all power sources must be
disabled, locked and tagged with a warning
label. Lockout/Tagout procedure establishes
the minimum requirements used to isolate all
power sources from potentially hazardous en-
ergy, and to ensure that the machine is“locked
out and tagged out” before anyone performs

.
De al
repairs on the machine.

pt
Sequence of procedures
g n
Only authorized employees performing repairs
o
on the machine shall perform Lockout/Tagout
in accordance with this procedure listed below. DA
NG
in ti

If the employee performing repairs to the ma- ER

chine is issued a lock and key, the employee
营
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公
司

DO
OP NO
et a

shall not share the lock or key with other em-

ER T
ployees until all repair procedures are com- AT
n

plete and the machine is ready to put back into E

rk er

service.
The following steps shall be performed in the
sequence listed when the equipment is to be
Ma t

either locked-out or tagged-out for repair.

In

Locking out of service

1. Notify all employees who may be poten-
tially affected by the repair process on the
machine.
Fig. 2-15
2. Secure the machine in a safe position.
If equipped, set the parking brake or hy-
draulic lock lever in the PARK or LOCKED
position.
3. Identify, remove or disconnect all power

Shop Manual - April 2014 2-13

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

or energy sources and be sure to install

a Lockout/Tagout device on them. If the
machine is equipped with a Maintenance
Alert Tag, attach this tag to the machine
controls. DANGER
4. Be sure all employees involved in the
repairs have installed there lock on the
DO NOT OPERATE
power source before performing any When this is not being used,
repairs. Once an employee has completed keep it in the storage compartment.
there repair procedure, they must remove
there lock and not access the machine in
any manor. Fig. 2-16

.
De al
Returning to service

pt
1. The authorized person who performed the
Lock out/Tagout procedure shall check the
g n
area around the machine to ensure that no
one is exposed to any hazard before start-
o
up.
in ti

2. The authorized person who performed

the Lock out/Tagout shall ensure that 营
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司

all guards have been reinstalled to their

et a

proper place, all tools and equipment have

n

been removed and all locks are removed.

rk er

3. The authorized person who performed the

Lock out/Tagout shall verify that all controls
are in the neutral or “off” position and
Ma t

all personnel are aware of the time the

machine will be back in service.
In

4. Remove the Lockout/Tagout equipment

and any additional alert equipment and re-
energize the machine for return to service.

2-14 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2.3.4 Two people when engine running

In order to prevent injury, do not perform the

service while the engine is running. If the ser-
vice must be performed while the engine is
running, operate only when two people are on
the spot and follow the regulations below:
● Always have one operator sit on the op-
eration seat and be ready to turn off the
engine at any time. All the operators must
keep in touch with each other.
● Set the safety lock control lever to the lock
position.

.
De al
● Do not touch any control lever. If some

pt
control lever must be operated, send signal
to other people and warn them to transfer
g n
to safe place quickly.
o
● Do not drop or insert the tools and other
in ti
objects into the fan or fan belt, or the parts
will be broken or thrown out.
司
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2.3.5 Safety Partners

rk er

No one should be allowed to perform work

operations in any shop alone. It should be a
general shop safety rule for a minimum of two
Ma t

people in the shop area at all times when work

In

procedures are performed. A person alone in

the shop might not be able to get emergency
help in the event of a shop accident.
When working together always maintain clear
contact with each other at all times to avoid
the occurrence of unexpected incidents.
When carrying out any operation with two or
more workers, always agree on the operating Fig. 2-17
procedures and signals before starting.

Shop Manual - April 2014 2-15

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

2.4 Repair Precautions

2.4.1 Running the Machine

Run the machine during repair procedures
ONLY if directed to do so in this shop manual.
If the machine must be run when making re-
pairs, it is important to follow some basic safe-
ty rules.
● Always be aware of rotating components.
● During repair operations while the engine
is running, one worker must remain in the
operator seat of the machine with clear

.
De al
contact between the person performing the CZ335-1102077

pt
repairs on the machine at all times.
Fig. 2-18
● If equipped, all lock levers must be in the
g n
LOCK position or the parking brake must
o
be in the PARK position.
in ti
● The person in the cab must never touch
any controls. If a control lever must be op-
erated, always maintain a clear view to the
司
公
销
营

person doing the repair and signal them

et a

when you are about to move the control le-

n

ver.
rk er

● Be aware of hot surfaces. During running

operations, most surfaces will be hot, and
some surfaces will be extremely hot. If
Ma t

necessary, use personnel protective equip- CC13031805

ment when working around high tempera-
In

Fig. 2-19
ture surfaces.
● Keep in mind that during running opera-
tions, hydraulic systems, cooling systems
and fuel systems will be under extremely
high pressure and at high temperatures.
● Always use caution when working on or
near these systems.

CZ335-1102012

Fig. 2-20

2-16 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2.4.2 Mounting and Dismounting

It is important to follow these procedures when
mounting or dismounting the equipment:
● Use all hand-holds and step plates on your
equipment.
● Never jump off or onto the equipment.
● Wipe off any oil, grease, or mud from your
shoes, rails, steps or platforms before get-
ting on the equipment; always keep these
areas clean and in good condition.
● Never get on or off moving equipment.

.
These actions may lead to serious injury.

De al
Fig. 2-21
Always bring the equipment to a full stop

pt
and turn the engine OFF.
g n
● When getting on or off the equipment,
always face the equipment and maintain
o
a three-point contact (both feet and one
in ti
hand or one foot and both hands) with the
handrails, steps and platforms to ensure
that you support yourself correctly.
司
公
销
营
et a

● Never climb on areas of the machine that

are not designated walk areas.
n

● Never climb on or off the machine with

rk er

tools, parts or similar objects in your

hands.
Ma t

● Never use machine controls or non-spec-

ified points on the equipment to get on or
In

off the machine.

● Use all hand-holds when on the machine. Fig. 2-22

Shop Manual - April 2014 2-17

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

2.4.3 Removing Attachments

● If you will be removing large heavy attach-
ments from the machine, always be sure to
use the correct lifting equipment rated for
the capacity of the load you will be lifting.
● After the attachment or part has been
removed, store it where it cannot fall or
move. Always be sure what you are stor-
ing is sitting stable on a stable surface and
clear of all walkways or fire exits.

WX235R-1200009

.
De al
Fig. 2-23

pt
2.4.4 Jacking Up the Machine
g n
● If you will be working under the machine
always use approved jack stands that will
o
support the weight of the machine you are
in ti

working on.
● Never rely on the hydraulics of the ma- 营
销
公
司

chine or a hydraulic jack to support the

et a

machine during repairs.

n

● Always lower the work equipment to the

rk er

ground and check the stability of the ma-

chine before going under the machine. CZ335-1102078

Fig. 2-24
Ma t
In

2.4.5 Adding Fluids to a System

If it should be necessary to add fluids to a
system during running operations, always be
aware that these systems may be hot and un-
der high pressure.
Before adding fluids, shut the machine down
and allow the systems to cool down to outdoor
ambient temperatures before removing any
caps. Failure to do so may result in serious
burns or a sudden loss of fluid.

Fig. 2-25

2-18 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2.4.6 Aligning Parts or Components

● Be careful when installing or aligning parts
or components.
● Avoid using your fingers or hands to posi-
tion holes or part mating surfaces, serious
injury could result if your hand or fingers
should get ought between the surfaces.
● Always use tools to align a part or compo-
nent to avoid any finger or hand injuries.

.
WX235R-1200012

De al
Fig. 2-26

pt
2.4.7 Driving Pins
g n
When using a hammer to drive pins, metal
o
particles may fly off. This may lead to serious
eye injuries. Always do the following:
in ti

● Always wear a face shield or goggles when

striking a metal object with a metal ham-
司
公
销
营
et a

mer.
n

● Before performing any of these proce-

dures, be sure all personnel are clear of
rk er

your work area.

● If possible, avoid using a steel hammer to CZ335-1102069

drive a component or pins in place. Dam-

Ma t

Fig. 2-27
age to the component may result. Always
In

use a soft or non-ferrous hammer to drive

a component or a pin.

2.4.8 When compressed air is used

When compressed air is used for cleaning, fly-
ing particles may cause personal injury. In this
case, wear goggles, dust-preventive mask,
gloves and other protective gear.

Shop Manual - April 2014 2-19

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

2.4.9 Welding operation

There is possibility of fire or electrocution dur-
ing welding. Therefore, welding must be per-
formed by qualified personnel with suitable
equipment. Never allow other people to do the
welding.

CZ335-1102070

.
Fig. 2-28

De al
pt
2.4.10 Track Recoil Springs
g n
If you are making repairs to a machine
o
equipped with tracks, always be aware of the
in ti
dangers involved with track recoil springs. This
spring is under extreme pressure at all times.
If it is disassembled by mistake, the spring
司
公
销
营
et a

may fly out and cause serious injury.

Be careful when removing or installing tracks
n

on track-type machines. When removing the

rk er

master track link the track system may sepa-

rate suddenly and cause possible injury.
Always stand clear of the track travel path
Ma t

Fig. 2-29
when separating the master link section of the
In

track.

2-20 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2.4.11 High-Pressure Fluid Lines

Always keep in mind that these systems are
under high pressure. When inspecting or re-
placing piping or hoses, always check to be
sure the pressure in the system has been
relieved before proceeding. Working on a sys-
tem still under pressure could lead to serious
injury, always do as follows:
● If you will be removing a line or component
with fluid in the system, always cap and
seal the opening to avoid leakage or sys-
tem contamination.

.
● Never carry out inspections or replace

De al
items while the system is under pressure.

pt
● Never use any part of your body to check
g n
or feel for leaks. Always wear safety
glasses and leather gloves when checking
o
for leaks and use a piece of wood or card-
in ti

board when checking for leaks from small

holes. 司
公
销
营

● If high pressure fluids should penetrate

et a

your skin or get into your eyes, seek medi-

CZ335-1102082
n

cal attention immediately.

Fig. 2-30
rk er
Ma t
In

Shop Manual - April 2014 2-21

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

2.4.12 Air-conditioning system maintenance

WARNING

● Refrigerant R134 a is a harmless gas

under room temperature. It will change
into highly toxic gas when burning.
● Refrigerant getting into eyes may cause
blindness. It may cause frostbite if
splashed on your skin.

● Keep fire source away when servicing air-

.
De al
conditioning system.

pt
● In maintenance of air-conditioning system,
observe the instruction on the refrigerant
g n
cylinder and use it correctly. The type of
o
refrigerant is R134a. Use of other refriger-
ants may damage the air-conditioning sys-
in ti

tem.
● Obey local material disposal regulations.
司
公
销
营
et a

Never discharge refrigerant directly into the CZ335-1102083

air.
n

Fig. 2-31
rk er

2.4.13 High voltage precautions

Ma t

You must understand the elements before

In

testing electric circuit. High voltage or current

could lead to machine damage, spark, explo-
sion or fire.
You must know the voltage before repairing
or testing electrical system. Always check the
circuit and make sure it is disconnected before
doing repair job.
Only explosion-proof light can be used when
you work near flammable fluids or explosive CZ335-1102084
system. Unapproved illumination equipment
Fig. 2-32
could lead to explosion or fire.

2-22 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2.4.14 Disconnecting the System

Power
Before starting any repair operations, remove
the battery leads from the battery or set the
main disconnect on the machine in the OFF
position.
For the location of the machine main electri-
cal disconnect switch, refer to the machines
Safety, Operation & Maintenance Manual for
location and procedures.
If the battery must be disconnected, remove
the negative (-) terminal clamp first then re-

.
move the positive (+) clamp last.

De al
pt
When reconnecting the battery, be sure every Fig. 2-33
electrical system switch is in the OFF position,
g n
connect the positive clamp (+) first, then the
negative clamp(-) last.
o
in ti

2.4.15 Accumulator 营
销
公
司
et a

If the machine is equipped with an accumula-

tor charged with high-pressure nitrogen gas, it
n

is important to follow these basic precautions.

rk er

● Do not disassemble the accumulator.

● Never expose the accumulator to high heat
Ma t

or open flames.
● Never weld on the accumulator.
In

● Never drill or cut on the accumulator.

● Never strike the accumulator.
CZ335-1102085
● Use only nitrogen gas to charge the ac-
Fig. 2-34
cumulator. Unapproved gases could be
explosive.

Shop Manual - April 2014 2-23

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

2.4.17 Battery Hazards

Working around batteries always poses a haz-
ard, especially if the battery has been in ser-
vice for a long period of time.
Listed below are some basic precautions to
be aware of when servicing or working around
batteries.
● Always wear personal protective equip-
ment when working around batteries.
● Battery gasses are extremely explosive.
When opening a battery compartment, al- CZ335-1102061

ways allow ample time for the gasses to

.
Fig. 2-35

De al
escape before servicing the battery.

pt
● When working with batteries, always work
g n
in a well ventilated area.
o
● If the battery is corroded, flush the area
in ti
with a baking soda and warm water mix.
司
公
销
营
et a
n
rk er

CZ335-1102062

Fig. 2-36
Ma t
In

● If battery acid should get on your skin or in

your eyes, flush the area immediately with
fresh water and seek medical attention.

CZ335-1102083

Fig. 2-37

2-24 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2.4.18 Jump-Start Safety

CAUTION

● Never use a welder or a machine with a

higher voltage system to jump-start the
machine. Doing so may damage the ma-
chine’s electrical system or cause an
unexpected explosion or fire resulting
in minor or major injury.

When using jumper cables to start the ma-

.
De al
chine, connect the positive (+) jumper first, Fig. 2-38

pt
then the negative (-) jumper to a remote loca-
tion on the chassis away from the battery.
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 2-25

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

2.4.19 Avoiding fire and explosion

WARNING

● Never smoke when handling the fuel or

maintaining the fuel system. The gases
in empty fuel tank can cause explosion
easily. Never carry out flame-cutting or
welding operation on fuel pipe, fuel tank
or fuel vessels, which can lead to fire,
explosion, injury or death.

.
De al
● Then engine must be shut down and elec-

pt
trical equipment must be switched off when
refueling the tank. Be extremely care-
g n
ful when adding fuel to a hot engine. No
sparks shall occur around the grounding
o
nozzle.
in ti

● Handle all solvents and dry chemicals in a

place with good ventilation according to the 营
销
公
司

steps indicated on vessel.

et a

● Clean the machine of all dust and residu- CZ335-1102014

n

als. Never place greasy rag or other flam- Fig. 2-39

mable materials on machine.
rk er

● When cleaning the parts and components,

use nonflammable solvents instead of gas-
Ma t

oline, diesel oil or other flammable fluids.

In

● Store flammable liquids and materials in

suitable vessels as required by safety laws
and regulations.
● Check fire extinguishers, fire-fighting sys-
tem and fire detectors (if equipment) and
make sure they are ready for use.

2-26 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2.4.20 Chemical hazard

Exposure to hazardous chemicals pose a
serious danger if released or mishandled.
Handling hazardous materials often releases
substances that could pose a hazard. Tempo-
rary implication or possible residual injury may
result unless proper precautions are observed
while working with these materials. All work-
ers involved in handling hazardous materi-
als should use approved personal protective
equipment and follow all environmental safety
regulations.

.
De al
pt
2.4.21 Material Safety Data Sheets
(MSDS)
g n
Material Safety Data Sheet (MSDS) informa-
o
tion relating to the materials the workers could
in ti
be exposed to.
● MSDS data sheets provide both workers 营
销
公
司

and emergency personnel with the proper

et a

procedures for handling or working with a

particular substance. Information includes
n

physical data, health effects, first aid, re-

rk er

activity, storage, disposal and protective

equipment required.
● Be sure all personnel involved are familiar
Ma t

Fig. 2-40
with all MSDS-related information as it re-
In

lates to the hazardous materials they could

be exposed to. Keep MSDS data sheets
handy in site of all employees and emer-
gency personnel where they can be easily
accessed.
● Never handle hazardous materials with-
out the proper MSDS information. Always
verify the data on the MSDS sheet before
handling any hazardous materials.

Shop Manual - April 2014 2-27

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

2.4.22 Proper disposal of wastes

Improper disposal of wastes harms the envi-
ronment and ecology. Consult local environ-
mental protection department or Sany dis-
tributors for methods of recycling and waste
disposal.
● Potential harmful substances used in Sany
products include hydraulic oil, fuel, cooling
liquid, refrigerant, filter and batteries etc..
● Use leak-proof vessels to hold discharged
fluids. Never use food or beverage contain- CZ335-1102086
ers.
Fig. 2-41

.
De al
● Never dump waste fluids directly to the

pt
ground, sewage or water source.
● Leaking of refrigerant from air conditioner
g n
can spoil the atmosphere of the globe.
o
Related laws and regulations must be fol-
lowed to recover or regenerate the refriger-
in ti

ant.
司
公
销
营
et a
n
rk er

CZ335-1102087

Fig. 2-42
Ma t
In

2-28 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2.5 Other Precautions

2.5.1 Sling work and giving signals
1. Only one appointed worker is allowed to
give signals and co-workers must commu-
nicate with each other frequently. The ap-

Load capacity kN(kg)

pointed signal person must give specified kN
kg
19.6
signals clearly at a place where he is seen 2000 18.6
16.7
well from the operator's seat and where he 19.6
1900
1700 13.7
1400
can see the working condition easily. The 2000 9.8
1000
signal person must always stand in front of 9.8 4.9
500
1000
the load and guide the operator safely.
● Do not stand under the load.

.
30 60 90 120 150

De al
Hanging angle (Deg.)
● Do not step on the load.

pt
ZX215-1000001
2. Check the slings before starting sling work.
g n Fig. 2-43
3. Always wear gloves during sling work.
o
(Wear leather gloves, if available.)
4. Measure the weight of the load by the eye
in ti

and check its center of gravity.

司
公

5. Use proper sling according to the weight of

销
营
et a

the load and method of slinging. If too thick

wire ropes are used to sling a light load,
n

the load may slip and fall.

rk er

6. Do not sling a load with 1 wire rope alone.

If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire ropes
Ma t

symmetrically.
In

7. Limit the hanging angle to 60º, as a rule.

Do not sling a heavy load with ropes
forming a wide hanging angle from the
hook. When hoisting a load with 2 or more
ropes, the force subjected to each rope will
increase with the hanging angle. The table
below shows the variation of allowable
load in kN {kg} when hoisting is made with
2 ropes, each of which is allowed to sling
up to 9.8 kN {1,000 kg} vertically, at various
hanging angles. When the 2 ropes sling a
load vertically, up to 19.6 kN {2,000 kg} of
total weight can be suspended. This weight
is reduced to 9.8 kN {1,000 kg} when the 2
ropes make a hanging angle of 120 ° . If
the 2 ropes sling a 19.6 kN {2,000 kg} load
Shop Manual - April 2014 2-29
Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

at a lifting angle of 150 ° , each of them

is subjected to a force as large as 39.2 kN
{4,000 kg}.
8. When installing wire ropes to an angular
load, apply softeners to protect the wire
ropes. If the load is slippery, apply proper
material to prevent the wire rope from slip-
ping.
9. Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
100% 88% 79% 71% 41%
10. Apply wire ropes to the middle portion of

.
the hook.

De al
pt
● Slinging near the tip of the hook may ZX215-1000002

cause the rope to slip off the hook dur-

g n Fig. 2-44
ing hoisting. The hook has the maxi-
mum strength at the middle portion.
o
11. Do not use twisted or kinked wire ropes.
in ti

12. When lifting up a load, observe the follow-

ing. 营
销
公
司
et a

● Wind in the crane slowly until wire

ropes are stretched. When settling the
n

wire ropes with the hand, do not grasp

rk er

them but press them from above. If

you grasp them, your fingers may be
caught.
Ma t

● After the wire ropes are stretched, stop

In

the crane and check the condition of

the slung load, wire ropes, and soft-
ener.
● If the load is unstable or the wire rope
or chains are twisted, lower the load
and lift it up again.
● Do not lift up the load slantingly.
13. When lifting down a load, observe the fol-
lowing.
● When lifting down a load, stop it tempo-
rarily at 30 cm above the floor, and then
lower it slowly.
● Check that the load is stable, and then
remove the sling.

2-30 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

● Remove kinks and dirt from the wire

ropes and chains used for the sling
work, and put them in the specified
place.

2.5.2 Using mobile crane

CAUTION

● Read the Operation and Maintenance

Manual of the crane carefully in ad-
vance and operate the crane safely.

.
De al
pt
2.5.3 Using overhead hoist crane
g n
1. Before starting work, inspect the wire
o
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock prevention
in ti

earth leakage breaker, crane collision

prevention device, and power application 营
销
公
司

warning lamp, and check safety.

et a

2. Observe the signals for sling work.

n

3. Operate the hoist at a safe place.

rk er

4. Check the direction indicator plates (east,

west, south, and north) and the directions
of the control buttons without fail
Ma t

5. Do not sling a load slantingly. Do not move

In

the crane while the slung load is swinging.

6. Do not raise or lower a load while the
crane is moving longitudinally or laterally.
7. Do not drag a sling.
8. When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9. Consider the travel route in advance and
lift up a load to a safe height.
10. Place the control switch on a position
where it will not be an obstacle to work and
passage.

Shop Manual - April 2014 2-31

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

11. After operating the hoist, do not swing the

control switch.
12. Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
13. If the hoist stops because of a power
failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth leak-
age breaker, check that the devices related
to that switch are not in operation state.
14. If you find an obstacle around the hoist,

.
stop the operation.

De al
pt
15. After finishing the work, stop the hoist at
the specified position and raise the hook to
g n
at least 2 m above the floor. Do not leave
the sling installed to the hook.
o
in ti

司
公
销
营
et a
n
rk er
Ma t
In

2-32 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety

2.5.4 Selecting wire ropes

Select adequate ropes according to the weight of parts to be hoisted. See the table below.

Wire Rope
(Standard Z or S type of strand, ungalvanized)
Nominal Diameter Allowable Load

mm kN t
10 9.8 1.0
11.5 13.7 1.4
12.5 15.7 1.6

.
De al
14 21.6 2.2

pt
16 27.5 2.8
18 35.5 3.6
20
g no
43.1 4.4
22.4 54.9 5.6
in ti
30 98.1 10.0
40 176.5 18.0
司
公
销
营

50 274.6 28.0
et a

60 392.2 40.0
n
rk er

CAUTION

● The allowable load is one-sixth of the

Ma t

breaking strength of the rope used

(Safety coefficient: 6).
In

Shop Manual - April 2014 2-33

Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator

tE.
DG al
ep
gA no
i
tKi t
nP

司
公
销
营
a
kNe rn
aAr et
BLM In

2-34 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Specifications

Specifications

.
3 Specifications

De al
pt
3.1 Specific Dimension .................................................................................................. 1-3
3.1.1 Dimension ...................................................................................................... 1-3
g n
3.1.2 Working ranges .............................................................................................. 1-4
o
3.2 Technical Specifications........................................................................................... 1-5
in ti

3.3 Weight Table ............................................................................................................ 1-7

3.4 Engine oil, Fuel and Coolant.................................................................................... 1-8
营
销
公
司
et a

3.5 Engine Performance Curves.................................................................................... 1-9

n
rk er
Ma t
In

Shop Manual - April 2014 3-1

Specifications SY365(B)H-9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

3-2 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Specifications

3 SPECIFICATIONS
3.1 Specific Dimension
3.1.1 Dimension

A
D
I

C
E

.
De al
pt
L
H
G F
B
J
g no
K
in ti
CZ425-1103002

Fig. 3-1 营
销
公
司
et a
n

Item Unit SY365H-9 SY365BH-9

rk er

A Shipping length mm 11,360 11,380

B Overall width mm 3,190 3,190
C Shipping height mm 3,550 3,640
Ma t

D Top width mm 3,150 3,150

In

E Overall height (to cab top) mm 3,320 3,320

F Standard width of track shoe mm 600 600
G Gauge mm 2,590 2,590
H Min. ground clearance mm 550 550
I Tail swing radius mm 3,380 3,380
J Track grounding length mm 4,140 4,140
K Track length mm 5,065 5,065
L Upper-structure ground clearance mm 1,250 1,250

Shop Manual - April 2014 1-3

Specifications SY365(B)H-9 Crawler Hydraulic Excavator

3.1.2 Working ranges

.
De al
pt
a
g
g n
b
o
in ti

司
公
销
营
et a
n
rk er
Ma t

d
In

CZ425-1103004

Fig. 3-2

1-4 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Specifications

Item Unit SY365H-9 SY365BH-9

a Max. cutting height mm 9,900 9,850
b Max. dumping height mm 6,930 6,815
c Max. digging depth mm 7,040 6,750
d Max. vertical wall depth mm 5,180 4,870
e Max. digging reach mm 10,610 10,405
f Min. swing radius mm 4,330 4,300
g Max. height at min. swing radius mm 8,600 8,720

.
3.2 Technical Specifications

De al
pt
Item Unit SY365H-9 SY365BH-9
g n
Bucket capacity m3 1.6（Rockwork） 1.8（Earthwork）
o
Operating weight kg 35,000 35,000
in ti

Max bucket digging force KN 235 235

Max arm-in force KN 营
销
公
司
180 206
Swing speed rpm 9.5 9.5
et a

Travel speed (high/low) km/h 5.5/3.5 5.5/3.5

n

Gradeability Degree 35 35
rk er

Specific ground pressures KPa 63 63

Ma t
In

Shop Manual - April 2014 1-5

Specifications SY365(B)H-9 Crawler Hydraulic Excavator

Machine Model SY365H-9 SY365BH-9

Model
ISUZU AA-6HK1XQP-01
Type 6 cylinders, 4 cycles, water cooling, in-line, and direct injection
No. Of cylinder-bore × 6-Φ115mm×125mm
mm
stroke 7.8
L
Total displacement
Engine

Rated power kW/rpm 190.5/ 2000

Performance

Max. torque N·m/rpm 873 / 1700

Max. speed at zero load rpm 2200±25
Min. speed at zero load rpm 1000±25
Min. fuel consumption g/kWh 237
Start motor 24V/5kW

.
Alternator 24V/50A

De al
Carrier roller (each side) 2

pt
Undercarriage

Track roller (each side) g n 9

Track shoe (each side) 49

o
in ti
Hydraulic pump

Type KAWASAKI (two variable swash plate plunger pumps, constant

Max main pump delivery power control and proportional solenoid valve)
营
销
公
司

L/min
2×158
et a

Main safety valve pres-

Mpa 34.3
sure
n
rk er
Control valve

Type X No. KMX32NA/P45001×1

Control method Hydraulic type
Ma t
Hydraulic system

In

Angle type variable plunger motor A6VE107HZ3/63W-

VZL22XB-S
Hydraulic motor

Travel motor
Planetary gear reducer F80/121/OM/MB
(Including brake valve and parking brake)×2
Angle type plunger motor - planetary gear reducer (upright)
Swing motor M5×180CHB-10A-3NA/265 - RG20D25G2-140
(Swing stop controller)×1
Hydraulic cylinder

Boom Arm Bucket Boom Arm Bucket

Type
Reciprocal plunger Reciprocal plunger
Cylinder inner diameter mm 140 170 140 140 160 140
Piston rod diameter mm 100 120 100 100 110 100
Stroke mm 1420 1748 1135 1480 1685 1748
Hydraulic tank Closed type
Hydraulic oil filter element Tank return side
Hydraulic oil cooler Air-cooling type

1-6 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Specifications

3.3 Weight Table

Unit: kg
Machine Model SY365H-9 SY365BH-9
Engine 720 720
Radiator assembly 118 118
Hydraulic tank assembly (excluding
234 234
hydraulic oil)
Fuel tank assembly (excluding fuel) 235 235
Swing platform 3040 3040
Operator station 150 150

.
Operator seat & console 76 76

De al
Counterweight 6800 6800

pt
Hydraulic pump g n 186 186
Main control valve 380 380
o
Swing reducer assembly 422 422
Travel reducer assembly 389×2 389×2
in ti

Swivel joint 45 45
Track frame 营
销
公
司

4612 4612
et a

Swing bearing 544 544

Idler 175×2 175×2
n

Tensioning device 190×2 190×2

35×4 35×4
rk er

Carrier roller
44×18 44×18
Track roller
Boom assembly 2574 2574
Ma t

Arm assembly 1165 1200

In

Bucket assembly 1620 1582

Boom cylinder assembly 264×2 264×2
Arm cylinder assembly 484 484
Bucket cylinder assembly 150 150
Connecting rod 114 105
Rocker arm 35×2 40×2

Note: The weight table is only used as a reference for handling the components or transporting
the machine.

Shop Manual - April 2014 1-7

Specifications SY365(B)H-9 Crawler Hydraulic Excavator

3.4 Engine oil, Fuel and Coolant

Ambient temperature
Liquid
Reservoir -22 -4 14 32 50 68 86 104 122 ℉
type
-30 -20 -10 0 10 20 30 40 50℃

SAE 30

SAE 10W
Engine oil pan
SAE 10W-30
Engine oil
SAE 15W-40

.
Carrier roller

De al
Idler

pt
Track roller SAE 30
Swing drive
Gear oil
Final drive
g no
SAE 10W
in ti

Engine oil SAE 10W-30

司
公
销
营

SAE 15W-40
et a

Hydraulic sys-
n

tem
HDZ32 low temp, wear-resistant
rk er

Hydraulic
oil HDZ46 wear-resistant
Ma t

HDZ68 wear-resistant
In

GB252 super 0#

Fuel tank Diesel oil GB252 super -20#

GB252 super -35#

Grease fitting Grease NLGI No.2

Cooling sys-
Coolant TEEC-L35 antifreeze
tem

Note: 1) Sany recommends using API CF-4 or above, not lower than API CD.
2) Sany recommends using gear oil GL-5.
3) To ensure oil quality, always buy genuine oil from Sany or your Sany distributor.

1-8 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Specifications

3.5 Engine Performance Curves

AA-6HK1XQP-01
Test condition:
1. Temperature 298K, one standard atmospheric pressure.
2. Maximum output power: 183.9KW (with fan); 190.5KW (without fan)

Max torque
872.8 or more Ｎｍ/approx.1700 min-1 1050
(872.8～/approx.1700 min -1)
950

850

.
De al
750

pt
g n 650

Max output power

183.9±2.9 kW/2000 min-1
o
200 (181.0～186.8kW/2000min-1 )
in ti

司
公
销
营
et a

150
n
rk er

100
Ma t
In

50
Max speed without load
2275±25 min-1
-1
(2250～2300min )

0
Rate of fuel consumption
(Max output power) 280
236.6 g/kWh or less
（～236.6 g/kWh) 260

240

220

200

180
800 1000 1200 1400 1600 1800 2000 2200 2400
W36531305

Fig. 3-3

Shop Manual - April 2014 1-9

Specifications SY365(B)H-9 Crawler Hydraulic Excavator

tE.
DG al
ep
gA no
i
tKi t
nP

司
公
销
营
a
kNe rn
aAr et
BLM In

1-10 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Structure and Functions

2

.
De al
pt
4 Structure and Functions
g n
4.1 Engine and Cooling System ................................................................................... 4-5
o
4.1.1 Engine-related parts....................................................................................... 4-5
in ti

4.1.2 Radiator and intercooler................................................................................. 4-6

4.2 Power Train.............................................................................................................. 4-7
营
销
公
司
et a

4.2.1 Overview ........................................................................................................ 4-7

4.2.2 Travel reducer AS ......................................................................................... 4-8
n

4.2.3 Swing reducer mechanism........................................................................... 4-10

rk er

4.2.4 Swing bearing .............................................................................................. 4-12

4.3 Undercarriage Travel System ............................................................................... 4-14
Ma t

4.3.1 Track frame and tensioning mechanism ...................................................... 4-14

In

4.3.2 Idler .............................................................................................................. 4-16

4.3.3 Carrier roller ................................................................................................. 4-18
4.3.4 Track roller ................................................................................................... 4-19
4.3.5 Track ........................................................................................................... 4-20
4.3.6 Tri-grouser track shoe .................................................................................. 4-23
4.4 Hydraulic System, Part 1 ....................................................................................... 4-24
4.4.1 Deployment of hydraulic parts ..................................................................... 4-24
4.4.2 Hydraulic tank and filter ............................................................................... 4-26
4.4.3 Hydraulic pump ............................................................................................ 4-28
4.4.3.1 Outline................................................................................................. 4-29
4.4.3.2 Function .............................................................................................. 4-31
4.4.3.3 Structure ............................................................................................. 4-31
4.4.3.4 Operating principle .............................................................................. 4-32
Shop Manual - April 2014 4-1
Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.4.3.5 Oil delivery control .............................................................................. 4-33

4.4.4 Pilot pump .................................................................................................... 4-34
4.4.5 Regulator .................................................................................................... 4-35
4.5 Hydraulic system, Part 2 ........................................................................................ 4-48
4.5.1 Main control valve ........................................................................................ 4-48
4.5.1.1 Overview ............................................................................................ 4-48
4.5.1.2 Main valve structure ............................................................................ 4-50
4.5.2 Hydraulic circuit (With bucket confluence function) .............................................. 4-56
4.6 Hydraulic System, Part 3 ....................................................................................... 4-79
4.6.1 Swing motor ................................................................................................. 4-79
4.6.2 Swing holding brake..................................................................................... 4-81

.
De al
4.6.3 Relief valve section ...................................................................................... 4-82

pt
4.6.4 Anti-jerk valve............................................................................................... 4-84
g n
4.6.4.1 Operation diagram .............................................................................. 4-84
4.6.4.2 Effect illustration.................................................................................. 4-84
o
4.6.5 Central Swivel Joint ..................................................................................... 4-86
in ti

4.6.6 Travel motor ................................................................................................. 4-87

4.6.7 Reducer ....................................................................................................... 4-89
司
公
销
营
et a

4.6.8 Travel motor (Nabtesco) .............................................................................. 4-91

n

4.6.9 Operating principle of the basic components ............................................... 4-93

4.6.9.1 Double-balanced valve ....................................................................... 4-93
rk er

4.6.9.2 Operation of parking brake ................................................................. 4-98

4.6.9.3 Operation of braking valve .................................................................. 4-99
Ma t

4.6.10 Control system ......................................................................................... 4-108

In

4.6.11 Manual pilot valve .....................................................................................4-110

4.6.12 Travel pilot valve .......................................................................................4-114
4.6.12.1 Operating principle ...........................................................................4-116
4.6.13 Solenoid valve...........................................................................................4-118
4.6.14 PPC accumulator ......................................................................................4-119
4.6.15 Pilot oil filter.............................................................................................. 4-121
4.6.16 Hydraulic cylinders ................................................................................... 4-122
4.6.16.2 Lubrication at every 100 service hours ........................................... 4-123
4.6.16.1 Lubrication at every 500 service hours ........................................... 4-123
4.7 Work Equipment .................................................................................................. 4-124
4.7.1 Component dimensions ............................................................................. 4-124
4.7.2 Arm dimensions ......................................................................................... 4-126

4-2 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.7.2.1 Bucket dimensions ............................................................................ 4-128

4.8 Operator Station and Its Attachments .................................................................. 4-130
4.8.1 Air conditioner lines .................................................................................... 4-130
4.8.1.1 Layout of A/C components ................................................................ 4-132
4.8.1.2 A/C control panel............................................................................... 4-133
4.8.1.3 Diagram of electrical circuit ............................................................... 4-134
4.8.1.4 Operating principle ............................................................................ 4-136
4.8.1.5 Compressor ...................................................................................... 4-137
4.8.1.6 Clutch ................................................................................................ 4-139
4.8.1.7 Condenser ........................................................................................ 4-140
4.8.1.8 Expansion valve ................................................................................ 4-141

.
De al
4.8.1.9 Evaporator ........................................................................................ 4-141

pt
4.8.1.10 Dehydrator ..................................................................................... 4-142
g n
4.8.1.11 Pressure switch .............................................................................. 4-143
4.8.1.12 Fresh air sensor .............................................................................. 4-144
o
4.8.2 Refrigerant ................................................................................................. 4-145
in ti

4.8.2.1 Compressor oil .................................................................................. 4-163

4.9 Engine Control ..................................................................................................... 4-164
司
公
销
营
et a

4.9.1 System operation ....................................................................................... 4-165

n

4.9.1.1 Engine starting .................................................................................. 4-165

4.9.1.2 Engine speed control ........................................................................ 4-165
rk er

4.9.1.3 Engine shutdown .............................................................................. 4-165

4.9.2 System components .................................................................................. 4-166
Ma t

4.9.2.1 Fuel control dial................................................................................. 4-166

In

4.9.2.2 Controller .......................................................................................... 4-168

4.10 Electrical Control System................................................................................... 4-170
4.10.1 Control function ........................................................................................ 4-170
4.10.2 Diagram of machine control system......................................................... 4-171
4.10.3 Engine-pump combination control ........................................................... 4-173
4.10.4 Pump control function .............................................................................. 4-177
4.10.4.1 Constant power control ................................................................... 4-180
4.10.4.2 ESS control ..................................................................................... 4-180
4.10.5 Valve control function ............................................................................... 4-181
4.10.6 Dual travel speed control ......................................................................... 4-183
4.10.7 Engine preheat/overheat alarm ............................................................... 4-185
4.10.8 Auto deceleration/acceleration control ..................................................... 4-187

Shop Manual - April 2014 4-3

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.10.9 Engine speed calibration function ............................................................ 4-188

4.10.10 System parts and components .............................................................. 4-190
4.11 Monitoring System ............................................................................................. 4-195
4.11.1 Monitor ..................................................................................................... 4-196
4.11.2 Monitor panel ........................................................................................... 4-197
4.11.2.1 Alert and signal indicators .............................................................. 4-197
4.11.2.2 Operation keys ................................................................................ 4-199
4.11.3 Monitor display and operation .................................................................. 4-201
4.11.3.1 Default page .................................................................................... 4-201
4.11.3.2 Password entry to system information ............................................ 4-202
4.11.3.3 Main menu ...................................................................................... 4-202

.
De al
4.11.3.4 Engine & throttle signals ................................................................. 4-203

pt
4.11.3.5 Pilot pressure signals ...................................................................... 4-203
g n
4.11.3.6 Main pump & main valve signals..................................................... 4-204
4.11.3.7 Failure codes................................................................................... 4-204
o
4.11.3.8 Throttle help information ................................................................. 4-205
in ti

4.11.3.9 Language selection ......................................................................... 4-205

4.11.3.10 System clock setup ....................................................................... 4-206
司
公
销
营
et a

4.11.3.11 GPS information ............................................................................ 4-207

n

4.11.3.12 System setup ................................................................................ 4-208

4.11.3.13 Machine configuration ................................................................... 4-208
rk er

4.11.3.14 Service hour setup ....................................................................... 4-209

4.11.3.15 Machine configuration setup ......................................................... 4-210
Ma t

4.11.3.16 Hydraulic oil temperature ...............................................................4-211

In

4.11.3.17 Screen brightness setup ................................................................4-211

4.11.3.18 System lockout (level 1) ................................................................ 4-212
4.11.3.19 System lockout (level 2) ................................................................ 4-212

4-4 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4 STRUCTURE AND FUNCTIONS

4.1 Engine and Cooling System
4.1.1 Engine-related parts

2
M6

M6 Ⅱ

.
De al
俁

pt
2
g n 4 Ⅰ

3
o
in ti
I

司
4
公
销
营
et a

Ⅱ
Coupling installation
n

4×M18×60-10.9
5
rk er

Tightening torque 320N•m

6
2×M16
Tightening torque 120N•m
Ma t

AA-6HK1XQA
In

W365413091

Fig. 4-1

(1) Air cleaner Specification

(2) Muffler AS
(3) Air cleaner Engine oil capacity: 35 L
(4) Damper
(5) Flywheel
(6) Coupling
(7) Plunger pump

Shop Manual - April 2014 4-5

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.1.2 Radiator and intercooler

3
4

.
De al
1 2 6 7

pt
g no
in ti

司
公
销
营
et a
n
rk er

W365413092

Fig. 4-2
Ma t

(1) Coolant tank Specification

In

(2) Water inlet pipe

Radiator AS: H1260×460×1100-S105Y100Z30
(3) Water outlet pipe
(4) Air intercooler Aluminum ribbon-tublar radiator
(5) Condenser Tank capacity: 8.4 L
(6) Oil radiator
(7) Water radiator

4-6 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.2 Power Train

4.2.1 Overview

3 2 1

.
De al
pt
g no
in ti

4 5 6 7 8 9
司
公
销
营
et a
n

10
rk er
Ma t
In

ZX365-1304003

Fig. 4-3

(1) Swing motor (M5×180CHB-10A-3NA/265) (6) Accumulator

(2) Swing reducer (RG20D25G2-140) (7) Main control valve (KMX32NA/P45001)
(3) Swing bearing (8) Travel reducer (F80/121/OM/MB)
(4) Idler (9) Plunger pump (K5V160DTH1×4R-9T06-V)
(5) Swivel joint (10) Engine (AA-6HK1XQP-01)

Shop Manual - April 2014 4-7

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.2.2 Travel reducer AS

10

.
De al
pt
g n
7
o
in ti

司
公
销
营

1
et a
n

9
rk er

8
Ma t
In

2 3 4 5

11

12°

12 ZX335-1002050

Fig. 4-4

4-8 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

(1) Gear hub (7) No.2 planetary carrier pin

(2) No.1 planetary gear (8) No.2 sun gear
(3) No.1 planetary carrier pin (9) No.2 planetary carrier
(4) No.1 sun gear (10) Motor
(5) No.1 planetary carrier (11) Check port
(6) No.2 planetary gear (12) Filler/drain port

No. Check item Criteria Remedy

Clearance between No.2 planetary gear and

13 0.100 ～ 0.356 1.10
gear hub

.
Clearance between No.1 planetary gear and

De al
14 0.133 ～ 0.386 1.00
gear hub

pt
Replace
Clearance between No.1 sun gear and
15 0.05 ～ 0.286 1.10
No.1 planetary gear
g n
Clearance between No.2 sun gear and
o
16 0.076 ～ 0.304 1.00
No.2 planetary gear
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 4-9

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.2.3 Swing reducer mechanism

19 20

.
De al
pt
21
8
g n
24
o
22
6 10
in ti

23
11
司
公

12
销
营

5
et a

26
n

7 4
rk er

13
14
3

2
Ma t
In

15 1

17

16

18

28
ZX335-1002004

Fig. 4-5

4-10 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

(1) Plug (11) No.2 planetary gear GP

(2) Oil seal (12) No.2 planetary gear (teeth: 23)
(3) Self-aligning bearing (13) Spring pin
(4) Gear ring (teeth: 66) (14) Screw plug
(5) No.2 planetary carrier (15) Grease fitting
(6) No.1 planetary carrier (16) Self-aligning bearing
(7) No.2 sun gear (teeth: 18) (17) Bearing seal
(8) No.1 sun gear (teeth: 15) (18) Pinion gear
(9) Swing motor (19) Dipstick
(10) No.1 planetary gear (teeth: 25) (20) Oil-filling tube

Specification

.
De al
Reduction ratio: 25.2

pt
No.
g no
Check Item Criteria Remedy

Clearance between swing motor Standard clearance Clearance limit

21 Replace
in ti

shaft and No.1 sun gear 0.18- 0.28 —

Clearance between No.1 sun gear
22 0.16- 0.50 1.00
司
公
销
营

and No.1 planetary gear

et a

Clearance between No.1 planetary

23 0.18- 0.59 1.10
n

gear and gear ring

Clearance between No.1 planetary
rk er

24 0.39- 0.71 1.20

carrier and No.2 sun gear
Clearance between No.2 sun gear Replace
25 0.16- 0.50 0.90
and No.2 planetary gear
Ma t

Clearance between No.2 planetary

26 0.18- 0.59 1.00
In

gear and gear ring

Clearance between No.2 planetary
27 0.07- 0.23 —
carrier and swing pinion gear
Clearance between swing pinion
28 0.22- 1.32 2.00
gear and swing bearing

Shop Manual - April 2014 4-11

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.2.4 Swing bearing

b
●

● ●

A
A

.
De al
pt
1
g no
2
in ti

司
公
销
营

3
et a
n
rk er
Ma t
In

927±103 Nm 927±103Nm
A-A
ZX335-1002005

Fig. 4-6

(1) Inner race (teeth: 78) Specification

(2) Steel ball Reduction ratio: 78/11= 7
(3) Outer race Grease volume filled: 27±1 Kg

a. Location S (soft zone of inner race)

b. Location S (soft zone of outer race)

4-12 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Check Item Criteria Remedy

Bearing axial clearance Standard clearance Clearance limit

Replace
(Mounted on chassis) 0.5-1.6 3.2

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 4-13

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.3 Undercarriage Travel System

4.3.1 Track frame and tensioning mechanism

1 2 3 4

.
De al
11

pt
9 8 7 6 5
g n
Ɣ
o
10
in ti
12

X
公
销
营
et a
n

X
rk er

ZX365-1304006
Ma t

Fig. 4-7
In

(1) Idler ● Dimension and number of track rollers may

(2) Track frame vary depending on the machine model, but
(3) Carrier roller their basic structures are the same.
(4) Sprocket ● Number of track rollers on one side: 9
(5) Track roller
(6) Track
(7) Long guard
(8) Short guard
(9) Guide seat

4-14 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Unit: mm

No. Check Item Standard Remedy

Standard
Tolerance Repair limit
Vertical width of size
10 idler guide +3
Track frame 123 —
-1 Build-up
Idler support 120 ±0.5 — welding
+4 or replace
Track frame 266 —
Horizontal width -1
11
of idler guide 0
Idler support 261 —
-0.5
Standard size Repair limit
Free

.
length Installation Installation Free Installation

De al
12 Tension spring × Outer length load length load Replace

pt
diameter
{21280kg}
g no
1225x 262 655
208.5KN
795 —
in ti

Standard track shoe 营

销
公
司
et a

Model
SY365H-9/SY365BH-9
n

Item
rk er

Shoe width (mm) 600

Link pitch (mm) 216
Number of track
Ma t

49
shoes on one side
In

Shop Manual - April 2014 4-15

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.3.2 Idler

4
3
7
8

.
157~255 Nm

De al
pt
g no
in ti
1 2

司
公
销
营
et a
n
rk er
Ma t
In

ZX215-1002010

Fig. 4-8

4-16 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Protrusion outer dia.
635 —
2 Tread outer dia. 590 578 Build-up
3 Tread thickness 30 24 welding
4 Tread difference 22.5 26 or replace

5 Overall width 190 —

6 Tread width 44 —

Standard Tolerance Standard Clearance

Clearance between size Shaft Hole clearance limit

.
7

De al
shaft and bushing

pt
φ80 — — — —

Standard Tolerance Standard Interference

g n
Interference be- size interference limit Replace
Shaft Hole
8 tween idler and bushing
o
bushing
φ86 — — — —
in ti

Clearance between Standard clearance 销

公
司
Clearance limit
bushing and support
营

9
et a

(Sum of clearances 0.5-1.0 —

at both sides)
n
rk er
Ma t
In

Shop Manual - April 2014 4-17

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.3.3 Carrier roller

5 3

.
De al
pt
4
g n
2 1
o
6 7
in ti

司
公
销
营
et a
n

ZX215-1002011
rk er

Fig. 4-9
Unit: mm
No. Check item Criteria Remedy
Ma t

Standard size Repair limit

In

1 Flange outer dia.

190 —
2 Tread outer dia. 150 136
3 Tread width 57 —
4 Tread thickness 39 32
5 Flange width 16 —

Standard Tolerance Standard Clearance

Clearance be- Replace
6 tween shaft and size Shaft Hole clearance limit
bushing
65 — — — —

Interference be- Standard Tolerance Standard Interference

7 tween carrier roller size Shaft Hole interference limit
and bushing 72 — — — —
Carrier roller axial Standard clearance Clearance limit
8
clearance 0.44-0.76 —

4-18 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.3.4 Track roller

10

8 9 2 1

.
549±59 Nm

De al
pt
g no
7 5 6
in ti

销
公
司
ZX215-1002012
营

Fig. 4-10
et a

Unit: mm
n

No. Check item Criteria Remedy

rk er

Standard clearance Repair limit

1 Flange outer dia.
216 —
2 Tread outer dia. 180 168
Ma t

Build-up
3 Tread thickness 51.5 40.5 welding or
In

replace
4 Overall width 250 —
5 Tread width 50.5 —
6 Flange width 27 —
7 Inner width 95
Standard Tolerance Standard Clearance
Clearance between size Shaft Hole clearance limit
8
shaft and bushing
70 — — — — Replace
Standard Tolerance Standard Interference bushing
Interference between
9 track roller and bush- size Shaft Hole interference limit
ing 77 — — — —
Clearance between Standard clearance Clearance limit
bushing and collar
10 Replace
(Sum of clearances 0.5 - 1.0 —
on both sides)

Shop Manual - April 2014 4-19

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.3.5 Track

.
De al
pt
g no
20
in ti

22 24
8
司
公
销
营

16 12
et a

13
5
n

11 21
rk er

23 25

7 6 15 2 9 3 14
Ma t

10
In

18 17 19
ZX215-1002013

Fig. 4-11

4-20 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit
1 Link pitch
216 219
Reverse or replace
Standard size Reverse
2 Bushing outer diameter
66.9 60.23
3 Bushing metal thickness 11.1 —
Standard size Repair limit
4 Link height Repair or replace
116 104.4
Link metal thickness (bushing press-
5 30.65 22.5
fitting portion)

.
De al
6 178.4

pt
7 Shoe bolt pitch 140.4
8 76.2
9
g no
Inside width 102
10 Link Overall width 23.2
in ti

11 Tread width 21.3

Adjust or replace
12 Pin protrusion 销
公
司
4.2
营

13 Bushing protrusion 5.3

et a

Overall length
14 242
n

of pin
Overall length
15 158.9
rk er

of bushing
16 Spacer thickness —
17 Bushing 88.2 -245 kN{9-25 ton}
Ma t

Press-fitting
18 Regular pin 127.4 -274.4 kN{13-28 ton} —
force
In

19 Master pin 78.4 -147 kN{8-15 ton}

Shop Manual - April 2014 4-21

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Unit: mm

No. Check item Criteria Remedy

Tightening torque(Nm{kgm}) Retightening angle (deg)
a. Regular
link Tri-grouser 1100±55
120±10
track shoe {112.2±5.6}
20 Shoe bolt Tightening Lower torque Retighten
b. Master torque Retightening angle (deg) limit
link (Nm) (Nm{kgm})
— — —
Tolerance Standard inter-
Standard size
Interference between Shaft Hole ference
21
bushing and link

.
+0.46 +0.074

De al
66.5 0.36-0.464
+0.41 0

pt
Interference between pin +0.19 –0.188 Adjust or
22 44.6 0.285-0.485 replace
and link g n +0.09 –0.20
Tolerance Standard clear-
Standard size
Clearance between pin Shaft Hole ance
o
23
and bushing +0.19 +1.35
44.6 0.18-0.83
in ti

+0.09 +0.85

司
公
销
营
et a
n
rk er
Ma t
In

4-22 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.3.6 Tri-grouser track shoe

5 6 7

1
8

2
3 4

.
De al
pt
g n ZX215-1002014

Fig. 4-12
o
Unit: mm
in ti

No. Check item 营

销
公
司
Criteria Remedy
et a

Standard size Repair limit

1 Height
30 20
n

2 Thickness 11
rk er

3 29
Length of base
4 24 Build-up welding
Ma t

5 22 or replace
6 Length at tip 16
In

7 22
Standard size Repair limit
8 Thickness
41 31

Shop Manual - April 2014 4-23

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.4 Hydraulic System, Part 1

2
4.4.1 Deployment of hydraulic parts

(1) Bucket cylinder

(2) Arm cylinder
(3) Boom cylinder
(4) Hydraulic tank
(5) Hydraulic oil filter
(6) Main control valve
(7) Main pump

.
(8) Radiator

De al
pt
(9) Accumulator
(10) Left travel motor
g n
(11) Right travel motor 1
o
(12) Swing motor
in ti

(13) Hydraulic lockout control

(14) Left pilot valve 营
销
公
司

(15) Central swivel joint

et a

(16) Right pilot valve

n

(17) Travel pilot valve

rk er

(18) Solenoid valve AS

18A. Hi/Lo travel speed shift solenoid valve
ZX335-1002007
18B. Negative flow solenoid valve (front
Ma t

pump) Fig. 4-13

In

18C. Negative flow solenoid valve (rear

pump)
18D. Pilot lockout solenoid valve

4-24 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

3 4 5 6 7 8

.
De al
pt
g no
in ti

司
公
销
营
et a
n

A
rk er
Ma t
In

10
18F18E A৥
11 18D
12 18C
13 17 18B
14 18A
15
16
18

W365-1304008

Fig. 4-14
Shop Manual - April 2014 4-25
Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.4.2 Hydraulic tank and filter

1 2 B

6<++&

.
De al
pt
B
g n
B-B
o
4 5 6 7
in ti

司
公
销
营
et a
n
rk er
Ma t
In

W365-1304009

Fig. 4-15

4-26 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

(1) Hydraulic tank

(2) Level gauge
(3) Filter element (oil drain)
(4) Filler cap
(5) Breather valve
(6) Filter element (oil suction)
(7) Filter element (oil return)

Specification
Tank capacity: 340 L

.
Breather valve

De al
pt
Filter fineness: 10μm
Ambient temp: -30℃ -100℃
g n
Pressure setting: Air inlet side → 0.005 MPa
o
Air outlet side → 0.05 MPa
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 4-27

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.4.3 Hydraulic pump

Type: K5V160DTH1×4R-9T06-V

B1
a5(16N·m)

a2(36N·m)
a1(36N·m)

.
1
2

De al
pt
g n B3
o
in ti

Dr1(170N·m) Dr4(170N·m)
司
公
销
营
et a

5 PH1 4
A2
n

A3
rk er
Ma t
In

Dr2(170N·m) PH2 A1 Dr4(170N·m)

Psv2 a3(36N·m) Psv1

a4(36N·m)
ZX335-1002010

Fig. 4-16

4-28 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.4.3.1 Outline
● This pump consists of 2 variable swash
plate plunger pumps, 2 adjustors, and 1 pi-
lot gear pump.

a1: Main pressure detection port (front pump)

a2: Main pressure detection port (rear pump)
a3: Regulator pressure detection port (front
pump)
a4: Regulator control pressure detection port
(rear pump)
a5: Delivery pressure detection port (pilot gear

.
De al
pump)

pt
PH1: Pressure sensor mounting port (front
pump)
g n
PH2: Pressure sensor mounting port (rear
o
pump)
in ti

A1: Oil delivery port (front pump)

A2: Oil delivery port (rear pump)
司
公
销
营
et a

A3: Oil delivery port (pilot gear pump)

n

Psv1: Regulator control port (front pump)

rk er

Psv2: Regulator control port (rear pump)

Dr1: Drain plug (front pump)
Dr2: Drain plug (rear pump)
Ma t

Dr4: Oil drain port

In

B1: Oil suction port (pump)

B3: Oil suction port (pilot gear pump)

(1) 1: Front pump

(2) 2: Rear pump
(3) 3: Pilot gear pump
(4) 4: Regulator (front pump)
(5) 5: Regulator (rear pump)

Shop Manual - April 2014 4-29

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

2 3 13 6 7 14 8 9 16 10

15

.
1

De al
pt
12

4 5
g no
11

ZX215-1002019
in ti

Fig. 4-17
司
公
销
营

(1) Front shaft (9) End cap

et a

(2) Min. delivery adjusting screw (10) Rear shaft

n

(3) Front casing (11) Rear casing

(4) Swash plate (12) Gear pump
rk er

(5) Slipper (13) Piston

(6) Plunger (14) Max. delivery adjusting screw
(7) Cylinder block (15) Gear pump shaft
Ma t

(8) Oil distributor (16) Driving pin

In

4-30 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

B 6 13 7 8

.
1

De al
pt
18
18 4
g no
A 5 17

ZX215-1002020
in ti

Fig. 4-18
司
公
销
营

4.4.3.2 Function
et a

● The torque of the engine is transmitted ● Swash plate (4) has flat surface (A), and
n

to the pump shaft (1), and drives cylinder slipper (5) is always pressed against this
block (7) to rotate. At the same time, nine surface while sliding in a circular move-
rk er

plungers (6) slide along the oil distributor ment.

(8). Plunger (6) moves back and forth in- ● Swash plate (4) conducts high pressure oil
side cylinder block (7) and pressurized oil
Ma t

to cylinder surface (B), and forms a static

is sucked in and discharged alternatively. pressure bearing when it slides.
In

● It is possible to change the displacement ● Plunger (6) carries out relative movement
by changing the swash plate angle. in the axial direction inside each cylinder
chamber of cylinder block (7).
4.4.3.3 Structure
● Cylinder block (7) seals the pressurized oil
● Cylinder block (7) is supported to shaft (1) to oil distributor (8) and carries out relative
by spline (17). rotation.
● Shaft (1) is supported by front and rear ● This surface is designed so that the oil
bearings (18). pressure balance is maintained at a suit-
● Tip of plunger (6) is shaped as a concave able level.
ball and slipper (5) is caulked to it to form ● The oil inside the respective cylinder cham-
one unit. bers of cylinder block (7) is sucked in and
● Plunger (6) and slipper (5) constitute the delivered through oil distributor (8).
spherical bearing.

Shop Manual - April 2014 4-31

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.4.3.4 Operating principle

● Cylinder block (7) rotates together with
1 4 5 7
shaft (1), and slipper (5) slides on flat sur- A
face (A).
● When this happens, swash plate (4) moves
along cylindrical surface (B), so angle (a)
between central line (X) of swash plate (4)
and the axial direction of cylinder block (7) a

changes. X

B ZX215-1002021
● (a) stands for the angle of the swash plate.
Fig. 4-19
● With central line (X) of swash plate (4) at
a swash plate angle (a) in relation to the

.
De al
axial direction of cylinder block (7), flat sur- 4 5 6

pt
A F
face (A) acts as a cam in relation to slipper
(5). g n
● In this way, plunger (6) slides on the in-
o
side of cylinder block (7), so a difference
between volumes (E) and (F) is created
in ti
a
inside cylinder block (7). X
E
● A single plunger sucks and discharges the
司
公
销

7
营

ZX215-1002022
et a

oil by the amount (F) – (E).

Fig. 4-20
● As cylinder block (7) rotates and the vol-
n

ume of chamber (E) becomes smaller, the

rk er

pressurized oil is discharged.

● On the other hand, the volume of chamber
(F) grows larger and, in this process, the
Ma t

oil is sucked in.

In

● As central line (X) of swash plate (4) over-

laps the axial direction of cylinder block (7)
(swash plate angle (a) = 0), the difference
between volumes (E) and (F) inside cylin- F
der block (7)becomes 0.
● Suction and discharging of pressurized
oil is not carried out in this state. Namely
pumping action is not performed. (In real-
ity, however, the swash plate angle is not
set to 0)
E
4 7 ZX215-1002023

Fig. 4-21

4-32 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.4.3.5 Oil delivery control 13 16 F

● If swash plate angle (a) becomes larger,

the difference between volumes (E) and
(F) becomes larger and pump delivery (Q)
increases.
● Piston (13) is used for changing swash
plate angle (a).
● Piston (13) makes linear reciprocal move- a
ment under the control of the regulator.
● This linear motion is transmitted to swash
plate (4) via drive pin (16). The sliding of 4 E
ZX215-1002024
the swash plate changes the swash plate

.
De al
angle and changes the displacement of the Fig. 4-22

pt
main pump.
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 4-33

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.4.4 Pilot pump

435 433 710 700 354 351

434

310
355

732

.
De al
pt
311

312
g no
309 307 308 434 850 466 725 435 361 353
in ti
ZX215-1002025

Fig. 4-23 销
公
司
营
et a

307: Valve stem 361: Body

n

308: Valve base 433: Screw

rk er

309: Retainer 434: Screw

310: Spring 435: screw
311: Adjusting screw 466: Plug
Ma t

312: Nut 700: Washer

351: Body 710: O-ring
In

353: Gear shaft 725: O-ring

354: Gear shaft 732: O-ring
355: Filter element 850: Washer

Function
The engine drives the main pump shaft and the pilot pump shaft through the gearbox. The pilot
pump is operated through gear engagement.

4-34 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.4.5 Regulator

755 541
545
543
ൟো
TYPE
ᑣ߫ো
SERIAL NUMBER
Pm

E E-E
铭牌
DETAIL OF STAMP FOR TYPE
AND SERIAL NUMBER

E 601

642 753 467,727 F向

D-D F

.
De al
B
496 418 079

pt
757 413
438
g no
439
646 438
in ti

656 D
司
公
销
营
et a

D
n

B 924
755
rk er

722 543 755 545 541 438 466 730 643 708 644 645 728 801
724 725 B-B

C向
Ma t

A-A
734
897 876 874 755 653
In

655 654 836 651 652 601 624 629 630

A
412 612 858 641 628
615 814 802

C
614
613
611 627
A 631
875 753
898
756
732
763
733
622 625 626 887
621 623
W365P130701

Fig. 4-24

Shop Manual - April 2014 4-35

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

No. Part name Material Quantity Part code Remark

— Regulator Alloy steel 1
412 Screw, socket head Alloy steel 2 60150559 JIS B1176 M8-50
413 Screw, socket head Alloy steel 2 60150560 JIS B1176 M8-70
418 Screw, socket head Alloy steel 2 60150556 JIS B1176 M5-12
438 Screw, socket head Alloy steel 10 60150557 JIS B1176 M6-20
439 Screw, socket head Rolled steel 3 60150558 JIS B1176 M6-35
466 Plug Rolled steel 1 60008724 G1/4
467 Plug Carbon steel 1 60008507 G3/8×M8
496 Plug Alloy steel 15 60008728
497 Plug Alloy steel 4

.
De al
541 Seat Alloy steel 2 60008884

pt
543 Stopper 1
g n Alloy steel 2 60008885
545 Steel ball Bearing steel 2
601 Housing Cast iron 1 60197213
o
611 Feedback rod block Alloy steel 1 60075481
in ti

612 Lever（1） Alloy steel 1 60008532

613 Lever（2） Alloy steel 营
销
公
司

1 60008522
et a

614 Pivot pin Carbon steel 1 60008533

Compensation pis-
n

615 Carbon steel 1 60008534

ton
rk er

621 In-cavity piston Alloy steel 1 60008535

622 Piston shell Cast iron 1 60008536
623 Compensation piece Alloy steel 1 60008524
Ma t

624 Spring seat（C） Alloy steel 1 60008494

In

625 Outer spring Spring steel 1

626 Inner spring Spring steel 1 60075415
627 Adjusting ring（C） Carbon steel 1 60008526
628 Adjusting bolt（C） Carbon steel 1 60008497
Aluminum al-
629 Cover（C） 1 60008529
loy
630 Locknut Rolled steel 1 60008537
631 PF sleeve Cast iron 1 60150553
Aluminum al-
641 Guide cover 1 60008510
loy
642 Valve stem Carbon steel 1 B229900001021
643 Guid piston Alloy steel 1 60008520
644 Spring seat（Q） Alloy steel 1 60008495
645 Adjusting ring（Q） Carbon steel 1 60197211

4-36 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

No. Part name Material Quantity Part code Remark

646 Guide spring Spring steel 1
651 Sleeve Alloy steel 1 60008503
652 Spool Alloy steel 1 60008538
653 Spring seat Carbon steel 1 60008539
654 Reset spring Spring steel 1 60008541
655 Adjusting spring Spring steel 1 60008540
656 Cover plate Cast iron 1 60008548
708 O-ring seal NBR 1 60008694 JISB 2401
722 O-ring seal NBR 3 60008707 JISB 2401
724 O-ring seal NBR 8 JISB 2401

.
De al
725 O-ring seal NBR 1 60008696 JISB 2401

pt
727 g nO-ring seal NBR 1 60008700 JISB 2401
728 O-ring seal NBR 1 60008702 JISB 2401
730 O-ring seal NBR 1 60008704 JISB 2401
o
732 O-ring seal NBR 1 60008701 JISB 2401
in ti

733 O-ring seal NBR 1 60221603 JISB 2401

734 O-ring seal NBR 营
销
公
司

1 60008692 JISB 2401

et a

753 O-ring seal NBR 2 60008709 JISB 2401

755 O-ring seal NBR 5 60008697 JISB 2401
n

756 O-ring seal NBR 1 60008706 JISB 2401

rk er

757 O-ring seal NBR 1 60008698 JISB 2401

763 O-ring seal NBR 1 60039416 JISB 2401
Ma t

801 Nut, hexagon Rolled steel 2 60150561 JIS B1181 RN-M8

802 Nut, hexagon Rolled steel 1 60008506 M10
In

814 Collar Tool steel 1 60009938 JIS B 2B04 SR-10

836 Collar Tool steel 1 60008748
858 Collar Tool steel 2 60009937 JIS B 2B04 RR-15
874 Pin Bearing steel 1 60008734 Φ4×11.7L
875 Pin Bearing steel 2 60008733 Φ4×8L
876 Pin Bearing steel 2 60008735 Φ5×8L
887 Pin Carbon steel 1 60008546
897 Pin Bearing steel 1 60008736 Φ5×19L
898 Pin Bearing steel 1 60150562 Φ8.5×10L
924 Screw, socket head Alloy steel 1 60008743
Pressure-reducing
079 1 60125194
solenoid valve
041 Check valve block 2 60117792

Shop Manual - April 2014 4-37

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Operating principle
● The regulator controls the flow of the main
pup through various pressure signal com- Psv A
1
mands, keeping the pump’s driving pow-
er lower than the engine power 2

● Pump 1 and pump 2 are each equipped

with a regulator. Primary components of P2 6
the regulator are electromagnetic propor-
tional pressure-reducing valve (1), electro- 5
hydraulic converter valve (2), variable 3
power regulator (3), positive flow regulator
(4), servo piston (5) and servo directional
a3
valve (6). The regulator opens or closes

.
4

De al
the oil passage of servo piston (5) accord- B

pt
ing to various pressure signal commands, W365P130702

change the inclination of swash plate, and

g n Fig. 4-25
control the flow of pump as a result.
o
Components of control mechanism
in ti

Electric current flow control: when normal 营

销
公
司

By changing the value I of command current flowing to the electromagnetic proportional pres-
et a

sure reducing valve, the inclination angle (output flow) of pump can be controlled freely. This is a
n

regulator featured with positive flow control (forward control), in which the output flow Q increases
with the value I of command current. With such a device, when you input a current necessary for
rk er

flow required by corresponding operation, the pump only delivers a flow as desired and no power
will be wasted.
Ma t

Power control (+ power shift): For emergency (with rod pulled out)
In

● In case of emergency, the power shift command pressure Pf is used to change the value of
power setting. The power shift command pressure (secondary pressure P2 of electromagnetic
proportional pressure reducing valve) is introduced via in-pump passage to the power control
component of each regulator and shifted to respective similar power setting value.
● When power shifting is being performed, the rising of self-pump output pressure Pd1 automat-
ically reduces the inclination (output flow) of the pump. As a result, the input torque is limited
under certain value. (In case of constant speed, the input power becomes constant too.)
● When power control is exercised, regulator of each pump is controlled to the same inclina-
tion (output flow). Therefore, power control is performed irrelevant to the load of both pumps.
Overload of prime mover is prevented as a result. In addition, the normal pressure for power
shift is 0 MPa. So the power control is inactive in normal hours.
● With this mechanism, optimum power can be achieved in butting operation.
Although the regulator has the two control mechanisms described above, each control in joint ac-
tion can put small inclination (flow) command to priority via mechanical calculation.

4-38 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Regulator adjustment
● Adjusting the adjusting screws (953, 954) at the pump body side can obtain the minimum flow
and the maximum flow. Power control characteristics can be changed by adjusting the screw
(C) (628) and the wheel (C) (627) of this adjustor. The flow control characteristics can be
achieved by adjusting the socket-headed setscrew (924).

532 548 531 808 954

806

953

.
De al
pt
g no
in ti

营
销
公
司

ZX335-1002014
et a

Fig. 4-26
n

531: Inclination pin

rk er

532: Servo piston

548: Feedback pin
Ma t

806: Retaining nut

808: Retaining nut
In

953: Adjusting screw (min. flow)

954: Adjusting screw (max. flow)

Shop Manual - April 2014 4-39

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Maximum flow adjustment (pump body

side)

Output flow Q
● Loosen the hex nut (808). Tighten (or
loosen) socket-headed setscrew (954). No
control characteristics except the maximum
flow changes.

Command current I
W365P130703

.
De al
Fig. 4-27

pt
Minimum flow adjustment (pump body
side) g n
● Loosen the hex nut (806). Tighten (or
Output flow Q

loosen) the socket-headed setscrew (953).

o
Though this action is the same as the ad-
in ti

justment of maximum flow and all the other

control characteristics do not change, 营
销
公
司

power required for maximum output pres-

et a

sure (at relief) is likely to increase if over-

tightened. Be careful in this case.
n
rk er

Command current I
W365P130704
Ma t

Fig. 4-28
In

Input power

1) Adjustment of the outer spring

Loosen the nut (630) and tighten or loosen the
Output flow Q

screw (C) (628) to perform adjustment. When

screw (C) (628) is tightened, the control line,
as shown in the right figure, moves rightward.
The input power increases. Moreover, When
the screw (C) (628) is turned by N turns, in-
ner spring (626) also changes along with its
setting. So turn the adjusting wheel (C) (627)
in the opposite direction by N×A turns. (For
value of A “Annexed Table: Regulator ad-
Output pressure (Pd1)
justing values” on page 4-47.) W365P130705

Fig. 4-29

4-40 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

2) Adjustment of inner spring

After hex nut (802) is loosened, tighten (or

Output flow Q
loosen) the adjusting roller (C) (627) to carry
out adjustment. When adjusting roller (C) (627)
is being tightened, the flow (as shown) will in-
crease and input power will also increase.

Output pressure (Pd1)

W365P130706

.
De al
Fig. 4-30

pt
Adjustment of flow control characteristics
g n
Loosen the hex nut (801) and tighten (or
o Output flow Q

loosen) the socket-headed setscrew (924) for

adjustment. When the setscrew (924) is being
in ti

tightened, The control lines will move right-

ward as shown by the illustration. 营
销
公
司
et a
n
rk er

Command current I

W365P130707
Ma t

Fig. 4-31
In

Operating principle
Pump displacement Q

Flow control
As shown in the illustration on the right, the
outflow of pump can be controlled indefinitely
via feedback pressure value.

Command current I
W365P130708

Fig. 4-32

Shop Manual - April 2014 4-41

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Increasing the flow

When the negative feedback pressure Pi2
reduces, the pilot plunger (643) will move in Port C1 connected with
direction A until a relative balance between head end of servo piston

P2 and the resilient force of the guide spring 652

(646) is achieved. The movement of the pilot
plunger is transmitted to lever (2) (613) via pin 646
613
(875) and rotates towards the arrow direction B
876
with B as the pivot. The movement of lever (2) D F
897
875
is transmitted to the feedback rod (611)via pin
611
shaft (897) and rotates in the same direction of A
643
B with C as the pivot. Along with this, the spool
C
(652) connected to the feedback rod moves to-

.
De al
wards direction D. The spool moving in direc- 532
E

pt
tion D connects port C1 with the oil tank port, W365P130709

and the pressure inside the large diameter end

g n Fig. 4-33
of the servo piston is relieved. As a result, the
output pressure Pd1 inside the small diameter
o
end moves the servo piston (532) in direction Psv A

E and flow is increased. Since the feedback

in ti

rod is connected with the servo piston and the

spool, movement of the servo piston in direc- 营
销
公
司

Pz
tion E makes the feedback rod rotate with F
et a

as the pivot. In this way, the spool is moved to

n

the original position. Through this movement, P2

the opening portion between the spool and the
rk er

valve block is closed slowly. The servo pis-

ton stops moving when the opening portion is
completely closed.
Ma t

Pd1
In

a3

B
W365P130710

Fig. 4-34

4-42 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Decreasing the flow

When the negative feedback pressure Pi2 613
Port C1 connected with
rises, the pilot plunger (643) will move in di- head end of servo piston
rection G until a relative balance between P2
and the resilient force of pilot spring (646) is 652 G
achieved. The movement of pilot plunger is
646
transmitted to the feedback rod (611) via pin
(897) and rotates in the same direction as H H
J 876 L
with I as the pivot. Along with this, spool (652) 897
875
connected to the feedback rod moves in direc-
611
tion J. If the spool moves in direction J, output
pressure Pd1 enters the large diameter end I 643
of the servo piston through the spool and port K

.
532

De al
C1. On the other hand, output pressure Pd1
W365P130711

pt
enters the small diameter end of the servo pis-
ton. As a result of the area difference, the ser-
g n Fig. 4-35
vo piston moves in direction K and the inclina-
tion is reduced, and the flow is also reduced.
o
Psv A
Since the feedback rod, the servo piston and
the spool form a whole unit, when the servo
in ti

piston is moving in direction K, the feedback

rod rotates with L as the pivot. This makes the 营
销
公
司

Pz
spool move to its original position. As a result,
et a

the opening portion between the spool and the P2

n

valve block is slowly closed. The servo pis-

ton stops moving when the opening portion is
rk er

completely closed.
Ma t

Pd1
In

a3

B
W365P130712

Fig. 4-36

Shop Manual - April 2014 4-43

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Power control (for emergency)

● As shown in the illustration, when load
pressure increases, pump inclination is
reduced to prevent the overloading of the

Output flow Q
prime mover.
● The action of power control is the same as
that of the flow control. The following is a
brief description.

