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Crawler Hydraulic

Crawler Hydraulic Excavator

Shop Manual SY65/75C
Excavator

SY65C3
SY75C3
SY75C9

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-SY65/75C

Shop Manual
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

SY65C3, SY75C3, SY75C9

Crawler Hydraulic Excavator
Shop Manual

● Compiled for experienced technicians, this shop manual aims to provide technical information
required for maintenance and repair of the machine.

● Work equipment or optional components not available locally may be included in this shop
manual. Consult authorized Sany dealers for information on these parts and components. Ma-
terial or technical specification is subject to change without prior notice.

● SY65C, SY75C excavators use ISUZU 4JG1-NABGB-04-02 engine. Information on the en-
gine is in Chapter 10.
 SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

WARNING
Read and follow the safety precautions and
instructions in this manual and on the ma-
chine decals. Failure to do so may cause
serious injury, death or property damage.
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Table of Contents

Table of Contents

1 Introduction
1.1 How to Read the Shop Manual ................................................................................ 1-3
1.2 Terms for Maintenance Standard............................................................................. 1-6
1.3 Handling Electrical and Hydraulic Components....................................................... 1-9
1.3.1 Points to remember when handling electric components .............................. 1-9
1.3.2 Points to remember when handling hydraulic equipment ............................ 1-18
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
1.9 Conversion Table ................................................................................................... 1-26

2 Shop Safety
2.1 Hazard Alert Information .......................................................................................... 2-3
2.2 General Shop Safety ............................................................................................... 2-6
2.2.1 Rules and shop behavior ............................................................................... 2-7
2.2.2 Housekeeping ................................................................................................ 2-7
2.2.3 Shop Liquids Storage..................................................................................... 2-8
2.2.4 Cleaning Parts ............................................................................................... 2-8
2.2.5 Jacking Up the Machine................................................................................. 2-9
2.2.6 Electrical Dangers .......................................................................................... 2-9
2.2.7 Removing Attachments ................................................................................ 2-10
2.2.8 Cleaning the Machine .................................................................................. 2-10
2.2.9 Using the Correct Tools................................................................................ 2-10
2.2.10 Hoisting a Load ...........................................................................................2-11
2.2.11 Appropriate Working Apparel ..................................................................... 2-12
2.2.12 Safety Partners .......................................................................................... 2-12
2.2.13 Two people when engine running .............................................................. 2-13
2.2.14 Driving Pins ................................................................................................ 2-13
2.2.15 Aligning Parts or Components ................................................................... 2-14

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2.2.16 Fire Extinguisher and Emergency Exits ..................................................... 2-14

2.2.17 Personal Protective Equipment.................................................................. 2-14
2.2.18 Running the Machine ................................................................................. 2-15
2.2.19 Accumulator ............................................................................................... 2-16
2.2.20 Adding Fluids to a System ......................................................................... 2-16
2.2.21 Track Recoil Springs .................................................................................. 2-17
2.2.22 High-Pressure Fluid Lines.......................................................................... 2-17
2.2.23 Safe Work Preparations ............................................................................. 2-18
2.2.24 Mounting and Dismounting ........................................................................ 2-19
2.2.25 Battery Hazards ......................................................................................... 2-20
2.2.26 Jump-Start Safety ...................................................................................... 2-21
2.2.27 Disconnecting the System Power .............................................................. 2-21
2.2.28 LOCKOUT/TAGOUT .................................................................................. 2-22
2.2.29 Sequence of Procedures ........................................................................... 2-22
2.2.30 CHEMICAL HAZARDS .............................................................................. 2-24
2.2.31 Material Safety Data Sheets (MSDS) ........................................................ 2-24

3 Specifications
3.1 Dimensions .............................................................................................................. 3-3
3.2 Working Ranges ...................................................................................................... 3-4
3.3 Technical Specifications........................................................................................... 3-6
3.4 Weight Table ............................................................................................................ 3-8
3.5 Recommended Oil, Fuel and Coolant...................................................................... 3-9
3.6 Engine Performance Curve ....................................................................................3-11

4 Structure and Function

4.1 Engine and Cooling System .................................................................................... 4-3
4.1.1 Radiator and oil cooler ................................................................................... 4-3
4.1.2 PTO (shaft coupling) ...................................................................................... 4-5
4.1.3 Engine control system.................................................................................... 4-6
4.2 Power Train.............................................................................................................. 4-7
4.2.1 Power transmission system .......................................................................... 4-7
4.2.2 Swing bearing ................................................................................................ 4-8
4.2.3 Swing mechanism .......................................................................................... 4-9
4.3 Undercarriage and Frame...................................................................................... 4-10
4.3.1 Track frame .................................................................................................. 4-10
4.3.2 Idler and recoil spring................................................................................... 4-12
4.4 Hydraulic System ................................................................................................... 4-14

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4.4.1 Hydraulic equipment layout drawing ............................................................ 4-14

4.4.2 Hydraulic circuit diagram.............................................................................. 4-15
4.4.3 Hydraulic tank and filter ............................................................................... 4-17
4.4.4 Hydraulic pump ................................................................................................... 4-18
4.4.5 Control valve ................................................................................................ 4-35
4.4.6 Oil source control valve................................................................................ 4-40
4.4.7 Load sensitive system.................................................................................. 4-42
4.4.8 Swing motor ................................................................................................. 4-67
4.4.9 Center swivel joint ........................................................................................ 4-72
4.4.10 Travel motor ............................................................................................... 4-74
4.4.10.1 Travel motor operating process ........................................................ 4-76
4.4.10.2 Parking brake operating process ...................................................... 4-78
4.4.10.3 Counterbalance valve operating process.......................................... 4-79
4.4.11 Control System........................................................................................... 4-81
4.4.11.1 Work equipment and swing pilot valve .............................................. 4-82
4.4.11.2 Travel pilot valve ............................................................................... 4-87
4.4.11.3 Option pilot valve............................................................................... 4-91
4.4.12 Hydraulic cylinder....................................................................................... 4-94
4.4.13 Work equipment ......................................................................................... 4-95
4.5 Electrical Control System....................................................................................... 4-96
4.5.1 General ........................................................................................................ 4-96
4.5.2 Electronic control system diagram ............................................................... 4-97
4.5.3 Diagram of electrical circuit .......................................................................... 4-98
4.5.4 Engine control function ................................................................................ 4-99
4.5.5 Valve control function ................................................................................. 4-100
4.5.6 Auto deceleration function.......................................................................... 4-101
4.5.7 Engine preheating and overheating protection function ............................ 4-102
4.5.8 Travel control selection .............................................................................. 4-104
4.6 Integrated Control Monitoring System ................................................................. 4-105
4.6.1 Monitor ....................................................................................................... 4-105
4.6.2 Monitor items and display .......................................................................... 4-108
4.6.3 Main screen function ...................................................................................4-110
4.6.4 Special functions ........................................................................................ 4-123

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
5.3 Standard Values for Electrical Parts .......................................................................5-11

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6 Testing and Adjusting

6.1 Engine Speed - Test ................................................................................................ 6-3
6.2 Exhaust Gas Color - Test ......................................................................................... 6-4
6.3 Valve Clearance - Adjust.......................................................................................... 6-6
6.4 Compression Pressure - Measure ........................................................................... 6-8
6.5 Fuel Injection Timing - Test and Adjust .................................................................... 6-9
6.5.1 Injection timing confirming steps .................................................................... 6-9
6.6 Engine Oil Pressure - Measure.............................................................................. 6-12
6.7 Alternator Belt Tension - Test and Adjust .............................................................. 6-13
6.7.1 Testing.......................................................................................................... 6-13
6.7.2 Adjusting ...................................................................................................... 6-13
6.8 Fuel Control Lever - Adjust .................................................................................... 6-14
6.9 Hydraulic Pressure in Oil Circuit – Test and Adjust................................................ 6-15
6.10 LS Differential pressure and Flow Control Valve - Test and Adjust ...................... 6-16
6.10.1 Check LS differential pressure ................................................................... 6-16
6.10.2 Adjust flow control valve............................................................................. 6-17
6.11 Hydraulic Pressure in Control Circuit - Test ......................................................... 6-18
6.12 Solenoid Valve Outlet Pressure - Test ................................................................. 6-19
6.13 Pilot Valve Output Pressure - Test ....................................................................... 6-20
6.14 Work Equipment and Swing Pilot Valve - Adjust.................................................. 6-21
6.15 Travel Deviation - Test ......................................................................................... 6-22
6.16 Oil Leakage - Test ................................................................................................ 6-23
6.17 Residual Pressure in Hydraulic Circuit - Release ................................................ 6-26
6.18 Swing Bearing Clearance - Check ....................................................................... 6-27
6.19 Track Tension - Check and Adjust ....................................................................... 6-28
6.20 Air in Each Component - Bleed............................................................................ 6-30

7 Troubleshooting
7.1 Points to Remember When Troubleshooting ........................................................... 7-3
7.2 Troubleshooting Procedures .................................................................................... 7-5
7.3 Connector Locations and System Circuit Diagram .................................................. 7-9
7.4 Troubleshooting with an Error Code ...................................................................... 7-19
7.5 How to Use the Judgement Chart.......................................................................... 7-20
7.6 How to Use Troubleshooting Table ........................................................................ 7-21
7.7 Troubleshooting of Electrical System..................................................................... 7-24
7.8 Troubleshooting of Engine ..................................................................................... 7-31
7.9 Troubleshooting of Hydraulic and Mechanical System .......................................... 7-57
7.10 Troubleshooting of Machine Monitoring System .................................................. 7-83

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Table of Contents

8 Disassembly And Assembly

8.1 Reading Guide ......................................................................................................... 8-7
8.2 Operation Precautions ............................................................................................. 8-8
8.3 Engine and Main Pump Assembly - Remove and Install ....................................... 8-10
8.3.1 Remove........................................................................................................ 8-10
8.3.2 Install............................................................................................................ 8-15
8.4 Radiator Assembly - Remove and Install ............................................................... 8-16
8.4.1 Remove........................................................................................................ 8-16
8.4.2 Installation .................................................................................................... 8-17
8.5 Fuel Tank Assembly - Remove and Install ............................................................. 8-18
8.5.1 Remove........................................................................................................ 8-18
8.5.2 Install............................................................................................................ 8-19
8.6 Center Swivel Joint Assembly - Remove and Install.............................................. 8-20
8.6.1 Remove........................................................................................................ 8-20
8.6.2 Install............................................................................................................ 8-21
8.7 Center Swivel Joint Assembly - Disassemble and assemble ................................ 8-22
8.7.1 Disassemble ................................................................................................ 8-22
8.7.2 Assemble ..................................................................................................... 8-22
8.8 Sprocket - Remove and Install............................................................................... 8-23
8.8.1 Remove........................................................................................................ 8-23
8.8.2 Install............................................................................................................ 8-24
8.9 Travel Motor Assembly - Remove and Install ........................................................ 8-25
8.9.1 Remove........................................................................................................ 8-25
8.9.2 Install............................................................................................................ 8-26
8.10 Disassembly and Assembly of Travel Motor (GM09VN) ...................................... 8-27
8.10.1 Sectional view of the travel motor assembly .............................................. 8-27
8.10.2 Exploded view of reducer assembly .......................................................... 8-29
8.10.3 Exploded view of hydraulic motor assembly .............................................. 8-30
8.10.4 Parts catalogue .......................................................................................... 8-31
8.10.5 Tools........................................................................................................... 8-32
8.10.6 Tightening torques ..................................................................................... 8-39
8.10.7 Table of weights ......................................................................................... 8-39
8.10.8 Disassembly............................................................................................... 8-40
8.10.9 Table of maintenance standard ................................................................. 8-66
8.10.10 Assembly.................................................................................................. 8-68
8.10.11 Table of dimensions for clearance adjustable parts ................................. 8-94
8.10.12 Confirmation of performance test............................................................. 8-95
8.11 Swing Motor and Swing Mechanism AS - Removal and Installation.................... 8-96

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8.11.1 Removal ..................................................................................................... 8-96

8.11.2 Installation .................................................................................................. 8-97
8.12 Swing Motor AS - Disassembly and Assembly .................................................... 8-98
8.12.1 Disassembly............................................................................................... 8-98
8.12.2 Assembly.................................................................................................. 8-106
8.13 Swing Mechanism Assembly - Disassemble and Assemble ...............................8-115
8.13.1 Disassemble .............................................................................................8-115
8.13.2 Assemble ..................................................................................................8-118
8.14 Swing Platform Assembly - Remove and Install ................................................ 8-122
8.14.1 Remove.................................................................................................... 8-122
8.14.2 Install........................................................................................................ 8-124
8.15 Swing Bearing Assembly - Remove and Install ................................................. 8-125
8.15.1 Remove.................................................................................................... 8-125
8.15.2 Install........................................................................................................ 8-125
8.16 Idler and Tension Spring Assembly - Remove and Install.................................. 8-126
8.16.1 Remove.................................................................................................... 8-126
8.16.2 Install........................................................................................................ 8-127
8.17 Tension Spring Assembly - Disassemble and Assemble ................................... 8-128
8.17.1 Disassemble ............................................................................................ 8-128
8.17.2 Assemble ................................................................................................. 8-132
8.18 Idler Assembly - Disassemble and Assemble .................................................... 8-134
8.18.1 Disassemble ............................................................................................ 8-134
8.18.2 Assemble ................................................................................................. 8-135
8.19 Track Roller Assembly - Remove and Install ..................................................... 8-138
8.19.1 Remove.................................................................................................... 8-138
8.19.2 Install........................................................................................................ 8-138
8.20 Track Roller Assembly - Disassemble and Assemble ........................................ 8-139
8.20.1 Disassembly............................................................................................. 8-139
8.20.2 Assemble ................................................................................................. 8-141
8.21 Carrier Roller Assembly - Remove and Install ................................................... 8-143
8.21.1 Remove.................................................................................................... 8-143
8.21.2 Install........................................................................................................ 8-143
8.22 Track Shoe Assembly - Remove and Install ...................................................... 8-144
8.22.1 Remove.................................................................................................... 8-144
8.22.2 Install........................................................................................................ 8-144
8.23 Hydraulic Tank Assembly - Remove Install ........................................................ 8-145
8.23.1 Remove.................................................................................................... 8-145
8.23.2 Install........................................................................................................ 8-146

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8.24 Main Pump Assembly - Remove and Install ...................................................... 8-147

8.24.1 Remove.................................................................................................... 8-147
8.24.2 Install........................................................................................................ 8-148
8.25 Main Pump Input Shaft Oil Seal - Remove and Install....................................... 8-149
8.25.1 Remove.................................................................................................... 8-149
8.25.2 Install........................................................................................................ 8-149
8.26 Control Valve Assembly - Remove and Install ................................................... 8-150
8.26.1 Removal ................................................................................................... 8-150
8.26.2 Installation ................................................................................................ 8-152
8.27 Control Valve AS - Disassembly and Assembly ................................................. 8-153
8.27.1 Disassembly............................................................................................. 8-153
8.27.2 Assembly.................................................................................................. 8-169
8.28 Oil Source Control Valve Assembly - Remove and Install ................................. 8-186
8.28.1 Removal ................................................................................................... 8-186
8.28.2 Installation ................................................................................................ 8-187
8.29 Left Pilot Valve Assembly - Remove and Install................................................. 8-188
8.29.1 Remove.................................................................................................... 8-188
8.29.2 Install........................................................................................................ 8-188
8.30 Right Pilot Valve Assembly - Remove and Install .............................................. 8-189
8.30.1 Remove.................................................................................................... 8-189
8.30.2 Install........................................................................................................ 8-189
8.31 Work Equipment Pilot Valve Assembly .............................................................. 8-190
8.31.1 Disassemble ............................................................................................ 8-190
8.31.2 Assemble ................................................................................................. 8-190
8.32 Travel Pilot Valve Assembly - Remove and Install ............................................. 8-192
8.32.1 Remove.................................................................................................... 8-192
8.32.2 Install........................................................................................................ 8-193
8.33 Travel Pilot Valve Assembly - Disassemble and Assemble ............................... 8-194
8.33.1 Assemble ................................................................................................. 8-195
8.34 Boom Cylinder Assembly - Remove and Install ................................................. 8-196
8.34.1 Removal ................................................................................................... 8-196
8.34.2 Install........................................................................................................ 8-197
8.35 Arm Cylinder Assembly - Remove and Install .................................................... 8-198
8.35.1 Remove.................................................................................................... 8-198
8.35.2 Install........................................................................................................ 8-199
8.36 Bucket Cylinder Assembly - Remove and Install .............................................. 8-200
8.36.1 Remove.................................................................................................... 8-200
8.36.2 Install........................................................................................................ 8-201

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8.37 Blade Cylinder Assembly - Remove and Install ................................................. 8-202

8.37.1 Remove.................................................................................................... 8-202
8.37.2 Install........................................................................................................ 8-203
8.38 Hydraulic Cylinder Assembly - Disassemble and Assemble .............................. 8-204
8.38.1 Disassembly............................................................................................. 8-204
8.38.2 Assembly.................................................................................................. 8-207
8.39 Work Equipment Assembly - Remove and Install .............................................. 8-210
8.38.3 Removal ................................................................................................... 8-210
8.39.1 Install.........................................................................................................8-211
8.40 Bucket Assembly - Remove and Install ............................................................. 8-212
8.40.1 Remove.................................................................................................... 8-212
8.40.2 Install........................................................................................................ 8-213
8.41 Arm Assembly - Remove and Install .................................................................. 8-214
8.41.1 Remove.................................................................................................... 8-214
8.41.2 Install........................................................................................................ 8-215
8.42 Bucket and Arm Assembly - Remove and Install ............................................... 8-216
8.42.1 Remove.................................................................................................... 8-216
8.42.2 Install........................................................................................................ 8-217
8.43 Boom Assembly - Remove and Install ............................................................... 8-218
8.43.1 Remove.................................................................................................... 8-218
8.43.2 Install........................................................................................................ 8-219
8.44 Dozer Blade Assembly – Remove and Install .................................................... 8-220
8.44.1 Remove.................................................................................................... 8-220
8.44.2 Install........................................................................................................ 8-221
8.45 Cab Assembly – Remove and Install ................................................................. 8-222
8.45.1 Remove.................................................................................................... 8-222
8.45.2 Install........................................................................................................ 8-224
8.46 Counterweight Assembly - Remove and Install ................................................. 8-225
8.46.1 Removal ................................................................................................... 8-225
8.46.2 Install........................................................................................................ 8-226
8.47 Monitor Assembly - Remove and Install ............................................................ 8-227
8.47.1 Remove.................................................................................................... 8-227
8.47.2 Install........................................................................................................ 8-227

9 Maintenance Standard
9.1 Swing Machinery ..................................................................................................... 9-3
9.2 Swing Bearing.......................................................................................................... 9-4
9.3 Track Frame............................................................................................................. 9-5

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9.4 Idler .......................................................................................................................... 9-7

9.5 Track Roller.............................................................................................................. 9-9
9.6 Track Shoe..............................................................................................................9-11
9.7 Control Valve ......................................................................................................... 9-14
9.8 Oil Source Control Valve........................................................................................ 9-18
9.9 Work Equipment and Swing Pilot Valve ................................................................. 9-19
9.10 Travel Pilot Valve ................................................................................................. 9-21
9.11 Work Equipment .................................................................................................. 9-23
9.11.1 Work equipment dimension ........................................................................ 9-25
9.12 Hydraulic Cylinder................................................................................................ 9-27

10 Engine
10.1 General ................................................................................................................ 10-5
10.1.1 General maintenance precautions ............................................................. 10-5
10.1.2 Reading guide ............................................................................................ 10-5
10.1.3 Technical data and specifications ............................................................ 10-10
10.1.4 Tightening torque ......................................................................................10-11
10.1.5 Fixing nuts and bolts for key parts ........................................................... 10-13
10.1.6 Engine maintenance and servicing .......................................................... 10-21
10.1.7 Lubricating system ................................................................................... 10-22
10.1.8 Fuel system.............................................................................................. 10-23
10.1.8.1 Fuel filter ......................................................................................... 10-23
10.1.8.2 Water separator (optional) .............................................................. 10-24
10.1.8.3 Air bleeding ..................................................................................... 10-24
10.1.8.4 Fuel injector .................................................................................... 10-25
10.1.9 Cooling system ........................................................................................ 10-28
10.1.10 Thermostat ............................................................................................. 10-29
10.1.11 Valve clearance – adjust ........................................................................ 10-30
10.1.12 Injection timing ....................................................................................... 10-32
10.1.13 Compression pressure – measure ......................................................... 10-33
10.1.14 Engine repair kit ..................................................................................... 10-35
10.2 Engine Assembly – Disassemble....................................................................... 10-36
10.2.1 General .................................................................................................... 10-36
10.2.2 Disassemble ............................................................................................ 10-37
10.2.3 Rocker shaft and rocker arm.................................................................... 10-51
10.2.4 Cylinder head ........................................................................................... 10-53
10.2.5 Piston and connecting rod ....................................................................... 10-55
10.2.6 Camshaft, camshaft timing gear and thrust plate .................................... 10-58

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10.3 Engine Assembly – Inspect and Repair ............................................................. 10-60

10.3.1 Cylinder head ........................................................................................... 10-60
10.3.2 Valve guide .............................................................................................. 10-62
10.3.3 Valve and valve seat ring ......................................................................... 10-64
10.3.4 Valve spring ............................................................................................. 10-68
10.3.5 Rock shaft and rocker arm ....................................................................... 10-69
10.3.6 Cylinder block .......................................................................................... 10-72
10.3.7 Tappet and push rod ................................................................................ 10-80
10.3.8 Camshaft.................................................................................................. 10-82
10.3.9 Camshaft and camshaft bearing .............................................................. 10-84
10.3.10 Crankshaft and bearing.......................................................................... 10-87
10.3.11 Flywheel and ring gear ........................................................................... 10-96
10.3.12 Piston ..................................................................................................... 10-97
10.3.13 Piston ring .............................................................................................. 10-98
10.3.14 Piston pin ............................................................................................. 10-100
10.3.15 Connecting rod..................................................................................... 10-102
10.3.16 Idle gear shaft and idle gear ................................................................ 10-103
10.4 Engine Assembly – Assemble.......................................................................... 10-105
10.4.1 Rocker shaft and rocker arm.................................................................. 10-105
10.4.2 Cylinder head ......................................................................................... 10-106
10.4.3 Piston and connecting rod ..................................................................... 10-109
10.4.4 Camshaft, camshaft timing gear and thrust plate ...................................10-112
10.4.5 Aluminium casting type timing gear housing PTO – Assemble .............. 10-131
10.5 Lubricating System .......................................................................................... 10-142
10.5.1 Technical data and specifications ......................................................... 10-142
10.5.2 General .................................................................................................. 10-143
10.5.3 Oil pump................................................................................................. 10-144
10.5.4 Main oil filter ........................................................................................... 10-145
10.5.5 Oil pump – disassemble......................................................................... 10-146
10.5.6 Oil filter with built-in oil cooler – Disassemble ........................................ 10-150
10.5.7 Oil filter with built-in oil cooler – Inspect and repair................................ 10-151
10.5.8 Oil filter with built-in oil cooler – Assemble ............................................. 10-152
10.6 Cooling System ............................................................................................... 10-154
10.6.1 Technical data and specifications .......................................................... 10-154
10.6.2 General .................................................................................................. 10-155
10.6.3 Water pump .......................................................................................... 10-156
10.6.4 Water pump – Inspect and repair .......................................................... 10-157
10.6.5 Water pump – Disassemble ................................................................... 10-158

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10.6.6 Water pump – Assemble ........................................................................ 10-161

10.6.7 Thermostat – inspect and repair ............................................................ 10-164
10.7 Fuel System .................................................................................................... 10-165
10.7.1 Technical data and specifications ......................................................... 10-165
10.7.2 General ................................................................................................. 10-166
10.7.3 Fuel filter and water separator .............................................................. 10-169
10.7.4 Injector – Disassemble........................................................................... 10-170
10.7.5 Injector – inspect and repair .................................................................. 10-172
10.7.6 Injector –Assemble ................................................................................ 10-173
10.7.7 Injector – adjust...................................................................................... 10-175
10.7.8 Dual injection type injector– Disassemble ............................................. 10-176
10.7.9 Dual injection type injector – Assemble and adjust ................................ 10-178
10.7.10 Injection pump calibration data ........................................................... 10-190
10.7.11 Governor adjustment............................................................................ 10-193
10.8 Engine Electrical System ................................................................................. 10-194
10.8.1 Starter motor .......................................................................................... 10-194
10.8.2 General .................................................................................................. 10-196
10.8.3 Electrical system – disassemble ............................................................ 10-197
10.8.4 Electrical system – inspect and repair ................................................... 10-202
10.8.5 Electrical system – assemble................................................................. 10-208
10.8.6 Selection of lube oil and tightening torque ............................................. 10-209
10.8.7 Performance testing ............................................................................... 10-210
10.9 Alternator ..........................................................................................................10-211
10.9.1 General .................................................................................................. 10-212
10.9.2 Alternator – Disassemble ....................................................................... 10-213
10.9.3 Alternator – Inspect and repair ............................................................... 10-216
10.9.4 Alternator – Assemble ............................................................................ 10-221
10.10 Troubleshooting ............................................................................................. 10-223
10.10.1 Startup failures ..................................................................................... 10-224
10.10.2 Engine unstable at idle ........................................................................ 10-228
10.10.3 Low power............................................................................................ 10-231
10.10.4 Excessive fuel consumption................................................................. 10-235
10.10.5 Excessive oil consumption ................................................................... 10-237
10.10.6 Engine overheating .............................................................................. 10-238
10.10.7 White smoke ........................................................................................ 10-240
10.10.8 Black smoke......................................................................................... 10-241
10.10.9 Low oil pressure ................................................................................... 10-242
10.10.10 Abnormal engine noise ...................................................................... 10-244

Shop Manual - November 2012 XI

Table of Contents SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.11 List of Special Tools ....................................................................................... 10-247

10.12 Repair Standard............................................................................................. 10-249

11 System Schematics
11.1 Hydraulic Line Layout ...........................................................................................11-3
11.2 Hydraulic Circuit Diagram .....................................................................................11-4
11.3 Overall System Diagram (1/5)...............................................................................11-6
11.4 Overall System Diagram (2/5)...............................................................................11-7
11.5 Overall System Diagram (3/5)...............................................................................11-8
11.6 Overall System Diagram (4/5)...............................................................................11-9
11.7 Overall System Diagram (5/5).............................................................................11-10
11.8 Electrical Circuit Diagram....................................................................................11-11

XII Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

Introduction

.
1 Introduction

De al
pt
1.1 How to Read the Shop Manual ................................................................................ 1-3
1.2 Terms for Maintenance Standard............................................................................. 1-6
g n
1.3 Handling Electrical and Hydraulic Components....................................................... 1-9
o
1.3.1 Points to remember when handling electric components .............................. 1-9
in ti
1.3.2 Points to remember when handling hydraulic equipment ............................ 1-18
1.4 Hose Connector ..................................................................................................... 1-20
1.4.1 Type of hose connector................................................................................ 1-21
et a

1.4.2 Hose connector tightening torque table ....................................................... 1-21

n

1.4.3 Connection of O-rings .................................................................................. 1-22

rk er

1.5 Table of Standard Tightening Torques .................................................................. 1-23

1.6 Type of Bolts .......................................................................................................... 1-24
1.7 Tightening Sequence ............................................................................................. 1-24
Ma t

1.8 Maintenance of Half Flanges ................................................................................. 1-25

In

1.8.1 Table of tightening torques for half flange bolts ........................................... 1-25
1.9 Conversion Table ................................................................................................... 1-26

Shop Manual - November 2012 1-1

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.

1-2 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

1 INTRODUCTION

1.1 How to Read the Shop Manual

1. Composition of shop manual

This shop manual contains the necessary

technical information for services performed
in a workshop. For ease of understanding, the
manual is divided into the following sections.

.
De al
Introduction

pt
This section provides an overview of what is
g n
covered in the rest of this manual and how to
use this manual,.
o
in ti
Shop Safety

This section covers basic shop safety infor-

et a

mation relating to this equipment. It also de-

scribes what the hazard alerts mean that are
n

used throughout the manual.

rk er

Specifications
Ma t

Technical specification of work equipment and

optional parts are given in this section.
In

Structure and function

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.

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

Shop Manual - November 2012 1-3

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

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 dur-
ing inspection and repair work. Troubleshoot-
ing table that involves “Fault”and “Cause”are
also included in this section.

Troubleshooting

.
This section explains the way to detect faulty

De al
parts and the method to repair them. This sec-

pt
tion is divided into the following parts: Electri-
cal system, Engine, Hydraulic and mechanical
g n
system and Monitoring system.
o
Disassembly and assembly
in ti

This section explains the procedures as well

as precautions for removing, installing, disas-
et a

sembling and assembling of each component.

n

Engine
rk er

This section explains the disassembling and

assembling of engine components. Detailed
Ma t

information on the cooling system, lubricating

system, electrical system and the alternator is
In

also provided in this section.

System Schematics

This section provides hydraulic circuit dia-

grams and electrical circuit diagrams.

2. Revision and distribution

Any additions, 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 - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

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
kg 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.

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

et a

Drain
drained.
n

4. Units
rk er

In this shop manual, the units are indicated with International System of units (SI). For reference,
conventionally used Gravitational System of units is indicated in parentheses { }.
Ma t
In

Shop Manual - November 2012 1-5

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

1.2 Terms for Maintenance Standard

The maintenance standard values necessary

for judgment of products and parts are de-
scribed by the following terms.

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-

.
De al
able difference from that size is indicated.

pt
● The above size set temporarily is called
g n
the "standard size" and the range of differ-
ence from the standard size is called the
o
"tolerance".
in ti

● The tolerance with the symbols of + or – is

indicated on the right side of the standard
et a

size.
n
rk er

Example

Standard size Tolerance

Ma t

–0.022
In

120 Std.size F 60
–0.126
Tolerance of hole
★ The tolerance may be indicated in the (upper):+0.046
Std.clearance (max.):0.122
text and a table as [standard size (upper
limit of tolerance/lower limit of tolerance)]. Std.clearance (min.):0.030

Example) 120 (–0.022/–0.126) Tolerance of shaft

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

● Indication of size of rotating shaft and

hole and relationship drawing of them.

1-6 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

Example

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

2. Standard clearance and standard 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-

clearance.
g n
ance is generally adjusted to the standard
o
in ti
● A value of performance and function of
new products or equivalent is called the
"standard value", which is indicated by a
et a

range or a target value.

n

● When some parts are repaired, the value

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

dard value.

3. Standard interference
Ma t
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 - November 2012 1-7

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

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".

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

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

5. Clearance limit
et a
n

● Parts can be used until the clearance be-

tween them is increased to a certain limit.
rk er

The limit at which those parts cannot be

used is called the "clearance limit".
Ma t

● If the clearance between the parts exceeds

In

the clearance limit, they must be replaced

or repaired.

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 - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

1.3 Handling Electrical and Hydraulic 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 handling electric components
g n
1. Handling wiring harnesses and connec-
o
tors
in ti
Wiring harnesses consist of wiring con-
necting one component to another compo-
et a

nent, connectors used for connecting and

disconnecting one wire from another wire,
n

and protectors or tubes used for protecting

rk er

the wiring.

Compared with other electrical compo-

Ma t

nents fitted in boxes or cases, wiring

harnesses are more likely to be affected
In

by the direct effects of rain, water, heat, or

vibration. Furthermore, during inspection ZX215-1000004

and repair operations, they are frequently

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 - November 2012 1-9

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2. Main failures occurring in wiring har-

ness

1) Defective contact of connectors (defective

contact between male and female)
Improper insertion

Problems with defective contact are likely

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
pt
2) Defective crimping or soldering of connec-
tors
g no
The pins of the male and female connec-
Crimped portion

tors are in contact at the crimped terminal

in ti
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
et a

improper connection or breakage.

n

ZX215-1000006
rk er

3) Disconnections in wiring
Ma t

If the wiring is held and the connectors are

In

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

1-10 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

4) High-pressure water entering connector

The connector is designed to make it

difficult for water to enter (drip-proof
structure), 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 connector is designed to prevent
ZX215-1000008
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 connector, the pins will be short-

De al
circuited by the water, so if any water gets

pt
in, immediately dry the connector or take
other appropriate action before passing
g n
electricity through it.
o
in ti
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector

et a

and an oil film is formed on the mating

n

surface between the male and female pins,

the oil will not let the electricity pass, so
rk er

there will be defective contact. If there is

oil or grease stuck to the connector, wipe
it off with a dry cloth or blow it dry with
Ma t

compressed air and spray it with a contact

In

ZX215-1000009
restorer.

★ When wiping the mating portion of the

connector, be careful not to use exces-
sive force or deform the pins.

★ If there is oil or water in the compressed

air, the contacts will become even
dirtier, so remove the oil and water from
the compressed air completely before
cleaning with compressed air.

Shop Manual - November 2012 1-11

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3. Removing, installing, and drying con-

nectors and wiring harnesses

1) Disconnecting connectors

a. Hold the connectors when disconnect-

ing. Press lightly
when removing
Lock stopper
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull apart.

.
For connectors which have a lock stop- ZX215-1000010

De al
per, press down the stopper with your

pt
thumb and pull the connectors apart.

g n
★ Never pull with one hand.
o
b. When removing from clips
in ti
Both stoppers

● Both of the connector and clip have

stoppers, which are engaged with each
et a

other when the connector is installed.

n
rk er

ZX215-1000011
Ma t
In

● When removing a connector from a clip,

pull the connector in a parallel direction
to the clip for removing stoppers.

ZX215-1000012

1-12 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 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 always ZX215-1000013
cover the connector.

.
De al
2) Connecting connectors

pt
a. Check the connector visually
g no
Check that there is no oil, dirt, or water
Clicks into position

stuck to the connector pins (mating

in ti
portion).

Check that there is no deformation,

et a

defective contact, corrosion, or damage

ZX215-1000021
n

to the connector pins.

rk er

Check that there is no damage or

breakage to the outside of the connec-
tor.
Ma t
In

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

to the connector, wipe it off with a dry
cloth. If any water has got inside the
connector, warm the inside of the wir-
ing with a dryer, but be careful not to
make it too hot as this will cause short
circuits.

Shop Manual - November 2012 1-13

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

★ If there is any damage or breakage,

replace the connector.

b. Fix the connector securely.

Align the position of the connector

correctly, and then insert it securely.
For connectors with lock stopper, push
in the connector until the stopper clicks
into position.
ZX215-1000014

c. Correct any protrusion of the boot and

any misalignment of the wiring harness.

.
De al
For connectors fitted with boots, correct

pt
any protrusion of the boot. In addition, if
the wiring harness is misaligned, or the
g n
clamp is out of position, adjust it to its
o
correct position.
in ti
★ If the connector cannot be corrected
easily, remove the clamp and adjust the
ZX215-1000015
position.
et a
n

● If the connector clamp has been re-

moved, be sure to return it to its origi-
rk er

nal position. Check also that there are

no loose clamps.
Ma t
In

3) Connecting DT connectors
2 a 1 c
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.

● Male connector: 1

● Female connector: 2
d
b
● Normal locking state (Horizontal): a, b, ZX215-1000016
d

● Incomplete locking state (Diagonal): c

1-14 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

4) Drying wiring harness

If there is any oil or dirt on the wiring

harness, 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.

ZX215-1000009
a. Disconnect the connector and wipe off
the water with a dry cloth.

.
★ If the connector is blown dry with

De al
compressed air, there is the risk that oil

pt
in the air may cause defective contact,
so remove all oil and water from the
g n
compressed air before blowing with air.
o
b. Dry the connector with a dryer.
in ti

If water gets inside the connector, use

a dryer to dry the connector.
et a

ZX215-1000017
n

★ Hot air from the dryer can be used, but

regulate the time that the hot air is used
rk er

in order not to make the connector or

related parts too hot, as this will cause
deformation or damage to the connec-
Ma t

tor.
In

c. Carry out a continuity test on the con-

nector. T adapter

After drying, leave the wiring harness

disconnected and carry out a continuity
ZX215-1000018
test to check for any short circuits
between pins caused by water.

★ After completely drying the connector,

blow it with contact restorer and reas-
semble.

Shop Manual - November 2012 1-15

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. Handling the integrated control monitor

1) The controller contains a microcomputer

and an electronic control circuits. 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 controller. ZX215-1000019

.
De al
3) Cover the control connectors with tape or a

pt
vinyl bag. Never touch the connector con-
tacts with your hand.
g no
4) Do not leave it where it may be exposed to
Tool
Box

rain.
in ti

5) Do not place the controller on oil, water, or

soil, or in any hot place, even for a short
et a

time.
n

ZX215-1000020
6) Precautions for arc welding
rk er

When welding on the controller, disconnect

all wiring harness connectors connected
Ma t

to the controller. Fit an arc welding ground

In

close to the welding point.

ZX215-1000021

1-16 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

5. Points to remember when troubleshoot-

ing electric circuits

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-

De al
tors before going on to the next step.

pt
★ If the power is turned ON with the con-
g n
nectors still disconnected, unnecessary
o
abnormality displays will be generated.
in ti
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
et a

wiring and connectors several times and

n

check that there is no change in the read-

ing of the tester.
rk er

★ If there is any change, there is probably

defective contact in that circuit.
Ma t
In

Shop Manual - November 2012 1-17

Introduction SY65C3, SY75C3, SY75C9 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. Be careful of the operating environment

.
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
2. Disassembly and maintenance work in
the field
in ti
ZX215-1000023
If disassembly or maintenance work is
carried out on hydraulic equipment in the
et a

field, there is danger of dust entering the

n

equipment. It is also difficult to check the

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.

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 ZX215-1000024
customer to dispose of it, or take it back
with you for disposal.

1-18 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

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.

5. Change hydraulic oil when the tempera- ZX215-1000025

.
ture is high

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

the oil from the filter and from the drain

n

plug in the circuit.) If any old oil is left, the

contaminants and sludge in it will mix with
rk er

the new oil and will shorten the life of the

hydraulic oil.
Ma t

6. Flushing operations
In

After disassembling and assembling the

equipment, or changing the oil, use flush- Flushing oil
ing oil to remove the contaminants, sludge,
and old oil from the hydraulic circuit.
Normally, 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

Shop Manual - November 2012 1-19

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

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
equipment is used to remove the ultra fine
(about 3 μ) particles that the filter built in
the hydraulic equipment cannot remove, so ZX215-1000027
it is an extremely effective device.

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

NOTICE
n

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

ZX215-1000028
sive force applied on the metal sealing
surface (4) and (5) may cause the joint
(1) to break. Be sure to tighten nut (3)
Ma t

according to technical specifications.

In

● Scratches or other damages on seal-

ing surface (4) and (5) may cause leaks
at the joint. Be extremely careful not
to damage the sealing surfaces during
connecting and disconnecting work.

1-20 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

1.4.1 Type of hose connector

24°

24°

Male Female

ZX215-1000029

1.4.2 Hose connector tightening torque table

.
De al
pt
Wrench size mm Wrench size mm Tightening torque
Type
Connecting nut Hose joint N·m(kgf·m,Ibf·ft)
g no 19
22
19
22
59(6,44)
98(10,72)
27 27 118(12,87)
in ti
36 36 235(24,173)
24° Male
41 41 295(30,218)
et a

50 50 490(50,361)
n

60 60 670(68,494)
70 70 980(100,723)
rk er

19 17 44(4.5,32)
22 19 59(6,44)
Ma t

27 22 118(12,87)
24° Female
In

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 - November 2012 1-21

Introduction SY65C3, SY75C3, SY75C9 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
when re-connecting hoses. Hose connector
8 10

● Before tightening nut (9), make sure the ZX215-1000030

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

.
De al
ring seat (8).Displacement of the o-ring

pt
may have it damaged and cause leaks.

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

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

et a

detected, do not try to stop the leakage

by tightening nut (9). Instead, replace
n

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

rk er

sure it is well positioned, and tighten

nut (9).
Ma t

Wrench size mm Wrench size mm Tightening torque

In

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 - November 2012

SY65C3, SY75C3, SY75C9 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 Bolt Wrench Hex wrench Hexagonal bolt Hexagonal socket head bolt
diameter 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
M20
g n
10.9
10.9
o 27
30
14
17
382
549
38.98
56.02
281.9
405.16
382
549
38.98
56.02
281.9
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 7.96 57.76 78 7.96 57.76
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 - November 2012 1-23

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

1.6 Type of Bolts

Tighten nuts and bolts properly to specified

torque values. The type and grade of bolts are
illustrated on the right. Hex bolt Socket head hex bolt

Use correct bolts and tighten them properly 8.8 10.9 12.9
when assembling machines or components.