Output pressure (Pd1)

.
De al
W365P130713

pt
Fig. 4-37
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

4-44 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Action against overloading

When the self pump output pressure Pd1 in- (For emergency) 876 625
creases, the output pressure Pd1 is acted onto 897 N 612 626
R
the ladder portion of the offset piston (621) , Port C1 connected with
head end of servo piston
and as a result, the offset rod (623) moves in
direction M until the output pressure Pd1 bal- 652
ances the elastic forces of outer spring (625)
and inner spring (626). The movement of the 6
offset rod is transmitted to the lever (1) (612) P M 875
via pin (875) and rotate in the arrow direction 623
621
with N as the pivot. Then, the movement of 611
lever (1) is transmitted to feedback rod (611)
via pin (897) and rotates in the same arrow O

.
Q

De al
direction as N with O as the pivot. Along with
532

pt
this, spool (652) which is connected to the W365P130714

feedback rod moves in direction P. If the spool

g n Fig. 4-38
moves in direction P, output pressure Pd1
enters the large diameter end of the servo pis-
o
ton through the spool and port C1. However, Psv A
output pressure Pd1 enters the small diam-
in ti

eter end of the servo piston, and as a result

of the area difference, the servo piston moves 营
销
公
司

in direction Q. The inclination is reduced as a

et a

result and the flow is also reduced. Since the

n

feedback rod, the servo piston and the spool is P2

a whole unit, when the servo piston is moving
rk er

in direction Q, the feedback rod rotates with R

as the pivot. This allows the spool to move to
its original position. Through this movement,
Ma t

the opening portion between the spool and the Pd1

In

valve block is slowly closed. The servo pis-

a3
ton stops moving when the opening portion is
completely closed. B
W365P130715

Fig. 4-39

Shop Manual - April 2014 4-45

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Action of flow recovery

When the self pump output pressure Pd1 (For emergency) 876 625
drops, elastic force offset rod (623) of outer 897 T 612 626
X S
spring (625) and inner spring (626) moves in Port C1 connected with
head end of servo piston
direction S to a point where the elastic force of
the outer spring and the inner spring balances 652
the output pressure Pd1. The movement of
the offset rod (623) is transmitted to lever (1)
(612) via pin (875) and rotates in the arrow V J 875
direction with T as the pivot. Then, the move- 621 623
ment of lever (1) is transmitted to feedback 611
rod (611) via pin (897) and rotates in the same
arrow direction as T with U as the pivot. Along U
W

.
De al
with this, spool (652) which is connected to
532

pt
W365P130716
the feedback rod moves in direction V. If the
spool is moving in direction V, port C1 is con-
g n Fig. 4-40
nected with the tank port, and the pressure
inside the large diameter end of the servo pis-
o
ton is relieved as a result. Servo piston (532) Psv A
moves in direction W through the output pres-
in ti

sure Pd1 of the small diameter end. The flow

is increased in this way. Since the feedback 营
销
公
司

rod, the servo piston and the spool is a whole

et a

unit, if the servo piston is moving in direction W,

n

the feedback rod will rotate with X as the pivot. P2

This allows the spool to move to its original
rk er

position. Through this movement, the opening

portion between the spool and the valve block
is slowly closed. The servo piston stops mov-
Ma t

ing when the opening portion is completely Pd1

In

closed. a3

B
W365P130717

Fig. 4-41

Prior mechanism of small inclination (small flow) command

● As described above, though the inclination command of delivery control and power control is
transmitted to the feedback rod (611) and spool (652) via lever (2) (613) and the big diameter
end of lever (1) (612) respectively, pin (φ5) on the big hole (φ9) , as a protrusive structure,
only contacts with the rod and pin at the small inclination side. It does not contact with the rod
φ9 and pin (897) on the large inclination side. Through this mechanical option, the inclination
command of the delivery control and power control is placed in priority.

4-46 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Power shift control (power control reduc-

tion)
● As shown in the right diagram, the power

Output flow Q
of the pump can be set freely through pow-
er shift pressure Pf.
● If the power shift pressure Pf is increased,
compensating rod (623) will be pushed to
the right side via pin (898) and the offset
piston (621). Through the same action as
described in the power control overload-
ing prevention, the power set value can be
reduced by reducing pump inclination. On Output pressure (Pd1)
the contrary, the power set value can be

.
ZX335-1002029

De al
increased by reducing the power shift pres-
Fig. 4-42

pt
sure Pf.
● When the pump is under normal condition,
g n
the power shift pressure Pf is 0 MPa. In an
o
emergency, the power shift pressure Pf is
4.9 MPa.
in ti

司
公
销
营

Annexed Table: Regulator adjusting values

et a

Model of regulator KR3K-9T06-V

n

RPM (min-1) 2100

rk er

Adjusting screw (954) screw-in (rotation) +1/4

Max flow regulation
Delivery change (l/min-1) 6
Ma t

Adjusting screw (953) screw-in (rotation) +1/4

Min flow regulation
Delivery change (l/min-1) +4.8
In

Adjusting screw (928) screw-in (rotation) +1/4

Compensation control initial pressure
Adjustment of +1.88
change (MPa)
outer spring
Adjustment Input torque change (N·m) +50.8
of input A 1.87
horse power
Adjusting wheel (627) screw-in (rotation) +1/4
Adjustment of
Flow change (l/min-1) +10
inner spring
Input torque change (N·m) +39
Adjusting screw (924) screw-in (rotation) +1/4
Adjustment of flow control Flow control initial current change (mA) Around 35mA
characteristics (Secondary pressure of proportional valve) （+0.18）
Delivery change (l/min-1) -19.4

Shop Manual - April 2014 4-47

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.5 Hydraulic system, Part 2

4.5.1 Main control valve

4.5.1.1 Overview

XBtr (PTb)
XBp2 Px
XBa1 XBtL
XBs
PaL,Dra
Pns XAb1
CCk Dr4 BbR
XAb2 XBc
(P3) (P4) Dr2
+
BcR
(XBo)
BoR XAa2
Pna1,Dr3 BaR

.
De al
Dr3

Rs1

pt
Pna1

CCo
XAa1
(R4) Rs2
g no
XBp1
XAa1 (R2)
A向
XBp1
in ti

CT2 CP2 Pns Btr MR (PTa) XAtr BtL CP1 CT1 CMR1 CMR2 AtL
As Atr Dr4 Py Bb
Bs (ROD)
司

XAtL XAs
公
销
营

XAtr
ে㸠䍄
XBtr (PTb)
Ⳉ㒓㸠䍄
(PTa)
et a

LCs Drb
XAs ಲ䕀
XBs P2
Pns XBtL Ꮊ㸠䍄 XAtL
PbL Dr4 Ab
LCb2
n

CCb XBb2 (HEAD)

XBb1 LCb PbL,Drb

XBb2
ࡼ㞖2
XAb2 Hvb AbR XAb1 XBb1
A (XAo) ࡼ㞖1
rk er

LCo
(Bo) AcR AoR LCk XAc PAcs

(XAo) OPTION

(XBo) XBc
(Ao) Dr3 Dr1 Dra Bc
䫆᭫
Ac
Dr3 (HEAD) (ROD)
Dra

᭫ᴚ1 ࡼ㞖2
XBa1 XAa1 Pna1 XAa2 XBa2
Ma t

PaL

ARC XBa2 PaL P1 CUT P2 CUT

XBp2
XBa1
XBp1
In

HVa XBp2 AaR XBp1 LCAT2

Ba1
Aa (HEAD) (Ba2) N2
(ROD) LCa Pra1 R1 N1
(HEAD) LCAP2

(PTb) XBtr PG
R3
P2

Pns,Dr4

P1
PH

(PTa) XAtr

W365V130701

Fig. 4-43

4-48 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

P1 : Pump port (P1 side) PAcs : Pilot port, bucket (DIG) travel limit
P2 : Pump port (P2 side) Pna1 : Pilot port, arm 1 logic control valve
Aa : Rod end port, arm cylinder (OUT) Pns : Pilot port, swing logic control valve
Ba1 : Head end port, arm cylinder (IN) PG : Pilot pressure source port
(Ba2) : Head end port, arm cylinder (IN) PH : Pilot pressure source port
Ab : Head end port, boom cylinder (UP) Pz : Pilot pressure for boosting main relief valve
Bb : Rod end port, boom cylinder (DOWN) PaL : Pilot port, lock valve (arm rod end )
Ac : Rod end port, bucket cylinder (DUMP) PbL : Pilot port, lock valve (boom head end)
Bc : Head end port, bucket cylinder (DIG) Px : Signal port used for work equipment
Atr : Motor port, right travel Py : Signal port used for travel
Btr : Motor port, right travel Drl : Oil drain port

.
AtL : Motor port, left travel Dr2 : Oil drain port

De al
pt
BtL : Motor port, left travel Dr3 : Oil drain port
As : Motor port, swing
g n Dr4 : Oil drain port
Bs : Motor port, swing Dra : Oil drain port
o
XAtr : Pilot port, right travel Drb : Oil drain port
XBtr : Pilot port, right travel R1 : Oil return port
in ti

XAtL : Pilot port, left travel (R2) : Oil return port

XBtL : Pilot port, left travel R3 : Oil return port
司
公
销
营
et a

XAs : Pilot port, swing Rs1 : Oil refi lling port

n

XBs : Pilot port, swing Rs2 : Oil refi lling port

XBb1 : Pilot port, boom 1 (DOWN) (Ao) : Backup port
rk er

XAb1 : Pilot port, boom 1 (UP) (Bo) : Backup port

XBb2 : Pilot port, boom confluence (DOWN) (XAo) : (Backup pilot port)
Ma t

XAb2 : Pilot port, boom confluence (UP) (XBo) : (Backup pilot port)
In

XBa1 : Pilot port, arm 1 (IN) (PTa)

XAa1 : Pilot port, arm 1 (OUT) (PTb)
XBa2 : Pilot port, arm 2 (IN) (N1)
XAa2 : Pilot port, arm 2 (OUT) (N2)
XAc : Pilot port, bucket (DUMP) (P3)
XBc : Pilot port, bucket (DIG) (P4)
XBp1 : Pilot port, bypass stop valve spool (P1 (R4)
side)
XBp2 : Pilot port, bypass stop valve spool (P2
side)

Shop Manual - April 2014 4-49

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.5.1.2 Main valve structure

B A XBp2
XBa1
N
MR M PaL,Dra
Right travel
Straight travel Py
971×6
Pz
101
C Pns C
Left travel Swing
N 273×4

C
PbL Drb
D 252 Dr4
D +
102 (P3) CCk
(P4)

Boom 1 P P Boom 2
991 AbR
Rs1
E 992×2
Hvb
AoR
E CCo

Bucket Backup

.
De al
Rs2

F AcR Q F
Dr3

pt
Dra
Dr1
211 (R4)

Arm 2 Arm 1
Pna1
PaL
G
g n AaR Arm regeneration stop
G M
P2 stop
o
252
H XBp2
Q H XAa1
103 XBp1
in ti

A 351 152 168 Direction J

B
167
营
销
公
司

Dra
PG
151
et a

J 541
542 PaL
554
n

151 167
(PTb) XBtr 166 151
167
971×6
rk er

543 Q-Q
151
L-L 167
R3
L PG L 515
Ma t

521
551
In

P2

CCk
P1 561
169
153
CCo
551
A 561
167 151 521
PH
515

PbL Drb
MR
M-M
Pz
(PTa) XAtr
P-P
N-N

W365V130704

Fig. 4-44

4-50 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

351 152 168 169 153

PH P2 PG

XAtr XBtr

271×2 271×2
XAs XBs

271×2 271×2

XBb2 XAb2

271×2 271×2
(XAo) (XBo)

.
341

De al
271×2 168

pt
XBa1 XAa1

271×2 271×2
g no
(R2)

(P4) Rs1 Rs2

in ti

153 169
A-A
司
公
销
营

R3 P1
et a

271×2 271×2
n

(PTb) (PTa)
rk er

271×2 271×2
XBtL XAtL

271×2 271×2
Ma t

XAb1 XBb1
In

271×2 271×2
XBc

271×2 271×2
XAa2 XBa2

272×2 272×2
XBp1 XBp2

162
162
561 551 561 551 163
B-B
W365V130705

Fig. 4-45

Shop Manual - April 2014 4-51

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

153 201
169 336
201 332
336 373
332 Straight travel Right travel
337
372 （Pta） 332
337 XAtr
261
332
261 MR
601
308
Py
512 301
522
511
552
521
562 CMR2 Atr
512 551
522
CMR1 CT2
552 561

.
562 CT1 CP2 561

De al
561 551

pt
551 521
Btr 511
521
511
g no
263 Px
203
in ti
169 (PTb) XBtr 263
153 203
Section C-C
销
公
司
营

201 201
et a

336 336
332 Left travel Swing 332
373 371
n

337 337
XAtL XAs
332 332
rk er

261 261

301 166 305

166 162
Ma t

165
163
In

511 AtL As
521
LCs
CP1 Pns
551
561 256
165 Bs
BtL 254
161

166
263 XBtL XBs 263
203 203
Section D-D

W365V130705

Fig. 4-46

4-52 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

201 201
336 336
332 332
373 Boom 1 Boom 2 371
337 337
332 XBb1 XBb2 332
261 602
AbR 261
553
561 307
523 Hvb
513 165
163
Ab
303 CCb
551
511
561
521
LCb 561
Lcb2
551

.
561 551

De al
Bb 521

pt
511
g no
Dr2
602
BbR XAb1 XAb2
263 263
in ti

203 Section E-E 203

153
555
司
公
销

169
营

563
201
et a

204
342 336
Bucket Backup 332
n

336 371
332 XBa2
337
371 (XAo) 332
rk er

PAcs
337 261
332 XAc 309
261
AcR AoR 605
602 166
Ma t

304
162
In

164 275×4
165
264
163 Ac (Ao)
213
511
521 511
521
LCk LCo
551 551
561 561
264
164 （Bo）
Bc 213
161
275×4

166 605
602 BoR
BcR XBc (XBo) 263
263 203
203 Section F-F 169
153 W365V130706

Fig. 4-47

Shop Manual - April 2014 4-53

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

201 201
336 336
332 332
375 Arm 2 Arm 1 371
337 337
332 XBa2 XBa1 332
261 261
306
302
Dra
Dr1 167
511 151
521 561
561 553
551 Hv6
523
276×4 LCAT2 LCa 513
285
266 Pna1
214

.
De al
531 255
522 Ba1 253

pt
514 Ba2
153
169
275×4
g n
214
o
264 261
602 BaR XAa2
in ti
263 205
203
XAa1
152 销
公
司

Section G-G
营

168
et a

202
333 P2 stop
331 Arm regeneration stop
n

324 XBp2
323 257
334
rk er

602
331
262
551 AaR
561
Ma t

169
153
In

(N2) CCk Aa
310

310 CCo
R1
(N1)

153
169
561
551 (R2)
262
331
267 215 277×4
334
323
324
331 XBp1
333 Section H-H
P1 stop W365V130707
202
Fig. 4-48

4-54 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Torque Torque
No. Part name Qty No. Part name Qty
（N.m） （N.m）
101 Valve body A 1 305 Swing spool 1
102 Valve body B 1 306 Spool, arm 2 1
103 Valve body C 1 307 Spool, boom 2 1
Spool AS, straight
151 Oil plug 6 13~17 308 1
travel
152 Oil plug 2 34~39 309 Backup 1
153 Oil plug 10 69~78 310 Spool, bypass stop 2
161 O-ring seal 4 323 Spring 2
162 O-ring seal 6 324 Spring 2
163 O-ring seal 9 331 Spring seat 4
164 O-ring seal 2 332 Spring seat 20
165 O-ring seal 4 333 Bolt with washer 2 16~18
166 O-ring seal 12 334 Stopper 2
167 O-ring seal 6 336 Bolt with washer 10 37~41

.
De al
168 O-ring seal 3 337 Stopper 10
169 O-ring seal 10 341 Oil plug 1 34~39

pt
201 Spring cap 9 342 Piston 1
202 Spring cap 2 351 节流塞（φ0.7） 3 7.8~9.8
203
g n
Spool cap 9 371 Spring 8
204 Spring cap 1 372 Spring 1
o
205 Spool cap 1 375 Spring 1
211 Plate 1 511 Cone valve 10
in ti

213 Flange 2 512 Cone valve 2

214 Check valve plate 1 营
销
公
司
513 Cone valve 2
Pipeless opening cover
275 1 514 Cone valve 1
et a

plate
Pipeless opening cover
216 1 515 Cone valve 2
n

plate
252 Lock valve selector GP 2 9.8~14 521 Spring 12
rk er

Logic valve component,

253 1 522 Spring 3
arm 1
Logic valve component,
254 1 523 Spring 2
swing
Ma t

255 Logic control valve 2 52~62 531 Spring seat 1

Stop valve GP, arm
In

257 1 120~140 541 Steel ball 1

regeneration
261 O-ring seal 11 542 Spring seat 1
262 O-ring seal 2 543 Spring 1
263 O-ring seal 9 551 Oil plug 17 370~410
264 O-ring seal 3 552 Oil plug 2 230~260
265 O-ring seal 1 553 Oil plug 2 370~410
266 O-ring seal 1 554 Oil plug 1 25~29
267 O-ring seal 1 555 Oil plug 1 220~260
271 Bolt, socket head 40 52~62 561 O-ring seal 19
272 Bolt, socket head 4 25~34 562 O-ring seal 2
273 Bolt, socket head 4 210~260 563 O-ring seal 1
275 Bolt, socket head 12 140~180 601 Main relief valve 1 120~140
276 Bolt, socket head 4 25~34 602 Port relief valve 6 120~140
277 Bolt, socket head 4 83~110 605 Port relief valve 2 120~140
301 Travel spool 2 971 Bolt, socket head 12 390~470
302 Spool GP, arm 1 1 991 Nameplate 1
303 Spool GP, boom 1 1 992 Rivet 2
304 Bucket spool 1

Shop Manual - April 2014 4-55

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.5.2 Hydraulic circuit (With bucket confluence function)

Straight travel Travel (R)

Travel (L)

.
Swing

De al
pt
Boom 1
g no
Boom 2
in ti

司
公
销
营
et a

Bucket Backup
n
rk er
Ma t
In

Arm 2 Arm 1

Bypass stop

W365V130703

Fig. 4-49

4-56 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Operating principle
1) When spool is neutral position
(Main circuit)
● When all spools are in neutral position, the working oil from (front) hydraulic pump enters the
pump port P1, is guided to the main oil passage (1), and returns to the oil tank via the return
ports R1 and R3 by passing through the neutral bypass (2) (function of neutral M-shaped
spool) of each spool in straight travel (308), left travel (301), boom 1 (303), bucket (304) and
arm 2 (306).
● The working oil from (rear) hydraulic pump enters the pump port P2, is guided to the main
oil passage (3), and returns to the oil tank via the return ports R1 and R3 by passing through
the neutral bypass (4) (function of neutral M-shaped spool) of each spool in right travel (301),
swing (305), boom 2 (307), backup (309) and arm 1 (302).

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 4-57

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

(1) R3 P1

(2)

(PTb) (PTa)

XBtL XAtL

XAb1 XBb1

XBc

.
De al
pt
XAa2 XBa2
g no
XBp1 XBp2
in ti

司
公
销
营
et a

(p3)
(3)
PH P2 PG
n

(4)
rk er

XAtr XBtr
Ma t

XAs XBs
In

XBb2 XAb2

(XAo) (XBo)

XBa1

(R2)

(p4) Rs1 Rs2

WJV3651305
Fig. 4-50
4-58 Shop Manual - April 2014
SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

2) Travel
(Pilot circuit)
● When switched to left travel spool or right travel spool, the side oil passage closes and the
pressure in port Py (travel signal port) rises.
(Main circuit)
● When pressure is present in pilot port XBtL used for left travel spool (301), the neutral bypass
(2) at the side of boom 1 closes. The working oil fed from (front) hydraulic pump is delivered
through port BtL to the left travel motor.
● Likewise, when pressure is present in pilot port XBtr used for right travel spool (301), the neu-
tral bypass (2) at the side of arm 1 closes. The working oil fed from (rear) hydraulic pump is
delivered through port Btr to the right travel motor.

.
De al
● On the other hand, the oil returning from both the left and right travel motors via port AtL (Atr)

pt
passes the left (right) travel spool and goes back to the oil tank via return ports R1 and R3.
● When operating travel in the opposite side (pressurizing the pilot ports XAtr and XAtL), the
g n
above principle also applies.
o
in ti

司
公
销
营
et a

XAtL XBtL
n
rk er
Ma t
In

AtL BtL

Travel motor

WJV3651306

Fig. 4-51

Shop Manual - April 2014 4-59

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

3) Arm

Arm-out operation
(Pilot circuit)
● When switched to the arm 2 spool (302), the side oil passage closes and the pressure in port
Px (work equipment signal port) rises.
(Main circuit)
● When performing the arm-out operation, the pilot oil is fed to port XAa1 and port XAa2. When
pilot oil is delivered to the two sides of port XAa1 and port XAa2, arm 1 spool and arm 2 spool
are switched to the left, as shown in Fig. 4-52. As a result, the working oil from port P2 is in-
troduced into the neutral bypass (4) via the main passage (3). The neutral bypass is cut off
by switching the arm 1 spool (302). Therefore, the working oil in the parallel passage pushes

.
De al
open the cone valve (253) of the logic valve, and enters the arm 1 spool (302) via the U pas-

pt
sage. The oil from arm 1 spool (302) is then delivered to the rod end (R) of arm cylinder.
● On the other hand, the working oil coming from port P1 is guided to the neutral bypass (2)
g n
via the main oil passage (1). The neutral bypass is cut off by switching the arm 2 spool (306).
o
Therefore, the working oil in the parallel passage pushes open the cone valve (514) of logic
valve, and working oil from neutral bypass pushes open the cone valve (511) of the check
in ti

valve and flows into the arm 2 spool (306) via the U passage. The oil then comes into conflu-
ence with oil from port Aa in the passage of neutral bypass (306) and is fed to the rod end (R)
营
销
公
司

of the arm cylinder.

et a

● Return oil from the arm cylinder head end (H) via port BaI flows respective tank circuits of arm
n

1 and arm 2, and returns to working oil tank via tank ports R1 and R3.
rk er
Ma t
In

4-60 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

511 514
(Ba2)

LCAT2

BaR
Dr1

XBa2
XAa2

.
De al
pt
XBa1 XAa1
g no
in ti

Dra 营
销
公
司
et a
n

LCa Ba1
Aa
rk er

253
Ma t

Pna1
In

R H
WJV3651307

Fig. 4-52

Shop Manual - April 2014 4-61

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Arm-in operation
(Pilot circuit)
● When switched to the arm 1 spool (302), the side oil passage closes and the pressure in port
Px (work equipment signal port) rises. Pressurized oil is fed to the port PaL at the same time.
Relief signal is sent to the lock valve selector GP (252).
(Main circuit)
● When performing the arm-in operation, pilot oil is fed to ports XBa1 and XBa2. When pilot oil
is delivered to the two sides of port XBa1 and port XBa2, arm 1 spool and arm 2 spool are
switched to the right as shown in Fig. 4-53. As a result, working oil from P2 is guided to the
neutral bypass (4) via the main passage (3). The neutral bypass is cut off by switching arm
1 spool (302). Therefore, the working oil in the parallel passage pushes open the cone valve
(253) of the check valve and flows to the arm 1 spool (302) via the U passage. Then, it flows

.
De al
to the periphery of arm 1 spool (302) and is delivered to the arm cylinder head end (H) via

pt
port Ba.
● On the one hand, the working oil from port P1 is guided to the neutral bypass (2) via the main
g n
passage (1). The neutral bypass is cut off by switching the arm 2 spool (306). Therefore,
o
the working oil in the parallel passage pushes open the cone valve (514) of the arm 2 check
valve, and the working oil from neutral bypass pushes open the cone valve (511) of the check
in ti

valve and flows to the arm 2 spool (306) via the U passage. Then, it comes into confluence
with oil from port BaI in the internal passage of arm 2 spool (306).
营
销
公
司

● On the other hand, the oil returning from the arm cylinder rod end (R) and the working oil
et a

whose pressure rises due to the dead weight of arm goes back to the port Aa. The working oil
n

returned to the port Aa flows into the valve spool via the holes (a) on the periphery of arm 1
spool (302), pushes open the cone valve (302-317) only under light load, and comes into con-
rk er

fluence in the peripheral holes with oil from port BaI.

● If the pressure at the arm cylinder head end and in the U passage rises, arm regeneration
Ma t

check valve spool (257-103) switches to the left, as shown in Fig. 4-54, and closes due to
the back pressure of the cone valve (302-317) in the spool. In this way, the arm regeneration
In

function is deactivated and return oil from the arm cylinder rod end (R) flows to the spool via
the hole (a) on the periphery of arm 1 spool (302). Then, it flows into arm regeneration stop
valve (257) via hole (c) on the periphery of arm 1 spool (302), and returns to the working oil
tank via tank ports R1 and R3.

4-62 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

● Light load

(Ba2)

LCAT2

BaR
Dr1

XBa2 XAa2

.
De al
pt
(302-317)
(a)
XBa1 XAa1
g no
in ti

(b)
Dra
司
公
销
营
et a
n

LCa Ba1
rk er

Aa
Ma t

Pna1
In

Arm dead weight R H

WJV3651308

Fig. 4-53

Shop Manual - April 2014 4-63

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

● When pressure in arm cylinder head end (H) rises

(Ba2)

LCAT2

BaR
Dr1

XBa2
XAa2

.
De al
pt
(a)
(302-317)
(c)
XAa1
XBa1
g no
in ti

司
公
销
营

Dra
et a
n
rk er

LCa Ba1
Aa
Ma t
In

Pna1

(257-103)

R H
WJV3651309

Fig. 4-54

4-64 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4) Boom

Boom-up operation
(Pilot circuit)
● When switched to the boom 1 spool (307), the side passage is closed and the pressure in port
Px (work equipment signal port) rises.
(Main circuit)
● When boom-up operation is performed, the pilot oil is fed to port XAb1 and boom 1 spool
(303) moves to the left as shown in Fig. 4-55. The working oil from port P1 is introduced to the
neutral bypass (2) via the main passage (1). The neutral bypass is cut off by switching boom
1 spool (303). In this way, the working oil in the parallel passage pushes open the cone valve
(511) of the check valve, and flows to the boom 1 spool (303) via the U passage. It then flows

.
De al
to the periphery of boom 1 spool (303) and is delivered to the boom cylinder head end (H) via

pt
port Ab.
● At the same time, the pilot oil is also fed to port XAb2 and boom 2 spool (307) moves to the
g n
left as shown in Fig. 4-55. The working oil from P2 flows the parallel passage. As the switch-
o
ing boom 2 spool (307) cuts off the neutral bypass, the working in the parallel passage flows
into boom 2 spool (307) via the U passage. The oil then pushes open the cone valve (511) of
in ti

the check valve, comes into confluence with the oil from port Ab, and is fed to the boom cylin-
der head end (H). (This is called the boom confluence function.)
营
销
公
司

● On the other hand, the oil flows to the periphery of boom 1 spool (303) via port Bb from oil re-
et a

turn side of the boom cylinder rod end (R) and goes back to the working oil tank via the ports
n

R1 and R3.
rk er
Ma t
In

Shop Manual - April 2014 4-65

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

H R

513 511

.
De al
pt
LCb
g n Ab Bb
o
in ti
BaR

司
公
销
营
et a

XBb1
n

XAb1
rk er
Ma t

XBb2
In

XAb2

Dr2
AbR

511 511
WJV3651310

Fig. 4-55

4-66 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Boom-down operation
(Pilot circuit)
● When switched to the boom 1 spool (303), the side passage is closed and the pressure in port
Px (work equipment signal port) rises. Pressurized oil is fed to the port PbL at the same time.
Relief signal is sent to the lock valve selector GP (252).
(Main circuit)
● When boom-down operation is performed, the pilot oil is fed to port XBb1 and boom 1 spool
(303) moves to the right as shown in Fig. 4-56. The working oil from port P1 is introduced to
the neutral bypass (2) via the main passage (1). The neutral bypass is cut off by switching
boom 1 spool (303). In this way, the working oil in the parallel passage pushes open the cone
valve (511) of the check valve, and flows to the boom 1 spool (303) via the U passage. It then
flows to the periphery of boom 1 spool (303) and is delivered to the boom cylinder rod end (R)

.
De al
via port Bb.

pt
● On the other hand, the oil returning from the head end (H) of boom cylinder flows to the hole (a)
and periphery of boom 1 spool (303).
g n
● The pressure of return oil rises due to the dead weight of boom. To maintain sufficient pres-
o
sure, with the help of the oil passage inside the spool, the cone valve (303-317) in spool is
in ti
pushed to the right, as shown in Fig. 4-56, and the oil flows out of the spool. As the working oil
for boom-down operation, the pressurized oil is again delivered to the boom cylinder rod end
(R) (which is called boom regeneration function). The return oil entering the internal passage
营
销
公
司

of spool via the hole (a) partially goes back to the oil tank via the hole (b).
et a
n

H R
rk er

513 511
Ma t
In

LCb
Ab Bb

BbR

XBb1 XAb1

(b) (a) (303-317)

WJV3651311

Fig. 4-56

Shop Manual - April 2014 4-67

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

5) Bucket

Bucket-dig operation
(Pilot circuit)
● When switched to the bucket spool (304), the side passage is closed and the pressure in port
Px (work equipment signal port) rises. The pressure oil is fed to port XBp2 at the same time.
(Main circuit)
● When bucket-dig operation is performed, the pilot oil is fed to the port XBc and the bucket
spool (304) moves to the left as shown in Fig. 4-57. The working oil from port P1 is guided
to the neutral bypass (2) via main passage (1). As the neutral bypass is cut off by switching
bucket spool (304), the working oil in the parallel passage pushes open the cone valve (511)
of the check valve, and flows to the bucket spool (304) via the U passage. It then flows to the

.
De al
periphery of bucket spool (304) and is fed to the bucket cylinder head end (H) via port Bc.

pt
● On the other hand, return oil from the bucket cylinder rod end (R) flows in via port Ac. It then
goes back to the oil tank via the ports R1 and R3 from the periphery of spool.
g n
● When boom-up and bucket-dig operations are performed at the same time, the pilot oil is led
o
to the port PAcs. Therefore, the travel of bucket spool is not restricted to the end, but can be
in ti
held in a position on the way. As a result, bucket cylinder passage is throttled and working oil
flows to boom 1 spool (303) via bucket spool (304). In this way, boom-up operation have the
priority.
司
公
销
营
et a
n
rk er

R H

511
Ma t

LCk
AC Bc
In

AcR BcR
PAcs XAc

XBc

Confluence WJV3651312

Fig. 4-57

4-68 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Bucket-dump operation
(Pilot circuit)
● When switched to the bucket spool (304), the side passage is closed and the pressure in port
Px (work equipment signal port) rises. The pilot oil is also fed to the port XBp2 at the same
time.
(Main circuit)
● When bucket-dump operation is performed, the pilot oil is fed to the port XAc and bucket
spool (304) moves to the right as shown in Fig. 4-58. The working oil from port P1 is led to the
neutral bypass (2) via the main passage (1). The neutral bypass is cut off by switching bucket
spool (304). Therefore, the working oil in the parallel passage pushes open the cone valve (511)
of the check valve and flows to the bucket spool (304) via the U passage. It then flows to the
periphery of bucket spool (304) and is fed to the bucket cylinder rod end (R) via the port Ac.

.
De al
● On the other hand, return oil from the bucket cylinder head end (H) enters via the port Bc,

pt
passes the spool periphery of spool, and goes back to working oil tank via the ports R1 and
R2.
g no
in ti

R H

司
公
销
营
et a

511
LCk
n

Ac Bc
rk er

AcR
XAc BcR
Ma t

PAcs
In

XBc

Confluence
WJV3651313

Fig. 4-58

Bucket confluence
● When bucket-dig or -dump operation is performed, the pilot oil is fed to the port XBp2 and the
neutral bypass stop valve spool (310) is switched. Working oil from port P2 is led to the neu-
tral bypass (4) via the main passage (3). The neutral bypass is cut off by switching neutral by-
pass valve spool (310). Therefore, working oil pushes open the check valve (515) and comes
into confluence with bucket spool (304) via the internal passage and the U passage.

Shop Manual - April 2014 4-69

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

6) Swing

When swing operation performed separately

(Pilot circuit)
● When switched to the swing spool (305), the side passage is closed and the pressure in the
port Px (work equipment signal port) rises.
(Main circuit)
● When swing is operated separately, the pilot oil is fed to the port XAs (or XBs) and swing
spool (305) is switched. Working oil from port P2 is led to the neutral bypass (4) via the main
passage (3). Neutral bypass is cut off by switching swing spool (305). Therefore, working oil
in the parallel passage pushes open the logic cone valve (254-101) of the swing logic com-
ponent and flows to the swing spool (305) via the U passage. It then flows to the periphery of

.
De al
swing spool (305) and is delivered to the swing motor via port As (or Bs).

pt
● On the other hand, return oil from the swing motor flows in via port Bs (or port As). Then, it
flows into tank ports R1 and R2 from the periphery of spool and goes back to the working oil
tank.
g no
in ti

Swing motor

司
公
销
营
et a

Pns
n
rk er
Ma t

As LCs Bs
In

(254-101)

XAs
XBs

WJV3651314

Fig. 4-59

4-70 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

7) Priority function
● This function enables the working oil from port P to be sufficiently allocated to the work equip-
ment under higher load in order to improve the operability when the arm-in operation is per-
formed along with swinging operation.
● The following shows the priority of swinging operation relative to the arm-in operation.
(Main circuit)
● When pressure oil is applied to the port Pna1 of the logic control valve (255), the piston (255-
356) and spool (253-107) move upward. The lifting distance of cone valve (253-101) is lim-
ited.
● In this way, the passage from the parallel passage to the U passage is throttle. As a result, oil
from the arm 1 spool has the priority to go to the swing spool, giving the priority to the boom-

.
up operation.

De al
pt
g no
in ti

XBa1
XAa1
司
公
销
营
et a
n
rk er

Aa LCa Ba1
Ma t

(253-101)
In

(253-107)
(255)
Pna1
(255-356
WJV3651315

Fig. 4-60

Shop Manual - April 2014 4-71

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

8) Backup
The backup spool is used to control attachment such as hydraulic shear.

Backup operation
(Pilot circuit)
● When switched to the backup spool (309), the side passage is closed and the pressure in port
Px (work equipment signal port) rises.
(Main circuit)
● When the backup is operated, the pilot oil is fed to the port XAo (or XBo) and the backup
spool (309) is switched. Working oil from port P2 is fed to the neutral bypass (4) via the main
passage (3). Neutral bypass is cut off by switching backup spool (309). Therefore, working oil

.
in the parallel passage pushes open the cone valve (511) of the check valve and flows to the

De al
backup spool (309) via the U passage. Then, it flows into the periphery of backup spool (309)

pt
and is supplied into the attachment via port Ao (or Bo).
g n
● On the other hand, return oil from the attachment flows in via port Bo (or port Ao). Then, it
flows into tank ports R1 and R2 from the spool periphery and returns to the working oil tank.
o
H R
in ti

司
公
销
营
et a

511
n

LCo
Ao Bo
rk er
Ma t

BoR
In

XAo XBo

Confluence WJV3651316

Fig. 4-61

Backup confluence
To achieve backup confluence, pilot oil is also fed to port XBp1 and the bypass stop valve spool
(310) is switched. Working oil from port P1 is introduced into neutral bypass (2) via main passage
(1). Neutral bypass is cut off by switching bypass valve spool (310). Therefore, working oil push-
es open the cone valve (515) of check valve and comes into confluence with backup spool (309)
via the internal passage and the U passage.

4-72 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

9) Straight travel
When travel spool (301) is operated along with other spools at the same time.
The following case shows when travel spool (301) and swing spool (305) are operated at the
same time.
(When pilot oil is delivered to the ports XAtL, XAtr and Xas)
(Pilot circuit)
● Close the side passage of right/left travel spool (301) and the downstream side passage of
swing spool (305). Pilot oil from port PG is fed to port PTa in order to switch the straight travel
spool (308).
(Main circuit)
● When straight travel spool (308) is switched, the port P2 and the right/left travel spool (301)

.
De al
are interconnected through for priority. The port 1 and the parallel passage of swing - boom

pt
2 - backup - arm 1 oil circuit / boom 1 - bucket/ - arm 2 circuit are interconnected through for
priority. Therefore, the working oil from port P2 is mainly delivered to the ports Atl and Atr and
g n
distributed evenly to the two travel motors.
o
● On the other hand, the working oil from port P1 is delivered to the swing motor via port As.
in ti

● When oil pressure in the port P2 is lower than that in the port P1, the working oil form port P1
will be partially delivered to the port P2. In this way, sudden drop of travel speed can be pre-
vented.
司
公
销
营
et a
n
rk er

P1 R3
Ma t

P2
In

(PTa) (PTb)

XAtL XBtL

WJV3651317

Fig. 4-62

Shop Manual - April 2014 4-73

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

10) Function of lockout valve

The lockout valve selector module (252) is mounted between the arm cylinder rod end (R) and
the arm 2 spool (302) and arm 2 spool (306). It is used to reduce the internal leakage of the spool
due to cylinder pressure.
Likewise, lockout valve selector module (252) is also mounted between the boom cylinder head
end (H) and the arm 1 spool (303) and boom 2 spool (307) to reduce the internal leakage of he
spool due to cylinder pressure.
The figure below shows the case of boom cylinder head end (H). (Similar case applies to the arm
cylinder rod end (R).)
Spool in neutral position
● When boom 1 spool (303) and boom 2 spool (307) are in a neutral position, the spool (252-511)

.
inside the lockout valve selector module is pressed against the seat of the body (252-101) of

De al
the lockout valve selector module, as shown in Fig. 4-63, by the preload of spring (252-512).

pt
● In this position, working oil in the boom cylinder head end (H) flows in via hole (a) and flows
g n
out from hole (b) through the periphery of the lockout valve selector module spool (252-511),
pressing the cone valve (513) against the seat of the valve block via hole (b). By this means,
o
oil leakage is reduced.
in ti

(252-512) 销
公
司
营
et a

Drb (252-511)
n

(b)
rk er

(252-101)

(a)
Ma t

PbL 513
In

LCb
Ab Bb

(RH)

BbR

XBb1 XAb1

WJV3651318

Fig. 4-63

4-74 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Boom-down operation
In boom-down operation the pilot oil is fed to the ports PbL, XBb1 and XBb2. Spool (252-511) in-
side the lockout valve selector module is pushed to the top by the pilot oil as shown in Fig. 4-64.
Due to the movement of spool (252-511) inside the lockout valve selector module, hole (a) is cut
off and working oil from boom cylinder head end (H) does not go to spring chamber (RH). In addi-
tion, oil in the spring chamber (RH) enters the oil leak circuit via the hole (b). In this way, the cone
valve (513) is pushed open by the pressure in boom cylinder head end (H) and the function of the
lockout valve selector module (252) is deactivated.

(252-512)

.
Drb
(252-511)

De al
pt
(b)

(252-101)
g no
(a)
in ti

513 511
PbL
司
公
销
营

LCb
et a

Ab Bb
n
rk er

(RH)

BbR
Ma t
In

XBb1 XAb1

WJV3651319

Fig. 4-64

Boom-up operation
In boom-up operation the pilot oil is fed to the ports XAb1 and XAb2. The cone valve (513) is
pushed open by the oil from boom 1 spool (303) and boom 2 spool (307). The working oil goes to
the port Ab as a result.

Shop Manual - April 2014 4-75

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

11) Function of main relief valve

The main relief valve is mounted on the valve block A (101). It has the following functions:
● Working oil fulfils the cavity (a) through the hole in valve post housing (601-101) and valve
post (601-511). The valve post (601-511) is therefore pressed against the housing (601-101).
Reliable sealing has formed as a result.
● When pressure in passage (P) exceeds the preload of spring (601-521), the cone valve (611)
opens. Therefore, the working oil passes through the gap between the housing (601-101) and
valve pocket (601-102) from the periphery of cone valve (601-401) and goes to the low pres-
sure passage (R).
● Opening of cone valve (601-401) causes pressure drop in cavity (a). So the valve post (601-
511) is opened. In this way, working oil in passage (P) flows to the low pressure passage (R)
directly.

.
De al
● When pressure oil higher than 3MPa is fed to the port Pz, it pushes plunger (601-302) to the

pt
left. The preload of spring (601-512) increases as a result and pressure boosts at the mo-
ment.
g no
in ti
(601-101) (601-401) (601-512) (601-102)

司
公
销
营
et a
n
rk er

P
Ma t
In

(a)
(601-511) (601-302)

Pz

WJV3651320

Fig. 4-65

4-76 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

12) Function of port relief valve

The port relief valve, mounted between the oil tank port and low pressure passage, can prevent
cavitation as an oil compensation check valve except working as a port relief valve. Functions of
the valve are given below:

Functioning as a relief valve

● Working oil fulfils into cavity (B) via the hole (A) on plunger (301). Valve post (511) is pressed
against valve seat (541), and valve seat (541) is pressed onto the seat of the valve block,
forming a reliable sealing.

(A) (B) 541

.
De al
pt
g n
P
o
in ti

司
公
销
营
et a

301 511 WJV3651321

n

Fig. 4-66
rk er

● When pressure in passage (P) exceeds the preload of spring (621), cone valve (611) is
pushed open. Therefore, working oil flows through hole (C) via the periphery of cone valve (611)
and enters the low pressure passage (R).
Ma t
In

(C)

621
611 WJV3651322

Fig. 4-67

Shop Manual - April 2014 4-77

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

● Opening of cone valve (611) causes pressure in cavity (B) to drop and valve post (511) is
opened. In this way, working oil in passage (P) goes to the low pressure passage (R) directly.

(B)

.
De al
R

pt
g n
511 611
o
WJV3651323
in ti

Fig. 4-68
司
公
销
营
et a

Functioning as oil complement check valve against cavitation

n

When negative pressure is formed in passage (P), working oil is fed from passage (R). When
pressure in passage (R) exceeds the pressure in passage (P), valve seat (541) moves to the right
rk er

direction. Therefore, working oil is delivered from passage (R) to passage (P) via the periphery of
valve seat (541). Cavitation is prevented as a result.
Ma t
In

541
WJV3651324

Fig. 4-69

4-78 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.6 Hydraulic System, Part 3

4.6.1 Swing motor
Type: M5X180CHB-10A-3NA/265

.
L

De al
SH PG

pt
PB
B
g n
IP
o
in ti

PA A
司
公
销
营
et a

1
M DB
n
rk er

2
Ma t
In

ZX215-1002081

Fig. 4-70

A: Main oil port Specifications

B: Main oil port
M: Makeup port Model M5X180CHB-10A-3NA/265
PA: Pressure detection port Theoretical dis-
180.1 cm3/rev
placement
PB: Pressure detection port
Safety valve
DB: Lubricant port 26.0 MPa
press. setting
PG: Brake release port Max swing speed 1470 rpm
SH: Brake command port Brake release
2.7-4.9 MPa
L: Level stick pressure
IP: Gear oil feed port
(1) Safety valve
(2) Anti-swing valve

Shop Manual - April 2014 4-79

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

7
6

.
De al
A-A

pt
g no
A
8 9
5
in ti

A
司
公
销
营
et a

10
n
rk er

11
3
Ma t

12
In

13
1
ZX215-1002082

Fig. 4-71

(1) Spacer (8) Oil distributor

(2) Housing (9) Cylinder barrel
(3) Disc (10) Brake piston
(4) Brake spring (11) Plate
(5) Shell (12) Piston
(6) Spring (13) Drive shaft
(7) Check valve

4-80 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.6.2 Swing holding brake

● Port PG is directly connected with the pilot gear pump and it is always under a pressure of
3.9MPa.

M
Pump a
1
Main
valve 7
PX
PG
6

.
De al
SH

pt
5
g no
ZX215-1002083

Fig. 4-72
in ti

● Port SH is in connection with port (PX) of the main control valve. In case of any operation (ex-
营
销
公
司

cept travel) is performed by the main control valve, Port (PX) will be put under pressure. This
et a

pressure establishes connection between PG and chamber (a) below piston (7). The pres-
n

surized oil pushes the brake piston upward to compress spring (1) and separate disc (5) from
plate (6). The brake is released.
rk er
Ma t
In

M
Pump a
1
Main
valve 7
PX

PG
6

SH

ZX215-1002084

Fig. 4-73

● Otherwise, without pressure acting upon the port (PX), the connection between (PG) and
chamber (a) below piston (7) is blocked. Brake spring (1) pushes the brake piston to press
disc (5) against plate (6). The brake is engaged.

Shop Manual - April 2014 4-81

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.6.3 Relief valve section

Structure
● The relief valve section consists of relief valves (1) and (2) and check valves (3) and (4).

Function
● When the machine is in the swing holding mode, control valve (5) closes the motor outlet cir-
cuit, but the motor rotation is continued due to inertial force. The motor output is, therefore,
abnormally increased, which could damage the motor.
● In order to prevent the motor from being damaged, the relief valve relieves the abnormally
high pressure oil to port (M) from the outlet side (high-pressure side) of the motor.

.
De al
Operating principle From oil port M

pt
1 2
1. When starting swing (suppose pressurized
oil is delivered to port A)
g n
● When the swing control lever is set to the
o
right- swing, pressurized oil from the pump
is delivered to port (A) via control valve (5).
in ti

● The pressure at port (A) rises, the starting

torque is generated in the motor, and the
司
公
销
营
et a

motor starts to rotate. 3

4
n

● The pressurized oil from the outlet port of

the motor passes from port (B) through the
rk er

C
control valve (5) and returns to the tank.
A B
Ma t

5
ZX215-1002085
In

Fig. 4-74

4-82 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

2. When swing is stopped From oil port M

1 2
● When the swing control lever is set neutral,
the supply of pressurized oil from the pump
to port (A) is stopped.
● The pressurized oil from the motor outlet
can't return to the tank since the returning
circuit to the tank is closed from control
valve (5). Thus, the pressure on port (B)
increases. 4
3
● Swing resistance is generated on the mo-
tor and hence the brake starts working.
C
● Pressurized oil will be relieved when the

.
A B

De al
pressure on port (B) rises to the set pres-

pt
sure of relief valve (2).
5
ZX215-1002086
● A high braking torque acts on the motor,
g n
thereby stopping the motor.
Fig. 4-75
o
● When relief valve (2) is being actuated, the
in ti
relieved oil and the pressurized oil from
port (M) are fed to port (B) via check valve
(4). 营
销
公
司
et a

● The above prevents the formation of cavi-

tation on port (B).
n
rk er
Ma t
In

Shop Manual - April 2014 4-83

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.6.4 Anti-jerk valve

4.6.4.1 Operation diagram

A T1
(1) Valve body
(2) Spool (side A)
(3) Spring (side A)
(4) Plug
(5) Spool (side B)
(6) Spring (side B)
T2 B (7) Plug
1 2
3 4

.
De al
pt
g no
7 6 5
Swing
in ti
motor T

B A
司
公
销
营
et a

Swing Control Valve

ZX215-1002087
n

Fig. 4-76
rk er

4.6.4.2 Effect illustration

: With antiswing valve
Ma t

：Without antiswing valve

Reversing pressure
In

Pressure MA

Suppressing pressure
Reversing pressure
Pressure MB

First reversing

Second reversing
Motor speed

Start Brake Reverse

Time ZX215-1002088

Fig. 4-77

4-84 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Outline
A
● The inertia of the swing body, the counter- T
action and rigidity of the mechanical sys- c e D4 a D3
tem, or the compressibility of the hydraulic
oil can cause shaking of machine during
swing operation. The anti-jerk valve is able
to reduce such impact. It is effective in pre-
venting collapsing of load when the swing
is stopped and in reducing the cycle time
(by better positioning performance and
D1 d 㔎ষ D2 % b f
quicker movement for next operation).
7
ZX215-1002089

.
Fig. 4-78

De al
pt
Operation g n $
1. When braking pressure is generated at port T
o
(B) F H ' D '
in ti

● Pressure (MB) is conducted to chamber (d)

via the notch. The pressure compresses
spring (6) by use of the difference in areas
司
公
销
营
et a

of circles (D1 > D2) of spool (5) and moves

the spring (6) to the left side. Port (B) and
n

chamber (e) will be interconnected. Since

rk er

pressure (A) is lower than the set pressure ' G 㔎ষ ' E I

%
of spring (3), spool (2) does not move and
T
the pressurized oil is stopped by spool (2). ZX215-1002090
Ma t

Thus the braking force is ensured.

Fig. 4-79
In

2. When motor is stopped

A
● The motor rotation is reversed by the clos- T
ing pressure generated at port (B). (1st a 2 3

reversing) Reversing pressure is gener-

ated on port (A) under the above condition.
Pressure (A) is conducted to chamber (a),
and spool (2) moves spring (3) to the right
side, and A and B is interconnected. At this
time, b is interconnected with f via the ori-
fice on spool (5), and reversing pressure
5 d B b f
on port A is bypassed to port T in order to
T
prevent second reversing.
ZX215-1002091

Fig. 4-80

Shop Manual - April 2014 4-85

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.6.5 Central Swivel Joint

12

11

9
10

8 15 E
E
7
D D

.
De al
C C

pt
g n B

B A A
6
o
5
in ti

4
司
公
销
营

3 13，14
2 1
et a
n
rk er
Ma t
In

W365R130401

Fig. 4-81

(1) Bolt (9) O-ring

(2) O-ring (10) Swivel shaft
(3) Cap (11) Rotor
(4) O-ring (12) Plug
(5) Washer (13) Bolt, socket-head
(6) Collar (14) Flat washer
(7) Rotary seal (CSI) (15) Dust boot
(8) Housing

4-86 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.6.6 Travel motor

Type: MAG-170VP-3800E

View of motor before installation

Z Motor positioning cut

Φ200H7
Bre X

B
T

.
De al
pt
S

Hexagon bolt
2-M20×40
g n
Torque 358Nm Bolt hole for
o
motor installation
Oil inlet of brake 2-M20
in ti
M12×1.5 Oil inlet of brake
Y向
X 营Z向
销
公
司

Direction B
et a

B
Bre
Oil inlet, level
n

M18×1.5
A
rk er

MB
MA
S
Ma t

Drain port
M18×1.5
W365T130401
In

Fig. 4-82

A, B: Working oil port

T: Oil drain port
MA, MB: Test port
S: Oil compensation port
X: Control pressure port
Bre: Oil port for releasing external brake

Shop Manual - April 2014 4-87

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Table 1 - Motor Specifications

Item Unit Specifications

Max input torque N·m 546
Max input speed r/min 4788
Max output torque N·m 69309
Max output speed r/min 37.7
Basic braking torque (without
N·m 730
back pressure)
Starting pressure bar 18
Max withstanding pressure bar 50

.
Oil refilling capacity L 8.5

De al
Speed ratio - 126.94

pt
Weight g n kg 400
Brake disc Disc type brake
Lubricant oil 220（40℃）industrial application
o
in ti

司
公
销
营
et a
n
rk er
Ma t
In

4-88 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.6.7 Reducer
Type: GFT80

105 15 3 20 5 21 6 19 48 47 8 12 13 14 13 18 11 16 53 55 59 54 58 89 91 93 66 90 94 67 92 200 199

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er

38 37 38 35 36 35
Ma t
In

23 22 39 1 28 26 32 31 25 44 46 30 29 27 4 99 100 17 49 52 88 87 69 70 51 103

W365T130402

Fig. 4-83

Shop Manual - April 2014 4-89

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

No. Code Description Qty No. Code Description Qty

E001 R988011946 Support shaft 1 E048 R913006477 Bolt, hexagon 24

E003 R988012090 Drive shaft 1 E049 R988010958 Gear ring 1

E004 R988011553 Planetary carrier 1 E051 R988011457 End cover 1

E005 R988012073 Bearing seat 1 E052 R988011597 Sun gear 1

E006 R916452282 Collar 1 E053 R988011951 Planetary carrier 1

E008 R916452408 Collar 1 E054 R988011483 Planetary gear 3

Cylindrical roller
E011 R988011587 Planetary gear 5 E055 R988012459 3
bearing
Cylidrical roller
E012 R916411696 10 E058 2916650023 Collar 3
bearing
E013 R988012373 Collar 10 E059 R913003909 Collar 1

E014 R916452254 Collar 5 E066 R988012492 Ring 1

.
De al
E015 R988013065 Float seal 1 E067 R913006441 Bolt, hexagon 12

pt
E016 2916650025 Elastic collar 5 E069 R913003865 Plug 2

E017 R988011192 Sun gear 1 E070 R916462052 Washer 2

g n
E018 R916452068 Elastic collar 1 E087 R988011630 Sun gear 1
o
E019 R988011289 Round nut 1 E088 R988012341 Collar 1
in ti
Tapered roller
E020 R916412778 1 E089 R988011188 Planetary carrier 1
bearing
Tapered roller E090 R988011840 Planetary gear 3
E021 R916412722 1
bearing
司
公
销
营

Cylindrical roller
E091 R988012458 3
et a

E022 R988012516 O-ring 1 bearing

E023 R913006409 Bolt, hexagon 2 E092 R916452026 Collar 3
n

E025 R988011598 Piston 1 E093 R916462507 Collar 6

rk er

E026 R988012185 Collar 1 E094 R916452244 Collar 6

Deep-grooved
E027 R988012320 Collar 2 E099 R988012398 1
ball bearing
Ma t

E028 R916452300 Collar 1 E100 R916462138 Collar 1

Friction disc,
E029 R988012929 6 E103 R988012357 Cylidrical roller 1
In

outside
Friction disc, E105 R902165278 Motor 1
E030 R988012931 5
inside
E031 R916423354 Spring 18 E199 R988012436 Rivet 4

E032 R916423355 Spring 18 E200 R909830326 Nameplate 1

E035 R988012913 Collar 2

E036 R988012397 Spring sleeve 1

E037 R988012404 X -ring 1

E038 R988012914 X -ring 2

E039 R902602007 Plug 1

E044 2917890148 Pin 2

E046 R988012493 O-ring 1

E047 R988011215 Bearing seat 1

4-90 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.6.8 Travel motor (Nabtesco)

Type: GM60VA

Pi

.
De al
pt
MA
Nabtesco Nabtesco

g no
Dr MB A
B
in ti

26XM20 18XM24
司
公
销
营
et a

FILL
lEVEL
n
rk er

Filling port DRAIN

Drain port
Ma t

ZX305-1102601
In

Fig. 4-84

A: Main oil port

B: Main oil port
Am: Pressure detection port
Bm: Pressure detection port
Pi: Two-speed pilot tubing port
Dr: Oil drain port

Shop Manual - April 2014 4-91

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Item Unit Specifications

Input flow L/min 280
Relief valve pressure setting Mpa 34.3
2
Motor displacement cm /rev 290.7/170.1
Reduction ratio — 40.67
2
Total displacement cm /rev —
Theoretical output torque KN·m 64.3/37.6
Theoretical output speed r·p·m 23.8/40.7
Braking torque KN·m 1.17
Brake release pressure Mpa 1.54
Auto switching pressure Mpa 26.5

.
De al
Operating temperature range ℃ -20~90

pt
Total weight kg 399
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

4-92 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.6.9 Operating principle of the basic components

4.6.9.1 Double-balanced valve

Function:
● When external load makes the plunger motor tend to go faster than the rated rotating speed
of feed flow (hereunder referred to pump effect), this valve controls motor speed and prevents
over-speed of the motor in relation with the feed flow.
● The double-balanced valve and the relief valve constitute the braking circuit. The braking cir-
cuit applies braking force onto the swing of plunger motor and stops the motor gradually.
● This valve can serve as a shuttle valve for high pressure selection to release the brake under
its own pressure.

.
De al
● The structure of a standard double-balanced valve is shown below. The following information

pt
describes the operating principle of a standard double-balanced valve.

A. When stopped
g no
● When the main valve is neutralized (motor stopped), port M1 and port M2 are shut off by
spool (1) and check valve (2) since no pressure is generated at port P1 and port P2. The mo-
in ti

tor is not rotating.

司
公
销
营
et a

8-1
n

8
rk er

8-2
Oil circuit B
Ma t

Oil circuit C2
In

Oil circuit C1 M2
M1
Orifice D3
Orifice D1
Damper chamber A2

Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber1

P1 P2
6-1 6-2

7-1 7-2

5-1 3 4-1 2-1 1 2-2 4-2 5-2

ZX215-1002094

Fig. 4-85

Shop Manual - April 2014 4-93

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

B. When motor is started

● When the hydraulic oil from the main pump enters port P1 of the double-balanced valve,
spring (3) is pushed to the left by check valve (2-1), opening circuit C1. The hydraulic oil en-
ters the plunger motor via port M, trying to make the motor rotating. At the same time, return
oil from the plunger motor enters the counterbalance valve via port M2, but it is stopped by
check valve (2-2). The output pressure of the main pump increases as a result, and the hy-
draulic oil works on the inside of spring chamber (1) and damper chamber (A1) via orifice (4-1)
and check valve (5-1). The force generated in this way pushes spring (7-2) on the other side
and moves plunger (1) to the right. At this time, return oil from port M2 passes through circuit
of the notch on the periphery of plunger (1), and through port P2 when pressure is generated
at port M2, and enters the tank via the main valve finally. The motor starts rotating at this time.

.
De al
pt
g n 8-1

8
o
in ti

8-2
Oil circuit B
司
公

Oil circuit C2
销
营
et a

Oil circuit C1
M1 M2
Orifice D3
Orifice D1
n

Damper chamber A2
rk er

Damper chamberA1
Orifice D4

Orifice D2
Spring chamber 2
Ma t

Spring chamber 1
In

P1 P2
6-2
6-1

7-1 7-2

5-1 3 4-1 2-1 1 2-2 4-2 5-2

ZX215-1002095

Fig. 4-86

4-94 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

C. Counterbalance function
● When the engine runs at an excessively high speed because of external force applied on it,
the motor may lose control. At this time, port P1 serves as the inlet side, and the pressure
drops. Pressure in spring chamber (1) and damper chamber A1 also drop. As a result, plunger
(1) moves to the left under the force of spring (7-2), closing circuit B. Circuit at the suction
side is also closed at the same time when the circuit at return side is closed. When circuit B is
closed, pressure at port P1 rises due to hydraulic oil from the main pump, moving plunger (1)
to the right again. In this way, when external load generates pump effect, slight movement of
plunger (1) keep circuit B open. The rotation speed of the motor keeps in line with fuel supply
of the main pump, and the motor will not lose control because of the vacuum in the hydraulic
system.

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 4-95

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

D. Braking of motor
● The double-balanced valve and the relief valve forms the braking circuit.
● When the main valve is in neutral position, hydraulic oil from the main pump is cut off, and
pressure at port P1 and P2 is the same. As a result, plunger (1) moves to the neutral position,
and the opening area of circuit B decreases.
● At the same time, because of the inertia of external force, the motor does not stop rotating
(pump effect), and pressure at port M2 rises and serves as the braking force of motor rotation.
● When the pressure at port M2 reaches the set pressure of relief valve (8), cone valve (8-1)
at port M1 overcomes the force of spring (8-2) and moves to the left, and hydraulic oil flows
to the port M1. In this way, the impacting force due to inertia at port M2 is under control, and
vacuum at port M1 is avoided.

.
De al
pt
g no
8-1

8
in ti

8-2
营
销
公
司
Oil circuit B
et a

Oil circuit C2
Oil circuit C1 M2
M1
n

Orifice D3
Orifice D1
Damper chamber A2
rk er

Damper chamber A1
Orifice D4
Orifice D2
Ma t

Spring chamber 2

Spring chamber 1
In

P1 P2
6-1 6-2

7-1
7-2

5-1 3 4-1 2-1 1 2-2 4-2 5-2

ZX215-1002096

Fig. 4-87

4-96 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

E. Shuttle valve function for high pressure selection

● The double-balanced valve can function as a shuttle valve to release travel brake.
● When hydraulic oil is fed to port P1, plunger (1) moves to the right, as shown in fig. 4. At this
time, drain passage F of motor housing is cut off, and passage D leading to cylinder chamber
E for travel braking is opened.
● Hydraulic oil flows to passage G via the orifice, and enters travel brake cylinder chamber E to
release the travel brake. In addition, plunger (1) moves to neutral position, as shown in fig 5
when motor stops. Passage D is closed and drain passage F of motor housing is opened.
● Hydraulic oil in travel braking cylinder chamber E is conducted to the drain passage of motor
housing, and travel brake is applied.

.
De al
1
Passage D

pt
g no
Passage D

Orifice
in ti
Passage F
Passage F
Passage D Passage G
营
销
公
司

Passage G Cylinder chamber E

et a
n

ZX215-1002097
rk er

Fig. 4-88
Ma t

1
Passage D
In

Passage D

Orifice
Passage F
Passage F
Passage D Passage G
Passage G Cylinder chamber E

ZX215-1002098

Fig. 4-89

Shop Manual - April 2014 4-97

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.6.9.2 Operation of parking brake

1) When starting travel

● As the travel lever is operated, pressurized
oil from the pump activates back pressure
valve spool (10), opens the parking brake 10
circuit, and flows to chamber A of brake
piston (12). Pressurized oil overcomes the
force of spring (11) and pushes piston (12)
toward the left.
● Since the pushing force to plate (13) and
disc (14) disappears, plate (13) is sepa-

.
De al
Travel control valve
rated from disc (14) and the brake is re-

pt
leased.
A M
g n 11 14 13 12 22
ZX215-1002099
o
Fig. 4-90
in ti

2) When travel is stopped 营

销
公
司
et a

● As the travel lever is placed in neutral,

back pressure valve spool (10) returns to
n

the neutral position and closes the parking 10

rk er

brake circuit. T
● he pressurized oil in chamber (A) of brake
piston (12) passes through the orifice of
Ma t

the brake piston and is drained to the mo-

tor casing. Brake piston (12) is pushed to
In

the right by spring (11).

Travel control valve
● Plate (13) and disc (14) are pushed against
each other, and the brake is applied. As
brake piston (12) returns, a time delay is A M
11 14 13 12 22
formed by making the pressurized oil pass ZX215-1002100
through a throttle valve in the slow return
valve (22). This time delay ensures an ac- Fig. 4-91
tive brake after the machine is stopped.

4-98 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.6.9.3 Operation of braking valve

Travel control valve

PA PB
● The brake valve consists of a suction safe-
ty valve (8A) and a counterbalance valve
8A
(18). As shown in the illustration on the
right, functions and operations of respec-
tive components are described below.

18

MA MB

.
De al
ZX215-1002101

pt
g n Fig. 4-92

1. Counterbalance valve and check valve

o
Travel control valve

PA PB
Function
in ti
8B

● When traveling downhill, the weight of the 销

公
司
8A
machine tends to make the travel speed
营
et a

faster than the motor speed. If the machine

travels with the engine at low speed, the
n

motor may rotate at zero load, resulting

rk er

in runaway and inviting a very dangerous

situation. These valves are used to avoid
such a situation by controlling the machine
Ma t

19 MA MB
to travel according to the engine speed
(pump flow).
In

ZX215-1002102

Fig. 4-93
Operation when pressurized oil is supplied
● Operating the travel control lever conducts
the pressurized oil from the control valve
to port (PA). The pressurized oil opens
suction safety valve (8A) and then flows to
motor outlet port (MB) via motor inlet port
(MA). The motor outlet side is closed by
suction safety valve (8B) and spool (19),
so the pressure at the supply side rises, as
shown in the right illustration.

Shop Manual - April 2014 4-99

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

● The pressurized oil on the supply side

flows to chamber (S1) via orifice (E1) and Travel control valve

orifice (E2) of the spool (19). As the pres- PA PB

sure in chamber (S1) goes above the spool
shift pressure, spool (19) is pushed toward
the right. Port (MB) and port (PB) are con-
nected, the motor outlet port side opens
and the motor starts rotating, as shown in
the right illustration. S1

19

MA MB

.
De al
E1 E2 ZX215-1002103

pt
g n Fig. 4-94
o
Brake operation in downhill travel
Travel control valve
in ti
● If the machine goes out of control while
PA PB
travelling downhill, the motor will be caused 20
to rotate without load to decrease the inlet
司
公
销
营
et a

side oil pressure. Pressure in chamber (S1)

drops via orifices (E1) and (E2). As the
n

pressure in chamber (S1) goes below the

rk er

spool shift pressure, spool (19) is returned S1

to the left by spring (20) and outlet port (MB)
is throttled. The pressure at the outlet port
Ma t

side rises, generating rotation resistance 19

on the motor to prevent the machine from
In

MA MB
losing control. On the other hand, the spool
moves to a position where the pressure on E1 E2 ZX215-1002104
outlet port (MB) can be balanced against
the machine's own weight and the inlet port Fig. 4-95
pressure. Oil flow from the outlet circuit is
reduced to ensure the travel speed corre-
sponded to the pump delivery, as shown in
the right illustration.

4-100 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

2. Safety valve

Function
● When the machine travel is stopped (or it
is travelling downhill), the double-balanced
valve closes the inlet and outlet circuits of
the motor. Since the motor is rotated by
inertial force, pressure in the motor outlet
port side is abnormally increased, poten-
tially resulting in damages on the motor
and piping. The safety valve relieves this
abnormal pressure to the inlet port side of
the motor in order to prevent damages to

.
De al
the equipment.

pt
Operation g n
1) When travel is stopped (or when travelling Travel control valve
o
downhill or swinging to the right) PA PB
20
in ti

● Reduction of the pressure at motor inlet

(PA) decreases the pressure in chamber
(S1). When it drops beyond the spool shift
司
公
销
营
et a

pressure, the spool is returned to the left

by spring (20), throttling the oil outlet pas- S1
n

sage (B1). At this time, the motor continues

rk er

rotating due to its inertial force, thus pres-

sure on the outlet port (MB) is increased,
as shown in the right illustration. MA MB
Ma t

A1 B1 ZX215-1002105
In

Fig. 4-96

● When the pressure rises above the set

pressure of the suction safety valve (8A),
the spool opens. The pressurized oil pass-
es through notch (A1) of the counterbal-
ance valve spool (19) into chamber (MA) of
the circuit at the opposite side, as shown in
the right illustration.
Spool MB MA

ZX215-1002107

Fig. 4-97

Shop Manual - April 2014 4-101

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

2) When starting travel (or traveling normally)

Travel control valve
● As the travel control lever is operated, the
PA PB 8B
pressurized oil from the pump moves the
counterbalance valve spool (19) toward
right. In this case, the passage to the suc- 8A
tion safety valve functions as a circuit
which passes through notch (B2) of spool
(19), producing large differential pressure. S1
The pump pressure rises, providing a large
tractional force to the valve, as shown in
19
the right illustration.
MA MB

.
E1 B2

De al
ZX215-1002106

pt
Fig. 4-98
3. Overload relief valve
g n
● The structure of the relief valve is shown
o
in the right figure. This valve is an area-
differential and direct-acting relief valve. It
in ti

has impact damping function during start-

ing and braking.
司
公
销
营
et a
n
rk er
Ma t

ZX365-1304108

Fig. 4-99
In

A. Operating principle and function

● When the main control valve makes the
motor to start or brake, front pressure of
2-9-2 2-9-5
cone valve (2-9-2) rises above the set pres-
sure and the force of spring (2-9-5), and
moves cone valve (2-9-2) to the right and
off the valve seat (2-9-3). Pressurized oil in
the front of cone valve (2-9-2) is bypassed
to the low pressure side. The impact due
to inertia energy at the high pressure side
2-9-3
is put under control and vacuum is pre-
vented from occurring at the low pressure
ZX365-1304109
side through bypassing pressurized oil to
the low pressure side. Fig. 4-100

4-102 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

B. Damping function
● When the relief valve begins to function, 2-9-2 Area S2 2-9-5
damping piston (2-9-9) moves to the left.
As a result, low pressure is maintained in
spring chamber D. At this time, the loaded
area of cone valve (2-9-2) is S1, and gen-
erally it is much larger than the set loaded
area S1-S2 of the relief valve. So, when
damping piston (2-9-9) is moving, the func-
2-9-3 Area S1 2-9-9 Spring chamber D
tional pressure of relief valve is maintained
at 1/3 of normal set pressure in order to
ZX365-1304110
absorb the impact at the high pressure
circuit side due to inertial energy. When Fig. 4-101

.
De al
the movement of damping piston stops,

pt
pressure in spring chamber D rises. Pres-
sure at both side of cone valve (2-9-2) is
g n
the same, and the relief valve is working
at normal set pressure. In this way, the re-
o
lief valve reduces the impact during motor
in ti
starting and braking by a two-stage action
to provide excellent performance.
司
公
销
营
et a
n
rk er Pressure (P)
Ma t
In

O Damping form time (T)

ZX215-1002111

Fig. 4-102

Shop Manual - April 2014 4-103

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Table 2 Repair standard of motor components

Components Check item Allowable limit Remedy

Grind the boot sliding
surface. Replace the
Roughness 0.8a or surface rough-
1. Boot sliding surface cylinder block assembly
ness, scratch 0.02mm+
if the scratch cannot be
corrected.
1-4-2 Plunger Roughness 1.2a or surface rough-
assembly 2. Plunger outer diameter
ness, scratch 0.02mm+
3. Plunger outer diameter Replace the cylinder
and cylinder block inner Clearance 0.060. block assembly.
diameter
4. Boot head clearance Clearance 0.4.

.
Grind the boot sliding

De al
surface. Replace the

pt
1. Valve leaf and sliding sur- Roughness 0.8a or surface rough-
cylinder block assembly
face ness, scratch 0.02mm+.
g n if the scratch cannot be
corrected.
Roughness 1.6a or surface rough-
o
1-4-1 Cylinder 2. Shaft hole inner diameter
ness, scratch 0.02mm+.
block
in ti
3. Shaft hole inner diameter
and 4-2 plunger assembly Clearance 0.060. Replace the cylinder
outer diameter 营
销
公
司 block assembly
Roller distance below 38.749
et a

4. Spline at shaft joint (measuring pin diameter

φ3.333(V1=2.80)); or damaged
n

Grind the sliding surface.

rk er

1-21 Oil distri- Roughness 0.8a, scratch 0.02mm+ Replace the valve sheet
1. Sliding surface
bution plate on sliding surface or burned sign if the scratch cannot be
corrected.
1-4-3 Retainer
Ma t

Roughness 0.8a, scratch 0.02mm+ Replace the retaining

1-4-4 Retain- 1. Sliding surface
on sliding surface or sign of burning plate or the retainer.
ing assembly
In

Grind the sliding surface.

Roughness 0.8a, abrasion on sling Replace the valve sheet
1. Sliding surface
surface or scratch 0.02mm+ if the scratch cannot be
corrected.
1-5 Swash
Roughness 1.6a.
plate 2. Hole for assembling steel
ball Scratch on spherical surface
0.02mm+ or surface roughness Replace the swash plate.
3. Hole for assembling steel
Ball depth 14.5
ball

4-104 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Components Check item Allowable limit Remedy

1. Oil seal sliding portion outer Roughness 1.6a, rough surface, or Replace the swash
diameter scratch 0.02mm+ plate.
Stick spans below 47.380 (testing
2. Cylinder block matching
pin diameter φ3.00), or the stick
1-3 Shaft spline
breakage.
Replace the shaft.
Stick spans below 30.498 (testing
3. Drive gear connection pin diameter φ3.33), or the stick
breakage.
1. Dimension Height 38.2
1-15 Brake pis- 2. Sliding surface Roughness 2.5a Replace the brake
ton piston.
3. Appearance Scratch 0.02mm+ or rough surface

.
1. Dimension Thickness 3.2

De al
Replace the disc
1-13 Disc plate

pt
Deep scratch on sliding surface or plate.
2. Appearance
friction material peeling
1-8 Ball bearing 1. Rolling surface Peeling or fracture
g n Replace the ball
Abnormal rotation (noise•uneven bearing.
1-9 Ball bearing 2. Action
o
rotation)
Grind the sliding
in ti

surface. Replace the

Roughness 1.6a, rough surface, or
1. Boot sliding surface flange plate parts if
scratch 0.02mm+
the scratch cannot
司
公
销
营
et a

1-7 Plunger as- be corrected

sembly Roughness 1.2a, rough surface,
2. Plunger outer diameter
n

scratch 0.02mm+
3. Plunger outer diameter and Replace the flange
rk er

Gap 0.040. plate parts.

flange part inner diameter
4. Boot head clearance Clearance 1.0
Roughness 0.8 a, scratch 0.02mm+
Ma t

1. Plunger outer diameter

1-2-2 Plunger or rough surface Replace the valve
assembly 2. Plunger outer diameter and sheet.
In

Clearance 0.060.
valve sheet inner diameter
1. Assemble the plunger as- Roughness 0.8 a, scratch 0.02mm+
sembly hole or rough surface
2. Valve sheet inner diameter
Clearance 0.060
and plunger outer diameter
3. Valve spool assembly instal- Roughness 0.8 a, scratch 0.02mm+
1-2-1 Valve lation hole or rough surface Replace the valve
sheet sheet and the parts.
4. Spool valve sheet inner di-
ameter and valve spool outer Clearance 0.060.
diameter
5. Movable plunger sliding part Scratch 0.02mm+ or surface rough-
and seat of the relief valve ness

Shop Manual - April 2014 4-105

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

4-106 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Components Check item Allowable limit Remedy

1. Valve spool out diam- Roughness 0.8 a, scratch 0.02mm+
eter or surface roughness
1-2-9 Spool as- Replace valve sheet
2. Valve spool outer diam-
sembly and parts
eter and valve sheet inner Clearance 0.060.
diameter
1-2-7-9 Movable 1. Sliding portion of valve Scratch 0.02mm+ or surface rough-
plunger sheet and valve seat ness
Replace relief valve
1. Sling portion of the
Scratch 0.02mm+ or surface rough- assembly
1-2-7-1 Case movable piston (outer
ness
diameter)
1. Dimension Free length 61.0
1-4-7 Spring
2. Appearance Deformation and surface damage

.
1. Dimension Free length 39.0

De al
1-18 Spring
2. Appearance Deformation and surface damage

pt
1. Dimension Free length 41.5
1-20 Spring
g no
2. Appearance Deformation and surface damage
1. Dimension Free length 48.5
1-2-4 Spring
2. Appearance Deformation and surface damage
in ti

1. Dimension Free length 28.3

1-2-10 Spring
2. Appearance Deformation and surface damage
司
公
销
营
et a

Replace o-ring and oil

O-ring and oil seal When removed
seal
n
rk er
Ma t
In

Shop Manual - April 2014 4-107

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.6.10 Control system

8

9
7

.
De al
pt
g n
4 1 2
5 10
o
9 7
5
in ti
6
3
4 12
11 司

10
公
销
营

8
et a

13
n

3 11
rk er

2
Ma t
In

12

ZX365-1304112

Fig. 4-103

4-108 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

(1) Pilot valve (travel)

(2) Control lever (left travel)
(3) Control lever (right travel)
(4) Pilot valve (Right)
(5) Control lever (right work equipment)
(6) Accumulator
(7) Block
(8) Hydraulic pump
(9) Main control valve
(10) Solenoid valve
(11) Control lever (left work equipment)
(12) Relay

.
De al
pt
Control lever positions
g n
1 HOLD
o
2 Boom UP
in ti

3 Boom DOWN
4 Bucket DUMP 营
销
公
司
et a

5 Bucket DIG
HOLD
n

7 Arm IN
rk er

8 Arm OUT
9 Right swing
Ma t

10 Left swing
In

11 Neutral
12 Travel BACKWARD
13 Travel FORWARD

Shop Manual - April 2014 4-109

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.6.11 Manual pilot valve

P3
P2
A

T
P

2
3
P

1
4

.
De al
pt
P4 P1
g n A

19~22Nm
o
64~73.5Nm
in ti

司
公
销
营
et a
n
rk er
Ma t
In

ZX365-1304113

Fig. 4-104

P: From pilot pump relief valve

P1: Left pilot valve: Arm OUT / Right pilot valve: Boom DOWN
P2: Left pilot valve: Arm IN / Right pilot valve: Boom UP
P3: Left pilot valve: Swing LEFT / Right pilot valve: Bucket DIG
P4: Left pilot valve: Swing RIGHT / Right pilot valve: Bucket DUMP
T: To tank

4-110 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

6
7

.
De al
pt
g n
4
o
9
in ti

3
司
公
销
营
et a

10
n

2
rk er
Ma t

1
In

A-A ZX215-1002114

Fig. 4-105

(1) Plunger (6) Nut (for control lever connection)

(2) Adjusting spring (7) Connector
(3) Center spring (8) Plate
(4) Piston (9) Retainer
(5) Disc (10) Valve body

Shop Manual - April 2014 4-111

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Operation

1. When in neutral
● Ports (A) and (B) of the control valve and
ports (P1) and (P2) of the pilot valve are D
connected to drain chamber (D) via orifice
(f) in plunger (1). f

2. During fine control (Neutral to fine control) 1 T

● When piston (4) is pushed by disc (5),

retainer (9) is pushed, plunger (1) is also P
pushed by adjusting spring (2), and moves
down.