ZX215-1000031

.
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
right to ensure even tightening. 1 1
o
6 3
3 4
in ti
4 5
2 2
et a

Central and diagonal tightening

n

12 9 4 1 6 7 14
rk er

13 8 5 2 3 10 11
Ma t

ZX215-1000032
In

CAUTION
● Always use suitable tools for specific
work. Use of improper tools and meth-
ods may cause a hazardous situation.

● Use tools of correct sizes when loosen-

ing or tightening the nuts or bolts. Oth-
erwise, the tools may slide and cause
personal injury.
ZX215-1000033

1-24 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 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
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 per-
pendicular to the oil opening. Tighten the
o
Improper
bolt manually to maintain the location of
in ti
the components.
et a
n

ZX215-1000035
rk er

1.8.1 Table of tightening torques for half flange bolts

Ma t
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 - November 2012 1-25

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

1.9 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

1. Convert 55 mm into inches

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw
a horizontal line from (A).

.
De al
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular

pt
line down from (B).
g n
3) Take the point where the two lines cross as (C). This point (C) gives the value when con-
o
verting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
in ti
2. Convert 550 mm into inches

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point
et a

one place to the left) to convert it to 55 mm.

n

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

rk er

3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the
decimal point one place to the right) to return to the original value. This gives 550 mm =
Ma t

21.65 inches.
In

1-26 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

Length

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)

.
De al
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

pt
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70
80
g n
2.756
3.150
o 2.795
3.189
2.835
3.228
2.874
3.268
2.913
3.307
2.953
3.346
2.992
3.386
3.031
3.425
3.071
3.465
3.110
3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
in ti
Millimeters to Inches
1mm=0.03937in
et a
n

0 1 2 3 4 5 6 7 8 9
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
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.535
Ma t

40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
In

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 - November 2012 1-27

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Inches to Millimeters

in. mm in. mm
1/64 0.3969 33/64 13.0969
1/32 0.7938 17/32 13.4938
3/64 1.1906 35/64 13.8906
1/16 1.5875 9/16 14.2875
5/64 1.9844 37/64 14.6844
3/32 2.3813 19/32 15.0813
7/64 2.7781 39/64 15.4781
1/8 3.1750 5/8 15.8750

.
De al
9/64 3.5719 41/64 16.2719

pt
5/32 3.9688 21/32 16.6688
11/64 4.3656 43/64 17.0656
3/16
g no
13/64
4.7625
5.1594
11/16
45/64
17.4625
17.8594
in ti
7/32 5.5563 23/32 18.2563
15/64 5.9531 47/64 18.6531
1/4 6.3500 3/4 19.0500
et a

17/64 6.7469 49/64 19.4469

n

9/32 7.1438 25/32 19.8438

rk er

19/64 7.5406 51/64 20.2406

5/16 7.9375 13/16 20.6375
21/64 8.3344 53/64 21.0344
Ma t

11/32 8.7313 27/32 21.4313

In

23/64 9.1281 55/64 21.8281

3/8 9.5250 7/8 22.2250
25/64 9.9219 57/64 22.6219
13/32 10.3188 29/32 23.0188
27/64 10.7156 59/64 23.4156
7/16 11.1125 15/16 23.8125
29/64 11.5094 61/64 24.2094
15/32 11.9063 31/32 24.6063
31/64 12.3031 63/64 25.0031
1/2 12.7000 1 25.4000

1-28 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

Feet to Meters

ft. 0 1 2 3 4 5 6 7 8 9 ft.
m m m m m m m m m m
- - 0.305 0.610 0.914 1.219 1.524 1.829 2.134 2.438 2.743 -
10 3.048 3.353 3.658 3.962 4.267 4.572 4.877 5.182 5.486 5.791 10
20 6.096 6.401 6.706 7.010 7.315 7.620 7.925 8.230 8.534 8.839 20
30 9.144 9.449 9.754 10.058 10.363 10.668 10.973 11.278 11.582 11.887 30
40 12.192 12.497 12.802 13.106 13.411 13.716 14.021 14.326 14.630 14.935 40
50 15.240 15.545 15.850 16.154 16.459 16.764 17.069 17.374 17.678 17.983 50
60 18.288 18.593 18.898 19.202 19.507 19.812 20.117 20.422 20.726 21.031 60

.
De al
70 21.336 21.641 21.946 22.250 22.555 22.860 23.165 23.470 23.774 24.079 70

pt
80 24.384 24.689 24.994 25.298 25.603 25.908 26.213 26.518 26.822 27.127 80
90 27.432 27.737 28.042 28.346 28.651 28.956 29.261 29.566 29.870 30.175 90
100
g n
30.480 30.785 31.090 31.394 31.699 32.004 32.309 32.614 32.918 33.223
o 100
in ti
Meters to Feet
et a

m 0 1 2 3 4 5 6 7 8 9 m
n

ft. ft. ft. ft. ft. ft. ft. ft. ft. ft.
- - 3.2808 6.5617 9.8425 13.1234 16.4042 19.6850 22.9659 26.2467 29.5276 -
rk er

10 32.8084 36.0892 39.3701 42.6509 45.9318 49.2126 52.4934 55.7743 59.0551 62.3360 10
20 65.6168 68.8976 72.1785 75.4593 78.7402 82.0210 85.3018 88.5827 91.8635 95.1444 20
Ma t

30 98.4252 101.7060 104.9869 108.2677 111.5486 114.8294 118.1102 121.3911 124.6719 127.9528 30
In

40 131.2336 134.5144 137.7953 141.0761 144.3570 147.6378 150.9186 154.1995 157.4803 160.7612 40
50 164.0420 167.3228 170.6037 173.8845 177.1654 180.4462 183.7270 187.0079 190.2887 193.5696 50
60 196.8504 200.1312 203.4121 206.6929 209.9738 213.2546 216.5354 219.8163 223.0971 226.3780 60
70 229.6588 232.9396 236.2205 239.5013 242.7822 246.0630 249.3438 252.6247 255.9055 259.1864 70
80 262.4672 265.7480 269.0289 272.3097 275.5906 278.8714 282.1522 285.4331 288.7139 291.9948 80
90 295.2756 298.5564 301.8373 305.1181 308.3990 311.6798 314.9606 318.2415 321.5223 324.8032 90
100 328.0840 331.3648 334.6457 337.9265 341.2074 344.4882 347.7690 351.0499 354.3307 357.6116 100

Shop Manual - November 2012 1-29

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Miles to Kilometers

miles 0 1 2 3 4 5 6 7 8 9 miles
km km km km km km km km km km
- - 1.609 3.219 4.828 6.437 8.047 9.656 11.265 12.875 14.484 -
10 16.093 17.703 19.312 20.921 22.531 24.140 25.749 27.359 28.968 30.577 10
20 32.187 33.796 35.405 37.015 38.624 40.234 41.843 43.452 45.062 46.671 20
30 48.280 49.890 51.499 53.108 54.718 56.327 57.936 59.546 61.155 62.764 30
40 64.374 65.983 67.592 69.202 70.811 72.420 74.030 75.639 77.248 78.858 40
50 80.467 82.077 83.686 85.295 86.904 88.514 90.123 91.732 93.342 94.951 50
60 96.561 98.170 99.779 101.388 102.998 104.607 106.216 107.826 109.435 111.044 60

.
De al
70 112.654 114.263 115.872 117.482 119.091 120.701 122.310 123.919 125.529 127.138 70

pt
80 128.748 130.357 131.966 133.575 135.185 136.794 138.403 140.013 141.622 143.231 80
90 144.841 146.450 148.059 149.669 151.278 152.887 154.497 156.106 157.715 159.325 90
g n
100 160.934 162.543 164.153 165.762 167.371 168.981 170.590 172.199 173.809 175.418 100
o
in ti
Kilometers to Miles

km 0 1 2 3 4 5 6 7 8 9 km
et a

miles miles miles miles miles miles miles miles miles miles
n

- - 0.621 1.243 1.864 2.485 3.107 3.728 4.350 4.971 5.592 -

rk er

10 6.214 6.835 7.456 8.078 8.699 9.321 9.942 10.563 11.185 11.806 10
20 12.427 13.049 13.670 14.292 14.913 15.534 16.156 16.777 17.398 18.020 20
Ma t

30 18.641 19.262 19.884 20.505 21.127 21.748 22.369 22.991 23.612 24.233 30
40 24.855 25.476 26.098 26.719 27.340 27.962 28.583 29.204 29.826 30.447 40
In

50 31.069 31.690 32.311 32.933 33.554 34.175 34.797 35.418 36.039 36.661 50
60 37.282 37.904 38.525 39.146 39.768 40.389 41.010 41.632 42.253 42.875 60
70 43.496 44.117 44.739 45.360 45.981 46.603 47.224 47.845 48.467 49.088 70
80 49.710 50.331 50.952 51.574 52.195 52.816 53.438 54.059 54.681 55.302 80
90 55.923 56.545 57.166 57.787 58.409 59.030 59.652 60.273 60.894 61.516 90
100 62.137 62.758 63.380 64.001 64.622 65.244 65.865 66.487 67.108 67.729 100

1-30 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

Area

Square inches to square centimeters

in2 0 1 2 3 4 5 6 7 8 9 in2
cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2
- - 6.452 12.903 19.355 25.806 32.258 38.710 45.161 51.613 58.064 -
10 64.516 70.968 77.419 83.871 90.322 96.774 103.226 109.677 116.129 122.580 10
20 129.032 135.484 141.935 148.387 154.838 161.290 167.742 174.193 180.645 187.096 20
30 193.548 200.000 206.451 212.903 219.354 225.806 232.258 238.709 245.161 251.612 30
40 258.064 264.516 270.967 277.419 283.870 290.322 296.774 303.225 309.677 316.128 40
50 322.580 329.032 335.483 341.935 348.386 354.838 361.290 367.741 374.193 380.644 50

.
De al
60 387.096 393.548 399.999 406.451 412.902 419.354 425.806 432.257 438.709 445.160 60

pt
70 451.612 458.064 464.515 470.967 477.418 483.870 490.322 496.773 503.225 509.676 70
80 516.128 522.580 529.031 535.483 541.934 548.386 554.838 561.289 567.741 574.192 80
90
g n
580.644 587.096 593.547 599.999 606.450 612.902 619.354 625.805 632.257 638.708
o 90
100 645.160 651.612 658.063 664.515 670.966 677.418 683.870 690.321 696.773 703.224 100
in ti

Square centimeters to square inches

et a

cm2 0 1 2 3 4 5 6 7 8 9 cm2
n

in2 in2 in2 in2 in2 in2 in2 in2 in2 in2
rk er

- - 0.155 0.310 0.465 0.620 0.775 0.930 1.085 1.240 1.395 -

10 1.550 1.705 1.860 2.015 2.170 2.325 2.480 2.635 2.790 2.945 10
20 3.100 3.255 3.410 3.565 3.720 3.875 4.030 4.185 4.340 4.495 20
Ma t

30 4.650 4.805 4.960 5.115 5.270 5.425 5.580 5.735 5.890 6.045 30
In

40 6.200 6.355 6.510 6.665 6.820 6.975 7.130 7.285 7.440 7.595 40
50 7.750 7.905 8.060 8.215 8.370 8.525 8.680 8.835 8.990 9.145 50
60 9.300 9.455 9.610 9.765 9.920 10.075 10.230 10.385 10.540 10.695 60
70 10.850 11.005 11.160 11.315 11.470 11.625 11.780 11.935 12.090 12.245 70
80 12.400 12.555 12.710 12.865 13.020 13.175 13.330 13.485 13.640 13.795 80
90 13.950 14.105 14.260 14.415 14.570 14.725 14.880 15.035 15.190 15.345 90
100 15.500 15.655 15.810 15.965 16.120 16.275 16.430 16.585 16.740 16.895 100

Shop Manual - November 2012 1-31

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Volume

Cubic inches to cubic centimeters

in3 0 1 2 3 4 5 6 7 8 9 in3
cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc)
- - 16.387 32.774 49.161 65.548 81.935 98.322 114.709 131.096 147.484 -
10 163.871 180.258 196.645 213.032 229.419 245.806 262.193 278.580 294.967 311.354 10
20 327.741 344.128 360.515 376.902 393.289 409.677 426.064 442.451 458.838 475.225 20
30 491.612 507.999 524.386 540.773 557.160 573.547 589.934 606.321 622.708 639.095 30
40 655.482 671.869 688.257 704.644 721.031 737.418 753.805 770.192 786.579 802.966 40
50 819.353 835.740 852.127 868.514 884.901 901.288 917.675 934.062 950.449 966.837 50

.
60 983.224 999.611 1015.998 1032.385 1048.772 1065.159 1081.546 1097.933 1114.320 1130.707 60

De al
pt
70 1147.094 1163.481 1179.868 1196.255 1212.642 1229.030 1245.417 1261.804 1278.191 1294.578 70
80 1310.965 1327.352 1343.739 1360.126 1376.513 1392.900 1409.287 1425.674 1442.061 1458.448 80
g n
90 1474.835 1491.222 1507.610 1523.997 1540.384 1556.771 1573.158 1589.545 1605.932 1622.319 90
o
100 1638.706 1655.093 1671.480 1687.867 1704.254 1720.641 1737.028 1753.415 1769.802 1786.190 100
in ti
Cubic centimeters to cubic inches

cm3 cm3
et a

0 1 2 3 4 5 6 7 8 9
(cc) (cc)
n

3 3 3 3 3 3 3 3 3 3
in in in in in in in in in in
rk er

- - 0.0610 0.1220 0.1831 0.2441 0.3051 0.3661 0.4272 0.4882 0.5492 -

10 0.6102 0.6713 0.7323 0.7933 0.8543 0.9153 0.9764 1.0374 1.0984 1.1594 10
20 1.2205 1.2815 1.3425 1.4035 1.4646 1.5256 1.5866 1.6476 1.7086 1.7697 20
Ma t

30 1.8307 1.8917 1.9527 2.0138 2.0748 2.1358 2.1968 2.2579 2.3189 2.3799 30
In

40 2.4409 2.5019 2.5630 2.6240 2.6850 2.7460 2.8071 2.8681 2.9291 2.9901 40
50 3.0512 3.1122 3.1732 3.2342 3.2952 3.3563 3.4173 3.4783 3.5393 3.6004 50
60 3.6614 3.7224 3.7834 3.8444 3.9055 3.9665 4.0275 4.0885 4.1496 4.2106 60
70 4.2716 4.3326 4.3937 4.4547 4.5157 4.5767 4.6377 4.6988 4.7598 4.8208 70
80 4.8818 4.9429 5.0039 5.0649 5.1259 5.1870 5.2480 5.3090 5.3700 5.4310 80
90 5.4921 5.5531 5.6141 5.6751 5.7362 5.7972 5.8582 5.9192 5.9803 6.0413 90
100 6.1023 6.1633 6.2243 6.2854 6.3464 6.4074 6.4684 6.5295 6.5905 6.6515 100

1-32 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

U.S. Gallons to liters

U.S. U.S.
0 1 2 3 4 5 6 7 8 9
gal gal
liters liters liters liters liters liters liters liters liters liters
- - 3.7854 7.5709 11.3563 15.1417 18.9271 22.7126 26.4980 30.2834 34.0688 -
10 37.8543 41.6397 45.4251 49.2106 52.9960 56.7814 60.5668 64.3523 68.1377 71.9231 10
20 75.7085 79.4940 83.2794 87.0648 90.8502 94.6357 98.4211 102.2065 105.9920 109.7774 20
30 113.5628 117.3482 121.1337 124.9191 128.7045 132.4899 136.2754 140.0608 143.8462 147.6317 30
40 151.4171 155.2025 158.9879 162.7734 166.5588 170.3442 174.1296 177.9151 181.7005 185.4859 40
50 189.2714 193.0568 196.8422 200.6276 204.4131 208.1985 211.9839 215.7693 219.5548 223.3402 50
60 227.1256 230.9110 234.6965 238.4819 242.2673 246.0528 249.8382 253.6236 257.4090 261.1945 60

.
De al
70 264.9799 268.7653 272.5507 276.3362 280.1216 283.9070 287.6925 291.4779 295.2633 299.0487 70

pt
80 302.8342 306.6196 310.4050 314.1904 317.9759 321.7613 325.5467 329.3321 333.1176 336.9030 80
90 340.6884 344.4739 348.2593 352.0447 355.8301 359.6156 363.4010 367.1864 370.9718 374.7573 90
g n
100 378.5427 382.3281 386.1136 389.8990 393.6844 397.4698 401.2553 405.0407 408.8261 412.6115 100
o
in ti
Liters to U.S. Gallons
et a

liters 0 1 2 3 4 5 6 7 8 9 liters
n

gal gal gal gal gal gal gal gal gal gal
- - 0.2642 0.5283 0.7925 1.0567 1.3209 1.5850 1.8492 2.1134 2.3775 -
rk er

10 2.6417 2.9059 3.1701 3.4342 3.6984 3.9626 4.2268 4.4909 4.7551 5.0193 10
20 5.2834 5.5476 5.8118 6.0760 6.3401 6.6043 6.8685 7.1326 7.3968 7.6610 20
Ma t

30 7.9252 8.1893 8.4535 8.7177 8.9818 9.2460 9.5102 9.7744 10.0385 10.3027 30
In

40 10.5669 10.8311 11.0952 11.3594 11.6236 11.8877 12.1519 12.4161 12.6803 12.9444 40
50 13.2086 13.4728 13.7369 14.0011 14.2653 14.5295 14.7936 15.0578 15.3220 15.5861 50
60 15.8503 16.1145 16.3787 16.6428 16.9070 17.1712 17.4354 17.6995 17.9637 18.2279 60
70 18.4920 18.7562 19.0204 19.2846 19.5487 19.8129 20.0771 20.3412 20.6054 20.8696 70
80 21.1338 21.3979 21.6621 21.9263 22.1904 22.4546 22.7188 22.9830 23.2471 23.5113 80
90 23.7755 24.0397 24.3038 24.5680 24.8322 25.0963 25.3605 25.6247 25.8889 26.1530 90
100 26.4172 26.6814 26.9455 27.2097 27.4739 27.7381 28.0022 28.2664 28.5306 28.7947 100

Shop Manual - November 2012 1-33

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

U.K. Gallons to Liters

lmp lmp
0 1 2 3 4 5 6 7 8 9
gal gal
liters liters liters liters liters liters liters liters liters liters
- - 4.5459 9.0918 13.6377 18.1836 22.7295 27.2754 31.8213 36.3672 40.9131 -
10 45.4590 50.0049 54.5508 59.0967 63.6426 68.1885 72.7344 77.2803 81.8262 86.3721 10
20 90.9180 95.4639 100.0098 104.5557 109.1016 113.6475 118.1934 122.7393 127.2852 131.8311 20
30 136.3770 140.9229 145.4688 150.0147 154.5606 159.1065 163.6524 168.1983 172.7442 177.2901 30
40 181.8360 186.3819 190.9278 195.4737 200.0196 204.5655 209.1114 213.6573 218.2032 222.7491 40
50 227.2950 231.8409 236.3868 240.9327 245.4786 250.0245 254.5704 259.1163 263.6622 268.2081 50
60 272.7540 277.2999 281.8458 286.3917 290.9376 295.4835 300.0294 304.5753 309.1212 313.6671 60

.
De al
70 318.2130 322.7589 327.3048 331.8507 336.3966 340.9425 345.4884 350.0343 354.5802 359.1261 70

pt
80 363.6720 368.2179 372.7638 377.3097 381.8556 386.4015 390.9474 395.4933 400.0392 404.5851 80
90 409.1310 413.6769 418.2228 422.7687 427.3146 431.8605 436.4064 440.9523 445.4982 450.0441 90
g n
100 454.5900 459.1359 463.6818 468.2277 472.7736 477.3195 481.8654 486.4113 490.9572 495.5031 100
o
in ti
Liters to U.K. Gallons

liters 0 1 2 3 4 5 6 7 8 9 liters
et a

gal gal gal gal gal gal gal gal gal gal
n

- - 0.2200 0.4400 0.6599 0.8799 1.0999 1.3199 1.5399 1.7598 1.9798 -

rk er

10 2.1998 2.4198 2.6398 2.8597 3.0797 3.2997 3.5197 3.7397 3.9596 4.1796 10
20 4.3996 4.6196 4.8396 5.0595 5.2795 5.4995 5.7195 5.9395 6.1594 6.3794 20
30 6.5994 6.8194 7.0394 7.2593 7.4793 7.6993 7.9193 8.1393 8.3592 8.5792 30
Ma t

40 8.7992 9.0192 9.2392 9.4591 9.6791 9.8991 10.1191 10.3391 10.5590 10.7790 40
In

50 10.9990 11.2190 11.4390 11.6589 11.8789 12.0989 12.3189 12.5389 12.7588 12.9788 50
60 13.1988 13.4188 13.6388 13.8587 14.0787 14.2987 14.5187 14.7387 14.9586 15.1786 60
70 15.3986 15.6186 15.8386 16.0585 16.2785 16.4985 16.7185 16.9385 17.1584 17.3784 70
80 17.5984 17.8184 18.0384 18.2583 18.4783 18.6983 18.9183 19.1383 19.3582 19.5782 80
90 19.7982 20.0182 20.2382 20.4581 20.6781 20.8981 21.1181 21.3381 21.5580 21.7780 90
100 21.9980 22.2180 22.4380 22.6579 22.8779 23.0979 23.3179 23.5379 23.7578 23.9778 100

1-34 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

Weight

Pound to Kilogram

lbs. 0 1 2 3 4 5 6 7 8 9 lbs.
kg kg kg kg kg kg kg kg kg kg
- - 0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082 -
10 4.536 4.989 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618 10
20 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154 20
30 13.608 14.061 14.515 14.968 15.422 15.876 16.329 16.783 17.236 17.690 30
40 18.144 18.597 19.051 19.504 19.958 20.412 20.865 21.319 21.772 22.226 40
50 22.680 23.133 23.587 24.040 24.494 24.947 25.401 25.855 26.308 26.762 50

.
De al
60 27.215 27.669 28.123 28.576 29.030 29.483 29.937 30.391 30.844 31.298 60

pt
70 31.751 32.205 32.658 33.112 33.566 34.019 34.473 34.926 35.380 35.834 70
80 36.287 36.741 37.194 37.648 38.102 38.555 39.009 39.462 39.916 40.370 80
90 40.823
100 45.359
g n
41.277
o
45.813
41.730
46.266
42.184
46.720
42.637
47.173
43.091
47.627
43.545
48.081
43.998
48.534
44.452
48.988
44.905
49.441 100
90
in ti

Kilogram to Pound
et a
n

kg 0 1 2 3 4 5 6 7 8 9 kg
rk er

lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs.
- - 2.205 4.409 6.614 8.818 11.023 13.228 15.432 17.637 19.842 -
10 22.046 24.251 26.455 28.660 30.865 33.069 35.274 37.479 39.683 41.888 10
Ma t

20 44.092 46.297 48.502 50.706 52.911 55.116 57.320 59.525 61.729 63.934 20
In

30 66.139 68.343 70.548 72.752 74.957 77.162 79.366 81.571 83.776 85.980 30
40 88.185 90.389 92.594 94.799 97.003 99.208 101.413 103.617 105.822 108.026 40
50 110.231 112.436 114.640 116.845 119.049 121.254 123.459 125.663 127.868 130.073 50
60 132.277 134.482 136.686 138.891 141.096 143.300 145.505 147.710 149.914 152.119 60
70 154.323 156.528 158.733 160.937 163.142 165.347 167.551 169.756 171.960 174.165 70
80 176.370 178.574 180.779 182.983 185.188 187.393 189.597 191.802 194.007 196.211 80
90 198.416 200.620 202.825 205.030 207.234 209.439 211.644 213.848 216.053 218.257 90
100 220.462 222.667 224.871 227.076 229.280 231.485 233.690 235.894 238.099 240.304 100

Shop Manual - November 2012 1-35

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Newton to Kilogram

N 0 10 20 30 40 50 60 70 80 90 N
kg kg kg kg kg kg kg kg kg kg
- - 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 -
100 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 100
200 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 200
300 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 300
400 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 400
500 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 500
600 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 600

.
De al
700 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 700

pt
800 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 800
900 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 900
g n
1000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 1000
o
in ti
Kilogram to Newton

kg 0 1 2 3 4 5 6 7 8 9 kg
et a

N N N N N N N N N N
n

- - 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 -

rk er

10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
Ma t

40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
In

50 490.34 500.14 509.95 519.76 529.56 539.37 549.18 558.98 568.79 578.60 50
60 588.40 598.21 608.02 617.82 627.63 637.44 647.24 657.05 666.86 676.66 60
70 686.47 696.28 706.08 715.89 725.70 735.50 745.31 755.12 764.92 774.73 70
80 784.54 794.34 804.15 813.96 823.76 833.57 843.38 853.18 862.99 872.80 80
90 882.60 892.41 902.22 912.02 921.83 931.64 941.44 951.25 961.06 970.86 90
100 980.67 990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100

1-36 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

Pressure

Lb/in² to Kg/cm²
lb/
0 1 2 3 4 5 6 7 8 9 lb/in2
in2
(psi) kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 (psi)
- - 0.0703 0.1406 0.2109 0.2812 0.3515 0.4218 0.4921 0.5625 0.6328 -
10 0.7031 0.7734 0.8437 0.9140 0.9843 1.0546 1.1249 1.1952 1.2655 1.3358 10
20 1.4061 1.4764 1.5468 1.6171 1.6874 1.7577 1.8280 1.8983 1.9686 2.0389 20
30 2.1092 2.1795 2.2498 2.3201 2.3904 2.4607 2.5311 2.6014 2.6717 2.7420 30
40 2.8123 2.8826 2.9529 3.0232 3.0935 3.1638 3.2341 3.3044 3.3747 3.4450 40
50 3.5154 3.5857 3.6560 3.7263 3.7966 3.8669 3.9372 4.0075 4.0778 4.1481 50

.
De al
60 4.2184 4.2887 4.3590 4.4293 4.4996 4.5700 4.6403 4.7106 4.7809 4.8512 60

pt
70 4.9215 4.9918 5.0621 5.1324 5.2027 5.2730 5.3433 5.4136 5.4839 5.5543 70
80 5.6246 5.6949 5.7652 5.8355 5.9058 5.9761 6.0464 6.1167 6.1870 6.2573 80
90 6.3276
g n
6.3979
o
6.4682 6.5386 6.6089 6.6792 6.7495 6.8198 6.8901 6.9604 90
100 7.0307 7.1010 7.1713 7.2416 7.3119 7.3822 7.4525 7.5228 7.5932 7.6635 100
in ti

Kg/cm² to Lb/in²
et a

kg/
0 1 2 3 4 5 6 7 8 9 kg/cm2
cm2
n

lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2
rk er

(psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi)
- - 14.22 28.45 42.67 56.89 71.12 85.34 99.56 113.78 128.01 -
10 142.23 156.45 170.68 184.90 199.12 213.35 227.57 241.79 256.01 270.24 10
Ma t

20 284.46 298.68 312.91 327.13 341.35 355.58 369.80 384.02 398.24 412.47 20
In

30 426.69 440.91 455.14 469.36 483.58 497.81 512.03 526.25 540.47 554.70 30
40 568.92 583.14 597.37 611.59 625.81 640.04 654.26 668.48 682.70 696.93 40
50 711.15 725.37 739.60 753.82 768.04 782.27 796.49 810.71 824.93 839.16 50
60 853.38 867.60 881.83 896.05 910.27 924.50 938.72 952.94 967.16 981.39 60
70 995.61 1009.83 1024.06 1038.28 1052.50 1066.73 1080.95 1095.17 1109.39 1123.62 70
80 1137.84 1152.06 1166.29 1180.51 1194.73 1208.96 1223.18 1237.40 1251.62 1265.85 80
90 1280.07 1294.29 1308.52 1322.74 1336.96 1351.19 1365.41 1379.63 1393.85 1408.08 90
100 1422.30 1436.52 1450.75 1464.97 1479.19 1493.42 1507.64 1521.86 1536.08 1550.31 100

Shop Manual - November 2012 1-37

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Kg/cm² to Kpa

kg/ kg/
0 1 2 3 4 5 6 7 8 9
cm2 cm2
Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa
- - 98.1 196.1 294.2 392.3 490.3 588.4 686.5 784.5 882.6 -
10 980.7 1078.7 1176.8 1274.9 1372.9 1471.0 1569.1 1667.1 1765.2 1863.3 10
20 1961.3 2059.4 2157.5 2255.5 2353.6 2451.7 2549.7 2647.8 2745.9 2843.9 20
30 2942.0 3040.1 3138.1 3236.2 3334.3 3432.3 3530.4 3628.5 3726.5 3824.6 30
40 3922.7 4020.7 4118.8 4216.9 4314.9 4413.0 4511.1 4609.1 4707.2 4805.3 40
50 4903.4 5001.4 5099.5 5197.6 5295.6 5393.7 5491.8 5589.8 5687.9 5786.0 50
60 5884.0 5982.1 6080.2 6178.2 6276.3 6374.4 6472.4 6570.5 6668.6 6766.6 60

.
De al
70 6864.7 6962.8 7060.8 7158.9 7257.0 7355.0 7453.1 7551.2 7649.2 7747.3 70

pt
80 7845.4 7943.4 8041.5 8139.6 8237.6 8335.7 8433.8 8531.8 8629.9 8728.0 80
90 8826.0 8924.1 9022.2 9120.2 9218.3 9316.4 9414.4 9512.5 9610.6 9708.6 90
100
g n
9806.7 9904.8 10002.8 10100.9 10199.0 10297.0 10395.1 10493.2 10591.2 10689.3
o 100
in ti
Kpa to Kg/cm²

Kpa 0 100 200 300 400 500 600 700 800 900 Kpa
et a

2 2 2 2 2 2 2 2 2 2
kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm
n

- - 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 -

rk er

1000 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 1000
2000 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 2000
Ma t

3000 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 3000
4000 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 4000
In

5000 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 5000
6000 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 6000
7000 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 7000
8000 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 8000
9000 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 9000
10000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 10000

1-38 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

Torque

Ft·lbs to Kg·m

ft·lbs 0 1 2 3 4 5 6 7 8 9 ft·lbs
kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m
- - 0.138 0.277 0.415 0.553 0.691 0.830 0.968 1.106 1.244 -
10 1.383 1.521 1.659 1.797 1.936 2.074 2.212 2.350 2.489 2.627 10
20 2.765 2.903 3.042 3.180 3.318 3.457 3.595 3.733 3.871 4.010 20
30 4.148 4.286 4.424 4.563 4.701 4.839 4.977 5.116 5.254 5.392 30
40 5.530 5.669 5.807 5.945 6.083 6.222 6.360 6.498 6.636 6.775 40
50 6.913 7.051 7.190 7.328 7.466 7.604 7.743 7.881 8.019 8.157 50

.
De al
60 8.296 8.434 8.572 8.710 8.849 8.987 9.125 9.263 9.402 9.540 60

pt
70 9.678 9.816 9.955 10.093 10.231 10.370 10.508 10.646 10.784 10.923 70
80 11.061 11.199 11.337 11.476 11.614 11.752 11.890 12.029 12.167 12.305 80
90 12.443
g n
12.582
o 12.720 12.858 12.996 13.135 13.273 13.411 13.549 13.688 90
100 13.826 13.964 14.103 14.241 14.379 14.517 14.656 14.794 14.932 15.070 100
in ti

Kg·m to Ft·lbs
et a

kg·m 0 1 2 3 4 5 6 7 8 9 kg·m
n

ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs
rk er

- - 7.23 14.47 21.70 28.93 36.17 43.40 50.63 57.86 65.10 -

10 72.33 79.56 86.80 94.03 101.26 108.50 115.73 122.96 130.19 137.43 10
20 144.66 151.89 159.13 166.36 173.59 180.83 188.06 195.29 202.52 209.76 20
Ma t

30 216.99 224.22 231.46 238.69 245.92 253.16 260.39 267.62 274.85 282.09 30
In

40 289.32 296.55 303.79 311.02 318.25 325.49 332.72 339.95 347.18 354.42 40
50 361.65 368.88 376.12 383.35 390.58 397.82 405.05 412.28 419.51 426.75 50
60 433.98 441.21 448.45 455.68 462.91 470.15 477.38 484.61 491.84 499.08 60
70 506.31 513.54 520.78 528.01 535.24 542.48 549.71 556.94 564.17 571.41 70
80 578.64 585.87 593.11 600.34 607.57 614.81 622.04 629.27 636.50 643.74 80
90 650.97 658.20 665.44 672.67 679.90 687.14 694.37 701.60 708.83 716.07 90
100 723.30 730.53 737.77 745.00 752.23 759.47 766.70 773.93 781.16 788.40 100

Shop Manual - November 2012 1-39

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Kg·m to N·m

kg·m 0 1 2 3 4 5 6 7 8 9 kg·m
N·m N·m N·m N·m N·m N·m N·m N·m N·m N·m
- - 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 -
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
50 490.34 500.14 509.95 519.76 529.56 539.37 549.18 558.98 568.79 578.60 50
60 588.40 598.21 608.02 617.82 627.63 637.44 647.24 657.05 666.86 676.66 60

.
De al
70 686.47 696.28 706.08 715.89 725.70 735.50 745.31 755.12 764.92 774.73 70

pt
80 784.54 794.34 804.15 813.96 823.76 833.57 843.38 853.18 862.99 872.80 80
90 882.60 892.41 902.22 912.02 921.83 931.64 941.44 951.25 961.06 970.86 90
100 980.67
g n
990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100
o
in ti
N·m to Kg·m

N·m 0 10 20 30 40 50 60 70 80 90 N·m
et a

kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m
n

- - 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 -

rk er

100 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 10
200 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 20
300 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 30
Ma t

400 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 40
In

500 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 50
600 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 60
700 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 70
800 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 80
900 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 90
1000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 100

1-40 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

Temperature
A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading
(or vice versa) is to enter the following table in the center (boldface column) of figures. These fig-
ures refer to the temperature in either Fahrenheit or Centigrade degrees.

To convert from Fahrenheit to Centigrade degrees, consider the center column as Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.

To convert from Centigrade to Fahrenheit degrees, consider the center column as Centigrade val-
ues, and read the corresponding Fahrenheit temperature on the right.

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 1-41

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

1°C = 33.8°F

°C °F °C °F °C °F °C °F
-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 -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
-28.9 -2
-20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-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 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

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

pt
-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
-24.4 -12 10.4
g no-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
in ti
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-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
et a

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

n

-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2

rk er

-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
Ma t

-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0

In

-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

1-42 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Introduction

tE.
PAD nal
eGp
ng o
i
tKi t
a
AkNe rn
ar e
BLM Int

Shop Manual - November 2012 1-43

Introduction SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

tE.
l
Pg Aona
DG
ep
in ti
etK a
n
ArkNer
Ma t
BL In

1-44 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 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 ............................................................................................... 2-6
g n
2.2.1 Rules and shop behavior ............................................................................... 2-7
o
2.2.2 Housekeeping ................................................................................................ 2-7
in ti
2.2.3 Shop Liquids Storage..................................................................................... 2-8
2.2.4 Cleaning Parts ............................................................................................... 2-8
2.2.5 Jacking Up the Machine................................................................................. 2-9
et a

2.2.6 Electrical Dangers .......................................................................................... 2-9

n

2.2.7 Removing Attachments ................................................................................ 2-10

rk er

2.2.8 Cleaning the Machine .................................................................................. 2-10

2.2.9 Using the Correct Tools................................................................................ 2-10
2.2.10 Hoisting a Load ...........................................................................................2-11
Ma t

2.2.11 Appropriate Working Apparel ..................................................................... 2-12

In

2.2.12 Safety Partners .......................................................................................... 2-12

2.2.13 Two people when engine running .............................................................. 2-13
2.2.14 Driving Pins ................................................................................................ 2-13
2.2.15 Aligning Parts or Components ................................................................... 2-14
2.2.16 Fire Extinguisher and Emergency Exits ..................................................... 2-14
2.2.17 Personal Protective Equipment.................................................................. 2-14
2.2.18 Running the Machine ................................................................................. 2-15
2.2.19 Accumulator ............................................................................................... 2-16
2.2.20 Adding Fluids to a System ......................................................................... 2-16
2.2.21 Track Recoil Springs .................................................................................. 2-17
2.2.22 High-Pressure Fluid Lines.......................................................................... 2-17
2.2.23 Safe Work Preparations ............................................................................. 2-18
2.2.24 Mounting and Dismounting ........................................................................ 2-19

Shop Manual - November 2012 2-1

Shop Safety SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2.2.25 Battery Hazards ......................................................................................... 2-20

2.2.26 Jump-Start Safety ...................................................................................... 2-21
2.2.27 Disconnecting the System Power .............................................................. 2-21
2.2.28 LOCKOUT/TAGOUT .................................................................................. 2-22
2.2.29 Sequence of Procedures ........................................................................... 2-22
2.2.30 CHEMICAL HAZARDS .............................................................................. 2-24
2.2.31 Material Safety Data Sheets (MSDS) ........................................................ 2-24

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.

2-2 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Shop Safety

2 SHOP SAFETY

2.1 Hazard Alert Information

Most accidents are usually caused by the fail-
ure 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 ma-
chine system.

.
The following (ANSI/ISO) signal words are

De al
used to inform you that there is a potentially

pt
hazardous situation that may lead to damage,
personal injury or even death. In this manual,
g n
on the machine, part or component decals and
o
different signal words are used to express the
potential level of a hazard.
in ti

DANGER
et a

Indicates an imminent hazard which WILL

result in serious injury or death if message
n

is ignored.
rk er

WARNING
Ma t

Indicates a potentially hazardous situation

which COULD result in serious injury or
In

death if message is ignored.

CAUTION
Indicates a potentially hazardous situation
which COULD RESULT IN MINOR OR MA-
JOR INJURY if message is ignored.

NOTICE
Indicates THE MACHINE MAY BE DAM-
AGED if improperly operated or main-
tained.

Shop Manual - November 2012 2-3

Shop Safety SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

This is to alert the user of a hazard. It is

usually used in a graphic.

This symbol is used in a graphic to alert

the user to not do something.

SANY cannot predict every circumstance that

might involve a potential hazard in a repair of
the machine. Therefore the safety message in
this manual and on the machine may not in-
clude all possible safety precautions.

If any procedures or actions not specified, rec-

.
De al
ommended or allowed in this manual are used,

pt
you must be sure that you and others can
perform such procedures and actions safely
g n
and without damaging the machine. If you are
unsure about the safety of some procedures,
o
contact your SANY representative.
in ti
et a
n
rk er
Ma t
In

2-4 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Shop Safety

WARNING
● Improper repair procedures on this ma-
chine can be hazardous and could re-
sult in serious injury or even death.

● All personnel involved with the repair

of this machine must read this manual
thoroughly before performing any pro-
cedures on this equipment.

● Some actions involved in the operation

or repair of this machine could cause
a serious accident if they are not per-

.
De al
formed in the manner described in this

pt
manual.

g n
● All precautions outlined in this manual
apply only to intended repair proce-
o
dures of the machine or system. If you
in ti
perform any repairs not specifically pro-
hibited, you must be sure that it is safe
for you and others. In no event should
et a

you or others engage in prohibited uses

or actions as described in this manual.
n
rk er

● SANY delivers machines that comply

with all applicable regulations and
standards of the country to which the
Ma t

machines have been shipped. If this

machine has been purchased in another
In

country or purchased from someone

in another country, it may lack certain
safety features and specifications that
are necessary for use in your country.
If there is any question about whether
your product complies with the appli-
cable standards and regulations of your
country, contact your SANY representa-
tive before performing repairs on this
machine.

Shop Manual - November 2012 2-5

Shop Safety SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

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-

De al
ect and then forgotten; most accidents are

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

WARNING
Mistakes in operation are extremely haz-
rk er

ardous. Read the Safety, Operation &

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

machine. Failure to follow this alert could

In

result in serious injury or death.

2-6 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Shop Safety

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.

.
De al
pt
● The shop is a place to work, not play. It is
NOT a place for “horseplay”. A “joker” in a
g n
repair shop is a “walking hazard” to every-
one. Daydreaming or socializing on the job
o
also increases your chances of injury.
in ti
● If you must smoke, smoke only in the area
provided for smoking. Never smoke while
on the shop floor or work area.
et a
n

2.2.2 Housekeeping
rk er

● Oils, grease, fuel, antifreeze or any fluid

spills should be mopped up immediately.
These items pose a serious slip hazard.
Ma t

Regardless of who was responsible for the

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

in their proper storage areas after each
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.

Shop Manual - November 2012 2-7

Shop Safety SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

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-

De al
uids.

pt
● Never store liquids in containers that are
g n
not properly labeled for that liquid. Confu-
o
sion could result in equipment damage, fire
or an unexpected explosion.
in ti

● Never smoke or bring open flames around

liquids, doing so could result in an unex-
et a

pected fire or explosion.

n

● Never handle liquids without using person-

rk er

al protective equipment. Treat all liquids

with caution.
Ma t
In

2.2.4 Cleaning Parts

Never use gasoline, diesel fuel or similar flam-

mable liquids to clean parts. Always use ap-
proved non-flammable solvents to clean parts.
Failure to do so could result in explosion or
fire.

2-8 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Shop Safety

2.2.5 Jacking Up the Machine

● If you will be working under the machine

always use approved jack stands that will
support the weight of the machine you are
working on.

● Never rely on the hydraulics of the ma-

chine or a hydraulic jack to support the
machine during repairs.

● Always lower the work equipment to the

ground and check the stability of the ma-

.
chine before going under the machine.

De al
pt
g n
2.2.6 Electrical Dangers
o
in ti
● When testing electrical circuits, always be
aware of what you will be checking in these
systems. High voltage or high amp circuits
et a

could damage your equipment or cause a

spark, explosion or possible fire.
n
rk er

● Before performing any repairs or testing on

an electrical system be sure of the system
voltage dangers. Always check the circuit
Ma t

to be sure it is off before performing any

repairs.
In

● When working around flammable liquids or

explosive systems, use only approved anti-
explosion proof work lamps. Non-approved
work lamps can cause an explosion or fire.

Shop Manual - November 2012 2-9

Shop Safety SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2.2.7 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.

.
De al
pt
2.2.8 Cleaning the Machine

g n
● Always use high-pressure hot water and
mild, nonflammable grease-cutting soaps
o
or cleaning agents to clean the machine
in ti
parts. Never use flammable or caustic
cleaning agents.
et a

● Never use high-pressure steam cleaners

to clean the machine. Steam cleaners will
n

damage the paint, hoses or electrical sys-

rk er

tem.

● Never pressure-wash or flood the inside of

Ma t

an operator cab. This will damage sensi-

tive electrical components.
In

2.2.9 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.

2-10 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Shop Safety

● Before starting the work, thoroughly check

the tools, machine, forklift, crane, service
car, etc.

● Keep your tools clean, and when the job is

complete, take inventory of the tools you
were using to be sure no tools were left in
the machine.

● Always put shop tools back in there proper

storage location when finished.

● If welding repairs are needed, always have

.
a trained, experienced or certified welder

De al
carry out the work.

pt
g no
2.2.10 Hoisting a Load
in ti

If you will be lifting parts or components that

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

to follow some basic rules.

n

● Always use the appropriate lifting equip-

rk er

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

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.

Shop Manual - November 2012 2-11

Shop Safety SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2.2.11 Appropriate Working Apparel

Improper or loose clothing, casual dress cloth-

ing, jewelry, incorrect shoes or long hair can
result in possible injury.

Make a list of the types of clothing that are not

allowed in the shop area. Go over the list with
personnel before they start a job.

.
De al
pt
g no
2.2.12 Safety Partners
in ti
No one should be allowed to perform work
operations in any shop alone. It should be a
et a

general shop safety rule for a minimum of two

people in the shop area at all times when work
n

procedures are performed. A person alone in

rk er

the shop might not be able to get emergency

help in the event of a shop accident.
Ma t

When working together always maintain clear

contact with each other at all times to avoid
In

the occurrence of unexpected incidents.

When carrying out any operation with two or

more workers, always agree on the operating
procedures and signals before starting.

2-12 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Shop Safety

2.2.13 Two people when engine run-

ning

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.

.
De al
● Set the safety lock control lever to the lock

pt
position.
g n
● Do not touch any control lever. If some
o
control lever must be operated, send signal
to other people and warn them to transfer
in ti
to safe place quickly.

● Do not drop or insert the tools and other

et a

objects into the fan or fan belt, or the parts

n

will be broken or thrown out.

rk er

2.2.14 Driving Pins

When using a hammer to drive pins, metal

Ma t

particles may fly off. This may lead to serious

In

eye injuries. Always do the following:

● Always wear a face shield or goggles when

striking a metal object with a metal ham-
mer.

● Before performing any of these proce-

dures, be sure all personnel are clear of
your work area.

● If possible, avoid using a steel hammer to

drive a component or pins in place. Dam-
age to the component may result. Always
use a soft or non-ferrous hammer to drive
a component or a pin.

Shop Manual - November 2012 2-13

Shop Safety SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2.2.15 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.

.
2.2.16 Fire Extinguisher and Emer-

De al
gency Exits

pt
● It is important to know where all emergen-
g n
cy exits and fire extinguishing equipment
o
are located if a fire should occur in the
shop.
in ti

● Before preparing for work, take time and

walk around the shop to make a mental
et a

note of where all exits and fire equipment

n

are located. If you are performing repairs

in the field, always have a fire extinguisher
rk er

handy and within reach.

● If you do not know how to use a fire extin-

Ma t

guisher contact someone who can instruct

In

you in the proper use of this equipment.

2.2.17 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.

2-14 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Shop Safety

2.2.18 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

.
contact between the person performing the

De al
repairs on the machine at all times.

pt
● 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
et a

person doing the repair and signal them

n

when you are about to move the control le-

ver.
rk er

● Be aware of hot surfaces. During running

operations, most surfaces will be hot, and
Ma t

some surfaces will be extremely hot. If

In

necessary, use personnel protective equip-

ment when working around high tempera-
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.

Shop Manual - November 2012 2-15

Shop Safety SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2.2.19 Accumulator

If the machine is equipped with an accumula-

tor charged with high-pressure nitrogen gas, it
is important to follow these basic precautions.

● Do not disassemble the accumulator.

● Never expose the accumulator to high heat

or open flames.

● Never weld on the accumulator.

.
● Never drill or cut on the accumulator.

De al
pt
● Never strike the accumulator.
g n
● Use only nitrogen gas to charge the ac-
o
cumulator. Unapproved gases could be
explosive.
in ti

2.2.20 Adding Fluids to a System

et a

If it should be necessary to add fluids to a

n

system during running operations, always be

rk er

aware that these systems may be hot and un-

der high pressure.
Ma t

Before adding fluids, shut the machine down

and allow the systems to cool down to outdoor
In

ambient temperatures before removing any

caps. Failure to do so may result in serious
burns or a sudden loss of fluid.

2-16 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Shop Safety

2.2.21 Track Recoil Springs

If you are making repairs to a machine

equipped with tracks, always be aware of the
dangers involved with track recoil springs. This
spring is under extreme pressure at all times.
If it is disassembled by mistake, the spring
may fly out and cause serious injury.

Be careful when removing or installing tracks

on track-type machines. When removing the
master track link the track system may sepa-
rate suddenly and cause possible injury.

.
De al
Always stand clear of the track travel path

pt
when separating the master link section of the
track.
g no
2.2.22 High-Pressure Fluid Lines
in ti
Always keep in mind that these systems are
under high pressure. When inspecting or re-
placing piping or hoses, always check to be
et a

sure the pressure in the system has been

n

relieved before proceeding. Working on a sys-

tem still under pressure could lead to serious
rk er

injury, always do as follows:

● If you will be removing a line or component

Ma t

with fluid in the system, always cap and

In

seal the opening to avoid leakage or sys-

tem contamination.

● Never carry out inspections or replace

items while the system is under pressure.

● Never use any part of your body to check

or feel for leaks. Always wear safety
glasses and leather gloves when checking
for leaks and use a piece of wood or card-
board when checking for leaks from small
holes.

● If high pressure fluids should penetrate

your skin or get into your eyes, seek medi-
cal attention immediately.

Shop Manual - November 2012 2-17

Shop Safety SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2.2.23 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.

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

De al
equipped) with chocks to prevent the machine

pt
from moving.
g n
If equipped, set the hydraulic lock lever in the
o
LOCKED position. If equipped, set the parking
brake in the PARK position.
in ti

Be sure all personnel and equipment is clear

of your work area and you can be seen by all
et a

working personnel especially if performing re-

n

pairs in the field.

rk er
Ma t
In

2-18 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Shop Safety

2.2.24 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.

De al
pt
● Never get on or off moving equipment.
These actions may lead to serious injury.
g n
Always bring the equipment to a full stop
o
and turn the engine OFF.
in ti
● When getting on or off the equipment,
always face the equipment and maintain
a three-point contact (both feet and one
et a

hand or one foot and both hands) with the

n

handrails, steps and platforms to ensure

that you support yourself correctly.
rk er

● Never climb on areas of the machine that

are not designated walk areas.
Ma t
In

● Never climb on or off the machine with

tools, parts or similar objects in your
hands.

● Never use machine controls or non-spec-

ified points on the equipment to get on or
off the machine.

● Use all hand-holds when on the machine.

Shop Manual - November 2012 2-19

Shop Safety SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2.2.25 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.

De al
When opening a battery compartment, al-

pt
ways allow ample time for the gasses to
escape before servicing the battery.
g n
● When working with batteries, always work
o
in a wellventilated area.
in ti
● If the battery is corroded, flush the area
with a baking soda and warm water mix.
et a
n
rk er
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.

2-20 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Shop Safety

2.2.26 Jump-Start Safety

When using jumper cables to start the ma-

chine, connect the positive (+) jumper first,
then the negative (-) jumper to a remote loca-
tion on the chassis away from the battery.

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 unex-

.
pected explosion or fire resulting in minor

De al
or major injury.

pt
Power
g n
2.2.27 Disconnecting the System
o
in ti
Before starting any repair operations, remove
the battery leads from the battery or set the
main disconnect on the machine in the OFF
et a

position.
n

For the location of the machine main electri-

rk er

cal disconnect switch, refer to the machines

Safety, Operation & Maintenance Manual for
location and procedures.
Ma t

If the battery must be disconnected, remove

In

the negative (-) terminal clamp first then re-

move the positive (+) clamp last.

When reconnecting the battery, be sure every

electrical system switch is in the OFF position,
connect the positive clamp (+) first, then the
negative clamp(-) last.

Shop Manual - November 2012 2-21

Shop Safety SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2.2.28 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
g no
2.2.29 Sequence of Procedures
in ti
Only authorized employees performing repairs
on the machine shall perform Lockout/Tagout DA
in accordance with this procedure listed below. NG
ER
et a

DO
n

If the employee performing repairs to the ma-

OP NO
chine is issued ER T
rk er

AT
E
a lock and key, the employee shall not share
the lock or key with other employees until all
Ma t

repair procedures are complete and the ma-

In

chine is ready to put back into service.

The following steps shall be performed in the

sequence listed when the equipment is to be
either locked-out or tagged-out for repair.

2-22 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Shop Safety

Locking out of service

1. Notify all employees who may be poten-

tially affected by the repair process on the
machine.

2. Secure the machine in a safe position. If

DANGER
equipped, set the parking brake or hydrau-
lic lock lever in the PARK or LOCKED posi- DO NOT OPERATE
tion. When this is not being used,
keep it in the storage compartment.
3. Identify, remove or disconnect all power
or energy sources and be sure to install a

.
Lockout/Tagout device on them. If the ma-

De al
chine is equipped with a Maintenance Alert

pt
Tag, attach this tag to the machine con-
trols.
g no
4. Be sure all employees involved in the re-
pairs have installed there lock on the pow-
in ti
er source before performing any repairs.
Once an employee has completed there
repair procedure, they must remove there
et a

lock and not access the machine in any

n

manor.
rk er

Returning to service

1. The authorized person who performed the

Ma t

Lock out/Tagout procedure shall check the

area around the machine to ensure that no
In

one is exposed to any hazard before start-

up.

2. The authorized person who performed

the Lock out/Tagout shall ensure that
all guards have been reinstalled to their
proper place, all tools and equipment have
been removed and all locks are removed.

3. The authorized person who performed the

Lock out/Tagout shall verify that all controls
are in the neutral or “off” position and all
personnel are aware of the time the ma-
chine will be back in service.

Shop Manual - November 2012 2-23

Shop Safety SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. Remove the Lockout/Tagout equipment

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

2.2.30 CHEMICAL HAZARDS

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-

.
De al
ers involved in handling hazardous materi-

pt
als should use approved personal protective
equipment and follow all environmental safety
regulations. g no
2.2.31 Material Safety Data Sheets
in ti
(MSDS)

Material Safety Data Sheet (MSDS) informa-

et a

tion relating to the materials the workers could

n

be exposed to.
rk er

● MSDS data sheets provide both workers

and emergency personnel with the proper
procedures for handling or working with a
Ma t

particular substance. Information includes

In

physical data, health effects, first aid, re-

activity, storage, disposal and protective
equipment required.

● Be sure all personnel involved are familiar

with all MSDS-related information as it re-
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.

2-24 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Shop Safety

tE.
PAD nal
eGp
ng o
i
tKi t
a
AkNe rn
ar e
BLM Int

Shop Manual - November 2012 2-25

Shop Safety SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

tE.
l
Pg Aona
DG
ep
in ti
etK a
n
ArkNer
Ma t
BL In

2-26 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Specifications

Specifications

.
3 Specifications

De al
pt
3.1 Dimensions .............................................................................................................. 3-3
3.2 Working Ranges ...................................................................................................... 3-4
3.3
g n
Technical Specifications........................................................................................... 3-6
o
3.4 Weight Table ............................................................................................................ 3-8
in ti
3.5 Recommended Oil, Fuel and Coolant...................................................................... 3-9
3.6 Engine Performance Curve ....................................................................................3-11
et a
n
rk er
Ma t
In

Shop Manual - November 2012 3-1

Specifications SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.

3-2 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Specifications

3 SPECIFICATIONS

3.1 Dimensions

SY65C

2040
1745 923

F1 启动回路 Starting circuit

F2 充电指示灯 Charging lamp
F3 喇叭回路 Horn
F4 工作灯 Working light
F5 雨刮器、清洗器 Washer and wiper
F6 音响 Radio
F7 驾驶室灯 Cab light
F8 空调 Air conditioner
F9 检修灯 Service light
F10 触摸屏 Monitor
F11 EC－7控制器 EC-7 controller

2565
2581

.
De al 1685

pt
743
警告 WARNING

卸压时只允许拧松一圈

g n It is permitted to adjust only

one circle when remove press
403
408 301

1103 882
o
671 2180 2000
in ti
6094 2117
ZX65-1001001
et a

SY75C
n
rk er

2040
1745 982
Ma t
In

F1 启动回路Starting circuit
F2 充电指示灯Charging lamp
F3 喇叭回路Horn
F4 工作灯 Working light
F5 雨刮器、清洗器 Washer and wiper
F6 音响 Radio
F7 驾驶室灯Cab light
F8 空调 Air conditioner
F9 检修灯 Service light
F10 触摸屏 Monitor
F11 EC－7控制器 controller
EC-7
2611
2627
1731
789
332 390

1155
982
2350
2217
6094
ZX75-1201001

Shop Manual - November 2012 3-3

Specifications SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3.2 Working Ranges

SY65C

2528

1745 1704

Swing axis

.
De al
pt
24
6

7012
g no
4
19

5502
5111
in ti
et a

2386
n

LWA
1359

102dB
履带式液压挖掘机（HYDRAULIC EXCAVATOR）
产品型号(MODEL NUMBER)：
整机重量(WEIGHT)：
出厂编号(ID NUMBER)：
三一重机有限公司
（SANY HEAVY MACHINERY INDUSTRY CO.,LTD.）
rk er
301

警告 WARNING

卸压时只允许拧松一圈
It is permitted to adjust only
one circle when remove press
408
Ma t
In

3337
4068

123 2488
4061
6094
6238

ZX65-1001002

3-4 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Specifications

SY75C

2528

1745 1704

Swing axis

.
24

De al
6

pt
7058
g n
4
19

5548
5157
o
in ti

2433
et a

L WA

102dB
1405

履带式液压挖掘机（HYDRAULIC EXCAVATOR）
产品型号(MODEL NUMBER)：
整机重量(WEIGHT)：
出厂编号(ID NUMBER)：
三一重机有限公司
（SANY HEAVY MACHINERY INDUSTRY CO.,LTD.）
n

警告 WARNING
rk er
332 390

卸压时只允许拧松一圈
It is permitted to adjust only
one circle when remove press

873
Ma t
R1
23
In

3291
4021

123 2488
4061
6094
6238

ZX75-1001002

Shop Manual - November 2012 3-5

Specifications SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3.3 Technical Specifications

Machine model SY65C3 SY75C3 SY75C9

Bucket capacity m³ 0.25 0.28
Operating weight kg 6700 7280
Max. digging depth 4065 4020
Max. vertical digging depth 3335 3290
Max. cutting radius 6235 6235
Working ranges

Max. ground cutting radius 6095 6095

Max. cutting height 7010 7060
mm

.
Max. dumping height 5110 5155

De al
Max. dozer raising height 300 390
Performance

pt
Max. dozer lowering depth 405 332

g n
Min. swing radius
Max. height @ min. swing radius
o 1800
5500
1800
5500
Max. bucket digging force 51 56
in ti
KN
Max. arm digging force 36 38
Swing speed rpm 11.5 11.5
et a

Travel speed (Lo/Hi) km/h 5.2/2.7 4.4/2.4

Gradeability ° 35 35
n

Ground pressure kPa 33 33

rk er

Overall length 6120 6120 6095

Overall width 2140 2220
Ma t

Overall height (to cab roof) 2645 2665 2610

Upper width 2040 2040
In

Upperstructure-ground distance 745 790

Cab height 1655 1655
Dimension

Min. ground clearance 370 380

mm
Tail swing radius 1800 1800
Length of track on ground 2185 2195
Track gauge 1600 1750
Track length 2700 2820
Undercarriage width 2000 2200
Standard track shoe width 400 450
Doze blade height 405 405

3-6 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Specifications

Machine model SY65C3 SY75C3, SY75C9

4JG1-NABGB-04
Model
4-cycle, water-cooled, in-line, vertical, direct
Type
injection
Cyliner No. - bore x stroke mm
4 – 95.4×107
Piston displacement L {cc}
3.059 {3,059}
kW/rpm {HP/rpm}
Flywheel power 40.9/2,100 {54.2/2,100}
Performance

Nm/rpm {kgm/
Engine

Max. torque 188/1,800 {19/1,800}

rpm}
Max. speed at zero load 2,250
rpm
Min. speed at zero load 1,050
rpm
Min. fuel consumption 224 {165}
g/kWh {g/HPh}

.
De al
Start motor 24V, 3.2 kW

pt
Alternator _ 24V, 30A
Battery 12V, 80Ah×2
g n
Radiator core model
o _ CF19 – 3
undercarriage

*Carrier roller (each side)

1 1
in ti
Track roller (each side)
_ 5 5
Track shoe (triple grouser) (each
42 39
side)
et a

Type x No. Variable displacement plunger type x 1

n

Oil displacement l/min 143

Pump
rk er

MPa
Set pressure 24.5 {250}
{kg/cm²}
Type x No. 8-spool type×1
Hydraulic system

Valve _
Ma t

Control method Hydraulic auxiliary

Fixed displacement plunger type (with brake
In

Travel motor valve and parking brake): ×2

Motor _
Swing motor Fixed displacement plunger type (with brake
valve and parking brake: ×1
Hydraulic cylinder Reciprocating piston
Hydraulic tank Open type
_
Hydraulic oil filter Tank return side
Hydraulic oil cooler Air-cooling type

Shop Manual - November 2012 3-7

Specifications SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3.4 Weight Table

Unit: kg

Machine Model SY65C3 SY75C3 SY75C9

Engine assembly (water and oil excluded) 267 267
PTO assembly 6 6
Radiator and oil cooler assembly 42 42
Slewing platform 653 653
Operator cab 270 276
Operator sea 55 55

.
Fuel tank (w/o fuel) 70 70

De al
Hydraulic tank (w/o hydraulic oil) 70 70

pt
Counterweight 540 767
Hydraulic pump assembly
Control valve
g no 40
45
40
45
Swing bearing assembly 99 99
in ti
Swing reductor assembly 22 22
Center swivel joint 16 16
et a

Track frame assembly 1342.2 1776.4

n

• Track frame 900 907.2

• Idler 49.5x2 62x2
rk er

• Tensioning device 32x2 48x2

• Carrier roller 8.9x2 13x2
Ma t

• Track roller 8.9x10 13.2x10

In

• Travel motor 80x2 90x2

• Sprocket 17.2x2 22.5x2
Track shoe assembly 315x2 414.2x2
Boom assembly 454 454
Arm assembly 166 166
Bucket assembly 212 226
Dozer blade assembly 244 244
Boom cylinder assembly 84 84
Arm cylinder assembly 64 64
Bucket cylinder assembly 48 48
Dozer blade cylinder assembly 55 55

3-8 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Specifications

3.5 Recommended Oil, Fuel and Coolant

Ambient temperature (°C) Capacity

Reservoir Fluid
-30 -20 -10 0 10 20 30 40 50 Specified Refill

SAE 300

SAE 10W
Engine oil Max 9.21L
8
pan Min 7.2L
SAE 10W-30

SAE 15W-40

.
De al
PTO casing 0.35 0.35

pt
Swing ma-
1.5 1.5
chine case Engine
Final drive
case
g noil
o 1.7 1.7

Idler SAE 300 0.06 -

in ti
Track roller 0.08 -
Carrier roller 0.03 -

SAE 10W
et a

Hydraulic sys-
n

SAE 10W-30 120 57

tem
rk er

SAE 15W-40
Ma t

GB252 super -35 diesel fuel

Diesel
Fuel tank 150 -
In

fuel
GB252 super -35 diesel fuel

Cooling sys-
Coolant Add AF-NAC coolant 12 -
tem

Shop Manual - November 2012 3-9

Specifications SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Fuel and oil

Select suitable fuel and oil according to ambient temperature as specified in the above table.

● Specified amount refers to the amount of fuel or oil in the component and piping; refill amount
refers to the amount of fuel or oil added into the component during routine inspection and
maintenance.

● To start the engine when ambient temperature drops below 0 °C, use of SAE 10W or SAE
10W-30 engine oil is recommended, even though temperature may rise up to 10°C.

Antifreeze

.
● Use of tap water as coolant is forbidden.

De al
pt
g no
in ti
et a
n
rk er
Ma t
In

3-10 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Specifications

3.6 Engine Performance Curve

Max torque (net) 210

191±9N·m/approx. 1800 min-1
200

Torque (Nm)
190

180

170

160
Max power (net)
45 +1.2
38.7 -0.4 kW/2100 min-1

.
De al
40

pt
35

30
g no
in ti
25
Power (kW)

et a

20
n

15
rk er

10 Max idling speed

Ma t

2310 ± 25 min-1

5
In

Fuel consumption at max power 250

236 g/kWh
Fuel consumption

240
(g/kWh)

230

220
800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Engine speed (min-1)

ZX55-1001003

Shop Manual - November 2012 3-11

Specifications SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

t.
ADGe al
pE
n
nPg o
i
ti ta
n
ArNk er
eK
Ma t
BL In

3-12 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

Structure and Function

.
4 Structure and Function

De al
pt
4.1 Engine and Cooling System .................................................................................... 4-3
4.1.1 Radiator and oil cooler ................................................................................... 4-3
g n
4.1.2 PTO (shaft coupling) ...................................................................................... 4-5
o
4.1.3 Engine control system.................................................................................... 4-6
in ti
4.2 Power Train.............................................................................................................. 4-7
4.2.1 Power transmission system .......................................................................... 4-7
4.2.2 Swing bearing ................................................................................................ 4-8
et a

4.2.3 Swing mechanism .......................................................................................... 4-9

n

4.3 Undercarriage and Frame...................................................................................... 4-10

rk er

4.3.1 Track frame .................................................................................................. 4-10

4.3.2 Idler and recoil spring................................................................................... 4-12
4.4 Hydraulic System ................................................................................................... 4-14
Ma t

4.4.1 Hydraulic equipment layout drawing ............................................................ 4-14

In

4.4.2 Hydraulic circuit diagram.............................................................................. 4-15

4.4.3 Hydraulic tank and filter ............................................................................... 4-17
4.4.4 Hydraulic pump ................................................................................................... 4-18
4.4.5 Control valve ................................................................................................ 4-35
4.4.6 Oil source control valve................................................................................ 4-40
4.4.7 Load sensitive system.................................................................................. 4-42
4.4.8 Swing motor ................................................................................................. 4-67
4.4.9 Center swivel joint ........................................................................................ 4-72
4.4.10 Travel motor ............................................................................................... 4-74
4.4.10.1 Travel motor operating process ........................................................ 4-76
4.4.10.2 Parking brake operating process ...................................................... 4-78
4.4.10.3 Counterbalance valve operating process.......................................... 4-79
4.4.11 Control System........................................................................................... 4-81

Shop Manual - November 2012 4-1

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.4.11.1 Work equipment and swing pilot valve .............................................. 4-82

4.4.11.2 Travel pilot valve ............................................................................... 4-87
4.4.11.3 Option pilot valve............................................................................... 4-91
4.4.12 Hydraulic cylinder....................................................................................... 4-94
4.4.13 Work equipment ......................................................................................... 4-95
4.5 Electrical Control System....................................................................................... 4-96
4.5.1 General ........................................................................................................ 4-96
4.5.2 Electronic control system diagram ............................................................... 4-97
4.5.3 Diagram of electrical circuit .......................................................................... 4-98
4.5.4 Engine control function ................................................................................ 4-99
4.5.5 Valve control function ................................................................................. 4-100

.
4.5.6 Auto deceleration function.......................................................................... 4-101

De al
pt
4.5.7 Engine preheating and overheating protection function ............................ 4-102
4.5.8 Travel control selection .............................................................................. 4-104
g n
4.6 Integrated Control Monitoring System ................................................................. 4-105
o
4.6.1 Monitor ....................................................................................................... 4-105
4.6.2 Monitor items and display .......................................................................... 4-108
in ti
4.6.3 Main screen function ...................................................................................4-110
4.6.4 Special functions ........................................................................................ 4-123
et a
n
rk er
Ma t
In

WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.

4-2 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4 STRUCTURE AND FUNCTION

4.1 Engine and Cooling System

4.1.1 Radiator and oil cooler

SY65C3, SY75C3
2 1 6 7 8

9
Fan axis

.
10

De al
Z

pt
4 Crankshaft axis 5

g no
in ti
Z
et a
n
rk er

3
Ma t
In

ZX75-1002001

1) Fan guard Specifications

2) Radiator inlet hose
3) Drain valve Radiator

4) Radiator outlet hose Core type: CF19-3

5) Oil cooler inlet Radiating area: 28.22 m²
6) Oil cooler outlet Blade pitch: 4.4/2
7) Oil cooler Water capacity: 6.5 L
8) Radiator Oil cooler
9) Guard Core type: AL-CF40
10) Reserve tank Radiating area: 22.41 m²
Blade pitch: 4.4/2
Oil capacity: 5.16 L

Shop Manual - November 2012 4-3

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

SY75C9

2 1 6 7 8

9
Fan axis
10
Z
4 Crankshaft axis

.
De al
Z

pt
g no
in ti

3
et a
n

ZX75-1204006
rk er

1) Fan guard Specifications

2) Radiator inlet hose
3) Drain valve Radiator
Ma t

4) Radiator outlet hose Core type: CF19-3

In

5) Oil cooler inlet Radiating area: 28.22 m²

6) Oil cooler outlet Blade pitch: 4.4/2
7) Oil cooler Water capacity: 6.5 L
8) Radiator
9) Guard Oil cooler
10) Reserve tank Core type: AL-CF40
Radiating area: 22.41 m²
Blade pitch: 4.4/2
Oil capacity: 5.16 L

4-4 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.1.2 PTO (shaft coupling)

Pin roll installation

.
De al
pt
g no
4
in ti
3 5
et a
n

2
rk er

6
Ma t

1
In

ZX75-1002002

1) Air vent 4) Flywheel

2) Engine crank 5) Main pump
3) Shaft coupling 6) Coupling disc

Shop Manual - November 2012 4-5

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.1.3 Engine control system

2
A
1

.
De al
pt
g no
Direction A
in ti
7
6 4
et a
n
rk er
Ma t

3
In

ZX75-1002003

1) Fuel control dial simply by turning the engine start switch.

2) Start switch
3) Starter motor ● When the start key is turned to the OFF
position, the throttle control device is actu-
4) Stop lever
ated and it pulls the injection pump stop
5) Battery arm to the STOP position. The engine
6) Injection pump shuts down. When the start key is turned
7) Governor lever to the ON position, the throttle control de-
vice is actuated again and it pushes the in-
8) Throttle control unit
jection pump stop arm to the RUN position.
Turn the start key to the START position in
General
order to start the engine. When abnormal
condition occurs in the electrical system,
● The engine can be started and shut down
the engine will not start.

4-6 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.2 Power Train

4.2.1 Power transmission system

1 2 3 4 5

.
De al
pt
7

g no
in ti
8
et a
n
rk er
Ma t
In

9 ZX75-1002004

1) Idler wheel 6) Main pump

2) Central swivel joint 7) Engine
3) Main control valve 8) Swing reducer
4) Oil source control valve 9) Swing bearing
5) Final drive assembly

Shop Manual - November 2012 4-7

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.2.2 Swing bearing

S
A

.
De al
4

pt
g no B
in ti

B
et a

A-A
n

1
rk er

2
Ma t

3
In

5
B-B

ZX75-1002005

1) Outer race Specifications

2) Steel ball
3) Inner race Reduction ratio: 76/12=6.33

4) Plug Amount of filled grease: 5L (G2-LI)

5) Grease fitting

S. Soft zone of outer race

4-8 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.2.3 Swing mechanism

13 15 14 11 12 5 6 4

22
3
16
23
1

z z

.
De al
pt
g no 24

21
in ti
2
20 21 18 17 9 10 7 8
et a
n

z-z
ZX75-1002006
rk er

1) Gear shaft 13) Shell

2) Tapered roller bearing 14) Ball bearing
Ma t

3) Oil seal 15) Shaft

In

4) Tapered roller bearing 16) Cylinder block

5) Needle bearing 17) Nine-hole disc
6) Planetary gear 18) Plunger
7) Thrust plate 19) Disc
8) Sun gear 20) Friction plate
9) Needle bearing 21) Braking piston
10) Planetary gear 22) Shuttle valve
11) Thrust plate 23) Relief valve
12) Drive shaft 24) Ball bearing

Shop Manual - November 2012 4-9

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.3 Undercarriage and Frame

4.3.1 Track frame

SY65C3

.
De al
pt
g no
in ti
et a
n
rk er

1 2 3 4 5
Ma t
In

8 7 6

ZX65-1002001

1) Idler wheel 5) Sprocket

2) Track frame 6) Track roller
3) Carrier roller 7) Track
4) Travel motor 8) Recoil spring

4-10 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

SY75C3, SY75C9

A G

.
De al
pt
g no
in ti

1 2 3 4 5
et a
n
rk er
Ma t
In

8 7 6
ZX75-1002007

1) Idler wheel 5) Sprocket

2) Track frame 6) Track roller
3) Carrier roller 7) Track
4) Travel motor 8) Recoil spring

Shop Manual - November 2012 4-11

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.3.2 Idler and recoil spring

SY65C3

.
De al
pt
g no
K
in ti
et a
n

1
rk er

2 3 4 5 6 7 8 9 10 11 12
Ma t
In

ZX65-1002002
1) Yoke 9) Rear support
2) Dust ring 10) Locknut
3) Seal ring 11) Check valve
4) Support ring 12) Grease fitting
5) Spring
6) Piston rod Specifications

7) Support ring
Grease 40 mL
8) Cylinder block

4-12 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

SY75C3, SY75C9

.
De al
pt
g no
in ti

8 9/10 11 12 13
et a
n
rk er
Ma t

1 2 3 4 5 6 7
In

ZX75-1002009

1) Piston rod group 8) Dust ring Specifications

2) Cylinder block group 9) Combined seal ring
3) Spring 10) Support ring Grease 90 mL

4) Pull rod 11) Support ring

5) Spring seat 12) Seal ring
6) Nut 13) Setscrew
7) Oil feed valve group

Shop Manual - November 2012 4-13

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.4 Hydraulic System

4.4.1 Hydraulic equipment layout drawing

11

2 3 4 5 6 7

.
De al
pt
1

g no
in ti
et a
n
rk er

13 12 12 10 9
Ma t

ZX75-1002010
In

(I) Left joystick 1) Main line (dozer blade)

(II) Right joystick 2) Main line (bucket)
(III) Joystick (dozer blade) 3) Main line (arm)
(IV) Swing reducer AS 4) Main line (boom)
(V) Main control valve 5) Main line (swing)
(VI) Pilot filter 6) Make-up line (swing)
(VII) Hydraulic tank 7) Main line (oil return)
(VIII) Oil source control valve 8) Main line (oil inlet)
(IX) Travel pilot valve 9) Oil drain line (main pump)
(X) Central swivel joint 10) Oil suction line
(XI) Bracket (main control valve) 11) Pilot oil inlet line
(XII) Main pump 12) Pilot line
13) Travel pilot line

4-14 Shop Manual - November 2012

Structure and Function

4-15
ZX65-1002003
L. Travel motor R. Travel motor
Breaking

R/G R/G
Swing motor
Hi/Lo speed switch valve
2

. SH
Dozer Lower 1

Hammer pilot valve (optional) PG

Dr
Dozer blade cylinder Arm cylinder Bucket cylinder Boom cylinder
pt
2

GA GB
1 Dozer Lift

A MU B
Dozer blade pilot valve
R.Travel

De al
Forward Reverse
4

PA PB PA PB
3
T

Swivel joint
Reverse
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Shop Manual - November 2012

Forward
1
L.Travel

Travle pilot valve

Shuttle valve
g n
R. Swing
4
Swing

o
L. Swing
T

Main valve
in ti
Main safety valve
3

Arm Out

b9 B9 A9
P

P2 b7 B7 A7 b6 B6 A6 b5 B5 A5 b4 B4 A4 b3 B3 A3 b2 B2 A2 b8 B8 A8 b1 B1 A1 P Sensor
LS
Arm In

L. Joystick
Arm

L. Travel R. Travel Dozer

1

Swing Hammer Standby Arm Bucket Boom

blade
Boom Lower Bucket Curl Bucket Dump
4

LS safety valve
Bucket

LS flush valve
Flush valve
T

T
2

et a
M
3

Swing speed regulator

P

a9 a7 a6 a5 a4 a3 a2 a8 a1 T3
Back pressure
Boom Raise

Boom deflect overload valve (optional) Arm overload valve Bucket overload valve Boom pressure
Boom

R. Joystick Dozer overload valve Boom overload valve measure port

1

compensating valve
Boom main spool
n
4.4.2 Hydraulic circuit diagram

Regulate power with relief valve

Pilot filter
X1
Pressure regulating valve
ΔPregulating
rk er Bv Pr Pv P1 Oil source control valve

Check valve

Check valve
Oil cooler

12 V DC
B Flow control valve
M
Ma t
Travel hi/lo speed
solenoid valve

12 V DC
Pressure reducing valve

PS
Safety valve
Pilot solenoid valve
In
T P2 P3
SY65C3
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

ZX75-1002011
R. Travel motor L. Travel motor
REG
Swing motor
Boom cylinder
.
Bucket cylinder Arm cylinder Dozer blade cylinder
pt
De al Center swivel joint

Blade
Lift
Lower
Blade
Blade pilot valve

R. travel
Reverse Forward

Shop Manual - November 2012

g n

T
o

Forward
in ti

P
1A 2A 3A 8A 8B
Main valve 1B 2B 3B 4A 4B 5A 5B 6A 6B 7A 7B

Reverse
Travel pilot valve

L. travel
LS Relief valve

Swing Swing
Swing

Right Left
et a
LS Pressure

T
detection point

Arm
In

P
Flush vavle

Arm
Out
Boom Bucket Arm Standby Arm L.pilot valve lever
Dozer blade R.travel L. travel Swing
n

Boom Boom Bucket Bucket

Lower Raise Dump Curl
Bucket
rk er

T
P
Boom R.pilot valve lever
Ma t Check valve
Structure and Function

Check valve
In
Breather valve, Normal pressure open
Radiator Oil source
Travel speed control valve control valve
Torque limit valve
PumpK3VL80
SY75C3, SY75C9
ΔP regulating
Pressure
cutoff
Pilot filter valve
M
Return oil filter
Pilot solenoid valve

4-16
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.4.3 Hydraulic tank and filter

4 A

1
A A-A

.
De al
pt
A
3

g no
in ti

2
et a
n

B
rk er

A B
Ma t
In

SY X 807 H 75C9I2H 001

5 ZX75-1204001

1) Hydraulic tank Specifications

2) Oil suction filter element
3) Return oil filter element Tank capacity: 90L

4) Breather valve Oil volume: 70L

5) Drain plug
6) Level gauge

Shop Manual - November 2012 4-17

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.4.4 Hydraulic pump

SY65C3

1 2 3 4 5

.
De al
pt
6

g no
in ti
et a
n

7
rk er

ZX65-1002004

1) Pump body 5) Pressure control valve+Flow control valve

Ma t

2) Constant power regulating valve 6) LS oil inlet port

In

3) Main pump oil drain port 7) Pressurized oil outlet

4) Oil inlet port

4-18 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

SY75C3, SY75C9

1 3 6 2

7
Dr
PL A

.
De al
pt
g no
in ti
et a

B
n

Dr
rk er

5 4
ZX75-1002013
Ma t

1) Pump body 5) Power regulating valve

In

2) Pressure control valve+Flow control valve 6) LS oil inlet port

3) Main pump oil drain port 7) Pressurized oil outlet port
4) Oil inlet port

Shop Manual - November 2012 4-19

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

1. Pump body

SY65C3

4 5 6 9 7 8

.
De al
pt
g no
in ti
et a
n
rk er

10

ZX65-1002005
Ma t

1) Drive shaft 6) Plunger

In

2) Rear end cover 7) Cylinder block

3) Casing 8) Thrust plate
4) Variable displacement swash plate 9) Spring
5) Slipper 10) Servo plunger

4-20 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

SY75C3, SY75C9

9 10 5 2 6

3
8
4

.
De al
pt
1
g no
in ti
et a
n
rk er

ZX75-1002014

1) Shaft 6) Plunger
Ma t

2) Deflector rod 7) Cylinder block

3) Casing 8) Thrust plate
In

4) Variable displacement swash plate 9) Spring

5) Slipper 10) Servo plunger

Shop Manual - November 2012 4-21

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Function

● Engine rotation and rotary moment transmitted onto the pump shaft is converted into hydrau-
lic energy. Hydraulic oil is delivered according to the load.

● Delivery amount of hydraulic oil can be changed by adjusting the swash plate angle.

5 6

.
De al
7

pt
3 8

4
g no
in ti

1
et a
n
rk er
Ma t
In

Spline a
Surface A ZX55-1002035

Structure

● Shaft (1) is supported by front and rear slipper (5) forms a layer of non-skid oil
bearings and drives the cylinder block to film with surface A as it slides around the
rotate via the spline. sphere.

● Tip of plunger (6) is shaped like a ball and ● Plunger (6) carries out relative movement
slipper (5) encloses the tip of plunger (6) inside each chamber of cylinder block (7).
forming a whole unit which can perform a
relative motion. Oil inside the respective chambers of cyl-
inder block (7) is sucked in and discharged
● Swash plate (4) has a flat surface A and through valve plate (8).

4-22 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

Pump operating process

1) Cylinder block (7) rotates together with

shaft (1), and slipper (5) slides on surface
A.