.
De al
● When orifice (f) is shut off from drain cham-

pt
Pilot
ber (D), it is almost simultaneously inter- pump P1 P2
connected to pump pressure chamber (PP).
g n
Pilot pressurized oil of the control pump is
led to port (A) from port (P1) via orifice (f).
o
A M M B
When the pressure at port (P1) becomes Control valve
in ti

higher, plunger (1) is pushed back and ZX365-1304115

orifice (f) is shut off from pump pressure
Fig. 4-106
司
公
销
营

chamber (PP). At almost the same time, it

et a

is connected to drain chamber (D) to re-

lease the pressure at port (P1). As a result,
n

plunger (1) moves up and down until the

rk er

force of adjusting spring (2) is balanced

with the pressure at port (P1).
● The relationship of the position of plunger
Ma t

D
(1) and body (10) [orifice (f) is in the middle
In

between drain chamber (D) and pump f

pressure chamber (PP)] does not change
until retainer (9) contacts plunger (1). Ad- 1 T
justing spring (2) contracts in proportion
to the stroke of the control lever. Pressure P
at port (P1) also rises in proportion to the
stroke of the control lever. In this way, the
control valve plunger moves to a position
where the pressure of chamber (A) (same Pilot
P1 P2
pump
as pressure at port (P1)) and the force of
the return spring of the control valve plung-
er are balanced.
A M M B
Control valve
ZX365-1304116

Fig. 4-107

4-112 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

3. Fine control (When control lever returns)

● When disc (5) starts to return, plunger (1)
is pushed up by the force of center spring
(3) and the pressure at port (P1).
● Because of this, orifice (f) is connected to D
drain chamber (D), and the pressurized oil
f
at port (P1) is released.
● If the pressure of port (P1) is lowered ex- 1 T
cessively, plunger (1) is pushed down by
adjusting spring (2). P
● Orifice (f) is shut off from drain chamber
(D), and it is almost simultaneously in-

.
De al
f1
terconnected to pump pressure chamber

pt
(PP). Pump pressure is supplied until the Pilot
pump P1 P2
pressure at port (P1) recovers to the level
g n PP
equivalent to the lever position.
o
● When the plunger of the control valve re-
A M M B
turns, the oil in drain chamber (D) flows in Control valve
in ti

from orifice (f) in the valve on the side that ZX365-1304117

is not working. The oil passes through port
Fig. 4-108
司
公
销
营

(P2) and enters chamber (B) to replenish

et a

the chamber with pressurized oil.

n
rk er

4. At full stroke
● Disc (5) pushes down piston (4), and re-
D
tainer (9) pushes down plunger (1).
Ma t

● Orifice (f) is shut off from drain chamber (D), f

In

and is interconnected to pump pressure

chamber (PP). 1 T

● Therefore, the pilot pressure oil from

P
the self pressure reducing valve passes
through orifice (f) and flows to chamber
(A) from port (P1) to push the control valve
f1
plunger.
Pilot
pump P1 P2
● The oil returning from chamber (B) passes PP
from port (P2) through orifice (f) and flows
to drain chamber (D).
A M M B
Control valve
ZX215-1002118

Fig. 4-109

Shop Manual - April 2014 4-113

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.6.12 Travel pilot valve

.
De al
pt
P
P
g no
P5 A
in ti
P6
P5

P2 P1 营
销
公
司
et a
n
rk er

2 1

4 3
Ma t
In

P4 P3
ZX215-1002119

Fig. 4-110

P: From pilot pump P4: R.H. forward

P1: L.H. reverse P5: Travel signal
P2: L.H. forward P6: Travel signal
P3: R.H. reverse T: To tank

4-114 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

37~30Nm
B

65~45Nm
1 8~6Nm

.
De al
pt
4

5
g no
6
C C
in ti

7
B-B
2，4 1，3 营
销
公
司

B
et a

13~11Nm
n
rk er
Ma t
In

C-C
8~6Nm
ZX215-1002120

Fig. 4-111

(1) Plate (5) Center spring

(2) Body (6) Adjusting spring
(3) Piston (7) Valve
(4) Collar

Shop Manual - April 2014 4-115

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.6.12.1 Operating principle

1) When in neutral
● Ports (A) and (B) of the control valve and
ports (P1) and (P2) of the pilot valve are D

connected to drain chamber (D) via orifice

f
(f) in spool (1).
T
2) Fine control (Neutral to fine control) P

● When piston (4) is pushed by lever (5), re-

1
tainer (9) is pushed, and plunger (1) is also
Pilot pump
pushed by adjusting spring (2), and moves
P1 P2
downward.

.
● When orifice (f) is shut off from drain

De al
A B
Control Valve
chamber (D), it is almost simultaneously

pt
interconnected to pump pressure chamber ZX215-1002121
(PP).
g n Fig. 4-112
● Pilot pressurized oil of the control pump is
o
led to port (A) from port (P1) via orifice (f).
in ti

● When the pressure at port (P1) becomes

higher, plunger (1) is pushed back and 营
销
公
司

orifice (f) is shut off from pump pressure

et a

5
chamber (PP). At almost the same time, it
4
is connected to drain chamber (D) to re-
n

lease the pressure at port (P1). 9

rk er

D
● As a result, plunger (1) moves up and 2
down until the force of adjusting plunger (2) f
T
is balanced with the pressure at port (P1).
Ma t

P
● The relationship of the position of plunger
In

(1) and body (10) [orifice (f) is in the middle 1

between drain chamber (D) and pump Pilot pump PP
P1 P2
pressure chamber (PP)] does not change
10
until retainer (9) contacts plunger (1).
A B
Control Valve
● Adjusting spring (2) contracts in proportion
to the stroke of the control lever. ZX215-1002122

● Pressure at port (P1) also rises in propor- Fig. 4-113

tion to the stroke of the control lever.
● In this way, the control valve spool moves
to a position where the pressure of cham-
ber (A) (same as pressure at port (P1)) and
the force of the return spring of the control
valve spool are balanced.

4-116 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

3) Fine control (When control lever returns)

● When lever (5) starts to return, plunger (1)
is pushed up by the force of center spring 5
(3) and pressure at port (P1).
● Because of this, orifice (f) is connected to
3 D
drain chamber (D), and the pressurized oil
2
at port (P1) is released.
f T
● If the pressure of port (P1) is lowered ex-
cessively, plunger (1) is pushed down by P
f’
adjusting spring (2).
1
● Orifice (f) is shut off from drain chamber (D), Pilot pump PP
and it is almost simultaneously intercon- P1 P2

.
De al
nected to pump pressure chamber (PP).

pt
A B
● Pump pressure is supplied until the pres- Control Valve
sure at port (P1) recovers to the level
g n
equivalent to the lever position.
ZX215-1002123

Fig. 4-114
o
● When the spool of the control valve re-
in ti
turns, the oil in drain chamber (D) flows in
from orifice (f) in the valve on the side that
is not working. The oil passes through port 营
销
公
司

(P2) and enters chamber (B) to replenish

et a

the chamber with pressurized oil.

n
rk er

4) At full stroke
● Lever (5) pushes down piston (4), and re-
tainer (9) pushes down plunger (1). 5
Ma t

4
● Orifice (f) is shut off from drain chamber (D),
In

and is interconnected to pump pressure D

9
chamber (PP).
● Therefore, the pilot pressure oil from f
T
the self pressure reducing valve passes
P
through orifice (f) and flows to chamber f’
(A) from port (P1) to push the control valve
1
spool. PP
Pilot pump
● The oil returning from chamber (B) passes P1 P2
from port (P2) through orifice (f) and flows
to drain chamber (D). A Control Valve B

ZX215-1002124

Fig. 4-115

Shop Manual - April 2014 4-117

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.6.13 Solenoid valve

P2 T A1 A2
2
P1

.
De al
pt
3 4 5 6 7 8
g n
W365-1304125
o
Fig. 4-116
in ti

(1) Solenoid valve block 营

销
公 P1: To pilot fi lter
司
et a

(2) Accumulator P2: To main valve port G

(3) High-speed travel solenoid valve T: To oil tank
n

(4) Backup valve A1: To swivel joint port X

rk er

(5) Backup valve A2: To pilot oil circuit block P

(6) Bucket confl uence solenoid valve
Ma t

(7) Backup
In

(8) Pilot pressure solenoid valve

4-118 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.6.14 PPC accumulator

(1) Gas plug

1
(2) Shell
(3) Poppet
2
(4) Holder
(5) Bladder
(6) Oil port 3

.
4

De al
Specifications

pt
Gas capacity: 300 cc (for PPC)
5
g no
6
in ti

营
销
公
司
ZX215-1002126

Fig. 4-117
et a
n
rk er
Ma t
In

Shop Manual - April 2014 4-119

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

4-120 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.6.15 Pilot oil filter

1
K

2
Model

Pressure
Precision

.
De al
pt
g no
5
in ti

6
司
公
销
营
et a
n
rk er

3
Ma t

ZX215-1002127
In

Fig. 4-118

(1) Nameplate Specifications

(2) Head cover Max. delivery: 40 L/min
(3) O-ring Filter fineness: 10 um
(4) Seal ring Operating pressure: 20 Mpa
(5) Filter Max. operating pressure: 40 Mpa
(6) Casing Pressure loss: 0.05 Mpa
Max. allowable pressure difference: 1 Mpa
Specification of inlet/outlet port O-ring: 30×3.1

Shop Manual - April 2014 4-121

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.6.16 Hydraulic cylinders

Boom cylinder

2 1 7960N·m 3

367N·m 56.9±10.7N·m

.
De al
ZX335-1002035

pt
Fig. 4-119 g n
Arm cylinder
o
in ti

2 1 营
销
公
司 22200N·m 3
et a
n
rk er

711N·m 96.6±18.2N·m
Ma t

ZX335-1002036
In

Fig. 4-120

Bucket cylinder

2 1 3
9550N.m

56.9±10.7N.m
367N.m

ZX335-1002037

Fig. 4-121

4-122 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.6.16.2 Lubrication at every 100 service hours

Unit: mm
No. Check Item Criteria Remedy
Standard Tolerance Standard Clearance
Cylinder
size Shaft Hole clearance limit
Clearance be- -0.012 +0.222
Boom 100 0.083-0.312 0.412
-0.034 +0.047 Replace the
1 tween piston rod
-0.012 +0.222 bushing.
and bushing Arm 120 0.083-0.312 0.412
-0.047 +0.047
-0.012 +0.258
Bucket 100 0.078-0.334 0.434
-0.034 +0.048
-0.036 +0.25
Clearance be- Boom 100 0.086-0.321 1.0
-0.071 +0.05
tween piston rod -0.036 +0.25

.
2 Arm 110 0.086-0.321 1.0

De al
support pin and -0.071 +0.05

pt
bushing -0.036 +0.25
Bucket 90 0.086-0.321 1.0 Replace the
-0.071 +0.05
pin or bush-
g n Boom 90
-0.036 +0.25
0.086-0.321 1.0 ing.
Clearance be- -0.071 +0.05
o
tween cylinder -0.036 +0.25
3 Arm 110 0.086-0.321 1.0
bottom support -0.071 +0.05
in ti

pin and bushing -0.036 +0.25

Bucket 90 0.086-0.321 1.0
-0.071
营
销
公
司 +0.05
et a
n

4.6.16.1 Lubrication at every 500 service hours

Unit: mm
rk er

No. Check Item Criteria Remedy

Standard Tolerance Standard Clearance

Cylinder
Ma t

size Shaft Hole clearance limit

-0.012 +0.222
In

Clearance be- Boom 100 0.083-0.312 0.412

-0.034 +0.047 Replace the
1 tween piston rod
-0.012 +0.222 bushing.
and bushing Arm 120 0.083-0.312 0.412
-0.047 +0.047
-0.012 +0.258
Bucket 100 0.078-0.334 0.434
-0.034 +0.048
-0.036 +0.25
Clearance be- Boom 100 0.086-0.321 1.0
-0.071 +0.05
tween piston rod -0.036 +0.25
2 Arm 110 0.086-0.321 1.0
support pin and -0.071 +0.05
bushing -0.036 +0.25
Bucket 90 0.086-0.321 1.0 Replace the
-0.071 +0.05
pin or bush-
-0.036 +0.25
Clearance be- Boom 90 0.086-0.321 1.0 ing.
-0.071 +0.05
tween cylinder -0.036 +0.25
3 Arm 110 0.086-0.321 1.0
bottom support -0.071 +0.05
pin and bushing -0.036 +0.25
Bucket 90 0.086-0.321 1.0
-0.071 +0.05

Shop Manual - April 2014 4-123

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.7 Work Equipment

4.7.1 Component dimensions

C
G

.
De al
pt
E
g no
J
in ti

,
K 营
销
公
司
et a
n
rk er

B
Ma t
In

H
ZX365-1304500

Fig. 4-122

4-124 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

1 3

D-D G-G J-J

A-A 5
2 4

B-B

H-H K-K

.
E-E 6

De al
pt
g no
C-C F-F I-I ZX285-1002022
in ti

Fig. 4-123
司
公
销
营
et a

Lubrication
Unit：mm
n
rk er

Std. tolerance Clear-

Bushing Lube Std. clear-
No. Item Std. size ance Remedy
material interval 轴 孔 ance
limit
Clearance between the pin and
–0.036 +0.063 0.036 ～
Ma t

1 bushing connecting the boom Copper 500 h Ф110 1.0

–0.071 0 0.134
with swing platform
In

Clearance between the pin and

–0.036 +0.087 0.036 ～
2 bushing connecting the boom Copper 500 h Ф110 1.0
–0.071 0 0.158
with arm
Clearance between the pin and
–0.036 +0.054 0.036 ～
3 bushing connecting the arm with Steel 100 h Ф90 1.0
–0.071 0 0.125
rocker
Replace
Clearance between the pin and
–0.036 +0.054 0.036 ～
4 bushing connecting the arm with Steel 100 h Ф90 1.0
–0.071 0 0.125
bucket
Clearance between the pin and
–0.036 +0.2 0.036 ～
5 bushing connecting the linkage Steel 100 h Ф90 1.0
–0.071 0 0.271
with bucket
Clearance between the pin and
–0.036 +0.054 0.036 ～
6 bushing connecting the linkage Steel 100 h Ф90 1.0
–0.071 0 0.125
with rocker

Shop Manual - April 2014 4-125

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.7.2 Arm dimensions

19
11
B

12 A A

5
13
C D
10
B

6
D
14

C
8

.
De al
pt
7
g no
in ti

司
公
销
营
et a
18

16
n
rk er

17 15
Ma t
In

A-A B-B
2
3

D-D
C-C
ZX285-1002501

Fig. 4-124

4-126 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

单位：mm

SY365H-9 SY365BH-9
No.
Standard size Tolerance Standard size Tolerance
+0.087 +0.087
1 φ100 φ100
0 0
+1.5 +1.5
2
131 0 131 0
0 0
3
345 -0.5 316 -0.5
-0.036 -0.071
4 φ90 φ110
-0.071 -0.036
5 473 ±1 602 ±0.8

.
6 354 ±1 215 ±0.5

De al
pt
7 989 ±1 976.6 ±0.8
8 g n 2914 ±3 2906 ±2
9 3018 ±3 3071 ±2
o
10 473 ±1 458 ±0.8
11 740 ±0.3 770 ±0.3
in ti

12 728 ±0.5 728 ±0.5

司
公

13 520 ±0.5 513.6 —

销
营
et a

14 1,661 — 1570 —
-0.036 -0.036
n

15 φ90 φ90
-0.071 -0.071
rk er

0 +1
16 345 346
-0.5 0
-0.036 -0.03
17 φ90 φ90
Ma t

-0.071 -0.06
0 0
Arm body
In

345 -0.5 329 -0.5

18 When bushing
345 — 344 —
is pressed on
Minimum 2,395 — 1,990 —
19 Maximum 4,145 — 3,275 —

Shop Manual - April 2014 4-127

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.7.2.1 Bucket dimensions

4
1

.
De al
pt
3

6
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
7
In
8

9 10
11
12

W365-1304502

Fig. 4-125

4-128 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Unit：mm

SY365H-9 SY365BH-9
No.
Standard size Tolerance Standard size Tolerance
1 520 ±0.5 567 ±0.5
2 1661 — 1714 —
3 R100 — R130 —
4 R125 — R130 —
5 1478 — 1451 —
6 1570 — 1889 —
+0.2 +0.2
7 φ90 φ100
0 0

.
+0.2 +0.2

De al
8 φ90 φ90
0 0

pt
9 36
g n — 36 —
10 34 — 36 —
+1 +1
o
11 346 346
0 0
in ti
12 486 — 500 —

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 4-129

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.8 Operator Station and Its Attachments

4.8.1 Air conditioner lines

.
De al
C

pt
C
g n C B
o
A
in ti

销
公
司

6
7
营

1
et a
n
rk er
Ma t
In

3
5
4 ZX335-1002042

Fig. 4-126

4-130 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

(1) Air conditioner

(2) Hot water pumping line
(3) Air compressor
(4) Refrigerant line
(5) Condenser
(6) Hot water return line
(7) Duct

A: Fresh air
B: Recirculated air

.
C: Warm air / cool air

De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 4-131

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.8.1.1 Layout of A/C components

2
1

3
4

.
De al
pt
5
g no
in ti

司
公
销
营
et a
n
rk er

7 6
Ma t
In

ZX215-1002138

Fig. 4-127

(1) Sunlight sensor

(2) Control panel
(3) Air conditioning unit
(4) Condenser
(5) Compressor
(6) Fresh air sensor
(7) Recirculated air sensor

4-132 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.8.1.2 A/C control panel

1 2 3 4 5

OFF

MODE AUTO
FULL AUTO AIRCONDITION
TEMP

A/C

.
De al
6 7 8

pt
W365413093

Fig. 4-128
g no
(1) OFF switch Remark:
in ti

(2) Fan speed control switch

When auto mode switch (5), fresh air/recircu-
(3) Temperature control switch
司
lation control (6) and A/C power (8) are turned
(4) Air outlet mode switch
公
销
营

on, indicator lights above these switches will

et a

(5) Auto mode switch light up.

(6) Fresh air/recirculation control
n

(7) LCD display

rk er

(8) A/C power

Ma t
In

Shop Manual - April 2014 4-133

 SY365(B)H-9 Crawler Hydraulic Excavator

ZX215-1002140
.
3
FL1
60A

3
pt
FUCD
15A

7
8

FURM
20A
1.25R

1.25R
8
FUM
5A

SW
H
OFF
ACC

B G1 G2 ACC M ST
De al ON
2 13
START MRF
8 8
2
CMB RLCD RLCC RLBM
13 15 13
M
RLCC RLCD RLBM
9 10

GND
REC
FFE
1

Vz
2RL 1.25RL

Pt
10 1.25L 15
RLSF 5 2

1
FLZ
40A
g no
M
MCD SPCD
11

D
1.256
M
10

MR
2G
200W
13 +B

16
16

16 19
19

25
25

24 22 26
24 26

25
in ti
5
80W 10 BLCM
6 16 19 22 23 1

Shop Manual - April 2014

10
5
1
SW 4 3
6 RLCH ACM
BAT BLC 2 8

司
公
12 12

销
营
1
ACC
et a
7
28 15 14 12 13 3 16 27 4 21 20 2 24 25 9 38 26 10
7 G 12 14 17 18 20 22 21 15 23 27 28 29 30 31 32 32 34 35
D1 9
RCD RLCH RLCH ECC THAM THW THI THF SSD
40W
G 4
n 22
4 4
rk er
02 02 02
03 15 15 15 15
4.8.1.3 Diagram of electrical circuit

CMB D2 30 31 22 32 15 33 34 35 35 22

1.25B

1.25B
3
SPHL
CM

0.85B

0.50
02 02
M M M

2B
0.5B
Ma t
06
2B 2B
Structure and Functions

01 02
06
03
MAM MV1 MV2
In

Fig. 4-129

4-134
SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Diameter/Color Diameter/Color
Wire No. Wire Color Wire No. Wire Color
Code Code
B Black 0.5VW Violet+white
Br(R) Brown 0.5YB Yellow+black
0.85W White 0.5WO White+orange
RL Red+blue 0.5PB Pink+black
G Green 0.5VR Violet+red
0.5BL Black+blue 0.5BG Black+green
0.5R Red+blue 0.5WY White+yellow
0.5Y Yellow 0.5WR White+red
0.5BR Black+red 0.5BrW Brown+white

.
0.5BrY Brown+yellow 0.5GO Green+orange

De al
0.5BY Black+yellow 0.5Sb Sky blue

pt
0.5GW g n Green+white 0.5OW Orange+white
0.5LO Blue+orange 1.25V Violet
o
0.5PG Pink+green 1.25RG Red+green
0.5RY Red+yellow 1.25RW Red+orange
in ti

0.5BW Black+white 0.85GL Green+Blue

0.5LgR Light green+red
司
公
销
营
et a
n

Code Name Code Name Code Name

rk er

Condenser high speed

ACM A/C amplifier FUCD Condenser fuse RLCH
relay
Ma t

BAT Battery FUM A/C main fuse RLSF Protective relay

BLC Speed regulating resistor G Alternator SSD Sunlight sensor
In

Condenser pressure
CMB Battery relay MAM A/M servo motor SPCD
switch
D Diode MB Blower motor SPHL Hi\Lo pressure switch
D1 Diode 1 MCD Condenser motor SW Switcher
Fresh/recirculated air Recirculated air therm-
D2 Diode 2 MRF THAM
servo motor istor
ECC Compressor clutch MV1 Air outlet servo motor THF Anti-frosting thermistor
Recirculated air therm-
FL1 Fuse MV2 FRONT outlet servo motor THI
istor
FL2 Fuse RCD Condenser resistor THW Water temp thermistor
FUBM Blower fuse RLBM Blower main relay
RLCC Compressor relay RLCD Condenser relay

Shop Manual - April 2014 4-135

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.8.1.4 Operating principle

Refrigeration cycle diagram

Expansion valve
Cool air

Lo temp\Lo press\Liquid (Mist)

Evaporator
Lo temp\Lo press\Gas

Hi temp\Hi press\Liquid
Cooling fan
Blower motor

Air in cab

.
Out side fresh air

De al
Hi-temp hi-pres gas

pt
Lo-pres.
side
Hi-pres.
side
g n
Reservoir
o
in ti

Compressor 营
销
公
司

Warm air
et a

Lo-pressure part Hi-pressure part

ZX215-1002141
n

Fig. 4-130
rk er

Heating cycle diagram

Ma t

Water tank radiator Water valve switch

In

Water pump Warm air

Engine

Blower motor

Air in cab

Low temp water

High temp water
ZX215-1002142

Fig. 4-131

4-136 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.8.1.5 Compressor

3 4

1 2

16

15

.
14

De al
pt
5
13
g no
in ti

司
公
销
营
et a

6
n

12
rk er

11 10 9 8 7
ZX215-1002143

Fig. 4-132
Ma t

(1) Stator Operating principle

In

(2) Front radial bearing

Compressor type: 10S15C. This compres-
(3) Thrust bearing
sor has 5 plungers in total with a piston at
(4) Front radial bearing
both sides of each plunger. The rotation of
(5) Rear cylinder head
the swash plate drives the pistons to move
(6) Safety valve back and forth and transforms the refrigerant
(7) Rear cylinder block sucked from the evaporator from low tempera-
(8) Swash plate ture and low pressure gas state to high tem-
(9) Slipper perature and high pressure state.
(10) Front cylinder block
(11) Piston
(12) Front cylinder head
(13) Shaft seal
(14) Main shaft
(15) Boss
(16) Rotor
Shop Manual - April 2014 4-137
Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Process1 Process2

HI press.end pipe LO press.end pipe HI press.end pipe LO press.end pipe

Valve plate

Outlet valve disc

Main shaft and swash plate Intlet valve disc

.
De al
pt
Process6 Process3
g n
HI press.end pipe LO press.end pipe
o
HI press.end pipe LO press.end pipe
in ti

司
公
销
营
et a
n
rk er
Ma t

Process5 Process4
In

HI press.end pipe LO press.end pipe HI press.end pipe LO press.end pipe

ZX215-1002144

Fig. 4-133

4-138 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.8.1.6 Clutch

● The electromagnetic clutch is used to

1
transmit moment of torsion. When the en-
gine is operating, the compressor may not 2

be working. The clutch controls the opera- 3

tion of the compressor only when the air 4
conditioner is under refrigerating mode.
● Operating principle
When the A/C power is turned on, the 5
clutch coil with an electromagnet gener-
ates a magnetic field and attracts the metal

.
piece. The stator and rotor of the clutch are

De al
6
engaged and bring the main shaft of the

pt
ZX215-1002145

compressor into rotation.

g n Fig. 4-134

(1) Rotor
o
(2) Stator coil
(3) Clasp
in ti

(4) Ball bearing

(5) Stator
司
公
销
营
et a

(6) Center piece

n
rk er
Ma t
In

Shop Manual - April 2014 4-139

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.8.1.7 Condenser

1
4
2

.
De al
pt
5
g no
ZX215-1002146

Fig. 4-135
in ti

司
公
销
营

(1) Condenser core Function

et a

(2) Bracket
● The condenser changes high-temperature,
n

(3) Bolt with washer

high-pressure gas refrigerant (16Kg/cm²,
(4) Refrigerant inlet
rk er

approx. 80 ℃ ) to high-temperature and

(5) Refrigerant outlet high-pressure liquid refrigerant (16Kg/cm²,
below approx. 60℃ ) through radiating.
Ma t
In

4-140 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.8.1.8 Expansion valve

Operating principle
Evaporator
Refrigerant from the reservoir spurts out via
the orifice, turns into low-temperature, low- 2
pressure liquid (mist) after immediate expan-
sion, and enters the evaporator. 1

.
De al
pt
4 Compressor
Reservoir
ZX215-1002147
g n
Fig. 4-136
o
(1) Spring
in ti

(2) Diaphragm
(3) Probe
司
公
销
营
et a

(4) Needle valve

4.8.1.9 Evaporator
n
rk er

Operating principle
The evaporator is a kind of heat exchanger
Ma t

that looks like a condenser. Warm air in the

cab is conducted into the evaporator via the
In

blower motor and undergoes heat exchange

with the surface of the evaporator. Heat is ab-
sorbed and warm air turns into cool air, which
flows into the cab through the air ducts. Evap-
orator surface absorbs heat → Refrigerant in 2
1
the evaporator absorbs heat → Refrigerant
evaporates . Evaporated refrigerant (gas) is
absorbed by the compressor. ZX215-1002148

Fig. 4-137

(1) Expansion valve

(2) Evaporator

Shop Manual - April 2014 4-141

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.8.1.10 Dehydrator 2
1

Function
● Temporary storage of refrigerant
● Dehydration of refrigerant
● Removing dust from refrigerant
3
● Measuring the volume of refrigerant

.
De al
pt
g no
in ti

司
公
销
营

ZX215-1002149
et a

Fig. 4-138
n

(1) Inlet
rk er

(2) Outlet
(3) Receiver/dehydrator
Ma t

(4) Desiccant
In

4-142 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.8.1.11 Pressure switch

Function
Pressure
● The pressure switch is installed between
the reservoir and the expansion valve (hi-
1
pressure pipe). It is a combination switch
7
(Hi-Lo pressure combination switch). 2
6
● When pressure is excessively high, the
compressor stops.
● When pressure is excessively low, the low-
temperature condition disappears.

.
3

De al
5

pt
g no
4

ZX215-1002150
in ti

Fig. 4-139
司
公

(1) O-ring
销
营
et a

(2) Mobile contact point

(3) Hood
n

(4) Plug and fixed contact

rk er

(5) Spring
(6) Chamber
(7) Diaphragm
Ma t

Operating features:
In

Feature

DIFF DIFF
High pressure ON
Above 0.02 MPa 0.59±0.2 MPa

OFF
Low pressure 0.196±0.02 MPa 0.196~0.250 MPa 2.94~3.19 MPa

ON

Medium pressure OFF

1.23±0.1 MPa 1.52±0.08 MPa

Shop Manual - April 2014 4-143

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.8.1.12 Fresh air sensor

Fresh air temperature sensor is mounted be-

side the condenser or at the fresh air inlet.
Consisting of thermistors, it is used to detect
12
ambient temperature.

Resistance /Kȍ
10
Specification
8
Item Specification
6
Applicable voltage 4.4~5.6 V
4
Applicable temperature -30~60 ℃

.
2

De al
Storage temperature -40~90 ℃

pt
Resistance 1700±85Ω
-10 0 10 20 30 40 AT
B Constant 3900±195 K ZX215-1002151
g n
Permissible working cur- Fig. 4-140
1.6 mA (MAX)
rent
o
in ti

司
公
销
营
et a
n
rk er
Ma t
In

4-144 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.8.2 Refrigerant

1. General property
● High heat absorption and easy liquefaction
● Non-flammable, nonexplosive
● Stable chemical composition and quality
● Non-toxic
● Non-corrosive
● No hazard to clothing

.
De al
pt
2. Refrigerant circulation
g n
● After evaporation in the evaporator, re-
frigerant turns from gas into liquid via the
o
compressor and the condenser, which fin-
in ti

ishes a refrigerant cycle.

司
公
销
营
et a
n

Compressor LO press. side (inlet): LO temp?LO press.?Gas

Compressor Pressure/Temperature:2Kg/cm²，approx. 8ć
Evaporator
rk er

IntakeėDischarge Absorb heatėEmit cold air

Ma t

Compress HI press. side(outlet): HI temp\HI press.\Gas

In

Pressure/Temperature:16Kg/cm²ˈapprox. 80ć

Condensor (outlet): LO temp\LO press.\Mist

Pressure/Temperature: 2Kg/cm²ˈapprox. 0~2ć

Condensor (outlet)˖HI temp?HI pressure?Liquid Expansion valve

Condensor Pressure/Tempterature˖16Kg/cm²ˈBelow 60ć
Hi pressureėLo pressure
Via radiating:Gas refri- Hi tempėLo temp
gerantėLiquid refrigerant
LiquidėMist

Shop Manual - April 2014 4-145

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

● Refrigerant cycle principle (pressure - enthalpy diagram)

lgp
Liquefaction completed Refrigerant cyclic curve
Liquefaction starts

Throttling point Condensor

Condensing process
Liquid
Expansion throttle

Expansion valve Compressing Compressor

.
process

De al
pt
Evaporating process
g no
Evaporator
in ti
Gas-liquid mixture
Gasification completed

司
公
销
营
et a

h=u+Apv(kJ/kg)
UInternal energy pPressure VSpecial volume AJoule equivalent
n

ZX215-1002152
rk er

Fig. 4-141
Ma t
In

4-146 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

3. Feeding of refrigerant
● Filling method and volume:
1) Refrigerant: HFC-134a
2) Feeding volume: 900±50 g (for refer-
ence)
3) Feeding method: Feeding of liquid re-
frigerant from the low-pressure end is
not allowed. If feeding operation fails,
discharge the refrigerant that has been
fed before re-feeding.

.
ZX215-1002153

De al
● Inspect the state of the refrigerant in the
Fig. 4-142

pt
A/C circulation system through the sight
glass: g n
1) Correct feeding: Foam is hardly ob-
o
served when the refrigerant is flowing. Sight glass
When engine speed increases from
in ti

idling to 1500 rpm, foam disappears

and the refrigerant turns clear. 营
销
公
司
et a

2) Over-feeding: No foam can be ob-

served when refrigerant is flowing. Proper filling
n

3) Under-feeding: Foam is always ob-

rk er

served when refrigerant is flowing.

Ma t

4. Evacuation Inadequate filling

In

ZX215-1002154
● Reason of evacuation
Fig. 4-143
No moisture shall be mixed inside the air
conditioning unit. Refrigerant (R134a) is
soluble in water. Very small amount of
moisture in the unit can cause the orifice of
the expansion valve to ice up, or cause the
valve of the compressor to rust. To avoid
such problems, moisture in the system
shall be removed before refrigerant is fed.
To reduce the residual moisture in the sys-
tem to the minimum, moisture in the sys-
tem can evaporate through evacuating. No
better means is available so far.

Shop Manual - April 2014 4-147

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

● Evacuating steps
1) Connection of manifold pressure Valve
Lo-pres.gauge
LO HI
above 750mmHg LO HI
gauge: Lo-pres. ON ON OFFOFF
gauge
a) Close the high-pressure valve (HI) Hi-pres. gauge
and low-pressure valve (LO) of the
manifold pressure gauge.
Lo-pres. valve (ON) Hi-pres. valve(ON)
b) Connect the air hose (red, blue) Green
to the auxiliary valve of the Red D
compressor.
Blue
Red hose——High pressure side S
(Mark D)

.
Blue hose——Low pressure side Compressor

De al
Vacuum pump (running)
(Mark S) ZX215-1002155

pt
★ Connect the end of the air hose
g n Fig. 4-144
with a L to the auxiliary valve of the
compressor. If connected inverse-
o
ly, the valve will not open. Besides,
in ti
do not inversely connect the high-
pressure end and the low-pressure
end. 营
销
公
司
et a

c) Connect the middle hose (green) to

the vacuum pump.
n

2) Evacuating
rk er

a) Open the high-pressure valve (HI)

and low-pressure valve (LO) on the
Ma t

manifold pressure gauge.

In

b) Turn on the vacuum pump and

evacuate for about 15 minutes.
c) When negative pressure reading
on the gauge (degree of vacuum)
reaches above 750 mmHg, turn off
the vacuum pump and close the Hi-
pressure valve and the Lo-pressure
valve on the gauge.

4-148 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

3) Air - proof check

Valve
a) Keep the Hi- and Lo-pressure valve Lo Hi Left at least
Lo-press gauge
OFFOFF for 5 minutes
of the manifold pressure gauge backs to zero.
Lo-press gauge
under closed state for more than 5
minutes, and make sure the pointer
on the gauge does not return to
zero.
Pointer backs
to zero.
b) If the pointer returns to near zero, Tighten the connector
a leakage is available somewhere. ZX215-1002156

Check and adjust the pipe joint. Fig. 4-145

Tighten the joint and conduct an-
other evacuating operation until no
leakage is detected.

.
De al
4) Leak check

pt
Valve
a) Connect the air hose (green) that is Lo Hi
OFF OFF
previously connected to the vacuum
g n
pump to the fluorine cylinder.
o
b) Connect the other end of the hose Vent valve
in ti

(green) to the pressure gauge. Release air

Open the valve
Open the valve of the cylinder and 司

press the vent valve of the pres-

公
销
营
et a

sure gauge. (Do not press the valve

with naked hand to avoid frostbite
n

Blue
Air hose (green) R134a
caused by refrigerant). Release the Red
rk er

air in the hose with the pressure of

To compressor Fluorine cylinder
the refrigerant. (Release the vent
ZX215-1002157
valve when you hear a squeezing
Ma t

sound). Fig. 4-146

In

c) Add refrigerant until pressure read-

ing on the Lo-pressure gauge is Lo-pres. gauge
reads1kg
1kgf/cm2. Hi-pressure valve of the Valve
gauge is open at this time. Close Lo Hi 1kg/cm2 Lo Hi
Lo-pres. gauge OFF ON OFFOFF
the Hi-pressure valve when feeding reads1kg/cm2
is finished.
d) Use a leak detector to check if
Lo-pres.valve (OFF) Open Hi-pres.valve
leakage is present in the cooling Cylinder valve (ON)
system. D
e) Make necessary repairs (tightening)
S
if leakage is observed. R134a
Compressor
Fluorine cylinder
ZX215-1002158

Fig. 4-147

Shop Manual - April 2014 4-149

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

5. Refrigerant filling operation

● When evacuation is finished, fill refrigerant
into the cooling system as per the following
instruction:

Fill refrigerant kg/cm2

Performance testing
Air-proofness check
Evacuation starts

Evacuation ends

Air leak check

Fill refrigerant
Air leak check
75cm-Hg or more

More than 15 min. Wait 5 min. Pres. gauge

normal

.
De al
Pres. gauge
Tighten pipe joint (1) Compressor stopped, fill at hi pressure end

pt
abnormal
Repair any leak. (2)Compressor running, add at lo pressure end
g no
● Fill from the hi-pressure side Valve
in ti

Lo Hi
1) Remove the air hose (green) of the OFFOFF
(Note)
manifold pressure gauge from the vac-
Refrigerant is released
司
公
销
营

uum pump and connect it to the fluorine when squeaking is heard.

et a

cylinder.
n

Vent valve
2) Open the valve of the cylinder and
press the vent valve on the pressure
rk er

Open the valve

Loosen
gauge. Use the pressure of the refriger- this nut
ant to release the air in the hose.
Ma t

Release the vent valve when you hear Blue

Air hose (green) R134a
a squeezing sound. Do not press the
In

Red
vent valve with naked hand to avoid
To compressor Fluorine cylinder
frostbite.
ZX215-1002159

Fig. 4-148

4-150 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

3) With the engine stopped, open the

high-pressure valve on the manifold
pressure gauge and the fluorine cylin- Valve
Filling one cylinder
Lo Hi (about 600g) Lo Hi
der valve and fill in one and a half cylin- OFF ON OFF OFF

der of fluorine (approximate 600g). (Never)

·Run the compressor
Do not run the compressor at this ·Open the low-press valve

moment. Once the compressor is Lo press valve (OFF) Open the high-press valve
started, the refrigerant could flow Fluorine cylinder
valve (ON)
back, causing the fluorine cylinder D
and hose to burst.
S
Operating the compressor without R134a

refrigerant will burn the compressor.

.
Never run the compressor without

De al
ZX215-1002160
refrigerant.

pt
Fig. 4-149
Do not open the low-pressure valve
on the manifold pressure gauge (liq-
g n
uid compression will occur, causing
o
damage tot he compressor).
in ti

4) Close the high-pressure valve on mani-

fold pressure gauge and the fluorine
cylinder valve.
司
公
销
营
et a
n
rk er

● Fill from lo-pressure side (additional fill-

ing) Hi-press valve (OFF) ON
Manifold
Press gauge
1) Confirm the hi-pressure valve of the
Ma t

manifold pressure gauge is closed.

In

H I
2) Start the engine and open the cab door.
(Note) Engine started
3) Turn on the air conditioner, and set Opening the high-pressure valve
can cause the fluorine cylinder
Temperature control switch to mini- to explode, resulting in serious
1300~1500rpm
ZX215-1002161
mum. injury

Fig. 4-150
4) Adjust engine speed to 1300 – 1500
rpm.
5) Open the Lo-pressure valve of the
manifold pressure gauge and the valve
of the fluorine cylinder, and fill refriger-
ant into the reservoir until no foam is
observed.

Shop Manual - April 2014 4-151

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Note:
Manifold pressure gauge reading (for refer-
ence):
High pressure 13~17kg/cm2 (ambient tempera-
ture 30℃ );
Low pressure 1.5~2kg/cm2 (ambient tempera-
ture 30℃ ).

6) When refrigerant filling is finished, close

the Lo-pressure valve of the manifold Fill until no foam is not
pressure gauge and the valve of the Valve observed via sight glass
Lo Hi Lo Hi
fluorine cylinder.

.
ON OFF OFFOFF

De al
Lo-pressure gauge
7) Check carefully for air leaks with a leak (1.5~2.5kgf/cm2)
Hi-pressure gauge

pt
(13~17kgf/cm2)
detector.
Lo-pressure Hi-pressure valve (close)
valve (open)
g n
Never open the Hi-pressure valve of Fluorine cylinder
(Never open it)

the manifold pressure gauge. If it is valve (open)

o
opened, high-pressure gas will coun-
terflow and cause the air hoses and
in ti

the fluorine cylinder to explode, result-

Compressor
ing in serious injury. 营
销
公
司

running
Fluorine cylinder
et a

(never placed upside down)

Do not position the fluorine cylinder ZX215-1002162

upside down (when engine is oper- Fig. 4-151

n

ating and filling in progress). If the

rk er

cylinder is placed upside down, liquid

refrigerant will be sucked directly into
the compressor and cause liquid com- Fill until no foam is seen
via the sight glass
Ma t

Valve
pression, resulting in damage to the
Lo Hi Lo Hi
compressor valve and the gaskets. ON OFF OFF OFF
In

Place the cylinder vertically and fill

gas refrigerant.
Lo-pressure
8) When ambient temperature is low valve (open) Hi-pressure valve
Cylinder valve (close)
When refrigerant filling can not be per- (open)
formed due to low ambient tempera-
ture, place the cylinder in water of less
than 40 ℃ to increase the pressure of
the refrigerant inside the cylinder. Compressor
Warm water less than 40°C running
9) When ambient temperature is high (Do not heat with hot water)
ZX215-1002163
When ambient temperature is very
high, cool the compressor with an elec- Fig. 4-152
trical fan.

4-152 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

● Replace the fluorine cylinder

Handle
When the refrigerant in a cylinder is used
up, replace the cylinder as per the follow-
ing instruction:
1) Close the Hi- and Lo-pressure valves of Air hose port
the manifold pressure gauge. Needle
valve
2) Raise the needle and disc plate of the
cylinder and remove the empty cylin- Gasket
der. Disc plate

3) Install a new cylinder onto the cylinder Refrigerant

cylinder
valve.

.
4) Release the air in the hose as per the ZX215-1002164

De al
following instruction:

pt
Fig. 4-153
a) Tighten the valve of the fluorine cyl-
g n
inder, and then, loosen it a bit. Valve
Lo Hi
b) Open the Lo-pressure valve of the
o
Loosen Close
Close the Lo-pressure valve
manifold pressure gauge a bit. immediately after the refrig-
in ti

c) Press the vent valve and allow a lit- erant squeaks.

tle refrigerant to come out. Immedi- 营

销
公
司

ately close the valve of the cylinder

et a

Loosen the valve a bit

and the Lo-pressure valve of the Lo-pressure
n

manifold pressure gauge. valve

rk er

★ Do not press the vent valve with Green

naked hand to avoid frostbite by Blue
R-134a
refrigerant. Red
Ma t

5) Turn the handle of the cylinder valve to To compressor Refrigerant cylinder

ZX215-1002165
In

pierce the cylinder and continue filling

operation. Fig. 4-154

Shop Manual - April 2014 4-153

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

6. Troubleshooting with manifold pressure gauge

After the engine has been preheated, read the

pressure value on the gauge under the follow-
ing conditions:
1) Temperature at air inlet: 30 – 35℃
2) Engine speed: 1500 rpm
3) Fan speed: High
4) Temperature control: Minimum.
5) Air mode: Recirculation

.
De al
pt
● Refrigerating system under normal condi-
tion
g n
Gauge reading:
o
Lo-pressure end 0.15~0.25 Mpa (1.5~2.5 Kg/
in ti

cm²)
Hi-pressure end 1.37~1.57 Mpa (14~16 Kg/ 营
销
公
司

cm²)
et a
n
rk er

04 15 2
03 05
4 15 20
3 5
1
02 06
25
Ma t

2 6 10 25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
In

0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa

R134a

ZX215-1002167

Fig. 4-155

4-154 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

● Moisture in the refrigerating system

Fault: Intermittent refrigeration to non-refriger-
ation

04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
8 3
0
-50 8.5 0
0 08 -76 35
-76

.
085 0
-01 15 -01 35

De al
MPa MPa

pt
g no
ZX215-1002168

Fig. 4-156
in ti

Symptom Cause 营
销
公
司
Analysis Remedy
● Replace receiver/
et a

● Moisture in the system ● Over-saturation of de- dehydrator

● When the system is hydrator.
n

ices up at the expan-

operating, pressure ● Remove the mois-
sion valve causing ● Moisture in the system
rk er

at the Lo-pressure ture in the system

temporary stop of ices up at the expan-
end unstable (some- through constant
circulation. When ice sion valve and hinders
times vacuum, pumping.
melts, the system be- the circulation of the
Ma t

sometimes normal)
comes normal again. refrigerating system. ● Add proper volume
In

of new refrigerant.

Shop Manual - April 2014 4-155

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

● Insufficient refrigeration
Fault: Insufficient refrigeration.

04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35

.
MPa MPa

De al
pt
g n ZX215-1002169

Fig. 4-157
o
in ti

Symptom Cause Analysis Remedy

营
销
公
司

● Check for air leakage with a leak

detector. Make necessary re-
et a

● Pressure at both Hi- and

● Insufficient re- pairs.
Ho-pressure ends very ● Air leaks
n

low somewhere frigerant in the ● Add proper amount of refriger-

rk er

in the refrig- system ant.

● Foam is continuously ob-
erating sys- ● Leak of refriger-
served via the sight glass ● When connected with the gauge,
tem ant if the reading is near zero, set
Ma t

● Insufficient refrigeration.
the system under vacuum state
In

after inspection and repair.

4-156 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

● Defective refrigerant circulation

Fault: insufficient refrigeration

04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa

.
De al
pt
g n ZX215-1002170

Fig. 4-158
o
in ti

Symptom Cause Analysis Remedy

● Pressure at both 营
销
公
司

Hi- and Lo-pressure

et a

sides very low ● Contaminant in the ● Blocked reservoir ● Replace reservoir

reservoir hinders the
n

● Frosting on the pip- flow of refrigerant.

rk er

ing between parts

and reservoir
Ma t
In

Shop Manual - April 2014 4-157

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

● Refrigerant not circulating

Fault: Non-refrigeration (intermittent refrigera-
tion)

04 15 2
03 05
4 15 20
3 5
1
02 06 25
2 6 10 25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35

.
MPa MPa

De al
pt
g n ZX215-1002171

Fig. 4-159
o
in ti

Symptom Cause Analysis Remedy

● Check the expansion valve
司
公
销
营
et a

and ERP.
● Vacuum at Lo-pres-
● Moisture or contami-
sure side; pressure ● Blow the contaminant in the
n

nant in the refrigerant

at Hi-pressure side expansion valve or replace
hinders the flow of
rk er

extremely low ● Refrigerant not the expansion valve if nec-

refrigerant.
circulating essary.
● Frosting or conden-
● Air leak at the thermal
sation on the pipes ● Replace the receiver
Ma t

pipe of the expansion

around the expan-
valve hinders the flow ● Release internal air and
In

sion valve or receiv-

of refrigerant. add refrigerant. If air leaks
er/dehydrator
from thermal pipe, replace
expansion valve.

4-158 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

● Over-filling of refrigerant or insufficient re-

frigeration of condenser
Fault: Insufficient refrigeration

04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35

.
MPa MPa

De al
pt
g n ZX215-1002172

Fig. 4-160
o
in ti

Symptom Cause Analysis Remedy

● Clean the condenser
司

● Excessive refrigerant in
公
销
营

● Pressure at both Hi-

system → Over-filling of ● Check the working
et a

● Over-filling of refriger-
and Lo-pressure condition of fan mo-
ant in the system. Re- refrigerant
n

sides very high tor

frigerating performance
● Insufficient refrigeration
rk er

● No foam can be ob- inadequate. ● If the two above

of condenser → Ra-
served via the sight items are normal,
● Insufficient refrigeration diator fins of condenser
glass even when check the volume of
of condenser plugged or failure of fan
Ma t

engine speed drops. refrigerant. Add re-

motor
frigerant as required.
In

Shop Manual - April 2014 4-159

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

● Air present in refrigerating system

Fault: Poor refrigeration

If refrigerant is added with no evacuation

operation performed, the following gauge
reading will appear:

04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25

.
7
1
01 07 5 30

De al
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0

pt
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
g no
ZX215-1002173
in ti

Fig. 4-161
司
公
销
营
et a

Symptom Cause Analysis Remedy

n

● Pressure at both Hi- and

Lo-pressure ends very ● Check if compressor
rk er

high ● Air enters the refriger- oil is contaminated

● Air enters the re- ant system or inadequate.
● Lo-pressure piping feel-
frigerating system
Ma t

ing hot ● Insufficient evacuation ● Evacuate and add

● Foam is observed new refrigerant.
In

through the sight glass

4-160 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

● Improper installation of expansion valve/

thermal pipe defect (wide opening)
Fault: insufficient refrigeration

04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25

7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35

.
MPa MPa

De al
pt
ZX215-1002174

Fig. 4-162
g no
in ti

Symptom Cause Analysis Remedy

司
公
销
营

● Pressure at both ● Excessive re- ● Check the installation of

● Improper installation of
et a

Hi- and Lo-pressure frigerant in Lo- thermal piping

thermal pipe/defective
ends very high pressure piping
n

thermal pipe (exces- ● If thermal piping is normal,

● Frosting or conden- sively wide opening) ● Expansion check the expansion valve.
rk er

sation on Lo-pres- valve opening Replace expansion valve if

sure piping too wide found defective.
Ma t
In

Shop Manual - April 2014 4-161

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

● Compressing error
Fault: No refrigeration

04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25

7
1 5
01 07 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 - 01 35
MPa MPa

.
De al
pt
ZX215-1002175

Fig. 4-163 g no
Symptom Cause Analysis Remedy
in ti

● Compressing fault;
● Pressure at Lo-pressure
● Leaking or damaged
司
公
销
营

side very high ● Compressor internal ● Repair or replace

et a

valve, or missing
● Pressure at Hi-pressure leakage compressor
parts
n

side very low

rk er
Ma t
In

4-162 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.8.2.1 Compressor oil

Oil shall be added into the A/C system for lubrication. Compressor oil is solved in the refrigerant
and circulates in the system. When the air conditioning system is shut down, compressor oil will
stay inside the components. If no compressor oil is added into the system when replacing com-
ponents, inadequate lubrication will result. Add compressor oil according to the chart below:

Replaced component
Compressor Condenser Evaporator
Volume (CC) See "NOTICE" below 40 40
ND8# (10P, 10PA, 10S series compressor)

.
De al
Compressor oil grade
ND9# (TV series compressor)

pt
g n
NOTICE
o
in ti

● Add oil into a new compressor according to the required volume of the system. When
the compressor is to be replaced, discharge the surplus oil in it.
司
公
销
营

● Filling of improper amount of compressor oil: Over-filling of compressor oil will reduce
et a

the refrigerating capacity. Short of compressor oil in the system will lead to an abnor-
n

mal compressor.
● Keep the pipe connectors and O-ring seals free from contamination when disassem-
rk er

bling the compressor.

Ma t
In

Shop Manual - April 2014 4-163

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.9 Engine Control

4 5

Z
3

.
De al
pt
g no
2
in ti

9
6 7 8
司
公
销
营
et a
n
rk er

Z
W365-1304503
Ma t

Fig. 4-164
In

(1) Battery relay Outline

(2) Battery
● The engine is only started and stopped
(3) Start switch with the start witch (3).
(4) Fuel control dial
(5) Start motor
● The engine controller (6) receives the sig-
nal from the fuel control dial (4) and trans-
(6) Controller
mits the drive signal to the throttle motor (8)
(7) Fuel injection pump
to control the governor lever angle of fuel
(8) Throttle motor
injection pump (7) in order to regulate en-
(9) Shutdown device
gine speed.
● When the start switch (3) is turned to the
OFF position, the shutdown device (9)
closes the injection nozzle of the fuel injec-
tion pump to cut off the engine fuel supply.
Then, the engine stops.

4-164 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.9.1 System operation

4.9.1.1 Engine starting (Power supply)

Fuel control dial Engine Start switch

Start motor Safety relay

● When the start switch is turned to the B s

Lo s
Hi Hi (Start signal) R E C
Governor E
motor

START position, the starting signal is sent Lo M

L
B E
B BR C

Throttle OFF
to the start motor. Then, the start motor Throttle ON P Alternator

(Potentiometer signal)

(Start signal)
starts the engine.

(Driving signal)
Shutdown Battery relay
device
Pilot switch
Start

When it happens, the engine controller de- Shutdown

relay
relay

tects the signal voltage sent from the fuel

Shutdown
delay relay
Monitor - controller
(Regulating signal)
control dial and sets the engine speed to (Start switch ON siganl)
ZX335-1002044
the speed set by the fuel control dial.
Fig. 4-165

.
De al
pt
4.9.1.2 Engine speed control
g n (Power supply)

Fuel control dial Engine Start switch

Start motor Safety relay

● The fuel control dial sends to the controller Hi Hi

Lo
Governor
s
E
(Start signal)
B
R E C
s
o
motor
a signal voltage corresponding to its angle. Lo Throttle OFF M
L
BE B BR C

P Alternator
in ti
According to the signal voltage, the control-
Throttle ON

(Potentiometer signal)

(Start signal)
(Driving signal)
ler sends a driving signal to throttle motor Shutdown
device
Battery relay Pilot switch

in order to control the fuel injection pump,

Start
营
销
公
司
Shutdown relay

relay

hence controlling the engine speed.

et a

Shutdown
delay relay
Monitor - controller
(Regulating signal)
(Start switch ON siganl)
n

ZX335-1002045

Fig. 4-166
rk er

4.9.1.3 Engine shutdown (Power supply)

Ma t

Engine Start switch

Start motor Safety relay

● When the start switch is turned to the Hi

Lo
Governor
s
E
(Start signal)
B
R E C
s
In

motor
STOP position, the shutdown controller L
B E
B BR C
Throttle OFF

controls the shutdown device to stop fuel Throttle ON Alternator

(Start signal)

supply to the fuel feed pump. The engine Shutdown Battery relay
device Pilot switch
is then stopped. Shutdown
Start
relay

relay
Shutdown

Monitor - controller delay relay

(Start switch ON siganl)

ZX335-1002046

Fig. 4-167

Shop Manual - April 2014 4-165

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.9.2 System components

4.9.2.1 Fuel control dial

140°
9×10°
1
Gear position 1
Gear position 10

2 25°

3 Leftmost position Rightmost position

.
De al
pt
4

5
g no
in ti

司
公
销
营
et a

6 1 Yellow
5V
n
rk er

2 Blue
VR

2
Ma t

1 3
Red
3 0V
In

ZX215-1002180

Fig. 4-168

(1) Knob
(2) Dial
(3) Spring
(4) Ball
(5) Potentiometer
(6) Plug

4-166 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Function
● Turning of the fuel control dial changes the
resistance of the sliding rheostat inside （%）
the dial and the voltage signal collected by 100

Dial angle
the controller. The controller calculates the
collected signals and drives the governor
motor via signal output and controls the in-
jection of the fuel pump so that the engine
can run at an optimal speed.
● When throttle voltage is beyond the area, 0 0.25 1.72 4.49 4.75 5（V）
Voltage (V)
the controller sends out alarm code and
ZX215-1002181
the engine runs at low idle. The area under
the sloping line is the abnormality detection Fig. 4-169

.
De al
area.

pt
Remark:
g n
The leftmost position is 0%; and the rightmost
o
position is 100%.
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 4-167

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.9.2.2 Controller
SEHC-281A (Huaxing)

.
De al
pt
g no
in ti

司
公
销
营
et a

J1-2（40 pins）
n

J1-1（81 pins） WT365-1304001

rk er

Fig. 4-170
Ma t

Controller ports
In

........
........ ...................
...................
........
........ ...................
...................

J1-2 J1-1 W365K-1304002

Fig. 4-171

4-168 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Controller signal distribution

J1-1 J1-2
No. Signal name I/O No. Signal name I/O
1 Power ground 82 High/low speed shift valve
2 Power ground 88 Front pump proportional valve
3 Power ground 89 Rear pump proportional valve
4 Power（24V） Input 98 Bucket confluence valve
5 Power（24V） Input 99 Engine start control
11 Fuel level sensor signal Input 100 Shutdown delay signal
13 GPS detecting signal 101 Bucket solenoid valve
15 Throttle position signal Input 105 Throttle motor drive signal+
23 RX232 113 Throttle motor drive signal-
28 Air filter plugging sensor signal Input 114 Power ground
30 Water temp sensor signal Input 115 Power ground

.
De al
31 Oil temp sensor signal Input 116 Power ground
34 Fuel control dial signal Input 117 Power ground

pt
38 Engine speed signal 118 Power（24V）
39 2RS 119 Power（24V）
40 RS
g n 120 Power（24V）
41 TX232 121 Power（24V）
o
42 2nd boost button signal
in ti
48 Engine oil pressure signal Input
49 L. travel pressure sensor Input
50 Bucket-dig pressure sensor Input 营
销
公
司

51 Boom-down pressure sensor Input

et a

52 Arm-in pressure sensor Input

Rear pump principal pressure
n

53 Input
sensor
54 Sensor power ground Input
rk er

55 Sensor power ground Input

56 Sensor power Output
58 Monitor CAN low
Ma t

60 Calibrator CAN high

65 Pilot switch
In

66 Coolant temp high Input

67 R. travel pressure sensor Input
68 Swing pressure sensor Input
69 Bucket-dump pressure sensor Input
70 Boom-up pressure sensor Input
71 Arm-out pressure sensor Input
Front pump principal pressure
72 Input
sensor
73 Sensor power ground Input
74 Sensor power Output
75 Sensor power Output
77 Monitor CAN low
78 Calibrator CAN high
79 Engine shutdown signal
80 Engine start signal

Shop Manual - April 2014 4-169

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.10 Electrical Control System

4.10.1 Control function

Engine - pump combination control

Pump control

.
Valve control

De al
pt
Dual-speed Travel control
g no
in ti
Electrical control system Engine preheat/overheat alarm
司
公
销
营
et a

Low Engine oil pressure alarm

n
rk er

Auto deceleration/acceleration control

Ma t

Engine speed calibration

In

Self-diagnostic function

4-170 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.10.2 Diagram of machine control system

Battery Battery relay drive

Fuel control dial
Fuse

Start switch Energizing signal Shutdown

delay relay

Power supply

Power supply
Power regulator valve signal 1
Preheating signal
Starting signal

Monitor controller Travel speed select signal

integration 11

CAN bus Right travel signal

Working mode signal 2
Travel speed select signal Left travel signal

.
Signal monitoring info 3
Auto deceleration signal

De al
Boom-up signal
Signal monitoring info
4

pt
Boom-down siganl
5

Arm-in signal
6
g n
Fuel level sensor
o
Fuel level signal Arm-out signal
7
Bucket-dig signal
8
Bucket-dump signal
in ti
9
Swing signal
10

营
销
公
司
Controller
HCU
et a
n
rk er

R pump outlet press signal

12
F pump outlet press signal
13
Ma t

F pump control signal

Start relay
14
R pump control signal
In

15

16
Real throttle position
Motor drive signal
Engine speed

feedback signal

PPC lock signal

Starting signal

Engine speed sensor Motor Potentiometer

Engine oil pressure

Eng oil press sensor
Safety relay Coolant temp signal
Eng coolant temp sensor
Battery charge signal
Charge indicator Alternator Engine

Start signal Air filter plugging switch

Start motor
Electric air heater
Preheater relay
Preheat signal W365413081

Fig. 4-172

Shop Manual - April 2014 4-171

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

2 R. travel pressure sensor

3 L. travel pressure sensor

4 Boom-up pressure sensor

5 Boom-down pressure sensor

PPC
6 Arm-in pressure sensor valve

7 Arm-out pressure sensor

8 Bucket-dig pressure sensor

Bucket-dump pressure sensor

9
10 Swing pressure sensor

.
De al
pt
Frong pump oil feed device
Work equipment rotating device
11
g n
14
o
15
in ti
PPC basic pressure

13
司
公
销
营

12
Rear pump Front pump Two-speed
et a

PPC
16 proportional proportional solenoid
lock valve
valve valve valve
n
rk er

Port for each action control valve

Power limit
solenoid valve
Main valve
Ma t
In

Swing motor
Servo Servo

F R

Swing motor
Main pump
Swing motor
Rear pump oil feed device
Work equipment rotating device

W365413082

Fig. 4-173

Note: The diagram above is a schematic diagram of electrical control. See the hydraulic section
for more information on the hydraulic circuits.

4-172 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.10.3 Engine-pump combination control

Cab
Pilot valve

A B
Travel Travel MAX

Boom up/down
Arm in/out Bucket dig/dump
Swing
MIN
F1
Esc
F2 F3
Enter
F4 F5
Fuel control dial

MC controller input
H/S/L/B
Pressure

.
Cancel auto deceleration
sensor

De al

Pilot oil pressure

Shift travel speed
Alarm output

pt
g no
in ti

司
公
销
营

Main control valve

et a
n

Engine chamber
rk er

Pressure
sensor
Controller
P2

P1
Ma t
In

Engine feed
Pump regulation

Pump proportional
pressure reducing
solenoid valve Throttle motor

Potentiometer Motor

Control rear pump inclination

Fuel, coolant temp & others

Control front pump inclination

Engine speed
Control motor
Actual throttle position feedback

W365413083

Fig. 4-174

Shop Manual - April 2014 4-173

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Function
● This function allows operator to select a 10

working mode and change the engine pow-

er output according to the kind of job that
the machine is to be engaged. The working
modes include H, S, L and B. A selector
button on the monitor is available for selec-
tion of a working mode.
● Pump controller controls the pump so that 7

the pump is able to absorb all torques at

6

engine output point. These torques are

1
determined by the pump absorption torque 9

specification, fuel control dial setting and

.
De al
real engine speed under each mode.
Fig. 4-175

pt
Technical specifications
g n
H mode H
o
S
Engine power KW
in ti

Speed (rpm) ~1750 1750~1900 1900~2180 L

司
公
销
营

Power(KW) 143 159 174

et a

S mode
n

Speed (rpm) ~1750 1750~2180

rk er

Power(KW) 133 166 Engine speed N

ZX335-1002051
L mode
Ma t

Fig. 4-176
Speed (rpm) ~1850
In

Power(KW) 150
H

L, B
Pump flow Q

Pump output pressure P

ZX335-1002052

Fig. 4-177

4-174 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Mode control methods

● Mode H
● H mode matching point: Rated speed
184kW/2180rpm

Engine torque T
● Engine speed decreases when pump load
increases and the pressure rises. In this
case, engine speed will be up to the prox-
imity of matching point, allowing pump con-
troller to reduce output. On the contrary,
when pump load reduces and the pressure Engine speed N

.
decreases, the pump controller will keep

De al
ZX335-1002053
increasing pump output until engine speed

pt
reaches the proximity of matching point. Fig. 4-178
g no
in ti
Engine power KW

司
公
销
营
et a
n
rk er

Engine speed N
Ma t

ZX335-1002054

Fig. 4-179
In

Pump flow Q

Pump output pressure P

ZX335-1002055

Fig. 4-180

Shop Manual - April 2014 4-175

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

● Power output percentage corresponding to 10

each mode

Mode H S L B
Power out-
put percent- 95% 90% 80% 80%
age

● The controller maintains the pump suction 7

force along the stable horse power curve 6

and controls engine speed through engine- 1

pump combination control. 9

Fig. 4-181

.
De al
pt
H
g no Engine power KW

L
in ti

司
公
销
营
et a
n

Engine speed N
rk er

ZX335-1002051

Fig. 4-182
Ma t
In

L, B
Pump flow Q

Pump output pressure P

ZX335-1002052

Fig. 4-183

4-176 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.10.4 Pump control function

Engine Pressure sensor Pressure sensor

Main pump
Injection Governor
pump motor F R

M
P Speed
Servo Servo
sensor

.
De al
pt
g no
Valve Valve

Fuel control dial

(Control signal)
(Control signal)

Hi
in ti (Engine speed signal)

Lo 销
公
司
营
et a
n
rk er

Controller
Ma t
In

Bucket DUMP signal

Boom DOWN signal

Bucket DIG signal

Right travel signal

Left travel signal
Boom UP signal
Arm OUT signal

Arm IN signal
Swing signal

W365413084

Fig. 4-184

Shop Manual - April 2014 4-177

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Pump 1
delivery
amount

Boom RAISE PPC pressure

Pump 1
delivery
amount

Arm IN PPC pressure

Pump 1
delivery
amount

.
De al
Arm OUT PPC pressure

pt
Pump 1
delivery Corresponding
amount
g no
MAX
delivery output

Bucket CURL PPC pressure

in ti
Pump 1
delivery
amount 司
公
销
营
et a

Bucket DUMP PPC pressure

n

Pump 1
delivery
rk er

amount

Swing PPC pressure

Pump 1
Ma t

delivery
amount
In

L. Travel PPC pressure

ZX215-1002197

Fig. 4-185

4-178 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Pump 2
delivery
amount

Boom RAISE PPC pressure

Pump 2
delivery
amount

Arm IN PPC pressure

Pump 2
delivery
amount

.
De al
pt
Arm OUT PPC pressure
Pump 2
delivery Corresponding
amount
g n delivery output
MAX
o
Bucket CURL PPC pressure
in ti

Pump 2
delivery
amount 营
销
公
司
et a

Bucket DUMP PPC pressure

n

Pump 2
delivery
rk er

amount

Boom LOWER PPC pressure

Ma t

Pump 2
delivery
In

amount

R. Travel PPC pressure

ZX215-1002198

Fig. 4-186
Function charge amount and pilot pressure. During
combined operation, the set discharge amount
Use the work equipment and swing pilot pres-
of each operation shall be added.
sure signal directly as the hydraulic pump dis-
charge control signal. Pilot pressure is applied
on the valve stem and, on the other hand, Operation
is collected by the controller. The controller When the work equipment is operating, the
keeps the discharge amount of the hydraulic controller collects the signal of pilot pressure
pump at the specified value of the correspond- sensor, and determines the control discharge
ing pilot pressure according to the functional amount of pump 1 and pump 2 according to
relation between the set hydraulic pump dis- the pressure signal.
Shop Manual - April 2014 4-179
Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.10.4.1 Constant power control

Function
● It is mainly used to calculate the theoreti-
cal maximum displacement. The system Q
employs constant power control. Two

Flow
Pump curve P-Q
regulators are interconnected hydraulically, P0
enabling synchronized operation of two PMax

actuators of the same specification at the

same time. Change of pump flow is deter-
PMax
mined by the sum P ∑ of working pressures
of both hydraulic pumps. So long as it sat- P

.
isfies 2P0 ≤ P ∑ ≤ 2 PMax, the sum of powers Pressure

De al
of both hydraulic pumps remains constant, ZX215-1002199

pt
exceeding not the power of diesel engine. Fig. 4-187
g no
Operation
● When work equipment is working, the con-
in ti

troller collects throttle position signal and

gives a constant current in order to control 营
销
公
司

power of pump.
et a
n
rk er

4.10.4.2 ESS control

Function
Ma t

● Changing of the engine speed due to load change controls the pump power, and engine out-
put can be used more efficiently. (This function can also prevent the engine from losing con-
In

trol when the machine is operating under harsh conditions (eg. high - altitude area).

Operation
The engine control panel controls the target operating speed of the engine.
● The engine controller collects the actual speed signal from the speed sensor, and preform a
loop control with the target operating speed. Then, the controller involves the output of loop
control with the calculation of the solenoid valve control signal, and sends the final regulating
current signal to the pump proportional solenoid valve.
● The solenoid valve controls pump flow by feeding pilot oil to the pump regulator according to
the signal sent from the controller.

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SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.10.5 Valve control function

Swing priority Bucket confluence

Main control valve

Engine Pressure sensor Pressure sensor

Main pump
Injection Governor
pump motor F R

M
P Speed
Servo

.
Servo
sensor

De al
pt
g no
(Throttle position feedback signal)
(Motor drive signal)

in ti

Valve Valve
司
公
销

Fuel control dial

营

(Control signal)
et a

Hi
(Control signal)
(Engine speed signal)
n

Lo
rk er
Ma t
In

Controller
A B

CAN bus
Bucket DUMP signal

Boom DOWN signal

Bucket DIG signal

Right travel signal

Left travel signal
Boom UP signal
Arm OUT signal

Arm IN signal
Swing signal

F1 F2 F3 F4 F5
Esc Enter

W365413086

Fig. 4-188

● Bucket fl ow control
● Swing priority control

Shop Manual - April 2014 4-181

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

1) Bucket flow control

Swash plate angle
Function
Control the pump swash plate angle according Max
to the operation of bucket control lever.

Operation
Min Bucket joystick
When the bucket control lever is operated, the pilot pressure
controller collects the signal from the bucket
DUMP pressure sensor and bucket CURL ZX215-1002201
pressure sensor, and controls the bucket con-
Fig. 4-189
fluence proportional valve.

.
De al
pt
Bucket confluence
valve current
g no
450mA
in ti

Bucket joystick
400mA
司
公
销
营

pilot pressure
et a
n

ZX305-1002202
rk er

Fig. 4-190

2) Swing priority control

Ma t
In

Function
● Pressurized oil from pump 1 bypasses bucket 1 valve spool, and flows first to swing motor
valve spool to activate swing first.

Operation
● When signals from pump 1 pressure sensor, arm pressure sensor and swing pressure sensor
meet the following conditions, the controller activates the solenoid valve. The solenoid valve
conducts pilot pressure oil to arm flow controller and limits the alternate circuit of arm 1 valve
spool. Swing valve spool first ensures swing motor power, preventing the counter acting force
when the arm is retracting from affecting the positioning of the upper swing structure.

Operating condition
● Swing pressure sensor: signal output available

4-182 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.10.6 Dual travel speed control

Travel Motor

Regulator Regulator
Right travel pressure sensor

.
De al
Main Control Valve
Left travel pressure sensor

pt
Travel Speed
Solenoid Valve
g no
Engine
Injection Governor
Pump Motor F Main Pump R
in ti

M
P Servo
营
销
公
司

Servo
et a
(Motor drive signal)

(Throttle position
feedback signal)
n
rk er

Fuel Control Dial

Hi
Ma t

(Control signal)

Lo
(Control signal)
In

A B

Controller F1
Esc
F2 F3
Enter
F4 F5

(CAN Bus)

W365413085

Fig. 4-191

Shop Manual - April 2014 4-183

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Function
Travel mode control

Operation
● When travel mode is set to LOW, the angle
travel motor swashplate reaches its maxi-
mum and travel speed is slow.
● When the controller receives signal from
travel pressure sensor under the following
condition, it activates the solenoid valve.
The solenoid valve delivers pilot oil to the
travel motor swashplate angle control valve

.
in order to reduce the angle to its minimum

De al
and increase travel speed.

pt
Operating condition
g no
Fast travel function on the monitor is on.
in ti

Note: When lifting the track on one side with

the help of work equipment and running the
司
公
销
营
et a

track, the pump control pressure on the side

increases to enable fast running of the track.
n

When the machine is traveling under HIGH

rk er

mode, the travel mode cannot be changed

even if work equipment is operated (work
equipment pressure sensor is turned ON).
Ma t
In

4-184 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.10.7 Engine preheat/overheat alarm

Start switch

Heat

Preheat Relay Main Control Valve

Engine Main Pump

.
Governor motor

De al
Coolant Temp F R

pt
Sensor

M
g n P Servo Servo
o
in ti
(Motor drive signal)

feedback signal)
(Throttle position

司
公
销
营
et a
n

(Control signal)
rk er

(Control signal)

Hi

Lo
Ma t
In

A B

Controller

(CAN bus)
F1 F2 F3 F4 F5
Esc Enter

W365413087

Fig. 4-192

Shop Manual - April 2014 4-185

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

1) Engine preheating

Function
● Preheat control

Operation
● The excavator starts preheating when it is powered on.

Operating condition
● Low temperature switch is closed; excavator is energized; auto preheating begins at starting.

2) Engine overheat alarm

.
De al
pt
Function
● When coolant temperature is high (over 103℃ ) during operation, the monitor displays alarm.
g no
Operation
● The controller collects signal from coolant temperature sensor. If coolant temperature is too
in ti

high, alarm message will be generated and sent to the monitor. Receiving the alarm message,
the monitor will illuminate the alarm indicator light.
营
销
公
司
et a

Operating condition
n

● Power on
rk er

● Coolant temperature greater than 103℃

3) Alarm - low engine oil pressure

Ma t
In

Function
● The controller collects signal from engine oil pressure sensor. When engine speed is greater
than 600 rpm and engine oil pressure is too low, alarm message will be generated and sent to
the monitor. Receiving the alarm message, the alarm indicator lights up.

4-186 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.10.8 Auto deceleration/acceleration control

Right Joystick control

Boom Bucket

Engine

DOWN

DUMP
DIG
UP
Engine
throttle
controller
Swing Left Arm
Joystick

RIGHT
LEFT

OUT
Control

IN
Fuel Control Dial

.
De al
(Throttle signal)

Left travel Travel Right travel

pt
Control

BWD
FWD

BWD
FWD
g n Levers
o
A B
in ti

Controller
司
公
销
营

F1 F2 F3 F4 F5
et a

CAN Bus
Esc Enter

Control lever signal

ZX225-1002022
n

Fig. 4-193
rk er

Function Speed (rmp)

Set speed
Ma t

● When all control levers are in the neutral Drop 100 rpm

position, lower engine speed in order to re-

In

Auto deceleration
duce fuel consumption and noise. (1400rpm)

● When any control lever is operated, engine 3.2S

0.5S 0.5S

speed will be back to the setting of the fuel 0.2S

Time (s)
Operated
control dial. Control lever
Unoperated Operated

ZX335-1002061

Fig. 4-194
Operation
● Engine speed will drop to the speed of gear position 1 (100 rpm lower than the set speed) 0.2
second after the control levers are placed in the neutral position. The engine will run at low
speed (1400 rpm) after another three (3) seconds. This can reduce void flow of hydraulic sys-
tem and wear of the engine, hence saving energy and reducing noise. When any control lever
is operated to resume the operation, the engine speed will be restored.
● When any control lever is operated during engine deceleration, engine speed will increase im-
mediately to the speed set by the fuel control dial.

Shop Manual - April 2014 4-187

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.10.9 Engine speed calibration function

Swing pripority Bucket confluence

Main valve

Pressure sensor Pressure sensor

Engine
Governor Main pump
Injection
pump motor F R

M
Speed
P

.
Servo Servo
sensor

De al
pt
g no
in ti

司
公
销
营

Fuel control dial

（Engine speed signal）

（Control signal）

（Control signal）
et a

Hi
n

Lo
rk er
Ma t
In

Controller A B

(CAN bus)
Bucket DUMP signal

Boom DOWN signal

Bucket DIG signal

Arm OUT signal

Boom UP signal

R. Travel signal
L. Travel signal
Arm IN signal
Swing signal

F1 F2 F3 F4 F5
Esc Enter

W365413088

Fig. 4-195

4-188 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Function
Enter the maximum engine speed for each
working mode as a criteria for engine speed
control. Throttle Help Info

Operation
Current Gear N：
1. Auto calibration of engine speed requires
starting the engine. Engine Speed rpm：

2. Call the interface of System Information

Gear Position V：
and select Throttle Installation Aid.
A. Turn the fuel control dial to position 1. Throttle Position V：

.
B. Press the key [F4] to start speed cali-

De al
bration process.

pt
s AUTO
rpm
C. Turn the fuel control dial after calibra-
n/min

tion.
g n XP2051203013

D. Repeat step (2) to finish calibration of

o
Fig. 4-196
speed at all positions.
in ti

E. Press the key [F5] or [ESC] to end

calibration. 营
销
公
司
et a
n
rk er
Ma t
In

Shop Manual - April 2014 4-189

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.10.10 System parts and components

1) Pump pressure sensor

Connector Housing Pressure joint

B
A C

.
De al
pt
Connection Diagram

Signal Name
g n Terminal No.

A
o
Power (+5V)
in ti
B Ground

司
C Output
公
销
营
et a

W365-1304208

Fig. 4-197
n
rk er

Operation
● The illustration on the right shows the rela- (V)
Ma t

tionship between the pressure acting upon 

In

the sensor and the output voltage.  


Ӵᛳ఼䕧ߎ⬉य़


 
(MPa)
     
⊍य़࡯
ZX335-1002067

Fig. 4-198

4-190 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

2) Pilot pressure sensor

Connector Housing Pressure joint

B
A C

Connection Diagram

.
De al
Terminal No. Signal Name

pt
g n A Power (+5V)

B Ground
o
C Output
in ti

W365-1304208

Fig. 4-199 营
销
公
司
et a

Operation
n

● The illustration on the right shows the rela- (V)

rk er

tionship between the pressure acting upon 

the sensor and the output voltage.  

Ma t

Ӵᛳ఼䕧ߎ⬉य़
In


 
(MPa)
     
⊍य़࡯
ZX335-1002067

Fig. 4-200

Shop Manual - April 2014 4-191

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

3) Engine speed sensor

2 1
ZX335-1002070

.
Fig. 4-201

De al
pt
Function g n
● Engine speed sensor is mounted on the gear ring of flywheel. It calculates the number of gear
o
teeth passing before the sensor and sends the result to the controller.
in ti

Note: If the engine speed sensor has not been tightened to the specific torque, it may fail to pro-
duce signal. Always tighten the engine speed sensor to the specific torque.
营
销
公
司
et a

4) Engine oil pressure switch

n

1
rk er
Ma t
In

W365413089

Fig. 4-202

(1) Pressure detector Function

(2) Connector Engine oil pressure switch is mounted on the
delivery pipe of engine oil filter. It detects en-
gine oil pressure and sends generated pres-
sure signal or alarm signal to the controller.

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SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

5) Fuel level sensor

1 2 3 4

.
De al
ZX215-1002246

pt
Fig. 4-203

(1) Float
g no
(2) Lever
(3) Shell
in ti

(4) Connector 销
公
司
营
et a

Function
n

Signal from the sensor will be collected by the controller and displayed on the monitor. Resis-
tance output sensors like hydraulic oil temperature sensor, fuel level sensor and coolant tempera-
rk er

ture sensor send signal to the controller. The controller collects, process and calculate voltage
signals and converts it into related information that will be displayed on the monitor.
Ma t

Specifications
In

Electrical parameters:
● Total resistance: 100Ω
● Tolerance: ±5%
● Upper limit: Ru ≤ 9.6Ω
● Lower limit: Rd ≥ 86Ω
● Variation: Nonlinear
● Max. input volt: 12VDC

Mechanical parameters:
● Rotor angle: 105°
● Vertical distance between upper and lower limits of the float (measurable range of fluid level):
500 mm

Shop Manual - April 2014 4-193

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

6) Coolant temperature sensor

.
De al
pt
ZX335-1002071

Fig. 4-204 g n
Function
o
The output resistance of engine coolant tem-
in ti

perature sensor changes with the tempera-

ture. The controller collects signal and works 营
销
公
司

out a cooling temperature.

et a
n
rk er
Ma t
In

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SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.11 Monitoring System

Monitor

A B

CAN signal

Controller

.
De al
F1 F2 F3 F4 F5
Esc Enter

pt
g no
in ti

Each sensor

Power
司
公
销
营
et a
n
rk er
Ma t

Battery
In

ZX335-1002073

Fig. 4-205

● The machine condition is monitored by the ● Information on the monitor display includes
sensors mounted on different locations of primarily:
the machine. The controller processes the
1. Alert information in case of machine fail-
signals and transmits the signals to the
ure
monitor display, informing the operator of
the machine condition. 2. Operating condition (coolant tempera-
ture, hydraulic oil temperature, fuel level,
● The monitor panel also contains mode se- etc. )
lector, functional keys and machine opera-
tion control outputs.

Shop Manual - April 2014 4-195

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.11.1 Monitor
SECD_5I7D

$ %

.
De al
pt
g no
F1 F2 F3 F4 F5
in ti
Esc Enter

司
公
销
营
et a

WX215-1204002H
n

Fig. 4-206
rk er

Outline IMPORTANT
● The monitor is used to display monitoring ● Technical specification allows a screen to
Ma t

information and select a working mode. have not-more-than 10 dark spots (not il-
luminated) or bright spots.
● The monitor has a CPU (Central Process-
In

ing Unit) which processes, displays, and ● It is normal to have blue bright spots on the
outputs information. screen when the monitor is on for a quite
period of time.
● The monitor uses a LCD (Liquid Crystal
Display). ● It is normal to have blinking strips on the
screen when the monitor initializes.
Port I/O signals

No. Signal name I/O

1 Digital input A Input
3 CAN high
4 CAN low
8 Trigger power (24V)
9 Power supply (24V)
10 Ground
12 Ground

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SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.11.2 Monitor panel

NOTICE A A B

● Stop operation immediately when the

alert indicator is on. Check and repair
related parts.
● The monitor does not display all work- B
ing conditions of the machine.
● Do not solely depend on what is dis-
played on the monitor when maintain-
ing and checking the machine.

.
De al
pt
F1 F2 F3 F4 F5
The monitor panel performs the functions of
monitoring and displaying, selecting a working
g n C Esc Enter

mode, and switching on/off an electrical ele-

ment.
o
XP235-13001
in ti

Overview Fig. 4-207

The monitor consists of three parts: 营
销
公
司
et a

A: Alert indicators
n

B: LCD display
C: Operation keys
rk er
Ma t

4.11.2.1 Alert and signal indicators

In

Alert indicator
When the excavator has a problem, the alert
indicator flashes five times along with five
buzzing. If the fault is still there, the indicator
light A will be kept on, telling user to solve the $ %
problem.

XP235-13002

Fig. 4-208

Shop Manual - April 2014 4-197

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.11.2.2 LCD display

When start switch of excavator is turned to
the ON position, the monitor is energized by
machine batteries and enters the initializing
Sany Hydraulic Excavator
screen. As shown by the figure on the right, a
fully displayed screen includes the following 1 S 1 10
information:
2
(1) Working mode
C H
(2) Coolant temperature gauge
(3) Fuel level gauge 3
E F
(4) Failure code
4 9

.
11/11/01 8

De al
(5) Total service hours 5 0032h25m E101 09:32:24 7
s

pt
(6) Function icons 6 AUTO

n/min

(7) Local time

g n XP235-13003
(8) Local date Fig. 4-209
o
(9) GPS signal indication
in ti

(10) Engine speed level

司
公
销
营

Coolant temperature gauge

et a

There are a total of 13 segments (yellow) for

n

the full range from zero to 120 degrees.

rk er

A: When the engine is just started.

B: When temperature is between zero and 110
degrees. A
Ma t

C: When temperature is over 110 degrees,

In

the last segment turns red and the alert

indicator is on at the same time. When the
temperature goes back to a level under 110
degrees, the alert indicator goes off auto-
matically.
B

C
XP235-13004

Fig. 4-210

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SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

Fuel level gauge

There are 13 yellow segments indicating a
range from 0 to 100%.
A: Fuel level is lower than 8%. There is no
segment shown. Alert indicator is on at the
same time. A
B: Fuel level is over 8%. Alert indicator goes
off.
C: Fuel level is 100%.

.
De al
B

pt
g no
in ti

C
营
销
公
司 XP235-13005

Fig. 4-211
et a
n
rk er

4.11.2.2 Operation keys

The operation keys include function keys and
navigation keys.
Ma t

A F1 F2 F3 F4 F5
A: Function keys
In

Esc Enter
B: Navigation keys B

XP235-13006

Fig. 4-212

Shop Manual - April 2014 4-199

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

Function keys
There are five function keys, i.e. F1, F2, F3, F4 and F5. These keys are defined by the icons dis-
played above them.
● Function of the same key may vary as the icon above it changes.
● A key is disabled when no icon is displayed above it.

Common icons and corresponding keys are given in the following table.

Icon dis-
Function keys Functions Display range
played
F1 s Change working mode. H→S→L→B

.
De al
F2 AUTO

Shift to full speed/auto idling. Full speed/auto idling

pt
n/min

F3 g n Shift to high/low travel speed. High/low speed

F4 Enter an option/setup item. Same as the Enter key

o
View system information. ——
in ti

F5
Back to previous page. 营
销
公
司
Same as the ESC key
et a
n

Operation keys
rk er

Operation keys Functions

Ma t

Enter Enter an option/setup item.

In

ESC Back to previous page.

UP (The highlight goes to the bottom item after the top one.) Increase the
value of digit at the cursor.
DOWN (The highlight goes to the top item after the bottom one.) Decrease the
value of digit at the cursor.
LEFT (The highlight goes to the right most item after the left most one.) Move
the cursor leftward.
RIGHT (The highlight goes to the left most item after the right most one.)
Move the cursor rightward.

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SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.11.3 Monitor display and operation

Sany Hydraulic Excavator
4.11.3.1 Default page
S 1
Default page is shown during normal operation
of the excavator.
C H
Operation
1. Working mode
Press the key F1 to change working mode E F
to H, S, L or B in a cycle manner. 11/11/01
0032h25m E101 09:32:24
H mode - Heavy-duty operation
s AUTO

n/min

S mode - Standard operation

.
De al
XP235-13007
L mode - Light-duty operation

pt
Fig. 4-213
B mode - Breaker operation
g n
NOTE: S is the default mode after the machine
o
is powered on.
in ti

2. Selecting auto idling 3. Selecting high/low travel speed

Press the key F2 to disable/enable auto idling营
销
公
司

Press the key F3 to switch between high and

function. low travel speeds. When the symbol ap-
et a

pears above the key F3 , press the key to

When the icon appears above the key F2 ,
n

AUTO

select high speed travel; when the symbol

n/min

press the key to disable auto idling; when the

appears above the key F3 , press the key to
rk er

icon appears above the key F2 , press the

select low speed travel.
n/min

key to enable auto idling.

NOTE: When the machine is powered on, low
NOTE: When the machine is powered on, auto
Ma t

speed is the default travel speed.

idling is enabled as default.
In

4. Viewing failure information

● Auto idling is active as default. When all
control levers are in neutral position for When alert indicator of the monitor is on, a fail-
more than 0.2 seconds, engine speed will ure code will appear on bottom line of monitor
drop by 100 rpm immediately and then screen. Meanwhile, a red tick appears above
enter auto idling after another 3 seconds the key F4 . Press the key to see failure infor-
(controller will reduce engine speed to mation.
idling) in order to reduce fuel consumption
5. Viewing system information
and noise.
Press the key F5 to see system information.
● In idling, if the controller detects any ma-
neuver or gear change, engine speed will NOTE: To see system information requires
restore respective level. password. Please contact your Sany distribu-
tor.

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Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.11.3.2 Password entry to system information

Press F5 on the default page to enter the

password entry to system information. You
need to enter the correct password prior to ac-
System Information
cess to System Information.
Key operation
Please enter password:
● Press F1 or or to increase or de-
crease the number on the digit with the
cursor.
● Press F2 or or to move the cursor to
the left or right digit.

.
De al
● Press F3 to enter System Unlock.

pt
● Press F4 to enter Backlight Adjustment.
g n
● Press F5 or ESC to return to the default
XP235-13008
page.
o
● Press Enter to check the validity of pass- Fig. 4-214
in ti

word. If the password is valid, you have ac-

cess to the Main Menu. 营
销
公
司
et a

4.11.3.3 Main menu

n

Key in the correct password and press Enter

rk er

on the password entry to access System Infor-

mation. Main Menu
This page contains a list of system functions.
Ma t

You can pick up an item and enter respective Operating Information

In

page. Failure Information

Throttle Help Info
Key operation Language Selection
SYS Clock Setup
● Press F1 or or to scroll up or down
GPS Information
the menu. When you scroll down the
menu, the highlight returns to the top item
Running parameters of engine,
after the bottom one. main pump and main valve.

● Press F2 or Enter to enter highlighted item.

● Press F4 to go to System Setup.
XP1251203007
● Press F5 or ESC to return to the default
page. Fig. 4-215

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SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.11.3.4 Engine & throttle signals

Select Running information on the Main Menu
and press F2 or Enter to see Engine & Throttle
Signals. Engine & Throttle Signals

This page contains operating parameters of

Coolant Temp ℃：10
engine and throttle signals.
Fuel Level %：10

Key operation Eng Oil Press kPa：10

● Press F1 to see Pilot Pressure Signals. Throttle Gear N：10

Engine Speed rpm：10

● Press F5 or ESC to return to the Main
Menu. Gear Position V：10

.
Throttle Position V：10

De al
pt
g no
XP1251203008

Fig. 4-216
in ti

司
公

4.11.3.5 Pilot pressure signals

销
营
et a

Press F1 on the page of Engine & Throttle

n

Signals to see Pilot Pressure Signals.

rk er

This page shows pilot pressure signals. Pilot Press Signals

Boom UP kg：10
Key operation Boom DOWN kg：10
Ma t

● Press F1 to see Main Pump & Main Valve Arm IN kg：10

In

Signals. Arm OUT kg：10

Bucket DIG kg：10

● Press F5 or ESC to return to the Main
Bucket DUMP kg：10
Menu.
Swing kg：10

Left travel kg：10

Right Travel kg：10

XP2051203009

Fig. 4-217

Shop Manual - April 2014 4-203

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.11.3.6 Main pump & main valve signals

Press F1 on the page of Pilot Pressure Sig-
nals to see Main Pump & Main Valve Signals.
This page shows main pump and main valve Main Pump & Main Valve
signals.
Pump_1 Main Press Kg：10

Pump_2 Main Press Kg：10

Key operation
Prop Valve_1 Current mA：10
● Press F1 to see Engine & Throttle Signals.
Prop Valve_2 Current mA：10
● Press F5 or ESC to return to the Main Bucket Confl valve ○
Menu. Swing Priority valve ○
Boom Priority valve ○

.
De al
High/Low Speed Shift ○

pt
g no
XP2051203010

Fig. 4-218
in ti

司
公

4.11.3.7 Failure codes

销
营
et a

Select Failure Codes on the Main Menu and

n

press F2 or Enter to enter the page.

rk er

This page contains failure codes and failure Failure Information

information. Current failure code：E101
E101：Controller failure
Ma t

E102：Controller temp abnormal

Key operation E103：Sensor power abnormal
E202：Voltage high
E203：Backup battery volt low
In

● Press F1 to see next page of failure codes. E401：CAN bus abnormal

E501：Fuel control dial abnormal
H101：F. pump press abnormal
● Press F5 or ESC to return to the Main H102：R. pump press abnormal
H105：F. pump valve current abnormal

Menu. H108：R. pump valve current abnormal

H112：Backup pilot press abnormal
H201：Bucket-dig pilot press abnormal
H202：Bucket-dump pilot press abnormal
H203：Arm-in pilot press abnormal
H204：Arm-out pilot press abnormal
H205：Boom-up pilot press abnormal

XP2051203011

Fig. 4-219

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SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.11.3.8 Throttle help information

Select Throttle Help Info on the Main Menu
and press F2 or Enter to enter the page.
This page contains help information for throttle Throttle Help Info
installation.
Current Gear N：
Key operation
Engine Speed rpm：
● Press F2 to select auto idling or full speed.
● Press F3 to select high or low speed travel. Gear Position V：

● When SYFCS controller is used, the icon Throttle Position V：

rpm will appear in blue or red color.

.
De al
● Press F5 or ESC to return to the Main

pt
Menu. s AUTO

n/min
rpm
Note: Only a SYFCS controller allows the
g n
change of rpm between blue and red colors.
o
XP2051203013

Fig. 4-220
in ti

司
公

4.11.3.9 Language selection

销
营
et a

Select Language Selection on the Main Menu

n

and press F2 or Enter to enter the page.

rk er

This page is used to select a language for the Language Selection

system.
Ma t

Key operation
中文系统
In

● Press F2 to select Chinese System ( 中文 English Systems

系统 ).
● Press F3 to select English System.
● Press F5 or ESC to return to the Main
Menu.
● Press or to highlight a language up
中文 Eng
or down the list.
XP2051203014

Fig. 4-221

Shop Manual - April 2014 4-205

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.11.3.10 System clock setup

Select System Clock Calibration on the Main
Menu and press F2 or Enter to enter the page.
This page is used to set up system clock. SYS Clock Setup

Key operation Local time and time zone：

● Press or to increase or decrease the 1234·12·12 12:12：12 12W

number on the digit with the cursor.

Time and time zone setup：
● Press or to move the cursor to the 1234·12·12 12:12：12 12W
left or right digit.
● Press F1 or Enter to finish calibration. You

.
will be prompted by “Calibration finished!

De al
Use [↑][↓][←][→] to set p system clock.
Please restart your machine.”

pt
● Press F5 or ESC to return to the default
g n
page. XP2051203015
o
NOTE: System clock can only be set up once Fig. 4-222
after the machine is powered on. When the
in ti

machine is powered on, the prompt of suc-

cessful calibration remains on the screen if 营
销
公
司

you press F1 or the Enter key.

et a
n
rk er
Ma t
In

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SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.11.3.11 GPS information

Select GPS Information on the Main Menu and
press F2 or Enter to enter the page.
This page shows GPS monitoring information. GPS Information

Longitude °：121.0W
Key operation Latitude °：31.40N

Press F5 or ESC to return to the default page. Altitude m：28.79P

Velocity Km/h：4.037
Number of Satellites ：0006
Note:
Communication Indicator ：1023
1. The letter “E” stands for East Longitude Signal to noise ratio 1： dB
and “W” for West Longitude. Signal to noise ratio 2： dB

.
Signal to noise ratio 3： dB
2. The letter “N” stands for North Latitude

De al
Signal to noise ratio 4： dB
and “S” for South Latitude.

pt
3. The letter “P” stands for a height above
g n
the seal level and “N” for a height below XP20512003026
the seal level.
o
Fig. 4-223
4. The signal-to-noise ratio ranges from 0 to
in ti

99, which is indicated by a bar. The value

on the right of the bar is real S/N ratio. 营
销
公
司

5. If the elevation value is not zero and no

et a

value is displayed for the longitude and lati-

n

tude, GPS data are being received but the

location has not been precisely defined yet.
rk er

6. When the communication signal is 1023,

GPRS communication is regular. When it
Ma t

is 615, the GPRS communication is abnor-

mal.
In

7. When the communication signal changes

from 7 to 0, the SIM card or the antenna
has a bad connection.
8. When the communication signal changes
from 15 to 0, GPRS service is not available,
the SIM card has insufficient fund, or GPRS
network is abnormal.
9. When the communication signal changes
from 31 to 0, the monitoring center is
closed.
10. This page is required for remote system
locking, remote system unlocking and re-
mote downloading.

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Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.11.3.12 System setup

Press the key F4 on the Main Menu to enter
System Setup.
This page is used to configure your machine. System Setup

Note: Access to System Setup requires en-

tering the password. For method of entering Machine Configuration
password see “Password entry to system Service Hour Setup
information” on page 4-202. Machine Configuration Setup

Hydraulic Oil Temperature

Key operation
● Press F1 or or to scroll up or down the
menu. When you scroll down the menu,

.
De al
the highlight returns to the top item after

pt
the bottom one.
● Press F2 or Enter to enter highlighted item.
g n XP2051203016
● Press F5 or ESC to return to the Main
o
Menu. Fig. 4-224
in ti

司
公
销
营

4.11.3.13 Machine configuration

et a

Select Machine Configuration on the Main

n

Menu and press F2 or Enter to enter the page.

rk er

This page shows machine configuration infor- Machine Configuration

mation.
Note: Access to System Setup requires en-
Ma t

Machine Model： SY215C \V217

tering the password. For method of entering

In

Machine S/N： 11SY0216 00008

password see “Password entry to system
information” on page 4-202. Engine Model： CUMMINS_II

Key operation HYD SYS Model： KPM_P

● Press F5 or ESC to return to System Set- Control SYS： KC-MB-001

up.
Note: “V217” following machine model is
software version.
XP2051203018

Fig. 4-225

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SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.11.3.14 Service hour setup

Select Service Hour Setup on the page of Sys-
tem Setup and press F2 or Enter to enter the
page. Service Hour Setup
This page is used to set up service hours of
the machine. Current Service Hours ：
100 h 50 m
Note: Access to System Setup requires en-
tering the password. For method of entering
Service Hour Setup ：
password see “Password entry to system 100 h 50 m
information” on page 4-202.

Key operation

.
De al
● Press F1 or Enter to save the change af- Use [↑][↓][←] and [→] to set up service hours.

pt
ter calibration. You will see on the screen
“Calibration finished! Please restart your
g n
machine.” XP2051203021
o
● Press F5 or ESC to return to System Set- Fig. 4-226
up.
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 4-209

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.11.3.15 Machine configuration setup

Select Machine Configuration Setup on the
page of System Setup and press F2 or Enter
to enter the page. Machine Configuration Setup

This page is used to set up machine configu-

Machine Model：SY215C\GPS 32
ration after monitor installation.
Note: Access to System Setup requires en- Engine Model：CUMMINS_II

tering the password. For method of entering HYD SYS Model：KPM P

password see “Password entry to system
information” on page 4-202. Controller Model：KC-MB-001

Machine S/N：11SY0216 00008

Key operation

.
De al
● When “215” after machine model is Use [↑][↓][←] and [→] to change machine S/N.

pt
blinking, each pressing of F1 will bring the Model Eng Hyd Ctrl
number up by 10; when “32” after GPS
g n
is blinking, each pressing of F1 will bring XP2051203023
the number up by 10.
o
Fig. 4-227
● Press F2 to change Engine Model.
in ti

● Press F3 to change Hydraulic System

Model.
司
公
销
营
et a

● Press F4 to change controller model.

n

● Press F5 to save the change. You will

see on the screen “Calibration finished!
rk er

Please restart your machine.”

● Press or to increase or decrease the
Ma t

selected machine S/N by 100.

In

● Press or to increase or decrease the

selected machine S/N by 1. Depress the
key to increase S/N quickly.
● Press ESC to return to System Setup.
● Each pressing of the key Enter enables
the number after machine S/N or model to
blink. A blinking number can be modified
using the keys.

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SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

4.11.3.16 Hydraulic oil temperature

Select Hydraulic Oil Temp on the page of Sys-
tem Setup and press F2 or Enter to enter the
page. HYD Oil Temp
This page shows temperature of hydraulic oil.
Hydraulic Oil Temp ℃：49
Key operation
● Press F5 or ESC to return to System Set-
up.

.
De al
pt
g no
XP2051203028

Fig. 4-228
in ti

司
公

4.11.3.17 Screen brightness setup

销
营
et a

Press F4 on the page of password entry to

n

system information to enter the page.

rk er

This page is used to adjust backlight bright- Screen Brightness Setup

ness of the screen.
Screen Brightness：20%
Ma t

Key operation
In

● Press F1 to dim backlight.

● Press F2 to enhance backlight.
● Press F3 to safe brightness change.
● Press F5 to return to System Information.
Press F3 to save setup！

XP2051203029

Fig. 4-229

Shop Manual - April 2014 4-211

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

4.11.3.18 System lockout (level 1)

When this page appear on monitor, it indicates
that the excavator is locked out in level 1.
System Lockout
Key operation
● Press F5 to enter the page for unlocking.
Machine Model：SY205C
NOTE: After 5 seconds according to the com- Machine S/N：00008
mand, corresponding state (Level 1 lockout, Lockout State：Level 1
level 2 lockout or no lockout) will be displayed. Current time：12：12：11
(Waiting for 5 seconds performs a function of
filtration.)

.
De al
System Locked
Contact your Sany distributor to unlock your machine.

pt
g no
XP2051203024

Fig. 4-230
in ti

4.11.3.19 System lockout (level 2) 营

销
公
司
et a

When this page appear on monitor, it indicates

that the excavator is locked out in level 2.
n

System Lockout
rk er

Key operation
● Press F5 to enter the page for unlocking. Machine Model：SY205C

Machine S/N：00008
NOTE: After 5 seconds according to the com-
Ma t

Lockout State：Level 2
mand, corresponding state (Level 1 lockout,
In

Current time：12：12：11
level 2 lockout or no lockout) will be displayed.
(Waiting for 5 seconds performs a function of
filtration.)
System Locked
Contact your Sany distributor to unlock your machine.

XP2051203025

Fig. 4-231

4-212 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions

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Shop Manual - April 2014 4-213

Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator

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4-214 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Standard Values

Standard Values

.
5 Table of Standard Values

De al
pt
5.1 Standard Values for Engine-Related Parts .............................................................. 5-3
5.2 Standard Values for Chassis-Related Parts ............................................................ 5-4
g no
in ti

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In

Shop Manual - April 2014 5-1

Standard Values SY365(B)H-9 Crawler Hydraulic Excavator

.
De al
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g no
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5-2 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Standard Values

5 TABLE OF STANDARD VALUES

5.1 Standard Values for Engine-Related Parts

Applicable Models SY365(B)H-9

Engine ISUZU AA-6HK1-XQP-01
Standard values for
Item Measurement condition Unit Repair limits
new machine
High idling rpm 2,250 ± 25 2,250 ± 25
Engine speed Low idling rpm 1,050 ± 25 1,050 ± 25

.
Rated speed rpm 2,000 2,000

De al
Intake pressure

pt
Air cleaner outlet location kPa Min 133 Min 133
(Negative
Arm-in relief ＋ max rpm {mmH2O} {Min 1,000} {Min 1,000}
pressure)
Exhaust color
g no
At sudden acceleration Bosch Max 25 35
At high idling Index — —
Valve clear- Intake valve mm 0.4 0.3– 0.5
in ti

ance Exhaust valve mm 0.4 0.3 – 0.5

Compression Oil temp：75℃ Mpa Min 3.0 2.5
司
公
销
营
et a

pressure Engine speed 250 rpm {kg/cm2} {31} {26}

n

Blow-by pres- Coolant temp：working range arm- kPa Max 0.98 1.96
sure in relief ＋ max rpm {mmH2O} {Max 100} {200}
rk er

MPa Min 0.29 0.25

High idling
Engine oil pres- {kg/cm2} {Min 3.0} {2.5}
Ma t

sure MPa Min 0.10 0.07

Low idling
{kg/cm2}
In

{Min 1.0} {0.7}

Engine oil temp Full speed range (in oil pan) ℃ 80 – 110 120

Between fan belt pulley and alterna-

Fan belt ten- tor belt pulley
mm 8.5 Min 7，Max 10
sion Deflection when pressed with finger
force of 58.8 N {6 kg}

Between fan belt pulley and com-

A/C compres- pressor belt pulley
mm 5–8 5–8
sor belt tension Deflection when pressed with finger
force of 58.8 N {6 kg}

Shop Manual - April 2014 5-3

Standard Values SY365(B)H-9 Crawler Hydraulic Excavator

5.2 Standard Values for Chassis-Related Parts

Applicable Models SY365(B)H-9

Standard Value
cate- Permissible
Item Measurement Condition Unit for New Ma-
gory Value
chine
● Engine coolant temperature: Within
operational range
● Hydraulic oil temperature: Within
2 pumps at relief operational range rpm 2,050±50 2,050±50
● Engine running at high idle
● Heavy-load operating mode (H)
Engine Speed

● Arm-in relief condition

.
De al
● Engine coolant temperature: Within
operational range

pt
● Hydraulic oil temperature: Within
2 pumps at relief +
operational range
g n
boosting (if avail-
● Engine running at high idle
rpm 2,050±50 2,050±50
able)
● Heavy-load operating mode (H)
o
● Arm-in relief condition + boost switch
in ti
on
Speed when auto ● Engine running at high idle
deceleration is op- ● Auto idling switch on rpm 1,350±50 1,400±100
司
公
销
营

erated ● All control levers neutral

et a

Raise mm 11.5±0.5 11.5±0.5

n

Boom control valve

Lower mm 9.5±0.5 9.5±0.5
rk er

● Engine stopped
Spool Stroke

● For measur- In mm 11.5±0.5 11.5±0.5

Arm control valve
ing points see Out mm 9.5±0.5 9.5±0.5
Control Valve
Ma t

Bucket control valve Curl/dump mm 9.5±0.5 9.5±0.5

on page 3-10.
Swing control valve Travel (L&R) mm 9.5±0.5 9.5±0.5
In

Travel control valve Forward & Reverse mm 9.5±0.5 9.5±0.5

Boom control lever mm 85±10 85±10
Arm control lever ● Engine stopped mm 85±10 85±10
● Control lever grip at center
Bucket control lever ● Max. reading up to stroke end (except mm 85±10 85±10
Travel of Control Lever

Swing control lever lever play in NEUTRAL position) mm 85±10 85±10

Travel control lever mm 115±12 115±12
● Engine stopped
● Slightly push
Work Equipment mm Max 15 Max 20
the control lever
with your hand.
Play of control lever Stop pushing
when you feel
clear resistance Travel mm Max 20 Max 25
● Max. reading up
to stroke end

5-4 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Standard Values

Applicable Models SY365(B)H-9

Cate- Standard Value for Permissible
Item Measurement Condition Unit
gory New Machine Value
Boom control Max 19.6 Max 24.5
Operating Force of Control Lever and

lever {Max 2.0} {Max 2.5}

Arm control Max 19.6 Max 24.5
lever {Max 2.0} {Max 2.5}
● Hydraulic oil temp：Within op-
Bucket con- erational range Max 15.6 Max 21.6
trol lever {Max 1.6} {Max 2.2}
Pedal

● Engine running at high idle N

Swing control ● Control lever grip at center {kg} Max 15.6 Max 21.6
lever ● Pedal at tip {Max 1.6} {Max 2.2}
● Max reading at stroke end
Travel control Max 30.4 Max 39.2

.
De al
lever {Max 3.1} {Max 4.0}

pt
Travel control Max 93.1 Max 107.6
pedal g n {Max 9.5} {Max 11}
● Hydraulic oil temp：Within op-
erational range
o
● Engine running at high idle
Unloaded 3.5 ± 1.0 3.5 ± 1.0
in ti
● Working mode：H
pressure {36 ± 10} {36 ± 10}
● Hydraulic pump output pressure
with all control levers in neutral
营
销
公
司

position
et a

Boom relief ● Hydraulic oil temp：Within op- 34.3 ± 1.0 33.3 – 35.3
erational range
n

{350 ± 10} {340 – 360}

● Operate corresponding control
34.8 ± 1.0 33.3 – 36.8
rk er

Arm relief lever after the engine runs at

high idling speed. {355 ± 10} {340 – 375}
Hydraulic Pressure

● Working mode：H
● Hydraulic pump output pressure 34.8 ± 1.0 33.3 – 36.8
Ma t

Bucket relief with all measurement circuits {355 ± 10} {340 – 375}
MPa
relieved
In

{kg/cm2}
● Hydraulic oil temp：Within op- 25.5 ± 1.0 24.5 － 27.5
Swing relief erational range {261 ± 10} {250 － 280}
● Operate corresponding control
lever after the engine runs at
high idling speed.
● Working mode：H 33.4 ± 1.0 32.4 – 34.4
Travel relief
● Hydraulic pump output pressure {342±10} {330 – 351}
with all measurement circuits
relieved
● Hydraulic oil temp：Within op-
erational range
Control circuit
● Engine running at high idle 3.9±0.2 3.7 – 4.1
source pres-
● Self pressure reducing valve {40±2} {37 – 41}
sure
output pressure with all control
levers in NEUTRAL position

Shop Manual - April 2014 5-5

Standard Values SY365(B)H-9 Crawler Hydraulic Excavator

Applicable Models SY365(B)H-9

Cate- Standard Value

Permissible
Item Measurement Condition Unit for New Ma-
gory Value
chine
● Hydraulic oil temp：Within operational range
Swing brake angle

● Engine running at high idle

● Working mode: H
degree Max 100 Max 130
● Swing circle misalignment amount when stopping
mm (—) (—)
after one turn
● For measuring posture see Swing 1 on page
3-10.

● Hydraulic oil temp：Within opera-

Time taken to start

tional range 90° sec. 3.1 ± 0.3 Max 3.7

.
● Engine running at high idle

De al
swing

● Working mode: H

pt
● Time required for passing points
90° and 180° from starting point
● For measuring posture see Swing 180° sec. 4.4 ± 0.4 Max 5.5
g n
1 on page 3-10.
o
Time taken to swing

● Hydraulic oil temp：Within operational range

in ti
● Engine running at high idle
Swing

● Working mode: H
+4
● Time required for 5 turns after making initial one
营
销
公
司
sec. 31 -2 Max 35
turn
et a

● For measuring posture see Swing 1 on page

3-10.
n

● Hydraulic oil temp：Within operational range

rk er

● Engine stopped
Hydraulic drift

● Keeping the upper structure transverse on a

grade of 15° . For more information see Swing 2
on page 3-10. mm 0 0
Ma t

● Notching a mating mark on inner and outer races

of the swing circle
In

● Mating mark misalignment amount during 5 min-

utes.
● Hydraulic oil temp：Within operational range
Motor leak-

● Engine running at high idle

age

● Swing lockout switch: ON ml/min Max 5 Max 10

● Leakage amount for one minute during swing
relief
● Hydraulic oil temp：Within opera-
tional range
● Engine running at high idle Lo 11.8± 3 8.8-14.8
Travel speed
(unloaded)

● Working mode: H
Travel

● Time required for track shoes to

sec.
make 5 turns after making one
initial turn
● For more information on measur- Hi 7.6 ± 3 4.6-10.6
ing posture see Travel 1 on page
3-11.

5-6 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Standard Values

Applicable Models SY365(B)H-9

Standard
Cate- Permissible
Item Measurement Condition Unit Value for New
gory Value
Machine

● Hydraulic oil temp：Within operational range

● Engine running at high idle
Travel speed

Lo 22 ± 2.5 19.5-24.5
(Actual run)

● Working mode: H
● Level ground sec.
● Time required for traveling 10 m after 10 m trial
run Hi 14 ± 2.5 11.5-16.5
● For measuring posture see Swing 2 on page 3-10.

● Hydraulic oil temp：Within operational range

● Engine running at high idle

.
De al
● Working mode: H
Deviation

● Travel Speed: Low

pt
● Hard level ground mm Max 800 Max 900
● Amount of deviation (χ) while traveling 20 m after ini-
Travel

g n tial 10 m trial run

● For measuring posture see Travel 2 and 3 on page
o
3-11.
in ti

● Hydraulic oil temp：Within operational range

Hydraulic drift

● Engine stopped
● Park the machine on a grade of 12° , with the sprock-
营
销
公
司

mm 0 0
et in the downhill direction
et a

● Measure the sliding distance for 5 minutes

n

● For measuring posture see Travel 4 on page 3-12.

● Hydraulic oil temp：Within operational range
rk er
travel motor
amount of
Leakage

● Engine running at high idle

● Traveling with the sprocket locked mm 13.6 27.2
● Oil leakage amount for one minute with traveling in re-
Ma t

lief condition
In Bucket

● Hydraulic oil temp: Within operational range

tips

mm Max 600 Max 900

● Flat and level ground
● Bucket full of earth or with rated load (0.8m3: 1,440 kg)
● Boom horizontal, arm fully retracted and bucket cylin-
cylinder
Arm cylin- Boom

der fully extended

mm Max 20 Max 27
Work Equipment

● Engine stopped
Hydraulic drift

● Work equipment control lever in neutral position

● Measure total amount of falling for 15 minutes by mea-
suring the falling every 5 minutes immediately after ini-
der

mm Max 20 Max 20
tial setting
★ Bucket tip lower distance
★ Boom cylinder: Cylinder retracting distance
Bucket cylinder

★ Arm cylinder: cylinder extending distance

★ Bucket cylinder: cylinder retracting distance
mm Max 35 Max 40
● For measuring posture see Work Equipment 1 on page
3-12.

Shop Manual - April 2014 5-7

Standard Values SY365(B)H-9 Crawler Hydraulic Excavator

Applicable Models SY365(B)H-9

Cate- Standard Value for Permissible
Item Measurement Condition Unit
gory New Machine Value
● Hydraulic oil temp：Within op-
erational range
● Engine running at high idle
● Working mode: H

Boom ● Time required for the bucket UP sec. 3.8 ± 0.3 Max 4.8
to raise from the ground to its
stroke end
● For measuring posture see
Work Equipment 2 on page

.
De al
3-12.

pt
● Hydraulic oil temp：Within op-
IN sec. 3.5 ± 0.3 Max 4.5
erational range
Work Equipment Speed

g n
● Engine running at high idle
Work Equipment

o
● Working mode: H
Arm ● Time required from dumping
in ti

stroke end to digging stroke end OUT sec. 3.0± 0.3 Max 3.5
● For measuring posture see 营
销
公
司

Work Equipment 3 on page

et a

3-13.
n

● Hydraulic oil temp：Within op- DIG sec. 3.1 ± 0.3 Max 3.4
rk er

erational range
● Engine running at high idle
Ma t

● Working mode: H
Bucket ● Time required from dumping
In

stroke end to digging stroke end DUMP sec. 2.0 ± 0.3 Max 2.3
● For measuring posture see
Work Equipment 4 on page
3-13.

5-8 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Standard Values

Applicable Models SY365(B)H-9

Cate- Standard Value Judgement

Item Measurement Condition Unit
gory for New Machine Criteria
● Hydraulic oil temp：Within opera-
tional range
● Engine running at low idle
● Working mode: H
● Time required from maneuvering
Boom the joystick to the moment that the sec. Max 1.0 Max 1.2
bucket reaches the ground and
begins to push the machine up-
ward, within 50 mm off the ground
● For measuring posture see Work

.
Equipment 5 on page 3-13.

De al
● Hydraulic oil temp：Within opera-

pt
tional range
Time Delay

● Engine running at low idle

g n ● Working mode: H
Work Equipment

● Average time required for operat-

o
Arm sec. Max 2.0 Max 2.8
ing the control lever back and forth
in ti

till the arm starts to move

● For measuring posture see Work
Equipment 6 on page 3-14.
司
公
销
营
et a

● Hydraulic oil temp：Within opera-

tional range
n

● Engine running at low idle

● Working mode: H
rk er

Bucket ● Average time required for operat- sec. Max 1.0 Max 3.6
ing the control lever back and forth
till the arm starts to move
Ma t

● For measuring posture see Work

Equipment 7 on page 3-14.
In

● Hydraulic oil temp：Within opera-

Internal Leakage

Cylinders tional range 5 20

● Engine running at high idle
Central ml/min
● Leakage amount for one (1) min-
Swivel ute with cylinder or travel mea- 10 50
Joint sured at relief condition
● Hydraulic oil temp：Within opera-
Performance in Combined

tional range
● Engine running at high idle
Amount of devia-
● Working mode: H
Operations

tion in simultane-
● Travel Speed: Low
ous operation of mm Max 200 Max 220
● Amount of deviation measured for
work equipment
20 m after traveling about 10 m on
and travel
a hard level ground
● For measuring posture see Travel
2 and 3 on page 3-11.

Shop Manual - April 2014 5-9

Standard Values SY365(B)H-9 Crawler Hydraulic Excavator

Machine attitudes applicable to perfor-

mance test and testing procedure of all
machine models

Control valve: Spool stroke

.
De al
pt
ZX335-1003002

Fig. 5-1
g no
Swing 1: Swing brake angle, time taken to
start swing and time taken to swing
in ti

司
公
销
营
et a
n
rk er
Ma t

ZX335-1003004
In

Fig. 5-2

Swing 2: Hydraulic drift of swing

15°

Sprocket

ZX335-1003006

Fig. 5-3

5-10 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Standard Values

Travel 1: Travel speed (without load)

ZX335-1003003

Fig. 5-4

.
De al
pt
Travel 2: Travel speed (actual run), Travel de-
viation g n 45°
o
in ti

司
公
销
营
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n
rk er

ZX335-1003005

Fig. 5-5
Ma t

Travel 3: Travel deviation

In

10m

ZX335-1003007

Fig. 5-6

Shop Manual - April 2014 5-11

Standard Values SY365(B)H-9 Crawler Hydraulic Excavator

Travel 4: Hydraulic drift of travel

12°

ZX335-1003008

Fig. 5-7

.
De al
pt
Work equipment 1: Hydraulic drift of work
equipment g no
in ti

司
公
销
营
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n
rk er

ZX335-1003010

Fig. 5-8
Ma t

Work equipment 2: Boom speed

In

ZX335-1003012

Fig. 5-9

5-12 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Standard Values

Work equipment 3: Arm speed

ZX335-1003009

Fig. 5-10

.
De al
pt
Work equipment 4: Bucket speed
g no
in ti

司
公
销
营
et a
n
rk er

ZX335-1003011

Fig. 5-11
Ma t

Work equipment 5: Boom delay

In

ZX335-1003013

Fig. 5-12

Shop Manual - April 2014 5-13

Standard Values SY365(B)H-9 Crawler Hydraulic Excavator

Work equipment 6: Arm delay

ZX335-1003014

Fig. 5-13

.
De al
pt
Work equipment 7: Bucket delay
g no
in ti

司
公
销
营
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n
rk er

ZX335-1003015

Fig. 5-14
Ma t
In

5-14 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Standard Values

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Shop Manual - April 2014 5-15

Standard Values SY365(B)H-9 Crawler Hydraulic Excavator

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5-16 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

Testing and Adjusting

.
6 Testing and adjusting

De al
pt
6.1 Engine Speed - Test and Adjust............................................................................... 6-3
6.2 Exhaust Gas Color - Test ......................................................................................... 6-5
g n
6.3 Valve Clearance - Adjust.......................................................................................... 6-7
o
6.3.1 Testing............................................................................................................ 6-8
in ti

6.3.2 Adjusting ........................................................................................................ 6-9

6.4 Compression force - Test ....................................................................................... 6-10
营
销
公
司
et a

6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13

6.5.1 Testing.......................................................................................................... 6-14
n

6.5.2 Adjusting ...................................................................................................... 6-18

rk er

6.6 A/C Compressor Belt Tension - Test and Adjust .................................................... 6-19
6.6.1 Testing ......................................................................................................... 6-19
Ma t

6.6.2 Adjusting ...................................................................................................... 6-19

In

6.7 Swing Bearing Clearance - Test ............................................................................ 6-20

6.8 Track Tensioner - Test and Adjust .......................................................................... 6-21
6.8.1 Testing.......................................................................................................... 6-21
6.8.2 Adjusting ...................................................................................................... 6-22
6.9 Oil in Hydraulic Circuits - Test and Adjust .............................................................. 6-23
6.9.1 Testing.......................................................................................................... 6-23
6.9.2 Adjusting ...................................................................................................... 6-25
6.10 Control Oil Circuit Pressure - Test and Adjust...................................................... 6-28
6.10.1 Testing........................................................................................................ 6-28
6.10.2 Adjusting .................................................................................................... 6-28
6.11 Solenoid Valve Output Pressure - Test ................................................................ 6-29
6.12 Pilot Valve Output Pressure - Test ....................................................................... 6-31
6.13 Work Equipment and Swing Pilot Valves - Adjust ................................................ 6-33
Shop Manual - April 2014 6-1
Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

6.14 Hydraulic Drift of Work Equipment - Test ............................................................. 6-34

6.15 Remaining Pressure in Hydraulic Lines - Relieve................................................ 6-36
6.16 Oil Leakage Amount - Test................................................................................... 6-37
6.17 Air in Each Component - Purge ........................................................................... 6-41

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

6-2 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

6 TESTING AND ADJUSTING

6.1 Engine Speed - Test and Adjust

Testing
Start the engine and keep the engine running
until coolant temperature enters operational Main Menu
range. Key in the password on the monitor
and check if the engine speed is normal in Operating Information

each gear position. Failure Information

Throttle Help Info
Testing Items: Language Selection

.
SYS Clock Setup
1. Engine speed at low idle

De al
GPS Information

pt
2. Engine speed at fuel control dial position
11 (H and S modes)
g n Running parameters of engine,
main pump and main valve.
3. Engine speed at relief, with fuel control dial
o
in position 11 (H and S modes)
4. Engine speed at auto deceleration
in ti

XP1251203007

Fig. 6-1
司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 6-3

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

Calibration
1. Preconditions for auto speed calibration:
A. Start the engine.
Throttle Help Info
B. Check the throttle position voltage for
gear position 1 on the Throttle Help Info
page on the monitor. Normal voltage Current Gear N：
should be 1.3±0.3V under normal
speed range of 1050±50. If the voltage Engine Speed rpm：

is out of the specified range, manually

Gear Position V：
adjust the throttle pull rod. Otherwise
abnormality would occur in speed Throttle Position V：
calibration and a red question mark“?”

.
would appear after Engine Speed on

De al
the Throttle Help Info page on the

pt
monitor.
s AUTO

n/min
rpm
g n
2. Enter the speed calibration page.
o
XP2051203013

Press F5 on the default page of monitor Fig. 6-2

and key in the password to access the
in ti

Main Menu. Choose Throttle Help Info on

the Main Menu to enter the page like the 营
销
公
司

figure on the right.

et a

3. Speed calibration
n

Press F4 on the Throttle Help Info page to

rk er

execute speed calibration. The system en-

ters speed calibration (when the icon turns
red) and it automatically shifts to full speed
Ma t

(when the icon turns red).

In

4. Successful calibration
If the calibration is done successfully, the
icon for calibration indication turns blue.
The switching to full deceleration requires
pressing F2 to switch it manually.

6-4 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

6.2 Exhaust Gas Color - Test

● Tools used for testing exhaust gas color

No. Part Name

1 Smoke meter
2 Opacimeter

CAUTION

● Be careful not to touch any hot part

when installing or removing a testing

.
De al
equipment.

pt
g n
1. Testing with smoke meter
A. Put the filter paper in the smoke meter.
o
B. Insert the waste gas intake pipe into
in ti

the exhaust pipe.

司

C. Start the engine and keep the engine

公
销
营
et a

running until engine coolant tempera-

ture is within the operational range.
n

D. When engine speed increases sud-

rk er

denly or is kept at high idle, direct

ZX335-1004002
exhaust gas through smoke meter to
the filter paper. Fig. 6-3
Ma t

E. Remove the filter paper from the smoke

In

meter. Read the smoke value through

the apparatus provided.
F. Remove the testing tools after testing.
Make sure the machine goes back to
its normal state.

2. Testing with opacimeter

A. Mount the opacimeter onto the exhaust
pipe by clamping it to the pipe outlet.
ZX335-1004003

Fig. 6-4

Shop Manual - April 2014 6-5

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

B. Open the opacimeter and preheat it for

about 15 minutes.
C. Start the engine and keep the engine
running until engine coolant tempera-
ture is within the operational range.
D. When engine speed increases sud-
denly or is kept at high idle, use the
opacimeter to read the smoke value of
exhaust gas.
E. Remove the testing tools after testing. ZX335-1004004
Make sure the machine goes back to Fig. 6-5
its normal state.

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

6-6 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

6.3 Valve Clearance - Adjust

● Service Standard (Unit: mm)

Correction meth-
Location Service Item Standard Value Limits
od
— Valve clearance (with engine cold) 0.4 — Adjust

● Special tools

Symbol Tool name and shape Part Number Application

Flat-head screwdriver

.
De al
pt
Adjustment of valve clearance (carried
MH060008
on machine)
g n
ZX335-1004006
o
in ti

Check and adjust the valve clearance in cold state as per the following procedure:
营
销
公
司
et a
n
rk er
Ma t
In

Shop Manual - April 2014 6-7

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

6.3.1 Testing
In cold state, valve clearance is to be checked
and adjusted as per the following procedure:
Aligning point
1. Remove the rocker arm cover.
2. Turn the No.1 piston or the No.6 piston to
the top dead center (TDC) of compression
stroke by following the steps below.
● Turn the engine until the TDC line on
the crankshaft pulley is in line with the
timing pointer.
● Turn the No.1 piston or the No.6 piston

.
to the TDC of compression stroke.

De al
ZX335-1004007

pt
Fig. 6-6
Note: When the rocker arm at the intake side
and rocker arm at the exhaust side cannot be
g n
turned by hands, it is indicated that the piston
o
has reached the TDC of compression stroke.
Turning the engine by one more turn, the TDC
in ti

of compression stroke of No.1 piston and No.6

piston swaps. 营
销
公
司
et a

3. When the No.1 piston is at the TDC, adjust

the valve clearance in a sequence marked
n

with a black dot ( ● ).

rk er

Cylinder 1 2 3 4 5 6
Ma t

Exhaust ● ○ ● ○ ● ○
Intake ● ● ○ ● ○ ○
In

A. When a feeler gauge is used for such

measurement, resistance to a moving ZX335-1004008
feeler gauge in the clearance should be
Fig. 6-7
felt.
B. If the feeler gauge moves easily in the
clearance, it is impossible to obtain
accurate result.
4. If the measured value is out of specifica-
tion, readjustment shall be performed
according to the following method.

6-8 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

6.3.2 Adjusting
1. In adjustment of valve clearance, loosen Adjusting screw
the locknut before adjusting the adjusting
screw. A standard clearance is achieved
when slight resistance to the feeler gauge Locknut
is felt when pulling it out from the clear-
ance.
2. After adjustment, hold the adjusting screw
with a screwdriver to prevent it from turn-
ing, and tighten the locknut.
Locknut: 21-30 N.m{2.1- 3.1 kgf.m}
Valve clearance
ZX335-1004009

.
3. Go on with the next step until all valve

De al
Fig. 6-8
clearances marked with a black dot ( ● )

pt
have been adjusted
g n
4. Recheck the clearances with the feeler
gauge. Readjustment should be made if
o
deviation from the standard valve is found.
in ti

5. When the engine is carried in vehicle,

using to turn the adjusting screw will营
销
公
司

make the job easy.

et a
n
rk er
Ma t
In

Shop Manual - April 2014 6-9

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

6.4 Compression force - Test

● Service standard

Correction
Location Service Item Standard value Limits
method
Every cylinder (200
3.0MPa {30.6kgf/cm2} 2.5MPa {25.5kgf/cm2} Check
Compression rpm/h)
—
force Inter-cylinder pres-
— 390 kPa { ≤ 4kgf/cm2 } Check
sure difference

● Special tool

.
De al
Symbol Tool name and shape Part number Application

pt
Pressure gauge connector 5-85317-001-0 (JKM- Checking the compres-
1015) sion force
g no
1. Reduction of compression force can be an
in ti

indication for engine overhaul.

司

2. Check the compression force regularly

公
销
营
et a

and pay attention to its variation from time

to time. Understanding the variation of
n

compression force is helpful for trouble-

rk er

shooting. In addition, in a new vehicle or

when new parts are installed for replace-
ment, the pressure may be higher due to
Ma t

running-in of the piston ring, valve seat, Pressure gauge connector

ZX335-1004010
etc. The pressure will become normal as
In

the parts wear. Fig. 6-9

3. Before testing, make sure that the engine
oil, start motor and battery are in normal
condition.
4. The vehicle is to meet the following condi-
tions.
A. Preheat the engine until engine coolant
temperature reaches 75~85℃ .
B. Switch off all lamps and auxiliary
devices.
C. Place the gear lever in a neutral posi-
tion.

6-10 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

5. Remove the entire fuel injector.

6. Cover the fuel injector mounting opening
with a rag.
7. Activate the start motor in order to run the
engine. Check the cloth if it is stuck with
foreign substances.
8. According to the substances (engine oil
and/or coolant) adhering to the cloth, the
WARNING
following factors might be involved.
● When coolant and/or engine oil is found
A. When engine oil is found, it might be attached to the rag, running the engine
improper sealing caused by piston ring. may cause the hot coolant and engine
Check the piston ring. oil to squirt out through the mounting

.
De al
B. When engine oil and coolant are found, hole of the fuel injector. This is very

pt
it might be cracking of cylinder. Replace dangerous. Never touch or look into the
the crankcase.
g n fuel injector mounting hole when the
engine is running.
9. Mount the gasket and to the fuel injec-
o
tor mounting hole and fix them with the
in ti
injector cap. Install the compression force
gauge.
司
公
销
营

10. Start the engine and measure the com-

et a

pression force of each cylinder. Calculate

the differential pressure between the
n

cylinders.
rk er

11. When the compression force and the

differential pressure between cylinders
deviate from their limits, inject a small
Ma t

amount of engine oil through the fuel

In

injector mounting hole, and measure the

compression force again.
● If the compression force is higher, it is
probably due to worn or damaged piston
ring or cylinder inner surface.
● If the compression force is still low, it is
probably due to stuck valve or improper
seating, or improperly mounted gasket
of cylinder head.

Shop Manual - April 2014 6-11

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

6-12 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

6.5 Fuel Injection Timing - Test and Adjust

● Service standard
Correction
Location Service Item Standard value Limits
method
— Fuel injection timing (BTDC) 8 degrees 7~9 degrees Adjust

● Tightening torque (Unit: N·m)

Symbol Part tightened Tightening torque Remark

— Body, fuel delivery valve 39~44 —

.
De al
— Nut, injection tube 28~32 —

pt
● Common tool (Unit: N·m)
g no
Symbol Tool name and shape Part number Application
in ti
Universal con-
necting rod with
extension Inspection and adjust-
司
公
销
营
et a

MH061099 ment of fuel injection

A
timing
n

14
A ZX335-1004011
rk er
Ma t

NOTICE
In

● Take care not let dust or foreign ma-

terials get into the fuel injection pump
when adjusting the injection timing.

Shop Manual - April 2014 6-13

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

6.5.1 Testing

1. Align the TDC mark on the crankshaft pul-

ley with the pointer. Remove the cap of the
inspection hole on the timing gear cover in
front of the fuel injection pump. Aligning point

Check if the pointer on the nut-fixing plate

on the gear of fuel injection pump is aligned
with the outstanding mark on the gear
chamber of fuel injection pump.
In case of misalignment, turn the crankshaft
pulley one more turn and repeat the above

.
steps in order to obtain proper alignment.

De al
pt
Check if the marking lines are aligned with
each other. g n ZX335-1004007

(The marking lines have been aligned prop- Fig. 6-10

erly when assembling the body of fuel injec-
o
tion pump and fixing the flange at factory)
in ti

Now, test the angle of crankshaft at the be-

ginning of fuel injection. 营
销
公
司
et a

2. Turn the crankshaft pulley counterclock-

n

wise approximate 30 degrees.

rk er

1
Ma t
In

ZX335-1004012

Fig. 6-11

6-14 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

3. Remove the injection tube from No.1

plunger. This allows you to observe the
fuel when it begins to flow out from No.1
plunger.

ZX335-1004013

Fig. 6-12

.
De al
pt
4. Remove from No.1 plunger the valve body
① , seat ② , spring ③ and spool ④ .
g n
1
5. Reassemble the valve body ① and tighten
o
it to the specific torque. Do no reassemble
in ti

the spring, seat and spool now. Leave

2
them for later reassembly. 销
公
司
营

3
et a
n

4
rk er

ZX335-1004014

Fig. 6-13
Ma t
In

6. Secure the fuel control lever in the fully

open position.

ZX335-1004015

Fig. 6-14

Shop Manual - April 2014 6-15

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

7. Slowly turn the crankshaft pulley clockwise

while operating the hand pump to feed the
fuel constantly.
Stop operating the pump immediately when
no fuel is seen coming out of No.1 fuel de-
livery valve.
The crankshaft angle is now the engine’s
fuel injection beginning angle.

ZX335-1004016

Fig. 6-15

.
De al
pt
8. Observe and make sure that the mark
g n
(of fuel injection beginning angle) on
crankshaft pulley is in line with the timing TD
C
o
pointer.
in ti

The timing mark is the engine’s fuel injec-

tion beginning angle. Discharge the remain- 销
公
司

ing fuel from the body of delivery valve. Damping pulley

营
et a

Make sure that no fuel is delivered from the

delivery pump.
n
rk er

Note: Engines of the same type may have a

fuel injection pump that is different in injec- ZX335-1004017
tion timing. To obtain an engine of required
Fig. 6-16
Ma t

specification, please contact machine supplier

or local ISUZU engine service station. These
In

specifications are provided by ISUZU or en-

gine manufacturer.

6-16 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

9. Remove the body of fuel delivery valve

from No.1 plunger.
10. Install the internal parts (valve seat, spring Body
and spool) on the body.
11. Reassemble the fuel delivery valve AS on
Seat
No.1 plunger and tighten it to the specific
torque.
Spring
12. Install the injection tube to No.1 cylinder
and tighten it to the specific torque.
Spool

ZX335-1004018
NOTICE Fig. 6-17

.
De al
pt
● Do not tighten the fuel injection pump
body more than specified. The pump
body is aluminum and it can be de-
g n
formed by over-tightening, resulting in
o
unfavorable impact on the operation of
control rack.
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 6-17

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

6.5.2 Adjusting

1. Align the timing pointer with the specific

mark on the crankshaft pulley.
2. Perform step 3 through step 6 described
in the testing procedure.
3. Loosen the four (4) nuts on the fuel injec-
tion pump.
Loosen the nuts.
4. Injection timing turns the fuel injection (Also loosen the nuts on the back.)

pump in advance along the drive shaft of

fuel injection pump in order to make it face

.
outward (getting away from the cylinder

De al
ZX335-1004019
block).

pt
Fig. 6-18
Injection timing turns the fuel injection pump
g n
in retard along the drive shaft of fuel injec-
tion pump in order to make it face inward
o
(approaching the cylinder block).
in ti

Ref: 1 mm difference between the two

marking lines approximates 2º of crankshaft 销
公
司

angle.
营
et a

5. Keep operating the hand pump to transfer

n

the fuel while slowly turning the fuel injec-

tion pump. Stop turning the injection pump
rk er

when no oil is seen coming out of the

fuel delivery valve body of No.1 cylinder.
Adjustment of fuel injection pump position
Ma t

is now finished.
In

6. Tighten the four (4) nuts of fuel injection

pump.
7. Remove again the fuel delivery valve body Pressure gauge connector
and assemble the spool, spring and seat. ZX335-1004010

Tighten the valve assembly to the specific Fig. 6-19

torque.
8. Install the injection tube of No.1 cylinder
and tighten it to the specific torque.

6-18 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

6.6 A/C Compressor Belt Tension - Test and Adjust

6.6.1 Testing Compressor belt pulley

Press the intermediate point of the belt be-

tween the drive pulley and the compressor belt A
pulley with a finger force of about 58.8 N(6
kgf), and check the deflection (A) of the belt,
which shall be 5~8 mm (0.20 in~0.31 in).

Drive belt pulley

.
ZX335-1004021

De al
Fig. 6-20

pt
6.6.2 Adjusting
g no
● If the belt deflection is abnormal, adjust it
according to the following procedure. 4
in ti

1. Loosen the bolts (1) and (2). 1

司
公
销
营

2. Move the compressor (3) and the bracket

et a

(4) together to adjust belt tension.

n

3. After positioning the compressor (3),

tighten the bolts (1) and (2).
rk er

4. Recheck belt tension after adjustment. 3

Ma t

ZXT335-1004022

Note: Fig. 6-21

In

● Check each belt for damage. Check the

V-groove and the V-belt for wear. In addi-
tion, it is especially important to keep the
V-belt free from friction with bottom of the
V-groove.
● Contact local Sany dealer and replace the
belt in case of the following conditions.
● The fan belt has been stretched and
little margin is left for adjustment.
● Cuts or cracks are found in the belt.
● Abnormal sliding or noise.
● When a new belt is mounted, readjust the
belt tension after one hour operation.

Shop Manual - April 2014 6-19

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

6.7 Swing Bearing Clearance - Test

● Tool used for testing swing bearing clear-

ance

Symbol Part Number Part Name

H 60033930 Dial gauge

● The following steps are to be followed H

when testing the clearance of swing bear-
ing.
ZX335-1004023

WARNING Fig. 6-22

.
De al
pt
● Park your machine on a level ground.
Lower your work equipment to the
g n
ground.
o
● Do not put your hands or feet under the
undercarriage during testing.
in ti

1. Fix the dial gauge (H) to the track frame 营

销
公
司

and make the pointer point the lower end

et a

of the outer race.

n

2. Place the work equipment to the maximum

reach position. Raise the bucket to a
rk er

height that the bucket tips and the swing

frame bottom are on the same level.
Ma t

At the moment, the front of upper structure

lowers while the rear rises.
In

3. Reset the dial gauge (H) to zero. ZX335-1004024

4. Set the arm almost perpendicular to the Fig. 6-23

ground and lower the boom until the front
track shoe tilts.
At the moment, the front of upper structure
rises while the rear lowers.
5. Read the dial gauge (H).
150～200mm

The value indicated by the dial gauge (H)

is the clearance of the bearing.
6. Restore the machine to the condition of
step 2. Check the dial gauge (H) to see if it
reads zero.
ZX335-1004025
Repeat step 3 through step 5 if the dial
Fig. 6-24
gauge (H) reads a value other than zero.
6-20 Shop Manual - April 2014
SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

6.8 Track Tensioner - Test and Adjust

6.8.1 Testing
1. Move your machine forward at a distance
that is equal to the length of track on the
ground. Keep running the engine at low 3 2
idle. Park your machine slowly. a

2. Place a straight edge on top of the track

grousers between the idler (1) and the
front carrier roller (2).
A straight edge of angle steel is recom-
mended for this purpose as angle steel

.
1

De al
bends little. In addition, an L-shaped beam

pt
has good performance against bending. ZX335-1004026

3. Measure the maximum clearance (a) Fig. 6-25

g n
between the upper surface of track and the
o
bottom of straight edge.
in ti
Max clearance (a): 10~30 mm(0.4~1.2 in)

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 6-21

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

6.8.2 Adjusting
If the track tension is incorrect, adjustment is
to be made in the following way.
1. Decreasing the tension
A. Loosen the valve (1) to discharge
grease. Tighten the valve after dis-
charging.
1

WARNING
2
● Never loosen the valve over one turn.

.
If the valve is loosened too much, the

De al
ZXT335-1004027
grease under high pressure may cause

pt
the valve to shoot.
g no
B. Recheck the track tension as per the
above method after adjustment.
in ti

2. Increasing the tension

司

A. Add grease through the grease fitting

公
销
营
et a

(2) with a grease gun.

n

B. Recheck the track tension as per the

above method after adjustment.
rk er

● Add grease until the gap (b) between

the idler guide and the track frame end
Ma t

becomes zero. If the tension is till low, it

In

indicates that the pins and bushings are

seriously worn. Replace the pins and
bushings, or remove one track shoe.

ZX335-1004028

Fig. 6-26

6-22 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

6.9 Oil in Hydraulic Circuits - Test and Adjust

Tools used for testing and adjusting hydraulic
pressure in work equipment, swing and travel
circuits

ID Part Number Part Name

60038932 Hydraulic Tester
—
B210770000084 Adaptor

● The hydraulic pressure in work equipment,

.
swing and travel (hydraulic pump output

De al
pressure) circuits can be viewed on the

pt
monitor.
g no
6.9.1 Testing
1. Preparatory work before measuring
in ti

Lower the work equipment to the ground 销

公
司

and stop the engine. After the engine is

营
et a

stopped, operate the control levers for sev-

eral times in order to release the remaining
n

pressure in hydraulic circuits. Open the

rk er

butterfly nut on the breather valve. Press

the relief button to release pressure in the
hydraulic tank.
Ma t

A. Remove the plug (1) and plug (2) for

In

testing the hydraulic pressure.

Plug (1): For oil circuit of back hydraulic
pump
Plug (2): For oil circuit of front hydraulic 1
pump
B. Install the priming adaptor and connect
it to the hydraulic tester.
Use an oil pressure gauge with a ca-
pacity of 40 MPa {408 kg/cm2}.
ZXT335-1004029
C. Start the engine and keep it running Fig. 6-27
until the hydraulic pressure rises to a
point within the operational range.

Shop Manual - April 2014 6-23

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

2. Testing the unloading pressure

A. Start the engine.
B. Test the hydraulic pressure when the engine is running at high idle and all control levers
are in neutral position.
The hydraulic pressure indicated is the pressure when the unloading valve unloads.
3. Testing the relief pressure of work equipment
A. Start the engine and move the cylinder to be measured to its stroke end.
B. Test the hydraulic pressure when the engine is running at high idle and the cylinder is in
relief condition.
The hydraulic pressure indicated is the pressure when the main relief valve is in relief con-
dition.

.
De al
4. Testing the swing relief pressure

pt
A. Start the engine. Reach out the work equipment as far as possible. Lower the work equip-
g n
ment on the ground in order to restrict swinging.
o
B. Test the hydraulic pressure when the engine is running at high idle and the swing circuit is
in relief condition.
in ti

The hydraulic pressure indicated is the pressure when the swing motor relief valve is in re-
lief condition.
司
公
销
营
et a

The relief pressure of swing motor is lower than the main relief pressure.
n
rk er

5. Testing the relief pressure of travel circuit

A. Start the engine and lock the travel
mechanism.
Ma t

Place the pin ① between the sprocket

In

and the track frame in order to block

the travel mechanism.
B. Test the hydraulic pressure when the
1
engine is running at high idle and the
travel circuit is in relief condition.
The hydraulic pressure indicated is the
ZXT335-1004031
pressure when the main relief valve is
in relief condition. When the travel cir- Fig. 6-28
cuit is in relief condition, the pressure
indicated is always the pressure at high
relief.

6-24 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

6.9.2 Adjusting

The unloading valve and safety valve for the

boom are not adjustable.
1. Adjusting the main relief pressure (at the
high pressure setting side)

If the high relief pressure in work equip- 3

ment and travel circuits is abnormal, adjust
the high pressure setting side of the main
relief valve (3) according to the following
procedure.

.
A. Disconnect the pilot hose. ZXT335-1004900

De al
Fig. 6-29

pt
B. Loosen the locknut (4). Turn the adjust-
ing screw (5) to adjust the pressure.
g n
The pressure increases as the retainer
is turned right.
o
The pressure decreases as the retainer
in ti

is turned left. 4

Each turn of the retainer approximates:

司
公
销
营
et a

12.5 MPa {128 kg/cm2}

n

Locknut:
53.5±4.9 Nm{5.5±0.5 kgm}
rk er

C. Check the pressure again after adjust-

ment. Test the pressure according to ZX335-1004033
Ma t

the procedure described above.

Fig. 6-30
In

Connect the pilot hose before testing

the pressure.
Adjustment of the high pressure setting
side will affect the low pressure setting
side. The low pressure setting side is,
therefore, to be adjusted too.

Shop Manual - April 2014 6-25

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

6-26 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

2. Adjusting the swing relief pressure

If the swing relief pressure is abnormal,
adjust the swing motor relief valve (6) ac-
cording to the following procedure.

6
6

77

8
8

ZXT335-1004034

.
De al
Fig. 6-31

pt
g n
A. Loosen the locknut (7). Turn the adjust-
7
ing screw (8) to adjust the pressure.
o
Pressure increases as the retainer is
in ti

turned right. The pressure decreases

as the retainer is turned left. 营
销
公
司
et a

Each turn of the retainer approximates:

6.71 MPa { 68.4 kg/cm2}
n

Locknut:
rk er

8
78-103 Nm{8.0-10.5 kgm}
B. Check the pressure again after adjust- ZX335-1004035
Ma t

ment. Test the pressure according to Fig. 6-32

the procedure described above.
In

Shop Manual - April 2014 6-27

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

6.10 Control Oil Circuit Pressure - Test and Adjust

6.10.1 Testing
Tools used for testing and adjusting the pressure in control oil circuit.

ID Part Number Part Name

21008760 Hydraulic Tester
—
B210770000084 Adaptor

Lower the work equipment to the ground and stop the engine. After the engine is stopped, oper-
ate the control levers for several times in order to release the remaining pressure in hydraulic cir-
cuits. Open the butterfly nut on the breather valve. Press the relief button to release pressure in

.
De al
the hydraulic tank.

pt
1. Remove the hydraulic pressure testing
plug (1).
g no
2. Install the priming adaptor and connect it
to the hydraulic tester.
in ti

● Use an oil pressure gauge with a capacity

of 6 MPa {61 kg/cm2}
司
公
销
营
et a

3. Start the engine and keep it running until

n

the hydraulic pressure rises to the opera- 1

tional range.
rk er

4. Test the oil pressure with the engine run-

ning at high idle and all control levers in 2
neutral position.
Ma t

ZXT215-1004007
In

Fig. 6-33

6.10.2 Adjusting
1. If the oil pressure measured is lower than
3.5 MPa {36 kgf/cm²}, loosen the locknut (2) 3 2
and screw in the stud (3). Observe pressure
change on the gauge at the same time.
Tighten the nut (2) when desired pressure is
reached.
2. Remove all measuring tools after testing.
Make sure that the

ZX215-1004031

Fig. 6-34

6-28 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

6.11 Solenoid Valve Output Pressure - Test

Tools used for testing the output pressure of solenoid valve

ID Part Number Part Name

21008760 Hydraulic Tester
—
B210770000084 Adaptor

● Make sure that the initial pressure of control oil circuit is normal before testing the output
pressure of solenoid valve.
Lower the work equipment to the ground and stop the engine. After the engine is stopped, oper-
ate the control levers for several times in order to release the remaining pressure in hydraulic cir-

.
cuits. Open the butterfly nut on the breather valve. Press the relief button to release pressure in

De al
the hydraulic tank.

pt
1. Disconnect the hose of solenoid valve in
g n
order to test the pressure at the outlet.
o
6
in ti

No. Solenoid valve to be tested

5
1 High travel speed valve 营
销
公
司

4
2 Backup proportional valve
et a

3
3 Backup proportional valve 2
n

1
4 Bucket confluence valve
rk er

5 Backup
6 Pilot pressure valve
W365613091
Ma t

Fig. 6-35
In

2. Install a tee to location (A) on each solenoid valve and connect the hose.
3. Mount the adaptor onto the tee and connect it to the hydraulic tester.
● Use a hydraulic tester with a capacity of 6 MPa {61 kg/cm2} .
4. Start the engine and keep it running until the hydraulic oil temperature rises to the operational
range.
5. Run the engine at full speed. Operate the control levers to open or close each solenoid valve,
and measure the pressure.
● The function of each solenoid valve can be checked through the monitor's monitoring func-
tion. (This is a special function of the monitor.)
6. Remove all measuring tools after measurement. Make sure that the machine returns to its
normal condition.

Shop Manual - April 2014 6-29

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

Pilot locking solenoid valve

Functioning state Function

Lock OFF
Hydraulic lockout control
Free ON

Travel speed shift solenoid valve

Functioning State Function

When the 2nd level overheat setting is on
Fuel control dial reads lower than 1500 rpm.
When travel speed switch is in Lo position

.
De al
OFF
Travel signal OFF

pt
When travel speed If pressure of both front and back pump is
24.5 MPa {250 kg/cm2}
switch is in Hi posi-
g n Travel signal ON
tion
If pressure of both front and back pump is
o
15.3 MPa {150 kg/cm2} ON
in ti

Other states
司
公
销
营
et a
n
rk er
Ma t
In

6-30 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

6.12 Pilot Valve Output Pressure - Test

● Tools used for testing the output pressure of pilot valve

ID Part Number Part Name

21008760 Hydraulic Tester
—
B210770000084 Adaptor

● Make sure that the initial pressure of con-

trol oil circuit is normal before testing the
output pressure of pilot valve.

.
De al
1. Remove the pilot oil pressure switch or

pt
plug.
g n
No. Oil circuit No. Oil circuit
o
1 Left travel 7 Boom DOWN
in ti

2 Right travel 8 Left swing

3 Arm IN 9 Bucket DIG 营
销
公
司

4 Right swing 10 Arm OUT

et a

1 2 3 4 5 6 7 8 9 10
5 Bucket DUMP
n

6 Boom UP ZXT335-1004902
rk er

2. Install the adaptor and connect it to the hydraulic tester.

Ma t

● Use a hydraulic tester with a capacity of 6 MPa{61 kg/cm2}.

In

3. Start the engine and keep it running until the hydraulic oil temperature rises to the operational
range.
4. Measure the output pressure with the engine running at high idle and all control levers of the
tested circuit in neutral position.
● When the measured output pressure reads the following values, the pilot valve is normal.
5. Remove all the tools after testing. Make sure that the machine returns to its normal condition.

Control lever Hydraulic pressure

Neutral position 0{0}
Close to the average initial pres-
Full stroke sure of oil control circuit
(See Table of Standard Values)

Shop Manual - April 2014 6-31

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

6-32 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

6.13 Work Equipment and Swing Pilot Valves - Adjust

● If the play of work equipment or swing 2

control lever is too big, adjustment can be
made through the following steps. 3

1. Remove the work equipment and swing 1

pilot valve assembly.
2. Remove the bellows (1).
4
3. Loosen the locknut (2). Screw on the disc
(3) until it contacts with the four heads of
plunger (4).

.
● Do not move the plunger.

De al
ZX215-1004032

pt
4. When the disc (3) is fixed, tighten the
locknut (2) to the specified torque.
g n
Locknut: 98~127 Nm {10~13 kgm}
o
5. Restore the bellows (1).
in ti

6. Restore the work equipment and swing

pilot valve assembly. 营
销
公
司
et a
n
rk er
Ma t
In

Shop Manual - April 2014 6-33

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

6.14 Hydraulic Drift of Work Equipment - Test

● If hydraulic drift occurs to the work equip-

ment (cylinder), check it according to the
following procedure. It is to determine
whether the failure is caused by cylinder
seal or control valve.
1. Check the boom and bucket cylinders.
A. Park your machine in an attitude as
shown in the illustration on the right,
and stop the engine.

.
● Load the bucket fully with soil or apply

De al
rated load to the bucket.

pt
B. Operate the control levers in order to
g n
keep the boom in the UP position and
the bucket in the DIG position.
o
● If the lowering speed increases, it is
in ti
ZX215-1004033
failure of cylinder seal.
● If nothing changes, it is failure of con- 营
销
公
司

trol valve.
et a

● Operate the control levers with engine

n

start switch in the ON position.

rk er

● If the pressure in accumulator drops,

recharge the accumulator after running
the engine for about 10 seconds.
Ma t

2. Check the arm cylinder.

In

A. Park your machine in an attitude as

shown in the illustration on the right.
The distance between the arm cylinder
and the digging stroke end is 100 mm.
Stop the engine.
B. Operate the control levers in order to
place the arm in the DIG position.
● If the lowering speed increases, it is the
failure of cylinder seal.
● If nothing changes, it is the failure of
ZX215-1004034
control valve.
● Operate the control levers with engine
start switch in the ON position.