4 5 7
Angle α between centerline X of swash E
plate (4) and the axial direction of cylinder
block (7) changes. (α is the angle of swash X
plate.)
a

2) With centerline X of swash plate (4) at a

swash plate angle (α) in relation to the

.
axial direction of cylinder block (7), slipper

De al
(5) carries out a circular movement in rela-

pt
tion to surface A with centerline X of swash F
Surface A
plate (4) as the axis.
g no
In this way, plunger (6) carries out an
ZX75-1002016

alternating movement inside cylinder block

in ti
(7), a volume difference between E and
F is generated, causing the pump to suck
in and discharge oil. In other words, when
et a

cylinder block (7) rotates and volume of

n

chamber E decreases, oil is discharged in

the course of stroke.
rk er

At the same time, volume of chamber

F increases, resulting in oil suction. As
Ma t

shown in the illustration, chamber F is at oil

In

suction stroke end; and chamber E is at oil

discharge stroke end.

3) As centerline X of swash plate (4) becomes

parallel with the axial direction of cylinder
block (7) (swash plate angle=0), difference
between volume E and F inside cylinder
block (7) becomes zero. The pump does
not carry out oil suction and discharge. (In
reality, however, the swash plate angle is
not set to 0).

4) In other words, a proportional relationship

exists between swash plate angle α and
pump delivery.

Shop Manual - November 2012 4-23

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2. Regulation of pressure, flow and power

SY65C3

1 2

.
De al
pt
3

g no
in ti
et a
n
rk er

4
Ma t

5 6 7
In

ZX65-1002006

1) Pressure regulation valve 5) To main pump servo piston

2) To relief valve 6) To oil tank
3) Flow control valve 7) From main control valve LS
4) From main pump outlet port

4-24 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

Function

Flow control valve

● Flow control valve controls pump delivery （L/min

as per control lever stroke; i.e. oil flows ac-
cording to the need of the actuator.

Pump delivery Q
● It detects pressure difference ΔPLS be-
tween main pump outlet port pressure
and the load according to the required oil
amount of the actuator and controls the
main pump delivery (Q). 1.7Mpa 2.5Mpa Mpa

.
kg/cm 2

De al
LS differential pressure △PLS
● In other words, it detects pressure loss

pt
(=LS pressure difference ΔPLS) gener-
ZX75-1002017
ated by oil flow through main control valve
g n
opening area. Pressure loss is maintained
o
at a stable level by controlling pump de-
livery (Q). Flow of pump is determined by
in ti
controlling pump delivery (Q) according to
the demand of control valve.
et a

● Relationship between pump delivery (Q)

n

and LS pressure difference ΔPLS is shown

on the right.
rk er

Pressure control valve

Ma t

SY65C
In

● Pump power is controlled through regula-

tion of relief pressure. The initial relief pres-
sure is the pressure at point a as shown on
the right.

SY75C

● Under normal working conditions, the pres-

sure cutoff valve is at the initial position.
When pressure at pump outlet port ex-
ceeds 32 Mpa, the valve is activated and
the pump outlet port becomes communica-
tive with the pump control piston. Pump
delivery drops to the minimum level and
the main pump is protected.

Shop Manual - November 2012 4-25

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Power regulating valve

● The constant power regulating valve does

not work when pump outlet pressure (P)
is lower than pressure (a) as illustrated on

Pump delivery Q
the right.

● When pump outlet pressure (P) becomes

higher than (a), power regulating valve is
activated. Some oil enters the head end
of main pump servo piston and moves the a

swash plate of the main pump. This causes Pump output pressure PP

reduction of the swash plate angle, and ZX75-1002018

.
hence the diminishing of pump delivery. If

De al
pump output pressure drops, pump output

pt
delivery will increase.

g n
● Relationship between pump output pres-
o
sure (PP) and pump delivery (Q) is shown
on the right.
in ti
et a
n
rk er
Ma t
In

4-26 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

Operating process

SY65C3

X1
Flow control valve

18bar

Pressure control valve

.
De al
17bar

pt
To main valve
Relief valve
g no B
in ti
et a
n

M
rk er
Ma t
In

S L1 L

ZX65-1002007

1. When the engine is shut down, port of the at the right end. Swash plate of the main
head end of servo piston is in communica- pump is at maximum angle while the main
tion with the oil tank and servo piston is pump delivery is at the maximum.

Shop Manual - November 2012 4-27

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Load pressure

Flow control valve

X1

18bar

Pressure control valve

17bar

To main valve
Relief valve
B

.
De al
pt
g no
M
in ti
et a
n

S L1 L
rk er

ZX65-1002008

2. When the machine is started and no opera- ated, and some oil enters the head end of
tion is performed, main control valve spool servo piston and activates the piston. This
Ma t

is at the neutral position and load pres- causes the swash plate angle to diminish,
In

sure is zero. Outlet pressure of the main and main pump delivery drops to the mini-
pump increases from zero. When pressure mum.
rises to 17bar, LS regulating valve is actu-

4-28 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

Load pressure

Flow control valve

X1

Pressure control valve 18bar

17bar
Relief valve To main valve

.
De al
B

pt
g no
in ti

M
et a
n
rk er

S L1 L
Ma t

ZX65-1002009
In

3. When LS pressure is lower than the regu- When the flow required by the load is more
lating pressure of the constant power regu- than the pump delivery, pump displace-
lating valve, if the required delivery of the ment increases. The pump will work at
load is less than the maximum delivery of maximum flow until it reaches its fl ow limit.
the pump, the flow control valve is actu-
ated and pump delivery drops so that the
difference between pressure at main pump
oil outlet port and LS pressure is 17 bar.

Shop Manual - November 2012 4-29

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Load pressure

Flow control valve

X1

18bar
Pressure control valve

17bar

.
Relief valve

De al
To main valve

pt
B

g no
in ti
et a

M
n
rk er
Ma t
In

S L1 L
ZX65-1002010

4. When LS pressure is larger than the regu- delivery to decrease and keep the product
lating pressure of the constant power regu- of pressure at main pump outlet port and
lating valve, main pump works under con- main pump output delivery constant; that
stant power. Meanwhile, constant power is, constant power.
regulating valve works to cause main pump

4-30 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

SY75C3, SY75C9

Load pressure To main valve

Power regulating valve

Flow control valve

Pressure control valve

.
De al
pt
g no
in ti
M
et a
n
rk er
Ma t

Oil tank
ZX75-1002019
In

1. When the engine is stopped, main pump some oil will enter the big chamber of servo
swash plate angle is at maximum exhaust piston to move the piston. This causes the
position. swash plate angle to diminish until main
pump delivery drops to the minimum.
When the machine is started and no opera-
tion is performed, main control valve spool
is at the neutral position and load pressure
is zero. Outlet pressure of the main pump
rises from zero. When pressure reaches
17 bar, flow control valve is activated, and

Shop Manual - November 2012 4-31

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Load pressure To main valve

Power regulating valve

Flow control valve

Pressure control valve

.
De al
pt
g no
M
in ti
et a
n
rk er

Oil tank
ZX75-1002020
Ma t
In

2. When joysticks are operated, load pres- When main pump outlet pressure is low, all
sure starts to increase. Main pump outlet valves shown in the illustration do not act.
pressure also rises and maintains a pres- Main pump swash plate is at the minimum
sure of 17 bar higher than load pressure. angle and pump delivery is minimized.

4-32 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

Load pressure To main valve

Power regulating valve

Flow control valve

Pressure control valve

.
De al
pt
g no
M
in ti
et a
n
rk er

Oil tank
ZX75-1002021
Ma t

3. When main pump outlet pressure rises ishing of consequent pump delivery. Mean-
In

to the point when power regulating valve while, servo piston regulates the opening
(1) is activated, some oil enters the big pressure of power regulating valve via the
chamber of servo piston, and servo piston deflector rod, causing the opening pres-
moves to the right, causing reduction of the sure of power regulating valve to increase
main pump swash plate angle and dimin- so as to maintain a new balance.

Shop Manual - November 2012 4-33

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Load pressure To main valve

Power regulating valve

Flow control valve

Pressure control valve

.
De al
pt
g no
in ti
et a
n
rk er

Oil tank
Ma t

ZX75-1002022
In

4. When pressure at pump outlet port ex- port directly to the tank and the main pump
ceeds 320 bar, the pressure control valve is thus protected.
is opened and takes the oil at pump outlet

4-34 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.4.5 Control valve

External view

SY65C3

T P LS T1

.
De al
pt
g no T3

8b 8a
in ti

8B 8A
P2
et a

7b 7a
n

7B 7A
rk er

6b 6a

6B 5b 5a 6A
Ma t
In

5B 4b 4a 5A

4B 3b 3a 4A

3B 2b 2a 3A

2B 1b 1a 2A

1B 1A

T TSW
M
LS T1
P
ZX65-1002011

Shop Manual - November 2012 4-35

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

SY75C3, SY75C9

TSW

.
De al
pt
8b
g n8B
o
7B
8A

7A
8a
in ti
7b
7a
6B 6A
6b
6a
et a

5B 5A
5b
5a
n

4B 4A
4b
rk er

4a
3B 3A
3b
3a
Ma t

2B 2A
2b
In

2a
1B 1A
1b

1a

GAGE PORT

T ZX75-1002023

4-36 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

P: From main pump T: To oil cooler

8A: To swing motor MB LS: To pump flow control valve
8B: To swing motor MA 8a: From left wing pilot valve
7A: Standby 8b: From right swing pilot valve
7B: Standby 7a: From standby pilot valve
6A: To left travel motor B 7b: From standby pilot valve
6B: To left travel motor A 6a: From left forward travel pilot valve
5A: To right travel motor B 6b: From left reverse travel pilot valve
5B: To right travel motor A 5a: From right forward travel valve
4A: To arm cylinder big chamber 5b: From right reverse travel pilot valve
4B: To arm cylinder small chamber 4a: From arm IN pilot valve

.
3A: To bucket cylinder big chamber 4b: From arm OUT pilot valve

De al
pt
3B: To bucket cylinder small chamber 3a: From bucket DIG pilot valve
2A: To dozer blade cylinder small chamber 3b: From bucket DUMP pilot valve
g n
2B: To dozer blade cylinder big chamber
o
1A: To boom cylinder small chamber
2a: From dozer blade UP pilot valve
2b: From dozer blade DOWN pilot valve
1B: To boom cylinder big chamber 1a: From boom DOWN pilot valve
in ti
GAGE port: To oil source control valve PD 1b: From boom UP pilot valve
TSW: To swing motor
et a
n
rk er
Ma t
In

Shop Manual - November 2012 4-37

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Section view
SY65C3

1 3 4 3

A B
5 6

LS

.
De al
pt
g no T
P
T
in ti
et a
n

2
rk er

ZX65-1002012

1) Valve body 4) Pressure compensation valve

Ma t

2) Valve spool 5) Secondary relief valve

In

3) Check valve 6) Plug

4-38 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

SY75C3, SY75C9

2 3 3

.
De al
pt
g no
in ti
9

8
et a

7
n

7 4 6 5
rk er

ZX75-1002024

1) Pilot oil line 6) LS load oil line

Ma t

2) Overload relief valve 7) Oil return line

In

3) Oil port 8) Main oil inlet line

4) Check valve 9) Main control valve spool
5) Compensation valve spool

Shop Manual - November 2012 4-39

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.4.6 Oil source control valve

The oil source control valve consists of a valve body, an accumulator, a pressure reducing valve,
a check valve and two solenoid valves.

Functions of the oil source control valve include:

1. Providing pilot oil;

2. Providing high/low speed shift oil;
3. Providing oil for releasing swing motor brake.

.
De al
pt
1 g no
in ti
et a
n
rk er
Ma t
In

2 5

4 3
ZX75-1002025

1) Accumulator 4) Pressure reducing valve

2) Pilot solenoid valve 5) High/Low travel speed solenoid valve
3) Safety valve

4-40 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

Operating process

● When the machine is operated, oil from line respectively. Pv line provides releas-
the main pump outlet enters partially into ing pressure for swing motor and regulates
port P2 of oil source control valve and then the high and low speed of travel motor by
passes the pressure reducing valve, where opening and closing the high/low travel
the pressure is limited to 3.5 Mpa. Oil of speed solenoid valve; Bv line provides oil
lower pressure passes through the check for each of the pilot lines by opening or
valve and enters the Pv line, Bv line and Pr closing the solenoid valves.

Accumulateur

.
De al
0.32 dm

pt
Bv Pr Pv P1
g no
12 V DC

Oil source control valve

in ti
Travel speed
solenoid valve
et a

Reducing valve
12 V DC
n
PS

Safety valve
rk er

actuating pressure
45bar
Pilot solenoid
valve
Ma t

T P2 P3
In

ZX75-1002026

Shop Manual - November 2012 4-41

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.4.7 Load sensitive system

1. Outline

Features 4) Energy saving using variable pump control.

1) Fine control not influenced by load. Structure

2) Controllability enabling fast digging with ● Load sensitive system is configured with a
precise control. variable displacement single piston pump,
a control valve and an actuator.
3) Ease of combined operation ensured by
flow divider function using area of spool ● The pump body consists of the main pump,

.
opening during combined operations. pressure control valve and flow control

De al
valve.

pt
g no Actuator
in ti
et a

PLS
Control valve
n
rk er
Ma t

Pressure control
valve
In

Main pump

Flow control
valve

PP

Servo valve

ZX75-1002027

4-42 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

2. Basic principle

Pump swash plate angle control

● Swash plate angle (pump delivery) is con- ● If LS differential pressure (ΔPLS) is lower
trolled via constant LS differential pres- than the set pressure of flow control valve,
sure (ΔPLS) (the difference between pump pump swash plate angle increases; if it is
pressure (PP) and control valve outlet port higher, the angle decreases.
LS pressure (PLS)) (load pressure of ac-
tuator). (ΔPLS = PP - PLS) ● For detailed operation procedures, see
“Hydraulic pump” on page 2-16.

.
Actuator

De al
pt
g no Control
valve Max.
in ti
Swash plate angle Q

Pump
PLS
passage
et a
n

Flow control valve

set pressure Min.
PP
rk er

LS passage
Main
pump O LS differential pressure PLS
Ma t

Min. Max.
In

Servo
piston

PLS

Flow control valve

Small differential
Large differential pressure(low)
pressure (high)

Pressure control valve

ZX75-1002028

Shop Manual - November 2012 4-43

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Pressure compensation control

● A pressure compensation valve is mounted difference (ΔP) is generated between the

at the outlet port side of the control valve upstream (inlet port) and downstream
and it is used to balance the load. (outlet port) of the spool of each valve.
The flow of oil from the pump is divided
When more than two actuators are oper- (compensated) in proportion to the area of
ated together, this valve acts and pressure opening (S1) and (S2) of each valve.

Load Load

W W

.
Actuator Actuator

De al
pt
g no
in ti
P P
S1 S2
et a
n
rk er
Ma t

Presssure Pressure
In

compensation compensation
valve valve

Pump

Flow control valve

ZX75-1002029

4-44 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

3. Operation of each function

Hydraulic circuit diagram

T
LS P

8B
8A 8b
8a

7B
7A 7b

.
De al
7a

pt
6B

g no 6A
6a
6b

5B
in ti
5A 5b
5a
et a

4B
n

4A 4b
rk er

4a

3B
Ma t

3A 3b
3a
In

2B
2A 2b
2a

1b
1a
T

LS
ZX75-1002030

Shop Manual - November 2012 4-45

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

1) Unload valve

Function

1. When the control valve is in neutral posi- Meanwhile, pump output pressure (PP)
tion, pump delivery (Q) is directed to the is set at 1.7 Mpa via spring (2) inside the
tank circuit via minimum swash plate an- valve. (LS pressure (PLS): 0 Mpa)
gle.

PLS
Pp

.
De al
pt
g no
in ti
et a
n

T 1 2 3
rk er
Ma t

ZX75-1002031
In

Operating process

When control valve is in neutral position

● Pump output pressure (PP) acts upon the ● When pump output pressure (PP) rises to
left end of spool (1), and LS pressure (PLS) the load of spring (2) (1.7 Mpa), spool (1)
acts upon the right end. moves to the right (→). However, oil in the
pump circuit became communicative with
● When the control valve is in neutral posi- the tank circuit (T) via the orifice inside
tion, no LS pressure (PLS) is generated valve barrel (3).
and only pump output pressure (PP) is
acting. PP is only set through the load of ● In this way, pump output pressure (PP) is
spring (2). set at 1.7 Mpa.

4-46 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

2. When the required flow of the actuator is pressure (PP) and LS pressure (PLS)
within the flow range when the pump is at reaches the load of spring (2) (1.7 Mpa),
minimum swash plate angle, pump out- the unload valve is activated. LS differen-
put pressure (PP) is set at PLS+1.7 Mpa. tial pressure ΔPLS becomes 1.7 Mpa as a
When difference between pump output result.

PLS
PP

.
De al
pt
g no
in ti

T 1 2 3
et a
n

ZX75-1002032
rk er

Operating process
Ma t

● When the control valve is performing fine pressure (PLS) reaches the load of spring
control, LS pressure (PLS) is generated (2) (1.7 Mpa), spool (1) moves to the right
In

and acted upon the right end of spool (1). (→) and pump oil circuit (PP) become
communicative with tank circuit (T).
The opening area of the control valve
spool is small at the moment, so differential ● In other words, when pump output pres-
pressure between LS pressure (PLS) and sure (PP) is set equal to spring force (1.7
pump output pressure (PP) is very large. Mpa) + LS pressure (PLS), LS differential
pressure ΔPLS becomes 1.7 Mpa.
● When pump output pressure (PP) and LS

Shop Manual - November 2012 4-47

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3. When the control valve is operated and the swash plate angle, oil flowing to the tank
required fl ow of the actuator is larger than circuit (T) is cut off and all pump delivery (Q)
the flow when the pump is at minimum flows to the actuator circuit.

PLS
PP

.
De al
pt
g no
T 1 2 3
in ti
et a

ZX75-1002033
n

Operating process
rk er

Operating process of control valve

Ma t

● When the control valve reaches the larger pump output pressure (PP) and LS pres-
stroke, LS pressure (PLS) is generated sure (PLS) can not reach the load of spring
In

and acted upon the right end of spool (1). (2) (1.7 Mpa), and spool (1) is pushed to
Meanwhile, opening area of control valve the left (←) by spring (2).
spool increases and differential pressure
between LS pressure (PLS) and pump out- ● The result of this is that pump circuit (PP)
put pressure (PP) becomes small. and tank circuit (T) is cut off and all pump
delivery (Q) enters actuator circuit.
● As a result, differential pressure between

4-48 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

2) LS pressure

Function
● LS pressure is the load pressure of the ac- upon the pressure compensation valve un-
tuator at the outlet port of the control valve. til it equals the acting pressure (A) via the
control valve and directs it to the LS circuit
● It reduces the pump pressure (PP) acted (PLS).

.
A B

De al
pt
1

g no
in ti
et a

2 4
a
n

3 c PLS1
rk er
Ma t

LS flush valve LS relief valve

ZX75-1002034
In

Operating process

● When spool (1) moves, pump pressure ● Meanwhile, LS circuit (PLS) is in commu-
(PP) enters the pressure compensator via nication with the tank circuit (T) from LS fl
control valve (2) and notch (a) inside valve ushing valve.
spool. Then, it enters actuator circuit (A)
via check valve and bridge passage (b). ● Pressure (PP) is acted upon the SLS on
the other end.
● At the same time, pressure compensa-
tor (3) also moves to the right (→). Pump ● The result is that, pressure compensator (3)
pressure (PP) enters notch c of pressure is balanced at the position where actuator
compensator and enters LS circuit. Pres- circuit pressure (PA) equals chamber pres-
sure (PP) enters LS circuit (PLS) and then sure (PLS1). Pump pressure (PP) which
chamber (PLS1). drops at notch (d) becomes actuator circuit
pressure (PA) and enters LS circuit (PLS).

Shop Manual - November 2012 4-49

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3) LS flushing valve

Outline

1) LS flushing valve can release the residual

pressure of LS pressure (PLS).

2) This function helps to achieve a smoother

increase of LS pressure (PLS).

3) Besides, with the drainage of reducing oil

fl ow, pressure loss is generated in the re-
ducing oil fl ow of the valve spool or shuttle
valve. Stability is enhanced by lowering ef-

.
De al
fectively the LS differential pressure.

pt
g no
in ti
et a
n
rk er
Ma t
In

4-50 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4) Pressure compensation valve

Function

● During combined operation, if load pres- Meanwhile, load of other actuators (right
sure is lower than the pressure of other side) for combined operation will be higher
actuators and flow amount is about to in- than that load of the actuator of this side
crease, pressure will be compensated. (left side).

.
De al
pt
A B A B
g no
in ti
et a

a
a
n

3 PLS1 3 PLS1
rk er
Ma t
In

ZX75-1002035

Operating process

● During combined operation, if the load ● Oil flow area of the joint section between
pressure of other actuators (right side) in- less loaded pressure compensator and
creases, fl ow amount in circuit (A) of the main control valve decreases and differen-
actuator on this side (left side) tends to in- tial pressure is generated until a new bal-
crease. ance is generated.

● Meanwhile, the LS pressure (PLS) of other ● Differential pressure of the two valve
actuator acts upon chamber (PLS1) and spools for combined operation is the same
pressure compensator (3) is pushed to the at the front and rear of notch (a). Pump fl
left (←). ow is distributed according to the opening
degree of notch (a) of each valve spool.

Shop Manual - November 2012 4-51

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

5) Left and right travel

Function

● The pressure compensation valve com- compensation of two travel pressures. In

pensates for fl ow difference in the left and this way, pressure of the two travel motor
right travel circuits. It connects the oil cir- is almost identical during machine travel
cuit between the two travel motors after the and travel deviation is avoided.

.
De al
A B A B
1

pt
1

g no
in ti

2
2
a
et a
n
rk er
Ma t

ZX75-1002036
In

Operating process

During straight travel

● When the left and right travel valve spools spools is distributed proportionally. Since
(1) act, oil fl ows from the pump to actuator the rated delivery of the two valve spools
circuit (A) via pump circuit (PP) and circuit are the same, oil flow through the two
(PA). valve spool is only related to the opening
degree of the tow valve spools.
● During straight travel, since the rated de-
livery of the two travel valve spools is the ● When the opening degree of main control
same, when the loads of the two travel mo- valve spool is the same, oil fed to the left
tors are different, pressure compensation and the right travel motors becomes identi-
valve in the load sensitive system will act cal and travel deviation is avoided.
so that oil flow through the two travel valve

4-52 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

6)Travel and other operation combined

Function

● When travel and other operations are per- to the opening degree of the valve spool.
formed at the same time, output delivery When opening degree is the same (straight
of the pump is distributed to each opera- travel), input delivery of the two travel mo-
tion proportionally. Oil delivery distributed tors is the same and travel deviation is
according to the opening area of the valve avoided.
spool is the same. Travel speed is related

.
De al
pt
1
g n
A
o B A B
in ti
et a
n
rk er
Ma t
In

ZX75-1002037

Operating process

Normal operation

● When opening degree is different (making delivery of the two travel motors is differ-
a turn), since the opening degree of the ent, i. e. a turn is made.
two travel valve spools is different, input

Shop Manual - November 2012 4-53

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

A B A B
1

.
De al
4

pt
2

c
g no PLS1 PLS1
in ti
et a

ZX75-1002038
n

Travel+other actuator operating process

rk er

● When boom valve spool (1) is acting, LS ● As a result, the reducing valve (2) moves
Ma t

circuit (PLS) becomes the same as boom to the left side and LS pressure of spring
circuit pressure (A1). chamber (PLS1) flows out via orifice A.
In

Check valve (4) is opened and oil flows

● Due to the action of the actuator circuit into travel circuit (PA) via passage (b) and
pressure, boom UP pressure is normally passage c.
higher than travel pressure (A1>A2). There-
fore, pressure in spring chamber (PLS1) of ● Based on this, LS circuit pressure (PLS)
travel valve pressure reducing valve (2) is (identical with boom circuit pressure (A1))
higher than travel circuit pressure (PA). flows to travel circuit (A2) in order to re-
duce pressure.

4-54 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

7) Regeneration circuit

Function
Take the boom regeneration circuit as an ex- sure (A) of cylinder (1) is higher than top
ample: pressure (B) and hydraulic drift exists, re-
turn oil from the bottom is fed to the top in
1) When the boom is lowering, if bottom pres- order to increase cylinder speed.

.
De al
pt
A B

g no
2
in ti
3
et a
n

a 4
rk er

T
Ma t
In

Pp PLS

ZX75-1002040

Operating process

● When the boom is lowering, if hydraulic the check valve and flows to the top via the
drift exists, bottom pressure (A) of boom regenerating passage (a) of boom valve
cylinder (1) will become higher than top spool (1).
pressure (B).
● Boom DOWN speed is consequently in-
● Meanwhile, return oil at the bottom opens creased.

Shop Manual - November 2012 4-55

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2) When the boom is lowering, if top pressure ging status, check valve (3) will close and
(B) of cylinder (1) is higher than bottom cut off the circuit between the top and the
pressure (A) and work equipment is in dig- bottom.

A B

.
De al
2

pt
3
g no
in ti

a 4
et a

T
n
rk er
Ma t
In

Pp PLS

ZX75-1002041

Operating process

● When the boom is lowering, if work equip- ● Meanwhile, check valve (3) is closed by
ment is digging, top pressure (B) of cyl- spring (4) and top pressure (B), and circuit
inder (1) will become higher than bottom between top circuit and bottom circuit is cut
pressure (A) gradually. off consequently.

4-56 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4. Operation of the whole system

1) When all control valves are neutralized

● Pump flow (Q) flows totally to the tank (1) Therefore, it is tank pressure.
via unload valve (6).
● Under this state, LS differential pressure
● Valve spool (each spool A) does not act ΔPLS = unload pressure - tank pressure.
and no LS pressure (PLS) is generated as ΔPLS is higher than LS set pressure of
a result. flow control valve (4). As a result, main
pump (2) is set at minimum swash plate
● At the same time, LS pressure (PLS) is angle.
transmitted to the tank by flushing valve (6).

.
De al
pt
1- Hydraulic tank 12- Left travel valve
Hydraulic pump 12A. Valve spool
2- Main pump g no
3- Power regulating valve
12B. Pressure compensation valve
13- Swing valve
4- Flow control valve 13A. Valve spool
in ti
5- Servo piston 13B. Pressure compensation valve
Control valve 14-
et a

6- LS flushing valve 15- Unload valve

n

8- Bucket valve 16- Main relief valve

8A. Valve spool 17- Cooler bypass valve
rk er

8B. Pressure compensation valve 18- Lifting check valve

8C. Check valve 19- Swing pump pressure circuit orifi ce
Ma t

9- Arm valve 20- Central safety valve

In

9A. Valve spool

9B. Pressure compensation valve Actuator
9C. Check valve 21- Bucket cylinder
10- Boom valve 22- Arm cylinder
10A. Valve spool 23- Boom cylinder
10B. Pressure compensation valve 24- Left travel motor
10C. Check valve 25- Right travel motor
11- Right travel valve 26- Swing motor
11A. Valve spool Oil source control valve
11B. Pressure compensation valve ● Suction valve is not shown.

Shop Manual - November 2012 4-57

4-58
6 8C
8A
8
In
8B
Structure and Function

9C
9A
Ma t
5 22
9
3 9B
10C
4 10A
rk er
n 10
21
23

10B
26
et a
11A
11
2
24 25
11B
in ti
12A
g no 12

Shop Manual - November 2012

12B
To pilot valve
13 13A

13B
De al
17 19

16 15
18
20
pt
1 .

ZX75-1002042
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

2) When swing is operated separately

● When swing valve spool (13A) is acting, pump (2) is kept between the maximum
pump delivery (Q) flows to swing motor and the minimum and the main pump de-
(26). At the same time, LS pressure (PLS) livers the amount of oil required by swing
is generated and unload valve (15) is circuit. When swing is operated separately,
closed. LS pressure (PLS) becomes load pump delivery (Q) will not rise to 100%.
pressure of swing motor (26).
● For swing pressure compensation valve
● In swing circuit, difference between pump (13B), pump pressure (PP) enters the right
output pressure (PP) and LS pressure end of the compensator via notch (C) of
(PLS), i.e LS differential pressure ΔPLS, pressure compensation valve and keeps a
becomes the same as LS set pressure of fl balance with the left end of the compensa-

.
ow control valve (4). tor. The whole pressure compensator is

De al
kept at the right end.

pt
● As a result, swash plate angle of main

1- Hydraulic tank
Hydraulic pump
g no 11A. Valve spool
11B. Pressure compensation valve
in ti
2- Main pump 12- Left travel valve
3- Power regulating valve 12A. Valve spool
4- Flow control valve 12B. Pressure compensation valve
et a

5- Servo piston 13- Swing valve

n

Control valve 13A. Valve spool

rk er

6- LS flushing valve 13B. Pressure compensation valve

7- 14- LS selection valve
8- Bucket valve 15- Unload valve
Ma t

8A. Valve spool 16- Main relief valve

In

8B. Pressure compensation valve 17- Cooler bypass valve

8C. Check valve 18- Lifting check valve
9- Arm valve 19- Swing pump pressure circuit orifice
9A. Valve spool 20- Center safety valve
9B. Pressure compensation valve Actuator
9C. Pressure compensation valve (reducing 21- Bucket cylinder
valve) 22- Arm cylinder
9D. Check valve 23- Boom cylinder
10- Boom valve 24- Left travel motor
10A. Valve spool 25- Right travel motor
10B. Pressure compensation valve 26- Swing motor
10C. Check valve Oil source control valve
11- Right travel valve ● Suction valve is not illustrated.

Shop Manual - November 2012 4-59

4-60
7 6 80
8A
8

8B 8C
In
9A 90
Structure and Function

5 22
9
Ma t
3 9B 9C
100
4 10A
10 23
rk er
n 21
10B 10C
11A 26
11
et a
2
24 25
11B 11C
27

12 12A
in ti
28
o 12B 12C
g n

Shop Manual - November 2012

To pilot valve
13A
13

13B 13C
17
19
De al
14
16 15
18
20
pt
1
.

ZX75-1002043
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

3) When left and right travel are operated

simultaneously

● When left and right travel valve spools side and the travel circuits open to each
(12A) and (11A) are operated simultane- other to prevent travel deviation.
ously, pump delivery (Q) flows to left and
right travel motors (24) and (25). At the ● If opening degree of left and right travel
same time, LS pressure (PLS) is gener- valve spools (12A) and (11A) is less than
ated and unload valve (15) is closed. 100%, pump delivery (Q) is regulated by
LS differential pressure ΔPLS according to
● Meanwhile, pressure compensators of the the opening area of valve spool.
left and right travel valves move to the right

.
1- Hydraulic tank 12- Left travel valve

De al
Hydraulic pump 12A. Valve spool

pt
2- Main pump 12B. Pressure compensation valve
g n
3- Power regulating valve
4- Flow control valve
o 13- Swing valve
13A. Valve spool
5- Servo piston 13B. Pressure compensation valve
in ti
Control valve 14- LS selection valve
6- LS flushing valve 15- Unload valve
et a

7- 16- Main relief valve

8- Bucket valve 17- Cooler bypass valve
n

8A. Valve spool 18- Lifting check valve

rk er

8B. Pressure compensation valve 19- Swing pump pressure circuit orifi ce
8C. Check valve 20- Central safety valve
Ma t

9- Arm valve Actuator

9A. Valve spool 21- Bucket cylinder
In

9B. Pressure compensation valve 22- Arm cylinder

9C. Check valve 23- Boom cylinder
10- Boom 24- Left travel motor
10A. Valve spool 25- Right travel motor
10B. Pressure compensation valve 26- Swing motor
10C. Check valve Oil source control valve
11- Right travel valve ● Suction valve is not illustrated.
11A. Valve spool
11B. Pressure compensation valve

Shop Manual - November 2012 4-61

4-62
7 6 80
8A
8

8B 8C
In
9A 90
Structure and Function

5 22
9
Ma t
3 9B 9C
100
4 10A
10 23
rk er
21
n 10B 10C
11A 26
et a
11
2
24 25
11B 11C
27
in ti
o 12 12A
28
g n 12B

Shop Manual - November 2012

12C
To pilot valve
13A
13

13B 13C
De al
17
19 14
16 15
18
20
pt
1 .

ZX75-1002044
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4) Boom+Arm operation

● If boom valve spool (10) is operated for ● Under this circumstance, the differential
raising, and arm valve spool (9A) is oper- pressure between upstream pressure
ated for dumping, pump delivery (Q) flows and downstream pressure of boom valve
to cylinders (23) and (22). spool (10A) and arm valve spool (9A) is
the same, and consequently, oil from main
● Meanwhile, load pressure of boom cylin- pump (2) is distributed according to the
der (23) is higher than that of arm cylinder opening area of each valve spool.
(22). Therefore, oil flows to arm cylinder
(22) with lower load pressure. However, ● When opening area of boom valve spool
upstream pressure of arm valve spool (9A) (10A) and arm valve spool (9A) is less than
is compensated for via pressure compen- 100%, pump delivery (Q) is controlled by

.
sation valve (9B) and receives boom load LS pressure differential ΔPLS according to

De al
pressure. (=Max. LS pressure (PLS)). the opening area of valve spool.

pt
1- Hydraulic tank
Hydraulic pump
g no 12- Left travel valve
12A. Valve spool
2- Main pump 12B. Pressure compensation valve
in ti
3- Power regulating valve 13- Swing valve
4- Flow control valve 13A. Valve spool
et a

5- Servo piston 13B. Pressure compensation valve

Control valve 14- LS selection valve
n

6- LS flushing valve 15- Unload valve

rk er

7- 16- Main relief valve

8- Bucket valve 17- Cooler bypass valve
Ma t

8A. Valve spool 18- Lifting check valve

8B. Pressure compensation valve 19- Swing pump pressure circuit orifi ce
In

8C. Check valve 20- Central safety valve

9- Arm valve Actuator
9A. Valve spool 21- Bucket cylinder
9B. Pressure compensation valve 22- Arm cylinder
9C. Check valve 23- Boom cylinder
10- Boom valve 24- Left travel motor
10A. Valve spool 25- Right travel motor
10B. Pressure compensation valve 26- Swing motor
10C. Check valve Oil source control valve
11- Right travel valve ● Suction valve is not illustrated.
11A. Valve spool
11B. Pressure compensation valve

Shop Manual - November 2012 4-63

4-64
7 6 80
8A
8
In
8B 8C
Structure and Function

9A 90
5 22
Ma t
9
3 9B 9C
100
4 10A
rk er
10 23
n 21
10B 10C
11A 26
et a
11
2
24 25
11B 11C
27
in ti
12 12A
28
g no

Shop Manual - November 2012

12B 12C
To pilot valve
13A

13B 13C
17
De al
19 14
16 15
18
20
pt
1 .

ZX75-1002045
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

5) Boom UP + swing operation

● When boom valve spool (10A) is operated ● When opening areas of boom valve spool
for raising and swing valve spool is oper- (10A) and swing valve spool (13A) are less
ated at the same time, pump delivery (Q) fl than 100%, pump delivery (Q) is controlled
ows to boom cylinder (23) and swing motor by LS differential pressure ΔPLS according
(26). to the opening area of valve spool.

1- Hydraulic tank 12- Left travel valve

Hydraulic pump 12A. Valve spool
2- Main pump 12B. Pressure compensation valve

.
3- Power regulating valve 13- Swing valve

De al
pt
4- Flow control valve 13A. Valve spool
5- Servo piston 13B. Pressure compensation valve
Control valve g n
6- LS flushing valve
o 14- LS selection valve
15- Unload valve
7- 16- Main relief valve
in ti
8- Bucket valve 17- Cooler bypass valve
8A. Valve spool 18- Lifting check valve
et a

8B. Pressure compensation valve 19- Swing pump pressure circuit orifi ce
n

8C. Check valve 20- Central safety valve

9- Arm valve Actuator
rk er

9A. Valve spool 21- Bucket cylinder

9B. Pressure compensation valve 22- Arm cylinder
Ma t

9C. Check valve 23- Swing cylinder

10- Boom valve 24- Left travel motor
In

10A. Valve spool 25- Right travel motor

10B. Pressure compensation valve 26- Swing motor
10C. Check valve Oil source control valve
11- Right travel valve ● Suction valve is not illustrated.
11A. Valve spool
11B. Pressure compensation valve

Shop Manual - November 2012 4-65

4-66
7 6 80
8A
8
In
8B 8C
Structure and Function

9A 90
5 22
Ma t
9
3 9B 9C
100
4 10A
rk er
10 23
n 10B 10C
21

11A 26
et a
11
2
24 25
11B 11C
27
in ti
o 12 12A
28
12B 12C
g n

Shop Manual - November 2012

To pilot valve

13 13A

13B 13C
17 19 14
De al
16 15
18
20
pt
1
.

ZX75-1002046
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.4.8 Swing motor

Jesung swing motor

.
De al
pt
Dr
PB
g no A B
in ti
ZX75-1002047

PB: From swing counterbalance valve Specifications

et a

A: From swing control valve

Model: 7SM430719
n

B: From swing control valve

M: From oil tank Motor capacity: 43mL/rev
rk er

Dr: To oil tank Safety valve set pressure: 23.5Mpa

Ma t
In

Shop Manual - November 2012 4-67

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

KYB swing motor

Dr
M

PB

.
De al
pt
g no
in ti
A B

ZX75-1002048
et a
n

PB: From swing counterbalance valve Specifications

rk er

A: From swing control valve

B: From swing control valve Model: MSG-44P-21-26

M: From oil tank Motor capacity: 44.1 mL/rev

Ma t

Dr: To oil tank Safety valve set pressure: 21.5 MPa

In

Safety valve

Outline keeps rotating under inertial force.

The safety valve consists of a makeup oil As a result, pressure at motor outlet side
check vale and a relief valve. becomes abnormally high which may result
in motor damage. To avoid this, the oil that
Function causes excessively high hydraulic pressure
is allowed to be relieved to port M from mo-
When swing stops, the motor outlet circuit tor outlet port (high pressure side) in order to
is shut off by the control valve but the motor avoid motor damage.

4-68 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

Operation
B A

1) When swing starts

● When the swing control lever is placed to

CB CA
the left swing position, pressurized oil from
the pump is supplied to port (MA) via con-
trol valve. The pressure at port (MA) rises,
starting torque is generated in the motor,
and the motor begins to run.

The pressurized oil from the outlet port of

the motor passes from port (B) through the

.
control valve and returns to the tank. S

De al
pt
MA
g no MB

Control valve
ZX75-1002053
in ti
et a

B A
2) When swing stops
n

● When the swing control lever is returned to

rk er

the neutral position, supply of pressurized

CB CA
oil from the pump to port (MA) is stopped.
Ma t

Return oil circuit to the tank is shut off by

In

the control valve and oil pressure from

motor outlet port rises at port (MB). Motor
rotation resistance increases and the brake
is actuated.

S
● When pressure at port (MB) rises to above
the set pressure of relief valve (B), a higher
braking torque works on the motor causing
it to stop. MB MA

● When relief valve (B) is acting, oil relieved Control valve

from it and the oil from port (S) flows to the ZX75-1002054

port (MA) via check valve (CA). In this way,

formation of cavitation at port (MA) is pre-
vented.