6-34 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

● If the pressure in accumulator drops, recharge the accumulator after running the engine
for about 10 seconds.
[Ref.] If the hydraulic drift is caused by failure of the cylinder seal, the reason for increase of low-
ering speed during the above operation is described below:
A. If the machine is set in the above position (where the holding pressure is applied to the head
end), the oil leaks from the head end to the rod end. The pressure in the rod end is increased
as a result.
B. As the pressure in the rod end decreases, the pressure in the head end increases to keep a
balance. This process is repeated until balance is reached at a certain level depending on the
amount of leakage.
C. When the pressure is balanced, the lowering speed decreases. If the control levers are oper-
ated according to the above procedure, the oil circuit in the rod end opens to the drain circuit

.
De al
(while the head end is closed by a check valve), and the oil flows to the drain circuit from the

pt
rod end. As a result, the lowering speed increases.
3. Check the pilot valve.
g n
Test the hydraulic drift respectively while the accumulator is pressurized and the hydraulic
o
lockout control in the LOCK/FREE position.
in ti

● Operate the control levers with engine start switch in the ON position.
● If the pressure in accumulator drops, recharge the accumulator after running the engine for
营
销
公
司

about 10 seconds.
et a

● If there is a difference in hydraulic drift between the LOCK position and the FREE position, it
n

is the failure (internal fault) of the pilot valve.

rk er
Ma t
In

Shop Manual - April 2014 6-35

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

6.15 Remaining Pressure in Hydraulic Lines - Relieve

Before disconnecting the lines between the hydraulic cylinders or between the hydraulic motor
and the control valve, perform the following steps in order to release the remaining pressure in
the hydraulic lines.
Even if there is no pressure remaining in the swing motor line and the travel motor line, they will
be influenced by the internal pressure of hydraulic tank. The breather valve must therefore be
opened to release pressure prior to operation.
1. Stop the engine, loosen the butterfly nut on the breather valve, and press the release button
to release the pressure in hydraulic tank.
2. Turn the engine start switch to the ON position and operate the control levers for several

.
De al
times.

pt
● The pilot lock valve must be energized. Operate the control levers with the engine start
switch in the ON position.
g n
● Operate the control levers 2 or 3 times to release the pressure in the accumulator.
o
3. Start the engine and keep the engine running at low idle for about 10 seconds in order to
in ti

increase the pressure in accumulator. And then stop the engine.

4. Repeat the above step 2 through step 3 several times.
营
销
公
司
et a
n
rk er
Ma t
In

6-36 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

6.16 Oil Leakage Amount - Test

1. Testing the oil leakage amount of boom

cylinder
A. Start the engine and keep the engine
running until the hydraulic oil tempera-
1
ture reaches the operational range. And
then fully extend the boom cylinder.
To release the pressure remaining in
the lines see “Remaining Pressure in
Hydraulic Lines - Relieve” on page 6-36.

.
B. Disconnect the hose (1) on the cylinder

De al
rod end and plug the hose opening.

pt
Take care not to disconnect the hose
g n
on the cylinder head end.
ZXT335-1004039
o
C. Start the engine and apply relief pres- Fig. 6-36
sure to the head end of the cylinder
in ti

while the engine is running at high idle.

D. Hold this state for 30 seconds and then 营
销
公
司

test the amount of oil leakage for one

et a

minute.
n

E. Make sure that the machine returns to

rk er

its normal condition after testing.

Ma t

2. Testing the oil leakage amount of arm

cylinder
In

A. Start the engine and keep the engine

running until the hydraulic oil tempera-
ture reaches the operational range. And
then fully extend the arm cylinder.
To release the pressure remaining in
the lines, See: Chapter 4 Testing and 2
Adjusting, “Remaining Pressure in
Hydraulic Lines - Relieve” on page 6-36.
B. Disconnect the hose (2) on the cylinder ZXT335-1004040

rod end and plug the hose opening. Fig. 6-37

Take care not to disconnect the hose
on the cylinder head end.

Shop Manual - April 2014 6-37

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

C. Start the engine and apply relief pres-

sure to the head end of the cylinder
while the engine is running at high idle.
D. Hold this state for 30 seconds. Test the
amount of oil leakage for one minute.
E. Make sure that the machine returns to
its normal condition after testing.

3. Testing the oil leakage amount of bucket

cylinder
A. Start the engine and keep the engine

.
running until the hydraulic oil tempera-

De al
ture reaches the operational range. And

pt
then fully extend the bucket cylinder. 3
g n
To release the pressure remaining in
the circuits see “Remaining Pressure
o
in Hydraulic Lines - Relieve” on page
6-36.
in ti

B. Disconnect the hose (3) on the cylinder 销

公
司
ZXT335-1004041

rod end and plug the hose opening.

营

Fig. 6-38
et a

Take care not to disconnect the hose

n

on the cylinder head end.

rk er

C. Start the engine and apply relief pres-

sure to the head end of the cylinder
while the engine is running at high idle.
Ma t

D. Hold this state for 30 seconds and then

In

test the amount of oil leakage for one

minute.
E. Make sure that the machine returns to
its normal condition after testing.

6-38 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

4. Testing the oil leakage amount of swing

motor
A. Fully extend the work equipment. Lower
the bucket on the ground and raise the
machine slightly. Stop the engine.
5
B. Disconnect the drain hoses (4) and (5).
Blind the hose ends with caps.
4
C. Start the engine and apply swing relief
pressure while the engine is running
at high idle. Measure the amount of oil
leakage under this condition. ZXT335-1004042

● Hold the state described in step Fig. 6-39

.
De al
3) for 30 seconds. Measure the

pt
amount of oil leakage for one min-
ute. g n
● After the first measurement, swing
o
the upper structure 180º and mea-
sure the leakage again in the same
in ti

way.
D. Make sure that the machine returns to 营
销
公
司

its normal condition after testing.

et a
n
rk er

5. Testing the oil leakage amount of the travel

motor
A. Remove the cover of the travel motor.
Ma t

B. Start the engine and lock the travel.

In

Insert the pin ① between the sprocket

and the track frame in order to prevent
traveling.
1

ZXT335-1004031

Fig. 6-40

Shop Manual - April 2014 6-39

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

C. Disconnect the drain hose (6) of the 6 6

travel motor. Blind the hose end with a
cap.
D. Start the engine and apply swing relief
pressure while the engine is running
at high idle. Measure the amount of oil
leakage under this condition.

WARNING

● During testing, misoperation of the con- ZXT335-1004043

trol levers can cause serious accidents. Fig. 6-41

.
Make sure that all signals are correct.

De al
pt
● Hold the condition described in step
g n
4) for 30 seconds. Test the amount
o
of oil leakage for one minute.
in ti

● Rotate the motor slightly. Swap the

positions of the oil distributor and
the cylinder and of the cylinder and
司
公
销
营
et a

piston. Repeat the testing several

times.
n

E. Make sure that the machine returns to

rk er

its normal condition after testing.

Ma t
In

6-40 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

6.17 Air in Each Component - Purge

Purging Steps
Item to Be Purged
1 2 3 4 5 6
Hydraulic Engine Oil Cylin- Swing Travel Operation
Job Description Pump Starting der Motor Motor Starting
● Changing the hydraulic oil
○ ○ ○ ○ ○ ○
● Cleaning the filter element
(Note) (Note)
● Replacing the return filter element ○ ○
● Repairing/replacing the hydraulic
pump ○ ○ ○ ○

.
● Disassembling the suction hose

De al
pt
● Repairing/replacing the control valve ○ ○ ○
● Replacing the oil cylinder
○ ○ ○
g n
● Disassembling the cylinder piping
● Replacing the swing motor
o
○ ○ ○
● Disassembling the swing motor
in ti

● Replacing the travel motor

○ ○ ○
● Disassembling the travel motor 营
销
公
司
et a

Note:
n

Purge air from the swing motor and travel motor only when the oil in the motor cases is drained.
rk er

1. Purging air from hydraulic pump

1
Ma t

A. Loosen the plug (1) and make sure that

In

oil leaks through the plug.

B. If you are sure of the leak, tighten the
plug (1).
Plug: 7.8~9.8 N·m{0.8~1.0 kgf·m}
● Engine starting precaution:
When engine is started after bleeding the air
as described above, run the engine at low
ZXT335-1004500
idle for 10 minutes.
Fig. 6-42

Shop Manual - April 2014 6-41

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

2. Bleeding air from hydraulic cylinder

A. Start the engine and keep the engine running at low idle.
B. Raise and lower the boom 4-5 times with the engine running at low idle.
● Do not apply relief pressure and stop the piston at about 100 mm to stroke end.
C. Repeat step 2) with the engine running at high idle.
D. Apply relief pressure when the piston comes to stroke end with the engine running at low idle.
E. Purge air from arm cylinder and bucket cylinder. Repeat step 2) through step 4).
● When a new cylinder is used for replacement, it is recommended to purge air from new cylinder
before it is installed to work equipment. Especially the boom cylinder, It must be purged prior to
installation because its piston is unable to reach the boom-down side stroke end after installa-
tion.

.
De al
● For an excavator whose hydraulic oil has been changed or which has been in storage for a long

pt
period of time, slowly operate the boom, arm and bucket cylinders in full stroke at low engine
speed under zero load in order to purge the air. Immediate pressurization and loaded operation
g n
after change of oil should be avoided.
o
3. Bleeding air from swing motor
in ti

A. Start the engine and run it at low idle.

B. Bleed air from swing motor by slowly turning the upper structure.
营
销
公
司
et a

4. Bleeding air from travel motor

n

C. Start the engine and run the engine at low idle.

rk er

D. Loosen the bleeder plug (1) and make sure that oil oozes through the plug.
E. If you are sure of the leak, tighten the plug (1).
Bleeder plug: 27.5 - 35.3 Nm {2.8 - 3.6 kgm}
Ma t
In

6-42 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting

tE.
PAD nal
eGp
ng o
i
tKi t

司
公
销
营
a
AkNe rn
e
BLMaInt
r

Shop Manual - April 2014 6-43

Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator

tE.
DG al
ep
gA no
i
tKi t
nP

司
公
销
营
a
kNe rn
aAr et
BLM In

6-44 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

Troubleshooting

.
7 Troubleshooting

De al
pt
7.1 Checks before Troubleshooting ............................................................................... 7-5
7.2 Failure Symptoms and Troubleshooting Codes ....................................................... 7-6
g n
7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-9
o
7.3.1 Connector location layout ............................................................................ 7-13
in ti

7.3.2 Diagram of system electrical elements ........................................................ 7-18

7.3.3 Diagram of electrical control system ........................................................... 7-20
营
销
公
司
et a

7.3.4 SWP connectors .......................................................................................... 7-22

7.3.5 A/AMP connectors ....................................................................................... 7-23
n

7.3.6 DT connectors.............................................................................................. 7-24

rk er

7.4 Troubleshooting with an Event Code ..................................................................... 7-25

7.5 Troubleshooting Electrical System (E-Mode)......................................................... 7-49
Ma t

7.6 Troubleshooting Hydraulic and Mechanical Systems (H-mode) ............................ 7-81

In

Shop Manual - April 2014 7-1

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

7-2 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

7 TROUBLESHOOTING

WARNING

● Stop the machine on a level ground, and check that lock pins, blocks, and parking
brake are effective.
● When carrying out the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
● If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, so wait for the engine to cool down before starting troubleshooting.
● Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

.
De al
● When disconnecting wiring, always disconnect the negative (–) terminal of the battery

pt
first.
● When removing the plug or cap from a location which is under pressure from oil, water,
g n
or air, always release the internal pressure fi rst. When installing measuring equipment,
o
be sure to connect it properly.
in ti

The aim of troubleshooting is to pinpoint the basic cause of the fault, to carry out repairs swiftly,
营
销
公
司

and to prevent reoccurrence of the fault.

et a

When carrying out troubleshooting, important point is to understand the structure and function.
n

However, a short cut to effective troubleshooting is to ask the operator various questions to form
rk er

some idea of possible causes of the fault that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components. If compo-
nents are disassembled immediately any fault occurs:
Ma t

● Parts that have no connection with the fault or other unnecessary parts will be disassembled.
In

● It will become impossible to find the cause of the fault.

It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also
lose the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fi xed procedure.
2. Points to ask user or operator:
A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the fault occurred?
C. Did the fault occur suddenly, or were there problems with the machine condition before
this?
D. Under what conditions did the fault occur?
E. Had any repairs been carried out before the fault? When were these repairs carried out?

Shop Manual - April 2014 7-3

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

F. Has the same kind of fault occurred before?

3. Check before troubleshooting
A. Check the oil level.
B. Check for any external leakage of oil from the piping or hydraulic equipment.
C. Check the travel of the control levers.
D. Check the stroke of the control valve spool.
E. Other maintenance items can be checked externally, so check any item that is considered
to be necessary.
4. Confirming fault
Confirm the extent of the fault yourself, and judge whether to handle it as a real fault or as a

.
De al
problem with the method of operation, etc.

pt
When operating the machine to reenact the troubleshooting symptoms, do not carry out any
investigation or measurement that may make the problem worse.
g n
5. Troubleshooting
o
Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes
in ti
of fault, then use the troubleshooting flowchart to locate the position of the fault exactly.
● The basic procedure for troubleshooting is as follows.
营
销
公
司

A. Start from the simple points.

et a

B. Start from the most likely points.

n

C. Investigate other related parts or information.

rk er

6. Measures to remove root cause of fault

Even if the fault is repaired, if the root cause of the fault is not repaired, the same fault will oc-
Ma t

cur again. To prevent this, always investigate why the problem occurred. Then, remove the
root cause.
In

7-4 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

7.1 Checks before Troubleshooting

Item Criterion Remedy

1. Check fuel level and type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil, coolant

3. Check hydraulic oil level — Add oil

4. Check hydraulic oil strainer — Clean, drain
5. Check swing drive oil level — Add oil
6. Check engine oil level (in oil pan) — Add oil
7. Check coolant level — Add water

.
8. Check dust indicator for clogging — Clean or replace

De al
9. Check hydraulic filter — Replace

pt
10. Check final drive oil level
g n — Add oil
—
mechanical Electrical equipment

1. Check for looseness, corrosion of battery terminal and

Tighten or replace
wiring
o
2. Check for looseness, corrosion of alternator terminal —
Tighten or replace
in ti

and wiring
3. Check for looseness, corrosion of start motor terminal —
营
销
公
司

Tighten or replace
and wiring
et a
equipment

1. Check for abnormal noise and smell — Repair

Hydraulic,

2. Check for oil leakage — Repair

rk er

3. Bleeding air — Bleed air

1. Check battery voltage (with engine stopped) 20-30V Replace
Ma t

2. Check electrolyte level — Add or replace

Electrics, electrical equipment

3. Check for discolored, burnt, exposed wiring — Replace

In

4. Check for missing wiring clips and hanging wiring — Repair

5. Check for wet wires (esp. wet connectors or terminals) — Disconnect con-
nector and dry
6. Check for blown or corroded fuses
7. Check alternator voltage (with engine speed at middle
or higher) — Replace
8. Check operating sound of battery relay (when start After running for Replace
switch is turned ON or OFF) several minutes:
27.5~ 29.5V
Replace
—

Shop Manual - April 2014 7-5

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

7.2 Failure Symptoms and Troubleshooting Codes

Troubleshooting
No. Symptom Code dis-
E mode H mode (Engine)
played
Action to be taken concerning Service Code, Failure code and Failure Code
1 Display Failure code in monitor panel
Accord-
Display Service Code in electrical system after ing to
2
checking failure history displayed
Display Failure Code in mechanical system after
3 code
checking failure history
Engine-related failure
Engine does not start up easily. (It always takes
4

.
some time to start up the engine)

De al
pt
5 Engine misfires. E-1
Color of exhaust gas is too dark.(Incomplete com-
6
bustion)
g n
7 Engine pickup is poor.
o
8 Engine runs rough or is unstable. E-2
in ti

9 Engine is short of output, or lacks power H-2

10 Auto Idle fails. 营
销
公
司
E-5 H-5
Excessive engine oil consumption, or color of ex-
et a

11
haust gas is blue
n

12 Premature engine oil contamination

rk er

13 Excessive fuel consumption

Engine cooling water is mixed with engine oil, spurts
14
out or decreases
Ma t

15 Engine oil amount increases. (Water or fuel gets in)

16 Abnormal noises are heard
In

17 Excessive vibrations are caused

Failure related to work equipment, swing and travel
18 Power supply of machine cannot be cut off. E-3
There are abnormal noises from around hydraulic
19 H-4
pump
20 All work equipment, travel and swing do not move H-3
Speeds of all work equipment, travel and swing are
21 H-1
slow
When Machine Swings and Travels Simultaneously,
22 H-13
Travel Speed Lowers Largely

7-6 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

Troubleshooting
No. Symptom Code dis-
E mode H mode (Engine)
played
Work equipment-related failure
23 All the equipment do not work E-7
24 Cylinder do not work singly H-9
25 Drift of cylinder is too large H-10
26 Work equipment time lag is too big H-11
Other work equipment moves, when specific
27 H-12
work equipment is relieved
28 Boom-up speed or power is low. E-8 H-6

.
29 Arm speed or power is low. E-9 H-7

De al
30 Bucket speed or power is low. E-10 H-8

pt
g n Travel-related failure
31 Travel speed or power is low. E-11 H-15
32 Dual Speed Travel Not Functioning E-14
o
33 Machine tends to swerve while in travel H-14
in ti

34 Machine is difficult to steer, or lacks power H-16

35 Travel speed cannot be shifted 营
销
公
司

H-17
et a

36 Track shoe does not move (only on one side) H-18

Swing-related failure
n

37 Machine does not swing H-19

rk er

Swing acceleration is poor, or swing speed is

38 H-20
slow
Upper structure overruns remarkably when
39 H-21
Ma t

stopping swinging
In

40 Large shock is made when stopping swinging H-22

41 Large sound is made when stopping swinging H-23
42 Hydraulic drift of swing is large H-24

Shop Manual - April 2014 7-7

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

Troubleshooting
No. Symptom Code dis-
E mode H mode (Engine)
played
Monitor panel-related failure
43 Monitor display is blank. E-12
44 Monitor displays nothing. E-13
Engine coolant temperature reading is incor-
45 E-15
rect.
46 Fuel level reading is incorrect. E-16
47 Arm-in pilot pressure reading is incorrect. E-18
48 Arm-out pilot pressure reading is incorrect. E-19
49 Boom-up pilot pressure reading is incorrect. E-20

.
Boom-down pilot pressure reading is incor-

De al
50 E-21
rect.

pt
Bucket-close pilot pressure reading is incor-
51 E-22
rect.
g n
Bucket-open pilot pressure reading is incor-
52 E-23
o
rect.
53 Swing pilot pressure reading is incorrect. E-24
in ti

54 Left travel pilot pressure reading is incorrect. E-25

Right travel pilot pressure reading is incor-
司
公
销
营

55 E-26
et a

rect.
Other failure
n

56 Preheat function fails. E-6

rk er

57 Wiper does not work. E-17

Ma t
In

7-8 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

7.3 Connector Location and Electrical Circuit Diagram

Num-
Stereo-
Connector No. Type ber of Component
gram
pins
CN-101M A 2 Platform lamp E-5
CN-102M S 1 Fuel level sensor F-6
CN-104M A 2 Boom lamp (L) E-7
CN-105M A 2 Boom lamp (R) E-7
T-117 Terminal 1 High-temp switch K-7
T-101 Terminal 1 Battery relay coil (+) M-2

.
T-102 Terminal 1 Battery relay coil (-) M-2

De al
T-103 Terminal 1 Battery relay contact (output) M-2

pt
T-104 g n Terminal 1 Battery relay contact (input) M-2
T-105 Terminal 1 Preheater fuse line 21# M-2
T-106 Terminal 1 Preheater fuse line 16# M-2
o
T-118 Terminal 1 Battery ground M-2
in ti

T-500 Terminal 1 Battery ground M-2

T-107 Terminal 1 营
销
公
司

Compressor clutch K-7

et a

T-109 Terminal 1 Engine oil pressure switch J-7

T-110 Terminal 1 Preheater resistance wire terminal J-7
n

T-111 Terminal 1 Start motor terminal B K-7

rk er

T-112 Terminal 1 Alternator terminal B K-6

T-135 Terminal 1 Start motor terminal S K-7
Ma t

T-202 Terminal 1 Chassis ground W-6

K5 R 5 Horn relay X-6
In

K2 R 5 Head lamp relay X-6

K6 R 5 Work lamp relay X-6
K4 R 5 Pilot valve relay X-6
KB — 5 Battery relay M-2
K7 R 5 Start relay X-6
KH — 5 Preheater relay Y-6
K3 R 5 Lockout relay X-6
K9 R 5 Shutdown delay relay X-6
CN-201F A 2 Joint connector W-6
CN-302F A 3 Intermediate connector R-6
F-501 Terminal 1 Intermediate connector R-6
F-502 Terminal 1 Intermediate connector R-6

Shop Manual - April 2014 7-9

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

Num-
Stereo-
Connector No. Type ber of Component
gram
pins
F-503 Terminal 1 Intermediate connector R-6
F-504 Terminal 1 Intermediate connector R-6
F-505 Terminal 1 Intermediate connector R-6
F-506 Terminal 1 Intermediate connector R-6
F-507 Terminal 1 Intermediate connector R-6
F-508 Terminal 1 Intermediate connector R-6
F-509 Terminal 1 Intermediate connector R-6
CN-502F D 12 Intermediate connector R-5

.
CN-1-110 D 6 Intermediate connector AD-6

De al
CN-1-112F 3 3 Intermediate connector W-6

pt
CN-1-111M g n S 8 Intermediate connector W-6
CN-142M A 35 Monitor P-5
CN-182P S 6 Intermediate connector I-7
o
CN-155M S 6 Intermediate connector J-7
in ti

CN-503F A 2 Intermediate connector W-6

CN-504F A 2 营
销
公
司

Intermediate connector X-6

et a

CN-505F A 2 Intermediate connector X-6

CN-507F A 2 Intermediate connector X-6
n

CN-106M A 2 Hyd oil temp sensor I-7

rk er

CN-502F D 8 Intermediate connector W-6

CN-181M L 6 Preheater controller X-6
Ma t

CN-506F S 16 Intermediate connector W-6

CN-180M S 6 Parking relay Y-6
In

CN-140M DF 3 Front principal pressure sensor I-7

CN-141M DF 3 Rear principal pressure sensor I-7
CN-129M DF 3 Arm-in pilot sensor I-6
CN-122M DF 3 Arm-out pilot sensor I-6
CN-126M DF 3 Boom-up pilot sensor I-6
CN-125M DF 3 Boom-down pilot sensor I-6
CN-124M DF 3 Bucket-dig pilot sensor I-6
CN-128M DF 3 Bucket-dump pilot sensor I-6
CN-123M DF 3 Swing pilot sensor I-6
CN-120M DF 3 Left travel pilot sensor I-6
CN-121M DF 3 Right travel pilot sensor I-6
CN-307M H 8 Head lamp switch R-5

7-10 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

Num-
Stereo-
Connector No. Type ber of Component
gram
pins
CN-303M H 8 Work lamp switch R-6
CN-305M H 8 Washer switch R-6
CN-304M H 8 Wiper switch R-6
CN-104M A 2 Horn switch R-6
CN-003F S 12 Air conditioner W-4
CN-150F AMP 2 Front pump solenoid valve I-7
CN-151F AMP 2 Rear pump solenoid valve I-7
CN-135F AMP 2 Boom priority 2 solenoid valve J-6

.
CN-134F AMP 2 Bucket confluence solenoid valve J-6

De al
CN-132F AMP 2 Boom priority 1 solenoid valve J-6

pt
CN-136F g n AMP 2 Pilot solenoid valve J-6
CN-131F AMP 2 High/low travel speed valve J-6
CN-133F AMP 2 Swing priority valve J-6
o
CN-211M AMP 2 Washer motor K-5
in ti

F-300 Terminal 1 Coolant temp sensor K-7

F-101 W 1 营
销
公
司

Right horn I-6

et a

F-100 W 1 Left horn I-6

CN-140M AMP 35 Controller W-6
n

CN-141M AMP 35 Controller W-6

rk er

CN-800F S 2 Alternator terminal L/R K-7

F-103 S 3 Safety relay X-6
Ma t

CN-7-707 AMP 2 Cigar lighter P-4

CN-150M D 8 Intermediate connector AE-3
In

CN-215F HL 7 Radio W-6

PF021 _ _ Fuse box X-4
CN-1-001 AMP 2 Left speaker AD-7
CN-1-002 AMP 2 Right speaker AE-6
CN-1-003 AMP 2 Right head lamp AB-5
CN-1-004 AMP 2 Left head lamp AB-5
CN-1-005 AMP 2 Cab lamp AE-7

Shop Manual - April 2014 7-11

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

Connector No. Description

S SWP type, Yazaki
A/AMP AMP, Japan
D DT type, made in Japan
H Hebi
HL Hulane
L Ling Xing
DF Delphi, U.S.
W AMP, Japan
Terminal Round

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

7-12 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

7.3.1 Connector location layout

CN-105M CN-104M CN-102M

.
De al
pt
6 g no
in ti

5
司

CN-101M
公
销
营
et a

Z
n
rk er

4
Ma t
In

ZX305-1005001

A B C D E F

Fig. 7-1

Shop Manual - April 2014 7-13

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

CN-111F CN-113M CN-155M

CN-113F T-111

CN-115M T-135
CN-116M
CN-182P T-110
CN-120M
T-109
CN-121M
CN-122M T-112

CN-123M CN-800F
CN-124M

.
T-107

De al
CN-125M

pt
T-117
CN-126M

CN-128M
g no
F-300

CN-129M
in ti

司
公
销
营
et a
n

CN-211M
rk er

CN-131F
Ma t

CN-132F

CN-133F
In

CN-134F
T-105 T-106
CN-135F T-101

T-102
CN-136F
KB
F-100
T-104
F-101
T-103

T-118
Z T-500

ZX305-1105041

Fig. 7-2

7-14 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

CN-304M CN-305M CN-307M CN-502F

9 CN-303M
CN-302M
CN-104M

F-506

F-507
8
F-508

F-509

F-501

.
F-502

De al
pt
F-503

F-504
g n
6
o
F-505
in ti

司
公
销
营

5 CN-142M
et a
n
rk er

4
Ma t
In

CN-7-707
3

1
ZX305-1105042

N O P Q R S T
Fig. 7-3

Shop Manual - April 2014 7-15

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

CN-1-111M CN-506F
T-202
CN-502F F-103
K5
CN-1-112F
K6

K2
CN-503F
K4

CN-504M
K3

K7
CN-505F
K9

CN-181M

.
CN-507M

De al
CN-615M

pt
CN-180M
g n
KH
o
in ti

司
公
销
营
et a
n
rk er
Ma t
In

CN-616M

PF021

CN-215F

CN-003F

CN-201F

ZX305-1105043

T U V W X Y Z

Fig. 7-4

7-16 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

CN-304M CN-305M CN-307M CN-502F

9 CN-303M
CN-302M
CN-104M

F-506

F-507
8
F-508

F-509

F-501

7 F-502

.
De al
F-503

pt
F-504
g n
6
F-505
o
in ti

5 CN-142M 营
销
公
司
et a
n
rk er

4
Ma t
In

CN-7-707
3

1
ZX305-1105042

N O P Q R S T
Fig. 7-5

Shop Manual - April 2014 7-17

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

7.3.2 Diagram of system electrical elements

CN-7-707F F1 20A PF021

(A-2) 22 20
Cigar F2 10A
CN-7-113M 14 13 CN-506F
(D-12) lighter F3 5A (S-16)
29 1 23 20
1 29 1 2 64 1 1 64
22 2 2 22 24 F4 15A 63 2 2 63
CN-7-705M
21

9
3 3 65 3 3 65
25 F5 5A 21
00A 4 4 00A
5 5 20b F6 10A 21
1 6 6 26 F7 5A
CAN+ 2 CAN+ 7 7
38 F8 20A
20 28
37
7 7 28
37
CAN- 3 8 8 00# 21 8 8
00# 9
CAN-
- 9 66 9 9 66
4 60a 10
61a 11
10 60a 27 F9
10A
21 14 10 10 14
5 11 61a 28 F10
5A
20
60
22
11 11
22
12 12 12 12
6 29 F1120A 21
90
13 13
24V 7 70 F125A 14 14 90
29 21
24V 8 22 90 F13
20A
21
GND 9 00# F145A
10 10A
20
GND 11 00#
100 F15 20 66
12 20b
38

8
CN-204F
(D-12)
24 1 24
1
25 2 25
2
37 3 3 37
14 4 14
4
60
36
5 5 60
36
Charging indicator
6

.
6
35H 35H 60
7 7 14
F-507
33 8 8 33 F-506

De al
50A
35L 9 9 35L 506
1 1
2 2
00A 3
3

7
CN-501F
(A-3) Fuel control dial
35L
35H

pt
37
36
33
72
CN-203M 69
(D-12) 61
69 1 69
62
1 25
2 2 62
61 3 61 14
22
3
4 4 22
13 5 13
5
g no 50A
6
7
8
00A 9
70 10
72 11
6
7
8
9
10
11
50A

00A
70
72
57
00A
00#

6
21

26
0#
24
CN-7-112F 23
(D-3)
in ti
CN-502M 70
To controller circuit CAN+
(D-12)
CN-112M
1
CAN- 1 1
2
2 2
S 57 3 3 57
3
60a 00A 4 4 00A
1 1 00# 5 5 00#
61a 6 6
2 2
7 7
Sunlight sensor CN-7-706M 8 8
(S-2) 营
销
公
司

60a
14 F-509
Preheat indicator 61a

5 69 F-508
et a

14 6 6 14
60 5 5 60

CN-506M
Compressor clutch 57 T-107 (D-8)
n

Servce lamp

Start relay Lockout relay

Pilot switch
rk er

Refuel
27 105

4
1 2 3 4 5 1 2 3 4 5
CN-205M
(A-2) 1 2 3 4 5 1 2 3 4 5
105
0 11a 11b 0 11a

610
Ma t
In

F-103 11b

60

Safety 0

relay F-104
Low-temp
21

3 switch
F-105
F-105
12
2 2
CN-505F

T-101 66

TERMINAL B BR ACC R1 R2 C

Start HEAT
OFF

switch ON

START
22 62 13 61 11

1 1
2 2

2 T-101 T-102 T-104 T-120

CN-504M

15 0 20 21

Start protection relay 1 2 3 4 5

1 2 3 4 5
KB
T-135 T-102 T-116
12 21 14 60 21 22 646563 62 0 64 6365
1 2 3 45 B A P1P2 1 2 3 45

1 2 3 45 Battery relay 1 2 3 45
36
25
11 0 11C 0 35L
T-500 T-501 24 33 25 37 35H 72 70

1 - + - + E E E
Parking relay
CN-503F
(H-8)
CN-507F
(H-8)
CN-505F
(H-8)
CN-508F
(H-8)
Work lamp Washer Wiper Head lamp
Start Chassis Parking
Chassis motor Alternator switch switch switch switch
Chassis motor
ground
ground ground ZX305-1105035

A B C D E F

Fig. 7-6

7-18 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

● This circuit diagram has been compiled by extracting the wiper system and the switch control
systems from the general electrical circuit diagram.
Preheat
controller Horn relay Work lamp relay Head lamp relay Preheater relay CN-124F
(S-6)

50A 1 1
K5 K6 K2 KH 507 2 2 1 Throttle
2

9
1 2 3 4 5 1 2 3 4 5 MT- 3 3 motor
1 2 3 4 5 1 2 3 4 5 3
5 AC-2000
CN-181M
(D-6)
6
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 00A 5 5
1 2 3 4 5 6 33
1 2 3 4 5
31 0 23 32 0 24 34 72 0 70 71 68 14 16 17
14 66 61 0 69 MT+ 6
6
Horn switch

23 31

T-107
8

.
De al
Preheater
T-105 T-106
7

pt
21 16

CN-1-110M
(D-6)
Wiper
35L
35H
37
36
14
g n 0

25
1
2
1
2
3
3
33
72
36
M
o
69 35H
61 4 4
35L
25

MT+
5 5
6
in ti
MT-
507
50A
00A
CN-112M
57
(A-2)
66
0 0
Washer motor
21 1 1
26
0# 营
销
公
司
37 2 2 37 M
24 CN-506F 6
23 (S-16)
et a

70
6
61a

60a Head lamp (R)

5
20b 0 0
1 1
38 71 77
n

2 2

Head lamp (L)

rk er

0 0
1 1
71 77
2 2

CN-150M
R+ (S-8) F-104
1 1 (W-1)
R-
2 2 Horn
4
Ma t

1 1
L+ 3 3
L- 4 4 CN-506M
0# (D-16)
5 5 32
6 6
32
F-103
In

71
6 6 34 16 16
34 (W-1)
0
7 7 1 1
26
8 8

CN-101M

3
Revolving frame
(A-2) work lamp
0
1 1
34
2 2

20b
1 CN-104M Left boom
R+ (A-2) work lamp
L+
2 1 1 0

3 2 2 34
0#
4
20b
5 CN-105M Right boom
R- (A-2)
6 1 1 0
work lamp
L-

CN-107M
7 2 2 34
2
To radio control panel
Radio speaker (R)

57 1
61a
0 57 4 Radio speaker (L)

60a
1 2
5
CN-109M 0#
6 Cab lamp
0
1 0
38
7 1
26 26
2 2
8
1
38

CN-207F
To A/C control panel

Fig. 7-7 ZX225-1105036

G H I J K L

Shop Manual - April 2014 7-19

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

7.3.3 Diagram of electrical control system

CN-502F
CN-152M (D-16)
(AMP-2)
240Ω 50
511 4 4
1
0 00
2 13 13

CN-616M
(AMP-81)
1 00#
2 42
5
509
11
13
15
108B
19
510
30
8 31
34
511

108A
38
508
48
200
L. travel pilot pressure 49 50
204
Bkt-dump pilot pressure 50
207 00
Boom-down pilot pressure 51
202
Arm-out pilot pressure 52 200
502
Rear pump main pressure53
00 201
54 00 202
55 50 203
56 CAN-
58 204
CAN+
60 208
11C

.
65 201 207
7
R. travel pilot pressure 67

De al
208
Swing pilot pressure
68 206
205
Bkt-dig pilot pressure 69 206 205
Boom-up pilot pressure 70
203 602

pt
Arm-in pilot pressure
71 501
Front pump main pressure72 603
00
73 50 604
74 50
75 607
CAN+
77 CAN- 608
78 702
g n80 703
501
502
6
o
508
509
510
511
in ti
CN-615M 108A
(AMP-40)
607
82
83
610 108B
611
84 702
27
88 公
司

0
703 营
销

89
608 42
98
604
5
et a

99
602
100
603
101
105
113
00#
114
n

00#
115
42
119
42
120
121
rk er

4
Ma t
In

3
TERMINAL
B BRACCR1 R2 C
HEAT
OFF
ON 27
START 42
22 13

2 T-101 T-102 T-104 T-103

13 0 20 21

1 2 3 45
1 2 3 45
KB

Battery relay

A B C A B

T-500 T-107
- +- +
1 CN-112M
(D-3) CN-115M
(D-3)
Battery To monitor circuit
GND 120 Ω

ZX335-1105037

A B C D E F G
Fig. 7-8

7-20 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

● This circuit diagram has been compiled by extracting the pressure collecting system and the
solenoid valve control systems from the general electrical circuit diagram.

CN-120M

9
(DF-3)
50
00
A
B
A
B
L. travel pilot
200 C C pressure sensor
CN-121M
(DF-3)
50 A
00 B
A
B
R. travel pilot
201 C C pressure sensor
CN-122M
(DF-3)
50 A A
00 B B
Arm-out pilot
202 C C pressure sensor
CN-129M
(DF-3)
50
00
A A Arm-in pilot
B B
203 C C pressure sensor
CN-128M
(DF-3)
50 A A
00 Bucket-dump pilot
8
B B
204 C C pressure sensor
CN-123M
50 50
(DF-3)

00
A
B
A
B
Swing pilot
00 208 C C pressure sensor
CN-125M
200 50
(DF-3)
A A

201 00 B B
Boom-down pilot
207 C C pressure sensor
202

.
CN-126M
203 50
(DF-3)
A

De al
A
00 Boom-up pilot
204 206
B B
C C pressure sensor
208 CN-124M
(DF-3)
50

pt
A
207 00 B
A
B
Bucket-dig pilot
205
pressure sensor
7
C C
206 CN-115M
(DF-3)
50
205 00
A
B
A
B
Front pump
501
501 C C pressure sensor
CN-116M
502 50
(DF-3)

602
603
604
g n 00
502

602
A
B
C
A

CN-132F
(AMP-2)

1
B
C

1
Rear pump
pressure sensor

0
Boom priority-1
o
607 2 2

608 CN-135F -prptnl valve

(AMP-2)
603
702
6
1 1
0 2 2 Boom priority-2
703
-prptnl valve
in ti
CN-134F
(AMP-2)
508 604 1 1
0
509 2 2
Bkt confluence
510 CN-131F -prptnl valve
(AMP-2)
607
511 0
1 1
2 2 High speed
108A
travel valve
司
公
销
营
CN-133F
(AMP-2)
608 1 1
0
et a

2 2 Swing priority
108B CN-111F prptnl valve
(AMP-2)
27
0
702
0
1

2
1
2 Front pump 5
prptnl valve
n

CN-113F
(AMP-2)
42 703 1 1
0 2 2
Rear pump
508 T-109 prptnl valve
rk er

Engine oil
prsur switch
509 CN-101M

Fuel level

510
T-116
Coolant temp 4
sensor
Ma t

CN-113M
(AMP-2)
511 1 Hyd oil temp
42
2
sensor
CN-125F
In

(S-2)

1 1
108A Engine speed
2 2 108B sensor

Pilot valve relay

Pilot switch

1 2 3 4 5
CN-205F
(A-2)
1 2 3 4 5
CN-136F

2
(AMP-2)

1 1

2
2 Pilot valve

1
ZX225-1105038

H I J K L M

Fig. 7-9

Shop Manual - April 2014 7-21

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

7.3.4 SWP connectors

Male (plug) Female (socket)

7222-7414-40 7123-7414-40 (1 pin)

.
De al
pt
g no
7222-1424-40 7123-1424-40 (2 pins)
in ti

司
公
销
营
et a
n
rk er

7222-7464-40 7123-7464-40 (6 pins)

Ma t
In

7222-7484-40 7123-7484-40 (8 pins)

7222-7564-40 7123-7564-40 (16 pins)

W365-130707

Fig. 7-10
7-22 Shop Manual - April 2014
SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

7.3.5 A/AMP connectors

Male (plug) Female (socket)

Part No. ：282104-1 Part No. ：282080-1 (2 pins)

.
De al
pt
g n
282105-1 282087-1 (3 pins)
o
in ti

司
公
销
营
et a
n

174354-2 174352-2 (2 pins)

rk er
Ma t
In

1473252-1 1473255-1 (40 pins)

1473244-1 1473247-1 (81 pins)

W365-130709

Fig. 7-11

Shop Manual - April 2014 7-23

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

7.3.6 DT connectors

Housing (plug) Housing (socket)

A B B A

DT06-2S DT04-2P

A
A B
B

.
De al
pt
g n C C
DT06-3S DT04-3P (3 pins)
o
in ti

1 6 6 1

5
司

2
公

5
销
营

2
et a

3 4 4 3
n

DT06-6S DT04-6P (6 pins)

rk er

5 8
8 5
Ma t
In

1 4 4 1
DT06-8S DT04-8P (8 pins)
12 7 7 12

1 6 6 1
DT06-12S DT04-12P (12 pins)
W365-130710

Fig. 7-12

7-24 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

7.4 Troubleshooting with an Event Code

Information contained in troubleshooting table ............................................................. 7-26

E015 Power voltage abnormal ..................................................................................... 7-27
E212 Irregular throttle motor current or defective motor connection ............................ 7-28
E240 Hydraulic oil temperature abnormal .................................................................... 7-29
E320 Front pump output pressure abnormal ................................................................ 7-30
E321 Rear pump output pressure abnormal ................................................................ 7-31
E322 Bucket-dig pilot pressure abnormal..................................................................... 7-32
E323 Bucket-dump pilot pressure abnormal ................................................................ 7-33

.
E324 Arm-in pilot pressure abnormal ........................................................................... 7-34

De al
E325 Arm-out pilot pressure abnormal ......................................................................... 7-35

pt
E326 Boom-up pilot pressure abnormal ....................................................................... 7-36
g n
E327 Boom-down pilot pressure abnormal .................................................................. 7-37
o
E328 Left travel pilot pressure abnormal ...................................................................... 7-38
E329 Right travel pilot pressure abnormal ................................................................... 7-39
in ti

E330 Swing pilot pressure abnormal ............................................................................ 7-40

销
公
司
营

E332 Motor built-in potentiometer irregular .................................................................. 7-41

et a

E434 Front pump proportional solenoid current abnormal (A) ..................................... 7-42
n

E435 Rear pump proportional solenoid current abnormal (A) ...................................... 7-43
rk er

E436 Front pump proportional solenoid current abnormal (B) ..................................... 7-44
E437 Rear pump proportional solenoid current abnormal (B) ...................................... 7-45
E543 Engine speed abnormal ...................................................................................... 7-46
Ma t

E244 Fuel control dial setting voltage abnormal .......................................................... 7-47

In

E145 CAN bus abnormal .............................................................................................. 7-48

Shop Manual - April 2014 7-25

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

Information contained in troubleshooting table

Failure code Service Code Failure symp-

Title of failure shown in failure history
Code displayed —— tom
Failure information Failure is described on the monitor display.
When failure is detected, the controller has taken action to protect the affected
Controller reaction
system or equipment.
Machine reaction Symptom that is shown on the machine due to action of controller.

Cause Standard values and troubleshooting references

.
De al
1

pt
2 <Inclusion>
Possible causes and standard values

3
g n • Standard value under normal condition can be used to judge pos-
sible causes
o
4
• Reference for passing the above "Good" or "No Good" judgement
in ti

Possible causes
of trouble (Given 司
公

numbers are ref- <Symptom of Wiring Harness Failure>

销
营
et a

erence numbers,
which do not in- • Open circuit
n

dicate priority) Faulty contact with connector or open circuit in wiring harness
rk er

5
• Faulty grounding
An ungrounded wiring is grounded.
Ma t

• Short circuit
In

A wiring has mistaken contact with a 24 V electric circuit.

Related circuit diagram

This is part of the circuit diagram which shows the portion where the failure occurred.
● Connector No.: A connector number Indicates a connector.
● Arrow: An arrow roughly indicates the installing location.

7-26 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E015 Power voltage abnormal

Failure code Failure
Power voltage abnormal
E015 symptom
Failure description Voltage of power supply is higher than 36V during machine operation.
Controller reaction Driving of motor and solenoid valve is cut off automatically by the system.
Machine symptom Engine fails to accelerate and machine moves slowly.
Possible causes and standard values

Cause Standard values and troubleshooting references

★ Turn the start switch to the OFF position and leave it in the position for trouble-
Power fail- shooting.
1
ure
Check battery voltage. Volt Under 25 V
★ Turn the start switch to the OFF position before proceeding. Turn the start

.
De al
Alternator switch to the START position for trouble shooting.
2
abnormal

pt
Measure between alternator terminal B and ground. Volt Around 28 V

3
g no
4
in ti

司
公
销
营
et a

Start switch
n

TERMINAL B BR ACC R1 R2 C
rk er

HEAT
OFF
ON
START
Ma t

13
In

Charging indicator
G

14 R L 60
B E
- + - +
Battery relay 0 Alternator 0
Safety relay
M
C B
S Start motor
S R
E
E
13 11b 0
0 Delay relay 0

ZX225-1105002

Fig. 7-13

Shop Manual - April 2014 7-27

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E212 Irregular throttle motor current or defective motor connection

g
Failure code Throttle motor loading circuit is abnormal and the engine
Failure symptom
E212 acceleration fails.
Failure description Motor feedback voltage is lower than 0.25V or higher than 4.75V
Controller reaction The controller stops the motor driving system when this failure is detected.
Symptom on machine Engine acceleration fails and the machine acts slowly. .

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of throttle Keep it in the OFF position while troubleshooting is performed.
1
motor coil

.
Between Ĺ and ļ of CN-124M Resistance 12.2ȍ
Possible causes and standard values

De al
Ɣ Turn engine start switch to the OFF position before troubleshooting.

pt
2 Open circuit of har- Keep it in the OFF position while troubleshooting is performed.
ness Unplug the controller and measure the resistance
g no
between the pins 32 and 33.
Resistance 12.2ȍ

Ɣ Turn engine start switch to the OFF position before troubleshooting.

Keep it in the OFF position while troubleshooting is performed.
in ti

Short circuit of har-

3 Unplug the connector CN-124M and measure the
ness (grounded)
resistance between motor Ĺ ( ļ ) and the hous- Resistance Above 2Mȍ
营
销
公
司

ing.
et a

No troubleshooting can be done for failure occurs in the inner of controller.

Internal failure of
n

4 (Except for the above reasons, the controller must be replaced in case of
controller
failure.)
rk er

5
Ma t
In

Controller
CN-124M Throttle motor
50A# Green
Sensor 25 1 1
507# White
Throttle feedback volt 7 2 2
MT- Red
MT- 33 3 3 M
GND 4 4
16
00A Yellow
5 5
MT+ 32
MT+ Blue
6 6

Operator station Chassis harness

ZX225-1105001

Fig. 7-14

7-28 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E240 Hydraulic oil temperature abnormal

0 yd au c o te pe atu e ab o a
Failure code Hydraulic oil temperature is abnormal. Only
Failure symptom
E240 alarm output is effective.
Controller detects a temperature resistance of hydraulic oil that is lower than
Failure description
10 ohms or higher than 120 ohms and it lasts more than 3s.
Only alarm output is effective. The alarm resets automatically when conditions
Controller reaction
become normal.
Symptom on machine ——

Cause Standard values and troubleshooting references

Ɣ Turn the start switch to the OFF position and then keep it in the ON

.
Failure of sen-

De al
position to perform troubleshooting.
Possible causes and standard values

1
sor

pt
Between CN-113M ķ and ground Voltage 0.2-4.75V
Ɣ Turn engine start switch to the OFF position before troubleshooting.
g n 2
Open circuit of Keep it in the OFF position while troubleshooting is performed.
harness
Under 1 :
o
Between CN-113M ķ and pin 21 of controller Resistance
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
in ti

3 of harness Keep it in the OFF position while troubleshooting is performed.

(grounded) Between CN-113M ķ and ground
营
销
公
司
Resistance Above 1M :
Ɣ Turn engine start switch to OFF position. Keep it at ON position to per-
et a

Failure of 24V form troubleshooting.

4
power supply
n

Between CN-113M ĸ and ground Voltage About 24V

rk er

5
Ma t

CN-115F
0#
In

1 1
240 ohms
Controller
2 2

CN-113M Hyd oil temp sensor

511 Signal
Hyd oil temp sensor 21 1 1

2 2 24V PWR
24V PWR

Operator station Chassis harness

ZX225-1105016
Fig. 7-15

Shop Manual - April 2014 7-29

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E320 Front pump output pressure abnormal

Failure code Front pump output pressure is abnormal. Only

Failure symptom
E320 alarm output is effective.
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200
Failure description
msec when the power is on.
Controller reaction Only alarm output is effective.
Symptom on machine ——

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of 5V Keep it in the ON position while troubleshooting is performed.
1

.
power supply

De al
Possible causes and standard values

Between CN-151M A and B Voltage About 5V

pt
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.
2
g n
Open circuit of
signal line Between CN-151M C and pin 29 of controller Under 1ȍ
Resistance
o
Between CN-115M B and ground Under 1ȍ
in ti

Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
3 of signal line Keep it in the OFF position while troubleshooting is performed.
(grounded)
司

Between CN-151M C and ground Resistance Above 2Mȍ

公
销
营
et a

Ɣ Turn engine start switch to the OFF position before troubleshooting.

Failure of sen- Turn the start switch to the ON position and keep it in the ON position
n

4 while troubleshooting is performed.

sor
rk er

Between CN-151M C and ground Voltage 0.5±0.2V

5
Ma t
In

Controller CN-151M Front pump

press. sensor
Front pump signal 501#
29 C Signal
collecting port
00#
GND 23 B GND

50#
5V PWR 12 A 5V

Operator station Chassis harness

ZX225-1105003

Fig. 7-16

7-30 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E321 Rear pump output pressure abnormal

p p p p
Failure code Reading of rear pump output pressure is abnor-
Failure symptom
E321 mal. Only alarm output is effective. .
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200
Failure description
msec when the power is on.
Controller reaction Only alarm output is effective.
Symptom on machine ——

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.

.
Turn the start switch to the ON position and keep it in the ON position

De al
Failure of 5V
1 while troubleshooting is performed.
power supply

pt
Possible causes and standard values

g n Between CN-116M A and B Voltage About 5V

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.
Open circuit of
o
2
signal line Between CN-116M C and pin 19 of controller Under 1ȍ
Resistance
in ti

Between CN-116M B and ground Under 1ȍ

Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
司

Keep it in the OFF position while troubleshooting is performed.

公
销
营

3 of signal line
et a

(grounded) Between CN-116M C and ground Resistance Above 2Mȍ

n

Ɣ Turn engine start switch to the OFF position before troubleshooting.

Failure of sen- Turn the start switch to the ON position and keep it in the ON position
rk er

4 while troubleshooting is performed.

sor
Between CN-116M C and ground Voltage 0.5±0.2V
Ma t

5
In

Controller Rear pump

CN-116M
press. sensor
Rear pump signal 502#
19 C Signal
collecting port
00#
20 B GND
GND
50#
5V PWR 12 A 5V

Operator station Chassis harness

ZX225-1105004
Fig. 7-17

Shop Manual - April 2014 7-31

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E322 Bucket-dig pilot pressure abnormal

Failure code Bucket-dig pilot pressure is abnormal. Only alarm

Failure symptom
E322 output is effective. .
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200
Failure description
msec when the power is on.
Controller reaction Only alarm output is effective.
Symptom on machine The bucket-dig motion is slow.

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn
the start switch to the ON position and keep it in the ON position while

.
Failure of 5V
1

De al
power supply troubleshooting is performed.
Possible causes and standard values

pt
Between CN-124M A and B Voltage About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting.
g n
Open circuit
Keep it in the OFF position while troubleshooting is performed.
2 Under 1 :
o
of signal line Between CN-124M C and pin 10 of controller
Resistance
Between CN-124M B and ground Under 1 :
in ti

Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
3 of signal line Keep it in the OFF position while troubleshooting is performed.
营
销
公
司

(grounded) Between CN-124M C and ground Resistance Above 2M :

et a

Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn
n

Failure of the start switch to the ON position and keep it in the ON position while
4 troubleshooting is performed.
rk er

sensor
Between CN-124M C and ground Voltage 0.5±0.2V

5
Ma t
In

Controller Bucket-dig pilot

CN-124M pressure sensor
Bucket-dig pilot press. 10 205#
C
signal collecting port Signal
00#
11 B GND
GND
50#
12 A 5V
5V PWR

Operator station Chassis harness

ZX225-1105005

Fig. 7-18

7-32 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E323 Bucket-dump pilot pressure abnormal

Failure code Reading of bucket-dump pilot pressure is abnor-

Failure symptom
E323 mal. Only alarm output is effective.
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200
Failure description
msec when the power is on.
Controller reaction Only alarm output is effective.
Symptom on machine Bucket-dump motion is slow.

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn

.
De al
Failure of 5V the start switch to the ON position and keep it in the ON position while
1

pt
power supply troubleshooting is performed.
Possible causes and standard values

g n Between CN-128M A and B Voltage About 5V

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.
o
Open circuit
2
of signal line Between CN-128M C and pin 33 of controller Under 1ȍ
Resistance
in ti

Between CN-128M B and ground Under 1ȍ

Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
营
销
公
司

3 of signal line Keep it in the OFF position while troubleshooting is performed. .

et a

(grounded) Between CN-128M C and ground Resistance Above 2Mȍ

n

Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn
Failure of sen- the start switch to the ON position and keep it in the ON position while
rk er

4 troubleshooting is performed.
sor
Between CN-128M C and ground Voltage 0.5±0.2V
Ma t

5
In

Controller Bucket-dump pilot

CN-128M pressure sensor
204#
Bucket-dump pilot press. 33 C
signal collecting port Signal
00#
11 B GND
GND
50#
12 A 5V
5V PWR

Operator station Chassis harness

ZX225-1105006

Fig. 7-19

Shop Manual - April 2014 7-33

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E324 Arm-in pilot pressure abnormal

Failure code Reading of Arm-in pilot pressure is abnormal. Only

Failure symptom
E324 alarm output is effective. .
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec
Failure description
when the power is on.
Controller reaction Only alarm output is effective.
Symptom on machine Arm-in motion is slow.

Cause Standard values and troubleshooting references

.
De al
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn

pt
Failure of 5V the start switch to the ON position and keep it in the ON position while
1 troubleshooting is performed.
power supply
Possible causes and standard values

g n Between CN-129M A and B Voltage About 5V

Ɣ Turn engine start switch to the OFF position before troubleshooting.
o
Keep it in the OFF position while troubleshooting is performed.
Open circuit
2
in ti

of signal line Between CN-129M C and controller pin 35 Under 1ȍ

Resistance
Between CN-129M B and ground
营
销
公
司
Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
et a

3 of signal line Keep it in the OFF position while troubleshooting is performed.

n

(grounded) Between CN-129M C and ground Resistance Above 2Mȍ

Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn
rk er

Failure of the start switch to the ON position and keep it in the ON position while
4 troubleshooting is performed.
sensor
Between CN-129M C and ground Voltage 0.5±0.2V
Ma t
In

Arm-in pilot
Controller CN-129M press. sensor
203#
Arm-in pilot pressure 35 C Signal
signal collecting port
00#
GND 11 B GND

50#
5V PWR 12 A 5V

Operator station Chassis harness

ZX225-1105007
Fig. 7-20

7-34 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E325 Arm-out pilot pressure abnormal

Failure code Reading of Arm-out pilot pressure is abnormal.

Failure symptom
E325 Only alarm output is effective. .
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200
Failure description
msec when the power is on.
Controller reaction Only alarm output is effective.
Symptom on machine Arm-out motion is slow.

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.

.
De al
Failure of 5V Turn the start switch to the ON position and keep it in the ON position
1 while troubleshooting is performed.

pt
power supply
Possible causes and standard values

g n Between CN-122M A and B Voltage About 5V

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.
Open circuit
o
2
of signal line Between CN-122M C and pin 22 of controller Under 1 :
Resistance
in ti

Between CN-122M B and ground Under 1 :

Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
营
销
公
司

3 of signal line Keep it in the OFF position while troubleshooting is performed.

et a

(grounded) Between CN-122M C and ground Resistance Above 2M :

n

Ɣ Turn engine start switch to the OFF position before troubleshooting.

Failure of Turn the start switch to the ON position and keep it in the ON position
rk er

4 while troubleshooting is performed.

sensor
Between CN-122M C and ground Voltage 0.5±0.2V
Ma t

5
In

Controller Arm-out pilot

CN-122M press. sensor
Arm-out pilot pressure 22 202#
C Signal
signal collecting port
00#
GND 11 B GND

50#
5V PWR 12 A 5V

Operator station Chassis harness

ZX225-1105008

Fig. 7-21

Shop Manual - April 2014 7-35

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E326 Boom-up pilot pressure abnormal

Failure code Reading of boom-up pilot pressure is abnormal.

Failure symptom
E326 Only alarm output is effective. .
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec
Failure description
when the power is on.
Controller reaction Only alarm output is effective.
Symptom on machine Boom-up motion is slow.

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn

.
the start switch to the ON position and keep it in the ON position while

De al
Failure of 5V
1 troubleshooting is performed.
power supply

pt
Possible causes and standard values

g n Between CN-126M A and B Voltage About 5V

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.
Open circuit
o
2
of signal line Between CN-126M C and controller pin 8. Under 1ȍ
Resistance
in ti

Between CN-126M B and ground Under 1ȍ

Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
司

Keep it in the OFF position while troubleshooting is performed.

公
销
营

3 of signal line
et a

(grounded) Between CN-126M C and ground Resistance Above 2Mȍ

n

Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn
Failure of the start switch to the ON position and keep it in the ON position while
rk er

4 troubleshooting is performed.
sensor
Between CN-126M C and ground Voltage 0.5±0.2V
Ma t

5
In

Controller Boom-up pilot

CN-126M press. sensor
206#
Boom-up pilot pressure 8 C Signal
signal collecting port
00#
11 B GND
GND
50#
12 A 5V
5V PWR

Operator station Chassis harness

ZX225-1105009
Fig. 7-22

7-36 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E327 Boom-down pilot pressure abnormal

Failure code Reading of boom-down pilot pressure is abnor-

Failure symptom
E327 mal. Only alarm output is effective. .
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200
Failure description
msec when the power is on.
Controller reaction Only alarm output is effective.
Symptom on machine Boom-down motion is slow.

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.

.
De al
Failure of 5V Turn the start switch to the ON position and keep it in the ON position
1 while troubleshooting is performed.

pt
power supply
Possible causes and standard values

g n Between CN-125M A and B Voltage About 5V

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.
Open circuit
o
2
of signal line Between CN-125M C and controller pin 9 Under 1ȍ
Resistance
in ti

Between CN-125M B and ground Under 1ȍ

Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
营
销
公
司

3 of signal line Keep it in the OFF position while troubleshooting is performed.

et a

(grounded) Between CN-125M C and ground Resistance Above 2Mȍ

n

Ɣ Turn engine start switch to the OFF position before troubleshooting.

Failure of Turn the start switch to the ON position and keep it in the ON position
rk er

4 while troubleshooting is performed.

sensor
Between CN-125M C and ground Voltage 0.5±0.2V
Ma t

5
In

Controller Boom-down pilot

CN-125M press. sensor
207#
Boom-down pilot pressure 9 C Signal
signal collecting port
00#
11 B GND
GND
50#
12 A 5V
5V PWR

Operator station Chassis harness

ZX225-1105010

Fig. 7-23

Shop Manual - April 2014 7-37

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E328 Left travel pilot pressure abnormal

Failure code Reading of left travel pilot pressure is abnormal.

Failure symptom
E328 Only alarm output is effective. .
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200
Failure description
msec when the power is on.
Controller reaction Only alarm output is effective.
Symptom on machine Left travel speed is low. Travel deviates.

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn

.
De al
Failure of 5V the start switch to the ON position and keep it in the ON position while
1 troubleshooting is performed.

pt
power supply
Possible causes and standard values

g n Between CN-120M A and B Voltage About 5V

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.
Open circuit of
o
2
signal line Between CN-120M C and pin 34 of controller Under 1ȍ
Resistance
in ti

Between CN-120M B and ground Under 1ȍ

Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
营
销
公
司

3 of signal line Keep it in the OFF position while troubleshooting is performed.

et a

(grounded) Between CN-120M C and ground Resistance Above 2Mȍ

n

Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn
Failure of sen- the start switch to the ON position and keep it in the ON position while
rk er

4 troubleshooting is performed.
sor
Between CN-120M C and ground Voltage 0.5±0.2V
Ma t

5
In

Controller Left travel pilot

CN-120M
pressure sensor
200#
Left travel pilot press. 34 C Signal
signal collecting port
00#
11 B GND
GND
50#
12 A 5V
5V PWR

Operator station Chassis harness

ZX225-1105011

Fig. 7-24

7-38 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E329 Right travel pilot pressure abnormal

Failure code Reading of right travel pilot pressure is abnormal.

Failure symptom
E329 Only alarm output is effective. .
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200
Failure description
msec when the power is on.
Controller reaction Only alarm output is effective.
Symptom on machine Right travel speed is low. Travel deviates.

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn

.
Failure of 5V the start switch to the ON position and keep it in the ON position while

De al
1 troubleshooting is performed.
power supply

pt
Possible causes and standard values

Between CN-121M A and B Voltage About 5V

Ɣ Turn engine start switch to the OFF position before troubleshooting.
g n Keep it in the OFF position while troubleshooting is performed.
Open circuit of
2
o
signal line Between CN-121M C and pin 30 of controller Under 1ȍ
Resistance
Between CN-121M B and ground Under 1ȍ
in ti

Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
3 of signal line Keep it in the OFF position while troubleshooting is performed.
营
销
公
司
et a

(grounded) Between CN-121M C and ground Resistance Above 2Mȍ

Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn
n

Failure of sen- the start switch to the ON position and keep it in the ON position while
4 troubleshooting is performed.
rk er

sor
Between CN-121M C and ground Voltage 0.5±0.2V

5
Ma t
In

Controller Right travel pilot

CN-121M
pressure sensor
Right travel pilot press. 201#
signal collecting port 30 C Signal
00#
11 B GND
GND
50#
5V PWR 12 A 5V

Operator station Chassis harness

ZX225-1105012
Fig. 7-25

Shop Manual - April 2014 7-39

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E330 Swing pilot pressure abnormal

Failure code Reading of swing pilot pressure is abnormal. Only

Failure symptom
E330 alarm output is effective. .
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200
Failure description
msec when the power is on.
Controller reaction Only alarm output is effective.
Symptom on machine Swinging motion is slow.

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn

.
the start switch to the ON position and keep it in the ON position while

De al
Failure of 5V
1 troubleshooting is performed.
power supply

pt
Possible causes and standard values

g n Between CN-123M A and B Voltage About 5V

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.
Open circuit of
o
2
signal line Between CN-123M C and pin 18 of controller Under 1ȍ
Resistance
in ti

Between CN-123M B and ground Under 1ȍ

Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.
司
公
销
营

3 of signal line
et a

(grounded) Between CN-123M C and ground Resistance Above 2Mȍ

n

Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn
Failure of sen- the start switch to the ON position and keep it in the ON position while
4
rk er

sor troubleshooting is performed.

Between CN-123M C and ground Voltage 0.5±0.2V
Ma t

5
In

Controller CN-123M Swing pilot pressure sensor

Swing pilot pressure 208#
18 C Signal
signal collecting port
00#
11 B GND
GND
50#
5V PWR 12 A 5V

Operator station Chassis harness

ZX225-1105013

Fig. 7-26

7-40 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E332 Motor built-in potentiometer irregular

Failure code The potentiometer built in the motor is irregular. It returns

Failure symptom
E332 to auto deceleration when time point is detected.
When machine power is on, throttle position feedback has a voltage other than
Failure description
0.25-4.75V lasting more 50 msec.
Controller reaction Returns to auto deceleration.
Symptom on machine The throttle fails to increase engine speed.

Causes Standard values and troubleshooting references

Possible causes and standard values

Failure of Ɣ Turn the start switch to the OFF position and then keep it in the ON position

.
De al
1 5V power to perform troubleshooting.

pt
source Between CN-155M ķ and Ļ Volt About 5V
g n Ɣ Turn the start switch to the OFF position before troubleshooting. Kee the
Open circuit switch in the OFF position to perform troubleshooting.
2
of signal
Between CN-155M ĸ and the controller port pin 7 Under 1ȍ
o
line Resistance
Between CN-155M Ļ and ground Under 1ȍ
in ti

Short cuit of Ɣ Turn the start switch to the OFF position before troubleshooting. Kee the
3 switch in the OFF position to perform troubleshooting.
signal line 营
销
公
司

(grounded) Between CN-155M ĸ and ground Resistance Above 2Mȍ

et a
n
rk er
Ma t

Controller CN-142M Throttle position

CN-113 CN-502 CN-155M
In

507# 507# 507# 507# Throttle

Throttle position 7 6 6 7 7 2 2 position
feedback
00A# 00A# 00A# 00A#
GND 16 4 4 4 4 5 5 GND

50A# 50A# 50A# 50A#

Sensor 5V 25 3 3 6 6 1 1 5V

Operator station Chassis harness

ZX225-1105045

Fig. 7-27

Shop Manual - April 2014 7-41

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E434 Front pump proportional solenoid current abnormal (A)

Failure code Front pump proportional solenoid current is abnor-

Failure symptom
E434 mal. The system operates slowly.
Abnormality occurs in loaded circuit of proportional solenoid. Current which is
Failure description above 1.3A lasts for 3 second. Differential current occurs in drive protection
loop.
Controller reaction Stop the solenoid when failure is detected. Power supply must be restored.
Symptom on machine System operates slowly.

Cause Standard values and troubleshooting references

.
Ɣ Turn engine start switch to the OFF position before troubleshooting.

De al
Keep it in the OFF position while troubleshooting is performed.

pt
Open circuit of
1
Possible causes and standard values

harness Between CN-111F ķ and pin 28 of controller Under 1ȍ

Resistance
g n Between CN-111F ĸ and ground Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
o
2 of harness Keep it in the OFF position while troubleshooting is performed.
in ti
(grounded) Between CN-111F ķ and wire 0# Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of pro- Keep it in the OFF position while troubleshooting is performed.
营
销
公
司

3 portional valve
et a

coil Unplug the connector CN-111F, and measure the

Resistance 17.5ȍ
resistance between solenoid valve's ķ and ĸ
n

No troubleshooting can be done for failure occurs in the inner of controller.

Failure of con-
rk er

4 (Except for the above reasons, the controller must be replaced in case of
troller
this failure.)

5
Ma t
In

Controller
CN-150F Front pump SV
702# Signal
Front pump SV 28 1
signal output port

0#
GND 3 2 GND

Operator station Chassis harness

ZX225-1105014

Fig. 7-28

7-42 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E435 Rear pump proportional solenoid current abnormal (A)

Failure code Rear pump proportional solenoid current is abnor-

Failure symptom
E435 mal. The system operates slowly.
Abnormality occurs in loaded circuit of proportional solenoid. Current which is
Failure description above 1.3A lasts for 3 second. Differential current occurs in drive protection
loop.
Controller reaction Stop the solenoid when failure is detected. Power supply must be restored.
Symptom on machine System operates slowly.

Cause Standard values and troubleshooting references

.
De al
Ɣ Turn engine start switch to the OFF position before troubleshooting.

pt
Keep it in the OFF position while troubleshooting is performed.
Open circuit of
1
Possible causes and standard values

harness Between CN-113F ķ and pin 17 of controller Under 1ȍ

g no
Between CN-113F ĸ and ground
Resistance
Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
2 of harness Keep it in the OFF position while troubleshooting is performed.
in ti

(grounded) Between CN-113F ķ and wire 0# Resistance Above 1Mȍ

Ɣ Turn engine start switch to the OFF position before troubleshooting.
司
公
销
营

Failure of pro- Keep it in the OFF position while troubleshooting is performed.

et a

3 portional valve
coil Unplug the connector CN-113F, and measure the
Resistance 17.5ȍ
n

resistance between solenoid valve's ķ and ĸ .

rk er

No troubleshooting can be done for failure occurs in the inner of controller.

Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of
troller
this failure.)
Ma t

5
In

Controller

CN-151F Rear pump SV

703#
Rear pump SV 1 Signal
17
signal output port

0#
GND 3 2 GND

Operator station Chassis harness

ZX225-1105015

Fig. 7-29

Shop Manual - April 2014 7-43

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E436 Front pump proportional solenoid current abnormal (B)

Failure code Front pump proportional solenoid current is ab-

Failure symptom
E436 normal. The system operates slowly.
Abnormality occurs in loaded circuit of proportional solenoid. Current which is
Failure description
under 0.2 A lasts for 3 seconds and PWM output is greater than 10V.
Controller reaction Stop the solenoid when failure is detected. Power supply must be restored.
Symptom on machine System operates slowly.

Cause Standard values and troubleshooting references

.
Ɣ Turn engine start switch to the OFF position before troubleshooting.

De al
Keep it in the OFF position while troubleshooting is performed.
Open circuit of

pt
1
harness Between CN-150F ķ and pin 28 of controller Under 1ȍ
Possible causes and standard values

Resistance
Between CN-150F ĸ and ground Under 1ȍ
g n
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
o
2 of harness Keep it in the OFF position while troubleshooting is performed.
(grounded) Between CN-150F ķ and wire 0# Resistance Above 1Mȍ
in ti

Ɣ Turn engine start switch to the OFF position before troubleshooting.

Failure of pro- Keep it in the OFF position while troubleshooting is performed.
营
销
公
司

3 portional valve Unplug the connector CN-150F, and measure

et a

coil the resistance between solenoid valve's ķ and Resistance 17.5ȍ

n

ĸ.
No troubleshooting can be done for failure occurs in the inner of controller.
rk er

Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of
troller
this failure.)
Ma t

5
In

Controller
CN-150F Front pump SV
702# Signal
Front pump SV 28 1
signal output port

0#
GND 3 2 GND

Operator station Chassis harness

ZX225-1105014

Fig. 7-30

7-44 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E437 Rear pump proportional solenoid current abnormal (B)

Failure code Rear pump proportional solenoid current is abnor-

Failure symptom
E437 mal. The system operates slowly.
Abnormality occurs in loaded circuit of proportional solenoid. Current which is
Failure description
under 0.2 A lasts for 3 seconds and PWM output is greater than 10V.
Controller reaction Stop the solenoid when failure is detected. Power supply must be restored.
Symptom on machine System operates slowly.

Cause Standard values and troubleshooting references

.
Ɣ Turn engine start switch to the OFF position before troubleshooting.

De al
Keep it in the OFF position while troubleshooting is performed.
Open circuit of

pt
1
harness Between CN-151F ķ and pin 17of controller Under 1ȍ
Possible causes and standard values

Resistance
Between CN-151F ĸ and ground Under 1ȍ
g n
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
o
2 of harness Keep it in the OFF position while troubleshooting is performed.
(grounded) Between CN-151F ķ and wire 0# Resistance Above 1Mȍ
in ti

Ɣ Turn engine start switch to the OFF position before troubleshooting.

Failure of pro- Keep it in the OFF position while troubleshooting is performed.
营
销
公
司

3 portional valve Unplug the connector CN-151F, and measure

et a

coil the resistance between solenoid valve's ķ and Resistance 17.5ȍ

n

ĸ
No troubleshooting can be done for failure occurs in the inner of controller.
rk er

Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of
troller
this failure.)
Ma t

5
In

Controller

CN-151F Rear pump SV

703#
Rear pump SV 1 Signal
17
signal output port

0#
GND 3 2 GND

Operator station Chassis harness

ZX225-1105015

Fig. 7-31

Shop Manual - April 2014 7-45

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E543 Engine speed abnormal

Failure code Engine speed is abnormal. Only alarm output is

Failure symptom
E543 effective.
Failure description CPU detects out that engine speed is too low (below 100 rpm).
Only alarm output is effective. The alarm resets automatically when conditions
Controller reaction
become normal.
Symptom on machine ——

Cause Standard values and troubleshooting references

Normal condi- Code 43 will be displayed on the monitor when the engine start switch is

.
1

De al
tion turned from the OFF position to the ON position.
Possible causes and standard values

pt
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.
Open circuit of
2
g n
harness Between CN-125M ķ and pin 16 of controller
Resistance
Under 1ȍ
Between CN-125M ĸ and pin 6 of controller Under 1ȍ
o
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
in ti

3 of harness Keep it in the OFF position while troubleshooting is performed.

(grounded) Between CN-125M ķ and ground
销
公
司
Resistance Above 1Mȍ
营

Ɣ Turn engine start switch to the OFF position before troubleshooting.

et a

Failure of sen- Keep it in the OFF position while troubleshooting is performed.

n

4 sor Unplug the connector CN-125M, and measure

the resistance between ķ and ĸ of the speed Resistance 2.3 r 0.2k :
rk er

sensor.

5
Ma t
In

Controller

CN-125M Engine speed sensor

108A
Engine speed collection 16 1 Signal

108B
GND 6 2 GND

Operator station Chassis harness

ZX225-1105017
Fig. 7-32

7-46 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E244 Fuel control dial setting voltage abnormal

Failure code Fuel control dial setting voltage is abnormal and engine
Failure symptom
E544 returns auto deceleration.
When power is on, voltage of fuel control dial other than 0.25-4.75V lasts for over
Failure description
200 msec.
Controller reaction Throttle is moved to idle position.
Symptom on machine Engine returns auto deceleration.

Causes Standard values and troubleshooting references

Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the
5V power

.
1 ON position while troubleshooting is performed.

De al
failure
CN-501F Ľ and Ŀ Volt About 5V

pt
Possible causes and standard values

Open circuit Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the
2 OFF position while troubleshooting is performed.
of signal
g n
line
o
CN-501F ľ and controller pin19 Resistance Under 1ȍ
Short cir- Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the
3 cuit of OFF position while troubleshooting is performed.
in ti

signal line
(grounded) CN-501F ľ and ground Resistance Above 2Mȍ
司
公
销
营

Short circuit Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the
et a

of signal ON position while troubleshooting is performed.

4 line (con-
n

tact with
CN-501F ľ and ground Volt Under 5V
rk er

power sup-
ply)
Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the
5 OFF position while troubleshooting is performed.
Ma t

Dial failure
Unplug connector CN-501F and measure fuel con-
Resistance 5K±15%ȍ
In

trol dial Ľ and Ŀ .

CN-7-113M CN-209F CN-501F

50# Yellow
Sensor 5V 25 3 3 3 3 7 7

Red Fuel
9 9
506#
GND 16 4 4 9 9 control
Blue dial
2 2 0#
Fuel control dial 19 5 5 8 8
setting voltage

Operator station

ZX225-1105018
Fig. 7-33
Shop Manual - April 2014 7-47
Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E145 CAN bus abnormal

Failure code
Failure symptom Abnormality of CAN bus activates alarm.
E145

Failure description Time-out of CAN bus communication lasts for over 3s.

Controller reaction Only alarm output is effective.

Symptom on machine ----

Causes Standard values and troubleshooting references

Possible causes and standard values

Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the
CAN re- OFF position while troubleshooting is performed.
1 sistance

.
Between CN-7-709 A and B Resistance 60ȍ

De al
failure
Between CN-185 A and B Resistance 60ȍ

pt
Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the
OFF position while troubleshooting is performed.
g n
Open circuit Unplug controller connector and measure pin
2 Under 1ȍ
o
of Harness 12 and CN-7-112 A.
Resistance
Unplug controller connector and measure pin
in ti

Under 1ȍ
11 and CN-7-112 B.
Control- 销
公
司

No troubleshooting can be done for failure occurs in the inner of controller. (Except
营

3 ler internal
et a

for the above reasons, the controller must be replaced in case of this failure.)
failure
n
rk er

CN-185M CN-7-709M
A A
120 ohms 120 ohms
Controller B B
Ma t

CN-7-112F CANH
CANH 12 A 35
In

CANL
CANL 11 B 12
42
Monitor

CN-7-113M 5
F11 15A CN222F
43 24
4 1
0
7 2 11
F13 10A CN-221M 0
9 31

21 20

PWR PWR

Operator station Chassis harness

ZX335-1005040
Fi
Fig. 77-34
30

7-48 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

7.5 Troubleshooting Electrical System (E-Mode)

E-1 Engine does not crank .......................................................................................... 7-51

E-2 Engine runs rough or is unstable .......................................................................... 7-54
E-3 Power supply of machine cannot be cut off .......................................................... 7-55
E-4 Throttle motor not working .................................................................................... 7-56
E-5 Auto idle not functioning ........................................................................................ 7-57
E-6 Preheat function fails ............................................................................................ 7-59
E-7 All components not working .................................................................................. 7-60
E-8 Boom-up speed or power is low............................................................................ 7-61

.
E-9 Arm speed or power is low .................................................................................... 7-62

De al
pt
E-10 Bucket speed or power is low ............................................................................. 7-63
E-11 Travel speed or power is low............................................................................... 7-65
g n
E-12 Blank monitor display .......................................................................................... 7-66
o
E-13 Monitor displays nothing ..................................................................................... 7-67
in ti

E-14 Dual speed travel not functioning........................................................................ 7-68

E-15 Incorrect engine coolant reading......................................................................... 7-69
营
销
公
司

E-16 Incorrect fuel level reading .................................................................................. 7-70

et a

E-17 Wiper does not work ........................................................................................... 7-71

n

E-18 Incorrect arm-in pilot pressure reading ............................................................... 7-72

rk er

E-19 Incorrect arm-out pilot pressure reading ............................................................. 7-73

E-20 Incorrect boom-up pilot pressure reading ........................................................... 7-74
Ma t

E-21 Incorrect boom-down pilot pressure reading....................................................... 7-75

E-22 Incorrect bucket-dig pilot pressure reading ......................................................... 7-76
In

E-23 Incorrect bucket-dump pilot pressure reading..................................................... 7-77

E-24 Incorrect swing pilot pressure reading ............................................................... 7-78
E-25 Left travel pilot pressure reading incorrect .......................................................... 7-79
E-26 Right travel pilot pressure reading incorrect ....................................................... 7-80

Shop Manual - April 2014 7-49

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

Fuse box connection table

● This table gives all power supply units and rated currents of fuse box power supplies.
● If power supply is normal, check the fuse box and fuses when you perform troubleshooting of
the electrical system.

Information contained in troubleshooting table

Failure information Symptom on machine

Related information Failure occurred and troubleshooting information

Standard values and troubleshooting referenc-

Cause
es

.
De al
pt
<Inclusion>
Possible causes and standard values

● Standard value under normal condition can

g no
be used to judge possible causes
● Reference for passing the above "Good" or
"No Good" judgement
in ti

Possible causes of trouble

(Given numbers are refer- <Symptom of Wiring Harness Failure>
司
公
销
营

1
et a

ence numbers, which do not ● Open circuit

indicate priority)
n

Faulty contact with connector or open cir-

cuit in wiring harness
rk er

● Faulty grounding
An ungrounded wiring is grounded.
Ma t

● Short circuit
In

A wiring has mistaken contact with a 24 V

electric circuit.

7-50 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E-1 Engine does not crank

Trouble Engine cannot be started.

Related information

Cause Standard values and troubleshooting references

★ Turn engine start switch to the OFF position before troubleshooting. Keep
Low battery it in the OFF position while troubleshooting is performed.
1
capacity
Battery voltage Voltage ≥ 24V

Internal fail- ★ Turn engine start switch to the OFF position before troubleshooting. Keep
2 ure of engine it in the OFF position while troubleshooting is performed.

.
Possible causes and standard values

≥ 1M Ω

De al
start switch OFF position: between wire 22# and wire 11# Resistance

pt
★ Turn engine start switch to the OFF position before troubleshooting. Keep
it in the OFF position while troubleshooting is performed.
Failure of pilot Lockout control in unlocked position: between
3
switch
g n 105 # and 27# wire
≤1 Ω
Resistance
Lockout control in locked position: between wire
o
≥1M Ω
105 # and wire 27#
in ti
★ Turn engine start switch to OFF position. Keep the engine running during
troubleshooting. (When all power supplies, grounding, signal and engine
inputs are normal except engine output, it is the failure of start motor)
营
销
公
司

4 Failure of Engine starting motor Start switch Voltage

et a

start motor Power supply: Terminal B and ground 20—30V

n

Start
Between start motor input terminal S and ground 20—30V
rk er

★ Turn engine start switch to OFF position before proceeding. Turn it to the
ON position to perform troubleshooting.
Open circuit Wire 21# and start motor terminal B ≤1 Ω
5
of harness
≤1 Ω
Ma t

Wire 12# and start motor terminal S Resistance

Start relay terminal L and safety relay terminal S ≤1 Ω
In

Shop Manual - April 2014 7-51

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

Cause Standard values and troubleshooting references

Failure of fuse Battery terminal "+" (wire 20#) and control dial
6 Resistance ≤1 Ω
F1 wire 22#
★ Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.
Possible causes and standard values

Short circuit
7 of harness Start relay terminal S and ground ≥1M Ω
(grounded) Resistance
Start motor input terminal S and ground ≥1M Ω
★ Turn engine start switch to the OFF position before troubleshooting. Turn
the start switch to the ON position and keep it in the ON position while
Internal failure
8 troubleshooting is performed.
of alternator
Alternator terminal R and ground Voltage ≤ 1.5V
★ Turn engine start switch to OFF position. Move it to ON position when

.
De al
performing troubleshooting.
9 Start relay
≥ 300 Ω

pt
Between relay coils
Resistance
Between start relay terminal B and line 11# ≤1 Ω
★ Turn engine start switch to the OFF position before troubleshooting. Turn
g n the start switch to the ON position and keep it in the ON position while
Failure of
o
10 troubleshooting is performed.
parking unit Check parking relay —
in ti
Resistance
Measure resistance of motor coil. Approx 63 Ω
司
公
销
营
et a
n
rk er
Ma t
In

7-52 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

21 16 2 1 17
F13-160A 14 4 3 GR-1 GLOW PLUG
Preheat
TERMINAL B BR ACC R1 R2 C 61
1
68 relay
3 4
HEAT 66 69
2 6
OFF 5 HL2
ON Low-temp switch PReheat indicator
START 0 Preheater R0
Preheat controller
S0 22 62 61 11
Start switch 64
897044-4180 13 3 6 65
5 A
B
1 2 63 P2

E3 P1 E

k7
Parking relay 0 HLR Charging indicator
Parking motor
22 G
14 60

.
14 R L

De al
F1-20A P600G B E
F2-10A
0
E2

pt
Engine
20 21
B1
g n B2 Safety relay
M1 B
C B 12 M
S
k1 11 11a 11b S R 60
- + - +
o
E
Battery E
0 Start motor
relay 620
k11 0
k3 k3 Start relay
in ti
Lockout relay
0 0
0
27 606
BAT-1 Battery
销
公
司
F7-10A 105
营

SQ1 Pilot switch

D-1
et a

K4 Pilot valve relay 0 VA7

15 15a 22 0
Pilot solenoid valve
D-10
n

0
k-8 Shutdown relay
rk er

ZX225-1105020
Fig. 7-35
Ma t
In

Shop Manual - April 2014 7-53

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E-2 Engine runs rough or is unstable

Failure information Engine Runs Rough or Is Unstable

Related information Engine speed can be read on the monitor.

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in
Open circuit of the OFF position while troubleshooting is performed.
1
harness Unplug the connector controller, and measure
Possible causes and standard values

Resistance 2.3±0.2 Kȍ
the resistance between pin 16 and pin 7.
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in

.
Internal failure the OFF position while troubleshooting is performed.
2

De al
in sensor
Between CN-125M A and B Resistance 2.3±0.2 Kȍ

pt
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in
the OFF position while troubleshooting is performed.
3
g n
of harness
(grounded) Between CN-125M A and ground Resistance Above 1Mȍ
o
Internal failure No troubleshooting can be done due to internal failure. (Failure lies in the control-
4
in ti

of controller ler if the reasons above are ruled out)

司
公
销
营
et a

5
n
rk er

Controller HCU_J1
CN-125M
Ma t

（S-2） RPM sensor

In

RPM sensor 16 A Signal

input signal

GND 7 B GND

Operator station Chassis harness

ZX225-1105021

Fig. 7-36

7-54 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E-3 Power supply of machine cannot be cut off

Failure information Engine cannot be stopped.

Engine stalls when start switch it turned to OFF position. There
Related information
is no time delay for power cutout.

Cause Standard values and troubleshooting references

Possible causes and standard

Failure of battery When the engine start switch is operated, if the operation of battery relay con-
1
relay tact is heard, the battery is normal. Turn the start switch OFFĺONĺOFF.
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep
values

Breakdown of it in the OFF position while troubleshooting is performed.

2
surge diode
Between battery relay wire 20# and wire 21# Resistance Above 1Mȍ

.
De al
pt
3
g no
21 16 2 1 17
in ti

F13-160A 14 4 3 GR-1 GLOW PLUG

Preheat
TERMINAL B BR ACC R1 R2 C 营
销
公
司

61
1
68 relay
3 4
HEAT 66 69
et a

2 6
OFF 5 HL2
ON PReheat indicator
n

Low-temp switch
START 0 Preheater R0
Preheat controller
S0 22 62 61 11
rk er

Start switch 64
897044-4180 13 3 6 65
5 A
B
1 2 63 P2

E3 P1 E
Ma t

k7
Parking relay 0 HLR Charging indicator
Parking motor
In

22 G
14 14 R L 60
F1-20A P600G B E
F2-10A
0
21 E2 Engine
20
B1
B2 Safety relay
M1 B
C B 12 M
S
k1 11 11a 11b S R 60
- + - + E
Battery E
0 Start motor
relay 620
k11 0
k3 Lockout relay k3 Start relay
0 0
0
27 606
BAT-1 Battery
F7-10A 105
SQ1 Pilot switch
D-1
K4 Pilot valve relay 0 VA7
15 15a 22 0
Pilot solenoid valve
D-10 0
k-8 Shutdown relay
ZX225-1105020

Fig. 7-37

Shop Manual - April 2014 7-55

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E-4 Throttle motor not working

Failure information Engine speed does not increase or decrease.

Turn the fuel control dial but engine speed does not
Related information
change.

Causes Standard values and troubleshooting references

Preheat Ɣ Turn he start switch to the ON position and keep it in the ON position while trouble-
1 fuse fail- shooting is performed.
Possible causes and standard values

ure. The monitor shows failure code 41. Coolant temperature and oil level are normal.
Ɣ Turn he start switch to the ON position and keep it in the ON position while trouble-
Sensor shooting is performed.

.
2 power

De al
abnormal Measure the voltage between motor plug, 50# wire
Volt 5.0V

pt
and ground.
g n Unplug the connector of the harness between throttle motor and chassis.
Throttle Measure the resistance between the blue and red
8~15ȍ
3 motor wires.
o
failure Resistance
Measure the resistance between the yellow and
5kȍ ± 10%
in ti

green wires.
Throttle Ɣ Turn he start switch to the ON position and keep it in the ON position while trouble-
shooting is performed.
司
公
销

4 motor
营
et a

failure The monitor shows failure codes 41, 12, 13, 14 and 32.
n
rk er
Ma t
In

7-56 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E-5 Auto idle not functioning

Failure information Auto idle speed do not work

Engine speed do not decrease wen the mode is auto idle
Related information
speed and grip keeps still in NEUTRAL position

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to OFF position. Start the engine and keep it run-
ning to perform troubleshooting.
Error of boom-
1
up signal Levers in NEUTRAL, pressure signal transmitted 0 KG
Pressure
Lever in operation, pressure signal transmitted 0-39 KG

.
Possible causes and standard values

Ɣ Turn engine start switch to OFF position. Start the engine and keep it run-

De al
ning to perform troubleshooting.
Error of boom-

pt
2
down signal Levers in NEUTRAL, pressure signal transmitted 0 KG
Pressure
Lever in operation, pressure signal transmitted 0-39 KG
g n
Ɣ Turn engine start switch to OFF position. Start the engine and keep it run-
o
ning to perform troubleshooting.
Error of arm-in
3
in ti
signal Levers in NEUTRAL, pressure signal transmitted 0 KG
Pressure
Lever in operation, pressure signal transmitted 0-39 KG
司
公
销
营

Ɣ Turn engine start switch to OFF position. Start the engine and keep it run-
et a

ning to perform troubleshooting.

Error of arm-out
4
signal Levers in NEUTRAL, pressure signal transmitted 0 KG
n

Pressure
Lever in operation, pressure signal transmitted 0-39 KG
rk er

Ɣ Turn engine start switch to OFF position. Start the engine and keep it run-
ning to perform troubleshooting.
Error of bucket-
5
dig signal Levers in NEUTRAL, pressure signal transmitted 0 KG
Ma t

Pressure
Lever in operation, pressure signal transmitted 0-39 KG
In

Shop Manual - April 2014 7-57

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to OFF position. Start the engine and keep it
running to perform troubleshooting.
Error of Bucket- Levers in NEUTRAL, pressure signal
6 0 KG
dump signal transmitted
Pressure
Lever in operation, pressure signal
0-39 KG
transmitted
Ɣ Turn engine start switch to OFF position. Start the engine and keep it
Possible causes and standard values

running to perform troubleshooting.

Error of swing Levers in NEUTRAL, pressure signal
7 0 KG
signal transmitted
Pressure
Lever in operation, pressure signal
0-39 KG
transmitted

.
De al
Ɣ urn engine start switch to OFF position. Start the engine and keep it

pt
running to perform troubleshooting.
Levers in NEUTRAL, pressure signal
8 Error of travel 0 KG
g n
signal
transmitted
Pressure
Lever in operation, pressure signal
o
0-39 KG
transmitted
in ti

Ɣ Turn engine start switch to OFF position. Start the engine and keep it
running to perform troubleshooting.
司
公

Error of attach- Levers in NEUTRAL, pressure signal

销
营

9 0 KG
et a

ment signal transmitted

Pressure
Lever in operation, pressure signal
n

0-39 KG
transmitted
rk er

Failure of con- No troubleshooting can be done for it is internal failure. (If it is not caused
10
troller by one of the factors listed above, it should be the failure of controller.)
Ma t
In

7-58 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E-6 Preheat function fails

Failure information Engine does not preheat.

Related information

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep
Failure of pre- it in the OFF position while troubleshooting is performed.
1
heat fuse
Between wire 21# and preheat relay wire 16# Resistance Under 1ȍ
Possible causes and standard values

When the preheat function is activated, if operation of the preheat relay

Failure of pre-
2 contact is heard, the relay is normal. The start switch is to be switched

.
heat relay

De al
HEATĺOFFĺHEAT.

pt
Short circuit
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep
3 of harness
it in the OFF position while troubleshooting is performed.
g n
(grounded)
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep
o
it in the OFF position while troubleshooting is performed.
in ti

Between preheat controller pin 3# and start switch

Under 1ȍ
wire 61#
Failure of pre-
Between preheat controller pin 4# and preheat relay
司
公
销
营

4 heat control- Under 1ȍ

wire 68#
et a

ler Resistance
Between preheat controller pin 1# and preheat relay
n

Under 1ȍ
wire 14#
rk er

Between preheat controller pin 2# and low temp

Under 1ȍ
switch wire 66#
Ma t

17 GR-1 GLOW PLUG

21 16
TERMINAL B BR ACC R1 R2 C
2 1
In

HEAT F13-160A 14 4 3

OFF Preheat relay

1
ON 61 68 P600G Preheater R0
3 4

START 66 2 6 69
20 21
S0 Low temp SW
5 HL2 - + - +

Start switch 22 62 13 61 11 Preheat indicator

21n4-10430 13 0 Preheat controller BAT-1 Battery

14 k1
Batt. relay
11 F2-10A
0
F1-20A

20
Control switch harness Cab harness Chassis harness

ZX225-1005039

Fig. 7-38

Shop Manual - April 2014 7-59

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E-7 All components not working

Failure information The machine is motionless while operated after starting.

Related information

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to OFF position. Start the engine and keep
Possible causes and standard values

it running to perform troubleshooting.

Failure of lockout Item Lockout control lever Resistance
1
switch
Between wire 105# and wire LOCK Under 1ȍ
27#

.
FREE Above 1Mȍ

De al
Ɣ Turn engine start switch to the OFF position before troubleshooting.

pt
Short circuit of Keep it in the OFF position while troubleshooting is performed.
2
wire (grounded)
Between 105# and ground Resistance Above 1Mȍ
g n Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of coil
o
3 inside lockout Keep it in the OFF position while troubleshooting is performed.
solenoid valve Between CN-136F 1 and 2 Resistance About 34ȍ
in ti

4 营
销
公
司
et a
n
rk er

1 2 3 4 5
Ma t

1 2 3 4 5

0
105 27
In

CN-302M CN-136F
105 CN-201F CN-205F (D-12) (AMP-2)
(D-12) 606 606 1
1
1 4 0
Pilot 8 0 2
switch 2 10

27

+24V

Cab harness Chassis harness

ZX225-1005040

Fig. 7-39

7-60 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E-8 Boom-up speed or power is low

Failure information Boom-up speed or power is low.

Pilot pressure of the boom in operation can be
Related information
checked on the monitor.

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to OFF position. Start the engine and keep it
Possible causes and standard values

running to perform troubleshooting.

Failure of sen-
1
sor Levers in NEUTRAL, boom-up pressure signal 0 KG
Pressure
Lever in operation, boom-up pressure signal 0-39 KG

.
De al
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Short circuit

pt
Keep it in the OFF position while troubleshooting is performed.
2 of harness
(grounded) Between harness ( from controller pin 8 to CN- Above
Resistance
g n 126M A) and ground 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting.
o
Open circuit of Keep it in the OFF position while troubleshooting is performed.
3
harness
in ti

Between controller pin 11 and CN-126M B Resistance Under 1ȍ

Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the
4 司

troller controller if the reasons above are ruled out)

公
销
营
et a
n

Controller Boom-up pilot

CN-126M press. sensor
rk er

206#
Boom-up pilot pressure 8 C Signal
signal collecting port
00#
11 B GND
GND
Ma t

50#
12 A 5V
In

5V PWR

Operator station Chassis harness

ZX225-1105009

Fig. 7-40

Shop Manual - April 2014 7-61

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E-9 Arm speed or power is low

Failure information Arm speed or power is low during operation.

Pilot pressure of the arm in operation can be checked on the
Related information
monitor.

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to OFF position. Start the engine and keep it running
to perform troubleshooting.
Failure of
1 Levers in NEUTRAL, arm-in and arm-out pressure
Possible causes and standard values

sensor 0 KG
signals Pressure
Levers in operation, arm-in and dump pressure signal 0-39 KG

.
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it

De al
in the OFF position while troubleshooting is performed.

pt
Short circuit
2 of harness Between harness (from controller pin 35 to CN-
(grounded) 129M A) and ground
Resistance Above 1Mȍ
g n Between harness (from controller pin 22 to CN-
122M A) and ground
o
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it
in ti

Open circuit in the OFF position while troubleshooting is performed.

3
of harness Between controller pin 11 and CN-129M B
Resistance Under 1ȍ
Between controller pin 11 and CN-122M B
司
公
销
营
et a

Failure of No troubleshooting can be done due to internal failure. (Failure lies in the control-
4
controller ler if the reasons above are ruled out)
n
rk er

CN-122M Arm out

（DF-3） press. sensor

A Signal
Ma t

B GND
In

C 5V

Controller

Arm out Arm in

CN-129M
press. sensor 22 press. sensor
（DF-3）
Arm in Signal
35 A
press. sensor
11 B GND
Sensor GND
Sensor 5V 12 C 5V

Operator Station Chassis harness

ZX225-1105022

Fig. 7-41

7-62 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E-10 Bucket speed or power is low

Failure information Bucket speed or power is low during operation.

Pilot pressure of the bucket can be checked on the moni-
Related information
tor.

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to OFF position. Start the engine and keep it
running to perform troubleshooting.
Failure of sen- Levers in NEUTRAL, bucket-dig/dump pressure
1 0 KG
sor signals
Pressure
Possible causes and standard values

Levers in operation, bucket-dig/dump pressure

0-39 KG

.
signals

De al
Ɣ Turn engine start switch to the OFF position before troubleshooting.

pt
Keep it in the OFF position while troubleshooting is performed.
Short circuit
Between harness (from controller pin 10 to CN-
2
g n of harness
124M A) and ground
(grounded) Resistance Above 1Mȍ
o
Between harness (from controller pin 33 to CN-
128M A) and ground
in ti

Ɣ Turn engine start switch to the OFF position before troubleshooting.

Open circuit of Keep it in the OFF position while troubleshooting is performed.
3 营
销
公
司

harness Between controller pin 11 and CN-124M B

Resistance Under 1ȍ
et a

Between controller pin 11 and CN-128M B

Defective buck- Ɣ Turn engine start switch to the OFF position before troubleshooting.
n

4 et conÀuence Keep it in the OFF position while troubleshooting is performed.

rk er

solenoid valve Between CN-134F 1 and 2 Resistance About 34ȍ

Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the
5
troller controller if the reasons above are ruled out)
Ma t
In

Shop Manual - April 2014 7-63

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

CN-128M Bucket dump

（DF-3） press. sensor

A Signal

B GND

C 5V
Controller

Bucket dump CN-124M Bucket dig

press. sensor 33 （DF-3） press. sensor
Bucket dig
10 A Signal

.
press. sensor

De al
Sensor GND 11 B GND

pt
Sensor 5V 12 C 5V
g n
Bucket confluence 27
signal
o
CN-134F Bucket confluence
（AMP-2） Proportional valve
in ti

1 Signal
司
公
销
营
et a

2 GND
n
rk er

Operator Station Chassis harness

ZX225-1105023
Ma t

Fig. 7-42
In

7-64 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E-11 Travel speed or power is low

Failure information Travel speed or power is low during operation.

Pilot pressure of travel operation can be checked on the
Related information
monitor.

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to OFF position. Start the engine and keep it
running to perform troubleshooting.
Failure of sen- Levers in NEUTRAL, left and right travel pressure
Possible causes and standard values

1 0 KG
sor signals
Pressure
Levers in operation, left and right travel pressure
0-39 KG

.
signals

De al
Ɣ Turn engine start switch to the OFF position before troubleshooting.

pt
Keep it in the OFF position while troubleshooting is performed.
Short circuit
Between harness (from controller pin 34 to CN-
g n2 of harness
120M A) and ground Above
(grounded) Resistance
1Mȍ
o
Between harness (from controller pin 30 to CN-
121M A) and ground
in ti

Ɣ Turn engine start switch to the OFF position before troubleshooting.

Open circuit of Keep it in the OFF position while troubleshooting is performed.
3 营
销
公
司

harness Between controller pin 11 and CN-120M B

Resistance Under 1ȍ
et a

Between controller pin 11 and CN-121M B

n

Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the
4
troller controller if the reasons above are ruled out)
rk er

CN-121M
R. travel press. sensor
（DF-3）
Ma t

A Signal
In

B GND

C 5V
Controller
HCU_J2
CN-120M
R. travel press. sensor L. travel press. sensor
30 （DF-3）
L. travel press. sensor 34 A Signal

Sensor grounding wire B GND

11

Sensor 5V 12 C 5V

HCU_J1

Operator station Chassis harness

Fig. 7-39 ZX225-1105024

Fig. 7-43
Shop Manual - April 2014 7-65
Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E-12 Blank monitor display

Failure information Monitor display is blank after the machine is powered on.
Related information

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to OFF position. Then, keep it at OFF position to
perform troubleshooting.
1 Failure of fuse
Between wire 42# and ground About 24V
Possible causes and standard values

Voltage
Between wire 43# and ground About 24V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep

.
it in the OFF position while troubleshooting is performed.

De al
Open circuit Between CN-7-113M pin 1 and CN-222F pin 4 Under 1ȍ

pt
2
of harness
g n Between CN-7-113M pin 2 and CN-222F pin 7 Resistance Under 1ȍ
Between CN-7-113M pin 9# and ground Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep
o
it in the OFF position while troubleshooting is performed.
in ti
Short circuit
Between harness (from CN-7-113M pin 1 to CN-
3 of harness Above 1Mȍ
222F pin 4 and ground
(grounded) 营
销
公
司

Resistance
Between harness (from CN-7-113M pin 2 to CN-
Above 1Mȍ
et a

222F pin 7 and ground

Failure of No troubleshooting can be done for it is internal failure. (If it is not caused by
n

4
monitor one of the factors listed above, it should be the failure of monitor.)
rk er

CN-185M CN-7-709M
A A
Ma t

120 ohms 120 ohms

B B
Controller HCU-J2
CN-7-112F
In

CANH
CANH 12 A 35
11 CANL
CANL B 12
Monitor

42
CN-7-113M 5
F11 15A CN-222F 43
4 1 24
F13 10A 0
7 2 11
CN-221M
0 31
9

21 20

PWR PWR

Operator station Chassis harness

ZX335-1005050

Fig. 7-44

7-66 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E-13 Monitor displays nothing

Display of monitor is illuminated but no information is

Failure information
shown on the screen after machine is powered on.
Related information

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep
Failure of it in the OFF position while troubleshooting is performed.
1
resistance
Possible causes and standard values

Between CN-1-185M A and B Resistance 120 ȍ

Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep
it in the OFF position while troubleshooting is performed.
Open circuit

.
2

De al
of harness Between CN-7-112F pin A and controller pin 12 Under 1ȍ
Resistance

pt
Between CN-7-112F pin B and controller pin 11 Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep
g n it in the OFF position while troubleshooting is performed.
Short circuit
Between harness (from CN-7-112F pin A to con-
o
3 of harness Above 1Mȍ
troller pin 12) and ground
(grounded) Resistance
in ti

Between harness (from CN-7-112F pin B to con-

Above 1Mȍ
troller pin 11 and ground
司
公
销
营

Failure of
No troubleshooting can be done for it is internal failure. (If it is not one of the
et a

4 monitor or
failures stated above, it should be the failure of monitor or controller.)
controller
n
rk er

CN-185M CN-7-709M
A A
120 ohms 120 ohms
B B
Ma t

Controller HCU-J2
CN-7-112F
CANH
CANH 12 A 35
In

11 CANL
CANL B 12
Monitor

42
CN-7-113M 5
F11 15A CN-222F 43
4 1 24
F13 10A 0
7 2 11
CN-221M
0 31
9

21 20

PWR PWR

Operator station Chassis harness

ZX335-1005050
Fig. 7-45

Shop Manual - April 2014 7-67

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E-14 Dual speed travel not functioning

Failure information Only low speed travel is functioning during operation.

Press the Hi/Lo button on the monitor to change
Related information
travel speed.

Cause Standard values and troubleshooting references

Possible causes and standard values

Failure of dual Ɣ Turn engine start switch to the OFF position before troubleshooting.
1 speed travel Keep it in the OFF position while troubleshooting is performed.
solenoid valve Between CN-131F A and B Resistance About 34ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.
Open circuit

.
2

De al
of harness Between CN-131F pin A and controller pin 7 Under 1ȍ
Resistance

pt
Between CN-131F pin B and controller pin 3 Under 1ȍ
g n Ɣ Turn engine start switch to the OFF position before troubleshooting.
Short circuit Keep it in the OFF position while troubleshooting is performed.
3 of harness
Between harness (from CN-131F pin A to con-
o
(grounded) Resistance Above 1Mȍ
troller pin 7) and ground
in ti

4
司
公
销
营

Controller
et a

CN-131F High speed travel

（AMP-2） solenoid valve
n

High speed travel

7 A Signal
rk er

solenoid valve

GND 3 B GND
Ma t
In

Operator Station Chassis harness

ZX225-1105025

Fig. 7-46

7-68 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E-15 Incorrect engine coolant reading

Engine coolant temperature sensor cannot correctly reÀect cur-

Failure information
rent coolant temperature.
Related information Coolant temperature can be checked on the monitor.

Cause Standard values and troubleshooting references

Standard values for engine coolant temperature sensor
50ć 130ȍ
Possible causes and standard values

Failure of cool-
1 ant temperature 80ć 48.5±4.2ȍ
sensor
100ć 26.7±2.5ȍ

.
110ć 20ȍ

De al
Ɣ Turn engine start switch to the OFF position before troubleshooting.

pt
Open circuit of Keep it in the OFF position while troubleshooting is performed.
2
g n lead
Between wire 510# and controller pin 32 Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting.
o
Short circuit of Keep it in the OFF position while troubleshooting is performed.
3
lead (grounded)
in ti

Between wire 510# and ground Resistance Above 1Mȍ

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Lead short to Keep it in the ON position while troubleshooting is performed.
司
公
销
营

4
24V circuit
et a

Wire 510# to ground Voltage Under 1V

n
rk er

Controller
Ma t

510
In

Coolant temperature sensor 32

Operator Station Chassis harness

ZX335-1005053
Fig. 7-47

Shop Manual - April 2014 7-69

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E-16 Incorrect fuel level reading

Failure information Engine fuel level sensor cannot correctly reÀect current fuel level.
Related information Fuel level can be checked on the monitor.

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.
Possible causes and standard values

Fuel level sen- Pin Fuel level Resistance

1
sor error
FULL (Upper limit) Approx. 10 ȍ
Between wire 509# and ground
EMPTY (Lower limit) 85-95ȍ

.
Ɣ Turn engine start switch to the OFF position before troubleshooting.

De al
Open circuit of Keep it in the OFF position while troubleshooting is performed.
2

pt
lead
Between wire 509# and controller pin 17 Resistance Under 1ȍ
Short circuit of Ɣ Turn engine start switch to the OFF position before troubleshooting.
g n Keep it in the OFF position while troubleshooting is performed.
3 lead (ground-
o
ed) Between wire 509# and ground Resistance Above 1Mȍ
in ti
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Lead short to Keep it in the OFF position while troubleshooting is performed.
4
24V
司
公
销
营

Wire 509# grounded Voltage Under 1V

et a
n

Controller
rk er
Ma t

509
Fuel level sensor 17
In

Operator Station Chassis harness

ZX335-1005054

Fig. 7-48

7-70 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E-17 Wiper does not work

Failure information Wiper does not work.

Related information

Cause Standard values and troubleshooting references

Internal Fail- Ɣ Turn engine start switch to the OFF position before troubleshooting.
1 ure of wiper Keep it in the OFF position while troubleshooting is performed.
Possible causes and standard values

motor Between wiper wire 25# and ground Resistance ˚ 10ȍ

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.

.
De al
Between CN-403F 1 and CN-1-110 2 Under 1ȍ
Open circuit of

pt
2 Between wiper switch wire 35L# and
lead Under 1ȍ
g n CN-1-110M 5 Resistance
Between wiper switch wire 35L# and
Under 1ȍ
CN-1-110M 4
o
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Short circuit of
in ti
Keep it in the OFF position while troubleshooting is performed.
3 lead (ground-
ed) Harness from CN-403F 1 to CN-1-110M
Resistance Above 1Mȍ
2 short to ground
营
销
公
司
et a

4
n
rk er

Wiper switch
CN-401F CN-204M CN-1-110M 25
（D-12） （D-12） CN-203F （D-6）
Ma t

2 2 （D-12）
F5 5A 36 2 2 36
In

6 6 6 35L 35L M
25 12 3 3
35H 35H
7 7 4 4
CN-403M
（D-12） 5 5
1
21

PWR

Operator station

ZX225-1005049

Fig. 7-49

Shop Manual - April 2014 7-71

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E-18 Incorrect arm-in pilot pressure reading

Failure information Reading of arm-in pilot pressure is incorrect.

Related information

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of 5V Keep it in the OFF position while troubleshooting is performed.
Possible causes and standard values

1
power supply
Between CN-129M ķ and Ĺ Voltage Approx. 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Open circuit of Keep it in the OFF position while troubleshooting is performed.
2
signal line

.
Between CN-129M ĸ and controller pin 35 Resistance Under 1ȍ

De al
Ɣ Turn engine start switch to the OFF position before troubleshooting.

pt
Short circuit of Keep it in the OFF position while troubleshooting is performed.
3
signal line
Between CN-129M ĸ and ground Resistance Above 2Mȍ
g n
Ɣ Turn engine start switch to the OFF position before troubleshooting.
o
Failure of sen- Keep it in the OFF position while troubleshooting is performed.
4
sor
Between CN-129M ĸ and ground Voltage 0.5V- 4.5V
in ti

5 营
销
公
司
et a
n

Controller
CN-129M
rk er

Arm in
（DF-3） pressure sensor
Arm in
35 2 Signal
pressure sensor
Ma t

Sensor GND 11 3 GND

Sensor 5V
In

12 1 5V

Operator Station Chassis harness

ZX225-1105026

Fig. 7-50

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SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E-19 Incorrect arm-out pilot pressure reading

Failure information Reading of arm-out pilot pressure is incorrect.

Related information

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of 5V Keep it in the OFF position while troubleshooting is performed.
Possible causes and standard values

1
power supply
Between CN-122M ķ and Ĺ Voltage About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Open circuit of Keep it in the OFF position while troubleshooting is performed.
2
signal line

.
De al
Between CN-122M ĸ and controller pin 22 Resistance Under 1ȍ

pt
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Short circuit of Keep it in the OFF position while troubleshooting is performed.
3
signal line
g n Between CN-122M ĸ and ground Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting.
o
Failure of sen- Keep it in the OFF position while troubleshooting is performed.
4
sor
in ti

Between CN-122M ĸ and ground Voltage 0.5V- 4.5V

5
司
公
销
营
et a
n
rk er

Controller
CN-122M Arm out
（DF-3） pressure sensor
Ma t

Arm out
22 2 Signal
pressure sensor
In

Sensor GND 11 3 GND

Sensor 5V 12 1 5V

Operator Station Chassis harness

ZX225-1105027

Fig. 7-51

Shop Manual - April 2014 7-73

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E-20 Incorrect boom-up pilot pressure reading

Failure information Incorrect Boom-up Pilot Pressure Reading

Related information

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of 5V Turn the start switch to the ON position and keep it in the ON position
1 while troubleshooting is performed.
Possible causes and standard values

power supply
Between CN-126M ķ and Ĺ Voltage About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Open circuit of Keep it in the OFF position while troubleshooting is performed.
2

.
signal line

De al
Between CN-126M ĸ and controller pin 8 Resistance Under 1ȍ

pt
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Short circuit of Keep it in the OFF position while troubleshooting is performed.
3
g nsignal line
o
Between CN-126M ĸ and ground Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of sen- Turn the start switch to the ON position and keep it in the ON position
in ti

4 while troubleshooting is performed.

sor
Between CN-126M ĸ and ground
营
销
公
司
Voltage 0.5V- 4.5V
et a

5
n
rk er

Controller
Ma t

CN-126M Boom up
（DF-3） pressure sensor
In

Boom up
8 2 Signal
pressure sensor
Sensor GND 11 3 GND

Sensor 5V 12 1 5V

Operator Station Chassis harness

ZX225-1105028

Fig. 7-52

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SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E-21 Incorrect boom-down pilot pressure reading

Failure information Boom-down pilot pressure reading is incorrect.

Related information

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of 5V Turn the start switch to the ON position and keep it in the ON position
1 while troubleshooting is performed.
Possible causes and standard values

power supply
Between CN-125M ķ and Ĺ Voltage About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Open circuit of

.
2 Keep it in the OFF position while troubleshooting is performed.

De al
signal line
Between CN-125M ĸ and controller pin 9 Resistance Under 1ȍ

pt
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Short circuit of Keep it in the OFF position while troubleshooting is performed.
g n
3
signal line
Between CN-125M ĸ and ground Resistance Above 2Mȍ
o
Ɣ Turn engine start switch to the OFF position before troubleshooting.
in ti

Failure of sen- Turn the start switch to the ON position and keep it in the ON position
4 while troubleshooting is performed.
sor
Between CN-125M ĸ and ground
营
销
公
司

Voltage 0.5V- 4.5V

et a

5
n
rk er

Controller
Ma t

CN-125M Boom down

（DF-3） pressure sensor
In

Boom down
9 2 Signal
pressure sensor
Sensor GND 11 3 GND

Sensor 5V 12 1 5V

Operator Station Chassis harness

ZX225-1105029
Fig. 7-53

Shop Manual - April 2014 7-75

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E-22 Incorrect bucket-dig pilot pressure reading

Failure information Bucket-dig pilot pressure reading is incorrect.

Related information

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of 5V Turn the start switch to the ON position and keep it in the ON position
Possible causes and standard values

1 while troubleshooting is performed.

power supply
Between CN-124M ķ and Ĺ Voltage About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Open circuit of

.
2 Keep it in the OFF position while troubleshooting is performed.

De al
signal line
Between CN-124M ĸ and controller pin 10 Resistance Under 1ȍ

pt
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Short circuit of Keep it in the OFF position while troubleshooting is performed.
3
g nsignal line
Between CN-124M ĸ and ground Resistance Above 2Mȍ
o
Ɣ Turn engine start switch to OFF position. Then, keep it at OFF posi-
Failure of sen- tion to perform troubleshooting.
in ti
4
sor
Between CN-124M ĸ and ground Voltage 0.5V- 4.5V
司
公
销
营

5
et a
n
rk er

Controller
CN-124M Bucket dig
Ma t

（DF-3） pressure sensor

Bucket dig
10 2 Signal
In

pressure sensor
Sensor GND 11 3 GND

Sensor 5V 12 1 5V

Operator Station Chassis harness

ZX225-1105030

Fig. 7-54

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SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E-23 Incorrect bucket-dump pilot pressure reading

Failure information Bucket-dump pilot pressure reading is incorrect.

Related information

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of 5V Turn the start switch to the ON position and keep it in the ON position
1 while troubleshooting is performed.
Possible causes and standard values

power supply
Between CN-128M ķ and Ĺ Voltage About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Open circuit of Keep it in the OFF position while troubleshooting is performed.
2

.
signal line

De al
Between CN-128M ĸ and controller pin 33 Resistance Under 1ȍ

pt
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Short circuit of Keep it in the OFF position while troubleshooting is performed.
3
signal line
g no
Between CN-128M ĸ and ground Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of sen- Turn the start switch to the ON position and keep it in the ON position
in ti
4 while troubleshooting is performed.
sor
Between CN-128M ĸ and ground
营
销
公
司
Voltage 0.5V- 4.5V
et a

5
n
rk er

Controller
Ma t

CN-128M Bucket dump

（DF-3） pressure sensor
In

Bucket dump Signal

33 2
pressure sensor
Sensor GND 11 3 GND

Sensor 5V 12 1 5V

Operator Station Chassis harness

ZX225-1105031

Fig. 7-55

Shop Manual - April 2014 7-77

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E-24 Incorrect swing pilot pressure reading

Failure information Swing pilot pressure reading is incorrect.

Related information

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of 5V Turn the start switch to the ON position and keep it in the ON position
1 while troubleshooting is performed.
Possible causes and standard values

power supply
Between CN-123M ķ and Ĺ Voltage About 5V

.
Ɣ Turn engine start switch to the OFF position before troubleshooting.

De al
Open circuit of Keep it in the OFF position while troubleshooting is performed.
2

pt
signal line
Between CN-123M ĸ and controller pin 18 Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting.
3
g n
Short circuit of Keep it in the OFF position while troubleshooting is performed.
signal line
o
Between CN-123M ĸ and ground Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting.
in ti

Failure of sen- Turn the start switch to the ON position and keep it in the ON position
4 while troubleshooting is performed.
sor 营
销
公
司

Between CN-123M ĸ and ground Voltage 0.5V- 4.5V

et a
n

5
rk er
Ma t

Controller
In

CN-123M
（DF-3） Swing pilot press. sensor

Swing pilot press. sensor 18 2 Signal

Sensor GND 11 3 GND

Sensor 5V 12 1 5V

Operator station Chassis harness

ZX225-1105032

Fig. 7-56

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SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

E-25 Left travel pilot pressure reading incorrect

Failure information Left Travel Pilot Pressure Reading is incorrect.

Related information

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of 5V Turn the start switch to the ON position and keep it in the ON position
1 while troubleshooting is performed.
Possible causes and standard values

power supply
Between CN-120M ķ and Ĺ Voltage About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Open circuit of

.
2 Keep it in the OFF position while troubleshooting is performed.

De al
signal line
Between CN-120M ĸ and controller pin 34 Resistance Under 1ȍ

pt
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Short circuit of Keep it in the OFF position while troubleshooting is performed.
g n
3
signal line
Between CN-120M ĸ and ground Resistance Above 2Mȍ
o
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Turn the start switch to the ON position and keep it in the ON position
in ti
Failure of sen-
4 while troubleshooting is performed.
sor
Between CN-120M ĸ and ground
营
销
公
司

Voltage 0.5V- 4.5V

et a

5
n
rk er
Ma t

Controller
CN-120M Left travel pilot
In

（DF-3） pressure sensor

Left travel pilot
34 2 Signal
pressure sensor
Sensor GND 11 3 GND

Sensor 5V 12 1 5V

Operator Station Chassis harness

ZX225-1105033

Fig. 7-57

Shop Manual - April 2014 7-79

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

E-26 Right travel pilot pressure reading incorrect

Failure information Right travel pilot pressure reading is incorrect.

Related information

Cause Standard values and troubleshooting references

Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of 5V Turn the start switch to the ON position and keep it in the ON position
1 while troubleshooting is performed.
Possible causes and standard values

power supply
Between CN-121M ķ and Ĺ Voltage About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Open circuit of Keep it in the OFF position while troubleshooting is performed.
2

.
signal line

De al
Between CN-121M ĸ and controller pin 30 Resistance Under 1ȍ

pt
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Short circuit of Keep it in the OFF position while troubleshooting is performed.
3
signal line
g no
Between CN-121M ĸ and ground Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of sen- Turn the start switch to the ON position and keep it in the ON position
in ti
4 while troubleshooting is performed.
sor
Between CN-121M ĸ and ground
营
销
公
司
Voltage 0.5V- 4.5V
et a

5
n
rk er

Controller
Ma t

CN-121M R. travel pilot

（DF-3） press. sensor
In

R. travel pilot press. sensor 30 2 Signal

Sensor GND 11 3 GND

Sensor 5V 12 1 5V

Operator station Chassis harness

ZX225-1105034

Fig. 7-58

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SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

7.6 Troubleshooting Hydraulic and Mechanical Systems (H-mode)

A schematic of hydraulic and mechanical systems ...................................................... 7-82

Information contained in troubleshooting table ............................................................. 7-84
H-1 Work equipment speed slow, or swing and travel speeds slow ............................. 7-85
H-2 Engine speed drops sharply or engine stalls ......................................................... 7-86
H-3 Work equipment, swing, and travel systems do not work ...................................... 7-87
H-4 Abnormal noise in hydraulic pump ......................................................................... 7-88
H-5 Auto deceleration not functioning........................................................................... 7-88
H-6 Boom speed slow .................................................................................................. 7-89
H-7 Arm speed slow ..................................................................................................... 7-90

.
De al
H-8 Bucket speed slow ................................................................................................. 7-91

pt
H-9 Work equipment cylinders no response in separate operation ............................. 7-92
H-10 Work equipment drifts excessively ...................................................................... 7-93
g n
H-11 Work equipment moves sluggishly ..................................................................... 7-96
o
H-12 Other work equipment moves while single oil circuit is relieved .......................... 7-96
in ti

H-13 Travel speed drops considerably while swinging and travelling .......................... 7-97
H-14 Machine deviates during travel ............................................................................ 7-98
司
公
销
营
et a

H-15 Travel speed low .................................................................................................. 7-99

n

H-16 Machine not steered easily or steering power low ............................................. 7-100
H-17 Travel speed cannot be shifted .......................................................................... 7-101
rk er

H-18 Travel system fails (only at one side)................................................................. 7-102

H-19 Swing operation fails.......................................................................................... 7-103
Ma t

H-20 Swing acceleration poor or swing speed low ..................................................... 7-105

In

H-21 Upper structure overrunning remarkably .......................................................... 7-107

H-22 Large shock produced upon swing stoppage .................................................... 7-108
H-23 High noise produced upon swing stoppage ....................................................... 7-109
H-24 Swing drift excessive ..........................................................................................7-110

Shop Manual - April 2014 7-81

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

A schematic of hydraulic and mechanical systems

This diagram is a simpli¿cation of the diagram of the whole hydraulic system and can be referred
to in troubleshooting the hydraulic and mechanical systems.

L. pilot valve Travel pilot valve R. pilot valve

Arm Swing L. travel R. travel Boom Bucket

RIGHT

DOWN
LEFT

DUMP
BWD
FWD
OUT

BWD
FWD

DIG
IN

UP

.
De al
Pilot valve

pt
16
Boom priority

1 2 3 4 15
g n 5 6 7 8 9 10 11 12 Bucket conflu.
14
Swing priority
o
13
in ti
Travel speed
change
Accumulator
司
公
销
营
et a
n

1
rk er

3
Ma t

19 20
In

17 18

Regulator Regulator

Servo Servo

P1 P2
M
FRONT REAR

ZX225-1105039
Fig. 7-59

7-82 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

6DSafety valve
6X
Suction valve

6 6 Safety & suction valve

1 Standby valve Bucket conf-

luence valve 15
confluence
Arm retai-
ner valve

1 S&S Arm regener-

S&S 2
ation valve
1 Arm 2 valve 2
14
Arm cylinder

Bucket S&S
Bucket 12 S&S Standby
S&S
10 11 valve S&S valve Standby actuating element
Cylinder
9
Boom retai-

.
ner valve

De al

Anti-swing
Boom

pt
Boom
9 S&S S&S 10
Boom 2
9

Su
valve
valve
Cylinder
Swing motor

Sa

Anti-swing
Su
g n 13 Brake release valve

valve
5 Su L. travel
valve
Su 6 3 Swing valve
4
o
13
Balance valve
Sa

Servo

R. travel
in ti
Straight travel 7 Su valve
Su 8

Balance valve
vavle

Sa
Sa

Servo
Sa
司
公
销
营

Left travel motor

et a

Right travel motor

n

1
rk er

2
3
Ma t

ZX225-1105040
Fig. 7-60
In

Shop Manual - April 2014 7-83

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

Information contained in troubleshooting table

● The following information is contained in the troubleshooting table and related electric circuit
diagrams. Fully understand these information before carrying out troubleshooting.

Failure information Trouble which occurs on the machine

Related information Information related to detected trouble or troubleshooting

Cause Standard values and troubleshooting references

1
Possible causes and standard values

.
De al
pt
2
g n
3 Possible causes of
● < Description >
o
trouble (Given num-
● Standard value in normal state, which is used to judge possible
4 bers are reference
in ti
causes that might be OK or N/G.
numbers, which do
not indicate priority) ● A reference value is used to determine OK or N/G.
营
销
公
司
et a

5
n
rk er
Ma t
In

7-84 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

H-1 Work equipment speed slow, or swing and travel speeds slow

● Work equipment speed is slow or the travel and swing speeds

Failure information
are slow.
● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

● Stop the engine before troubleshooting. Perform troubleshooting while

the engine is running at high idle.
Defective adjust-
Possible causes and standard values

.
Control levers Main relief pressure

De al
ment or malfunc-
1

pt
tion of main relief 33~34.3 MPa
Arm IN
valveg n {337~350 kg/cm2}
If normal pressure cannot be restored after adjustment, it is possible the
o
failure of main relief valve or internal defect. Check the valve directly.
● Stop the engine before troubleshooting. Perform troubleshooting while
in ti

the engine is running at high idle.

Malfunction of Control levers Pilot control pressure
2
司
公
销
营

pilot relief valve

et a

3.9~4.1 MPa
All levers in NEUTRAL
{40~42 kg/cm2}
n

Malfunction of
3 The regulator possibly fails. Check the servo mechanism of the regulator.
rk er

regulator
Malfunction of If the trouble is caused by other factors, it might be the main pump that
4
main pump has performance deterioration, malfunction or internal defect.
Ma t
In

Shop Manual - April 2014 7-85

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

H-2 Engine speed drops sharply or engine stalls

Failure information ● Engine speed drops sharply or engine stalls.

Related information ● Information concerned

Cause Standard values and troubleshooting references

Failure of injection
Possible causes and standard values

1 Injection pump may be defective. Check it directly.

pump
Malfunction of
2 Regulator may have malfunction. Check its servo mechanism.
regulator
Clogging of oil filter
3 Oil filter element may be clogged. Check the element directly.

.
element

De al
Carbon buildup at

pt
4 fuel injection noz- Carbon built up at fuel injection nozzle. Check it directly.
zle
5
g n
Clogging of air
Air cleaner may be clogged. Check it directly.
cleaner
o
Abnormal wear of
6 Engine may be worn abnormally. Check it directly.
in ti

engine
7 Failure of oil pump Oil pump may be defective. Check it directly.
营
销
公
司
et a
n
rk er
Ma t
In

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SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

H-3 Work equipment, swing, and travel systems do not work

Failure information ● Whole work equipment, swing, and travel systems do not work.
● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

● Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.
Pilot lockout control lever Pilot relief pressure
Malfunction of pilot
1 LOCKED 0 {0}
relief solenoid valve

.
Possible causes and standard values

De al
3.9~4.1 MPa
FREE

pt
{40~42 kg/cm2}
g n ● Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.
Failure of relief valve Control lever Pilot relief pressure
o
2
(pilot pump)
3.9~4.1 MPa
in ti
All levers in NEUTRAL
{40~42 kg/cm2}
The main pump may have malfunction or internal defect. Check it by
营
销
公
司

following method.
et a

Failure of hydraulic
3 ● Remove the oil pressure measurement plug and start the en-
pump
n

gine. If oil flows out of the opening, the piston pump is in good
condition.
rk er

Internal failure of the coupling can stop rotation of the pump shaft.
Check the coupling.
4 Failure of coupling
Ma t

● Loosen the oil delivery line of the pilot pump. If no oil is seen, it
is probably the failure of coupling.
In

Shop Manual - April 2014 7-87

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

H-4 Abnormal noise in hydraulic pump

Failure information ● Abnormal noise is produced from the hydraulic pump

Related information ―

Cause Standard values and troubleshooting references

Possible causes and standard values

Low level of
1 Make a visual check.
hydraulic oil
Inferior hy-
2 Hydraulic oil probably contains air. Make a visual check.
draulic oil
Clogging of It is probably the clogging of the vent on top of the hydraulic tank that

.
De al
3 vent on top of causes negative pressure in the hydraulic tank. Press the release button

pt
hydraulic tank of the breather valve to eliminate air. Check again if the noise disappears.
Clogging of
It is probably the clogging of hydraulic tank strainer that causes negative
g n
4 hydraulic tank
pressure in the oil suction line. Make a visual check.
strainer
o
Failure of
5 The main pump may have internal defect. Check the main pump.
in ti

main pump

司
公
销
营
et a

H-5 Auto deceleration not functioning

n

Failure information ● Auto-deceleration is not functioning.

rk er

● Set working mode to S and fuel control dial at position 10 to carry

Related information
out troubleshooting.
Ma t

Cause Standard values and troubleshooting references

In

● Stop the engine before troubleshooting. Perform troubleshooting while

Possible causes and standard values

the engine is running at high idle.

Control levers Pilot valve output pressure
Sensor fail-
1 NEUTRAL 0 {0}
ure
3.5~4.1MPa
Operation
{36~42 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshooting while
the engine is running at high idle.
Failure of Control levers Pilot valve output pressure
2
pilot valve NEUTRAL 0 {0}
3.5~4.1MPa
Operation
{36~42 kg/cm2}
Controller
3 Controller may be defective. Check it directly.
failure

7-88 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

H-6 Boom speed slow

Failure information ● The boom moves slowly.

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

● Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.
Malfunction of right Boom control lever Pilot valve output pressure
1 pilot valve (boom NEUTRAL 0 {0}

.
circuit)

De al
Boom UP ≥ 3.5MPa

pt
Boom DOWN {36 kg/cm2}
Malfunction of boom
g n 2 Spool of boom control valve may have malfunction. Check it directly.
Possible causes and standard values

control valve (spool)

o
● Stop the engine before troubleshooting. Perform troubleshooting
3 Press sensor failure while the engine is running at high idle.
in ti

Check the sensor by replacing it with a new one.

Malfunction of boom
Retaining valve of boom control valve may have malfunction. Check
销
公
司

4 control valve (retain-

营

the valve directly.

et a

ing valve)
Malfunction or de-
n

fective seal of boom

The relief valve and makeup valve in boom control valve may have
rk er

5 control valve
malfunction or defective seal. Check the valves directly.
(Relief valve and
makeup valve)
Ma t

● Stop the engine before troubleshooting. Perform troubleshooting

while the engine is running at high idle.
In

Charge the bucket with a load of approximate 1260 kg. Cut off the oil
passage to the high-pressure side of the cylinder. Disconnect the cyl-
Failure of boom
6 inder from the main valve. Measure the displacement of piston for 15
cylinder
minutes after the cylinder becomes stable. If the measured value is
greater than 10 mm, it is deemed that cylinder has a defective seal.
For more information on the measuring procedure see "Hydraulic
Drift of Work Equipment - Test" on page 6-34.

Shop Manual - April 2014 7-89

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

H-7 Arm speed slow

Failure information ● The arm moves slowly.

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

● Stop the engine before troubleshooting. Perform troubleshooting while
the engine is running at high idle.
Malfunction of left Arm control lever Pilot valve output pressure
1 pilot valve (arm NEUTRAL 0 {0}
circuit)

.
De al
≥ 3.5MPa
Arm IN or Arm OUT

pt
{36 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshooting while
Possible causes and standard values

g n
2 Press sensor failure the engine is running at high idle.
Check the sensor by replacing it with a new one.
o
Malfunction of arm
in ti
3 Spool of arm control valve may have malfunction. Check it directly.
control valve (spool)
Malfunction of arm
Regeneration valve of arm control valve may have malfunction.
营
销
公
司

4 control valve (re-

et a

Check it directly.
generation valve)
Malfunction or de-
n

fective seal of arm

The relief valve or makeup valve inside the arm control valve may have
rk er

5 control valve (Relief

malfunction or defective seal. Check the valves directly.
valve and makeup
valve)
Ma t

● Stop the engine before troubleshooting. Perform troubleshooting while

the engine is running at high idle.
In

Cut off the oil passage to the high-pressure side of the cylinder. Discon-
Failure of arm cylin- nect the cylinder from the main valve. Measure the displacement of piston
6
der for 15 minutes after the cylinder becomes stable. If the measured value is
greater than 10 mm, it is deemed that cylinder has a defective seal. For
more information on the measuring procedure see "Hydraulic Drift of
Work Equipment - Test" on page 6-34.

7-90 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

H-8 Bucket speed slow

Failure information ● The bucket moves slowly.

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

● Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.
Malfunction of right Bucket control lever Pilot valve output pressure
1 pilot valve (bucket NEUTRAL 0 {0}

.
circuit)

De al
≥ 3.5MPa
Bucket DIG or Bucket DUMP

pt
{36 kg/cm2}
Possible causes and standard values

● Stop the engine before troubleshooting. Perform troubleshooting

g n2 Press sensor failure
o
while the engine is running at high idle.
Check the sensor by replacing it with a new one.
Malfunction of
in ti

3 bucket control valve Spool of bucket control valve may have malfunction. Check it directly.
(spool) 营
销
公
司

Malfunction or
et a

defective seal of
Relief valve and makeup valve in bucket control valve may have mal-
n

4 bucket control valve

function or defective seal. Check the valves directly.
(relief valve and
rk er

makeup valve)
● Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.
Ma t

Charge the bucket with a load of approximate 1260 kg. Cut off the oil
passage to the high-pressure side of the cylinder. Disconnect the cyl-
In

Failure of bucket
5 inder from the main valve. Measure the displacement of piston for 15
cylinder
minutes after the cylinder becomes stable. If the measured value is
greater than 10 mm, it is deemed that cylinder has a defective seal.
For more information on the measuring procedure see "Hydraulic
Drift of Work Equipment - Test" on page 6-34.

Shop Manual - April 2014 7-91

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

H-9 Work equipment cylinders no response in separate operation

● Boom cylinder gives no response in separate operation.

Failure information ● Arm cylinder gives no response in separate operation.
● Bucket cylinder gives no response in separate operation.
● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

Possible causes and standard values

● Stop the engine before troubleshooting. Perform troubleshooting

.
while the engine is running at high idle.

De al
Work equipment control lever Pilot valve output pressure

pt
Malfunction of pilot
1 NEUTRAL 0 {0}
valve
g n ≥ 3.5MPa
DIG or DUMP
{36 kg/cm2}
o
● Stop the engine before troubleshooting. Perform troubleshooting
in ti

2 Press sensor failure while the engine is running at high idle.

Check the sensor by replacing it with a new one.
营
销
公
司
et a

Malfunction of con-
3 Spool of control valve may have malfunction. Check it directly.
trol valve (spool)
n
rk er
Ma t
In

7-92 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

H-10 Work equipment drifts excessively

Failure information (1) ● The boom drifts at excessive speed.

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

● Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.
Charge the bucket with a load of approximate 1260 kg. Cut off the oil
Possible causes and standard values

passage to the high-pressure side of the cylinder. Disconnect the cyl-

Failure of boom

.
1 inder from the main valve. Measure the displacement of piston for 15

De al
cylinder
minutes after the cylinder becomes stable. If the measured value is

pt
greater than 10 mm, it is deemed that cylinder has a defective seal. For
more information on the measuring procedure see "Hydraulic Drift of
g n Work Equipment - Test" on page 6-34.
Failure of boom Boom retaining valve or pilot valve may be worn or sluggish. Check the
o
2
retaining valve valves.
in ti

Malfunction or
defective seal of
The relief valve and the makeup valve in the boom control valve may
公
司

3 boom control valve

销
营

have a defective seal. Check the seals.

et a

(relief valve and

makeup valve)
n

Failure of boom
4 Spool of boom valve may be worn excessively. Check the spool.
rk er

valve spool
Ma t
In

Shop Manual - April 2014 7-93

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

Failure information (2) ● The arm drifts excessively.

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

● Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.
Possible causes and standard values

Cut off the oil passage to the high-pressure side of the cylinder. Discon-
Failure of arm nect the cylinder from the main valve. Measure the displacement of pis-
1
cylinder ton for 15 minutes after the cylinder becomes stable. If the measured
value is greater than 10 mm, it is deemed that cylinder has a defective
seal. For more information on the measuring procedure see "Hydraulic

.
Drift of Work Equipment - Test" on page 6-34.

De al
Malfunction or Relief valve or makeup valve of the arm control valve may be defective.

pt
defective seal of Check the valves directly.
2 arm control valve ★ The performance of seal can be judged by replacing it with another
g n
(relief valve and relief valve or makeup valve.(Never replace it with the boom-down
o
makeup valve) relief valve or makeup valve as their pressures are set differently.)
Failure of arm Arm retaining valve or pilot valve may be worn or sluggish. Check the
in ti

3
retaining valve valves.
Failure of arm
4 Arm valve (spool) may be worn excessively. Check it directly.
司
公
销
营

valve (spool)
et a
n
rk er
Ma t
In

7-94 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

Failure information (3) ● The bucket drifts excessively.

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

Possible causes and standard values

● Stop the engine before troubleshooting. Perform troubleshooting

Failure of bucket while the engine is running at high idle.
1 Bucket control levers Leakage from bucket cylinder
cylinder
Bucket-dig relief 20 ml/min
Seal of relief valve or makeup valve of bucket control valve may be
Defective seal of defective. Check it directly.
bucket control valve ★ The performance of seal can be judged by replacing it with anoth-

.
2

De al
(relief valve and er relief valve or makeup valve. (Never replace it with the boom-

pt
makeup valve) down relief valve or makeup valve as their pressures are set dif-
ferently. )
g n Defective seal of
Seal of bucket control valve spool may be defective. Check it direct-
3 bucket control valve
o
ly.
(spool)
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 7-95

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

H-11 Work equipment moves sluggishly

Failure information ● Work equipment moves sluggishly.

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.
Possible causes and standard values

Cause Standard values and troubleshooting references

Malfunction of
1 arm regenera- Regeneration valve of arm may have malfunction. Check it directly.
tion valve

.
Relief valve or makeup valve of control valve may have malfunction.

De al
Malfunction of Check it directly.

pt
control valve ● For arm and boom, whether a valve has malfunction can be judged
2
(relief valve and by replacing it with another relief valve or makeup valve.
g n
makeup valve) (Never replace it with the boom-down relief valve or makeup valve as
o
their pressures are set differently. )
in ti

司
公
销
营
et a

H-12 Other work equipment moves while single oil circuit is relieved
n
rk er

● Other work equipment moves while single oil circuit of certain work equip-
Failure information
ment is relieved.
Related information ● Set the working mode to S to perform troubleshooting.
Ma t
In

Cause Standard values and troubleshooting references

Possible causes and standard values

Defective seal
1 Seal of control valve may be defective. Check it directly.
of control valve

7-96 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

H-13 Travel speed drops considerably while swinging and travelling

Failure information ● Travel speed drops considerably in swinging plus travelling operation.
● If the travel speed is low in only travelling operation, check first ac-
Related information
cording to H-15.
Possible causes and standard values

Cause Standard values and troubleshooting references

.
De al
Failure of straight The straight travel valve gives no response. Check the spool and
1

pt
travel valve the logic oil circuit drain port.
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 7-97

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

H-14 Machine deviates during travel

Failure information ● Machine deviates during travel.

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

● Stop the engine before troubleshooting. Perform trouble-
shooting while the engine is running at high idle.
Travel control lever Pilot valve output pressure
Malfunction of travel pilot
1 Forward 3.5~3.9 MPa
valve

.
Reverse { 36~40 kg/cm2}

De al
Difference occurs between

pt
0.4 MPa {4 kg/cm2}
left and right output
● Stop the engine before troubleshooting. Perform trouble-
g n shooting while the engine is running at high idle.
Malfunction of pilot relief
o
2 Control lever Control circuit source pressure
valve
3.5~3.9 MPa
in ti

All levers in NEUTRAL

{ 36~40 kg/cm2}
Possible causes and standard values

司
公
销

3 Failure of regulator Check the regulator by swapping the front and back regulators.
营
et a

● Stop the engine before troubleshooting. Perform trouble-

shooting while the engine is running at high idle.
n

Sluggishness of propor-
4 Travel control lever Proportional valve output pressure
tional solenoid valve
rk er

Operate both control levers ≤ 0.1 MPa

Sluggishness of travel con-
5 Check the valve spool to see whether it works well.
trol valve (spool)
Ma t

Internal leakage of central

6 Check it by swapping the lines.
In

swivel joint
● Stop the engine before troubleshooting. Perform trouble-
shooting while the engine is running at high idle.
7 Malfunction of travel motor Travel control lever Leakage of travel motor
Travel relief 27.2 ml/min
Final drive may have internal defect. Check it directly.
● Internal defect of the final drive can be determined through
8 Failure of final drive
abnormal noise, abnormal heat, and metal powder or debris
contained in the oil drained.
Travel control levers Pilot valve output pressure
The monitor reads:
Forward or backward 3.5~3.9MPa
Failure of travel pilot pres-
9 { 36~40 kgf/cm2}
sure sensor
Output difference between the
0.4 MPa {4 kgf/cm2}
left and the right
Check it by swapping.

7-98 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

H-15 Travel speed low

Failure information ● Machine travel speed is low.

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

● Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.
Travel control lever Pilot valve output pressure
Malfunction of travel
1 3.5~3.9 MPa

.
pilot valve Forward or reverse

De al
{ 36~40 kg/cm2}

pt
Difference occurs between front ≤ 0.4 MPa
g n output and rear output ≤ {4 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.
o
Malfunction of pilot Control lever Control circuit source pressure
2
Possible causes and standard values

relief valve
in ti

3.5~3.9 MPa
All levers in NEUTRAL
营
销
公
司
{ 36~40 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshooting
et a

while the engine is running at high idle.

n

Travel speed Travel control

3.5~3.9 MPa
rk er

3 Sensor failure Low Operation

{ 36~40 kgf/cm2}
3.5~3.9 MPa
High Operation
{ 36~40 kgf/cm2}
Ma t

Check it by replacement.
Malfunction of travel
In

4 Spool of travel control valve may have malfunction. Check it directly.

control valve (spool)
Malfunction of
The makeup valve in travel control valve may have malfunction. Check it
5 travel control valve
directly.
(makeup valve)
● Stop the engine before troubleshooting. Perform troubleshooting
Failure of travel mo- while the engine is running at high idle.
6 Travel control lever Oil leakage of travel motor
tor
Travel relief 27.2 ml/min
Final drive may have internal defect. Check it directly.
● Internal defect of the final drive can be determined through abnormal
7 Failure of final drive
noise, abnormal heat, and metal powder or debris contained in the
oil drained.

Shop Manual - April 2014 7-99

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

H-16 Machine not steered easily or steering power low

Failure information ● Machine is not steered well or steering power is low

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

● Stop the engine before troubleshooting. Perform troubleshoot-
ing while the engine is running at high idle.
Malfunction of travel Travel control lever Pilot valve output pressure
1
pilot valve Both sides in NEUTRAL 0 {0}

.
De al
3.5~3.9 MPa
Either side operated
{ 36~40 kg/cm2}

pt
● Stop the engine before troubleshooting. Perform troubleshoot-
Possible causes and standard values

ing while the engine is running at high idle.

g n Travel control lever Pilot valve output pressure
Failure of travel pilot
o
2 3.5~3.9 MPa
pressure sensor Both sides operated
{ 36~40 kgf/cm2}
in ti

3.5~3.9 MPa
Either side operated
营
销
公
司 { 36~40 kg/cm2}
Malfunction of travel Spool of travel control valve may have malfunction. Check it direct-
et a

3
control valve (spool) ly.
n

Malfunction of travel
The makeup valve in travel control valve may have malfunction.
4 control valve (makeup
rk er

Check it directly.
valve)
Seal of relief valve in travel motor may be defective. Check it di-
Failure of travel motor rectly.
Ma t

5
(relief valve) ● The failure of seal can be determined by swapping the front
In

and back motors or the left and right motors.

Seal of check valve in travel motor may be defective. Check it di-
Failure of travel motor rectly.
6
(check valve) ● The failure of seal can be determined by swapping the front
and back motors or the left and right motors.

7-100 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

H-17 Travel speed cannot be shifted

Failure information ● Travel speed cannot be shifted.

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

Possible causes and standard values

● Stop the engine before troubleshooting. Perform troubleshooting

while the engine is running at high idle.
Solenoid valve output
Malfunction of travel Travel speed Travel control lever
pressure
1 speed shifting sole-

.
noid valve Lo Operated 0 {0}

De al
3.5~3.9 MPa

pt
Hi Operated
g n { 36~40 kg/cm2}

Failure of travel mo- Speed shifting assembly of travel motor may have malfunction.
o
2
tor (in speed change) Check it directly.
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 7-101

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

H-18 Travel system fails (only at one side)

Failure information ● One side of the tracks cannot make a turn.

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

Defective seat of
Seat of makeup valve in travel control valve may have malfunction.
1 travel control valve
Check it directly.
(makeup valve)
Defective seat of
Seat of relief valve in travel control valve may have malfunction.

.
2 travel motor (relief

De al
Check it directly.
valve)

pt
Possible causes and standard values

Defective seat of
Seat of check valve in travel motor valve may have malfunction.
3 travel motor valve
g n
(makeup valve)
Check it directly.
● Stop the engine before troubleshooting. Perform troubleshooting
o
Speed of travel mo- while the engine is running at high idle.
in ti
4 Travel control lever Leakage from travel motor
tor drops.
Travel relief
营
销
公
司 27.2 ml/min
Final drive may have internal defect. Check it directly.
et a

● Internal defect of final drive can be determined with abnormal

5 Failure of final drive
n

noise, overheat, and metal powder or debris contained in the oil

drained.
rk er

● Stop the engine before troubleshooting. Perform troubleshooting

while the engine is running at high idle.
Travel control lever Pilot valve output pressure
Ma t

Failure of pilot pres- The monitor read: 3.5~3.9 MPa

6 Forward or backward
sure sensor { 36~40 kgf/cm2}
In

Output difference between the left

0.4 MPa {4 kgf/cm2}
and the right
Check it by swapping.

7-102 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

H-19 Swing operation fails

Failure information (1) ● Upper structure fails to swing in either direction.

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

Malfunction of
1 swing motor (park- Parking brake of swing motor may have malfunction. Check it directly.
ing brake)
● Stop the engine before troubleshooting. Perform troubleshooting
Possible causes and standard values

while the engine is running at high idle.

.
De al
Improper adjust- Swing control lever Swing relief pressure

pt
ment or malfunc- 25.5~28.5 MPa
2 Swing relief
tion of swing motor {260~291 kg/cm2}
g n (relief valve) If oil pressure does not become normal after adjustment, swing motor
o
relief valve may have malfunction or internal defect. Check the relief
in ti
valve directly.
● Stop the engine before troubleshooting. Perform troubleshooting
Failure of swing while the engine is running at high idle.
营
销
公
司

3 Swing control lever Leakage from swing motor

et a

motor
Swing relief ≥ 10 ml/min
n

Swing mechanism may have internal defect. Check it directly.

rk er

Failure of swing ● Internal defect of swing mechanism can be determined with ab-
4
mechanism normal noise, overheat, and metal powder or debris contained in
the oil drained.
Ma t
In

Shop Manual - April 2014 7-103

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

Trouble (2) ● Upper structure only fails to swing in one direction.

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

Possible causes and standard values

● Stop the engine before troubleshooting. Perform troubleshooting

while the engine is running at high idle.
Malfunction of Left control lever Pilot valve output pressure
1
pilot valve
NEUTRAL 0 {0}
Swing ≥ 3.5MPa { ≥ 36 kg/cm2}
Malfunction of

.
2 swing control Spool of swing control valve may have malfunction. Check it directly.

De al
valve (spool)

pt
Defective seal Seal of makeup valve in swing motor may have defect. Check it directly.
3 of swing motor ● Failure of the seal can be determined by swapping the right and left
g n
(makeup valve)
o
makeup valves and check for any changes.
in ti

司
公
销
营
et a
n
rk er
Ma t
In

7-104 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

H-20 Swing acceleration poor or swing speed low

Failure information (1) ● Swing acceleration is poor, or swing speed is low.

● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

Malfunction of
1 swing motor (park- Parking brake of swing motor may have malfunction. Check it directly.
ing brake)
Possible causes and standard values

● Stop the engine before troubleshooting. Perform troubleshooting

while the engine is running at high idle.

.
De al
Improper adjust- Swing control lever Swing relief valve

pt
ment or malfunc- 25.5~28.5 MPa
2 Swing relief
tion of swing motor {260~291 kg/cm2}
g n
(relief valve) If oil pressure does not become normal after adjustment, swing motor
o
relief valve may have malfunction or internal defect. Check the relief
valve directly.
in ti

● Stop the engine before troubleshooting. Perform troubleshooting

Failure of swing while the engine is running at high idle.
营
销
公
司

3 Swing control lever Leakage from swing motor

et a

motor
Swing relief ≤ 10 ml/min
n

Clogging of brake
4 Disassemble, clean and check.
rk er

control lines
Ma t
In

Shop Manual - April 2014 7-105

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

● Swing acceleration is only poor on one side, or swing speed is

Failure information (2)
low.
● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

● Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.
Malfunction of Swing control lever Pilot valve output pressure
1
Possible causes and standard values

pilot valve NEUTRAL 0 {0}

Left swing
≥ 3.5MPa { ≥ 36 kg/cm2}
Right swing

.
De al
Malfunction of

pt
swing motor Pressure compensation valve of swing motor may have malfunction.
2
(pressure com- Check it directly.
g n
pensation valve)
Defective seal Seal of makeup valve in swing motor may have defect. Check it directly.
o
3 of swing motor ● Swap the left and right makeup valves and observe the result to de-
in ti
(makeup valve) termine whether the seal fails.
● Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.
司
公
销

One-side leak-
营
et a

age of swing pilot Swing control lever Pilot valve output pressure
4
pressure sensor NEUTRAL 0 {0}
n

(shuttle valve) Left swing

3.5~3.9MPa {36~40 kg/cm2}
rk er

Right swing
Ma t
In

7-106 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

H-21 Upper structure overrunning remarkably

● Upper structure overruns remarkably when it stops swinging in

Failure information (1)
both directions.
● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

Possible causes and standard values

● Stop the engine before troubleshooting. Perform troubleshooting

while the engine is running at high idle.
Improper adjust- Swing control lever Swing relief pressure

.
ment or malfunc- 25.5~28.5 MPa

De al
1 Swing relief
tion of swing motor {260~291 kg/cm2}

pt
(relief valve) If oil pressure does not become normal after adjustment, swing motor
relief valve may have malfunction or internal defect. Check the relief
g n
valve directly.
o
● Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.
in ti
Failure of swing
2 Control lever Leakage from swing motor
motor
Swing relief ≤ 10 ml/min
司
公
销
营
et a
n

● Swing acceleration is only poor on one side, or swing speed is

rk er

Failure information (2)

low.
● Set the working mode at gear (10) of power mode (S) to perform
Related information
troubleshooting.
Ma t
In

Cause Standard values and troubleshooting references

Possible causes and standard values

● Stop the engine before troubleshooting. Perform troubleshooting

while the engine is running at high idle.
Malfunction of pilot Swing control lever Pilot valve output pressure
1
valve NEUTRAL 0 {0}
Left swing
≥ 3.5MPa { ≥ 36 kg/cm2}
Right swing
Malfunction of swing
2 Spool of swing control valve may have malfunction. Check it directly.
control valve (spool)
Seal of makeup valve in swing motor may be defective. Check it di-
Defective seal of
rectly.
3 swing motor (make-
● Swap the left and right makeup valves and observe the result to
up valve)
determine whether the seal fails.

Shop Manual - April 2014 7-107

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

H-22 Large shock produced upon swing stoppage

Failure information ● Large shock is produced when upper structure stops swinging.
● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

Possible causes and standard values

● Stop the engine before troubleshooting. Perform troubleshooting

while the engine is running at high idle.

Malfunction of swing Swing control lever Pilot valve output pressure

1
pilot valve NEUTRAL 0 {0}

.
De al
Left swing
≥ 3.5MPa { ≥ 36 kg/cm2}

pt
Right swing
Reverse prevention valve of swing motor may have malfunction.
g n
Malfunction of swing
Check it directly.
2 reverse prevention
o
● Replace the valve with a new on to determine whether the valve
valve
fails.
in ti

Malfunction of swing
3 Swing relief valve may be worn or sluggish.
relief valve 营
销
公
司
et a
n
rk er
Ma t
In

7-108 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

H-23 High noise produced upon swing stoppage

Failure information ● High noise is produced when upper structure stops swinging.
● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.

Cause Standard values and troubleshooting references

Malfunction of
Possible causes and standard values

1 back pressure Back pressure valve may have malfunction. Check it directly.
valve
Malfunction of

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

pt
(relief valve)
Seal of makeup valve in swing motor may have malfunction. Check it di-
Malfunction of
rectly.
g n
3 swing motor
● Swap the left and right makeup valves and observe the result to deter-
o
(makeup valve)
mine whether the seal fails. .
in ti
The swing mechanism is suspected of an internal failure. Check the inside
of the machinery itself.
Failure of swing
4 ● Internal defect of swing mechanism can be determined with abnor-
司
公
销
营

mechanism
et a

mal noise, overheat, and metal powder or debris contained in the oil
drained.
n
rk er
Ma t
In

Shop Manual - April 2014 7-109

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

H-24 Swing drift excessive

● Hydraulic drift of swing is large (when swing holding brake is ap-

Failure information (1)
plied).
● When swing lock switch is turned ON or when swing holding
Related information brake release switch is in normal position, swing holding brake
operates and upper structure is fixed with disc brake.

Cause Standard values and troubleshooting references

Possible causes and standard values

Failure of swing
Swing holding brake control lines and holding brake pilot valve may be

.
1 holding brake

De al
defective. Check them directly.
control lines

pt
g n
Malfunction of
o
2 swing motor Parking brake of swing motor may have malfunction. Check it directly.
in ti
(parking brake)

司
公
销
营
et a
n

● Hydraulic drift of swing is large (when swing holding brake is re-

Failure information (2)
rk er

leased).
● When swing holding brake release switch is in release position,
Related information swing holding brake is released and upper structure is secured
by only hydraulic pressure.
Ma t
In
Possible causes and standard values

Cause Standard values and troubleshooting references

Malfunction or de-
Swing control valve spool may have malfunction or defective seal.
1 fective seal of swing
Check it directly.
control valve (spool)

Failure of swing mo-

2 Seal of relief valve in swing motor may be defective. Check it directly.
tor (relief valve)

Failure of swing mo- Seal of makeup valve in swing motor may be defective. Check it di-
3
tor (makeup valve) rectly.