Shop Manual - November 2012 4-69

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Operation of swing brake valve

Jesung swing motor

Swing pilot
1) When swing is not operated, the swing Oil source control valve
brake valve is closed. At this time, port (B)
is connected with the tank.
M
As a result, the brake piston (10) is pushed Main pump
Swing
downward by brake spring (9). Disc (12) brake valve 9
and plate (11) are also pushed and the
10
brake is applied.
B

.
a

De al
11

pt
12

g no
in ti
ZX75-1002055
et a
n

2) When swing is operated, swing brake valve Swing pilot

(d) is open. Pilot pressure of oil source
rk er

Oil source control valve

control valve is sent to port (B) and brought
into the brake chamber (a).
Ma t

M
Pressurized oil in chamber (a) overcomes Main pump
Swing
In

the force of brake spring (9) and pushes brake valve 9

the brake piston (10) upward. In this way,
10
disc (12) and plate (11) are separated and
B
the brake is released.
a
11
12

ZX75-1002056

4-70 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

KYB swing motor

1) When the machine is stopped, pressure Oil source control valve

at port (B) drops via the oil drainage of oil
source control valve.
M
As a result, the brake piston (10) is pushed
Main pump
downward by brake spring (9). Disc (12)
9
and plate (11) are also pushed and the
brake is applied. 10
B
a
11

.
12

De al
pt
g no
ZX75-1002057
in ti
2) When the machine is started, pilot oil en-
ters port (B) via oil source control valve
et a

and flows into brake chamber (a).

n

Pressurized oil in chamber (a) overcomes Oil source control valve

rk er

the force of brake spring (9) and pushes

brake piston (10) upward. In this way, disc
(12) and plate (11) are separated and the
Ma t

brake is released. M
Main pump
In

9
10
B
a
11
12

ZX75-1002058

Shop Manual - November 2012 4-71

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.4.9 Center swivel joint

+1
A2 B2 C2 D2 Port 45 0

A1 C1 E1 G1

A A

.
De al
E2 F2 G2 Port 22

pt
B1 D1 F1

A-A
g no
in ti
et a
n

Dr1
Dr2
rk er

ZX75-1002059
Ma t

A2: Left travel motor port P2 F2: Dozer blade port (B)
B2: Left travel motor port P1 G2: Left/Right travel motor Ps port
In

C2: R. travel motor port P1 Dr1: To tank

D2: R. travel motor port P2 D1: To main control valve port 5A
A1: To main control valve port 6B E1: To main control valve port 2B
B1: To main control valve port 6A F1: To main control valve port 2A
C1: To main control valve port 5B Dr2: To left/right travel motor oil drain port
E2: Dozer blade port A G1: To oil source control valve

4-72 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

Locations of ports A2, B2, C2, D2, E2 and F2 are shown in the figure below:

E2

B2

A2 T
G2

.
De al
pt
g no
in ti
G2 C2 T

D2
et a

F2
n
rk er

ZX75-1002060
Ma t
In

Shop Manual - November 2012 4-73

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.4.10 Travel motor

.
d

De al
pt
e

g no
ZX55-1002068
in ti

a. Oil relief port DR2 (To oil tank) Specifications

b. Port A (from control valve) Model: GM09VN
et a

c. Port D (Hi/Lo speed solenoid valve)

n

d. Port B (from control valve) Hydraulic motor

rk er

e. Plug Motor capacity: Low speed 34.4 ml/rev

High speed 18 ml/rev
Rated speed: Low speed 1587rpm
Ma t

High speed 2933rpm

In

Brake release press: 0.47Mpa {4.8kg/cm²}

Travel speed switching pressure:
1.96 - 6.86 MPa {20 - 70 kg/cm²}

Final drive
Reduction ratio: 68
Speed: Low speed 23 rpm
High speed 43.1 rpm

4-74 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

9 10 11 12 13 14 15
1 2 3
8

7
4 16

6
17
5

18
29
19

.
20

De al
28

pt
21
30
g no 27 26 25 24 23 22
in ti
ZX55-1002069

1) Check valve 16) Driven gear

et a

2) Spring 17) Cover

n

3) Counterbalance valve 18) Driving gear

4) Return spring 19) Shaft
rk er

5) End cover 20) Shaft coupling

6) Spring 21) Drain plug
Ma t

7) Regulating valve 22) Center shaft

In

8) Brake piston 23) Regulating plunger

9) Plate 24) Casing
10) Disc 25) Spindle
11) Swash plate 26) Plunger
12) Float seal 27) Cylinder
13) RV gear 28) Brake spring
14) RV gear 29) Thrust plate
15) Crankshaft 30) Check valve

Shop Manual - November 2012 4-75

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.4.10.1 Travel motor operating process

1. At low speed (swash plate at max angle)

5 D 6 b 7

Brake
valve

.
De al
pt
g no 32
in ti
Travel speed
solenoid valve
Main pump
P 11 23 a
et a
n

Oil tank
rk er

Reducing valve
ZX75-1002063
Ma t

● High/Low travel speed solenoid valve is ● At the same time, pressurized oil at cham-
closed and pressurized oil from oil source ber (a) of regulating plunger (23) is drained
In

control valve does not flow into port D. to the motor casing via passage (b) of the
regulating valve (6).
● As a result, regulating valve (6) is pushed
to the left (←) by spring (7). ● As a result, swash plate (11) is pushed to
the max angle direction by the main pres-
● As a result, it pushes check valve (32) and sure in cylinder chamber (P). The motor
pressurized oil between control valve and reaches its maximum capacity and the sys-
end cover (5) is cut off by the regulating tem is set to low speed.
valve (6).

4-76 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

2. At high speed (swash plate at minimum angle)

5 D 6 b 7

Brake
valve

.
De al
32

pt
g no
Main pump
Travel speed
solenoid valve

P 11 23 a
in ti

Oil tank
et a

Reducing valve
n

ZX75-1002064
rk er

● When the travel speed solenoid valve is lating valve (6) and pushes the regulating
excited, pilot oil from the oil source control plunger (23) to the left (←).
Ma t

valve flows to port D and pushes the regu-

In

lating valve (6) to the right (→). ● As a result, swash plate (11) is pushed to
the minimum angle direction. Motor capac-
● As a result, main pressurized oil from the ity is minimized and the system is set to
control valve enters the regulating plunger high speed.
(6) at the bottom via passage (b) of regu-

Shop Manual - November 2012 4-77

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.4.10.2 Parking brake operating process

28 8 26 27

1. When travel starts

● As the travel lever is operated, pressurized

oil from the pump activates counterbal-
ance valve spool (3), opens the circuit to
the parking brake, pushes check valve (31)
open and flows to chamber (a) of brake
piston (8). a
31
3
● Pressurized oil overcomes the force of
spring (28) and pushes piston (8) to the left

.
(←).

De al
pt
● Since the force that pushes plate (26) and
disc (27) together disappears, plate (26) is

released.
g n
separated from disc (27) and the brake is
o Travel control
valve

M
in ti
ZX75-1002065

2. When travel stops

et a

28 8 26 27
n

● As the travel lever is placed in neutral

position, counterbalance valve spool (3)
rk er

returns to the neutral position and circuit to

the parking brake is closed.
Ma t

● The pressurized oil in chamber (a) of brake

In

piston (8) is drained to the casing via the

orifice of check valve. Brake piston (8) is a
pushed to the right (→) by spring (28). 31
3

● The plate (26) and disc (27) are pushed to-

gether, and the brake is applied.

Travel control
valve

M
ZX75-1002066

4-78 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.4.10.3 Counterbalance valve operating process

Function
Control valve
● When traveling downhill, the weight of the PA PB
machine tends to make the travel speed
2a 2b
faster than the motor speed.

3
● If the machine travels with the engine at
low speed, the motor may rotate at zero
load, resulting in runaway and inviting a
MA MB
very dangerous situation.

.
De al
● This valve is used to avoid such a situation

pt
by controlling the machine to travel at the
ZX75-1002067
engine speed (pump delivery).
g no
in ti
Control valve

PA PB
Operation when pressurized oil is supplied
et a

● When the travel levers are being operated, E1 3

n

pressurized oil flows from the control valve

to port (PA). The pressurized oil opens
rk er

S1
check valve (2a) and then flows to motor 4
MA MB
outlet port (MB) via motor inlet port (MA).
Ma t

● However, the motor outlet is closed by

In

check valve (2b) and spool (3), so the

ZX75-1002068
pressure at the supply side rises.

● The pressurized oil on the supply side

flows to chamber (S1) via orifice (E1) of
the spool (3). As the pressure in chamber
(S1) goes above the spool shift pressure,
spool (3) is pushed toward the right (→).

● Port (MB) and port (PB) become communi-

cative, the motor outlet port opens and the
motor starts rotating.

Shop Manual - November 2012 4-79

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Operation of brake when travelling down-

hill

● If the machine loses control while travel-

ling downhill, the motor will rotate at zero
Control valve
load to decrease the inlet side oil pressure.
Pressure in chamber (S1) will also drop via PA PB
orifices (E1).

● As the pressure in chamber (S1) goes be- E1 3

low the spool shift pressure, spool (3) is
returned to the left (←) via spring (4) and S1
4
outlet port (MB) is throttled. MA MB

.
De al
● The pressure at the outlet port side rises,

pt
generating rotation resistance on the motor
to prevent the machine from losing control. ZX75-1002069
g no
in ti
et a
n
rk er
Ma t
In

4-80 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.4.11 Control System

4 5 6

H
G E
F
K L

.
C A

De al
B

pt
g no
I J
in ti
et a
n

1 2 3 8 7
rk er

ZX75-1002070
Ma t

1) Travel control valve A: Arm IN

2) Arm/Swing control valve B: Swing LEFT
In

3) Boom/Bucket control valve C: Arm OUT

4) Dozer blade control valve D: Swing RIGHT
5) Pilot filter E: Boom UP
6) Oil source control valve F: Bucket DIG
7) Hydraulic pump G: Boom DOWN
8) Main control valve H: Bucket DUMP
I: Travel FORWARD
J: travel BACKWARD
K: Dozer blade UP
L: Dozer blade DOWN

Shop Manual - November 2012 4-81

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.4.11.1 Work equipment and swing pilot

valve

SY65C3

Left pilot valve schematics

P 1
P T
2 T

4
3

.
1 2 3 4

De al
pt
Right pilot valve schematics
g no P T
in ti

0.6 0.6
et a

1 2 3 4
n
rk er
Ma t
In

ZX65-1002013

a- Port P (From oil source control valve) d- Port 4 (L: Swing RIGHT/R: Bucket DIG)
b- Port T (To oil tank) e- Port 3 (L: Arm OUT/R: Boom UP)
c- Port 2 (L: Swing LEFT/R: Bucket DUMP) f- Port 1 (L: Arm IN/R: Boom DOWN)

4-82 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

5 7

3 9

2 10

.
De al
pt
11
g no
in ti
et a
n
rk er
Ma t
In

ZX55-1002078

1) Valve spool 7) Connector

2) Metering spring 8) Plate
3) Centering spring 9) Retainer
4) Plunger 10) Valve body
5) Disc 11) Filter element
6) Nut (for lever connection)

Shop Manual - November 2012 4-83

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

SY75C3, SY75C9

Left pilot valve schematics

X X

.
0.6

De al
pt
3 2 1 pT 4

g no
in ti
Right pilot valve schematics
et a
n
rk er
Ma t

0.8 0.8
Section X-X
In

Y-Y
3 2 1 pT 4

T
Y Y
2 P 4
M

ZX75-1002071

4-84 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

Operating process

1. When in neutral position

● Ports (A) and (B) of the control valve and

ports (P1) and (P2) of the pilot valve are
connected to drain chamber (D) via fine D
control orifice (f) of valve spool (1). f T
P
2. Fine control (Neutral → fine control)
1

● When plunger (4) is pushed by disc (5), re- P1 P2

tainer (9) is also pushed down, valve spool

.
(1) is also pushed by metering spring (2),

De al
and moves downward. A

pt
Control valve B
Reducing
● Meanwhile, fine control orifice (f) is shut valve
g n
off from drain chamber (D). At almost the
o
same time, it is interconnected to pump
PPilot

ZX75-1002072
pressure chamber (PP). Pilot pressure
in ti
from port (Ppilot) of main control valve pass-
es fine control orifice (f) and flows to port (A)
via port (P1).
et a
n

● When the pressure at port (P1) rises, valve

spool (1) is pushed back and fine control 5
rk er

orifice (f) is shut off from pump pressure 4

chamber (PP). At almost the same time, it
communicates with drain chamber (D) to
Ma t

9
release the pressure at port (P1).
In

2 D
● As a result, valve spool (1) moves up and f T
down so that the force of metering spring P
(2) is balanced with the pressure at port
(P1). 1
Pp

P1 10
P2
● The position relationship between valve
spool (1) and valve body (10) (fine control
orifice (f) is at a certain point between drain A B
Control valve
chamber (D) and pump pressure chamber
Reducing
PP ) does not change until retainer (9) con- valve
PPilot
tacts valve spool (1).
ZX75-1002073

● Metering spring (2) contracts in proportion

to control lever stroke. Pressure at port (P1)
also rises in proportion to lever stroke.

Shop Manual - November 2012 4-85

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

● 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.
3. Fine control (When control lever returns)
5

● When disc (5) starts to return, valve spool 4

(1) is pushed up by the force of centering
spring (3) and the pressure at port (P1).
3

● As a result, the fine control orifice (f) be- 2 D

comes communicative with drain chamber T

.
f

De al
(D), and the pressurized oil at port (P1) is P
f＇

pt
released.
1
Pp
g n
● If the pressure of port (P1) is lowered too
much, valve spool (1) will be pushed down
o P1 P2

by metering spring (2) and fine control ori-

in ti
fice (f) will be shut off from drain chamber A
Control valve
B
(D). At almost the same time, fine control Reducing
orifice is interconnected with pump pres- valve
PPilot
et a

sure chamber (PP). Pump pressure is

ZX75-1002074
supplied until the pressure at port (P1) re-
n

covers to the level equivalent to the lever

rk er

position.

● When the control valve returns, oil in the

5
Ma t

drain chamber (D) flows to port P2 and en-

ters chamber B via the fine control orifice (f') 4
In

at the unmoving side and fill this chamber.

9
4. At full stroke
D
● When disc (5) pushes plunger (4) down- f T
ward, retainer (9) pushes valve spool (1) P
downward, and fine control orifice (f) is
shut off from drain chamber (D) and inter- 1 Pp
connected with pump pressure chamber
P1 P2
(PP). Therefore, pressurized oil from main
control valve port (Ppilot) passes through fi
ne control orifice (f) and flows into cham- A B
Control valve
ber (A) via port (P1) and shifts the control
Reducing
valve spool. Return oil in chamber (B) valve
PPilot
passes through orifice (P2) and flows into
drain chamber (D) via fine control orifice (f'). ZX75-1002075

4-86 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.4.11.2 Travel pilot valve

SY65C3

c e

f
d

.
De al
pt
g no
in ti
et a
n
rk er
Ma t

a
In

ZX55-1002083

a- Port P (from oil source control valve) d- Port P3 (right forward)

b- Port T (to oil tank) e- Port P2 (left reverse)
c- Port P1 (left forward) f- Port P4 (right reverse)

Shop Manual - November 2012 4-87

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

SY75C3, SY75C9

e
f

.
De al
c
d

pt
g no
in ti
P T
et a
n
1
rk er
3
Ma t

a b
In

ZX75-1002076

a- Port P (from oil source control valve) d- Port P3 (right forward)

b- Port T (to oil tank) e- Port P2 (left reverse)
c- Port P1 (left forward) f- Port P4 (right reverse)

4-88 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

Operating process

1. When in neutral position

● Ports (A) and (B) of the control valve and D

ports (P1) and (P2) of the pilot valve are
connected to drain chamber (D) via fine
control orifice (f) of valve spool (1). f

Oil source control valve

T
2. Fine control (Neutral → fine control) P

1
● When the plunger (4) is pushed by disc
(5), retainer (9) is also pushed down, valve
spool (1) is also pushed by metering spring P1 P2

.
De al
(2), and moves downward.

pt
A B
● Meanwhile, fine control orifice (f) is shut Control valve

g n
off from drain chamber (D). At almost the
same time, it is interconnected to pump
o ZX55-1002084

pressure chamber (PP). Pilot pressure

in ti
from the oil source control valve passes
through the fi ne control orifi ce (f) and fl
ows to port (A) via port (P1).
et a

● When pressure at port (P1) rises, valve

n

spool (1) is pushed back and fine control

orifice (f) is shut off from pump pressure
rk er

5
chamber (PP). At almost the same time,
it becomes communicative with the drain 4

chamber (D) to release the pressure at D

Ma t

9
port (P1).
2
In

Oil source control valve

f
● As a result, the valve spool (1) moves up T
and down so that the force of metering P
spring (2) is balanced with the pressure at
1
port (P1).
Pp
P1 P2
● The position relationship between valve 10
spool (1) and valve body (10) (fi ne con-
trol orifi ce (f) is at a certain point between A Control valve B

drain chamber (D) and pump pressure

chamber PP ) does not change until retain- ZX55-1002085

er (9) contacts valve spool (1).

● Metering spring (2) contracts in proportion

to control lever stroke. Pressure at port (P1)
also rises in proportion to lever stroke.

Shop Manual - November 2012 4-89

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

● 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. 5

3. Fine control (When control lever returns)

D
● When disc (5) starts to return, valve spool 3
2
(1) is pushed up by the force of centering

Oil source control valve

spring (3) and the pressure at port (P1). f T
P
● As a result, fine control orifice (f) is con- f
nected to drain chamber (D), and the pres- 1

.
surized oil at port (P1) is released. Pp

De al
P1 P2

pt
● If the pressure of port (P1) is lowered ex-
cessively, valve spool (1) will be pushed A B
g n
down by metering spring (2) and fine con-
o
trol orifice (f) will be shut off from drain
Control valve

ZX55-1002086

chamber (D). At almost the same time, fine

in ti
control orifice is interconnected with pump
pressure chamber (PP). Pump pressure
is supplied until the pressure at port (P1)
et a

recovers to the level equivalent to the lever

position.
n
rk er

● When the control valve returns, oil in the 5

drain chamber (D) flows in drain chamber 4
(D) via the fine control orifice (f') at the un- D
Ma t

moving side and then flows into chamber 9

(B) via port P2 and fill this chamber.
Oil source control valve
In

f T
4. At full stroke P
f

● When disc (5) pushes plunger (4) down- 1

ward, retainer (9) pushes valve spool (1) Pp
downward, and fine control orifice (f) is P1 P2
shut off from drain chamber (D) and inter-
connected with pump pressure chamber A Control valve B
(PP). Therefore, pressurized oil from the
oil source control valve passes fi ne control ZX55-1002087
orifice (f) and flows into chamber (A) via
port P1 and moves the control valve spool.

● Return oil in chamber (B) passes orifice P2

and flows into drain chamber (D) via fine
control orifice (f').

4-90 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.4.11.3 Option pilot valve

.
b

De al
pt
g no
in ti

c d
et a

5
n

4
6
rk er

3
Ma t

2
In

ZX55-1002024

a- Port T (to oil tank) 1- Valve spool

b- Port P (from oil source control valve) 2- Metering spring
c- Port P1 3- Centering spring
d- Port P2 4- Plunger
5- Lever
6- Plate
7- Retainer
8- Valve body

Shop Manual - November 2012 4-91

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Operating process

1. When in neutral position

● Ports (A) and (B) of the control valve and

ports (P1) and (P2) of the pilot valve are
connected to drain chamber (D) via fine
control orifice (f) of valve spool (1).
D
2. Fine control (Neutral → fine control)
T
● When plunger (4) is pushed by lever (5),
retainer (7) is also pushed down, valve f P
spool (1) is also pushed by metering spring

.
De al
(2), and moves downward. 1

pt
P1 P2
● Meanwhile, fine control orifice (f) is shut Oil source
control valve
g n
off from drain chamber (D). At almost the
same time, it is interconnected to pump
o
pressure chamber (PP). Pilot pressure A Control valve B
ZX55-1002088
in ti
from the oil source control valve passes fi
ne control orifice (f) and flows to port (A)
via port (P1).
et a

● When pressure at port (P1) rises, valve

n

spool (1) is pushed back and fine control

orifice (f) is shut off from pump pressure
rk er

5
chamber (PP). At almost the same time, it
is connected to drain chamber (D) to re- 4
lease the pressure at port (P1).
Ma t
In

● As a result, valve spool (1) moves up and

D
down so that the force of metering spring
(2) is balanced with the pressure at port 7 T
(P1). 8
2 P
● The position relationship between valve
f
spool (1) and valve body (8) (fine control
orifi ce f is at a certain point between drain 1
P1 P2 PP
chamber (D) and pump pressure chamber Oil source
PP ) does not change until retainer (7) con- control valve

tacts valve spool (1).

A Control valve B
ZX55-1002089
● Metering spring (2) contracts in proportion
to the stroke of the control lever. Pressure
at port (P1) also rises in proportion to the
stroke of the control lever.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

● 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
5
the force of the return spring of the control
valve spool are balanced.
4
3. Fine control (When control lever returns)

● When lever (5) starts to return, valve spool

(1) is pushed up by the force of centering 3 D
spring (3) and the pressure at port (P1).
T
2 8
● As a result, the fine control orifice (f) is
P
connected to drain chamber (D), and the f

.
pressurized oil at port (P1) is released. f

De al
pt
1
● If the pressure of the port (P1) is lowered P1 P2 PP
excessively, valve spool (1) will be pushed Oil source
g n
down by metering spring (2) and fine con-
trol orifice (f) will be shut off from drain
o
A Control valve B
control valve

chamber (D). At almost the same time, fi ZX55-1002090

in ti
ne control orifice is interconnected with
pump pressure chamber (PP). Pump pres-
sure is supplied until the pressure at port
et a

(P1) recovers to the level equivalent to the

lever position.
n

5
rk er

● When the control valve returns, oil in the

drain chamber (D) flows in drain chamber 4
(D) via the fine control orifice (f') at the un-
Ma t

moving side and then flows into chamber

(B) via port P2 and fill this chamber. 7 D
In

4. At full stroke T
2 8
● When lever (5) pushes plunger (4) down- P
f
ward, retainer (7) pushes valve spool (1) f
downward, and fine control orifice (f) is
1
shut off from drain chamber (D) and inter- P1 P2
PP
connected with pump pressure chamber Oil source
control valve
(PP). Therefore, pressurized oil from the
oil source control valve passes fi ne control
A Control valve B
orifice (f) and flows into chamber (A) via ZX55-1002091
port P1 and moves the control valve spool.

● Return oil in chamber (B) passes orifice P2

and flows into drain chamber (D) via fine
control orifice (f').

Shop Manual - November 2012 4-93

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.4.12 Hydraulic cylinder

Dozer cylinder

1 2

.
De al
pt
g n
7
o 6 5 4 3

ZX75-1002086
in ti
1) Grease fitting 5) Piston
2) Cylinder barrel 6) Piston rod
et a

3) Bottom bushing 7) Top bushing

4) Locknut
n
rk er

Boom Arm Bucket Dozer

Cylinder bore 110 90 80 130
Ma t

Piston rod O.D. 65 60 50 70

In

Stroke 885 900 730 145

Max. stroke 885+1,311 900+1,300 1,120+730 565+145
Min. stroke 1,311 1,300 1,120 565
Piston nut square size 70 65 60 80

4-94 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.4.13 Work equipment

4 5

.
3

De al
pt
6
2
g no
in ti
et a

1
n
rk er

7 8
ZXT75-1002087
Ma t

1) Bucket 5) Boom
In

2) Bucket cylinder 6) Boom cylinder

3) Arm 7) Dozer blade
4) Arm cylinder 8) Dozer blade cylinder

Shop Manual - November 2012 4-95

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.5 Electrical Control System

4.5.1 General

Engine control function

Valve control function

.
Auto-deceleration function

De al
pt
Electrical control system

g no Engine preheating and over-

heating protection function
in ti

Travel control function

et a
n

Self-diagnosis function
rk er
Ma t
In

4-96 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.5.2 Electronic control system diagram

BATTERY BATTERY RELAY

FUEL CONTROL DIAL

FUEL CONTROL DIAL SIGNAL

START SWITCH

POWER

.
De al
POWER SIGNAL WORKING MODE SELECTION
TRAVEL SPEED SELECTION

pt
AUTO IDLE SELECTION

START SIGNAL
g no POWER

THROTTLE POSITION SIGNAL

ENG. RORATION SIGNAL THROTTLE

INTEGRATE CONTROL
in ti
RELAY
CONTROLLER ENG. REVERSE SIGNAL UNIT

SAFETY RELAY
et a
n
rk er
Ma t
In

ENG.SPEED SENSOR

OIL PRESS.SWITCH

WATER TEMP SENSOR

HIGH TEMP SWITCH

AIR FILTER CLOG SW ENGINE

STARTER MOTOR
ALTERNATOR

PREHEAT LOW TEMP SWITCH

CONTROLLER
PREHEAT PLUG

ZX75-1204007

Shop Manual - November 2012 4-97

4-98
Starter
24V-3.2KW Safety relay Preheat fuse
5 12 C
50R 21 C Preheat controller
5 B
M
+ - T-103 21 16 T-109
Battery relay
B R S E 5 5
21 60 70 0
T-132 T-131

5
1.25
1.25
1.25
50B 20 21 21 5 171 2 16 5
- + 50R B M 5 5 0.8568 140.85 0.85 14 66 0.85
0 3 4 0.85 61 1 2 0 0.85
E BR 15 3 5
5B 2 Charge indicator Preheat relay 0.85 68 69 0.85
Preheat plug 4 6
In
5B 0 21 L 14 0.85 T-106 CN-134M
B V5 14
1.25B 0 5 R 14 0.85
Structure and Function

0.85B 0 1.25 Preheat indicator

E
6 63
64 3 5 65
Ma t
Alternator 24V-30A 14 62 1 2
0
Start switch
2
启动 ON OFF
21
22 2 5 Park relay
B
Br 62

5W
R1
4.5.3 Diagram of electrical circuit

Acc
13
Throttle control
rk er
R2
61
mechanism
C
11
n 00 3
CN-139F

507
4 2
50
70 5 1 M
Shutdown relay 3 11
4 Start relay 1 2 602 701
et a
Horn 23 V3 4
15 5 3 21 601 3
F-103 F-104 0.85 009
1 2 603 2
Integrated monitor 010
4 1

1.25

5
1.25
1.25

2
1.25
1.25
1.25
1.25

1.25
32 5 3 Wire Terminal Terminal
20 13 20 21 21 21 20 21 20 21
Air cleanor
0 1 2 31 23 43 34 1 CAN-L
clogging alarm
p
● Refer to Chapter 11 for a better view of this drawing.

0.85 0 1 2 3 4 5 6 7 8 9 10 Lighter 000 33 2 CAN-H

HA1 103 CN-105M
20 15 10 10 10 15 10 15 15 10 CN-225M
in ti
32 3 108b
A A A A A A A A A A 105 Pilot s/w CN-205F
o

Fuse box
509 31 4 11
Cab lamp 506 506 30 5 13
23 22 14 23 24 25 38 43 42 100
100 0 Fuel control dial

5
2
0.85 0 50 511 29 6 Pilot oil pressure

1.25
1.25
1.25
1.25
1.25
CN-501M

1.25R
1.25
g n 00 603 28 CN-117F

Shop Manual - November 2012

Check lamp 7
511
T-203 T-204 602 27 8 00 50
23 607 26 9 50 00
0.85 43 801 43 25 10
CN-701 00 24 11 010 108 CN-125F
24
S2 Sol valve, travel 510 23 12 103
CN-108M 607 22 13 105 Hi temp alarm s/w
106
4 507 21 14 106 T-115
25
De al
57 3 5 38 601 20 15 508 508 Oil press s/w
K6 33 56 2 1 701 19 16 009
86 87 S3 SB2 Sol valve, pilot 509 T-119
25 0 0 57 34 CN-107M 606 18 17 42
85 30 56 55 0.85 606 Fuel level sensor
CN-101F
35 36 37 51 52 A/C

clutch
34 510
Temp sensorT-118
pt

0.85
0.85
0.85
0.85

0.85
Electromagnetic
L R

A/C compressor
M M3 M C.P

M2 A/C panel

Work lamp
Wiper
Washer Speaker CN-206F
.

ZX75-1204002
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.5.4 Engine control function

Engine

Throttle control
unit
Speed sensor

Engine positive rotation signal

.
De al
pt
Engine reverse signal
Throttle position signal
Speed signal

g n
Fuel control dial
o
in ti
et a

Integrated controller
n
rk er

ZX75-1204008
Ma t
In

Function

● Operator can switch the working mode to S or L on the panel of integrated control monitor.

● Speed governor detects the speed of the engine fuel control device set by the fuel control dial
and the real engine speed.

Control method of working mode

1 2 3 4 5 6 7 8 9 10 11
S Mode 1100 1200 1300 1400 1500 1650 1800 1900 2000 2200 2200
L Mode 1100 1100 1200 1300 1400 1500 1650 1800 1900 2100 1900
B Mode 1500 1500 1500 1500 1500 1650 1800 1900 2000 2200 2200

Shop Manual - November 2012 4-99

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.5.5 Valve control function

Joysticks

Engine

Main pump
Main valve
Throttle control
Engine positive rotation signal unit

.
De al
Throttle position signal

Engine reverse signal

pt
g n
Pilot lockout
switch
o
Reducing
valve
in ti

Integrated controller
et a
n
rk er
Ma t

Pilot solenoid
valve
In

ZX75-1204009

4-100 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.5.6 Auto deceleration function

Joysticks

Engine
Main pump

Main Press. sensor

valve
Throttle control
unit
Speed sensor
Eng positive rotation signal

Throttle position signal

Engine reverse signal

.
De al
Speed signal

pt
Fuel control dial

g no
in ti
Integrated controller

ZX75-1204010
et a
n
rk er

Function

● If all control levers are neutralized for more than 5 minutes when machine operation is sus-
Ma t

pended, engine speed drops to 1400 rpm automatically in order to reduce fuel consumption
and noise.
In

● Once a control lever is operated, engine speed rises to the preset speed immediately.

Shop Manual - November 2012 4-101

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.5.7 Engine preheating and overheating protection function

Lo-temp S/W Hi-temp S/W

Engine Temp sensor

Preheat plug
Throttle control
unit
Speed sensor

Engine positive rotation signal

.
De al
Engine reverse signal
Throttle position signal
Temperature signal

pt
Preheat
Speed signal

controller

g no
in ti
Hi-temp signal

Integrated controller
et a
n
rk er

Function

● If coolant temperature is lower than the preset value when start switch is turned to the ON
Ma t

position, low temperature switch is turned on and the preheating plug is energized to heat the
coolant.
In

● If coolant temperature is higher than the preset value after the engine has been started, high
temperature switch will be turned on. The controller reduces engine speed to the predeter-
mined speed in order to protect the engine.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

1. Auto preheating function

Operating condition
Operation
Start switch turned to ON
Coolant temperature below 3 Engine preheating starts

Operating condition
Operation
Start switch turned to ON Engine preheating ends

.
Coolant temperature above 3

De al
pt
g no
2. Overheat protection function
in ti

Operating condition
Operation
et a

Engine runs at high speed

Engine speed drops to 1100r/min
Coolant high temp switch ON
n
rk er
Ma t

Operating condition
Operation
In

Engine runs at high speed

Engine resums previous speed
Coolant high temp switch OFF

Shop Manual - November 2012 4-103

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.5.8 Travel control selection

Joysticks

Engine

Main pump
Main
valve Press. sensor

.
De al
Pilot lockout Hi-spd travel S/W

pt
switch

Pilot reducing
valve
g no
Integrated controller
in ti
et a

Pilot solenoid
valve
n
rk er

Travel speed Left/Right travel motor

solenoid valve
Ma t

ZX75-1204011
In

Function

● Default travel speed is Low. Travel speed turns Hi when the Hi/Lo Speed switch on the moni-
tor is pressed.

Travel speed shift function

● Default travel speed is Lo. Once the Hi/Lo Speed switch on the monitor is pressed, travel
speed is switched to Hi, the monitor actuates the Hi speed travel solenoid and the left/right
travel motor capacity decreases. Press this switch again, travel speed returns to Lo.

Hi/Lo travel speed switch Low speed (Lo) High speed (Hi)
Travel motor capacity Max. Min.
SY65C: 2.25 SY65C: 4.31
Travel speed (km/h)
SY75C: 2.47 SY75C: 4.63

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.6 Integrated Control Monitoring System

4.6.1 Monitor

A B 8 9 10 11

SANY HYDRAULIC EXCAVATOR SANY HYDRAULIC EXCAVATOR

S
1 5 S Please put the gear to 1 N!
11

.
De al
pt
6
2
Manual idle speed in process 20

F1
g no
F2 F3 F4 3
7 19
in ti
12 13 14 15 16 17 18
ESC Enter
4
et a
n

ZX75-1002089
rk er

1) Display Screen 11) Engine Speed Indicator

2) Guidance Icons 12) Operating Mode (F1)
Ma t

3) Function Keys 13) Idle/Full Speed (F2)

4) Navigation Keys 14) Fault Code
In

5) Working Mode Indicator 15) Maintenance Indicator

6) Coolant Temperature 16) GPS Signal Indicator
7) Service Hour Meter 17) Hi/Lo Speed Switch
8) Fuel control Level Indicator 18) Menu Key (F4)
9) Date 19) System Time
10) Fuel Level 20) Manual Idle Speed

1. General
● The monitor panel has two functions: moni- and outputs data.
toring and working mode selection.
● The display screen is an LCD (Liquid Crys-
● The monitor has a built-in CPU (Central tal Display) monitor
Processing Unit) which processes, displays

Shop Manual - November 2012 4-105

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2. Input and output signal

Pin No. Signal Name Input/Output

1 CAN- Output
2 CAN+ Output
3 Engine speed sensor Input
4 Start signal Input
5 Shutoff signal Input
6 N/A —
7 N/A —

.
8 Ground Input

De al
9 5V Power Output

pt
10 N/A —
11
12
g no Throttle motor A+
Air cleaner switch
Output
Input
13 Pilot switch Input
in ti
14 Hi-temp switch Input
15 Oil pressure switch signal Input
et a

16 Throttle motor A- Output

17 24V power supply Input
n

18 Pilot solenoid valve drive Output

rk er

19 Throttle motor B+ Output

20 Throttle motor B- Output
Ma t

21 Throttle position signal Input

22 N/A —
In

23 Temperature sensor Input

24 Ground Input
25 +24V permanent power source Input
26 Hi speed travel solenoid valve drive Output
27 Start relay drive Output
28 Shutdown relay drive Output
29 LS oil pressure signal Input
30 Fuel control dial signal Input
31 Fuel level sensor signal Input
32 N/A —
33 Ground Input
34 +24V permanent power source Input

4-106 Shop Manual - November 2012

 Starter
24V-3.2KW Safety relay Preheat fuse
5 12 C
50R 21 C Preheat controller
5 B
M
+ - T-103 21 16 T-109
Battery relay
B R S E 5 5
21 60 70 0
T-132 T-131

5
1.25
1.25
1.25
50B 20 21 21 5 171 2 16 5
- + B M 5 5 0.85 14 66 0.85
In
50R 0.8568 140.85
0 3 4 0.85 61 1 2 0 0.85
E BR 15 3 5
5B 2 Charge indicator Preheat relay 0.85 68 69 0.85
Preheat plug 4 6
5B 0 21 L 14 0.85 T-106 CN-134M
B V5 14
1.25B 0 5 R 14
0.85B 0 0.85 Preheat indicator
Ma t
1.25
E
3. Electrical circuit diagram

6 63
64 3 5 65
Alternator 24V-30A 14 62 1 2
0
Start switch
2
启动 ON OFF
21
22 2 5 Park relay
rk er
B
Br 62
n

5W
R1
Acc
13
Throttle control
R2
61
11 mechanism
C CN-139F
00 3
et a
507
4 2
50
70 5 1 M
Shutdown relay 3 11
4 Start relay 1 2 602 701
Horn 23 V3 4
15 5 3 21 601 3
F-103 F-104 0.85 009
1 2 603 2
Integrated monitor 010
4 1

1.25

5
1.25
1.25

2
1.25
1.25
1.25
1.25

1.25
Wire Terminal Terminal
in ti
32 5 3 Air cleanor
23 20 13 20 21 21 21 20 21 20 21 43 34 1 CAN-L
0 1 2 31
o clogging alarm
p

0.85 0 1 2 3 4 5 6 7 8 9 10 Lighter 000 33 2 CAN-H

HA1 103 CN-105M
20 15 10 10 10 15 10 15 15 10 CN-225M 32 108b
3
A A A A A A A A A A 105 Pilot s/w CN-205F

Fuse box
509 31 4 11
Cab lamp
23 22 14 23 24 25 38 43 42 100
g n 506 506 30 5 13
100 0 Fuel control dial

5
2
0.85 0 50 511 29 6 Pilot oil pressure

1.25
1.25
1.25
1.25
1.25
CN-501M

1.25R
1.25
00 603 28 CN-117F

Shop Manual - November 2012

Check lamp 7
511
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

T-203 T-204 602 27 8 00 50

23 607 26 9 50 00
0.85 43 801 43 25 10
CN-701 00 24 11 010 108 CN-125F
24
23
De al
S2 Sol valve, travel 510 12 103
CN-108M 607 22 13 105 Hi temp alarm s/w
106
4 507 21 14 106 T-115
25 57 3 5 38 601 20 15 508 508 Oil press s/w
K6 33 56 2 1 701 19 16 009
86 87 S3 SB2 Sol valve, pilot 509 T-119
25 0 0 57 34 CN-107M 606 18 17 42
85 30 56 55 0.85 606 Fuel level sensor
pt
CN-101F
35 36 37 51 52 A/C

clutch
34 510
Temp sensorT-118

0.85
0.85
0.85
0.85
.

0.85
Electromagnetic
L R

A/C compressor
M M3 M C.P

M2 Washer Speaker CN-206F A/C panel

Wiper
Work lamp

ZX75-1204002

4-107
Structure and Function
Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.6.2 Monitor items and display

Screen display [1]

This is the operation interface in normal work-

ing condition, which displays working modes, SANY HYDRAULIC EXCAVATOR
current date, gear warning, gear position, wa-
ter temperature, fuel level, manual idle speed S 11
Please put the gear to 1 N!
indication, working hours, alarm notice, main-
tenance notice, lock indication, real-time time
display, etc.. The working conditions can be
set as well. Manual idle speed in process

.
De al
pt
Function Keys [3]

g n
The functions of the 4 keys are determined by
the 4 guidance icons [2] on the screen.
o ZX75-1002091
in ti
● F1: Switch working modes to S or L.

● F2: Choose full-speed or idle-speed.

et a

● F3: Choose high-speed or low-speed.

n

● F4: Go to “SYSTEM INFORMATION”.

rk er

Navigation Keys [4]

Ma t

[↑], [↓], [←], [→] are used to move the image,

In

select lists and modify data.

[↓]: Go to "FAILURE INFORMATION"

[→]: Go to “MAINTENANCE INFORMATION”

when maintenance is required.

Enter: Select an entry.

ECS: Return to the previous display or reject a

menu option.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

Coolant Temperature Indicator [6]

This gauge shows the temperature of the cool-

ant. The indicator points to the GREEN range
on the gauge when the machine is work-
ing. Normal coolant temperature is less than
103°C.

ZX75-1002092

.
Fuel Level Gauge [10]

De al
pt
Refuel the engine before the indicator points
to the RED range.
g no
in ti
et a
n
rk er

ZX75-1002093
Ma t
In

Shop Manual - November 2012 4-109

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4.6.3 Main screen function

1. SYSTEM INFORMATION

A password is needed to access SYSTEM IN- SYSTEM INFORMATION

FORMATION.
PLS ENTER PASSWORD FOR SYS INFO
Keypad control
1
● [↑], [↓]: Increase or decrease the digit value
at where the cursor is located.

● [←], [→]: Move the cursor to the left or

right digit.

.
● F1: Go to “SYSTEM UNLOCK”

De al
pt
● F2: Go to “DATE & TIME SETUP” 2 3 4 5 ZX75-1002094

● F3: Check the validity of password. If the

g n
password is valid, the screen changes to
o
show “INFORMATION MENU”.
in ti
● F4: Return to “HOME”.

● ESC: Return to “HOME”

et a

● Enter: Check the validity of password. If

n

the password is valid, the screen changes

to show “INFORMATION MENU”.
rk er

Screen display

3) A 5-digit SYSTEM INFORMATION pass-

Ma t

word. Each digit is shown by an asterisk (*)

In

standing for a number valued from 0 to 9.

The asterisk will become a number once
the cursor moves there. Press F3 to turn
all digits into asterisks.

4) Go to “SYSTEM UNLOCK” when F1 is

pressed.

5) Go to “DATE & TIME SETUP” when F2 is

pressed.

6) Press F3 to check the validity of password.

If the password is valid, the screen chang-
es to show “INFORMATION MENU”. If not,
you will be prompted by “INVALID PASS-
WORD! TRY AGAIN!”.

7) Go to “HOME” when F4 is pressed.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

2. INFORMATION MENU
INFORMATION MENU
This display lists system functions. Access an 1 OPERATING INFORMATION
entry by selecting an option. MACHINE CONFIGURATION
FAILURE INFORMATION
MAINTENANCE INFORMATION
Keypad control GPS INFORMATION
ENG SPEED LEVEL & RPM CALIBRATION
SYSTEM LANGUAGE SETUP

● [↑] , [↓]: Scroll through the list of options.

2 PARAMETERS OF ENGINE, MAIN PUMP AND MAIN VALVE

● F2: Enter the highlighted entry.

● F3: Go to “SYSTEM SETUP”.

● F4: Go to “HOME”. 3 4 5
ZX75-1002095

.
De al
● ESC: Return to “HOME”.

pt
Screen display

g n
1) List of system functions
o
2) Brief description of the highlighted entry.
in ti
3) Press F2 to access the selected entry.

4) Press F3 to go to “SYSTEM SETUP”.

et a

5) Press F4 to return to “HOME”.

n

3. ENGINE & THROTTLE SIGNALS ENGINE & THROTTLE SIGNALS

rk er

These indicators show the operating param- 1 COOLANT TEMP : 123.4 FUEL CTRL DIAL N:11
eters of the engine.
Ma t

FUEL LEVEL %: 123.4 GEAR VOLT V:1.23

OIL PRESSURE: OK ENGINE RPM:1234

In

Keypad control LS PRESS MPA:12.3 THROTTLE VOLT V:1.23

● F1: Go to “Inquiry of switch signal” .

● F4: Go to “Information list”.

● ESC: Return to "Information list".

2 3
ZX75-1002096
Screen display

1) A real-time display of engine signals col-

lected by the control system.

2) Press F1 to view “SWITCH SIGNALS”.

3) Press F4 to go to “INFORMATION MENU”

Shop Manual - November 2012 4-111

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. SWITCH SIGNALS
SWITCH SIGNALS

This indicator shows the switch input and out-

1 START INPUT START OUTPUT
put signals
AIR CLEANER CLOGGING PREHEAT OUTPUT

SHUTDOWN INPUT SHUTDOWN OUTPUT

Keypad control
PILOT INPUT PILOT OUTPUT

SPEED INPUT SPEED OUTPUT

● F1: Go to “SECD-3I SYSTEM INFORMA-
TION”.

● F4: Go to “INFORMATION MENU”.

2 3
● ESC: Return to “INFORMATION MENU”. ZX75-1002097

.
De al
pt
Screen display
g n
1) A Real-time display of throttle System I/O
o
signals in the controller.
in ti
2) Press F1 to go to “SECD-3I SYSTEM IN-
FORMATION”. MACHINE CONFIGURATION
et a

3) Press F4 to return to “INFORMATION

1 MACHINE MODEL: SY65C
n

MENU”. MACHINE NUMBER: 00000

rk er

CONTROL SYSTEM: SECD-3I

5. MACHINE CONFIGURATION
Ma t

The screen displays the key parts information

of the machine.
In

Keypad control 2
ZX75-1002098

● F4: Go to “INFORMATION MENU”.

● ESC: Return to “INFORMATION MENU”.

Screen display

1) Machine configuration information.

2) Press F4 to Go to the “INFORMATION

MENU”.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

6. FAILURE INFORMATION
FAILURE INFORMATION
The screen displays failure codes and failure
information. CURRENT FAILURE CODE: 2 3
1 CHECK FAILURE DESCRIPTION AS PER CODE NUMBER.

Keypad control 1 OIL PRESSURE TOO LOW

2. FUEL LEVEL TOO LOW
● F4: Go to “HOME”. 3. COOLANT TEMPERATURE TOO HIGH
4. AIR FILTER CLOGGED
● ESC: Return to “HOME”, and turn off the 5. ENGINE SCUFFING
buzzer. 6. OVERVOLTAGE

Screen display

1) A list of failure information corresponding 2

to failure codes.

.
ZX75-1002099

De al
pt
2) Press F4 to return to “HOME”

3) Failure codes

Remark:
g no
The failure codes display is rolling every 2
in ti
seconds.
7. MAINTENANCE INFORMATION
et a

The screen displays maintenance information

n

in 50 hours.
rk er

Keypad control

● F1: Waiting for confirmation when the

Ma t

maintenance is completed.
In

● F3: Start/Pause the rolling display of main-

tenance information.

● F4: Go to “HOME”

Screen display

1) Display current maintenance period.

2) Display current maintenance information.

3) When [F1] is pressed, maintenance confir-

mation sign is shown: a red “√”.

4) When [F3] is pressed,the rolling display of

maintenance period and maintenance in-
formation is started or paused.

5) Press F4 to return to “HOME”.

Shop Manual - November 2012 4-113

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

50 Hours maintenance schedule

MAINTENANCE INFORMATION

1 50 H MAINTENANCE SCHEDULE
2 1. ENG OIL AND OIL FILTER - REPLACE
2. FAN BELT TENSION - CHECK AND ADJUST
3. BOLT AND NUT TIGHTENING TORQUE -

3 4 5
ZX75-1002100

.
De al
pt
250 Hours maintenance schedule
MAINTENANCE INFORMATION
g no
1 250 H MAINTENANCE SCHEDULE
1. SWING REDUCER ASSY BEARING GREASE - ADD
2
2. SWING REDUCER ASSY GEAR OIL LEVEL - CHECK
in ti
3. AIR CLEANER OUTER ELEMENT - CLEAN
4. ENG OIL AND OIL FILTER - REPLACE
5. FUEL FILTER ELEMENT - REPLACE
et a
n
rk er

3 4 5
ZX75-1002101
Ma t
In

500 Hours maintenance schedule

MAINTENANCE INFORMATION
1 500 H MAINTENANCE SCHEDULE
2 1. 250-HOUR MAINTENANCE
2. SWING BEARING LUBRICANT - ADD
3. SWING BEARING INTERNAL GEAR LUBRICANT- ADD
4. TRAVEL REDUCER ASSY GEAR OIL LEVEL - CHECK
5. RETURN/SUCTION/PILOT FILTER ELEMENT - REPLACE
6. FAN BELT TENSION - ADJUST
7. RADIATOR INSIDE/OUTSIDE SURFACE - CLEAN
8. TRACK DEFLECTION - CHECK
9. OIL COOLER FRONT STRAINER - CLEAN
10. AIR CLEANER ELEMENT - REPLACE

3 4 5
ZX75-1002102

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

1000 Hours maintenance schedule

MAINTENANCE INFORMATION

1 1000 H MAINTENANCE SCHEDULE

2 1. 500-HOUR MAINTENANCE
2. START MOTOR AND ALTERNATOR - CHECK
3. SWING REDUCER ASSY GEAR OIL - REPLACE
4. TENSIONER - RELEASE GREASE AND RETIGHTEN

3 4 5
ZX75-1002103

.
De al
pt
2000 Hours maintenance schedule
MAINTENANCE INFORMATION
g no 1
2
2000 H MAINTENANCE SCHEDULE
1. 1000-H MAINTENANCE
2. TRAVEL REDUCER ASSY GEAR OIL - REPLACE
in ti
et a
n
rk er

3 4 5
ZX75-1002104
Ma t
In

4000 Hours maintenance schedule

MAINTENANCE INFORMATION

1 4000 H MAINTENANCE SCHEDULE

1. 2000-HOUR MAINTENANCE
2
2. HOSE - REPLACE
3. WATER PUMP GREASE - REPLACE

3 4 5
ZX75-1002105

Shop Manual - November 2012 4-115

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8. GPS MONITORING INFORMATION

GPS MONITORING INFORMATION
The screen displays GPS monitoring informa-
tion. 1 LONGITUDE O: .000000E

LATITUDE O: .000000S

ALTITUDE M: .00000N
Keypad control
SPEED KM/H: .0000

NO. OF SAT: 0
● F4: Go to “INFORMATION MENU”.
SIGNAL: 1023
00 00 00 00
● ESC: Go to “INFORMATION MENU”.

Screen display
2

.
1) A real-time display of GPS monitoring in- ZX75-1002106

De al
formation.

pt
2) Press F4 to go to “INFORMATION MENU”.
g no
Remark:
in ti
● Longitude: “E” stands for “East”, while “W” ● When the signal indication changes to 0
for “West”. from 7, a connection failure occurs either
in the SIM card or in the antenna.
et a

● Latitude: “N” stands for “North”, while “S”

n

for “South”. ● When the signal indication changes to

0 from 15, it is either because the GPS
rk er

● Altitude: “P” means “Above Sea Level”, service is not available, or the SIM card
while “N” means “Below Sea Level”. charge is overdue, or the GPS network is
abnormal.
Ma t

● The blue-white bars show signal-to-Noise

In

ratio ranges from 0 to 99. ● When the signal indication changes to 0

from 31, it is because the monitoring cen-
● When the altitude is nonzero and the longi- ter suspends.
tude and latitude is zero, it means that the
system is receiving GPS data, yet still in
the process of precise positioning.

● GPS is normal when the signal indicator

shows 1023, otherwise it is abnormal when
the signal indicator shows 615.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

9. AUTO CALIBRATION 1

Realize the automatic calibration of gear and AUTO CALIBRATION

rotation speed.
FUEL CONTROL DIAL N: 12 √
Keypad control TARGET SPEED RPM: 1234
REAL SPEED RPM: 1234
● F1: Select working mode (S and L) ALLOWABLE DEVIATION: 123
REAL DEVIATION: 1234
● F2: Select full speed/idle speed.

● F3: Start/Stop gear calibration. S rpm

.
2 3 5
● F4: Start/Stop rpm calibration.

De al
ZX75-1002107

pt
● ESC: Go to “INFORMATION MENU”
g n
● Enter: Confirm rpm calibration.
o
● [↑]: Permissible Deviation adds 1
in ti

● [↓]: Permissible Deviation subtracts 1

et a

● [→]: Permissible Deviation adds 5

n

● [←]: Permissible Deviation subtracts 5

rk er
Ma t

Screen display
In

1) When gear calibration is successful, it will

be marked with a red “√”.

2) Display working modes S or L when F1 is

pressed.

3) Display full speed/idle speed.

4) When F3 is pressed, start or stop automat-

ic calibration of the gear position

5) Start or Stop rpm calibration When F4 is

pressed.

Shop Manual - November 2012 4-117

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10. SYSTEM LANGUAGE SETUP

SYSTEM LANGUAGE SETUP
Select system language
1
Keypad control
English System
● F1: Select “ ” (Chinese System)

● F2: Select “ENGLISH SYSTEM”

● F4: Go to “INFORMATION MENU” 中文 Eng

● ESC: Returns to “INFORMATION MENU” 2 3 4

.
ZX75-1002108

De al
pt
Screen display

lected language.
g n
1) A yellow “√” is marked in front of the se-
o
in ti
2) Press F1 to select “ ” (Chinese sys-
tem)
et a

3) Press F2 to select ENGLISH SYSTEM.

n

4) Press F4 to go to “INFORMATION MENU”.

rk er

Remark:
Ma t

System language will be selected with im-

In

mediate effect when F2 or F3 is pressed. The

language interface will stay in the screen after
the selection. Please press F4 to go back to
“INFORMATION MENU”.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

11. SYSTEM SETUP

SYSTEM SETUP
Password page displayed before the configu-
ration of the machine.
PLS ENTER THE PASSWORD FOR SYSTEM SETUP:

Keypad control 1

● [↑], [↓]: Increase or decrease the value of

password digit at where the cursor is lo-
cated.

● [←], [→]: Move the cursor to the left or

right digit of password. 2 3

.
ZX75-1002109

De al
● F1: Go to “SYSTEM UNLOCK”

pt
● F2: Go to “DATE & TIME SETUP”
g no
● F3: check the validity of the password.
in ti
● F4: Go to “INFORMATION MENU”.

● ESC: Return to “INFORMATION MENU”.

et a
n

● Enter: Check the validity of the password.

rk er

Screen Display
Ma t

1) A 5-digit SYSTEM INFORMATION pass-

word. Each digit is shown by an asterisk (*)
In

Standing for a number valued from 0 to 9.

The asterisk will become a number once
the cursor moves there. Press F3 to turn
all digits into asterisks.

2) Press F3 to check the validity of password.

If the password is valid, the screen chang-
es to show “INFORMATION MENU”. If not,
you will be prompted by “INVALID PASS-
WORD! TRY AGAIN!”.

3) Press F4 to go to “INFORMATION MENU”.

Shop Manual - November 2012 4-119

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

12. SYSTEM LOCKING INFORMATION

SYSTEM LOCKING INFORMATION
Display information on system locking (level 1)
MACHINE MODEL: SY65C
Keypad control MACHINE NUMBER: 00000

1 SYSTEM LOCKING LEVEL 1

● F4: Go to "SYSTEM UNLOCK".

ATTENTION! SYSTEM LOCKED. PLS CONTACT SANY

Screen display OR AUTHORIZED DEALERS. TEL: 4008282318

1) Display locking status: SYSTEM LOCKING

LEVEL 1.
2

.
2) Press F4 to go to “SYSTEM UNLOCK”. ZX75-1002110

De al
pt
Remark:
g n
● When machine system is locked in level 1,
o
all the other keys are disabled except F4.
in ti
● Machine system will switch to the page
“HOME” automatically when unlocked. SYSTEM LOCKING INFORMATION
et a

MACHINE MODEL: SY65C

n

13 . SYSTEM LOCKING INFORMATION MACHINE NUMBER: 00000

rk er

Display information on system locking (level 2). 1 SYSTEM LOCKING LEVEL 2

ATTENTION! SYSTEM LOCKED. PLS CONTACT SANY

Keypad control
Ma t

OR AUTHORIZED DEALERS. TEL: 4008282318

In

● F4: Go to "SYSTEM UNLOCK".

Screen display 2
ZX75-1002111
1) Display locking status: SYSTEM LOCKING
LEVEL 2.

2) Press F4 to go to “SYSTEM UNLOCK”.

Remark:

● When machine system is locked in level 2,

all the other keys are disabled except F4.

● Machine system will switch to the page

“HOME” automatically when unlocked.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

14. SYSTEM LOCKING INFORMATION

SYSTEM LOCKING INFORMATION
Display information on system locking (level 3).
MACHINE MODEL: SY65C
Keypad control MACHINE NUMBER: 00000

1 SYSTEM LOCKING LEVEL 3

● F4: Go to "SYSTEM UNLOCK".

ATTENTION! SYSTEM LOCKED. PLS CONTACT SANY

Screen display OR AUTHORIZED DEALERS. TEL: 4008282318

1) Display locking status: SYSTEM LOCKING

LEVEL 3.
2

.
2) Press F4 to go to “SYSTEM UNLOCK”. ZX75-1002112

De al
pt
Remark:
g no
● When machine system is locked in level 3,
all the other keys are disabled except F4.
in ti

● Machine system will switch to the page

SYSTEM UNLOCK
“HOME” automatically when unlocked.
et a

PLS ENTER THE SYSTEM UNLOCKING PASSWORD:

n

1 000000000000
15. SYSTEM UNLOCK
rk er

MACHINE MODEL: SY65C MACHINE NUMBER: 00000

Show the procedures of unlocking the system. RANDOM CODE: 12345 TIME LEFT H: 00000
2
LOCKING LEVEL: 2 LOCKING TIMES: 000
Ma t

Keypad control
In

● [↑], [↓]: Increase or decrease the value of

password digit at where the cursor is lo- 3 4
cated. ZX75-1002113

● [←], [→]: Move the cursor to the left or

right digit of password.

● F3: Check the validity of password.

● F4: The screen will go to “HOME” if the

machine is unlocked, otherwise, it will go
to “SYSTEM LOCKING INFORMATION”
showing the corresponding locking level.

● Enter: Check the validity of password.

Shop Manual - November 2012 4-121

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Screen display

1) The 12-digit password to unlock system.

2) Machine status and its locking status.

3) Press F3 to confirm the validity of the

password.

4) The screen will go to “HOME”if the ma-

chine is unlocked when F4 is pressed,
otherwise, it will go to ”SYSTEM LOCKING
INFORMATION” showing the correspond-

.
ing locking level.

De al
pt
DATE & TIME SETUP
16. DATE & TIME SETUP

Set date and time

g no
Y/M/D H/M/S TZ
1 2007 07 27 11 25 26 08 E
in ti
Keypad control

● [↑], [↓]: Increase or decrease the numeral

et a

value at where the cursor is located.

n

● [←], [→]: Move the cursor to the left or 2 3

rk er

right position. ZX75-1002114

● F3: Confirm the date and time.

Ma t

● F4: Go to “SYSTEM INFORMATION”.

In

Screen display

1) Display the date (y/m/d), time (h/m/s) and

the time zone.

2) Press F3 to confirm the time entered.

3) Press F4 to view “SYSTEM INFORMA-

TION”.

Remark:

The time set by the user will be further cali-

brated by GPS.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

4.6.4 Special functions

1. Interface

A B

.
De al
pt
g no
in ti
et a

F1 F2 F3 F4
n
rk er

ESC Enter
Ma t
In

ZX75-1002115

1. Press F2 to enter the corresponding page of highlighted option.

2. Press F4 to switch to “SYSTEM INFORMATION”.

3. Press ↑ to enter “SERVICE CALL”.

4. Press ↓ to enter “FAILURE INFORMATION”

5. Press → to enter “MAINTENANCE INFORMATION” when specified maintenance is required.

Shop Manual - November 2012 4-123

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2. Monitored items

No. Check Item Sensor Type Signal Type Remark

1 Fuel level Fuel level sensor Digital signal
2 Coolant temperature Water temp sensor Digital signal
3 Oil pressure Pressure sensor Switching signal
4 Throttle dial position Position sensor Digital signal Real-time monitoring
5 Throttle position Position sensor Digital signal
6 Engine speed Speed sensor Pulse signal
7 LS pressure Pressure sensor Digital signal

.
8 Oil pressure Pressure sensor Switching signal

De al
9 Coolant temp too high Temperature sensor Switching signal

pt
Alarm information
10 Air filter clogged Pressure sensor Switching signal
11 g n
Fuel level too low
o Fuel level sensor Digital signal
in ti
et a
n
rk er
Ma t
In

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Structure and Function

E.
PgAD nal
Gpt
e
Kin tio
a
ANke rn
t
ar e
BLM Int

Shop Manual - November 2012 4-125

Structure and Function SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Et.
al
ep
DG
gA n
o
i
ti t
nP
na
ArNk er
eK
Ma t
BL In

4-126 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 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 n
5.3 Standard Values for Electrical Parts .......................................................................5-11
o
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 5-1

Standard Values SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.

5-2 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Standard Values

5 TABLE OF STANDARD VALUES

5.1 Standard Values for Engine-Related Parts

Machine Model SY65/75C

Standard Permis-
Item Measuring Condition Unit
Value sible Value
High idle 2, 200±25 —
Engine speed Low idle rpm 1,100±25 —
Rated speed 2,100 —

.
Color of exhaust When accelerated suddenly Max. 5.0 Max. 7.0

De al
Bosh
gas When operated at high idle Max. 1.0 Max. 2.0

pt
Intake 0.4 —
Valve clearance mm
g no Exhaust (ambient temperature)

Oil temp: 40 - 60°C

0.4 —

Compression pres-
(Engine speed: 250 rpm) MPa Min. 2.94 Min. 2.06
in ti
sure
(SAE 15W – 40 oil)

Blow-by pressure (Coolant temp: within operational

Max. 490
et a

(port diameter: range) Pa Max. 980 (Ref.)

(Ref.)
5.613 mm) At rated output (oil SAE 15W – 40)
n

At 1400 rpm 0.29 – 0.44 0.196g

rk er

Engine oil pressure MPa

Oil pressure alarm switch Min. 0.1 Min. 0.08

Oil temperature At full speed (in oil pan) °C 80 – 110 120

Ma t
In

Injection timing Before top dead Center (B.T.D.C.) ° 10 ± 0.75 —

Belt tension Deflection at finger pressing force of 98

mm 8 – 10.2 —
(Air Compressor) N {10 kg}
Initial injection
MPa 18.1 —
pressure
Actuating temp (@ standard atmo-
82.0
Thermostat spheric pressure) °C —
95.0
Valve opens more than 8 mm.

Starter Mitsubishi — 24V/3.2Kw —

Alternator Mitsubishi Motor — 24V/30A —

Shop Manual - November 2012 5-3

Standard Values SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

5.2 Standard Values for Chassis-Related Parts

Machine Model SY65/75C

Standard Permis-
Category Item Measuring Condition Unit
Value sible Value
● Hydraulic oil temp: 45~55°C
Engine rpm

Pump 1 overflow ● Coolant temp: within operation-

rpm Min. 2,000 Min. 2,000
(LS overflow) al range
● Pump 1 relief: arm relief
Boom lever 110 ± 10 110 ± 10
Arm lever ● Center of joystick 110 ± 10 110 ± 10
Control lever stroke

.
Bucket lever ● Max value to stoke end 110 ± 10 110 ± 10

De al
Swing lever 110 ± 10 110 ± 10

pt
● Engine shut down
Travel lever ● Divided by play in neutral posi- mm 135 ± 15 135 ± 15
g n
Dozer lever
o tion
Boom, bucket, arm, swing and
60 ± 10

Max. 5
60 ± 10

Max. 5
Control lever play dozer blade
in ti
Travel control lever Max. 10 Max. 10
Boom lever 4.4 – 6.8 4.4 – 6.8
Control Lever Operat-

● Engine at full speed

et a

Arm lever ● Hydraulic oil temp: 45~55°C 2.3 – 5.2 2.3 – 5.2
ing Force

Bucket lever 3.2 3.2

n

● Measure by mounting a push-

N
Swing lever pull type scale onto the joystick. 2.0 – 2.4 2.0 – 2.4
rk er

Travel lever ● Measure the max value to stoke 10.4 – 11.6 10.4 – 11.6
Dozer lever end.
Ma t

Boom
● Hydraulic oil temp: 45~55 °C
Arm
In

● Engine releases pressure at

26.3 26.3
high idle (in only the circuit to
Hydraulic Pressure

Bucket
Swing be tested).
MPa
Travel Relief pressure at one side 26.3 26.3
● Engine running at high idle
Dozer blade 26.3 26.3
● Hydraulic oil temp: 45~55 °C
PPC set pressure – 3.5 3.5

LS differential – 1.7 –

5-4 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Standard Values

Machine Model SY65/75C

Standard Permis-
Category Item Measuring Condition Unit
Value sible Value
Boom
● Under H mode, arm cylinder/bucket mm >7200
cylinder retracts; boom lowers until height
Combined
work equipment reaches the ground;
operation of
swing at full speed; raise the boom; Time
swing and
stop swinging at 90°. Record the needed
boom s 4.5±0.4
height of bucket tip and swinging to swing
time. 90°

Work equipment attitude

.
De al
Swing

Max. reach

pt
Swinging
g no
Empty
ZX75-1003001
s 28±2 32
time
in ti
● Engine running at high speed
● H mode
● Hydraulic oil temp: 45~55°C
et a

● Measure the time necessary for making five

n

swinging turns after the initial one turn.

rk er
Ma t
In

Shop Manual - November 2012 5-5

Standard Values SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Machine Model SY65/75C

Standard Permis-
Category Item Measuring Condition Unit
Value sible Value
45°

ZX75-1003002

● Engine running at high idle

● Hydraulic oil temp: 45~55°C

.
● Measure the deflection for a travel dis-

De al
Travel

Travel tance of 20 m after traveling 10 m on a flat

mm

pt
Max. 200 Max. 220
deviation ground.
★ Choose a hard, level surface
g no 20m
in ti
a

10m

ZX55-1003013
et a

★ Measure the dimension l

n
rk er
Ma t
In

5-6 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Standard Values

Machine Model SY65/75C

Cate- Standard Permis-
Item Measuring Condition Unit
gory Value sible Value

45°

Low 30~34 –
Travel

Travel speed s
ZX75-1003002

● Engine running at high idle

● Hydraulic oil temp: 45~55°C High 20~22 –
● Measure the time necessary for a

.
travel distance of 20 m after travel-

De al
ing 10 m on a flat ground.

pt
Measuring attitude
Work equipment
g n as a whole (Hy-
Hydraulic Drift of Work Equipment

<95 143
draulic drift of
o
bucket tips)
Empty
in ti
Boom cylinder

mm/10min.
(Cylinder retrac- <7 11
h

ZX75-1003004
et a

tion)
Arm cylinder
n

The bucket lowers freely 5 min. after engine

(Cylinder exten- <10 11
shutdown. Check the functions with the bucket
rk er

sion) 150 cm above ground. Retract arm cylinder.

Bucket cylinder Extend bucket cylinder to its maximum limit.
(Cylinder retrac- Measure the dropping amount of bucket tips. <10 15
Work Equipment

Ma t

tion)
Boom
In

Empty
Bucket tips reach Up
the ground.
S 2.9~3.4 3.9
Down
ZX75-1003005
Cylinder fully ● Engine running at high idle
Work Equipment

extended ● Hydraulic oil temp: 45~55°C

Arm In 3.0~3.3 4.5

Cylinder fully
retracted
Empty
S
Out 2.1~3.0 3.5
ZX75-1003006

Fully extended ● Engine running at high idle

● Hydraulic oil temp: 45~55°C

Shop Manual - November 2012 5-7

Standard Values SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Machine Model SY65/75C

Cate- Standard Permis-
Item Measuring Condition Unit
gory Value sible Value

Bucket

CURL
2.9~3.5 3.9
Work Equipment

Work Equipment

Cylinder fully Empty

retracted s

DUMP
● Engine running at high idle ZX75-1003007 2.0~2.6 2.8
Fully extended ● Hydraulic oil temp: 45~55°C

.
De al
pt
Boom g no Max. 2.9 3.9

ZX75-1003008
in ti
● Engine running at low idle
● Hydraulic oil temp: 45~55°C
et a
n

Empty
rk er
Work Equipment

Time delay

Arm 0 1.0
Ma t

ZX75-1003006

s
In

● Stop the arm suddenly and measure the

time necessary for the arm to stop.
● Engine running at low idle
● Hydraulic oil temp: 45~55°C

Bucket 0 10
ZX75-1003009

● Stop the bucket and measure the time

necessary for the bucket to move again
after its stoppage at bottom.
● Engine running at low idle
● Hydraulic oil temp: 45~55°C

5-8 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Standard Values

Machine Model SY65/75C

Cate- Standard Permis-
Item Measuring Condition Unit
gory Value sible Value
Boom Max. 2.3
Performance of combined operation Work Equipment

Internal leakage

Cylinder ● Hydraulic oil temp: 45~55°C Arm Max. 2.2 15

● Engine running at high idle Bucket cc/min Max. 2.0
● Oil relief circuit to be tested
Swivel joint Max. 10 50

● Engine running at high idle

● Hydraulic oil temp: 45~55°C
Travel de- ★ Choose a hard, level surface.

.
De al
flection when
20m

pt
work equip-
mm Max. 500 550
ment is oper-
g no ated while
traveling 10m
ZX55-1003014
in ti
★ Measure the dimension l
Hydraulic Pump Performance

et a
Hydraulic pump delivery

n
rk er

See next
Main pump See next page. l/min
page.
Ma t
In

Shop Manual - November 2012 5-9

Standard Values SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Category

SY65C3 main pump delivery

100

75
Flow rate Q v/%

50

.
De al
pt
25
Hydraulic pump performance

g no
0 50 100 150 200 250 280 300
in ti
Working pressure p/bar

SY75C3 main pump delivery

et a
n
rk er
Flow rate /L/min

Ma t
In

0 5 10 15 20 25 30 35

Working pressure /MPa

ZX65-1003001

5-10 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Standard Values

5.3 Standard Values for Electrical Parts

Sys-
Component Connector Checking Judgement Table Test Condition
tem
Normal condition: 1) Place the start
Between Conductivity switch in the
Oil pressure Conductiv- Normal
T-119 terminal and not detected OFF position;
sensor ity
body ground- Conductivity 2) Disconnect
Abnormal
ing detected T-119.
With engine running
(Throttle position 1/2 or above) →27.5 –
CN-800M 29.5 V
Alternator Voltage Start the engine.

.
T-117 Voltage may not rise for certain time

De al
period after starting the engine with aged

pt
batteries or in a cold area.
1) Place the start
Coolant
g no Normal condition:
switch in the
Monitoring system

Temp 110 100 80 50

temperature T-118 Resistance OFF position;
Resist 20 26.7 48.5 130
in ti
sensor Error - ±2.5 ±4.2 - 2) Disconnect
T-118.
1) Place the start
Normal condition:
et a

switch i n the
Fuel level Full Uniform change Appr. 8.7Ω
CN-101F Resistance OFF position;
n

sensor between full

Empty Appr. 87.2Ω 2) Disconnect
and empty
rk er

CN-101F
Normal condition: 1) Place the start
Conductivity switchinth
High temp Conductiv- Normal Between termi-
Ma t

T-115 not detected e OFF position;

alarm switch ity nal and body
Conductivity 2) Disconnect
In

Abnormal grounding
detected T-115.
Normal condition: 1) Place the start
Air cleaner Conductivity switch in the
F-103 Conductiv- Normal Between ter-
clogging not detected OFF position;
F104 ity minal F-103
sensor Conductivity 2) Disconnect
Abnormal and F-104
detected F-103 and F-104

Shop Manual - November 2012 5-11

Standard Values SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

tE.
l
Pg Aona
DG
ep
in ti
etK a
n
ArkNer
Ma t
BL In

5-12 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

Testing and Adjusting

.
6 Testing and Adjusting

De al
pt
6.1 Engine Speed - Test ................................................................................................ 6-3
6.2 Exhaust Gas Color - Test ......................................................................................... 6-4
6.3
g n
Valve Clearance - Adjust.......................................................................................... 6-6
o
6.4 Compression Pressure - Measure ........................................................................... 6-8
in ti
6.5 Fuel Injection Timing - Test and Adjust .................................................................... 6-9
6.5.1 Injection timing confirming steps .................................................................... 6-9
6.6 Engine Oil Pressure - Measure.............................................................................. 6-12
et a

6.7 Alternator Belt Tension - Test and Adjust .............................................................. 6-13

n

6.7.1 Testing.......................................................................................................... 6-13

rk er

6.7.2 Adjusting ...................................................................................................... 6-13

6.8 Fuel Control Lever - Adjust .................................................................................... 6-14
6.9 Hydraulic Pressure in Oil Circuit – Test and Adjust................................................ 6-15
Ma t

6.10 LS Differential pressure and Flow Control Valve - Test and Adjust ...................... 6-16
In

6.10.1 Check LS differential pressure ................................................................... 6-16

6.10.2 Adjust flow control valve............................................................................. 6-17
6.11 Hydraulic Pressure in Control Circuit - Test ......................................................... 6-18
6.12 Solenoid Valve Outlet Pressure - Test ................................................................. 6-19
6.13 Pilot Valve Output Pressure - Test ....................................................................... 6-20
6.14 Work Equipment and Swing Pilot Valve - Adjust.................................................. 6-21
6.15 Travel Deviation - Test ......................................................................................... 6-22
6.16 Oil Leakage - Test ................................................................................................ 6-23
6.17 Residual Pressure in Hydraulic Circuit - Release ................................................ 6-26
6.18 Swing Bearing Clearance - Check ....................................................................... 6-27
6.19 Track Tension - Check and Adjust ....................................................................... 6-28
6.20 Air in Each Component - Bleed............................................................................ 6-30

Shop Manual - November 2012 6-1

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.

6-2 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

6 TESTING AND ADJUSTING

6.1 Engine Speed - Test

Be careful not to touch any hot part when

installing or removing a testing equip-
ment.

Test the engine speed under the following

conditions:

Coolant temperature: within working range

.
De al
Hydraulic oil temp: 45-55°C

pt
1. Remove the fan guard (1).
g no
2. Install the tachometer sensor.
in ti
3. Start the engine. Set the engine speed to 1
testing condition and test the speed.
et a
n
rk er

ZXT75-1004001

Since the fan guard has been removed for

Ma t

engine speed testing, do not stand near

the fan (rotating part). Be careful not to
In

move the tachometer cable.

1) Testing the speed at low idle and high idle:

Set the fuel control dial to low idle and high

idle respectively. Test the engine speed.

2) Testing the speed at pump relief:

Test the engine speed at full power during

relief of each pump.

Shop Manual - November 2012 6-3

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6.2 Exhaust Gas Color - Test

● A smoke tester is used to test exhaust
gas color where compressed air or power
source is not available. A smokemeter is Smoke tester
used to record actual data.

★ Heat up the coolant to a temperature

within the working range before the test is
performed.

Be careful not to touch any hot part when

installing or removing a testing equip- ZX55-1004001

.
ment.

De al
pt
1. Test with portable smoke tester
g n
1) Place a filter paper in the tester.
o
2) Insert the probe of the tester into the ex-
in ti
Smokemeter
haust pipe. Increase the engine speed
suddenly and operate the portable smoke
tester in order to let exhaust gas penetrate
et a

the filter paper.

n

3) Remove the filter paper and compare it

rk er

with the provided scale in order to make a

judgement. ZX55-1004002
Ma t

2. Test with a smokemeter

In

1) Insert the probe in the exhaust pipe and

secure it with clips.

2) Connect the probe hose, accelerator

switch plug and air hose to the smokeme-
ter.

★ Pressure of feeding air shall not be greater

than 1.5 MPa {15kg/cm²}.

3) Connect a power line to the AC100V outlet.

★ Before connecting the power line to the

outlet, check whether power switch of the
smokemeter is in the OFF position.

6-4 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

4) Loosen the nut on the cover of the suction

pump. Load the filter paper.

★ Load the filter paper properly in order to Smokemeter

prevent gas leakage.

5) Turn the power switch of the smokemeter

to the ON position.

6) Increase the engine speed suddenly. Push

down the acceleration pedal at the same
time in order to discharge exhaust gas
onto the filter paper. ZX55-1004003

.
De al
7) Remove the filter paper and place it on

pt
new filter papers (at least 10 pieces) in the
box and read its value.
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 6-5

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6.3 Valve Clearance - Adjust

1. Retighten the bolts of the rocker shaft in

the illustrated sequence on the right.

Tightening torque: 49 - 59 N·m

3 1 2 4

ZX75-1004005

.
De al
pt
2. Rotate the crankshaft to align the top dead
center (TDC) of its pulley with the timing
g n
pointer in order to position the piston of
cylinder No. 1 or No.4 cylinder at the TDC
o
TDC
of compression stroke.
in ti
3. Check the rocker arms of the intake valve
and exhaust valve of cylinder No.1 for any
et a

clearance.
ZX75-1004006
n

● If clearance is observed in the rocker arms

rk er

of the intake and exhaust valve of cylinder

No.1, piston of cylinder No.1 is at the TDC
of compression stroke.
Ma t

● If the rocker arms of the intake and ex-

In

haust valve of cylinder No.1 are pushed

down, piston of cylinder No.4 is at the TDC
of compression stroke.

● Adjust the valve clearance when cylinder

No.1 or No.4 is in the TDC position.

● Valve clearance: 0.40 mm (0.016 in)

ZX75-1004007

● Loosen the valve clearance adjusting

screws as shown on the right illustration.
(The illustration shows that cylinder No.1 is
on the TDC of compression stroke.)

6-6 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

● Insert feeler gauges of proper thickness

between the rocker arm and the valve stem
end.

4. Turn the valve clearance adjusting screws

till slight resistance is felt through the feeler
gauges.

5. Tighten the locknuts securely.

ZX75-1004008
6. Rotate the crankshaft by 360°.

● Realign the TDC of crankshaft pulley to the

.
timing pointer.

De al
pt
● Adjust the clearance of other valves as
shown on the right illustration. (The illustra-
g n
tion shows that No.4 cylinder is on the TDC
o
of compression stroke.)
in ti

ZX75-1004009
et a
n
rk er
Ma t
In

Shop Manual - November 2012 6-7

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6.4 Compression Pressure - Measure

1. Start the engine to warm it up for several

minutes.
1
2. Stop the engine and cut off fuel supply.

3. Remove all preheat plugs.

4. Install the pressure gauge and its connec-

tor to the socket of preheat plug of cylinder
No.1.

.
De al
5. Rotate the engine with the start motor and ZX75-1004010

pt
note down the engine reading.

g n
Compression pressure at 200 rpm:
o
MPa (kgf/cm²/psi)
in ti
Standard Limit
3.04(31/441) 2.2 (22/313)
et a
n
rk er
Ma t
In

6-8 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

6.5 Fuel Injection Timing - Test and Adjust

6.5.1 Injection timing confirming steps

1. In line fuel injection pump

1) Rotate the crankshaft clockwise till the 1

camshaft gear timing mark “O” is aligned
with the timing gear chamber pointer.

2) No.1 cylinder will be close to the position

2
of injection timing.

.
De al
3) Remove the fuel injection line from No.1

pt
cylinder.
g no ZX55-1004004
in ti
4) Remove the seat (1), spring (2) and deliv- 1
ery valve (3) from No.1 cylinder. 2
et a

3
5) Tighten the seat to the specified torque.
n

Tightening torque:
rk er

39~44N·m {4.0~4.5kgf·m}
Ma t
In

ZX75-1004012

Shop Manual - November 2012 6-9

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6) Operate the feed pump on the injection

pump. Rotate the crankshaft slowly at the
same time till the fuel stops flowing out of
the seat of delivery valve
7
TDC 1
7) Make sure that the mark on crankshaft pul-
ley is in line with the pointer of timing gear
chamber.

Injection timing (static, BTDC) 16°

8) Remove the seat from delivery valve. ZX55-1004006

.
9) Install the delivery valve (1), spring (2) and

De al
seat (3).

pt
2
10) Tighten the seat of delivery valve to the
specified torque.
g no 3 1

11) Install the fuel injection pipe and tight-

in ti
en it to the specified torque.

Tightening torque:
et a
n

20~39N·m {2~4kgf·m}
rk er

ZX75-1004014
12) Purge the air from injection pump.

2. Distributor type injection pump

Ma t
In

1) Rotate the crankshaft clockwise till the

camshaft gear timing mark “O” is aligned 1
with the timing gear chamber pointer.

No.1 cylinder will be close to the position

of injection timing.
2

2) Remove the bolts from the distributor head

of injection pump.

ZX55-1004004

6-10 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

3) Install a dial indicator. The pointer of timing

device should be pressed down approxi-
mately 1 mm (0.039 in).

4) Position the TDC mark of crankshaft pulley

about 45° before the timing pointer.

5) Set the dial indicator to zero.

6) Turn the crankshaft pulley slightly forward

and backward in order to check whether
the pointer is stable in zero position. ZX55-1004008

.
The plunger rises to 0.5 mm (0.02 in) posi-

De al
tion when fuel injection begins.

pt
7) Slowly turn the crankshaft in the engine
g n
working direction and note down the read-
o
ing of dial indicator at TDC.
in ti
8) Proceed with the following steps if the in-
jection timing is out of the specified range.
et a

9) Loosen the injection pump mounting bolts

n

and bracket bolts.

rk er

10) Adjust the injection pump installation ZX55-1004009

angle.
Ma t

● Moving the injection pump away from the

In

engine can reduce the injection timing.

● Moving the injection pump close to the en-

gine can increase the injection timing.

Tighten the injection pump mounting bolts,

the adjusting bolts and the distributor head
bolts to the following torques.

Injection pump mounting bolts:

19 N·m {1.9 kgf·m}
Distributor head bolts:
17 N·m {1.7 kgf·m}

Shop Manual - November 2012 6-11

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6.6 Engine Oil Pressure - Measure

★ Test oil pressure under the following condi-

tion:

● Coolant temperature: within working range

1. Remove the oil pressure sensor (1) and

mount the connector of the pressure gauge
kit (threaded end PT 1/8) and the oil pres- 1
sure gauge (1.0 MPa {10 kg/cm²}).

2. Start the engine. Test oil pressure while the

.
De al
engine is running at idle and at high speed.

pt
g no
ZXT75-1004017
in ti
et a
n
rk er
Ma t
In

6-12 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

6.7 Alternator Belt Tension - Test and Adjust

6.7.1 Testing

● Press the middle of the belt between the Press

alternator and the fan with a pressure of Deflection A
58.8 N{6 kg} in order to check whether the
belt deflection is within the range of 6-10
mm {0.39 in}.