7-110 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting

tE.
PAD nal
eGp
ng o
i
tKi t

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公
销
营
a
AkNe rn
e
BLMaInt
r

Shop Manual - April 2014 7-111

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator

tE.
DG al
ep
gA no
i
tKi t
nP

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销
营
a
kNe rn
aAr et
BLM In

7-112 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

Disassembly and Assembly

.
8 Disassembly and Assembly

De al
pt
8.1 How to Read This Manual ....................................................................................... 8-5
8.1.1 Removing and installing an assembly............................................................ 8-5
g n
8.2 Operating Precautions ............................................................................................. 8-6
o
8.3 Start Motor AS ........................................................................................................ 8-9
in ti

8.3.1 Removal ......................................................................................................... 8-9

8.3.2 Installation ...................................................................................................... 8-9
营
销
公
司
et a

8.4 Fuel Injection Pump AS ........................................................................................ 8-10

8.4.1 Removal ....................................................................................................... 8-10
n

8.4.2 Installation .................................................................................................... 8-12

rk er

8.5 Engine Front Oil Seal ............................................................................................ 8-13

8.5.1 Removal ....................................................................................................... 8-13
Ma t

8.5.2 Installation .................................................................................................... 8-13

In

8.6 Engine Rear Oil Seal ............................................................................................ 8-14

8.6.1 Removal ....................................................................................................... 8-14
8.6.2 Installation .................................................................................................... 8-14
8.7 Cylinder Head AS .................................................................................................. 8-15
8.7.1 Removal ....................................................................................................... 8-15
8.7.2 Installation .................................................................................................... 8-19
8.8 Radiator AS ........................................................................................................... 8-20
8.8.1 Removal ....................................................................................................... 8-20
8.8.2 Installation .................................................................................................... 8-23
8.9 Engine and Hydraulic Pump AS ............................................................................ 8-24
8.9.1 Removal ....................................................................................................... 8-24
8.9.2 Installation .................................................................................................... 8-30
8.10 Final Drive AS ..................................................................................................... 8-31
Shop Manual - April 2014 8-1
Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.10.1 Removal ..................................................................................................... 8-31

8.10.2 Installation .................................................................................................. 8-32
8.11 Final Drive AS ...................................................................................................... 8-33
8.11.1 Disassembly ............................................................................................... 8-33
8.11.2 Assembly .................................................................................................... 8-36
8.12 Swing Motor and Swing Drive AS ....................................................................... 8-42
8.12.1 Removal ..................................................................................................... 8-42
8.12.2 Installation .................................................................................................. 8-43
8.13 Swing Motor and Swing Drive AS ....................................................................... 8-44
8.13.1 Disassembly............................................................................................... 8-44
8.13.2 Assembly.................................................................................................... 8-49

.
De al
8.14 Idler AS ............................................................................................................... 8-54

pt
8.14.1 Disassembly............................................................................................... 8-54
g n
8.14.2 Assembly.................................................................................................... 8-55
8.15 Sprocket .............................................................................................................. 8-58
o
8.15.1 Removal ..................................................................................................... 8-58
in ti

8.15.2 Installation .................................................................................................. 8-58

8.16 Track AS ............................................................................................................. 8-59
司
公
销
营
et a

8.16.1 Removal ..................................................................................................... 8-59

n

8.16.2 Installation .................................................................................................. 8-60

8.17 Swing Bearing AS ............................................................................................... 8-62
rk er

8.17.1 Removal ..................................................................................................... 8-62

8.17.2 Installation .................................................................................................. 8-63
Ma t

8.18 Swing frame AS .................................................................................................. 8-64

In

8.18.1 Removal ..................................................................................................... 8-64

8.18.2 Installation .................................................................................................. 8-66
8.19 Swivel Joint AS .................................................................................................... 8-67
8.19.1 Removal ..................................................................................................... 8-67
8.19.2 Installation .................................................................................................. 8-69
8.20 Central Swivel Joint AS ....................................................................................... 8-70
8.20.1 Disassembly............................................................................................... 8-70
8.20.2 Assembly.................................................................................................... 8-70
8.21 Hydraulic Tank AS ............................................................................................... 8-71
8.21.1 Removal ..................................................................................................... 8-71
8.21.2 Installation .................................................................................................. 8-73
8.22 Control Valve AS .................................................................................................. 8-74

8-2 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.22.1 Removal ..................................................................................................... 8-74

8.22.2 Installation .................................................................................................. 8-79
8.23 Hydraulic Pump AS ............................................................................................. 8-80
8.23.1 Removal ..................................................................................................... 8-80
8.23.2 Installation .................................................................................................. 8-83
8.24 Middle Oil Seal (Hydraulic Pump Input Shaft) ..................................................... 8-84
8.24.1 Removal ..................................................................................................... 8-84
8.24.2 Installation .................................................................................................. 8-84
8.25 Pilot Valve AS (Work Equipment) ....................................................................... 8-85
8.26 Travel Pilot Valve AS ........................................................................................... 8-86
8.27 Hydraulic Cylinder AS ......................................................................................... 8-87

.
De al
8.27.1 Disassembly............................................................................................... 8-88

pt
8.27.2 Assembly.................................................................................................... 8-92
g n
8.28 Work Equipment AS ............................................................................................ 8-97
8.28.1 Removal ..................................................................................................... 8-97
o
8.28.2 Installation .................................................................................................. 8-99
in ti

8.29 Air Conditioner AS ............................................................................................. 8-100

8.29.1 Removal ................................................................................................... 8-100
司
公
销
营
et a

8.29.2 Installation ................................................................................................ 8-103

n

8.30 Counterweight AS ............................................................................................. 8-104

8.30.1 Removal ................................................................................................... 8-104
rk er

8.30.2 Installation ................................................................................................ 8-105

8.31 Cab AS .............................................................................................................. 8-106
Ma t

8.31.1 Removal ................................................................................................... 8-106

In

8.31.2 Installation ................................................................................................ 8-109

8.32 Cab Window Glass ............................................................................................8-110
8.32.1 Removal ....................................................................................................8-111
8.32.2 Installation .................................................................................................8-114
8.33 Front Window AS ............................................................................................... 8-126
8.33.1 Disassembly............................................................................................. 8-126
8.33.2 Assembly.................................................................................................. 8-129
8.34 Monitor - Remove and Install ............................................................................. 8-135
8.34.1 Removal ................................................................................................... 8-135
8.34.2 Installation ................................................................................................ 8-135
8.35 Controller AS ..................................................................................................... 8-136
8.35.1 Removal ................................................................................................... 8-136

Shop Manual - April 2014 8-3

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.35.2 Installation ................................................................................................ 8-136

8.36 Radio ................................................................................................................. 8-137
8.36.1 Structure .................................................................................................. 8-137
8.36.2 Removal and installation .......................................................................... 8-139
8.36.3 Connector model and wiring .................................................................... 8-140
8.37 Battery ............................................................................................................... 8-141
8.37.1 Structure .................................................................................................. 8-141
8.37.2 Removal and installation .......................................................................... 8-142
8.37.3 Replacement ............................................................................................ 8-143
8.38 Start Switch........................................................................................................ 8-144
8.38.1 Structure ................................................................................................. 8-144

.
De al
8.38.2 Removal ................................................................................................... 8-145

pt
8.38.3 Working principle ..................................................................................... 8-146
g n
8.38.4 Wiring ....................................................................................................... 8-146
8.39 Fuse Box............................................................................................................ 8-147
o
8.40 Wiper ................................................................................................................. 8-148
in ti

8.40.1 Structure .................................................................................................. 8-148

8.40.2 Working principle ..................................................................................... 8-149
司
公
销
营
et a

8.40.3 Removal ................................................................................................... 8-150

n

8.40.4 Installation ................................................................................................ 8-150

8.40.5 Angle adjustment of wiper arm................................................................. 8-151
rk er

8.41 Relays ................................................................................................................ 8-152

8.41.1 Engine relays ........................................................................................... 8-152
Ma t

8.41.2 Other relays ............................................................................................. 8-153

In

8.41.3 Removal and installation .......................................................................... 8-154

8.41.4 Relay connector and wiring...................................................................... 8-154
8.42 Sensors.............................................................................................................. 8-155
8.43 Connector Terminals ......................................................................................... 8-157
8.43.1 Insertion ................................................................................................... 8-157
8.43.2 Removal ................................................................................................... 8-158

8-4 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8 DISASSEMBLY AND ASSEMBLY

8.1 How to Read This Manual
8.1.1 Removing and installing an assembly
Special tools
● Special tools for parts removal and installation are listed.
● Necessary characteristics of the tools are noted in the list of special tools.
■ : Special tools that cannot be substituted and must be used.
● : Very important tools, which can be substituted with commercially available ones.

.
Removal of parts

De al
● The "Removal" section contains procedure, precautions and the amount of oil or coolant to be

pt
discharged. g n
● The symbols used the in the "Removal" section are described below:
o
in ti

This symbol indicates that safety-related precautions must be observed when doing the
job. 营
销
公
司

★ This symbol is followed by instructions or precautions when performing a procedure.

et a

This symbol indicates related rules and precautions that must be obeyed when installing
n

the pats.
This symbol indicates the amount of oil or coolant to be discharged.
rk er

Installation of parts
Ma t

● Unless specified otherwise, installation of a part is to be performed in a reverse order of re-

moving the part.
In

● The mark used in the "Installation" section indicates the rules and precautions related to
parts installation.
● Symbols used in the "Installation" sections are shown below:

This symbol indicates that safety-related precautions must be observed when doing the job.
★ This symbol is followed by instructions or precautions when performing a procedure.
This symbol indicates that specific coating agent must be used.
This symbol indicates the lubricant required.
This symbol indicates a torque specified.
This symbol indicates the amount of oil or coolant to be added.

Shop Manual - April 2014 8-5

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.2 Operating Precautions

Observe the following precautions before removing or installing (disassembling or assembling) a

component.
1. Precautions to be observed prior to removal operation
● Dispose the engine coolant properly if antifreeze is used in the engine coolant.
● After disconnecting a hose or tube, seal the openings to prevent invasion of dirt or dust.
● Use a suitable container to contain oil drained.
● Matching mark must be made at where is necessary before removing a part in order to
avoid mistake during reinstallation.

.
● Do not pull the wire and avoid the wire coming off its contact. To avoid excessive force im-

De al
posing on the wire, hold the connector when disconnecting a wire.

pt
● Tag the wires and the hoses in order to ensure their connecting positions. By doing so,
g n
mistakes can be avoided during reinstallation.
o
● Count and check the number and thickness of the shims, and keep them in a safe place.
● When raising or lifting a component, be sure to use a proper lifting equipment of ample
in ti

strength.
司

● When forcing screws are used to remove any components, tighten the screws evenly in
公
销
营
et a

turn.
n

● The surrounding area must be cleaned before removing a component. Cover the compo-
nent after removal in order to prevent invasion of dirt or dust.
rk er
Ma t
In

8-6 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

● Precautions to be observed when disassembling the lines

The lines disassembled must be blinded with plugs.

A. Thread-connected hoses

Inner Diameter (mm) Code Description

Light Thread Connection
6 B210780001189 Plug
8 B210780001190 Plug
10 B210780000077 Plug
12 B210780000078 Plug

.
15 B210780000883 Plug

De al
20 B210780000079 Plug

pt
22 g n 60056667 Plug
Heavy Thread Connection
o
12 B210780001142 Plug
16 60002397 Plug
in ti

20 B210780000080 Plug
25 B210780000081 Plug
司
公
销
营
et a
n

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

rk er

Inner Dia.(mm) Code Description Code Description

Light Thread Connection
Ma t

6 B210780000903 Cone Plug 23002925 Nut

In

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

Shop Manual - April 2014 8-7

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

2. Precautions to be observed prior to instal- performed as the following:

lation (1) Start the engine and run the engine at
● Tighten all the screws and nuts (sleeve low idle.
nuts) to specified torques. (2) Operate the work equipment control
lever in order to cycle the movement of the
● Install the hoses without twisting or in- hydraulic cylinder 4 or 5 times. Hold the cyl-
terference. inder at where it is 100 mm from its stroke
end.
● Replace the gaskets, O-rings, cotter
(3) Go on operating the hydraulic cylinder
pins and lock plates with new ones. 3 or 4 times to its stroke end.
● Bend the cotter pin or lock plate se- (4) You can run the engine at normal
curely. speed after this operation.

● Before applying the adhesive, clean the ● This procedure is to be performed be-
fore using your machine for the first

.
parts of oil and dust. Apply 2 or 3 drops

De al
of adhesive to the threaded portion. time after repair or long storage.

pt
● Before applying the sealant to the gas- 3. Precautions to be observed upon comple-
tion of the operations
g n
ket, clean the gasket surface of oil and
dust. Check the gasket for contamina- ● Completely discharge the engine cool-
o
tion or damage. Apply the gasket seal- ant, tighten the drain valve, and add
in ti
ant evenly. coolant to the specified level. Run the
● Clean all parts, and correct any dam- engine to circulate the coolant through
the system. Check the coolant level
司
公
销
营

age, dents, burrs, or rust.

again.
et a

● Apply engine oil to the moving parts.

● Add hydraulic oil to the specified level
n

● Before installing a snap ring, make sure after disassembly and reinstallation of
rk er

that the snap ring is mounted properly a hydraulic unit. Run the engine to cir-
in the circular groove. culate the hydraulic oil through the sys-
● Before connecting the wiring connector, tem. Check the oil level again.
Ma t

clean the wiring connector of oil, dirt or ● Purge the air from the system after
In

water. Make sure that the wiring con- removing and repairing the lines or hy-
nector is connected securely. draulic unit and reassembling the parts.
● Before using an eyebolt, check the ● To purge the air, see related informa-
eyebolt for deformation or deterioration. tion in “Testing and Adjusting”.
Screw on the eyebolt as far as possible
and align it to the direction of the hook. ● Add the specified amount of grease
(MoS2) to the work equipment related
● Before tightening the half flanges, tight- parts.
en it evenly in turn in order to prevent
over tightening on one side.
● After reassembling the hydraulic cylinder,
main pump or other hydraulic equipment
that has been disassembled and repaired,
it is necessary to purge the air from the
hydraulic cylinder prior to initial operation
of the cylinder. The purging procedure is

8-8 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.3 Start Motor AS

8.3.1 Removal

NOTICE

● Before removing the start motor assem-

bly, disconnect the cable from the nega-
tive post (-) of the battery. Insulate the
cable and negative post (-) with tape.

.
1. Open the engine hood.

De al
2. Disconnect the Cables (2), (3) and (4).

pt
2 3
3. Remove the start motor fixing bolt (1) in
g n 1
order to remove the start motor. 4
o
in ti

司
公
销
营
et a
n

ZXT335-1006001

Fig. 8-1
rk er

8.3.2 Installation
Ma t

● Installation is performed in the reverse pro-

cedure of removal.
In

Shop Manual - April 2014 8-9

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.4 Fuel Injection Pump AS

8.4.1 Removal

NOTICE

● Disconnect the negative (-) post of bat-

tery.

1. Open the engine hood.

.
De al
ZXT335-1006002

pt
Fig. 8-2
g n
2. Disconnect the air hoses (1) and (2) of the
o
1
crankcase.
in ti

司
公
销
营
et a
n
rk er
Ma t

ZXT335-1006003
In

Fig. 8-3

3. Remove the fuel return line (3), fuel

delivery line (4), fuel supply line (5) and 3
lubrication line (7). 4

● After disconnecting the hoses, cork

them to prevent fuel leak. 5
6

ZXT335-1006004

Fig. 8-4

8-10 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

4. Remove the six (6) fuel delivery lines (8) 8

ZXT335-1006005

Fig. 8-5

.
De al
pt
5. Remove the air hose (9).
g n
6. Remove the bolt (10) fixing the electronic 9
shutdown device and the bolt (11) of gov-
o
10
ernor motor.
in ti

7. Remove the fuel injection pump mounting 11

nut in order to remove the fuel injection 营
销
公
司

pump assembly.
et a
n
rk er

ZXT335-1006006

Fig. 8-6
Ma t
In

Shop Manual - April 2014 8-11

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.4.2 Installation
● Installation is performed in the reverse procedure of removal.
Torques for:
Fuel supply line connector bolt: 28-46 N•m
Fuel return line nut: 28-46N•m
Fuel delivery line nut: 28-32N•m
Engine oil line nut: 16-25N•m
● Install the fuel injection pump as the following:
A. Check the fuel injection timing.
See “Fuel Injection Timing - Test and Adjust” on page 6-13.

.
De al
B. Assemble the fuel injection pump assembly and tighten the nuts.

pt
Nut: 9.8±2 Nm {10±0.2 kgm}
g n
● Purge the air.
o
Purge the air from the fuel injection system.
in ti

司
公
销
营
et a
n
rk er
Ma t
In

8-12 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.5 Engine Front Oil Seal

8.5.1 Removal
3
1. Remove the radiator assembly. See
“Radiator AS” on page 8-20. 2

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

pulley (3).
3. R e m o v e t h e b o l t ( 4 ) a n d t h e n t h e

.
De al
pt
ZX335-1006007

Fig. 8-7
g no
crankshaft belt pulley (5).
in ti

4. Remove the front oil seal (6).

6
5
司
公
销
营
et a

4
n
rk er

ZX335-1006008
Ma t

Fig. 8-8
In

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

Shop Manual - April 2014 8-13

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.6 Engine Rear Oil Seal

8.6.1 Removal
1. Remove the hydraulic pump assembly. 2
See “Hydraulic Pump AS” on page 8-80.
2. Remove the flywheel (1).
3. Remove the rear oil seal (2).

.
De al
pt
ZX335-10
g no
Fig. 8-9
in ti

8.6.2 Installation
● Installation is performed in the reverse pro- 营
销
公
司

cedure of removal.
et a

Sealant
● Install the rear oil seal as the following:
n

A. Apply engine oil to the lip of rear oil

rk er

seal. ø2mm
B. Clean the seal surface.
Ma t

C. Apply sealant along the sealing line

continuously and uniformly.
In

Line
Sealant (Tianshan 1596) ZX335-1006010

D. Installation is to be performed within Fig. 8-10

three (3) minutes after application of
sealant. It is important to keep the ap-
plied sealant in proper area.

8-14 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.7 Cylinder Head AS

8.7.1 Removal

NOTICE

● Disconnect the cable from the negative

post (-) of the battery.

1. Drain coolant from the engine.

Coolant: 26 L
2. Open the engine hood.

.
ZXT335-1006011

De al
Fig. 8-11

pt
g n
3. Remove the air intake hose (1).
o
1
in ti

司
公
销
营
et a
n
rk er

ZXT335-1006012
Ma t

Fig. 8-12
In

4. Disconnect the lines (2) and (3) between

4
the fuel filter and the fuel injection pump. 2

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

fuel filter assembly (5).
5 3

ZXT335-1006013

Fig. 8-13

Shop Manual - April 2014 8-15

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

6. Disconnect the six (6) fuel delivery lines (6). 6

ZXT335-1006014

Fig. 8-14

.
De al
pt
7. Remove the cover (7) of exhaust muffler
7
connector.
g no
8. Disconnect the air intake hose (8).
9. Disconnect the air intake hose (9) and the
in ti

8
crankcase breathing hose (10) between
turbocharger and intercooler. 营
销
公
司

9
10
et a
n
rk er

ZXT335-1006015

Fig. 8-15
Ma t
In

8-16 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

10. Disconnect the oil delivery line (11) and the oil return line (12).
11. Remove the turbocharger system assembly.
12. Remove the exhaust manifold (13).

.
De al
pt
g no
in ti

司
公
销
营
et a

11
n
rk er
Ma t

13
In

12

ZX335-1006016

Fig. 8-16
Shop Manual - April 2014 8-17
Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

13. Remove the radiator inlet hose (14) and

14
outlet hose (15).

15

ZXT335-1006017

Fig. 8-17

.
De al
pt
14. Remove the six (6) nozzle seats (16).
16
g no
in ti

司
公
销
营
et a
n
rk er

ZXT335-1006018

Fig. 8-18
Ma t
In

8-18 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

15. Remove the rocker arm cover (17).

16. Remove the camshaft assembly (18).

17. Remove the rocker arm assembly (19).

18. Remove the bolts of cylinder head and

lift the cylinder head assembly in order to
disassemble it.

19. Remove the cylinder head gasket (21).

.
De al
8.7.2 Installation

pt
● Installation is performed in the reverse pro-
g n
cedure of removal.
o
in ti

Rocker cover bolt:

7.8-9.8N.m{0.8-1.0kgf.m} 营
销
公
司

Cylinder head bolt:

et a

88N.m{9.0 kgf.m }+90°

n
rk er

Cylinder head bolt threads: engine oil

Camshaft flange surface: engine oil
Ma t

Camshaft journal circumference: en-

In

gine oil
● Adjusting valve clearance
● See “Valve Clearance - Adjust” on
page 6-7.
● Adding coolant
Add engine coolant to the specific level.
ZX335-1006019
Start the engine to circulate coolant in or-
der to eliminate all foams. Check the cool- Fig. 8-19
ant level again.

Shop Manual - April 2014 8-19

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.8 Radiator AS

8.8.1 Removal
1. Open the engine hood
2. Open the pressure cap (1). Drain engine
coolant via the drain valve beneath the
coolant tank.
Coolant: Approx. 26 L 1

.
De al
ZXT335-1006020

pt
g n Fig. 8-20

3. Disconnect the pipes from the hydraulic oil

o
cooler delivery port (2) and supply port (3).
in ti

Seal the ports in order to prevent the leak-

age of hydraulic oil in the hydraulic system.
司
公
销
营

4. Drain hydraulic oil from the cooler and from

et a

radiator. 2
n

Hydraulic oil radiator: Approx. 8 L

3
rk er
Ma t

ZXT335-1006021

Fig. 8-21
In

5. Remove hose (4) of coolant tank.

ZXT335-1006022

Fig. 8-22

8-20 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

6. Remove the inlet and outlet houses (5) and

6
(6) of the water cooler.
Hydraulic oil radiator: Approx. 5.6 L

ZXT335-1006023

Fig. 8-23

.
De al
pt
7. Remove the inlet and outlet air hoses (7)
g n
and (8) of the intercooler.
o
in ti

8
7
司
公
销
营
et a
n
rk er

ZXT335-1006024

Fig. 8-24
Ma t
In

8. Remove the four bolts (9) of the A/C radia-

tor. Remove the A/C radiator and put it in a 9

suitable place.

ZXT335-1006025

Fig. 8-25

Shop Manual - April 2014 8-21

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

9. Remove the radiator fan guard (10).

10

ZXT335-1006026

Fig. 8-26

.
De al
pt
10. Remove the four bolts (11) from the bottom
of radiator.
g no
in ti

司
公
销
营

11 11
et a
n
rk er

ZXT335-1006027

Fig. 8-27
Ma t
In

11. Remove the bolts (12) and (13) of both left

12
and right brackets.
13

ZXT335-1006028

Fig. 8-28

8-22 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

12. Install eyebolts (14) on both sides of the

radiator and lift the radiator assembly.
● Before lifting the radiator assembly, move
the radiator assembly in axial direction until
14
the fan is free from the fan guard.

ZXT335-1006029

Fig. 8-29

.
8.8.2 Installation

De al
pt
● Installation is performed in the reverse pro-
cedure of removal.
g no
● Adjust the clearance (a) between the fan
in ti

and guard so that the clearance is uni-

form around the fan.
司
公
销
营

● The clearance (a) should read as the fol-

et a

lowing on the left, right, top and bottom

n

points.
● Standard clearance (a) (around the
rk er

fan): 10 mm
● Fan dia. (b): ø830 mm
Ma t

● Guard inner dia. (c): ø850 mm

In

● Refilling engine coolant and hydraulic oil

Refill engine coolant and hydraulic oil to
the specific levels. Start the engine to cir-
culate the coolant and oil. Check the cool-
ant level and oil level again.

Engine coolant: Approx. 26 L.

Hyd oil radiator: Approx. 8 L.

Shop Manual - April 2014 8-23

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.9 Engine and Hydraulic Pump AS

8.9.1 Removal
Lower the work equipment to the ground in
order to ensure safety. Stop the engine. Dis-
connect the cable from the battery negative (-)
post.
Loosen the butterfly nut on the breather valve
and press the relief button to release internal
pressure.
● Mark the lines to avoid mistakes during re-

.
installation.

De al
pt
1. Remove the hydraulic tank suction filter
and block the opening.
g n
2. Discharge engine coolant.
o
Coolant: About 22.9 L
in ti

3. Open the engine hood.

ZXT335-1006030
司
公
销
营

Fig. 8-30
et a
n
rk er

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

2
Ma t
In

ZXT335-1006031

Fig. 8-31

8-24 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

5. D i s c o n n e c t h o s e s ( 4 ) , ( 6 ) a n d ( 7 ) .
Disconnect the cables (5) and (8) of main 6
5
pump pressure sensors. 7

ZXT335-1006032

Fig. 8-32

.
De al
6. Remove the hose (9) and the clamps (10).

pt
g no
9
10
in ti

司
公
销
营
et a
n

10
rk er

ZXT335-1006033

Fig. 8-33
Ma t
In

7. Remove the main pump negative feedback

12
hoses (11) and (12).

11

ZXT335-1006034

Fig. 8-34

Shop Manual - April 2014 8-25

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8. Remove the main pump PSV hose (13),

clamp (14) and cable (15).

13

15 14

ZXT335-1006035

Fig. 8-35

.
9. Disconnect the engine fuel hoses (16) and

De al
21
(17) and the engine oil hoses (18) and (19).

pt
20 22

10. Disconnect the engine speed sensor

g n
cables (20) and (21) as well as the clamp
(22).
o
16 17 18 19
in ti

司
公
销
营
et a
n

ZXT335-1006036

Fig. 8-36
rk er

11. Unscrew the throttle guy connecting bolt

Ma t

(23) and the electronic shutdown device

In

connecting bolt (24).

24
23

ZXT335-1006037

Fig. 8-37

8-26 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

12. Remove the coolant temperature sensor,

high temperature switch external cables
(25) and (26) as well as the hose clamps
(27).
25

26

27
ZXT335-1006038

Fig. 8-38

.
De al
pt
13. Disconnect the compressor cables (28)
g n 28
and (29) as well as the hoses (30) and (31).
29
o
in ti

31
司
公
销
营
et a

30
n
rk er

ZXT335-1006039

Fig. 8-39
Ma t
In

14. Disconnect the external cable (32) of

engine oil pressure sensor and the cable
(33) of engine oil pressure sensor. 32

34
15. Remove the clamps (34).
36
16. Remove the starter main cable (35).
17. Disconnect the alternator cable (36).
35

33
ZXT335-1006040

Fig. 8-40

Shop Manual - April 2014 8-27

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

18. Remove the hose clamp (37).

37

ZXT335-1006041

Fig. 8-41

.
De al
pt
19. Disconnect the hoses (38), (39) and (40)
g n
between the engine and the radiator.
o
20. Disconnect the air intake hose (41).
39
in ti

38
司
公
销
营

40 41
et a
n
rk er

ZXT335-1006042

Fig. 8-42
Ma t
In

21. Disconnect the hose (42) between the

engine and the radiator.

42

ZXT335-1006043

Fig. 8-43

8-28 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

22. Disconnect the radiator fan guard (43).

43

ZXT335-1006044

.
Fig. 8-44

De al
pt
g n
23. Remove the fixing bolt (44) on each of the
four (4) mounting plates of the damper. Lift
o
44
the engine and main pump assembly.
in ti

Engine and hydraulic pump AS: 44

836 kg营
销
公
司
et a
n
rk er

ZXT335-1006045

Fig. 8-45
Ma t
In

Shop Manual - April 2014 8-29

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.9.2 Installation
● Installation is performed in the reverse procedure of removal.
● Open the radiator tank cap to refill coolant. Add coolant to the coolant tank.
Engine coolant:Approx. 26 L

● Refill the hydraulic tank with hydraulic oil.

Hydraulic tank: Approx. 380 L

● Start the engine to circulate the coolant in order release the foams, and check the coolant
level again.

.
De al
● Start the engine to circulate the hydraulic oil in the hydraulic system, and check the oil level

pt
again.
● Purging the air.
g n
See “Air in Each Component - Purge” on page 6-41.
o
in ti

司
公
销
营
et a
n
rk er
Ma t
In

8-30 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.10 Final Drive AS

8.10.1 Removal
1. Remove the sprocket. See “Sprocket” on
page 8-58.

WARNING

● Lower the work equipment to the

ground in order to ensure safety. Stop
the engine. Operate the breather valve 1
to release internal pressure. ZX335-1006046

.
De al
Fig. 8-46

pt
g n
2. Remove the motor cover plate (1).
3
3. Disconnect the four hoses (2) of the travel
o
motor and the corresponding hose connec-
in ti

tors.
4. Remove the 24 mounting bolts (3) con- 营
销
公
司

2
necting the final drive assembly with the
et a

sprocket. And the remove the sprocket.

n

5. Remove the bolts (4) connecting the final

rk er

drive with the track frame. Lift the final

drive (5) in order to disassemble it. 4
ZXT3355-1006247
● Take care not to damage the surface
Ma t

of mounting seal installed on the hose Fig. 8-47

base.
In

● Never use the threaded holes to lift the

cover when lifting the final drive.
3

2
SY365(B)H-9
Number of Bolts 18
Travel motor plus reducer 389 kg

ZX335-1006147

Fig. 8-48

Shop Manual - April 2014 8-31

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.10.2 Installation
● Installation is performed in the reverse procedure of removal.

Mounting bolts (final drive AS): 245~309 Nm {25~31 kgm}

● Refilling hydraulic oil.
Add hydraulic oil through the filler opening to the specified level. Start the engine to circulate
oil in the hydraulic system, and check the oil level again.
● Purging the air.
See “Air in Each Component - Purge” on page 6-41.

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

8-32 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.11 Final Drive AS

8.11.1 Disassembly
1. Discharging the oil
Open the drain plug to discharge oil from
the final drive tank.
Final drive tank: About 4.0 L

2. Cover
①
Unscrew the mounting bolts. Remove the

.
cover (1) with the help of eyebolts ① .

De al
pt
g no
in ti

1
司
公
销

ZX335-1006049
营
et a

Fig. 8-49
n
rk er

3. Spacer
2
Remove the spacer (2).
Ma t
In

ZX335-1006050

Fig. 8-50

Shop Manual - April 2014 8-33

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

4. No. 1 planetary carrier assembly

A. Remove No.1 planetary carrier assem- 3
bly (3).

ZX335-1006051

Fig. 8-51

.
De al
pt
B. Disassembling No.1 planetary carrier
assembly.
g n
9 7 4 5 10 8
o
a. Remove the screw (4). Remove the
coverplate (5) from the planetary
in ti

carrier (6).
b. Remove the thrust washer (7), gear
司
公
销
营
et a

(8), bearing (9), bearing inner race

(10) and thrust washer (11). 11
n

6
rk er

ZX335-1006052

Fig. 8-52
Ma t

5. No.1 sun gear shaft

In

12

Remove No.1 sun gear shaft (12).

ZX335-1006053

Fig. 8-53

8-34 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

6. Thrust washer. 13 14
Remove the thrust washer (13).
7. No.2 sun gear
Remove No.2 sun gear (14).

ZX335-1006054

Fig. 8-54

.
De al
8. Disassembling No.2 planetary carrier as-

pt
18 19 15
sembly g n
A. Remove the screw (15). Remove the 16
plate (16) and the planetary gear (17) 17
o
from the carrier (22). 20
in ti

23
B. Remove the bearing inner race (19) 21
and outer race (18). Remove the plate 营
销
公
司

(20). 22
et a

C. Remove the screw (21) in order to take

n

down the planetary carrier (22) and ZX335-1006055

shims (23) from the body.

rk er

Fig. 8-55

9. Boss assembly
Ma t

②
A. Remove the boss assembly (24) from
In

the travel motor with the help eyebolts

②.

24

ZX335-1006056

Fig. 8-56

Shop Manual - April 2014 8-35

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

B. Disassemble the boss assembly as the

following. 26 27

a. Remove the floating seal (25).

b. Remove the bearings (26) and (27)
from the boss (28).
● Take care not to damage the bear-
ing retainer while disassembling the
bearing (26).
25 28
ZX335-1006057

Fig. 8-57

.
De al
pt
C. Remove the floating seal (29) from the
travel motor (30).
g no
29
in ti

司
公
销
营
et a
n

30
ZX335-1006058
rk er

Fig. 8-58
Ma t

8.11.2 Assembly
26 27
In

● Clean all the parts. Make sure that these

parts are free from contamination or dam-
age. Apply some engine oil to the sliding
surfaces prior to installation.
1. Boss assembly
A. Install the bearings (26) and (27) by
pressing them onto the boss (28).
25 28
B. Install the floating seals (25).
ZX335-1006057

Fig. 8-59

8-36 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

● Remove any oil or dust from the O-ring

or O-ring contact surfaces. Dry the
parts before installing the floating seals.
● After installing the floating seal, make
sure that the angle of floating seal is
within 1 mm.
● Apply a thin layer of engine oil to the
sliding surface after the floating seal ZX335-1006059
has been installed.
Fig. 8-60

C. Install the floating seal (29) on the

.
travel motor (30).

De al
pt
● See the above step 2 for the installa-
tion procedure.
g n 29
o
in ti

司
公
销
营

30
et a

ZX335-1006058

Fig. 8-61
n
rk er

D. Place the boss assembly (24) on the

②
travel motor with the help of eyebolts
Ma t

② . Carefully tap the bearing to press-

In

fit it.

24

ZX335-1006056

Fig. 8-62

Shop Manual - April 2014 8-37

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

2. Calculation of shim thickness

A. Measure the thickness (H) of the raised 22
part of No.2 planetary carrier (22).

ZX335-1006060

B. Measurement of raised thickness Fig. 8-63

Apply 3000 Kg load to the bearing and
measure the value (H) of the raised

.
De al
part of bearing.

pt
● Turn the boss 2-3 times before applying
a pushing force.
g n
● Do not use a spray gun to cushion the Load 3000Kg
o
bearing.
h
in ti
● Do not push or strike the retaining
valve.
C. Shim thickness calculation: C=H-h.
司
公
销
营
et a

ZX335-1006061
n

Fig. 8-64
rk er

D. Place the shims on the body and insert

the dowel pin. Press the carrier as-
Ma t

sembly onto the dowel pin and tighten it

In

with screw (21). Apply locking adhesive Tensiometer

to the threads.
Screw-locking adhesive:
(Kesaixin 1277)
Screw (21):
539±28 Nm {55±2.9 kgm} ZX335-1006062

● Use a tensiometer to measure the tan- Fig. 8-65

gential force of boss to motor case ro-
tation.
Tangential force: Max. 294N {30 kg}
Maximum tangential force occurs at the
beginning of direction change.

8-38 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

3. Assembly of No.2 planetary carrier assem- 18 19 15

bly
Assemble the No.2 planetary carrier as- 16
sembly through to the following steps. 17

● Replace the plates (20) and (16) with 20

23
new ones. 21
A. Assemble the bearings (18) and (19) 22
on the gear (17). Assemble the top and
bottom plates (16) and (20), and place
the gear assembly into the planetary ZX335-1006055

carrier (22). Fig. 8-66

B. Lock it with screw (15).

.
De al
Screw (15):

pt
13 14
g n 539±28 Nm {55±2.9 kgm}
● Check the flexibility of gear (17) after
assembling the planetary carrier as-
o
sembly.
in ti

4. Thrust washer
Install the thrust washer (13).
司
公
销
营
et a

5. No.2 sun gear

n

Install No.2 sun gear (14).

ZX335-1006054
rk er

Fig. 8-67
Ma t

6. No.1 sun gear shaft 12

In

Install No.1 sun gear shaft (12).

ZX335-1006053

Fig. 8-68

Shop Manual - April 2014 8-39

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

7. No.1 planetary carrier assembly

A. Install No.1 planetary carrier assembly 9 7 4 5 10 8
as the following.
● Replace the thrust washers (7) and (11)
with new ones.
a. Assemble bearings (9,10) on gear
(8). Assemble the top washer (7)
11
and the bottom washer (11). Place 6
the gear assembly in the carrier
assembly (6). ZX335-1006052

b. Secure the coverplate (5) to the Fig. 8-69

planetary carrier (6) with screw (4).

.
De al
B. Install No.1 planetary carrier assembly

pt
(3). g n 3
o
in ti

司
公
销
营
et a
n
rk er

ZX335-1006051

Fig. 8-70
Ma t
In

8. Spacer
2
Install the spacer (2).

ZX335-1006050

Fig. 8-71

8-40 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

9. Cover
①
Assemble the cover (1) with the help of
eyebolts ① . Use a torque wrench to tighten
the bolts.

Bolts:
73.4±3.63 Nm {7.5±0.4 kgm}

ZX335-1006049

Fig. 8-72

.
De al
pt
g no
in ti

司
公
销
营

Torque wrench
et a
n
rk er

ZX335-1006063
Ma t

Fig. 8-73
In

10. Refilling the oil

Tighten the drain plug and refill engine oil
through a filler.

Final drive case: About 4.7 L

● After the final drive has been success-
fully installed to the chassis, check the
oil to see if it has reached the specified
level.

Shop Manual - April 2014 8-41

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.12 Swing Motor and Swing Drive AS

8.12.1 Removal
Release the remaining pressure in the hydrau-
lic return circuit. See “Remaining Pressure
in Hydraulic Lines - Relieve” on page 6-36.
Lower the work equipment to the ground in 3 4

order to ensure safety. Stop the engine. Press

the release button of the breather valve to 6
release remaining pressure in the hydraulic
tank. Place the hydraulic lockout control in the
locked position.

.
De al
1. Disconnect the hose (1) through the hose 2

pt
(9). 7
5
(1): Between oil tank and swing motor (port
g n
Dr)
1
o
(2): Between central swivel joint and swing
in ti

motor (port Dr)

(3): Between swing motor and main valve 营
销
公
司

ZXT335-1006064
(port M)
et a

Fig. 8-74
(4): Between swing motor and main valve
n

port Px (port A)
rk er

(5): Between swing motor and main valve

(port B)
(6): Between swing motor and main valve
Ma t

port Px (port SH)

In

(7): Between swing motor and solenoid

valve block (port PG) 9

2. Remove the 14 fixing bolts (8).

3. Lift the swing motor and swing mechanism
assembly (9) in order to disassemble it.
Slowly lift the swing motor and swing 8
mechanism assembly in order to avoid
damaging the hoses and other parts.
ZXT335-1006065
Swing motor and swing drive AS:
Fig. 8-75
425.5 kg

8-42 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

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

Mounting bolts (swing motor and

swing mechanism AS):
490~608 Nm {50~62 kgm}
● Refilling of hydraulic oil
Refill hydraulic oil through the filler open-
ing to the specified level. Start the engine
to circulate oil in the hydraulic system, and

.
De al
check the oil level again.

pt
● Purging of air
g n
See “Air in Each Component - Purge”
on page 6-41.
o
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 8-43

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.13 Swing Motor and Swing Drive AS

8.13.1 Disassembly
1. Draining of oil
Open the drain plug to drain the oil from 2
the swing mechanism.
Swing drive case: Approx. 10.5 L 1

2. Swing motor assembly

A. Place the swing motor and swing
mechanism assembly on a suitable

.
cribbing. Take care not to damage the

De al
drive gear or let it contact the ground.

pt
B. Unscrew the four(4) bolts (1) in order to
remove the swing motor assembly (2).
g n ZXT335-1006066

Swing motor assembly: 67.5 kg Fig. 8-76

o
in ti

3. No.1 sun gear

公
销
营

2
et a

Remove No.1 sun gear (2).

n
rk er
Ma t
In

ZX335-1006067

Fig. 8-77

8-44 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

4. No.1 planetary carrier assembly 3 4

A. Remove No.1 carrier assembly (3) and
the plate (4).

.
De al
ZX335-1006068

pt
Fig. 8-78

B. Disassemble No.1 carrier assembly.

g n
Cut the rivets on the shaft (8) to re-
o
move the shaft (8), and remove in turn
in ti

the gear (6), bearing (9) and plate (7). 6 7 8 9

5
司
公
销
营
et a
n
rk er

ZX335-1006069
Ma t

Fig. 8-79
In

5. Gear ring 10

Unscrew the mounting bolts to remove the

gear ring (10).

ZX335-1006070

Fig. 8-80

Shop Manual - April 2014 8-45

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

6. No.2 sun gear 11

Remove No.2 sun gear (11).

.
De al
pt
ZX335-1006071

Fig. 8-81
g no
7. No.2 planetary carrier assembly
in ti

12
A. Remove No.2 carrier assembly (12).
司
公
销
营
et a
n
rk er
Ma t
In

ZX335-1006072

Fig. 8-82

8-46 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

B. Disassemble No.2 carrier assembly

with hands through the following steps.
a. Hammer the pin (13) in the shaft (14) 19 16 15 18
in order to push the shaft (14) out of
the carrier assembly (19). 17

● Hammer out the pin (13) after removing 14

the shaft.
13
b. Remove the thrust washer (16) and
gear (17).
c. Insert the pin (15) to remove the
ZX335-1006073
bearing (18) from the shaft. Remove
the pin (15). Fig. 8-83

.
De al
pt
8. Snap ring 20
Remove the snap ring (20).
g no
in ti

司
公
销
营
et a
n
rk er

ZX335-1006074

Fig. 8-84
Ma t
In

9. Disassembling the main shaft

Push 21 22
A. Place the shaft housing assembly on a
press and push the shaft assembly (21)
out of the shaft housing assembly (22).

ZX335-1006075

Fig. 8-85

Shop Manual - April 2014 8-47

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

B. Disassemble the shaft assembly in the Push

following procedure.
Remove the bearing (23) from the shaft
(24).

23

24

.
ZX335-1006076

De al
Fig. 8-86

pt
g no
10. Bearing 26
27
Remove the bearing (25) and the oil seal
in ti

(26) from the housing (27).

司
公
销
营
et a
n
rk er
Ma t
In

25 ZX335-1006077

Fig. 8-87

8-48 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.13.2 Assembly 23
● Clean all the parts and check for any con-
tamination or damage. Apply engine oil to
the sliding surfaces of the parts.
1. Bearing
Press the bearing (23) into the housing (27).

27
ZX335-1006078

Fig. 8-88

.
De al
pt
2. Oil seal g n
Press the oil seal (26) into the housing (27). 27 26
o
Oil seal mounting surface: gasket
in ti

sealant (Loctite 515)

司
公
销
营
et a
n
rk er

ZX335-1006079

Fig. 8-89
Ma t
In

3. Housing assembly 24
A. Position the plate (28) on the shaft (24).
B. Position the housing assembly (22) on
the shaft (24). Press to fit the bearing.
22

28
ZX335-1006080

Fig. 8-90

Shop Manual - April 2014 8-49

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

4. Bearing 22 25
Press to fit the bearing (25).
● When press-fitting the bearing, press
the bearing inner race and outer race
simultaneously. Never press only the
inner race.
● After assembling the bearing, check if
the housing rotates freely.

ZX335-1006081

.
Fig. 8-91

De al
pt
5. No.2 Planetary carrier assembly
g n
Reassemble No.2 carrier assembly through
o
the following steps. 19 16 15 18
in ti

A. Assemble the plate (16) in the carrier

assembly (19). 17
司
公
销
营

B. Assemble the gear (17) in the carrier 14

et a

assembly (19). Put the bearing (18)

n

on the shaft (14). Slightly tap the pin 13

(15) into the bore after alignment. Use
rk er

a rubber hammer to tap the pin. Make

sure that the pin (15) must not be ZX335-1006073

higher than the bearing (18). Fig. 8-92

Ma t

C. Push the shaft assembly into the car-

In

rier assembly (19). Be careful not to

damage the gear and the plate. Align
the pin hole of the shaft with that of the
carrier assembly, and install the pin
(13). Carefully tap the pin with a rubber
hammer during installation.
● Installation of the shaft requires rotat-
ing the planetary gear. Take care not to
damage the thrust washer.

8-50 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

6. Assemble in turn the snap ring (20), No.2 No.2 planetary 11

20
carrier assembly and No.2 sun gear (11). carrier

ZX335-1006082

.
Fig. 8-93

De al
pt
7. Installation of gear ring
g n 10

Apply sealant on the mating surface

o
indicated by (C) and tighten it with screws.
Never get the sealant onto the gear ring c
in ti

(10).
Mating surface: Sealant (Loctite 515)
营
销
公
司
et a
n
rk er
Ma t

ZX335-1006083

Fig. 8-94
In

8. No.1 planetary carrier assembly

A. No.1 carrier assembly is assembled as
the following.
a. Install the plate (7) on the carrier 6 7 8 9
5
assembly (5).
b. Install the gear (6) onto the plate
after installing the bearing (9) into
the gear.
c. Press the shaft (8) into the gear (6)
and the carrier assembly (5). Rivet
ZX335-1006069
one end of the shaft.
Fig. 8-95
● Check if the gear rotates freely.

Shop Manual - April 2014 8-51

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

B. Install No.1 carrier assembly (3) and 3 4

the plate (4).

.
De al
ZX335-1006068

pt
Fig. 8-96
g n
9. No.1 sun gear assembly
o
2

Install No.1 sun gear (2).

in ti

司
公
销
营
et a
n
rk er
Ma t
In

ZX335-1006067

Fig. 8-97

8-52 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

10. Installation of swing motor assembly

Install the swing motor assembly after ap-
plying sealant to the mating surfaces of the
gear ring and the motor cover.
Mating surface: sealant (Loctite
515)

Swing motor assembly: 55 kg

Mounting bolts (swing motor):
156±5 Nm {16±0.5 kg}
● The 14 bolt holes of the swing motor
and swing drive assembly are distribut-

.
De al
ed nonuniform. The mating direction of

pt
each hole is exclusive, as shown in the
illustration on the right. The installation
g n
of swing motor requires proper align-
ment of the bolt holes in order to ensure
o
the installation orientation.
in ti

11. Refilling of lubricant

Screw on the drain plug and refill lubricant 营
销
公
司

through the filler to the specified level (the

et a

upper mark of oil stick).

n

ZX335-1006084

Fig. 8-98
rk er

Swing drive case: About 4 L

Ma t
In

Shop Manual - April 2014 8-53

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.14 Idler AS

8.14.1 Disassembly 7
8
1. Remove the dowel pin (1) and the support 6
(2). 13
12
10
2. Remove the floating seals (3) from the 5
support (2) and the idler (4).
3. Remove the O-ring (11). Remove the idler
(4) from the shaft (5) and the support as-
9
sembly (7). 11
3
● The idler contains 80 ml oil, which 1

.
De al
should be drained completely before

pt
disassembling. Spread a cloth on the
floor to prevent smearing of the floor by
g n
the oil. 4
2
o
ZX335-1006085

Fig. 8-99
in ti

4. Remove the floating seals (6) on the other 4 6

side from the idler (4), shaft (5) and sup-
司
公
销
营

5
et a

port assembly (7).

n
rk er
Ma t

6
In

7
ZX335-1006086

Fig. 8-100

5. Remove the dowel pin (8) in order to

remove the support (7) from the shaft (5). 5
9，10 4
6. Remove the bushings (9) and (10) from the
idler (4).

7 8
ZX335-1006087

Fig. 8-101

8-54 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.14.2 Assembly
1. Install the bushings (9) and (10) in the idler
(4).

9 10 4

ZX335-1006088

Fig. 8-102

.
De al
pt
2. Assemble the O-ring. Use the dowel pin (8)
to install the support (7) on the shaft (5). 5
g no
9，10 4
in ti

司
公
销
营
et a

7
n

8
ZX335-1006087
rk er

Fig. 8-103
Ma t

3. Install the floating seals (6) on the idler (4),

In

shaft (5) and support (7) assembly.

● Floating seals
Completely remove the grease from 6
the contact surfaces (hatched area in
the illustration on the right) of O-ring
and floating seal before installing the
floating seal. In addition, care must be
taken to keep the contact surface of
floating seal free from dust.
ZX335-1006089

Fig. 8-104

Shop Manual - April 2014 8-55

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

● After installation of the floating seals,

check that the sealing inclination should
be less than 1 mm and the seal protru-
sion be within a range of 5-7 mm. a

ZX335-1006090

Fig. 8-105

.
De al
4. Install the shaft (5) and support (7) assem-

pt
7 5
bly to the idler (4).
g n 4
o
in ti

司
公
销
营
et a
n

ZX335-1006091
rk er

Fig. 8-106
Ma t
In

8-56 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

5. Install the floating seal (3) to the idler (4)

and support (2).
4 3
● Apply oil to the sliding surface of float-
2 3
ing seal. Care must be taken to keep
the sliding surface from any contami-
nants or dust.
● Remove the oil and dust from the con-
tact surfaces of the O-ring and floating
seal.
ZX335-1006092

Fig. 8-107

.
De al
pt
g n
3
o
in ti

司
公
销
营
et a
n

ZX335-1006093

Fig. 8-108
rk er

6. Install the O-ring. Use the dowel pin (1) to

Ma t

7
8
install the support (2). 6
In

13
7. Refill oil and screw on the plug. 12
10
Oil: About 80 ml (No.18 hyperbola 5
gear oil)
Plug: 205.8±49 Nm {21±5 kgm}
9
11
3
1

4
2 ZX335-1006085

Fig. 8-109

Shop Manual - April 2014 8-57

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.15 Sprocket

8.15.1 Removal
1
1. Remove the track assembly. For more
information see “Track AS” on page 8-59.
2. Swing the work equipment 90° and lift the
chassis with the help of the work equip-
①
ment. Place a block ① between the track
frame and the track shoe.
3. Remove the sprocket (1).
Sprocket: 98.4 kg

.
De al
ZX335-1006094

pt
Fig. 8-110
g no
8.15.2 Installation
in ti
● Installation is performed in the reverse pro-
cedure of removal.
司
公
销
营
et a

Threads (bolt - sprocket):

n

Thread sealant (Kesaixin 1277).

rk er

Bolts (sprocket):
927±103 N·m {94.6±10.5 kgf·m}
Ma t
In

8-58 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.16 Track AS

Special tools

Mark Part Name Necessity Qty

Manual/electric hydraulic
M track removing/installing ● 1
machine

8.16.1 Removal
1. Choose a place that has enough space to
spread the track. Park the machine when

.
De al
the master pin is between the idler and the

pt
carrier roller.
2. Lower the work equipment. Loosen the
g n
grease fitting (1) and release the track ten-
o
sion.
in ti

1
WARNING 营
销
公
司
ZXT335-1006095

Fig. 8-111
et a

● The adjustment cylinder is under ex-

tremely high pressure. Never loosen the
n

grease fitting by more than one turn.

rk er

Move the machine back and forth if no

grease is seen.
Ma t

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

ZX335-1006096

Fig. 8-112

Shop Manual - April 2014 8-59

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

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

forward so that the temporary pin ② is in
front of the idler. Place the block ① .
5. Remove the temporary pin ② and the
dust seal. Move the machine backward to ②
3
spread the track (3).

ZX335-1006097

Fig. 8-113

.
De al
pt
8.16.2 Installationg n
● Installation is performed in the reverse pro-
o
cedure of removal. Corner Track shoe nut
(Square)
in ti
See “Track Tensioner - Test and Adjust” on
page 6-21.
营
销
公
司

R
● Installation procedure of track shoe bolts
et a

R
and nuts Corner
n

A. Bring the R side of the track shoe nut Corner

(1) to the link seat surface. Both seat R
rk er

surfaces should be in close contact

when assembling the track shoe.
Ma t

Seat surface
● If the track shoe bolts are installed Must be in
from the other side, the corner of nut Close contact.
In

will interfere with the link seat surface,

causing the nut to raise and the bolt to
loosen.
B. Tighten the bolts of track shoe to the
torque below.
Track shoe bolts:
1029±60 Nm {105±6 kgm}
ZX335-1006098

Fig. 8-114

8-60 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator 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): 4.2±2mm

ZX335-1006099

Fig. 8-115

.
● Before installing the dust seal, apply

De al
grease (G2-LI) to its contact surface

pt
with the bushing.
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 8-61

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.17 Swing Bearing AS

8.17.1 Removal
1. Remove the swing frame assembly. For
more information See “Swing frame AS”
on page 8-64.
2. Remove the 36 bolts (1) in order to take off
the swing bearing assembly.
3. Lift the swing bearing assembly (2).
1
ZXT335-1006100

.
Fig. 8-116

De al
pt
Swing bearing assembly; 526 kg
g no
in ti

营
销
公
司
2
et a
n
rk er

ZXT335-1006101

Fig. 8-117
Ma t
In

8-62 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

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

Threads (bolt - swing bearing):

Thread adhesive (Tianshan 1277)
Mounting bolts (swing bearing):
Step 1:
Use a pneumatic spanner to tighten the
bolts.

.
De al
Step 2:

pt
Tightened to:
927±103 Nm {94.6±10.5 kgm}
g n
A. When a torque wrench is used to
o
tighten the bolts, tighten first the four
in ti

corners and then mark them.

B. Other bolts will be tightened clockwise 营
销
公
司

or counterclockwise. After one bolt is

et a

tightened, tighten the next one on the

n

diagonal position and make a mark.

C. Tighten the rest bolts in the same way.
rk er

● Let the S mark in the soft zone of the

Ma t

inner race of the inner ring face the

In

right side, as shown in the photo, and

install the swing bearing to the track Inner race
frame. soft zone

● Apply grease to the inside of the gear

ring of the swing bearing.
All gear teeth must be covered by
grease .
Swing bearing:
ZXT335-1006102
Grease(MoS2 G2-LI):15 L Fig. 8-118

Shop Manual - April 2014 8-63

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.18 Swing frame AS

8.18.1 Removal
Fully extend the arm and the bucket. Lower
the work equipment to the ground and engage
the hydraulic lockout control.
1. Disassemble the work equipment assem-
bly. See “Work Equipment AS” on page 8-97.
2. Remove the counterweight assembly. See
“Counterweight AS” on page 8-104. 1

3. Remove the four (4) hoses (1) of boom

.
De al
cylinder.

pt
Cork the hoses to stop oil flowing out.
ZXT335-1006103
4. Lift the boom cylinder assembly (2).
g no
Fig. 8-119
in ti

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

司
公
销
营
et a
n
rk er
Ma t

2
In

ZXT335-1006104

Fig. 8-120

8-64 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

the boom cylinder assembly (2) in order to

disassemble it.
Remove the boom cylinder assembly on 4
the other side in the same way.
Boom cylinder AS: 264 kg
6. Remove the plate (5), air intake hose (6) 3

ZXT335-1006105

Fig. 8-121

.
De al
and fan guard (7).

pt
Removal of the swing frame requires
g n
removing other parts that interfere with the
lifting of swing frame.
o
7. Disconnect the six (6) hoses over the
in ti

6 7
5
司
公
销
营
et a
n

rotary joint assembly on the side of swivel ZXT335-1006106

rk er

joint. Fig. 8-122

(8): Central swivel joint (port A)-
Ma t

Left travel control valve (port BTL)

In

(9): Central swivel joint (port C)-

Left travel control valve (port ATL)
(10): Central swivel joint (port F)-
Solenoid valve
(11): Central swivel joint (port G)-
Swing motor (port T)
8 9 10 11 12 13
(12): Central swivel joint (port D)-
ZXT335-1006107
Right travel control valve (port ATR)
Fig. 8-123
(13): Central swivel joint (port B)-
Right travel control valve (port BTR)
8. Remove the bolt (14).
9. Unscrew the 32 swing frame mounting

Shop Manual - April 2014 8-65

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

bolts in order to remove the swing frame

assembly (15). Lift the swing frame as-
sembly off the machine. 15

● Remove the front and rear mounting

bolts of the platform. Use a lever block
to adjust the swing frame so that the
platform can reach a balance both
longitudinally and laterally. Remove the
last two bolts finally.
Take care not to damage the central
swivel joint assembly while removing ZXT335-1006108
the swing frame assembly.

.
Swing frame assembly:

De al
pt
Only swing
Model Assembly (kg)
g n frame (kg)
SY365(B)H-9 14,755 3,040
o
in ti

司
公

8.18.2 Installation
销
营
et a

● Installation is performed in the reverse procedure of removal.

n
rk er

Clamping screws (air intake hose): 5.4~6.4 Nm {0.55~0.65 kgm}

Ma t

Mating surface (swing bearing): Flat surface sealant (Tianshan 1596)

In

Threads (bolt - swing frame): Thread adhesive: (Tianshan 1277)

Mounting bolts (swing frame):
Step 1: Tighten the bolts with a pneumatic spanner.
Step 2: tighten them again. 490~608 Nm {50~62 kgm}
● Refilling of hydraulic oil
Refill through the filler opening the hydraulic oil to the specified level. Start the engine to circu-
late oil in the hydraulic system, and check the oil level again.
● Purging the air
Purge the air from the travel motor. See “Air in Each Component - Purge” on page 6-41.

8-66 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.19 Swivel Joint AS

8.19.1 Removal
Release remaining pressure in the hydraulic
return circuit. See “Remaining Pressure in
Hydraulic Lines - Relieve” on page 6-36.
● Tag each line so as to ensure correct rein-
stallation.
1. Disconnect the hoses (1) through (8) on
the central swivel joint of the travel motor.
1
(1): Central swivel joint (port T) -

.
2

De al
Left travel motor (port T)

pt
(2): Central swivel joint (port T) -
g n ZXT335-1006109

Right travel motor (port T) Fig. 8-124

o
(3): Central swivel joint (port B) -
in ti

Left travel motor (port PA)

(4): Central swivel joint (port D) - 销
公
司
3
4
营

8
et a

Right travel motor (port PB)

5
(5): Central swivel joint (port A) -
n

Left travel motor (port PB)

rk er

6
(6): Central swivel joint (port C) - 7
Right travel motor (port PA)
Ma t

ZXT335-1006110
(7): Central swivel joint (port E)-
In

Fig. 8-125
Left travel motor (port X)
(8): Central swivel joint (port E) -
Right travel motor (port X)

Shop Manual - April 2014 8-67

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

2. Disconnect the hoses (7) through (12)

between:
(9): Central swivel joint (port T) - 14
Swing motor (port Dr) 13
(10): Central swivel joint (port E) -
Solenoid valve (port PT)
11 12
(11): Central swivel joint (port C) -
Left travel control valve (port BTL)
9
(12): Central swivel joint (port A) - 10
Right travel control valve (port ATL)

.
De al
(13): Central swivel joint (port D) - ZXT365-1308111

pt
Left travel control valve (port BTR) Fig. 8-126
g n
(14) Central swivel joint (port B) -
Right travel control valve (port ATR)
o
in ti

3. Remove the two(2) pin rolls (16) in order to

remove the plate (15). 营
销
公
司
et a

4. Remove the four bolts (a) in order to

16
remove the plate (b).
n

15
b
rk er

16
Ma t

ZXT335-1006112
In

Fig. 8-127

5. Remove the four mounting bolts (17).

17

ZXT335-1006113

Fig. 8-128

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SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

6. Remove the swivel joint assembly (18).

Central swivel joint: 45 kg

18

ZXT335-1006114

Fig. 8-129

.
De al
pt
8.19.2 Installation
g n
● Installation is performed in the reverse pro-
o
cedure of removal. B D
in ti

Install the central swivel joint facing the di- 营

销
公
司

rection indicated in the illustration.

et a

Central swivel joint

(In the illustration, the machine is viewed
n

from the above.) Sprocket

rk er

● Refilling of oil (hydraulic tank)

Refill through the filler opening the hydrau-
lic oil to the specified level. Start the engine
Ma t

to circulate oil in the hydraulic system, and

In

check the oil level again.

A C
ZX335-1006115
● Purging the air
Fig. 8-130
Purge the air from the travel motor. See
“Air in Each Component - Purge” on
page 6-41.

Shop Manual - April 2014 8-69

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.20 Central Swivel Joint AS

8.20.1 Disassembly
1
1. Remove the fixing bolt (1).
2
2. Remove the cover (2).
3
3. Remove the rotor (12) from the housing (6). 4
5
● Take care not to damage the sliding
surface of the seal of the rotor (12).
4. Remove the O-ring (3), oil seal (8) and 6
retainer (7) from the housing (6).

.
5. Remove the rotary seal (9) and O-ring (10)

De al
7
from the housing (6).

pt
8
6. Remove the oil seal (11) from the rotor (12).
g n 9
10
11
o
in ti

8.20.2 Assembly
1. Install the oil seal (11) on the rotor (12). 营
销
公
司

12
et a

● Let the lip face the dust ring of housing.

n

2. Install the O-ring (10), rotary seal (9) in the

housing (6).
rk er

13
3. Fix the rotor (12) on a work bench. Install
the housing (6) on the rotor (12).
Ma t

ZX335-1006116
The clearance between the housing (6)
and the rotor (12) approximates 0.1 mm, Fig. 8-131
In

so the rotor must be inserted slowly in the

axial direction. Take care not to damage
the rotary seal and the O-ring. Dust ring

4. Use a rubber hammer to tap the housing (6)

in order to match the rotor (12) properly.
Lip
5. Install the O-ring (3) and retainer (7) on the
rotor (12).
6. Install the cover (2) and tighten the bolts Housing

(1).
ZX335-1006117

Fixing bolts: 49 Nm {5 kgm} Fig. 8-132

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SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.21 Hydraulic Tank AS

8.21.1 Removal
1. Drain oil from the hydraulic tank. 1

Hydraulic oil: About 260 L

2. Open the engine hood.
2
3. Remove the engine hood (1), beam (2)
and control valve cover (3).
3

.
De al
pt
ZXT335-1006118

g n Fig. 8-133
o
4. Remove the covering (4) and the main 4
pump partition (5).
in ti

6
5. Remove the engine partition (6) and the
bracket (7) at the hydraulic tank side. 营
销
公
司
et a
n
rk er

5
7
Ma t

ZXT335-1006119

Fig. 8-134
In

6. Remove the two(2) oil return tubes (8) and 8

(9) of the hydraulic tank.

ZXT335-1006120

Fig. 8-135

Shop Manual - April 2014 8-71

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

7. Remove the six hoses.

(10): Oil return (T-block, pilot)
15 16
(11): Oil return D2 (main valve) 14

(12) & (13): Oil return (leak of main pump)

(14): Oil return (solenoid valve) 13

(15): Oil return D1/D3 (main valve)

(16): Oil return (swing motor) 12

● Tag the hoses for identification. 10 11

● Use socket nuts to protect the hose ZXT335-1006121

connectors and cone seals against Fig. 8-136

.
damage.

De al
pt
g n
8. Disconnect the oil suction tube (17) from
o
the bottom of hydraulic tank and the oil
suction hose (18) connected with the oil 17 18
in ti

suction tube of the main pump.

9. Remove the six (6) mounting bolts (19) 营
销
公
司

19
from the bottom of hydraulic tank. Lift the
et a

hydraulic tank assembly.

n

10. Move the hydraulic tank assembly away in

rk er

order to disassemble it. ZXT335-1006122

Hydraulic tank AS: 234 kg Fig. 8-137

Ma t
In

8-72 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

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

Drain plug (hydraulic tank):

58.8~78.5 Nm {6.0~8.0 kgm} Screw

● After tightening the hose clamping

screw, check that the screw should be
Upper side
in the range indicated in the illustration. Lower side

.
Screw (hose clamp):

De al
8.8±0.5 Nm {0.9±0.05 kgm}

pt
g n ZX335-1006123

Fig. 8-138
o
in ti

● Install the hose clamp and tighten the

screw according to the illustration on 营
销
公
司

the right. Tube Hose

et a
n

Bolt:
rk er

245.2~308.9 Nm {25~31.5 kgm} O-ring seal 2 O-ring seal 1

● Refilling the oil (to hydraulic tank)

Ma t

Refill hydraulic oil through the filler opening

In

to the specified level. Start the engine to Clamp 2 Clamp 1

circulate oil in the hydraulic system, and ZX335-1006124
check the oil level again. Fig. 8-139
● Purging the air
See “Air in Each Component - Purge”
on page 6-41.

Shop Manual - April 2014 8-73

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.22 Control Valve AS

8.22.1 Removal
Lower the work equipment to the ground in
order to ensure safety. Stop the engine. Power
on the machine and relieve system pressure.
Use the breather valve to release the pressure
in the hydraulic tank. Place the hydraulic lock- 1
out control in the LOCK position.
2
● Tag each line so as to ensure correction
reinstallation.

.
1. Remove the engine hood (1).

De al
2. Remove the coverplate (2) on the control

pt
valve. ZXT335-1006125

Fig. 8-140
g no
3. Remove the engine partition (3).
in ti

司
公
销
营
et a

3
n
rk er
Ma t

ZXT335-1006900
In

Fig. 8-141

4. Remove the pressure sensor guard (4).

ZXT335-1006901

Fig. 8-142

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SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

5. Remove the ten (10) pilot hoses (from left

to right) and tag them properly. The hoses
are for:
(5) Left travel
14
(6) Right travel 12 13
5 6 7 8 9 10 11
(7) Arm OUT
(8) Left swing
(9) Bucket DIG
(10) Boom DOWN
ZXT335-1006902
ZXT335-1006902
(11) Boom UP
Fig. 8-143

.
(12) Right swing

De al
pt
(13) Bucket DUMP
(14) Arm IN
g n
6. Remove the two(2) pilot hoses on the
o
16
control valve and tag them properly. The
in ti
hoses for:
15
(15): Right travel forward 营
销
公
司

(16): Left travel forward

et a
n
rk er

ZXT335-1006903

Fig. 8-144
Ma t
In

7. Remove the pressure sensor harness (17).

17

ZXT335-1006904

Fig. 8-145

Shop Manual - April 2014 8-75

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8. Remove the clamp (18) fixing the harness

of solenoid valve.

18

ZXT335-1006905

Fig. 8-146

.
De al
pt
9. Disconnect the hoses (19) and (20) from
g n
the check valve block to the pilot pump and
swing motor port (PG).
o
in ti

司
公
销
营
et a
n

19
rk er

20
ZXT335-1006906

Fig. 8-147
Ma t
In

23 22
10. Remove the boom tube clamp (21) on the
main valve.
11. Remove the tubes (22) and (23) from the
main valve to boom cylinder. Seal the ports
properly.

21

ZXT335-1006907

Fig. 8-148

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SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

12. Disconnect the bucket hoses (24) and (25).

Seal the ports properly.
13. Disconnect the arm hoses (26) and (27).
Seal the ports properly.

24 25
26 27

ZXT335-1006908

Fig. 8-149

.
De al
14. Disconnect the hoses (28), (29), (30) and 29

pt
(31) between the central swivel joint and 30
the main valve. Seal the ports properly.
g n 28 31

15. Disconnect the swing motor hoses (32)

o
and (33). Seal the ports properly.
32
in ti

16. Disconnect the hose (34) between control 35

33
valve and swing motor port (M) and the 34
hose (35) between control valve and swivel
司
公
销
营
et a

joint.
n

ZXT335-1006909
rk er

Fig. 8-150
Ma t

17. Disconnect the tube or hose (36) of radia- 36

37
tor and the oil return tube (37) of hydraulic
In

tank. Seal the ports properly.

ZXT335-1006137

Fig. 8-151

Shop Manual - April 2014 8-77

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

18. Disconnect the hydraulic pump hoses (38)

and (39).

39
38

ZXT335-1006138

Fig. 8-152

.
De al
pt
19. Remove the two pilot hoses under the
control valve and tag them properly.
g n
(40) Right travel backward 41
40
o
(41) Left travel backward
in ti

司
公
销
营
et a
n

ZXT335-1006139

Fig. 8-153
rk er

20. Remove the harness and hoses of the

Ma t

solenoid valve and tag them properly. 42

In

(42) Oil return hose 43

(43) Harness
(44) Negative feedback hose from solenoid
valve to front pump 45
44 46
(45) Negative feedback hose from solenoid
valve to rear pump ZXT335-1006140

(46) Oil feed hose from solenoid valve to Fig. 8-154

PT block

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SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

21. Remove the bolts (48) of the control valve

assembly. Lift the control valve assembly
in order to dissemble it.

Control valve AS: 380 kg

47

ZXT335-1006141

Fig. 8-155

.
De al
pt
8.22.2 Installation
g n
● Installation is performed in the reverse pro-
cedure of removal.
o
● Refilling the oil (to hydraulic tank)
in ti

Refill hydraulic oil through the filler open-

ing to the specified level. Start the engine
司
公
销
营
et a

to circulate oil in the hydraulic system, and

check the oil level again.
n

● Purging the air

rk er

See “Air in Each Component - Purge”

on page 6-41.
Ma t
In

Shop Manual - April 2014 8-79

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.23 Hydraulic Pump AS

8.23.1 Removal
Lower the work equipment to the ground in
order to ensure safety. Stop the engine. Press
the release button of the breather valve to re-
lease remaining pressure in the hydraulic tank.
Disconnect the cable from the negative (-)
post of the battery before performing the job.
Oil stopper
● Tag each line so as to ensure correction
reinstallation.

.
De al
1. Remove the oil inlet filter element from the

pt
ZX335-1006142
hydraulic tank and stop oil outflow with an
oil stopper. g n Fig. 8-156
If no oil stopper is used, remove the drain
o
plug and drain the oil from the hydraulic
tank and the lines. 1
in ti

Hydraulic oil tank: About 340 L

司
公
销
营

2. Remove the engine hood (1)

et a
n
rk er

WT365081301
Ma t

Fig. 8-157
In

3. Remove the rod (2) and bolts (3). Lift the

engine hood.

2
ZXT335-1006144

Fig. 8-158

8-80 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

4. Remove the upper right coverplate (4).

ZXT335-1006145

Fig. 8-159

.
De al
pt
5. Disconnect the hose (5) supplying oil to the
lower proportional valve and the hose (6)
g n
delivering oil from the pilot pump. Seal the
o
ports properly.
5
in ti

营
销
公
司

6
et a
n
rk er

ZXT335-1006146

Fig. 8-160
Ma t
In

6. Remove the shutdown device line (7).

7
ZXT335-1006147

Fig. 8-161

Shop Manual - April 2014 8-81

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

7. Remove the right door (8).

8. Remove the hydraulic pump cover (9).

8
9

ZXT335-1006148

Fig. 8-162

.
De al
pt
9. Disconnect the oil drain hose (10) and seal
the ports properly.
g n 13
10. Disconnect the high-pressure hoses (11)
o
and (12) connected to the control valve,
in ti

and seal the port properly.

12
11. Disconnect the harness (13) of the pres- 营
销
公
司

sure transducer. 11
et a

12. Disconnect the pilot pump oil suction hose 10

n

(14) and seal the port properly.

rk er

13. Disconnect the hydraulic pump oil suction 14 15 ZXT335-1006149

tube (15) and seal the port properly.
Fig. 8-163
Ma t
In

14. Disconnect the solenoid valve harnesses

(16) and (17).
16

17

ZXT335-1006150

Fig. 8-164

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SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

15. Remove the four bolts (18) of the hydraulic

pump. Lift the hydraulic pump assembly 19
(19) in order to disassemble it.
Hydraulic pump assembly: 186 kg

18
ZXT335-1006151

Fig. 8-165

.
8.23.2 Installation

De al
pt
● Installation is performed in the reverse pro-
cedure of removal.
g n Screw
o
● After tightening the hose clamping
screw, check that the screw should be
in ti

in the range indicated on the right illus- Upper side

tration. 营
销
公
司
Lower side
et a

Screw (suction hose clamp):

n

10~13 N·m {1.0~1.3 kgf·m}

ZX335-1006123
rk er

● Install the hose clamp and tighten the Fig. 8-166

screw according to the illustration on
the right.
Ma t
In

Mating surface (hydraulic pump

housing):
Tube Hose
Gasket sealant: (Loctite 515)
● Refilling the oil (to hydraulic tank)
Refill hydraulic oil through the filler open-
ing to the specified level. Start the engine O-ring seal 2 O-ring seal 1
to circulate oil in the hydraulic system, and
check the oil level again.

Clamp 2 Clamp 1

Hydraulic tank: About 340 L ZX335-1006124

● Purging the air Fig. 8-167

See “Air in Each Component - Purge”
on page 6-41.

Shop Manual - April 2014 8-83

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)

8.24.1 Removal
1. Remove the hydraulic pump assembly (1).
See “Hydraulic Pump AS” on page 8-80.
1
2. Remove the screw (2). Remove the bear-
ing cover (3). 2
3
3. Pry the oil seal (4) out with a screwdriver. 4

● Take care not to damage the shaft

while prying the oil seal.

.
De al
pt
8.24.2 Installation
g n ZX335-1006152

● Installation is performed in the reverse pro- Fig. 8-168

o
cedure of removal.
in ti

司
公
销
营

Seal lip: grease (No.1 Calcium base 4

et a

grease)
n

Seal circumference: grease (No.1

rk er

Calcium base grease)

● Apply a thin layer of grease to the oil
Ma t

seal circumference.
In

ZX335-1006153

Fig. 8-169

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SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.25 Pilot Valve AS (Work Equipment)

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

8 9

1 2 3 4 5 6 7 10

.
De al
ZXT335-1006154

pt
Fig. 8-170 g n
● Reassembly of the work equipment pilot Apply the thread adhesive (Tianshan 1277)
o
valve assembly to two points on the inner threads, as
in ti
indicated in the illustration on the right. The
1. Install the plate (9) in the valve body
amount of application is approximately 0.02
(8) with O-ring seal. Tighten the socket-
g.
司
公
销
营

headed screw (10).

et a

U-joint (3): 98~133 Nm {10~13.5

Screw (socket head): 25~33 Nm
kgm}
n

{2.55~3.36 kgm}
● Tightening is to be made to the speci-
rk er

2. Insert the spring (7) into the spool hole in

fied torque.
the valve body (8). Put the spool (6) in the
spring. Install the plug (5) on the spool.
Ma t

Push the plug (5) to the spool hole.

5~7 mm
In

3. Install the plate (4) on the plug (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 Nm {10~13.5 kgm}
● Location of each oil port is stamped on
the bottom of valve body. ZX335-1006155

Plug (5) circumference: Grease Fig. 8-171

(No.1 Calcium base grease)
Contact surface between plug (5)
U-joint working surface: Grease
and plate (2): Grease 0.3~0.8cc (G2-L1)
(No.1 Calcium base grease)
● After assembling plate (2) see “Work
Threads in valve body: Thread ad-
Equipment and Swing Pilot Valves -
hesive (Tianshan 1277)
Adjust” on page 6-33.

Shop Manual - April 2014 8-85

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.26 Travel Pilot Valve AS

● This section discusses only the precautions when reassembling the travel pilot valve assem-
bly.