.
ZX55-1004010

De al
pt
6.7.2 Adjusting
g n
1. Remove the cover at the alternator side.
o
1
in ti
2. Loosen the belt tension adjusting bolt (1)
and the alternator mounting nut (2).
3
3. Move the alternator toward body of ma-
et a

chine. Tighten the belt tension adjusting

n

bolt (1).
rk er

4. Tighten the mounting nut (2).

2
Ma t

ZX55-1004011
In

Shop Manual - November 2012 6-13

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6.8 Fuel Control Lever - Adjust

1. Adjusting the control lever

1) The cable of any part, if replaced, should

be securely connected to the governor le-
ver (1) of the injection pump.
5
★ Plug the cable into the bottom socket of 10mm 3
the governor lever.
2
2) A 10mm gap between the throttle lever and 4
retaining nut (3) shall be maintained when

.
1

De al
fixing the nut (2).

pt
3) The rpm calibration must be carried out by
g n
a service engineer. When engine rpm at
S1 is not within 1100±50 rpm, adjust the
o ZXT75-1206001

position of the shutdown lever till engine

in ti
speed is within 1100±50 rpm.

4) Tighten nut (2) after adjustment.

et a

2. Adjusting shutdown lever

n
rk er

1) After the shutdown lever is installed, adjust

the nuts (5) of the lever so that a deflection
of 10 mm is maintained on the shutdown
Ma t

wire.
In

2) After adjustment, tighten the nuts (5).

6-14 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

6.9 Hydraulic Pressure in Oil Circuit – Test and Adjust

1. Testing

★ Hydraulic oil pressure at testing: 45-55°C

Lower the work equipment to the ground

and shut off the engine. Slowly loosen the
filler cap (1) on the hydraulic oil tank to re-
lief the pressure within. Place the lockout
lever to the LOCKED position.

● Check the LS pressure on the monitor.

.
De al
1

pt
● Measure hydraulic oil pressure with the
engine running at full speed and all control ZXT75-1004021

2.5 MPa)
g n
levers neutralized. (Hydraulic oil pressure:
o
in ti
et a
n

2. Adjusting main relief valve pressure

rk er

Loosen the locknut (2) and turn the adjust-

ing screw (3) in order to make adjustment. 2
Ma t

★ Turn the adjusting screw:

In

● Turn it clockwise to increase the pressure;

● Turn it counterclockwise to decrease the

pressure. 3
ZX75-1004022

Shop Manual - November 2012 6-15

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6.10 LS Differential pressure and Flow Control Valve - Test and Adjust

6.10.1 Check LS differential pressure

1. Test the main pump outlet pressure

● Disconnect the hose from position (1), in-

stall a Tee for pressure test, and connect
the hose to the Tee.
1

● Start the engine. Read the gauge value of

the main pump outlet pressure when a mo-
tion of excavator causes relief.

.
De al
ZXT75-1004023

pt
2. Test the LS pressure
g n
● Disconnect the hose from position (2) and
o
connect a Tee for pressure test.
in ti
● Connect the hose to the Tee.

● Start the engine. As per the above operat-

et a

ing condition, read the pressure when a

n

motion of excavator causes relief.

rk er

LS pressure:

LS differential pressure = main pump outlet 2

Ma t

ZXT75-1004024
pressure - LS pressure
In

6-16 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

6.10.2 Adjust flow control valve

If the value of differential pressure obtained

under the above condition is out of the “stan-
dard range”, the flow control valve shall be ad-
justed through the following steps.

1. Remove the protective cap of the flow con-

trol valve with a pliers.

ZXT75-1004025

.
De al
pt
2. Loosen the locknut (2). Turn the screw (3)
g n
to make adjustment.
o
● Turn the adjusting screw:
in ti
Turn it clockwise to increase differential
pressure; 2
et a

Turn it counterclockwise to decrease dif- 3

n

ferential pressure.
rk er

ZXT75-1004026
Ma t
In

Shop Manual - November 2012 6-17

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6.11 Hydraulic Pressure in Control Circuit - Test

★ Hydraulic oil temp for testing: 45-55ºC

1. Remove the pressure testing plug (1) (PT

1/4) and install the hydraulic pressure
gauge (6 MPa).
1
2. Start the engine. Perform the testing at full
engine speed.

.
De al
pt
g no ZXT75-1004027
in ti
et a
n
rk er
Ma t
In

6-18 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

6.12 Solenoid Valve Outlet Pressure - Test

★ Hydraulic oil temp for testing: 45-55°C

1. Disconnect the solenoid valve output hose

(1) and install a Tee for pressure test. Con-
nect the hose (1) to the Tee. Read the out-
let pressure on the gauge.

2. Check the solenoid valve output pressure

according to the conditions shown in the
following table.

.
De al
pt
1
g no ZXT75-1004028

Solenoid Running SV Oil Pressure

in ti
Testing Condition Remark
Valve Condition action MPa{kg/cm²}
Operation of swing or work equip- 3.0-3.5
Brake released ON
ment control lever {30-35}
et a

Swing All control levers, except travel

1
n

brake control lever, are in neutral position 3.0-3.5

Brake applied OFF
(5 seconds after returning to neutral {30-35}
rk er

position).
Selection of travel speed in
Motor swash
Hi position 3.0-3.5
Ma t

Hi-speed travel ON plate angle at

Travel ● Engine is running. {30-35}
minimum.
In

2 speed ● Travel control lever is operated.

selection Motor swash
Selection of travel speed in 0
Lo-speed travel OFF plate angle at
Lo position or full speed {0}
minimum.
Oil pressure acts
The hydraulic lockout control is in 3.0-3.5
upon the pilot ON
Pilot FREE position. {30-35}
valve circuit.
3 pressure
Oil pressure does
lockout The hydraulic lockout control is in 0
not act upon the OFF
LOCKED position. {0}
pilot valve circuit.

Action of solenoid valve

ON: open (oil pressure created)

OFF: close (oil pressure: 0)

Shop Manual - November 2012 6-19

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6.13 Pilot Valve Output Pressure - Test

★ Hydraulic oil Temp for testing: 45-55°C

1. Disconnect the hose (1) from the oil circuit

to be tested.

2. Install a connector between the hose and

the elbow.

3. Install oil pressure gauge (5.9MPa) onto

the Tee connector.
1

.
De al
4. Run the engine at high idle, operate the

pt
control lever of the oil circuit to be tested,
and check the oil pressure.
g no ZXT75-1004029
in ti
et a
n
rk er
Ma t
In

6-20 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

6.14 Work Equipment and Swing Pilot Valve - Adjust

★ If the work equipment control lever or the

swing control lever has excessive play, it
should be adjusted through the following
procedure:

Lower the work equipment to the ground

and turn off the engine. Slowly loosen the
filler cap of the hydraulic tank in order to
release the tank pressure.

1. Pull up the rubber sleeve on the lever.

.
De al
pt
2. Remove the cover (1).

g n
3. Loosen the locknut (2). Adjust the play of
control lever by repositioning the disc (3).
o 3
2
in ti
★ Play of control lever: 0.5 - 3 mm 1

(In a distance of 200 mm from the control lever

et a

revolving center)
n

★ The play of control lever reduces when

rk er

the locknut (2) is tightened. Therefore, the

adjustment is to be made according to the
amount to be reduced. ZXT55-1004019
Ma t

4. Fix the disc (3) and tighten the locknut (2)

In

to the specified torque.

Locknut: 112.7±14.7 N·m

Shop Manual - November 2012 6-21

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6.15 Travel Deviation - Test

1. Adjust the excavator to the attitude of trav-

el.

★ In the attitude of travel, fully extend the

bucket cylinder rod and the arm cylinder 45°
rod. Hold the boom at an angle of 45°.

2. Travel 10m, and then travel 20m to check

the amount of deviation.

★ Check the amount of deviation when the

.
De al
engine is running at high idle.
ZX75-1004031

pt
★ Install the hydraulic pressure gauge and
g n
measure the pump output pressure.
o
★ Operate the machine at low speed.
in ti

20m Travel 10 m
et a

Travel continuously in
a straight line.
n
rk er
Ma t

Make a mark Make a mark at the Make a mark

midpoint of 10 m
In

Midpoint of 10 m
Benchmark
20m

Mark Mark
Check deviation (a).
Mark

ZX75-1004032

6-22 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

6.16 Oil Leakage - Test

★ Hydraulic oil temp for testing: 45-55°C

1. Work equipment cylinder

★ If the hydraulic drift of work equipment is

out of the standard range, the amount of
Attitude for boom
oil leakage in the cylinder is to be tested as cylinder testing
per the following procedure. It is also nec-
essary to determine whether the hydraulic
drift is caused by internal failure of the
cylinder or the failure of control valve.

.
De al
pt
● If the amount of leakage is within the stan-
dard range, it is the fault of control valve.
g n
● If the amount of leakage is greater than the
o
standard value, it is the internal failure of
in ti
ZX75-1004033
the cylinder.
et a
n

Attitude for arm and bucket cylinder testing

rk er
Ma t
In

ZX75-1004034

Disconnect the hose.

Stroke end

Hose
Relief pressure

ZX75-1004035

Shop Manual - November 2012 6-23

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

1) Fully extend the rod of the cylinder to be

Boom cylinder
tested and then turn off the engine.

2) Disconnect the line (1) from the end of cyl-

inder and then plug the line to the chassis.

Be careful not to disconnect the circuit at

the boom side.
1
3) Leave it for 10-15 minutes and then check
the hydraulic drift of the cylinder immedi-
ZXT75-1004036
ately.

.
De al
Arm cylinder

pt
g no
in ti

1
et a

ZXT75-1004038
n
rk er

Bucket cylinder
Ma t
In

ZXT75-1004037

6-24 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

2. Swing motor

1) Disconnect drain hose (4) of the swing mo-

tor. Then plug the hose.

2) Connect a drain hose to the swing motor

side. Hold the oil leakage with a beaker.

3) Start the engine. Operate the swing relief

with the engine running at high speed.
4
4) Maintain this state for 30 seconds and then
check the amount of leakage.

.
De al
ZXT75-1004039
★ After the first measurement, swing by 180°

pt
and measure the amount of leakage again.

3. Travel motor
g no
1) Disconnect the drain hose (3) of the travel
in ti
motor and plug the hose end.

2) Connect a polyethylene hose to the elbow

et a

and hole the leaked oil with a beaker.

n

3
3) Place block 1 under the grouser of track
rk er

shoe. Place block 2 between carrier roller

and the track frame to lock the track shoe.
Ma t

4) Start the engine. Operate the travel relief

In

when the engine is running at high idle. ZXT75-1004040

Misoperation of the control levers may

cause accidents. Always operate prop-
erly and make sure of the signals.

5) Maintain this state for 30 seconds and then

2
check the amount of oil leakage.

1
★ Repeat the test several times with the
motor running under light load. (Change
the relative position between oil distributor
and oil cylinder and between piston and oil
cylinder.)
ZX75-1004041

Shop Manual - November 2012 6-25

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6.17 Residual Pressure in Hydraulic Circuit - Release

1. Turn the fuel control dial (2) to MIN position

and stop the engine.

2. Switch on power supply and operate all

pilot valves to relieve pressure. (Keep the
lockout control lever at FREE position.)

3. Switch off power supply and move the

lockout control lever to the LOCKED posi- 2
tion.
ZXT75-1004043

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

6-26 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

6.18 Swing Bearing Clearance - Check

Checking procedures:

1. Install a magnetic dial gauge to the outer

race (or inner race) of the swing bearing. Swing Plat. Swing Plat.
Install a probe on the end face of inner Outer Outer
Ring Ring
race (or outer race). The dial gauge is in-
stalled either on the front or rear end. Inner Ring Inner Ring

Track Frame Track Frame

.
Dial Indicator

De al
ZX55-1004020

pt
g n
2. Place the work equipment to the maximum
o
working position. Adjust the bucket so that
in ti
its tips are in the same plane of the swing
platform bottom. Now, the front part of up-
per structure will tilt forward and its rear
et a

part will rise.

n

3. Reset the dial gauge to zero. ZX75-1004045

rk er

4. Keep the arm approximately vertical to the

ground. Lower the boom till the front part
Ma t

of machine rises off the ground. Now, the

front part of upper structure will rise and
In

the rear will tilt backward.

5. Read the dial gauge now. The reading is

the clearance of swing bearing.

Do not put your hand or foot under the

chassis during testing.
150 200mm
ZX75-1004046

6. Resume step 2 and check whether the

dial gauge is back to zero. Repeat step 2
through step 5 if the dial gauge is not back
to zero.

Shop Manual - November 2012 6-27

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6.19 Track Tension - Check and Adjust

Checking

1. Drive the excavator straight forward on a

hard, level ground more than 3 meters.
1
2. Use the bucket as the support on one side
in order to raise the track of one side off
the ground.

3. Place a straight edge (3) between the mid-

dle track roller (1) and the track (2). 3
2 a

.
De al
4. Measure the deflection between the track ZX75-1004047

pt
roller tread and the track link surface.

g n
● If the deflection (a) is within the following
range, the track tension is normal.
o
in ti
Model Std. deflection (a)
SY65C3 30±5mm
SY75C3, 75C9 35±5mm
et a
n

Adjusting
rk er

★ Adjust track tension as per the following

procedure:
Ma t

1. When the tension is high

In

1) Loosen valve (1) to slowly discharge the

grease.

Do not loosen the valve by over one 1 2

turn. Otherwise, the grease may squirt
out due to high internal pressure.

★ If the grease is not discharged completely,

slowly move the machine back and forth.

2) Before checking the track tension, it is ZX75-1004048

necessary to run the engine at idle speed,

move the machine forward to a distance
equal to the grounding length of track, and
slowly park the machine.

6-28 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

3) Recheck the track tension and, if incorrect,

adjust it again by following the above pro-
cedure.

2. When the tension is low

1) Add grease through grease fitting (2).

★ If normal track tension cannot be ensured

during filling of grease, it is necessary to
slowly move the machine back and forth.

Grease fitting: Grease (G2-LI)

.
De al
2) Before checking the track tension, it is

pt
necessary to run the engine at idle speed,
move the machine forward to a distance
g n
equal to the grounding length of track, and
o
slowly park the machine.
in ti
3) Recheck the track tension and make fur-
ther adjustment if necessary as per the
procedure above.
et a
n
rk er
Ma t
In

Shop Manual - November 2012 6-29

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6.20 Air in Each Component - Bleed

Air bleeding procedures

Air bleeding item
1 2 3 4 5 6
Bleed air Bleed Bleed air Bleed air
Contents of work Starting Starting
from hydrau- air from from swing form travel
engine operation
lic pump cylinder motor motor

● Replacing hydraulic oil

○ ○ ○ ○ ○ ○
● Cleaning filter element
(Note) (Note)
● Replacing return filter element ○ ○
● Repairing/replacing hydraulic pump
○ ○ ○ ○

.
● Removing suction piping

De al
pt
● Repairing/replacing control valve ○ ○ ○
● Replacing cylinder
○ ○ ○
g n
● Removing cylinder piping
● Replacing swing motor
o
○ ○ ○
● Removing swing motor piping
in ti
● Replacing travel motor
○ ○ ○
● Removing travel motor piping
et a

Note:
n

Bleed air from the swing motor and travel motor only when the oil in the motor housing is drained.
rk er

1. Bleed air from hydraulic pump

Ma t

1) Loosen the air bleeder (1) and check

In

that oil oozes out through the air bleed-

er.

2) Tighten the air bleeder (1) if oil is seen.

Bleeder:
1

7.8~9.8 N·m{0.8~1.0 kgf·m}

● Engine starting precautions

Run the engine at low idle for 10 min-

ZXT75-1004049
utes after bleeding the air according to
the above procedure.

6-30 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

2. Bleed air from hydraulic cylinder

1) Start the engine and keep the engine

running at low idle for 5 minutes.

2) Raise or lower the boom 4 or 5 times

with the engine running at low idle.

★ Be careful not to apply relief pressure.

Stop the piston when the piston rod is
about 100 mm before stroke end.

3) Repeat step 2) with the engine running

.
at high idle.

De al
pt
4) While running the engine at low idle,
move the piston rod to the stroke end
g n
and apply relief pressure.
o
5) Bleed air from arm cylinder and bucket
in ti
cylinder by performing step 2) through
step 4).
et a

● When a new cylinder is installed for re-

n

placement, bleed the air from the new

cylinder before mounting it to the work
rk er

equipment. Especially the boom cylin-

der, once mounted to the work equip-
ment, its piston rod is unable to reach
Ma t

its stroke end in lowering operation.

In

Therefore, the air must be bled from

the boom cylinder before it is mounted
to the work equipment.

3. Bleed air from swing motor

1) Start the engine and run the engine at

low idle.

2) Bleed air from the swing motor by turn-

ing the upper structure slowly.

Shop Manual - November 2012 6-31

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. Bleed air from travel motor

1) Start the engine and run the engine at

low idle.

2) Loosen the bleeder (2) and check that

oil oozes out through the air bleeder. 2

3) Tighten the air bleeder (2) if oil is seen.

ZXT75-1004050

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

6-32 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Testing and Adjusting

tE.
PAD nal
eGp
ng o
i
tKi t
a
AkNe rn
ar e
BLM Int

Shop Manual - November 2012 6-33

Testing and Adjusting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

tE.
l
Pg Aona
DG
ep
in ti
etK a
n
ArkNer
Ma t
BL In

6-34 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

Troubleshooting

.
7 Troubleshooting

De al
pt
7.1 Points to Remember When Troubleshooting ........................................................... 7-3
7.2 Troubleshooting Procedures .................................................................................... 7-5
g n
7.3 Connector Locations and System Circuit Diagram .................................................. 7-9
o
7.4 Troubleshooting with an Error Code ...................................................................... 7-19
in ti
7.5 How to Use the Judgement Chart.......................................................................... 7-20
7.6 How to Use Troubleshooting Table ........................................................................ 7-21
7.7 Troubleshooting of Electrical System..................................................................... 7-24
et a

7.8 Troubleshooting of Engine ..................................................................................... 7-31

n

7.9 Troubleshooting of Hydraulic and Mechanical System .......................................... 7-57

rk er

7.10 Troubleshooting of Machine Monitoring System .................................................. 7-83

Ma t
In

Shop Manual - November 2012 7-1

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.

7-2 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

7 TROUBLESHOOTING

7.1 Points to Remember When Troubleshooting

Stop the machine in a level ground, and check that lock pins, blocks, and parking brake are
securely fitted.

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.

De al
pt
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
g n
When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
o
in ti
When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.
et a

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly,
n

and to prevent reoccurrence of the failure.

rk er

When carrying out troubleshooting, important point is to understand the structure and function.

However, a short cut to effective troubleshooting is to ask the operator various questions to form
Ma t

some idea of possible causes of the failure that would produce the reported symptoms.
In

1. When carrying out troubleshooting, do not It will also cause a waste of man-hours,
hurry to disassemble the components. parts, or oil or grease, and at the same
time, will also lose the confidence of the
If components are disassembled immedi- user or operator.
ately any failure occurs:
For this reason, when carrying out
● Parts that have no connection with the troubleshooting, it is necessary to carry out
failure or other unnecessary parts will thorough prior investigation and to carry
be disassembled. out troubleshooting in accordance with the
fixed procedure.
● It will become impossible to find the
cause of the failure. 2. Points to ask user or operator:

Shop Manual - November 2012 7-3

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

1) Have any other problems occurred 4. Confirming failure

apart from the problem that has been
reported? ● Confirm the extent of the failure yourself,
and judge whether to handle it as a real
2) Was there anything strange about the failure or as a problem with the method of
machine before the failure occurred? operation, etc.

3) Did the failure occur suddenly, or were ★ When operating the machine to reenact
there problems with the machine condi- the troubleshooting symptoms, do not
tion before this? carry out any investigation or measure-
ment that may make the problem
4) Under what conditions did the failure worse.
occur?

.
5. Troubleshooting

De al
5) Had any repairs been carried out before

pt
the failure? When were these repairs ● Use the results of the investigation and
carried out? inspection in Items 2 – 4 to narrow down
g no
6) Has the same kind of failure occurred
the causes of failure, then use the trouble-
shooting flowchart to locate the position of
before? the failure exactly.
in ti

3. Check before troubleshooting ★ The basic procedure for troubleshoot-

ing is as follows.
et a

1) Check the oil level.

n

1) Start from the simple points.

2) Check for any external leakage of oil
rk er

from the piping or hydraulic equipment. 2) Start from the most likely points.

3) Check the travel of the control levers. 3) Investigate other related parts or infor-
Ma t

mation.
In

4) Check the stroke of the control valve

spool. 6. Measures to remove root cause of failure

5) Other maintenance items can be ● Even if the failure is repaired, if the root
checked externally, so check any item cause of the failure is not repaired, the
that is considered to be necessary. same failure will occur again. To prevent
this, always investigate why the problem
occurred. Then, remove the root cause.

7-4 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

7.2 Troubleshooting Procedures

If some phenomenon occurs on a machine that looks like a failure, identify the corresponding
troubleshooting No. and proceed to the explanations for diagnosis.

Follow six steps listed below to diagnose and analyze for troubleshooting, and find the causes
and work out the corresponding methods.

1. Read related technical manuals in detail. d. What kind of trouble did machine have
Have a knowledge of related system, before?
principle of operation, and structure,
function and technical specification of For example: Which parts have been

.
parts. repaired or replaced?

De al
pt
2. Ask operator e. What has been done after troubles take
place and how about the reaction?
g n
Before checking, ask related person, i.e.
o
the operator for all information about the f. Will the trouble reoccur? Does the trou-
failure. ble occur regularly?
in ti

a. Current working condition of machine 3. Check before starting

(Whether machine is operated prop-
et a

erly). Before starting troubleshooting, check

n

the operator's records on operation,

b. When troubles are found and what kind maintenance and service of the machine.
rk er

of operation does machine perform at Understand whether related personnel has

that time? done wrong in operation, maintenance and
service. Check for wrong operation and
Ma t

c. Development of troubles (Whether maintenance at the same time.

troubles are becoming severer or occur
In

for the first time.)

Shop Manual - November 2012 7-5

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

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
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil

.
De al
—
mechanical Electrical equipment

pt
1. Check for looseness, corrosion of battery terminal and
— Tighten or replace
wiring
—
and wiring
g n
2. Check for looseness, corrosion of alternator terminal
o Tighten or replace

3. Check for looseness, corrosion of start motor terminal

Tighten or replace
in ti
and wiring
equipment
Hydraulic,

1. Check for abnormal noise and smell — Repair

et a

2. Check for oil leakage — Repair

3. Bleeding air — Bleed air
n

1. Check battery voltage (with engine stopped) 20-30V Replace

rk er
Electrics, electrical equipment

2. Check electrolyte level — Add or replace

3. Check for discolored, burnt, exposed wiring — Replace
4. Check for missing wiring clips and hanging wiring — Repair
Ma t

5. Check for wet wires (esp. wet connectors or terminals) — Disconnect con-
In

6. Check for blown or corroded fuses nector and dry

7. Check alternator voltage (with engine speed at middle —
or higher) After running for Replace
8. Check operating sound of battery relay (when start several minutes: Replace
switch is turned ON or OFF) 27.5~ 29.5V Replace
—

7-6 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

4. Operate machine by yourself (trial run) ● Failure codes may not indicate machine
trouble. Temporary electrical failure can oc-
Confirming that the third item above is cur in controller memory, such as low bat-
normal, run startup check on the machine tery output voltage, or open circuit in switch
to determine the cause of failure. If the or sensor. Therefore, make repeated trials
failure cannot be determined, turn off the to erase the accumulated failure codes
engine and get more information from the from the controller memory and confirm
operator. whether the failure codes are displayed af-
ter repeated trials. That is to say, "reoccur-
5. Perform troubleshooting rence" of this trouble is possible.

Conduct deep analysis and determine the 6. Find out possible causes
cause of trouble according to the symp-

.
toms of the machine and the information Before making a conclusion, check the

De al
displayed on the monitor. most possible causes again and try to de-

pt
termine the root causes of troubles. Make
Remark: a feasible repair scheme according to your
g no
● Never disconnect harness and hydraulic
conclusion.

lines when the engine is running. Oil and

in ti
water under high pressure and high tem-
perature may squirt and cause personal
injuries. Shut off then engine when discon-
et a

necting the harness and hydraulic lines.

n
rk er
Ma t
In

Shop Manual - November 2012 7-7

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

7-8 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

7.3 Connector Locations and System Circuit Diagram

● The location code given in the table below corresponds to the location of connector.

Connector Code Connector Type No. of Pins Installation location Location Code
AMP1 AMP:282080-1 2 Horn button M2
AMP2 AMP:282105-1 3 Fuel control dial H3
AMP3 AMP:282104-1 2 Lockout lever I2
AMP4 AMP:282080-1 2 Boom M4
AMP5 AMP:735075-0 1 Horn M3

.
Yazaki 1 Yazaki 7123-7464-30 6 Ignition key H3

De al
Yazaki 2 Yazaki 7123-7464-40 6 Preheat controller I3

pt
Yazaki 3 Yazaki X01FGY-M/C 1 Oil level sensor N4
Yazaki 4
Yazaki 5
g no Yazaki 7222-1424-30
Yazaki 7123-7464-40
2
6
Solenoid valve
Throttle motor
O3
N3
Mitsubishi 1 PK465-32127-C01B 32 Cab/Chassis harness I2
in ti
Delphi 1 Delphi 12078090 3 Main valve N3
DJ1 DJ7072-3-21 8 Radio I2
et a

DJ2 DJ7061Y-2.3-1.0 6 Parking solenoid valve N3

HSG1 HSG 7123-2830 3 Safety relay J3
n

HSG2 7123-2128 2 Alternator O3

rk er

Deutsch 1 DT04-12P 12 Cab/Chassis harness I2

Deutsch 2 DT06-12S 12 Cab/Chassis harness I2
Ma t

Deutsch 3 DT04-8P 12 Cab/Chassis harness I2

Deutsch 4 DT06-8S 12 Cab/Chassis harness I3
In

Hella 1 H8JA713631 8 Lamp switch H3

JIS1 JIS-D5403-104(CA) 1 Air cleaner sensor O3
JIS2 JIS-D5403-104(CB) 1 Air cleaner sensor O3

Shop Manual - November 2012 7-9

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Yazaki 2 HSG1
Deutsch 1
4

AMP2
Yazaki 1 Hella 1
AMP1

.
De al
pt
g no Deutsch 2

2 Mitsubishi 1
in ti
et a
n

DJ1
AMP3
rk er

1
Ma t

G H I J
In

ZX75-1005001

7-10 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

AMP4

Yazaki 3 Delphi 1

HSG2
Yazaki 4
4

Yazaki 5

AMP5

.
De al
3

pt
JIS1
JIS2

2
g no
DJ2
in ti
et a

1
n
rk er

L M N O
Ma t

ZX75-1005002
In

Shop Manual - November 2012 7-11

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Number of pins required for connection

AMP
No. of
pins
Plug Socket
735075-0

1 _

.
De al
ZX55-1005007

pt
282080-1 282104-1
g no 1
1
in ti

2
et a

2 2
n
rk er

ZX55-1005008 ZX55-1005009

AMP:282105-1
Ma t
In

ZX55-1005010
ZX55-1005011

7-12 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

Deutsch
No. of pins
Plug Socket
DT04-8P DT06-8S

5 5 1
1

.
De al
4 8 8 4

pt
ZX55-1005013

ZX55-1005012

g n
DT04-12P
o
12
DT06-12S

6
12 6
in ti
et a

12
n
rk er

1 7
7 1 ZX55-1005015
ZX55-1005014
Ma t
In

Shop Manual - November 2012 7-13

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Yazaki
No. of pins
Plug Socket
X01FGY-M/C

1 _

ZX55-1005016

.
De al
7123 － 7464 － 40 7123-7464-30

pt
3 1 1 3
g no
6
in ti

4 6
et a

6 4 ZX55-1005017 ZX55-1005018
n
rk er
Ma t
In

7-14 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

No. of pins Hella

H8JA713631

ZX55-1005019

.
De al
Delphi

pt
No. of pins
Plug Socket
g n
12078090
o
1 3
in ti

3 _
et a
n

2
rk er

ZX55-1005020
Ma t
In

Shop Manual - November 2012 7-15

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

DJ
No. of pins
Plug Socket
7061Y-2.3-1.0

1 4 4 1

.
6 3 ZX55-1005022

De al
3 6

pt
ZX55-1005021

g n
7072-3-21
o
1 5 5 1
in ti

5
et a
n
rk er

ZX55-1005024
2 3 3 2
ZX55-1005023
Ma t
In

7-16 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

HSG
No. of pins
Plug Socket
HSG 7122-3012

1 _

ZX55-1005025

.
De al
7123-2128

pt
2
g no
in ti
_

ZX55-1005026
et a
n

HSG 7123-2830
rk er

1
1
Ma t

3
In

3 2 2
3
ZX55-1005027 ZX55-1005028

Shop Manual - November 2012 7-17

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

MIC
No. of pins
Plug Socket

1 3 1
3

4 5 4
5
5

ZX55-1005030
ZX55-1005029

.
De al
1
1 5 5

pt
9
6 g no 9 9 6
in ti

ZX55-1005031 ZX55-1005032
et a
n

S type connector
No. of pins
rk er

Plug Socket

1 6 6 1
Ma t
In

5 10
ZX55-1005033 10 5 ZX55-1005034

1 6 6 1

5 12 ZX55-1005036
ZX55-1005035 12 5

7-18 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

7.4 Troubleshooting with an Error Code

No. Error Code Description

1 1 Engine oil pressure low
2 2 Fuel level low
3 3 Coolant temperature high
4 4 Air cleaner clogged
5 5 Engine racing
6 6 Battery over-voltage
7 7 Battery under-voltage

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 7-19

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

7.5 How to Use the Judgement Chart

The judgement chart is a tool to determine whether a fault is caused by abnormality of the electri-
cal system, the hydraulic system or the mechanical system. For abnormality indication (warning)
displayed on the monitor panel, see Troubleshooting of the Monitoring System.

Failure mode and judgement chart

Pump Control Valve Solenoid Valve Swing Motor Travel Motor

Travel speed selector solenoid Pilot pressure lockout solenoid

1) Connect the Tee connector with the 1) Connect the Tee connector with the hydraulic

Troubleshooting modes of hydraulic system

Defective Part speed selector solenoid V5. pressure lockout solenoid V1.

Internal leakage or breakage of housing

Internal leakage or breakage of housing
2) Operate the speed selector switch with 2) Operate the hydraulic lockout control with the
Pressure compensation valve

the start switch in ON position. start switch in ON position.

Safety and oil suction valve

Boom regeneration valve

Travel speed selector follower

3) Is the voltage between (1) and (2) of 3) Is the voltage between (1) and (2) of V1 iden-
Function control valve

V5 identical to the voltage shown below? tical to the voltage shown below?
LS oil throttle valve

Swing pressure switch

Center swivel joint

Counterbalance valve
Flow control valve

Pilot shuttle valve

LS selector valve

Back pressure valve

PTO spline shaft

(Normal) (Normal)

Oil suction valve

Main relief valve
Unloading valve
Reducing valve

Swing mechanism

Hydraulic cylinder
Failure Modes
Servo plunger

Oil suction valve

Travel speed Voltage Pilot pressure Voltage
Filter screen

Engine system
Blade valve
Pump body

lockout lever reading

Pilot valve
selector switch reading

Safety valve

Check valve

Final drive
Lo 0V FREE 20-30V
Spool

Brake
Hi 20-30V LOCKED 0V
Travel, swing and work

○ ○ ○ ○ ○ ○ H-1
power is weak
equipment

.
Engine speed drops sharply or engine stalls ○ ○ ○ H-2
○ ○ ○ ○ H-3

De al
Abnormal noise occurs (around the pump) ○ ○ H-4
Poor precise control performance or bad sensitivity ○ ○ H-5

pt
Boom moves slowly or power is weak ○ ○ ○ ○ ○ ○ ○ H-6
Arm moves slowly or power is weak ○ ○ ○ ○ ○ ○ H-7
Work equipment

Bucket moves slowly or power is weak ○ ○ ○ ○ ○ ○ H-8

Boom fails to move. ○ ○
Arm fails to move. ○ ○ H-9
Bucket fails to move.
Excessive hydraulic drift
Excessive time delay
g n
Work equipment: The side with greater load moves slowly.
○
○ ○
○
○
○
○
○
○
○ H-10
H-11
H-12
Combined opera-

o
Swing + Boom: Boom raises slowly. ○ H-13
tion

Travel + Swing: Travel speed drops sharply. ○ H-14

Travel + Work Equipment (Boom RAISE): Travel speed drops
○ H-15
sharply.
in ti
Move forward and backward in the ○ ○
○ ○ ○ ○
Cannot make a straight same direction.
H-16
travel Move forward and backward in different
○ ○
Travel system

directions.
Big deviation at beginning ○ ○ ○ H-17
Travel speed low or powerless ○ ○ ○ H-18
Dif cult in changing direction ○ ○ ○ ○ ○ H-19
Absence of travel speed selection ○ H-20
et a

Travel system fails (only at one side). ○ ○ ○ ○ H-21

In both left and right directions ○ ○ ○ ○
Swing fails H-22
In only one direction ○ ○ ○

In both left and right directions ○ ○

Bad swing acceleration H-23
n

In only one direction ○ ○ ○ ○ ○

Excessive overrunning In both left and right directions ○

Swing system

H-24
upon swing stoppage In only one direction ○ ○ ○
Considerable Shaking Resulted from Swing Stoppage (in Only
○ ○ H-25
rk er

One Direction)
Abnormally High Noise Resulted from Swing Stoppage ○ ○ ○ ○ H-26

Excessive Hydraulic Brake ON ○

H-27
Drift of Swing Brake OFF ○ ○ ○ ○

Swing speed faster than speci ed speed ○ H-28

Blade movement slow or power weak ○ ○ H-29
Blade does not work. ○ H-30
Blade

Excessive hydraulic drift of blade ○ ○ H-31

Ma t

Troubleshooting mode of electrical system E-5 E-1, E-2

Step 1 check whether the voltage in each check-

In

ing location is normal.

Find failure mode.
2) Is the voltage identical to that in the chart
Ask the operator and determine, if possible, (when it is normal)?
the failure (the symptom of fault on the ma-
chine). Find out the corresponding failure Voltage identical to that in the chart (when
mode in the Judgement Chart. it is normal) → Proceed with troubleshoot-
ing on hydraulic or mechanical system.
Step 2
Voltage not identical to that in the cart
Determine whether it is a fault of electrical sys- (when it is normal) →Proceed with trouble-
tem, hydraulic system or mechanical system. shooting on electrical system.
1) Connect a Tee connector or a socket Step 3
between the wiring harness and the con-
nector with solenoid indicated with an "O" Perform necessary troubleshooting (YES/NO
mark. Follow the troubleshooting steps to diagnosis).

7-20 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

7.6 How to Use Troubleshooting Table

1. Troubleshooting codes and problems value under is correct or the answer to

the question inside is “YES”, continue
The title of troubleshooting schematics troubleshooting by following the “YES”
contains troubleshooting code and failure line. If the value is incorrect or the answer
mode (problem of machine) is “NO”, follow the “NO” line.

2. Identification ● Under is preparatory work and judge-

ment value necessary for checking and
The same failure mode (problem) can measuring. If the preparatory work is
have different troubleshooting methods neglected or the operation and handling

.
according to model, part or problem. In this method are performed in a wrong way, it

De al
case, the failure mode (problem) is further could lead to wrong judgement or machine

pt
divided into a number of parts indicated damage. Therefore, carefully read the de-
with lowercase letters (such as a). Perform scription inside and start from item 1)
g n
troubleshooting in the corresponding part.
o before checking and measuring operation.

If there is only one troubleshooting table, 4. General precautions

in ti
begin troubleshooting with the first check-
ing item. For troubleshooting of failure mode
(problem), precautions (indicated with )
et a

3. The way of following troubleshooting flow applicable to all items are provided on top
chart of each page.
n
rk er

● Check or measure the items in and en-

YES
NO No precautions (indicated with ) are pro-
ter the next according to the answer or vided in , but the indicated ones must be
following the line indicated with “YES” or followed when checking the item described
Ma t

“NO” . in .
In

(Note: The upper right number of is an 5. Installation location and pin number
index, not a serial number.)
Sketch or schematic drawing is presented
● According to checking or measuring result, to describe the connector type, installation
the cause column will be reached finally location and pin numbers. When trouble-
following the “YES” line or the “NO” line. shooting is performed, see the schematic
Check the cause and do as told in the drawing of connector pin numbers and
Remedy column. location detail for each failure mode (prob-
lem) and for checking and testing the lead
● Under is the method or judgement val- connector numbers indicated in the flow
ue used for checking or measuring. If the chart.

Shop Manual - November 2012 7-21

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Failure mode and judgement chart

Pump Control Valve

Defective Part

Pressure compensation valve

Safety and oil suction valve

Boom regeneration valve
Function control valve

LS oil throttle valve

Center swivel joint

Flow control valve

Pilot shuttle valve

LS selector valve
PTO spline shaft

Oil suction valve

Main relief valve
Unloading valve
Reducing valve
Failure Modes

Servo plunger

Filter screen

Blade valve
Pump body

Pilot valve
Spool
Work equipment, swing drive and final drive operate slowly or
Travel, swing and work

○ ○ ○ ○ ○ ○
power is weak

.
equipment

Engine speed drops sharply or engine stalls ○ ○

De al
Work equipment, final drive and swing drive do not work ○ ○ ○

pt
Abnormal noise occurs (around the pump) ○ ○
Poor precise control performance or bad sensitivity ○ ○

g n
Boom moves slowly or power is weak
Arm moves slowly or power is weak
o ○
○
○
○
○ ○
○
○
○
○
○
Work equipment

Bucket moves slowly or power is weak ○ ○ ○ ○ ○

Boom fails to move. ○ ○
in ti
Arm fails to move. ○ ○
Bucket fails to move. ○ ○
Excessive hydraulic drift ○ ○ ○ ○
Excessive time delay ○ ○
et a

Work equipment: The side with greater load moves slowly. ○

Combined opera-

Swing + Boom: Boom raises slowly. ○

n
tion

Travel + Swing: Travel speed drops sharply. ○

Travel + Work Equipment (Boom RAISE): Travel speed drops
rk er

○
sharply.
Move forward and backward in the
○ ○ ○ ○
Cannot make a straight same direction.
travel Move forward and backward in different
○ ○
Ma t
Travel system

directions.
Big deviation at beginning ○ ○
In

Travel speed low or powerless ○ ○

Difficult in changing direction ○ ○ ○
Absence of travel speed selection
Travel system fails (only at one side). ○
In both left and right directions
Swing fails
In only one direction ○ ○
In both left and right directions ○
Bad swing acceleration
In only one direction ○ ○ ○

Excessive overrunning In both left and right directions

Swing system

upon swing stoppage In only one direction ○ ○

Considerable Shaking Resulted from Swing Stoppage (in Only
○ ○
One Direction)
Abnormally High Noise Resulted from Swing Stoppage

Excessive Hydraulic Brake ON

Drift of Swing Brake OFF ○
Swing speed faster than specified speed ○
Blade movement slow or power weak ○
Blade does not work. ○
Blade

Excessive hydraulic drift of blade ○

Troubleshooting mode of electrical system

7-22 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

Solenoid Valve Swing Motor Travel Motor

Travel speed selector solenoid Pilot pressure lockout solenoid

1) Connect the Tee connector with the 1) Connect the Tee connector with the hydraulic

Troubleshooting modes of hydraulic system

speed selector solenoid V5. pressure lockout solenoid V1.

Internal leakage or breakage of housing

Internal leakage or breakage of housing

2) Operate the speed selector switch with 2) Operate the hydraulic lockout control with the
the start switch in ON position. start switch in ON position.

Travel speed selector follower

3) Is the voltage between (1) and (2) of 3) Is the voltage between (1) and (2) of V1 iden-
V5 identical to the voltage shown below? tical to the voltage shown below?

Swing pressure switch

Counterbalance valve

Back pressure valve

(Normal) (Normal)

Swing mechanism

Hydraulic cylinder
Oil suction valve
Travel speed Voltage Pilot pressure Voltage

Engine system
selector switch reading lockout lever reading

Safety valve

Check valve

Final drive
Lo 0V FREE 20-30V

Brake
Hi 20-30V LOCKED 0V

H-1

.
○ H-2

De al
○ H-3

pt
H-4
H-5

g no ○
○
○
H-6
H-7
H-8
in ti
H-9

○ H-10
H-11
et a

H-12
H-13
n

H-14
rk er

H-15

○ ○

H-16
Ma t

○ H-17
In

○ H-18
○ ○ H-19
○ H-20
○ ○ ○ H-21
○ ○ ○ ○
H-22
○
○
H-23
○ ○
○
H-24
○

H-25

○ ○ ○ ○ H-26
○
H-27
○ ○ ○

H-28
○ H-29
H-30
○ H-31
E-5 E-1, E-2

Shop Manual - November 2012 7-23

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

7.7 Troubleshooting of Electrical System

Troubleshooting of electrical system ......................................................................................... 7-24

Travel speed is unchangeable ................................................................................................... 7-25
Engine does not start................................................................................................................. 7-26
Engine shutdown solenoid does not work ................................................................................. 7-27
Engine cannot be stopped ......................................................................................................... 7-28
Wiper does not work .................................................................................................................. 7-29

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

7-24 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

Troubleshooting of electrical system

With the pilot joystick UNLOCKED, the machine does not move while operating the control le-
vers.