Pushrod

.
De al
pt
9
g n
8 7 6 4 3 2 1
o
5 ZXT335-1006156
in ti

Fig. 8-172
司
公

● Reassembly of pedal pilot valve assembly

销
营
et a

1. Install the spring (8) into the spool installation hole in the body assembly (9). Install the spool
n

(7). Place the cover assembly (6) on the spool and press the cover assembly (6) with a hand.
rk er

2. Install the cover (4) after aligning the holes. Tighten the socket-headed bolts (1).
Bolt (socket head): 98~114 Nm {10~11.6 kgm}
3. Install the dust ring (3) on the plug. Install the cover (2) and fix the cover (2) with the camshaft
Ma t

(5).
In

Contact surface between the plug and the dust ring (3): Grease (No.1 Calcium base
grease)

8-86 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.27 Hydraulic Cylinder AS

Special tools

Tool Description Sketches Necessity Quantity

For pulling out/

pushing in the ■ 1
bushing

.
De al
For press fitting the
■ 1

pt
dust ring

g no
in ti

For O-ring seal cor-

■ 1
rection 营
销
公
司


et a


For insertion For correction
n


rk er

For inserting the

■ 1
cylinder head 
Ma t
In

For inserting the

■ 1
piston


Shop Manual - April 2014 8-87

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.27.1 Disassembly
1. Drain the oil and remove the tubing.
2. Fix the cylinder.
● Fix the cylinder in a vertical or level
manner. A vertically fixed cylinder can
be disassembled and assembled eas-
ily.
● The pin hole in the head end can be
used for fixing of the cylinder. The pin
roll can prevent the cylinder from turn-
ing.

.
● Remove the tubing in case of tubing in-

De al
terference while fixing the cylinder.

pt
g no
Secure the cylinder
in ti

司
公
销
营
et a
n
rk er
Ma t

ZX335-1006162
In

Fig. 8-173

3. Removal of cylinder head

Approx 1.5 m
● Unscrew the bolts with Allen Wrench.
● Using an extension rod, as shown in
the illustration on the right, will make
the work easy.

ZX335-1006163

Fig. 8-174

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SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

4. Pulling out the piston rod

● Be sure to have removed the tubing
cover.
● Prepare a suitable container to collect 1 2
oil coming out of the oil port.
● After pulling out the piston rod (1) to its
limit, slowly loosen the cylinder head Sleeper

and pull it out.

● Remove piston rod (1) with cylinder ZX335-1006164
head (2) and place them on a wooden Fig. 8-175
sleeper.

.
De al
pt
5. Securing the piston rod
g n Secure 5
● Pin hole on the rod end or the flat part
o
of the ear can be used to fix the piston
rod and prevent it from turning.
in ti

司
公
销
营
et a

ZX335-1006165

Fig. 8-176
n
rk er

6. Remove of piston nut (5)

Drill bit
Ma t

A. Remove the fixing screw (3) from the

3
piston nut (5).
In

● Around the fixing screw there are two

points that have been punched against
loosening. After removing the riveted
part with a hand drill, loosen and re-
move the fixing screw (3).
B. Remove the steel ball (4) inside the
fixing screw.
4 ZX335-1006166

Fig. 8-177

Shop Manual - April 2014 8-89

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

C. Remove the piston nut (5). 5

● The piston nut (5) is very tight. To
loosen the piston nut (5), prepare a
hydraulic jack or a spanner powered
by hydraulic cylinder. An extension rod
should be ready when removing the
piston nut (5) manually. Hydraulic jack

Hydraulic cylinder

ZX335-1006167

Fig. 8-178

.
7. Removal of piston assembly

De al
pt
Remove in turn the piston (7), buffer sleeve 2 6 7
(6) and cylinder head (2).
g no
in ti

ZX335-1006168

Fig. 8-179
司
公
销
营
et a
n

8. Removal of the buffer sleeve (8) on the

Threads
rk er

head end
A. Remove first the piston nut (5).
B. Use a tool like rubber hammer to tap
Ma t

Piston rod
the piston nut (5) slightly in order to
In

remove it. The piston rod and the

buffer sleeve (8) should be kept intact.
Remove the elastic retainer (9).
C. Slide the buffer sleeve (8) toward the
9 11
piston threads in order to remove the 10 8
With one opening (two-piece type)
two-piece stopper ring.
ZX335-1006169
D. Remove the buffer sleeve (8). Fig. 8-180
E. There is an opening in the buffer seal
(10). Take advantage of this opening to
remove the buffer seal (10).

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SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

9. Removal of piston seal

Screwdriver
A. The slide ring (12) and the guard
ring (13) can be simply removed with 14 12
Piston
hands.
B. The seal (14) can be removed with a Bench clamp
hammer and a flat-head screwdriver.
C. Remove the O-ring seal (15) with a pry
bar.
● The removed seals should not be re- 15 13 ZX335-1006170
used.
Fig. 8-181
10. Removal of buffer ring (16)

.
De al
● The buffer ring (16) is installed in the

pt
inner groove in the cylinder head. Use
a tool with sharp end to pry it out and
18
g n
remove it with a scraper.
11. Removal of the U-ring (17) and the dust
o
ring (18).
in ti

A. Remove the U-ring (17) with a tool such

as screwdriver. 20
17 16 19
司
公
销
营
et a

B. Press a tool (such as a screwdriver) ZX335-1006171

against the dust ring (18) and hammer Fig. 8-182

n

the screwdriver to remove the dust ring

rk er

(18).
● The removed seals should not be re-
used.
Ma t

Press
12. Removal of bushing (19)
In

A. Remove the elastic ring (20) from the

cylinder head (2) with a screwdriver.
B. Push the bushing (19) out with the help Block

of clamps and press.

13. Removal of pin bushing (21)
21
A. Remove the dust ring (22) on the side
of cylinder barrel and piston rod with a
tool such as screwdriver.
B. Remove the bushing (21) with the help
of a suitable cushion block. Support
ZX335-1006172

Fig. 8-183

Shop Manual - April 2014 8-91

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.27.2 Assembly
Press
1. Installation of bushing (21)
Installation tool
A. Use an installation tool to press the
bushing (21) into the bushing (lubricated Block
Piston rod
with hydraulic oil) on the side of piston 21
22
rod and cylinder barrel.
B. Install the dust ring (22) with the help of 21
a suitable cushion block. ZX335-1006173

Fig. 8-184

2. Assembly of cylinder head (2)

.
De al
Hydraulic press
A. Use the press to push in the bushing

pt
(19). g n
● Apply hydraulic oil to the inside of
cylinder head in advance. Make sure 2
o
Too
that the bushing (19) pushed in is
in ti
free from a raised shoulder.

司
公
销
营
et a

B. Use the press to push in the dust ring

(18).
n

19
C. Install the guard ring and the U-ring (17) Under pressure
rk er

sequentially in the U-groove.

● Install the U-ring (17) in correct direc- ZX335-1006174
tion. Make sure that the U-ring is in-
Ma t

Fig. 8-185
tact before installation.
In

● Inverse installation will cause leak of

oil.
● Make sure that the U-ring is free from 18
Tool
any corrugation or permanent defor- U-groove
mation after installation.
D. Installation of buffer ring (16) Press in

● Make sure that the seal is installed in

correct direction. Inverse installation
can cause high pressure between the ZX335-1006175
buffer ring (16) and the U-ring (17), Fig. 8-186
which may lead to deformation or
breakage of oil cylinder.
E. Install the elastic ring (20) to prevent
the fall of the bushing (19).

8-92 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

3. Assembling the piston assembly

Press in
Block Press in
A. Installation of seal (14).
● Install first the O-ring seal and the Tool
one-side guard ring (13) on the pis- 13
ton. Place the piston on the press. As
shown in the illustration on the right, Tool Tool for
the seal (14) is installed with the tools correction

indicated.
Piston
B. Correction of seal (14)
12 O-ring
● Install the seal (14) and the guard ring
14
(13) on the other side. In order to pre-
13
vent the expansion of the seal (14), a

.
De al
corrector must be used to correct the ZX335-1006176

pt
seal (14) which has been stretched Fig. 8-187
during installation. The piston rod
g n
may not be able to go in the cylinder
barrel if the seal (14) is not corrected
o
timely.
in ti

C. Installation of slide ring (12)

● Slightly open the slide ring (12) and 营
销
公
司

install it axially. Excessive opening of

et a

the slide ring (12) can fail installation.

n
rk er

4. Assembling the piston rod assembly

Assembling tool 2
A. Fix the piston rod (1).
Ma t

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

In

● 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. 1 ZX335-1006177

Fig. 8-188

Shop Manual - April 2014 8-93

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

C. If the bottom side of cylinder contains

a buffer (not for bucket cylinder), install The opening faces the threads.
the buffer bearing and the buffer seal in Threads

the following order.

a. Let the notched side of the buffer
seal (10) face the piston while Piston rod
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.
9 10 8 11
c. Install the stopper ring (11) in the With one opening (Two piece type)

.
groove. Install the elastic ring after

De al
the buffer sleeve (8) is pushed Head end buffering

pt
ZX335-1006178
to the bottom. A rubber hammer Fig. 8-189
should be used for the tapping job
g n
in order to avoid damaging the
o
piston rod and the buffer bearing.
in ti

D. If the head side of cylinder contains a

buffer, install the buffer sleeve (6) and 23 6
5
the buffer seal (23) according to the
司
公
销
营
et a

following order.
n

a. The piston nut must be installed

after installation of the buffer bear-
rk er

ing.
b. T h e b u ff e r s e a l ( 2 3 ) m u s t b e
installed in the groove, with its
Ma t

notches facing the piston.

In

The opening faces the piston side.

c. The buffer sleeve (6) must be
Rod end buffer
installed according to the illustration ZX335-1006179
on the right.
Fig. 8-190
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

8-94 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

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-
Punch
ening the nuts. Rivet

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- 3
eral points.
4
Setscrew (3):

.
De al
66.9 Nm {6.8 kgm}

pt
5. Install the piston into the cylinder barrel.
g n ZX335-1006180
A. Fix the barrel in a vertical or level man-
ner.
o
Fig. 8-191
B. Install the piston rod into the cylinder
in ti

barrel.
Tool
● If fixed in a vertical manner, the pis-
司
公
销
营

Nylon sleeve
et a

ton rod falls into the barrel under its (two pieces)
gravity.
n

● Make sure that the slide ring does

rk er

not fall while the piston is inserted (Move the notch

into the barrel. 180 degrees away.)
Ma t
In

ZX335-1006181

Fig. 8-192

Shop Manual - April 2014 8-95

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

6. Tightening of cylinder head

Tighten the bolts following the sequence 8 1
shown in the illustration on the right.
4 9
Bolt: 267 Nm {27.2 kgm}
7. Install the tubing.
12 5

6 11

10 3

.
2 7

De al
pt
Bolt tightening sequence
g n ZX335-1006182

Fig. 8-193
o
in ti

司
公
销
营
et a
n
rk er
Ma t
In

8-96 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

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).
5

.
De al
2. Lift the boom cylinder assembly (2). 1 3

pt
Remove the lockbolt (3).
3. Remove the plate (4) and then the pin roll (5
).
g no
● There are shims installed. Count the 4
shims and check the thickness. Place
in ti

the shims in a safe place.

4. Start the engine and retract the piston rod.
司
公
销
营

2
et a

● Secure the piston rod with a wire rope

ZXT335-1006183
n

in order to prevent the piston from slip-

ping out. Place the cylinder on a bench Fig. 8-194
rk er

or support. The grease fitting on the

bottom side must be removed in the
later case.
Ma t

● Remove the other boom cylinder in the

In

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 outflow of oil.
Tie the hoses to the valve side
6. Remove the mid-connector (8) used for
work lamp. 8
6
7 7 7 6
ZXT335-1006184

Fig. 8-195

Shop Manual - April 2014 8-97

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

7. Lift the work equipment and remove the

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

There are shims installed. Count the shims 10

and mark their locations.

9
ZXT335-1006185

Fig. 8-196

.
De al
pt
8. Lift the work equipment assembly (11) in
order to disassemble it.
g n 11
o
Work equipment assembly:
in ti

Model Weight

SY365H-9 5,652 kg 营
销
公
司
et a

SY365BH-9 7,102 kg
n

ZXT335-1006186
rk er

Fig. 8-197
Ma t
In

8-98 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

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 (MoS2 G2-L1)

WARNING

.
a

De al
ZX335-1006187
● Never use your finger to align the pin

pt
holes. Fig. 8-198
g n
● Adjust the shim thickness in order to
o
have a desired clearance (a: 0.5 ＜ a 12 a
4
＜ 1 mm) between the piston end (12)
in ti

and the plate (4).

司
公
销

● Standard shim thickness: 1.0 mm and

营
et a

2.0 mm.
n
rk er

Greasing after assembling the pin: ZX335-1006188

Grease (MoS2 G2-LI) Fig. 8-199

Ma t
In

WARNING

● Never use your finger to align the pin

holes.

● Refilling 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.

Shop Manual - April 2014 8-99

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.29 Air Conditioner AS

Special tools

ID Part Name Model Necessity Qty

Refrigerant
S - ● 1
refiller

8.29.1 Removal

NOTICE S

.
De al
● Always disconnect the cable from nega-

pt
tive post of the battery before you pro- ZXT335-1006189
ceed.
Fig. 8-200
g no
1. Drain the coolant.
in ti

Coolant: Approx 22.5 L

2. Recover refrigerant from the air-condition- 营
销
公
司

ing system with the tool (S).

et a

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

n
rk er
Ma t

ZXT335-1006190
In

Fig. 8-201

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

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

Cover 2
ZXT335-1006191

Fig. 8-202

8-100 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

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.

4
3
5
ZXT335-1006192

Fig. 8-203

.
De al
pt
7. Remove the back cover (6).
g no
in ti
6

司
公
销
营
et a
n
rk er

ZXT335-1006193

Fig. 8-204
Ma t
In

8. Remove the back air duct (7).

7 8
9. Remove the left air duct (8).
10. Remove the baffle (9).
11. Remove the right air duct (10). 10
9

ZXT365-1308197

Fig. 8-205

Shop Manual - April 2014 8-101

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

12. Remove the cover (11).

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

13
12

11
ZXT335-1006195

Fig. 8-206

.
De al
pt
15. Remove the air duct (14) and the control-
ler wiring connector (15). Disconnect the
g n
wiring connector (16). Remove the air 17
o
conditioner relay (17). Remove the three 16
(3) mounting bolts (18) and then the board
in ti

(19).
司
公
销
营
et a
n

19
18
rk er

15
14 ZXT335-1006196

Fig. 8-207
Ma t
In

16. Remove the air conditioner water pipes

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

ZXT335-1006197

Fig. 8-208

8-102 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

17. Remove the air conditioner unit (23).

Also disconnect the two hoses connecting
to the bottom of the air conditioner when 23
removing the air conditioner unit.

ZXT335-1006198

Fig. 8-209

.
De al
pt
8.29.2 Installation
g n
● Installation is performed in the reverse pro-
cedure of removal.
o
Keep the hoses free from contamination by
in ti

dirt, dust or water while installing the return

hose of the air conditioner. 营
销
公
司
et a

Make sure that the O-ring seal is present

in the connection before connecting a hose
n

of the air conditioner.

rk er

Make sure that the O-ring seals are free

from any damage or deformation.
Ma t

● Apply compressor oil (ND8#) to the

In

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

Shop Manual - April 2014 8-103

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
2
equipment to hold the counterweight.

.
De al
ZX365-1308163

pt
g n Fig. 8-210
o
2. Remove the four mounting bolts (2 ) and
washers.
in ti

3. Lift the counterweight with lifting equip-

ment. 营
销
公
司
et a

Take care not to damage the engine, radia-

tor and cooler.
n

Counterweight AS: 6800 kg

rk er

3
Ma t

ZX365-1308164
In

8-104 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

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}

.
De al
● Counterweight Installation and adjustment

pt
A. Lift the counterweight with a crane to a Unit: mm
suitable position over the frame.
g n 门


B. Push the counterweight and install the

c=0±5
Counterweight

o
bolts. Adjustment is to be made accord-
ing to the following specification.
in ti

a=10±4
● Clearance with swivel: 公
司
销
营

10±5 mm(L&R)
et a

b=0±5
● Clearance with bodywork door:
n

Swing frame
10±5 mm(L&R) ZX335-1006202
rk er

● Step difference from swing frame in left Fig. 8-211

to right direction
Ma t

b: max. 5 mm
In

● Step difference from bodywork door in

left to right direction
a: 10±4
● Step difference from bodywork top cov-
er in upper to lower direction
c: max. 5 mm

Shop Manual - April 2014 8-105

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.31 Cab AS

8.31.1 Removal

NOTICE

● Always disconnect the cable from nega-

1
tive post of the battery before you pro-
ceed.

1. Remove the floor mat (1).

.
De al
ZXT335-1006203

pt
Fig. 8-212
g n
2. Remove the back covers (2) and (3).
o
2
in ti

司
公
销
营
et a

3
n
rk er
Ma t

ZXT335-1006204

Fig. 8-213
In

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

harness connector (5) and the window
washer harness (6).
5 4
4. Remove the right air duct (7).

ZXT335-1006205

Fig. 8-214

8-106 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

5. Remove the fresh air filter element (8).

ZXT335-1006206

Fig. 8-215

.
De al
pt
6. Remove the fresh air duct (9).
g no
in ti

9
司
公
销
营
et a
n
rk er
Ma t

ZXT335-1006207

Fig. 8-216
In

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

10

ZXT335-1006208

Fig. 8-217

Shop Manual - April 2014 8-107

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8. Disconnect the radio connector (11).

9. Disconnect the radio harness (12).

11

12

ZXT335-1006209

Fig. 8-218

.
De al
pt
10. Remove the window washer fluid reservoir
g n
(13).
o
13
in ti

司
公
销
营
et a
n
rk er

ZXT335-1006210

Fig. 8-219
Ma t
In

11. Remove the window washer hose (14).

14

ZXT335-1006211

Fig. 8-220

8-108 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

12. Remove the decorative cap (15).

15

ZXT335-1006212

Fig. 8-221

.
De al
pt
13. Remove the five (5) bolts (16) and the
four(4) nuts (17).
g n
● Check the length of bolt before removal.
o
16
in ti
17

司
公
销
营
et a

ZXT365-1308210
n

Fig. 8-222
rk er

14. Lift the cab assembly (18) in order to

18
remove it.
Ma t

Cab AS: 105 kg

In

8.31.2 Installation
● Installation is performed in the reverse pro-
cedure of removal.
ZXT365-1308211

Bolt: 200 Nm {20.4 kgm} Fig. 8-223

Nut: 210 Nm {21.4 kgm}

Shop Manual - April 2014 8-109

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.32 Cab Window Glass

10 10

9
8
1

10

.
7

De al
pt
g no
6
in ti

10 11
司
公
销
营

4
et a

5
n

12
rk er

10
3
Ma t

ZX215-1006218
In

Fig. 8-224

(1) Right window glass ● Cab window glasses (1), (2), (5), (7) and (9)
(2) Front window glass are adhered to the window frame.
(3) Lower front glass ● When replacing front window glass (2),
(4) Cab door window glass (upper) disassemble front window assembly (12).
(5) Cab door window glass (lower) (If the cab is install with a front window as-
(6) Cab door window glass (upper) sembly, do not only replace the front win-
(7) Left side rear window glass dow glass.)
(8) Rear window glass
● For detailed information, See “Front Win-
(9) Roof window glass
dow AS” on page 8-126.
(10) Rubber sealing strip
(11) Center adjusting seal
(12) Front window assembly
(Glass and frame)

8-110 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.32.1 Removal

CAUTION

● Be careful with sharp edges that may

cut your fingers when handling broken
or cracked window glasses. Put a piece
of adhesive film (or adhesive tapes )
onto the broken or cracked window
glass to prevent possible personal in- 3
jury before you proceed. Remove all
glass fragments.

.
ZX215-1006219

De al
1. Removal of glass (3)
Fig. 8-225

pt
Glass (3) is hold in place by sealing strips.
Pull it upward carefully to remove it.
g n
2. Removal of glass (4) and (6)
o
A. Remove the sealing strip from the
in ti

frame of the cab door.

B. Push the glass outward carefully from 营
销
公
司

inside of the cab and remove glass (4)

et a

and (6) together with the frame.

n

6
rk er

4
Ma t

ZX215-1006220

Fig. 8-226
In

C. Remove glass (4) and (6) from the

frame with a screw driver.

Frame

Seal

ZX215-1006221

Fig. 8-227

Shop Manual - April 2014 8-111

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

3. Removal of glass (8)

A. Remove the retainer from the groove
8
on the rubber with an ordinary screw
driver.
B. Put a thin bamboo chip inside part A
of the retaining rubber and detach the
retainer along the edge.
C. Pat the glass from inside of the cab and
remove it. This job requires two people.

ZX215-1006222

Fig. 8-228

.
De al
pt
4. Removal of glass (1), (2), (5), (7) and (9)
9
g no
1

7
in ti

2
司
公
销
营
et a
n

5
rk er

ZX215-1006223

Fig. 8-229
Ma t
In

A. Remove the resin board, decor strip

and retainer along the edge of the
glass. Cab
Glass
B. Punch a hole through the adhesive with Drill
a drill (or a cutter) as illustrated.

Adhesive

ZX215-1006224

Fig. 8-230

8-112 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

C. Pull a piece of piano string (or steel

wire) through the hole as illustrated.

Piano string
(or metal wire)

ZX215-1006225

Fig. 8-231

.
De al
pt
D. Fix both ends of the piano string onto
(Outside of cab)
two screw drivers. Pull the wire back Cab
g n
and forth in order to cut the adhesive
Glass
o
and detach the glass from the cab. This
job requires 2-3 people.
in ti

Run the string along the center of the 司

adhesive. The string may break when

公
销
营
et a

it becomes very hot. Use different

sections of the string while cutting the
n

adhesive. Adhesive
rk er

(Inside of cab)
ZX215-1006226

Fig. 8-232
Ma t
In

Shop Manual - April 2014 8-113

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.32.2 Installation
1. Clean the remaining adhesive and rubber
on cab frame (contact surface) with a knife
or scraper (5).
● Remove the remaining adhesive and
rubber so that they will not affect the
application of new adhesive. Do not
scrape the original paint on the surface.
(Scraping of paint reduces the perfor-
mance of the adhesive.)
5

.
ZXT215-1006227

De al
Fig. 8-233

pt
g n
2. Clean the grease, dust and dirt on the
o
cab (8) and the glass (9) with unleaded
gasoline.
in ti

● Contaminant on the contact surface re-

duces the performance of adhesive.
司
公
销
营
et a

● Clean the black part on the back of the

8
n

glass.
● After cleaning, dry the glass for at least
rk er

5 minutes.
Ma t

ZXT215-1006228

Fig. 8-234
In

ZXT215-1006229

Fig. 8-235

8-114 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

3. Priming coat (10)

● Priming paint expires four (4) months af-
ter production. Do not use expired paint. Cab
11
● Use the paint within two (2) hours after it
is unsealed. 10
● Use the paint within 24 hours even if it Old adhesive edge
is sealed again immediately unsealing. on cab side
(Dispose the paint 24 hours after it is un-
sealed)
ZX215-1006230
A. Make sure the adhesive paint and glass
priming paint are well agitated before Fig. 8-236
application.

.
De al
● If the priming paint is stored in a re-

pt
frigerator, keep it under ambient tem-
perature for at least half a day before
g n
agitation.
o
(If the paint is unsealed immediately
in ti
after it is taken out of a refrigerator,
water will condense on it.)
司
公
销
营

B. Always wash a used brush (11) with

et a

unleaded gasoline before using it.

n

● Check the brush for contaminants af-

ter it has been washed. 8
rk er

● Prepare two brushes for priming

paint, one for painted surface and the
Ma t

other for glass surface.

In

C. Apply priming paint (for painted sur-

face) evenly onto the surface where
sealing rubber is to be adhered and
where adhesive agent is to be applied ZXT215-1006231
(on the cab (8)).
Fig. 8-237
Priming paint (for painted sur-
face): Sunrise MSI Primer 24
8
● Do not apply primer more than twice;
otherwise, the performance of the
primer will be reduced.
6
● Applying location: Cover the whole
area of (a) a

● Dimension of (a): 25mm ZX215-1006232

Fig. 8-238

Shop Manual - April 2014 8-115

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

● Besides the above locations, apply

primer also onto the right window
glass and the cab door lower window
glass. b

● Additional priming area on the right

window glass: (b)
● Additional priming area on the cab
door lower window glass: (c)
● Dry the primer for at least 5 minutes
(within 8 hours).
ZX215-1006233
● Do not use wrong priming paint.

.
If, for example, glass primer is mis-

De al
takenly used, wash it with unleaded

pt
gasoline. g no
in ti

营
销
公
司

c
et a
n

ZX215-1006234
rk er

Fig. 8-239
Ma t

D. Apply priming paint (for glass surface)

9
In

onto the contact surface of window

glass (9).
Glass primer:
Sunrise MSI Primer 35
● Do not apply the primer more than
twice; otherwise, the performance of
the primer will be reduced.

ZX215-1006235

Fig. 8-240

8-116 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

● Priming area: Apply the priming paint

8
on the contact surface of glass (9)
(rubber seal (6)adhering location) and
along cab frame (8).
6
● Leave a 5 mm margin uncoated along
the black strip adjacent to the clear d
area of the glass.
● When priming paint has been coated, 9
dry it for at least 5 minutes (within 8 ZX215-1006236
hours).
Fig. 8-241
● Do not use wrong primer.
If wrong glass primer is used, wash it

.
De al
with unleaded gasoline.

pt
4. Adhere rubber seal (6) (with adhesive tape
on both sides) along the inner edge of the
g n
contact surface of the glass.
o
● Do not detach the waxed paper on the
in ti
rubber seal before the window glass is
installed.
司
公
销
营

● Do not touch the cleaned area on the

et a

glass before rubber seal is adhered.

n

● Be careful not to allow the rubber seal

6
on the corners to peel off.
rk er

ZXT225-1006245

● When sticking rubber seal (6) along the

Fig. 8-242
window frame, do not overlap the two
Ma t

ends of the seal. A 5 mm gap (e) be-

tween the two ends of the seal is recom-
In

mended.
A. Stick rubber seal (6) onto the right cab
window frame as illustrated.

e 6

ZXT225-1006246

Fig. 8-243

Shop Manual - April 2014 8-117

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

● Adhere additional rubber seal (6a) onto the f

right cab window 6a
Position of the additional rubber seal:
(f): 50 mm
h
(f): 90 mm
(h): 250 mm

g
ZXT225-1006247

Fig. 8-244

.
De al
pt
B. Adhere rubber seal (6) on the left cab
window as illustrated.
g n
6
o
in ti

司
公
销
营
et a
n

ZXT225-1006248
rk er

Fig. 8-245
Ma t

C. Adhere rubber seal (6) onto the lower

In

cab door window as illustrated.

ZXT225-1006249

Fig. 8-246

8-118 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

● Adhere additional rubber seal (6b) onto the

lower cab door window frame as illustrated. j

Position of additional rubber seal:

6b
(j): 110 mm
(k): 90 mm
m
(m): 200 mm

k ZXT225-1006250

Fig. 8-247

.
De al
pt
D. Adhere rubber seal (6) onto the front 6
window glass as illustrated.
g no
in ti

司
公
销
营
et a
n

ZX215-1006243
rk er

Fig. 8-248
Ma t

● Different from the rubber seal (6) on

other window, rubber seal (6c) on the
In

bottom of the front window shall be 6

adhered onto the external edge of the 6c
lower part of the front window frame.
(If it is adhered along the inner edge,
the rubber seal will be seen through the
clear part of the glass.)

ZXT225-1006252

Fig. 8-249

Shop Manual - April 2014 8-119

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

5. Positioning of new window glass

9
A. Check the clearance between the edge
of glass and the cab in 4 directions,
and position the glass. Make sure the n
clearance is even.
B. Put a tape [6] across the glass (9) and [6]
cab (8) and draw a line (n) on it for
alignment.
Adhere tape [6] at 3 points as illustrated
for precise alignment of right window 8
glass, left rear window glass and cab ZXT215-1006245

door lower window glass. Fig. 8-250

.
De al
C. Cut the tapes across the glass (9) and

pt
the cab (8) and remove the glass.
● Do not remove the tape on the left
g n
side of the glass until the glass is
o
[6]
[6]
installed.
in ti
8 [6]

司
公
销
营

9
et a
n

ZX215-1006246
rk er

Fig. 8-251

● When positioning front window

Ma t

glass (4), cover it across the width

In

of the window frame in the horizon-

P
tal direction.
Set the clearance (p) between the
top edge of the glass and the upper
frame at 3 mm when positioning it in 4
the vertical direction.

ZX225-1006255

Fig. 8-252

8-120 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

6. Adhesive
● Store adhesion agent in dark places 13

where temperature is blow 25℃ .

● Do not heat the adhesive to above 30℃ .
● Before using adhesive that has been un- 12
sealed, remove the hardened part at the
nozzle.
A. Open the aluminum seal (13) on the
head of the cylinder (12) and install the
ZX215-1006247
nozzle.
Fig. 8-253
Adhesive:

.
De al
Sunrise MSI SR sealant U90 4463876

pt
B. Cut the tip of nozzle as illustrated.
g n
Dimension of the cut:
14
o
(q): 10 mm r
in ti

(r): 5 mm

营
销
公
司

q
et a
n
rk er

ZX215-1006248

Fig. 8-254
Ma t
In

C. Set the cylinder (12) in the gun [7].

An electrical caulking gun is more ef- 12 [7]
ficient.

ZX215-1006249

Fig. 8-255

Shop Manual - April 2014 8-121

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

4) Remove the waxed paper of the rubber

seal on the surface where adhesive is
15
to be applied.
6
5) Apply adhesive (15) along the external
edge of the rubber seal (6).

ZX215-1006250

Fig. 8-256

.
De al
pt
● Adhesive (15) for rubber seal (6) on cab
8
(8) shall be applied as illustrated:
g n s
Dimension of (s): 10 mm
o
Dimension of (t): 15 mm 6
in ti

● Adhesive (15) shall be thicker that the t

rubber seal (6). 营
销
公
司
15
et a

● Apply adhesive of the same thickness

evenly.
n

ZX215-1006251
rk er

Fig. 8-257
Ma t
In

8-122 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

● Apply adhesive (15) onto the additional

rubber seal of the right window (6a) and 6a
15
additional rubber seal of the cab door low-
er window (6b).

ZX215-1006252

Fig. 8-258

.
De al
pt
6b 15
g no
in ti

司
公
销
营
et a
n

ZX215-1006253
rk er

Fig. 8-259

7. Install window glass

Ma t

A. Install window glass (9) and align it with

In

the mark on the cab. (See step 5)

● Since the glass can not be remove
once installed, be very careful when
performing this task.
9
● Install the glass properly within 5 min-
utes after adhesive has been applied.
B. Press the perimeter of the glass (9)
after is has been put in place until it is
ZXT215-1006254
securely stuck to the rubber seal.
Fig. 8-260
● Press the corners of the glass hard.

Shop Manual - April 2014 8-123

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

● After the front window glass has been

installed, fill the clearance between the
glass on area (s) and the center adjust-
ing seal (16) to the dimension of (t) and
(u). Coat primer onto glass (4) on sec- A
tion A-A and apply the adhesive as fill-
ers.
A
● Dimension of (t): 2 mm S
● Dimension of (u): 5 mm
● Use a rubber spatula to cover the edge
of the glass and trim the adhesive. t
4
● Remove surplus adhesive.

.
De al
Glass primer：

pt
g nSunrise MSI Primer 35
u
Adhesive：
o
Sunrise MSI SR Sealant U90 4463876
16
in ti

A-A
ZX215-1006255
司
公
销
营

Fig. 8-261
et a
n

8. Fix the glass

rk er

A. After the right window glass (1) has

been adhered to the cab, put position-
ing chips (a) (1 or 2 pcs) beneath the
Ma t

glass in order to fix it.

In

a
ZXT215-1006256

8-124 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

B. Use foam polystyrene blocks [9] and

[10]
rubber band [10] to fix the glass and
the rubber seal as illustrated.
9. After the glass has been fixed, remove all
the remaining primer and adhesive on the
cab and on the glass.
● Clean the adhesive with unleaded gaso-
line before it is hardened.
● Do not apply impacting force onto the [9]
glass when cleaning it.
10. Protection of fixed window glass ZX215-1006257

Fig. 8-262

.
A. Remove the positioning chips, foam

De al
polystyrene blocks and the rubber band

pt
after 10 hours.
g n
(Condition: Temperature: 20; humidity:
60%)
o
B. Wait for another 14 hours after the
in ti

removal of positioning chips, foam

polystyrene blocks and rubber band 营
销
公
司

before operating the machine.

et a
n
rk er
Ma t
In

Shop Manual - April 2014 8-125

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.33 Front Window AS

Lower the work equipment onto the ground
and shut down the engine.
● The front window assembly must be re-
moved from the cab in order to replace the
front window glass. Disassembling and as-
sembling method of front window assembly
(frame and glass) is illustrated in the fol-
lowing part.

8.33.1 Disassembly

.
1. Raise the front window assembly to the

De al
roof and secure it with the rear locks (at

pt
both sides). g n
2. Remove left corner plate (1) and right
corner plate (2). 2
o
● Mounting bolt (4) and washer (3) of the 4
in ti
3
left corner plate will be used in Step 6 to 1

hang the pull rod. 营

销
公
司

ZX215-1006258
et a

Fig. 8-263
n
rk er

3. Release the rear lock of the cab.

4. Lower the front window assembly carefully
a bit. Take out and hold the rollers (5) and
Ma t

(6) at the bottom of the front window from

In

the removed parts in Step 2.

5. Remove roller (5) and (6) from both sides
of the bottom of the front window.

6 5
ZX215-1006259

Fig. 8-264

8-126 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

6. Remove pin (7) at the lower left side.

9
● Plate (8) at the end of the pull rod (9)
will come out by removing of pin (7). 8
● Hang plate (8) onto the mounting bolt
of left corner plate (using the washer)
and fix it. 6

NOTICE
7 ZX215-1006260
● A return load of 58.8 N {6 kg}is applied
onto the rear of the cab. Be very care-
ful when removing pin (7) to disconnect

.
pull rod (9).

De al
pt
9 8
g no
in ti

司
公
销
营
et a

ZX215-1006261
n

Fig. 8-265
rk er

7. Pull out the front window assembly (10)

10
from the opened part of the guide rail and
Ma t

lower the assembly gradually.

In

ZX215-1006262

Fig. 8-266

Shop Manual - April 2014 8-127

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8. Lower the front window assembly (10)

completely.
10
● Be careful not to allow the front window
assembly to damage the machine moni-
tor.

ZX215-1006263

Fig. 8-267

.
De al
9. Move the front window assembly (10) to

pt
the right and the left and remove the two
upper rollers (11) and (12) from the guide
g n 10
rail. Then, remove the front window as-
sembly (10).
o
in ti

司
公
销
营
et a

ZX215-1006264
n

Fig. 8-268
rk er

12 11
Ma t
In

10 ZX215-1006265

Fig. 8-269

8-128 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.33.2 Assembly
● Reverse the disassembling sequence.

● Adjust the opening and closing of the front

window assembly as per the following in-
struction.
1. Open and close the front window assembly
and check if it interferes with the guide rail.
Check if the roller is jammed.
2. If the front window can not be opened or
closed properly, loosen the mounting bolt

.
De al
of the roller adjusting bracket (13) and

pt
adjust the condition of the front window. 13 ZX215-1006266
Tighten the mounting bolt after adjusting.
Fig. 8-270
g n
● Make sure bracket (13) is installed with-
out an angle.
o
Mounting bolt ： 34.3 N·m {3.5
in ti

kgf·m}
司
公
销

3. Raise the front window assemble and fix it

营
et a

with rear locks (at both sides).

n

● Check if the locks at the rear of the cab a

are securely fixed.
rk er

4. Install the right corner plate (2).

2
● After the "locked" position is adjusted in
Ma t

Step 6, tighten the corner plate. a ZX215-1006267

In

● Install the right corner plate. Clearance Fig. 8-271

(a) between the guide rail and the right
corner plate (2) is 0 – 2.0 mm.
● Install the right corner plate. Keep the
R
surface (R) of the roller without a level
error.

ZX215-1006268

Fig. 8-272

Shop Manual - April 2014 8-129

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

5. Install left corner plate (1)

● After the "locked" position is adjusted in b
Step 6, tighten the corner plate.
● Install left corner plate. Clearance (b)
between the guide rail and the left corner
plate (1) is 0 – 2.0 mm.
● Install left corner plate and keep the sur- b
face (R) of the roller without a level error.
(See the previous illustration). 1

ZX215-1006269

Fig. 8-273

.
De al
pt
6. Adjust the "locked" position of the lock of
front window assembly as per the following
g n
instruction.
o
A. Tighten the left corner plate (1) and the
in ti

right corner plate (2) in a nearly correct

position so that front window glass (14) 15
司

is pressed closely against the adjusting

公
销
营
et a

seal (19) on the cab.

14
n
rk er

ZX215-1006270

Fig. 8-274
Ma t
In

8-130 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

B. Open and close the front window

assembly and check the working condi-
tion of left lock (16) and right lock (17).
● If left lock (16) and right lock (17) do 16 17
not work properly,
a. Loosen the mounting bolt (18) of
the lock and move the lock (16)
forward. Tighten the bolt after that.
Adjust the right lock with the same
method. ZX215 1006271

b. C h e c k a g a i n t h e a d a p t a b i l i t y
between the front window assembly

.
De al
(14) and the adjusting seal (15) on

pt
the cab. (Checked in Step 1)
Repeat Step a) and Step b) until the
g n
condition of front window glass and
o
lock (16) and (17) is satisfactory.
Tighten the mounting bolts of the
in ti

left and right corner plates.

7. After adjustment is finished, flush the front
司
公
销
营
et a

window glass with abundant water and 16 18

check if any water penetrates into the cab.
n

ZX215-1006272

8. Adjust the "locked" position of the lock of

rk er

front window assembly

A. After the "locked" position of the lock of
front window assembly is adjusted in
Ma t

Step 6 and Step 7, raise the assembly

In

to the roof.
B. Set the locks of the front window
assembly at the rear of the cab at the
"locked" position, and check the follow- 19 18
ing items:
● Check the conditions of left lock (16)
and right lock (17).
● The front window assembly must con- ZX215-1006273

tact the left and right rubber stopper

(18), and the rubber stoppers must be
pushed backward by 1.5 – 3.0 mm.
● The front window assembly shall push
the limit switch 4 – 7mm backward.

Shop Manual - April 2014 8-131

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

C. Close the front window assembly (10).

D. Loosen the retaining nut (20) at the left
and right side of rubber stopper (18), 18 20
and pull the two rubber stoppers (18)
inward so that they can not contact the
"unlocked" front window assembly.

ZX215-1006274

Fig. 8-275

.
De al
E. Adjust the position of latch bolt (21).

pt
Latch bolt(21): M10, Inner diameter of
plate (23): ø14.5 mm
g no
in ti

21
司

23
公
销
营
et a
n

ZXT225-1006284

Fig. 8-276
rk er

F. Adjustment of left and right rubber stop-

Ma t

per (18)
In

a. Allow front window assembly (10)

to contact the left and right rubber
stopper (18). (when the lock is
"unlocked")
10 19

17 21
ZX215-1006276

Fig. 8-277

8-132 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

b. Lock front window assembly (10).

c. Turn the left/right rubber stopper
(18) to the left by one and a half
round.
● Turning the rubber stopper (18) left-
ward for one round is equivalent to
pressing it by 1.5 mm.
18
● When front window assembly is
“unlocked”, it must move the left/
right rubber stopper (18) by 1.5 – 3.0 ZX215-1006278
mm. Fig. 8-278

.
De al
pt
d. Tighten the retaining nuts (20) at
both sides of the rubber stopper
g n
(18). 20
18
o
in ti

司
公
销
营
et a
n

ZX225-1006287
rk er

Fig. 8-279
Ma t
In

Shop Manual - April 2014 8-133

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

9. Adjust the front window assembly retainer

(24).
A. Adjust and lock both sides of the re-
tainer (24) so that surface (d) of stopper
(D) of front window assembly contacts
surface (c) of retainer (24) when front 24
10
window assembly is raised.

D
ZX215-1006279

Fig. 8-280

.
De al
pt
g no
24
D
in ti
d

司
公
销
营
et a

c
n

ZX215-1006280

Fig. 8-281
rk er

10. Check the locking ability of front window

Ma t

assembly.
In

A. After the adjustment from Step 6 to

Step 9 is finished, check the locking 16 17
force of left lock (16) and right lock (17).
● Check the locking force at the "locked"
side (front of cab) and the "unlocked"
side (rear of cab).

ZX215-1006271
Left lower pin: Fig. 8-282
27 – 34 N·m {2.75 – 3.47 kgf·m}
Mounting bolt：adhesive(LT-2)

8-134 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.34 Monitor - Remove and Install

8.34.1 Removal

NOTICE
3 4

● Always disconnect the cable from nega- 5

tive post of the battery before you pro- 2
ceed.
1
1. Unscrew the three (3) bolts (4). Remove
the mounting plate and the monitor as-

.
De al
sembly from the bracket (3).

pt
2. Remove the nut (1) and the gasket (2) to ZX335-1006215
separate the monitor (5) from the mounting
plate.
g no
Fig. 8-283

8.34.2 Installation
in ti

● Installation is to be performed in the re- 营

销
公
司

verse order of removal.

et a
n
rk er
Ma t
In

Shop Manual - April 2014 8-135

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.35 Controller AS
8.35.1 Removal

NOTICE 1

● Always disconnect the cable from nega-

tive post of the battery before you pro-
ceed.
2
1. Remove the back plates (1) and (2).
2. Remove the controller wiring connectors (3)

.
and (4).

De al
ZXT335-1006216

pt
3. Remove the two(2) bolts. Remove the
Fig. 8-284
controller assembly (5).
g no
in ti

2
司
公
销
营
et a

4
n

3
rk er
Ma t

ZXT335-1006217
In

Fig. 8-285
8.35.2 Installation
● Installation is to be performed in the re-
verse order of removal.

8-136 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.36 Radio
8.36.1 Structure
1. Main structure

.
De al
pt
g no
in ti

营
销
公
司

ZX335-1006218
et a

Fig. 8-286
n
rk er
Ma t
In

Shop Manual - April 2014 8-137

8-138
2. Wiring

Fig. 8-287
RED — L. SOUND TRACK INPUT

AUDIO INPUT
In
WHITE — R. SOUND TRACK INPUT
Ma t
Disassembly and Assembly

RED — ACC IGNITION

rk er
n YELLOW — BATT POWER SUPPLY

BLACK — GROUND
et a

营
销
公
司
POWER, GROUND AND AUDIO OUTPUT

GRAY — R. SOUND TRACK OUTPUT +

BACK PANEL

Shop Manual - April 2014

LIGHT
in ti
— R. SOUND TRACK OUTPUT –
BLACK
o
WHITE — L. SOUND TRACK OUTPUT +
g n
BLACK — L. SOUND TRACK OUTPUT –
De al
RADIO ANTENNA
pt
.
ZX335-1006219
SY365(B)H-9 Crawler Hydraulic Excavator
SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.36.2 Removal and installation

Console
Removal cover

1. Remove the console cover (1).

NOTICE

● The power must be turned off before re-

Radio
moval.
ZX335-1006220

Fig. 8-288

.
De al
2. Remove the radio connector CN-003F.

pt
g no
in ti

司
公
销
营
et a

Connector CN-003F Cab harness

n

ZX335-1006221

Fig. 8-289
rk er

3. Remove the four(4) screws and the wash-

Ma t

ers in order to remove the radio and the

In

radio mounting brackets from the console

cover.
Console
4. Remove the four(4) screws and the wash-
ers in order to remove the radio from the
radio mounting brackets.

Radio
Radio bracket Washer
Screw
ZX335-1006222
Installation Fig. 8-290
● Installation is to be performed in the re-
verse order of removal.

Shop Manual - April 2014 8-139

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.36.3 Connector model and wiring

1 2 3

1 2 3
20b R+ L+

4 5 6 7 0 20b R- L-

4 5 6 7

.
De al
Radio wiring terminals Harness socket terminals

pt
Model: Deutsch DJ7072-3-21
ZX335

Fig. 8-291
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

8-140 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.37 Battery
8.37.1 Structure

A
2 B

10 J
C
11

6 E

.
De al
D

pt
g no
I

G
in ti

H
司
公
销
营
et a

F
n

8 7 5 9 4 3 1
rk er

ZX335-1006224

Fig. 8-292
Ma t

(1) Spinning post (7) Paste (active material)

In

(2) Charge densimeter (8) "Bag-type" screen

(3) Heat-sealing cover (9) Polar group
(4) PP casing (10) Liquid-gas separator
(5) Central polar ear (11) Central busbar
(6) Forged grid

Shop Manual - April 2014 8-141

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.37.2 Removal and installation

NOTICE

● Turn the start switch to the OFF posi-

tion before removal.
● Do not remove the charge densimeter.
Tighten the densimeter clockwise, if it
is loosened, with a suitable tool.

Removal

.
Bolt Grounding cable

De al
3. Removal of battery grounding wire Terminal

pt
● Open the tarpaulin, unscrew the bolt, and
remove the terminal from the battery wiring
post.
g no
VART
A

CAUTION
in ti
Battery
TTER Y
FREE BA
NANGE-
MAINTE

● Battery gas can cause explosion. No 营

销
公
司

sparks or flames are allowed near the

et a

ZX335-1006225
battery. Fig. 8-293
n
rk er

2. Disconnect the battery wiring cable and the

Cable
battery breaker cable.
Ma t
In

VARTA

VARTA

Battery Breaker cable

ZX335-1006226

Fig. 8-294

8-142 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

3. Remove the four(4) bolts and washers. Battery

Remove the battery assembly from the
bottom plate. Remove the battery.

VAR
TA

TA
VAR
.
De al
Washer Battery box

pt
Bolt
ZX335-1006227
g no
Fig. 8-295

Installation
in ti
● Installation is to be performed in the re-
verse order of removal.
司
公
销
营
et a
n

8.37.3 Replacement
rk er

There are two 12V batteries with ground-

ing negative (-) posts in the machine. If one
battery fails in the 24V system, it must be re-
Ma t

placed with one of the same type. Batteries of

different types are probably charged at differ-
In

ent speeds, which may cause one of them to

fail due to overloading.

NOTICE

● Apply Vaseline, when required during

installation, to battery terminals to pre-
vent corrosion.

Shop Manual - April 2014 8-143

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.38 Start Switch

8.38.1 Structure

23 22 20 18 17 15 13 12,11 28 6 10,9,8,7

.
De al
pt
g no
in ti

25,24 21 1 14 19 16 26 营
销
公
司 5 4,3,2
et a
n
rk er

27
Ma t
In
4 5 6

1 2 3

ZX335-1006228

Fig. 8-296

(1) Housing (8) Shield (15) Cover (22) Contact SPR-A

(2) Key (9) Pin (16) Spring (23) Contact B
(3) Ring (10) Spring (17) Ball (24) Terminal
(4) Dial (11) Disc (18) Spring (25) Bolt
(5) Nut (12) Spring (19) Contact SPR-B (26) O-ring seal
(6) Cylinder (13) Plug (20) Contact A (27) Harness AS
(7) Cap (14) Rotor (21) Seat (28) Washer

8-144 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.38.2 Removal
1. Unscrew the setscrew to remove the 21
67$5
7 0$
;

console cover.

2))
&.
/2
0,1

Start switch Console cover Setscrew

ZX335-1006229

Fig. 8-297

2. Remove both setscrews in order to remove Setscrew Console cover

.
the mounting plate and the start switch

De al
from the console cover.

pt
g n
NOTICE
o
● Disconnect the power supply of the
in ti

start switch before removal.

司
公
销
营
et a
n
rk er

Mounting plate Start switch

ZX335-1006230

Fig. 8-298
Ma t

3. Remove the nut so as to remove the start

In

switch from its mounting plate.

Start switch Mounting plate Nut

ZX335-1006231

Fig. 8-299

Shop Manual - April 2014 8-145

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.38.3 Working principle

On/off status
Gear
Battery Battery Accessory Preheat plug Start relay
position
(B) relay (BR) (ACC) (C)
(R1) (R2)
3B
OFF
1B
2B
ZX335-1006232

Fig. 8-300

.
De al
8.38.4 Wiring

pt
g no
in ti
1 22 13 3
1 B BR ACC 3

司
公
销
营

4 R1 R2 C 6 4 16 11 6
et a
n

Harness plug terminal

rk er

Start switch wiring terminal Jacket model: Yazaki: 7123-7464-30

Jacket model: Yazaki 7222-7464-30
ZX335-1006233

Fig. 8-301
Ma t
In

8-146 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.39 Fuse Box

Removal
Cover
1. Remove the cover.

ZX335-1006234

.
Fig. 8-302

De al
pt
2. Remove the bolts and take off the back
Back cover
g n
cover along with the fuse box.
o
Fuse box cover
in ti

司
公
销
营
et a
n
rk er
Ma t

Bolt
ZX335-1006235
In

Fig. 8-303

3. Remove the bolts so as to separate the

Harness
fuse box and harness from the back cover.
Bolts

Back cover
ZX335-1006236

Fig. 8-304

Shop Manual - April 2014 8-147

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.40 Wiper
8.40.1 Structure

Wiper blade

Driving mechanism

.
Wiper arm

De al
pt
g no
Wiper motor
Connector
in ti

司
公
销
营

Mounting bracket
et a
n

ZX335-1006237
rk er

Fig. 8-305
Ma t
In

8-148 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.40.2 Working principle

Green (low speed)

Yellow (reset)
M
Blue (high speed)

Red (power +)

.
De al
pt
g no
in ti

Black (power -)
司
公

ZX335-1006238
销
营
et a

Fig. 8-306
n
rk er
Ma t
In

Shop Manual - April 2014 8-149

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.40.3 Removal
1. Remove the decorative button in order to Decorative button

remove the interior decoration.

Interior decoration

ZX335-1006239

Fig. 8-307

2. Remove the moving mechanism and the

.
De al
motor.

pt
● Unscrew the bolts to remove the wiper
Bolt
motor and moving mechanism from the
cab.
g no
Moving mechanism
in ti

司
Wiper motor
公
销
营
et a
n
rk er

Bolt

ZX335-1006240

Fig. 8-308
Ma t
In

3. Remove the arm and the blade.

● Unscrew the nut to remove the wiper
arm and blade from the cab.

Arm bracket
8.40.4 Installation
● Installation is to be performed in the re-
verse order of removal. Guard

Locknut

Cab
ZX335-1006241

Fig. 8-309

8-150 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.40.5 Angle adjustment of wiper arm

● The arm should stops moving when the
Mechanical stopper
blade reaches the stopper.
● If the arm is still working when the blade
reaches the stopper or the arm already
stops working before the blade reaches the Wiper blade
stopper, the moving angle of wiper should
be adjusted to prevent breakdown of the
wiper.
● Adjust the wiper in such a way. Loosen the Arm

locknut; adjust the arm working angle ac-

cording to actual condition. Make sure that

.
the wiper motor stops working at the mo-

De al
ment that the blade reaches the mechani-

pt
cal stopper. g n Locknut
o
in ti

ZX335-1006242

Fig. 8-310
司
公
销
营
et a
n
rk er
Ma t
In

Shop Manual - April 2014 8-151

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.41 Relays S

8.41.1 Engine relays

1. Starter relay - check B

● Check the conduction and action. Replace

S
the relay in case of any failure. SW L
B 1 SW(-)

AA2A
2 L(-)
ZX335-1006243

Fig. 8-311

2. Mains relay - check

.
De al
● Check the conduction and action. Replace 1(+)
2(-)

pt
the relay in case of any failure.
g no
in ti

3 4
司
Battery terminal (+)
公
销
营
et a

3 4
n
rk er

1(+)
Ma t

2(-)
In

ZX335-1006244

Fig. 8-312

3. Heater relay
● Check the conduction and action. Replace 5(-)

the relay in case of any failure.

1
4. Safety relay 5 1 2 3 4
(-) (+)
● Measure the resistance between terminal
2 and terminal 3.
2 4(+)
Standard Value Approx. 200W Fuse 3
ZX335-1006245
● Check the conduction and action. Replace
Fig. 8-313
the relay in case of any failure.

8-152 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.41.2 Other relays

Function and location

Relay harness

Start control relay Horn relay

Pilot cotnrol relay

Headlight relay

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t

Parking relay
In

Work lamp relay

Mounting plate
ZX335-1006246

Fig. 8-314

Shop Manual - April 2014 8-153

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.41.3 Removal and installation Relay harness Mounting plate

Removal
1. Remove relay from its seat.
2. Remove the screw in order to remove the
relay seat and harness from the mounting
plate.
Installation
● Installation is to be performed in the re-
verse order of removal.
Setscrew

.
Relay seat Relay

De al
ZX335-1006247

pt
g n Fig. 8-315
8.41.4 Relay connector and wiring
o
in ti

1 4 2 销
公
司
营
et a

3
n
rk er

Relay wiring terminal

Relay model：HELLA 4RD 007 903-027

Ma t
In

Headlight Sart switch Pilot valve Horn Work lamp Shutdown delay
K2 K3 K4 K5 K6 K8

77 ③ 11 ③ 27 ③ 32 ③ 34 ③ 21 ③
① ② ① ② ① ② ① ② ① ② ① ②

④ 0 620 ④ 105 27 ④ 105 31 ④ 0 33 ④ 0 621 ④ 0

74
606
⑤ ⑤ ⑤ ⑤ ⑤ ⑤
73 11a 23 24 15a

Relay socket Jacket 8JA003526-00

Wiring socket terminal

Relay socket model: Jacket 8JA003526-00
ZX335-1006248

Fig. 8-316

8-154 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.42 Sensors

1. Water temperature sensor - check

1
● Put the sensor into a vessel containing en-
gine oil.
● Heat the oil to the specified temperature. Sensor body
Stir the oil at the same time.
● Measure the resistance value between the
terminal 1 and the sensor body at different
temperatures.
ZX335-1006249
50±0.2℃ 80±10Ω

.
Fig. 8-317

De al
60℃ 56.3Ω(ref.)

pt
Standard 80℃ 29.5Ω(ref.)
Value 100℃ 16.5Ω(ref.)
g n
106±0.3℃ 14.3±1.0Ω
o
120℃ 10Ω(ref.)
in ti

● Replace the sensor if the measured value

exceeds the standard one.
司
公
销
营
et a
n

2. Engine speed sensor - check

● Measure the resistance between terminal
rk er

1 and terminal 2.
Std. Value(25℃ ) 2.3±0.2kΩ
Ma t
In

● Replace the sensor if the measured value

exceeds the standard one.
2 1
ZX335-1006250

NOTICE Fig. 8-318

● Insufficient tightening of the engine

speed sensor may cause signal output
failure. Tighten the sensor to specified
torque.

Shop Manual - April 2014 8-155

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

3. Pressure sensor - check

Pressure joint Body Connector
● Input volt: 4.75~5.25 VDC
● Output volt: 0.5~4.5 V
● Pressure range: 0~50 BAR
Terminal B
Terminal A Terminal C

W365813081

Fig. 8-319

.
De al
4. Fuel level sensor - check

pt
● Swing the float up and down in order
g n
to measure the effective angle of radial
swing, i.e. the line through the float and the
o
Float
turning point will swing 105° .
in ti

● Swing the float up and down. The vertical

distance between the upper limit and the 司

Lever
公
销
营

lower limit of the float should be 500 mm.

et a

● Move the float to its upper limit. Measure

n

the resistance between the sensor terminal

R and ground with a multimeter. The mea-
rk er

Terminal R
sured resistance should be Ru ≦ 9.6Ω. Shell

● Move the float to its lower limit. Measure

Ma t

the resistance between the sensor terminal Connector

R and ground with a multimeter. The mea-

In

sured resistance should be Rd ≧ 86Ω. ZX335-1006252

Fig. 8-320

8-156 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

8.43 Connector Terminals

8.43.1 Insertion
1. Hold tightly a wire terminal at a distance of
about 25 mm from its end.

.
ZX215-1006320

De al
Fig. 8-321

pt
g n
2. Hold the connector. Let the rear seal face
o
you.
in ti

司
公
销
营
et a
n
rk er

ZX215-1006321

Fig. 8-322
Ma t
In

3. Align the terminal with a hole on the seal

and push it perpendicularly to the bottom.
Slightly pull back the wire in order to
ensure that the terminal is locked in place.

ZX215-1006322

Fig. 8-323

Shop Manual - April 2014 8-157

Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator

8.43.2 Removal
1. Hold the connector, with its back end fac-
ing you. Select a suitable tool and clip on
the wire.

ZX215-1006323

.
Fig. 8-324

De al
pt
2. Push the tool along the wire into the
connector so that the tool can expand
g n
the terminal lock shoulder and reach its
flanged part.
o
in ti

司
公
销
营
et a
n
rk er

ZX215-1006324

Fig. 8-325
Ma t
In

3. Pull out the tool to remove the wire with

terminal.

ZX215-1006325

Fig. 8-326

8-158 Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly

tE.
PAD nal
eGp
ng o
i
tKi t

司
公
销
营
a
AkNe rn
e
BLMaInt
r

Shop Manual - April 2014 8-159

SY365(B)H-9 Crawler Hydraulic Excavator System Schematics

System Schematics

.
9 System Schematics

De al
pt
9.1 Diagram of Hydraulic Lines...................................................................................... 9-3
9.2 Electrical diagram of chassis ................................................................................... 9-4
g n
9.3 Electrical diagram of control switches...................................................................... 9-5
o
9.4 Electrical diagram of operator station ...................................................................... 9-6
in ti

9.5 Electrical diagram of air conditioner......................................................................... 9-7

9.6 Electrical diagram of monitor ................................................................................... 9-8
营
销
公
司
et a
n
rk er
Ma t
In

Shop Manual - April 2014 9-1

System Schematics SY365(B)H-9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti

司
公
销
营
et a
n
rk er
Ma t
In

9-2 Shop Manual - April 2014

System Schematics SY365(B)H-9 Crawler Hydraulic Excavator
9.1 Diagram of Hydraulic Lines Swing Arm Bucket Boom Left travel Right travel

SH
PG

D
DB

P
M

.
GER REG

MB

MB
MA

MA
pt
PB

PA
Transitional block

De

VB
VB

VA

VA
1
(8) Left swing To XAs
Swing

(4) Right swing To XBs

T

3
4

(3)Arm out To XAa1 lower

P

OUT

g
XAa2

To XBa1

n
XBa2
IN (10)Arm in PaL Arm hold valve RS1 RS2 P4 (R4) (P4)

Arm
2

R1
R2

ti
1

Bucket (5)Bucket dig To XBc N2 Central

N1
DUMP
Dra
XBp1 swivel
XBp2
PaL HVa
XBp2
joint
DIG Aa Dr1
CC0 CCk
(9)Bucket dump To XAc lower (ROD) AaR

e
T

Ba1
Ba2(HEAD)
3

(HEAD) BaR

Arm 2
XBa1 XBa2
2

(6)Boom down To XBb1 upper

P

UP XBb2 XAa2

rk
PbL Boom hold valve XAa1 LCAT2
Arm 1 Pna1
ARC LCAP2 AcR
Ac(ROD)
DOWN (7)Boom up ToXAb2
XAb1 lower Dr3 LCa
BcR
BoR
PAcs (Bo) Bc(HEAD)
4

Boom (Ao)
AoR
PAcs

Bucket

Ma
XAo XAc
Backup
3

Right travel To XBtr lower XBc

XBo
Backward 营
销
公
司

LCo LCk Drb

(2)Right travel HVb PbL
Ccb Ab
AbR
(HEAD)
BbR Bb
Forward Dr2 (ROD)
To XAtr upper Boom 2 Boom 1
4

XBb2
T

XBb1
XAb2 Lcb2 LCb XAb1
AtL
P

To XBtL lower Bs cp1

1

BtL

l
As
Backward Swing XAs XAtL
(1)Left travel Xbs
Dr4
Pns
LCs XBtL Left travel
Px

Left travel
Forward To XAtL upper

na Right travel
Btr
Atr
XAtr
CP2 CT2 CpG

(PTb) (PTa)
2

XBtr CT1
CMR1 Pz

Py Φ0.7 CMR2 MR
Φ0.7 Φ0.7
io
PH P2 front pump PG R3 P1 rear pump
at
rn

T
PH1 A1 A2 PH2
a1 a2
Psv1 Psv2
te

(COOLER)
电液比例阀

Travel speed
Front pump
Rear pump
PPC lock

A1 2nd bost
adjuster
adjuster

change
valve
P2

P1
电液控转换

4.5bar
bb

A3

A2
A6

A4
A8

A7

A5
2.5bar
变功率调节 cc
Pf C Pf
dd
Pi1 负压调节 Pi2
In

B
A4

A
P1 P2

Engine
FRONT REAR
As

DR B1 B3 A3
10μm

10μm
10μm

80~150目
WX365-1309001

9-3
System Schematics SY365(B)H-9 Crawler Hydraulic Excavator
9.2 Electrical diagram of chassis

Air plugging Fuel level Oil press High-temp Low-temp Hydraulic oil
To cab harness CN-502M To cab harness CN-506M Alternator terminals Start motor switch sensor switch switch Temp sensor switch temp sensor
9 T-501 To power supply
CN-501M CN-502F CN-506F CN-113M
T-103 T-116 CN-800F T-102 T-135 CN-103M CN-101F F-301 T-100 F-300 T-101 T-500 grounding wire

.
0
To cab harness CN-501F 2 3 4 5 6 7 8 9 10 11 12 345678 1 2

15
T-102
42 34 60 14 15 32 0 21 14 60 21 12 103 509 0 508 106 510 66 42 511 T-101 To battery
22 65 50A 64 63 MT- MT+ 507 50 00 57 20
T-104 relay KB

pt
200
1 21
T-120
201
2
202
3 To compressor
203 57
T-107
8 4 clutch

De
204
5
205
6
206 21 T-134
7 16
T-109
To preheat fuse
207
8
208 17 To preheat
9 T-107
resistance

g
602
7 10 108A
To rpm sensor
108B
603 CN-125F
11

n
606 50A 1
13 507 2

ti
607
14 MT- 3 To throttle motor
4 CN-124F
608 00 5
15 MT+ 6
609
16
501

e
6 17 22 1
502 64 2 To parking motor
18 63 3 CN-801F

rk
702 0 4
19 65 5
703 6
20
21 511

22 108A

Ma
609 1
108B
5
23 营
销
公
司

0 CN-137F
24 106 2

510
25 606
1
To pilot SV
26 508
0 2 CN-136F
S
27

l
66
28 608
1
103
4
29
30
32
509

704
na 0

703
2

1
CN-133F

To R. pump SV
io
0 CN-134F
2

702
1
To F. pump SV
3 CN-132F
at

0
2

602
1

0 CN-138F
2
rn

607 1
Hi/Lo travel SV
0
2 2 CN-131F
te

603
1

0 2 CN-135F
50 00 502 50 00 501 50 00 200 50 00 201 50 00 202 50 00 208 50 00 205 50 00 207 50 00 206 50 00 204 50 00 203
704
A B C A B C A B C A B C A B C A B C A B C A B C A B C A B C A B C 1
In

Power limit SV
0 2 CN-114F
0 34 32 0# 16 17 21 12 20 CN-116F CN-115F CN-120M CN-121M CN-122M CN-123M CN-124M CN-125M CN-126M CN-128M CN-129M
1
1 2 1 2 1 2 1 2 R. pump main F. pump main Left travel Right travel Arm OUT Swing Bucket DIG Boom DOWN Boom UP Bucket DUMP Arm IN
1 2
pressure sensor pressure sensor pressure sensor pressure sensor pressure sensor pressure sensor pressure sensor pressure sensor pressure sensor pressure sensor pressure sensor
CN-102M F-104 F-103 CN-507M CN-503F CN-504F CN-505M
To work lamp To horn
A B C D E F G H I J K L M N

9-4
System Schematics SY365(B)H-9 Crawler Hydraulic Excavator
9.3 Electrical diagram of control switches

Wrok lamp switch Wiper switch Washer switch

Start switch

.
CN-503F CN-505F CN-507F

TERMINAL B BR ACC R1 R2 C

pt
HEAT 108B
1
506
OFF 1 3 5 7 1 3 5 7 1 3 5 7 2
50
3
8
ON 33 24 35H 25 35L 36 37 25
61
4

De
START 62
5

22 62 13 61 11 6
7
8
9
69
10

g
7 73
11
74 12

n
CN-202F

ti
To cab harness CN-202M

e
25
1
33

rk
2
35H 3
36
4
37 5
50 506 00 74 73 35L 6

Ma
60 14 69 14 60
5
1 2 3 销
公
司
1 3 5 7 7
营

11
8
13
9
14
F-507 F-505 F-508 F-509 10
CN-501F CN-508F 22
11
To fuel control dial Head lamp switch 24 12

l
CN-203M
4

Fuse No.
Fuse box harness
Rated value System
na 20
21

13
20

13
To cab harness CN-203F
io
1
F1 20A Start loop 14 2

10A 29 3
F2 Charging indicator
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 42 4
3
F3 5A Horn loop 20 5
at

15A 20 6
F4 work lamp 22 14 23 24 25 20b 26 38 28 29 42 73 43 27 100 21
7
F5 5A wiper & washer 21 8
F6 10A Radio
rn

10A CN-222F
F7 Cab lamp
F8 20A Air conditioner To cab harness CN-122M
2

F9 5A Access lamp
te

F10 5A Monitor
F11 20A Controller
F12 15A Head lamp 27 28 38 73 22 100 43 20b 23 24 25 26
In

F13 10A 1 2 3 4 5 6 7 8 9 10 11 12
Aux. controller
CN-221M
1
F14 10A
Solenoid valve GP
F15 15A Cigarette lighter
To cab harness CN-121F

A B C D E F G H I J K L M N

9-5
System Schematics SY365(B)H-9 Crawler Hydraulic Excavator
9.4 Electrical diagram of operator station
To control switch harness CN-202F To chassis harness CN-502F
Head lamp relay Start control relay Pilot valve relay Horn relay Work lamp relay Shutdown delay relay
25 CN-202M CN-502M
1
9 33 31
2 1 CN-201F

.
35H 2 3 4 5 6 7 8 9 10 11 12 To horn button
3 1 2 3 4 5 6 10 11 12 23
2
108 B 506 50A 61 62 0 69 73 74 22 65 50A 63 64 MT- MT+ 507 50 00 57 1 2 3 45 1 2 3 45 1 2 3 45 1 2 3 4 5 1 2 3 45 1 2 3 45
36
4

pt
1 2 3 45 1 2 3 45 1 2 3 45 1 2 3 4 5 1 2 3 45 1 2 3 45 13
37 1
5
74 0 77 73 620 105 11 11a 27 0 27 606 31 0 32 23 33 0 34 24 621 0 21 15a
35L 15
CN-203F 6 2
8
60
To control sw- 7 15a

De
itch harness 1
CN-203M 8 11

13 15 2
9
14
10 37
22 2
11 To washer motor
0# 1

g
24
7
12

n
42 0
3 1 CN-106F
34 105

ti
4 2 To pilot switch
60
CN-506M 5 0 11a 60 68 14
14 0#
6 1 2 3 1 2 1
14 66 61 68 0 69 0 62 63 64 65 20b R+ L+ 20b 0# R- L-
15

e
6
To chassis 7 25
harness To alternator 1 2 3 4 5 6 1 2 3 4 5 1 2 3 4 5 6 7 2
32 To safety relay
CN-506F 8 36 CN-110M

rk
CN-181M To preheat relay To parking relay CN-180M 3
CN-003F
200 To radio control panel 35H
1 4 To wiper harness
201 CN-112M
2 C B A 120Ω 35 L 5
202 0-S CAN- CAN+
3

Ma
C B A CN-115
CAN- CAN+
203
4
司
公

5 营
销

5 204
57
6 205 1
206 61a
7 4
207 60a
8

l
208 5
9 0# CN-207F
4

13
14
606

607
42
1
42
2
0

3
0 0-S CAN-CAN+

8 10 11 12 17 18 19 20 22
na
703 208 502 00

23
702 501 201

28 29 30 31
00 00 206 207

7 8 9
205 00 50 00 511 202

10 11 12 19 21 22 23 30 32 33
00 0 510 204 200

34 35
203
38

38
6
7

8
To A/C panel
io
26
CN-501F 8
CN-141M CN-140M 0#
501
3 To chassis 17 7
at

harness
502
CN-501F 18 77
702
6
19
703 0# 5
20 CN-150M
L-
rn

511 4
21
L+ To cab radio
22 108 A 3 harness
2 23 108 B R-
2
106 R+
24
te

1
510
25
508
26
27 28 38 73 22 100 43 20 b 23 24 25 26 13 14 42 20 20 21 21 42 43 100 11 13 607 MT- MT+ 0 0# 620 621 103 106 506 507 508 509 50A 704 60a 61a 108 A 108 B
In

66 1 2 3 4 5 6 7 8 9 10 11 12 1 2 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 1 2
28
103 CN-114F
1 29 20 12
CN-121F 1 2 CN-113F
30 CN-111M
CN-122M
Access lamp To fuse box harness CN-221M To monitor harness CN-7-113M To monitor harness CN-7-111M To monitor harness CN-7-114M
704 CN-505M
32 To fuse box harness CN-222M To start motor

A B C D E F G H I J K L M N

9-6
System Schematics SY365(B)H-9 Crawler Hydraulic Excavator
9.5 Electrical diagram of air conditioner
Control panel
ACM

10
6
7

21
22
23

26
27
28
29
30
31
32

35
36
4
2
3

8
9

17
18
19
20

24
25

33
34
1

11
12
13
14
15
16
CN-M30 CN-M29

10
4

10

6
2

7
3

11
12
13
14
15
16

4
2
1

8
9

17
18
19
8
9

11
12
13
14
15
16
0.5BrW

0.5BrY
0.5LgR

0.5WY

0.5GO
0.5WO

0.5OW

0.5GW

0.5VR
0.5RY

0.5WR
0.5RW

0.5LO
0.5BG
0.5BW

0.5VW

0.5BR
0.5BL

0.5BY

0.5PB
0.5YB
0.5PG

0.5Sb

.
0.5R

0.5B

pt
8

De
0.5LgR

0.5BrW

0.5BrY
0.5BW
0.5WO

0.5OW
0.5GW

0.5WR
0.5VW

0.5WY
0.5RY

0.5GO
0.5BY

0.5LO

0.5YB
0.5BG

0.5RW
0.5PG

0.5VR

0.5BR
0.5PB
0.5BL

0.5Sb
0.5R

0.5B
SWP SWP SWP

4
2

2
6

6
3

8
9

8
9
7

6
7
1

10

12

10

12
13
14
15
16

4
2
3

8
11

11

1
CN-M28 CN-M27 CN-M33

4
2

6
3

8
9
7
1

10

12
13
14
15
16

6
7
11

4
2
3

8
4
2

6
3

8
9
7

1
1

10

12
11

g
7

0.5LgR

0.5BrW

0.5RW
0.5BW
0.5WO

0.5WR
0.5OW
0.5GW

0.5BrY

0.5WY
0.5VW
0.5BG

0.5GO
0.5RY
0.5BY

0.5YB
0.5LO
0.5PG

0.5BR
0.5VR
0.5PB
0.5BL

0.5Sb
0.5R

0.5B

n
Diffuser conversion

ti
servo motor
MV 2

Internal temp sensor

FACE(DEF)
THI

FOOT

GND

Vz
Pt
6

2
6
5

3
7

1
CN-M34

2
1

2
6
5

3
7

1
2
1
rk
0.5GW

0.5OW

0.5BW
0.5GO
0.5BR

0.5BR
0.5Sb
050
CN-P15
2 2
1 1

S S 0.5WY FACE

Ma
7 7
0.5WR FOOT
6 6
0.5BrW Pt Diffuser conversion
5 司
5 5
公
销
4 4
servo motor
营

0.5BW Vz
3 3
2 2
0.5BR GND
1 1 MV I

CN-A30

l
2 2 0.5YB FRE
7 7
1 1 0.5VW REC
6 6
0.5WO Pt
5 5
TH A M Fresh air/recirculation
4

ECC
EC
na 0.5BW

0.5BR
4
3
2
1
4
3
2
1
Vz

GND
conversion sero motor
io
CN-E06 S 0.5PB
1

Mcool
0.5VR 7 7
CN-M26 Mhot
6 6
1

12 12 0.5BG Pt
5 5
11 11 4 4 A/M servo motor
TO CN-M26-A TO CN-E06-1 0.85W 0.5BW Vz
10 10 3 3
3 9 9 2B 2 2
0.5BR GND
8 8 1 1
at

TO CN-M26-7 TO CN-P15-1 0.5BW MA M

7 7
TO CN-M26-7 TO CN-A30-2 0.5RW
6 6
2Br
5 5 1.25R
20A 4 4
TO CN-M26-2 TO CN-P15-2 3 3 0.5RY 5A
2 2
TO CN-M26-1 TO CN-A30-1 0.5BR
1 1

24V
rn

0.5BR
1 1 Low-temp sensor
0.5PG
2 2
1.25G THF
1.25RL 72C 40C 1.25G
2
1.25RL

2G

1.25RL
2RL

0.5BL
2G
te

2B
0.5BrY
0.85W

0.5LO
0.5R
0.5R

2RL

0.5lgR
2RL
2Br

2Br

0.5BR
0.5BY
2G

0.5B
4

3
1
4

3
1
4
2
3

4
2

2
1

2
1

1
4
2
3

2
4
2
1

1
1

PROTECTION
FOR TEMP.

2
1

1
DRIVING TRANSACTION OF
In

CIRCUIT INPUT SIGNEL

RL RL VOLTAGE
CORRECTION

R L C C R LB M MB BLC SPH L THW

1 Compressor cltch relay Blower relay Blower motor Hi/Lo pressure switch Coolant temp sensor

A B C D E F G H I J K L M N

9-7
System Schematics SY365(B)H-9 Crawler Hydraulic Excavator
9.6 Electrical diagram of monitor

.
Cigar lighter Sunlight sensor

pt
CN-7-707M CN-7-706M

1 2

De
1 2

0# 100 60a 61a

CN-7-113M

g
7 CN-142M
To cab harness
Start signal
Power-on signal 1
11 CN-113F
13

n
2
3 103 42
24V power supply 4 1
42 43

ti
Air block sw sgnl input 5 2
thrttl mtr position fdbck sgnl 6 100
7 507 3
11
8 4
Pwr lmt vlv ctrl sgnl 9 13
10
704 5
6 GND
0 607
11 6

e
CAN bus low
CAN-
RPM sensor signal 12 MT-
Coolant temp high switch 13 108A 7
Eng oil press sw input 14 106 MT+

rk
508 8
RPM sensor GND 15 0
Oil level sensor signal 16 108B 9
17 509 0#
10
Fuel control dial signal 18
506 620 11
Start control signal 19
620
Hi/Lo travel speed ctrl sgnl 20 621 12

Ma
21 607
5
22 营
销
公
司

24 V power supply 23
5V power output 24 43
25 50 A
26
27
28
29

l
GND 30
Motor driving signal + 31 0 CN-7-111F
Motor driving signal - 32 MT+
MT- To cab harness
4 Shutdown delay control
CAN bus high
33
34
35
621
CAN+
na 103
106
CN-111M

1
2
io
506
3
507
4
508
5
3 509 6
at

50 A 7
704 8
60 a
9
61 a 10
rn

108A 108B S CAN+ CAN- 0-S

A B C A B C
2
te

CN-7-114M
To cab harness CN-7-112F
CN-114F To cab harness
CN-112M
In

A B C D E F G H I J K L M N

9-8