● Check related connectors for improper contact before carrying out troubleshooting.

● Make sure that the disconnected connectors are restored before proceeding to the next step.

Cause Remedy

Solenoid valve
damaged, or Check the
YES harness of the harness.
solenoid valve

.
Is the contro- broken

De al
YES ller pilot out-
put normal?

pt
Failure of Repair or
Is the contro- NO controller replace.
YES ller pilot input
normal?
g no Is the conduc-
YES tivity between
pilot switch
grounding and
NO
Harness from
joystick switch
to the controller
broken
Check the
harness.

Is the pilot chassis ground- Open circuit Check the

YES
in ti
switch po- ing conductible? NO in grounding harness.
sitive volt- harness
tage normal?
Is the pilot Open circuit in Check the
joystick NO power supply harness.
normal? harness
et a

Check the con-

Harness of joy- Replace
n

ductivity of the NO
pilot joystick. stick pushbutton
damaged
rk er

Related circuit diagram

Ma t
In

Integrated controller
Pilot solenoid valve
CN-107M
CN-145F CN-226M CN-235M CN-603F CN-601F
606 606
606
105

Pilot switch CN-205F

0 105
0

ZX55-1005037

Shop Manual - November 2012 7-25

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Travel speed is unchangeable

● Check related connectors for improper contact before carrying out troubleshooting.

● Make sure that the disconnected connectors are restored before proceeding to the next step.

Cause Remedy

YES
Solenoid valve Repair or replace
damaged
YES Is the negative voltage
of solenoid valve
normal?

.
De al
Improper grounding or Check the harness.

pt
NO short circuit of ground-
Is the positive voltage ing harness
of solenoid valve
normal? YES
g no
Is the controller
output normal?
Open circuit in harness Check the harness.

NO
in ti
Failure of controller Repair or replace
NO
et a

Related circuit diagram

n
rk er

Travel motor

Integrated controller
Ma t

Hi/Lo speed travel

solenoid valve
In

Main pump

Main valve

Engine ZX55-1005038

7-26 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

Engine does not start

● Check related connectors for improper contact before carrying out troubleshooting.

● Make sure that the disconnected connectors are restored before proceeding to the next step.

Cause Remedy

YES
Fault of start motor Overhaul
YES Is the starter or the engine
properly
grounded?

Check the grounding

Grounding resistance
Is the positive Improper grounding harness or use addi-
YES voltage of start
should be small.
NO tional grounding
motor normal? wire.

.
De al
pt
Approximate 24 V
Low voltage may YES
cause the start Open circuit in the Check the harness
motor to produce harness connecting

g no insufficient torque.

NO
Is battery volt-
tage normal?
the battery

Battery power low Charge

in ti
NO
Does the engine rotate
when starting?

YES
et a

Start switch damaged Replace

n

YES Is the start

switch ener-
rk er

gized?
YES
Open circuit in the Check the harness
harness connecting
Is controller the start switch
output
Ma t

normal?
Is the positive NO
pole of start
motor energized? Check the
NO
In

Fault of controller Repair or replace

start output
pins. NO

Open circuit in the Check the harness

harness connecting
NO the battery

Shop Manual - November 2012 7-27

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Engine shutdown solenoid does not work

Cause Remedy

YES
Failure of engine Replace
shutdown solenoid
YES Is the resistance reading
between engine shutdown
solenoid terminal and
chassis normal?
Open circuit in the Check the harness.
Is the voltage reading
harness between
between engine shutdown NO shutdown solenoid
solenoid terminal and
terminal and chassis
chassis normal?

.
De al
YES

pt
Open circuit in the Check the harness.
harness between
shutdown solenoid
Is controller parking terminal and

g nNO
o output normal? controller

Failure of controller Repair or replace

NO
in ti
et a
n
rk er
Ma t
In

7-28 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

Engine cannot be stopped

● Check related connectors for improper contact before carrying out troubleshooting.

● Make sure that the disconnected connectors are restored before proceeding to the next step.

Cause Remedy

YES Damage of shut- Replace

down solenoid

YES Open circuit in Check the harness.

Is there output from the harness

.
the shutdown relay? between controller

De al
and shutdow relay

pt
Is there extinguishing
signal output from the
controller?
NO YES
g no
Is there output
from the start
Open circuit in
the harness
between controller
and sart switch
Check the harness.

NO switch?
in ti
Failure of start Replace
switch
NO
et a
n
rk er
Ma t
In

Shop Manual - November 2012 7-29

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Wiper does not work

● Check related connectors for improper contact before carrying out troubleshooting.

● Make sure that the disconnected connectors are restored before proceeding to the next step.

Cause Remedy

YES
Defective assembly Unplug and plug
or fault of supplier again

YES Is the hardness of

.
wiper is properly

De al
grounded?

pt
Failure of wiper Repair or replace

NO

of the wiper normal?

g n
Is the voltage between the
positive and negative poles
o YES
Wiper short-
circuited or
Check the wiper.

blocked
in ti
Is the wiper fuse
blown?
NO
et a

Open circuit of Check the harness.

NO harness
n
rk er
Ma t
In

7-30 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

7.8 Troubleshooting of Engine

How to use the chart of troubleshooting .................................................................................... 7-31

1 Poor starting performance (It always takes excessive time to start) ..................................... 7-35
2 Engine fails to start ................................................................................................................ 7-38
3 Engine acceleration is instable (poor follow-up performance) ............................................... 7-41
4 Engine stops during operation ............................................................................................... 7-42
5 Engine rotates unstably (vibrates) ......................................................................................... 7-43
6 Low power output (lack of power).......................................................................................... 7-44
7 Black exhaust gas (incomplete combustion) ......................................................................... 7-45
8 Engine oil consumes excessively (or exhaust gas turns blue) .............................................. 7-46
9 Engine oil is contaminated quickly......................................................................................... 7-47

.
10 Fuel consumption is excessive ............................................................................................ 7-48

De al
11 Coolant contains engine oil, water sprays back or water level drops .................................. 7-49

pt
12 Engine oil pressure alert indicator lights up (oil pressure drops) ........................................ 7-50
13 Higher oil level (engine oil contaminated by water and/or fuel) .......................... 7-51
g n
14 Higher water temperature (overheated) .............................................................................. 7-52
o
15 Abnormal noise ................................................................................................................... 7-53
in ti
16 Violent vibration .................................................................................................................. 7-54
et a
n
rk er
Ma t
In

Shop Manual - November 2012 7-31

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

How to use the chart of troubleshooting

The Chart of Troubleshooting consists of three

parts: Symptom, Investigate and Diagnose.
“Symptom” and “Investigate” are used to point
out the most possible causes through trouble
symptoms or simple investigation without us-
ing any troubleshooting tools.

Troubleshooting tools or direct investiga-

tion are used to determine the most possible
causes.

.
Symptom

De al
pt
Part A + B in the chart refers to information
Cause
that can be provided by the user. B refers to
g n
information that might be provided by users at
o
different levels.
in ti
(1) (2) (3)
Investigate

Maintenance personnel shall carry out simple

et a

(a)
Symptom

investigation in order to focus on the causes.

n

Items below C are corresponding checks. A (b)

rk er

(c)
The maintenance personnel shall focus on the (d)
possible causes according to information A ,
(e)
which is drawn from the user and his own test-
Ma t

ing results. C
In

Diagnose
Inves-
tigate

“Diagnose” are performed in the possible se-

i
quence, starting from the most possible cause
Diagnose

obtained from “Symptom” and “Investigate”. ii

iii

7-32 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

The use of this Chart of Troubleshooting is de-

scribed as the following:

In the chart, related items of “Symptom” and

“Investigate” are marked with , while the
most possible causes are marked with .

Check each item of “Symptom” and “Inves-

tigate” and mark the corresponding problems
with or . The “Cause” column with the
most points shows the most possible cause.
Therefore, the troubleshooting shall begin from
the item that is decided as the final cause.

.
De al
1. “Records of recent repairs” under

pt
“Symptom” shall be obtained from the
user and marked with as a refer- Cause
g n
ence for troubleshooting. However,

Failure of injection pump (excessive injection)

o
this information shall not be counted
when pinpointing the most possible
in ti

Injection nozzle seized or blocked

Turbocharger seized or interfered

Wear of piston ring and cylinder

causes.
Air cleaner element plugged

Injection timing incorrect

2. Causes marked with are used as
et a

reference. “Service hours (long-term

n

operation)” under “Symptom” are also

used as reference. Generally, This
rk er

mark shall not be counted to deter-

mine the cause, but is can be count-
ed when deciding on troubleshooting
Ma t

sequence.
In

Records of recent
1
repairs
Long-term
2 Service hours
operation

Shop Manual - November 2012 7-33

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Example: Suppose a clogged air cleaner is the possible cause for black exhaust gas. This trou-
ble is shown in 3 symptoms: a) Exhaust gas turns black gradually; b) Power drops slowly; c) Air
cleaner sensor alarm. Five causes can be found after an investigation.
The following example explains how this troubleshooting procedure works.
7 Black exhaust gas (incomplete combustion)

General causes:
Cause
● Insufficient air intake

Injection nozzle blocked or seized

Turbocharger seized or interfered

Wear of piston ring and cylinder

Air leak, turbocharger-cylinder head

● Improper injection condition

Muffler squeezed or plugged

Improper contact of air valve

Air valve clearance incorrect
Air cleaner element plugged
● Excessive injection

Failure of injection pump

Failure of injection pump

Injection timing incorrect
Symbols:

.
○: Possible causes (judged by Symptom and Investigate).

De al
◎: Most possible causes (judged by Symptom and Investigate).

pt
△: Long service hours may be a possible cause.
●: Item that determines the Cause.
g n
Records of recent repairs
o
Service hours long service hours △ △ △ △
Blacken suddenly ◎ ○
Symptom

in ti
Exhaust gas
Blacken gradually ◎ ○ ○
color
Blue under light load ◎
Engine oil must be added more often. ◎
Suddenly ◎ ○ ○ ○
et a

Power loss
Gradually ○ ○ ○ ○
Unapproved fuel has been used all the time. ○ ○
n

Noise of interference is heard around the turbocharger. ◎

Air cleaner sensor alarms. ◎
rk er

Excessive blow-by ◎
Poor engine acceleration performance or nonuniform combustion ○ ◎ ○ ○ ○
Feel the exhaust manifold with hand immediately after the engine
◎ ○
Ma t

is started. Temperature of air cylinders is low.

Investigate

The matching marks on the injection pump are not aligned. ◎

In

Seal of injection pump has detached. ◎

Clang is heard around the cylinder head. ◎
Abnormal noise of exhaust ○ ○ ◎
The muffler was squeezed. ◎
Gas leak between turbocharger and cylinder head, loose clamps ◎
Heavy resistance felt when turning the turbocharger with hand. ●
Air cleaner is blocked. ●
The compression force measured is too low. ● ●
Some cylinders does not change speed when pressure-reducing
Diagnose

●
cylinder is operated.
Injection timing found wrong when checked with oil flow method. ●
Injection pump testing suggests improper injection amount. ●
The air valve clearance is out of the standard range. ●
Exhaust gas color turns normal when muffler is removed. ●
The adjusting rack is heavy or does not return when pushed. ●
Replace

Replace
Replace

Replace

Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean

Remedy

7-34 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

Five causes

.
De al
Analyze the relationship between the 3 entries in [symp-

pt
tom] and [investigate] and the 5 causes in the columns.

g no
Three symptom
in ti
et a
n
rk er

Count the number of and at where the row of symp-

Ma t

tom meets the column of cause.

(1) Air cleaner element is plugged:
In

(2) Air leaks between turbocharger and cylinder head:

(3) Injection nozzle is blocked or seized:
(4) Improper contact of air valve with its seat:
(5) Wear of piston ring and cylinder:

Step 2 shows that it is more likely to be caused by the

plugging of air cleaner. Go to the diagnostic area along
this line and exclude the items marked with . The given
method is [cleaning]. Cleaning should be able to restore
the exhaust gas to its normal color.

Shop Manual - November 2012 7-35

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

1 Poor starting performance (It always takes excessive time to start)

General causes for smoking but poor starting performance

● Failure of the electrical system

● Insufficient fuel feed
● Low air intake
● Inappropriate fuel selection
(Diesel oil ASTM D975 #1 should be used at where the ambient temperature is -10°C or below.)

Diesel Grade 10# 5# 0# -10# -20# -35# -50#

.
De al
Min. applicable temperature Diesel with preheater 8°C 4°C -5°C -14°C -29°C -44°C

pt
*The above temperature is the lowest temperature in a region where the risk of the month is up to
10%. Refer to GB 252-2000.
g no
Battery charging rate
in ti
Charging rate
Ambient temp 100% 90% 80% 75% 70%

20°C 1.28 1.26 1.24 1.23 1.22

et a

0°C 1.29 1.27 1.25 1.24 1.23

n

-10°C 1.30 1.28 1.26 1.25 1.24

rk er

● The specific gravity of battery shall be greater than the value corresponding to charging rate
of 70%.
Ma t

● In a cold area, the specific gravity shall be greater than the value corresponding to the charg-
In

ing rate of 75%.

7-36 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

Cause

Fuel filter or primary filter element plugged

Improper contact of air valve with its seat
Wear of piston ring and cylinder

Feeder pump screen plugged

Air cleaner element plugged

Failure of intake air heater

Symbols:
○: Possible causes (judged by Symptom and Investigate).
◎: Most possible causes (judged by Symptom and Investigate).
△: Long service hours may be a possible cause.
●: Item that determines the Cause.

Confirm records of recent repairs

Service hours Long service hours △ △ △

.
De al
Getting worse ◎ ◎ ○ ○ ○
Starting problems

pt
Warm-up start
Symptom

◎
Preheat indicator does not light up. ◎
Consumption of engine oil increases.
g n
Filter element was not replaced as per Operation and Maintenance Manual.
o
Unapproved fuel has been used all the time.
◎
◎ ◎
○
◎
○
The dust indicator light is ON. ◎
in ti
The battery charging indicator light is ON.
The start motor runs slowly.
Feel the exhaust manifold with hand after the engine is started. Temperature of some cylin-
et a

ders is low.
Engine acceleration is not stable and combustion not uniform. ○ ○
n

Excessive blowby ◎
The matching marks on the injection pump are not aligned.
rk er

Dirt covers the fuel tank cap breather

Investigate

When the start motor is used to start the engine,

1)Only a small amount of fuel is seen coming out even if injection pump connecting nuts are
Ma t

loosened.
2)Only a small amount of fuel is seen coming out even if fuel filter bleeding plug is loosened. ◎ ◎
In

Leaking in the fuel lines

Engine vibrates (or rotates unstably). ○ ○
The compression force measured is too low. ● ●
The filter element of air cleaner is blocked. ●
The element of fuel filter or primary filter is blocked. ●
The primary filter element of feeder pump is blocked ●
The heater does not heat up. ●
Diagnose

Is the voltage between the alternator terminals B and E 26-30V while the en- Yes
gine is running at low idle? No
Either low specific gravity of the electrolyte or low voltage of the battery
The speed does not change while operation of some cylinders is stopped.
The control rack is felt resistant or does not return when pushed. (By removing the sealing cap
on the back of the pump, you may find that the sleeve of the plunger control valve does not
move.)
The fuel tank cap breather is blocked.
Replace

Replace
Repair

Clean

Clean

Clean

Remedy

Shop Manual - November 2012 7-37

7-38
◎
Failure of alternator (with external regulator)

●
Replace

◎
Failure of alternator (built-in regulator)

●
Replace

◎
◎
△
Failure or aging of battery

●
Replace

◎
◎
○
○
Failure of injection nozzle

●
Troubleshooting

Replace

◎
◎
Adjust Injection timing incorrect
In
Cause

◎
◎
○
○
Failure of injection pump (seized rack or plunger)

●
Replace
Ma t

○
○
Leaking or blocking of fuel lines; air exists in fuel pipe

●
Repair

◎
Plugging of fuel system breather

●
Clean

Replace Failure of feeder pump

rk er
n

◎
Replace Boosting compensator cancelling function fails.
et a
in ti
g no

Shop Manual - November 2012

De al
pt
.
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

2 Engine fails to start

(1) Engine fails to rotate

General causes:
● Seizure of internal engine parts
★ If any internal part of the engine is seized, perform troubleshooting on "engine failure during
operation."
Cause
● Failure of electrical system

Failure of the line of the starting circuit

Failure of safety relay or safety switch

● Failure of power train

Battery terminal connection error

Failure of fuel cutoff solenoid

Failure or aging of battery

.
Symbols:

De al

Failure of battery relay

Failure of start switch

Cracking of gear ring
Failure of start motor
○: Possible causes (judged by Symptom and Investigate).

pt
◎: Most possible causes (judged by Symptom and Investigate).
△: Long service hours may be a possible cause.
g n
●: Item that determines the Cause.
o
Confirm records of recent repairs
in ti
Symptom

Service hours Long service hours △ △

Dead horn ◎ ○ ○
Horn condition when start switch is turned to ON.
Horn volume low ◎
et a

The rotating speed decreases. ◎

n

When the start switch is turned to the START po- Harsh sound is produced. ◎ ◎
sition and the pinion gear moves outward,
rk er

It is disengaged immediately. ◎
It clicks but does not rotate. ○ ○ ○
When the start switch is turned to START position, the pinion gear does not engage ◎ ○
Ma t

There is no click when the start switch is turned to the ON position. ○ ◎

Investigate

Perform diagnosis on the faulty line of the starting circuit.

Loose battery terminal ◎

In

When start switch is turned to the ON position and the linkage does not move, ◎
Battery electrolyte level is low. ◎

The specific gravity of electrolyte is small and the battery voltage is low. ●
Under the conditions from 1) to 5), turn OFF the start switch, connect the wires and
carry out troubleshooting: ● ●
1)The engine starts when the start switch terminals B and C are connected.
2)The engine starts when the start motor terminals B and C are connected. ●
Diagnose

3)The engine starts when the safety relay terminals B and C are connected. ●
4)The engine starts when the safety switch terminal and the start motor terminal B
●
are connected.
5)The voltage between battery relay terminal b and terminal E is not 24V. ●
Cracks are found on the surface of gear ring.
No movement is seen even if the fuel cutoff solenoid link is disconnected. ●
Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Remedy

Shop Manual - November 2012 7-39

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

(2) The engine rotates but produces no exhaust (with no fuel injection)

General causes:
● No fuel feeding.
● Fuel feed is too small.
● Inappropriate fuel selection (esp. in winter)
★ Applicable fuel standard

Ambient Temperature
Fuel Cause
-4 14 32 50 68 86°F

Injection pump error (seized rack and plunger)

Type

Crack of drive shaft and key of injection pump

-20 -10 0 10 20 30°C

Fuel filter or primary filter element plugged

.
De al Feeder pump plunger is seized or cracks.
ASTM D975 No.2

pt
Failure of engine shutdown motor
Diesel GB252 QUALITY-20 DIESEL OIL

Fuel tank breather is blocked.

Feeder pump screen plugged

Failure of fuel cutoff solenoid

Fuel line is blocked or leaks.
GB252 QUALITY-35 DIESEL OIL
g n
Insufficient fuel in the rack
o
Symbols:
○: Possible causes (judged by Symptom and Investigate).
in ti
◎: Most possible causes (judged by Symptom and Investigate).

Incorrect fuel
△: Long service hours may be a possible cause.
●: Item that determines the Cause.
et a

Confirm records of recent repairs

n

Service hours Long service hours △ △ △

Smoke disappears suddenly when restarted. ◎ ◎ ◎
Symptom

rk er

Filter element not replaced as per Operation and Maintenance Manual. ◎ ◎

Fuel tank is empty. ◎
Fuel line leaks. ◎
Ma t

Dirt covers the fuel tank cap breather. ◎

Linkage does not move when start switch is turned to ON position. ◎ ◎
In

No fuel is seen flowing out when the fuel filter element is drained. ◎
When the start motor is used to start the engine,
◎
1)The coupling of injection pump does not rotate.
Investigate

2)No fuel flows out when air vent plug of filter element is loosened. ◎ ○ ○ ○

3)No fuel squirts out when injection pump connecting nuts are loosened. ◎ ◎ ◎
Rust and water are found in the fuel drained. ○ ○

Check the injection pump directly. ●

The control rack is felt resistant or does not return when pushed. ●
Check the feeder pump directly. Check the feeder pump directly. ●
Diagnose

The fuel filter element and the primary filter are plugged. ● ●
The screen of feeder pump is plugged. ●
The fuel tank cap breather is blocked. ●
No movement is seen even if the fuel cutoff solenoid link is disconnected. ●
No movement is seen when engine shutdown motor link is disconnected. ●
Replace

Replace

Replace

Replace

Replace

Replace
Repair

Repair
Clean

Clean

Remedy
Add

7-40 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

(3) Fume is seen but the engine does not start (with fuel injection)

General causes:
● Rotating power looses due to failure of electrical system. Cause

Failure of injection pump (seized rack and plunger)

Valve system (valve or rocker arm) fails or cracks .

Injection nozzle is blocked and the injection fails.

● Insufficient fuel feeding
● Insufficient air intake

Fuel filter or primary filter element plugged

Wear of piston ring and cylinder sleeve
● Inappropriate selection of fuel and oil

The fuel system leaks or is blocked.

The fuel tank breather is blocked.

Feeder pump screen plugged
Air cleaner element plugged
Failure of intaken air heater
Failure or aging of battery

Use of inappropriate fuel

Symbols:
○: Possible causes (judged by Symptom and Investigate).

.
De al
◎: Most possible causes (judged by Symptom and Investigate).

pt
△: Long service hours may be a possible cause.
●: Item that determines the Cause.

g n
Confirm records of recent repairs
Service hours
o
Long service hours △ △ △ △
Engine starting fails suddenly. ◎ ◎
in ti
Symptom

When the engine is started, abnormal noise is heard around the cylinder head. ◎
Engine oil must be added more frequently. ◎
Unapproved fuel was used. ○ ○
Filter element was not replaced as per Operation and Maintenance Manual. ◎ ◎ ◎
et a

Rust and water are found in the fuel drained. ◎ ◎

Air cleaner sensor alarms. ◎
n

The indicator fails to light up. ◎

The start motor starts the engine slowly.
rk er

◎
Dirt covers the fuel tank cap breather ○
The stopper is not reached when fuel control lever is placed at FULL position. ○
When the start motor is used to start the engine,
Ma t

1)Only a small amount of fuel is seen flowing out even if the injection pump ◎
connecting nuts are loosened.
Investigate

In

2)No fuel flows out when air vent plug of filter element is loosened. ◎ ◎ ○
Fuel line leaks. ◎
Feel the exhaust manifold with hand immediately after the engine is started.
◎
Temperature of cylinder is low.
No fuel is seen flowing out when the fuel filter element is drained. ◎
Check it directly by removing the cover of cylinder head. ●
The control rack is felt resistant or does not return when pushed. ●
The compression force is found low. ●
The elements of fuel filter and primary filter are blocked. ● ●
Diagnose

The feeder pump screen is plugged. ●

The air cleaner element is plugged. ●
The heater does not heat up. ●
Small specific gravity of electrolyte or low battery voltage ●
The resistance is little or too much when operating the feeder pump. ●
The speed does not change when operation of some cylinders are stopped. ●
The fuel tank cap breather is blocked. ●
Replace
Replace
Replace
Replace

Replace
Repair

Repair
Clean
Clean
Clean

Clean
Clean

Remedy

Shop Manual - November 2012 7-41

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3 Engine acceleration is instable (poor follow-up performance)

General causes:
● Insufficient air intake
Cause
● Insufficient fuel feeding

Injection failure due to clogged injection nozzle

Fuel filter or primary filter element plugged
● Inappropriate injection condition

Improper contact of air valve with its seat

Wear of piston ring and cylinder sleeve
● Use of incorrect fuel

Turbocharger is seized or interfered.

Plunger of injection pump is seized.

The fuel tank breather is blocked.

Air valve clearance is incorrect.
Feeder pump screen plugged

Fuel line is blocked or leaks.

Air cleaner element plugged
Symbols:
○: Possible causes (judged by Symptom and Investigate).

.
◎: Most possible causes (judged by Symptom and Investigate).

De al
△: Long service hours may be a possible cause.

pt
●: Item that determines the Cause.

Service hours
g n
Confirm records of recent repairs
o
Long service hours △ △ △ △ △
Filter element was not replaced as per Operation and Maintenance Manual. ◎ ◎ ◎
in ti
Symptom

Unapproved fuel has been used all the time. ◎ ◎ ◎ ◎

Engine oil must be added more often. ◎
Rust and water are found in the fuel drained. ◎ ◎
et a

Air cleaner sensor alarms. ◎

Interfering noise is heard around the turbocharger. ◎
n

Engine acceleration becomes worse suddenly. ○ ◎ ○ ○

Blue under light load ○ ◎
rk er

Color of exhaust gas

Black ◎ ◎ ◎ ○
Clangs are heard around the cylinder head. ◎
Dirt covers the fuel tank cap breather ◎
Ma t

Fuel line leaks. ◎

Investigate

Engine speed is normal at unloaded high idle but drops suddenly when loaded. ◎ ◎ ○
In

Engine vibrates (rotates unstably). ○ ◎ ○ ○

Feel the exhaust manifold immediately after the engine is started. Temperature of
◎ ○
cylinder is low.
Excessive blowby ◎

The air cleaner element is blocked. ●

The fuel filter element and the primary filter element are blocked. ●
The feeder pump screen is plugged. ●
The speed does not change when operation of some cylinders is stopped. ●
Diagnose

The control rack is felt resistant or does not return when pushed. ●
Compression force is low. ● ●
The turbocharger is felt resistant when turned with hand. ●
The air valve clearance is out of standard range. ●
The fuel tank cap breather is blocked. ●
The feeder pump operates too easy or too difficult. ●
Replace
Replace
Replace

Replace
Repair

Repair
Adjust
Clean
Clean
Clean

Clean

Remedy

7-42 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

4 Engine stops during operation

General causes:
● Internal part of engine is seized.
● Insufficient fuel feeding
● Overheating
Cause
★ When overheated with engine stoppage, perform

Primary filter element of feeder pump clogged.

diagnostic analysis on overheating.

Injection pump error (seized rack or plunger)

Valve system breaks (valve and rocker arm)

The injection pup drive shaft or key breaks

Fuel filter or primary filter element plugged

Feeder pump plunger is broken or seized.

The auxiliary equipment of pump breaks.
● Failure of power train

Crankshaft bearing breaks or is seized.

Piston or lever breaks or is seized.
★ If the engine stops due to failure of the power

Fuel tank breather is blocked.

The gear breaks or is seized.

Fuel line is blocked or leaks.

.
train, perform diagnostic analysis on the chassis.

De al
pt

Failure of power train

Symbols:

Fuel insufficiency
○: Possible causes (judged by Symptom and Investigate).
g n
◎: Most possible causes (judged by Symptom and Investigate).
△: Long service hours may be a possible cause.
o
●: Item that determines the Cause.
in ti
Confirm records of recent repairs
Service hours Long service hours △ △
Engine stops suddenly at abnormal sound. ◎ ◎ ◎ ◎ ◎ ◎ ○ ○ ◎
Symptom

et a

Conditions when engine Engine is overheated and stops. ◎ ○ ○

stops Engine stops gradually. ◎ ○ ○
n

Engine stops due to vibration. ◎ ○ ○ ○

Fuel level indicator light comes on. ◎
rk er

Fuel tank is empty. ◎

Filter element not replaced as per Operation and Maintenance Manual. ◎ ◎
Unapproved fuel has been used all the time. ○ ○ ○ ○
The feeder pump fails or operates sluggishly. ○ ○ ◎
Ma t

Dirt covers the fuel tank cap breather. ◎

In

The engine is running but stops when the power train is operated. ◎
No rotation ◎ ◎
Investigate

Rotate in the opposite direction. ◎

Test run manually with
barring gear. Moving distance is equivalent to back
◎ ◎
clearance.
The shaft does not rotate. ◎
Rust and water are found in the fuel drained. ◎ ◎
Metallic chips are found in the oil drained. ◎ ◎ ○ ○

Remove and check the engine oil pan. ● ●

Remove and check the cylinder head cover. ●
Chassis Diagnose

The gear does not rotate when the gear system is checked. ●
Diagnose

The pump runs after the pump’s auxiliary device is removed. ●

The fuel filter element and the primary filter element are blocked. ●
The feeder pump screen is plugged. ●
Check the feeder pump directly. ●
The control rack is felt resistant or does not return when pushed. ●
Replace
Replace
Replace
Replace
Replace
Replace

Replace

Replace
Repair

_____
Clean
Clean

Clean

Remedy
Add

Shop Manual - November 2012 7-43

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

5 Engine rotates unstably (vibrates) Cause

Oil circuit between feeder pump and injection nozzle is blocked; qirt exists in the circuit.
General causes:
● Air present in the fuel system

Oil circuit between fuel tank and feeder pump is blocked; air exists in the circuit
● Failure of speed governor
● Failure of electronic speed governor (if equipped)
★ If the vibration stops when the electronic governor rod
disengages, perform diagnostic analysis on the chassis.

. Fuel filter or primary filter element plugged

De al
pt
Failure in operation of control rack

The fuel tank breather is blocked.

Failure in operation of governor

Feeder pump screen plugged

Error of governor adjustment
Symbols:
g n
○: Possible causes (judged by Symptom and Investigate).
o
◎: Most possible causes (judged by Symptom and Investigate).

Low idle is too low.

△: Long service hours may be a possible cause.
in ti

Insufficient fuel
●: Item that determines the Cause.
et a

Confirm records of recent repairs

n

Service hours Long service hours △ △

rk er

Within certain speed range ◎ ◎ ◎

Symptom

At low idle ○ ◎ ○ ○ ○ ○
Conditions for vibration
Even if the speed increases ○ ○ ○ ○
On a slope ◎
Ma t

Fuel tank is empty ◎

In

Filter element was not replaced as per Operation and Maintenance Manual. ◎ ◎
Rust and water are found in the fuel drained. ○ ○
Fuel line leaks. ◎ ◎
When the feeder pump is operated, ◎
1)No response, too light, quick return ◎
Investigate

2) No response, too light, normal return

Engine speed sometimes increases too fast. ◎ ◎
Sometimes it is difficult to stop the engine. ◎ ◎
Seal of injection pump detaches. ◎ ◎

It is difficult to move the shift lever. ● ●

Adjustment of governor is found inappropriate when checking injection pump. ●
Diagnose

The control rack is felt resistant or does not return when moved. ●
The fuel tank cap breather is blocked. ● ●
The primary filter of feeder pump is blocked. ●
The fuel filter element and the primary filter are blocked. ●
Repair

Repair
Adjust

Adjust

Adjust

Adjust

Clean

Clean

Clean

Remedy
Add

7-44 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

6 Low power output (lack of power)

General causes:
● Insufficient air intake and fuel feeding
● Inappropriate injection condition Cause
● Use of incorrect fuel

Failure of boosting compensator diaphragm

Fuel filter or primary filter element clogged

Improper contact of air valve with its seat

Bent fuel control lever or mis-adjustment
(Power output may drop if unapproved fuel is used.)

Turbocharger is seized or interfered.

Plunger of injection pump is seized.

The fuel tank breather is blocked.

● Lower power output caused by overheating.

Nozzle plugged or injection error

Wear of piston ring and cylinder

Air valve clearance is incorrect.

Feeder pump screen plugged

Fuel line is blocked or leaks.

Air cleaner element plugged
★ If the engine is overheated or lacks power output,
perform diagnostic analysis on overheating.
Symbols:

.
De al
○: Possible causes (judged by Symptom and Investigate).
◎: Most possible causes (judged by Symptom and Investigate).

pt
△: Long service hours may be a possible cause.
●: Item that determines the Cause.
g n
Confirm records of recent repairs
Service hours
o
Long service hours △ △ △ △ △
Suddenly ◎ ◎
Symptom

in ti
Power loss
Gradually ○ ○ ○ ○ ○ ○
Engine oil must be added more often. ◎
Filter element not replaced as per Operation and Maintenance Manual. ◎ ◎ ◎
Unapproved fuel has been used all the time. ◎ ◎ ◎ ◎
et a

Air cleaner sensor alarms. ◎

n

Black ◎ ◎
Color of exhaust gas
Blue under light load ◎
rk er

Interfering noise is heard around the turbocharger. ◎

Excessive blowby ◎ ○
Poor engine acceleration and incomplete combustion ◎ ○ ○ ○
Engine speed is normal at unloaded high idle but drops suddenly when
Ma t

◎ ◎ ○
loaded.
Investigate

Feel the exhaust manifold immediately after the engine is started. Tem-
In

◎ ○
perature of cylinder is low.
Engine vibrates (rotates unstably). ○ ○ ○ ○
Clangs are heard around cylinder head. ◎
Engine speed is low at high idle. ○ ◎
Fuel line leaks. ◎

The air cleaner element is blocked. ●

The turbocharger is felt resistant when turned with hand. ●
Compression force is low. ● ●
The fuel filter element and the primary filter element are blocked. ●
Diagnose

The feeder pump screen is plugged. ●

The speed does not change when operation of some cylinders is stopped. ●
The control rack is felt resistant or does not return when pushed. ●
Air valve clearance is out of the standard range. ●
Control lever cannot reach the stopper when moved to the FULL position. ●
The feeder pump operates too easy or too difficult. ●
The fuel tank cap breather is blocked. ●
Replace
Replace

Replace

Replace

Replace
Repair

Repair
Adjust

Adjust
Clean

Clean
Clean

Clean

Remedy

Shop Manual - November 2012 7-45

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

7 Black exhaust gas (incomplete combustion)

Cause
General causes:

Gas leaks between turbocharger and cylinder head.

Failure of injection pump (seized rack and plunger)

● Insufficient air intake

Failure of injection pump (excessive injection)

● Inappropriate injection condition

Improper contact of air valve with its seat

Failure of injection due to blocked nozzle
● Excessive injection

Turbocharger seized or interfered

Muffler is squeezed and blocked.

Wear of piston ring and cylinder

Air valve clearance is incorrect.

Air cleaner element plugged

Injection timing is incorrect.

Symbols:

○: Possible causes (judged by Symptom and Investigate).

◎ : Most possible causes (judged by Symptom and Investigate).

.
De al
△ : Long service hours may be a possible cause.

pt
●: Item that determines the Cause.

Confirm records of recent repairs

Service hours g no Long service hours
Blacken suddenly ◎
△ △ △
○
△
○
Symptom

Color of exhaust gas Blacken gradually ◎ ○ ○

in ti
Blue under light load ◎
Engine oil must be added more often. ◎
Suddenly ◎ ○ ○ ○
Power loss
et a

Gradually ○ ○ ○ ○
Unapproved fuel has been used all the time. ○ ○
n

Noise of interference is heard around the turbocharger. ◎

Dust indicator lights up. ◎
rk er

Excessive blowby ◎
Poor engine acceleration performance or nonuniform combustion ○ ◎ ○ ○ ○ ○
Feel the exhaust manifold with hand immediately after the engine is started. Tem-
◎ ○
Ma t

perature of air cylinders is low.

Investigate

The matching marks on the injection pump are not aligned. ◎

In

Seal of injection pump has detached. ◎

Clangs are heard around the cylinder head. ◎
Abnormal noise of exhaust ○ ○ ◎
The muffler was squeezed. ◎
Loose clamp allows gas to escape between the turbocharger and cylinder head. ◎

The turbocharger is felt resistant when turned with hand. ●

Air cleaner is blocked. ●
Compression force is low. ● ●
The speed does not change when operation of some cylinders is stopped. ●
Diagnose

Injection timing is found incorrect when checking it with oil outlet method. ●
Injection amount is inappropriate according to the testing of injection pump. ●
The air valve clearance is out of the standard range. ●
The color of exhaust gas goes back to normal when the muffler has been re-
●
moved.
The control rack is felt resistant or does not return when pushed. ●
Replace

Replace
Replace

Replace

Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean

Remedy

7-46 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

8 Engine oil consumes excessively (or exhaust gas turns blue)

★ Do not idle the engine continuously for more than 20 minutes. (Either low idle or high idle.)

Cause
General causes:

Wear or damage of rear oil seal and sealing surface

Wear of valve (stem and guide) and damage of seal

Turbocharger
● Engine oil burns.
● Engine oil leaks.
● Wear of lubrication system.

Dust taken in from the air intake system

Wear of piston ring and cylinder sleeve

Engine oil pan or cylinder head leaks.

Breather or breather hose is blocked.

Wear of air compressor end seal

Engine oil drain plug leaks.

Wear of turbine end seal

Engine oil pipe leaks.

.
Symbols:

De al
Piston ring breaks.

Oil cooler breaks.

○: Possible causes (judged by Symptom and Investigate).

pt
◎: Most possible causes (judged by Symptom and Investigate).
△: Long service hours may be a possible cause.
g n
●: Item that determines the Cause.
o
Confirm records of recent repairs
in ti
Service hours Long service hours △
Symptom

Engine oil consumption increases suddenly. ◎ ○

Engine oil must be added more often. ◎ ○

et a

Engine oil becomes dirty soon. ○ ◎ ○

n

Blue smoke under light load ◎ ◎

rk er

Abnormally high ◎ ◎ ○ ○
Blowby amount
None ◎

Dirty engine oil is found around the engine. ◎ ◎ ◎

Ma t

Oil is found in engine cooling water. ◎

In

Dirty oil is found in the exhaust pipe disassembled. ◎ ○

Investigate

Dirty oil is found in disassembled air supply pipe of turbocharger. ◎

Dirty oil found at end cover of engine flywheel ◎

The clamps of air intake system are loose. ◎

Compression force is low. ● ●

The breather element is full of dirty oil. ●
Engine oil leaks. ● ● ●
Diagnose

The airtight test on oil cooler indicates the presence of leakage. ●

The turbocharger shaft clearance is too big. ● ●
Check the rear oil seal directly. ●
Dust is found in the air intake manifold removed. ●
Dirty oil is found in the air intake manifold removed. ●
Replace

Replace

Replace

Replace

Replace
Repair

Repair

Repair

Repair

Repair

Repair
Clean

Remedy

Shop Manual - November 2012 7-47

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

9 Engine oil is contaminated quickly

General causes:
● Exhaust gas is taken in due to internal wear.
● Lubrication channel is blocked.
● Use of inappropriate fuel Cause

● Use of inappropriate engine oil

● Overloaded running

Turbocharger discharge pipe is blocked.

Wear of piston ring and cylinder sleeve

Breather or breather tube is blocked.

Wear of air valve and its guide tube

Oil filter element is plugged.

Damage of turbine end seal

.
Symbols:

De al
Oil cooler is blocked.
○: Possible causes (judged by Symptom and Investigate).

pt
Black exhaust gas
◎: Most possible causes (judged by Symptom and Investigate).
△: Long service hours may be a possible cause.
●: Item that determines the Cause.g no
in ti
Confirm records of recent repairs
Symptom

Service hours Long service hours △ △ △

Engine oil must be added more often. ◎

et a

Unapproved engine oil has been used all the time. ○

n

Blue under light load ◎

Color of exhaust gas
rk er

Black ◎

Abnormally high ◎ ○ ○ ○
Blowby amount
None ◎
Ma t

Proceed with S-7 (Black Exhaust Gas” .

Metal chips are found in oil filter element. ○ ◎ ○
Investigate

In

Dirty oil is found in the exhaust pipe disassembled. ◎

Engine oil temperature rises quickly. ◎

Compression force is low. ● ●

The breather element is full of dirty oil or its hose is broken. ●

Engine oil filter element is plugged. ●

Diagnose

Engine oil cooler is blocked. ●

Turbocharger drain pipe is blocked. ●

The axial clearance of turbocharger is too big. ●

The spring of safety valve is seized or broken.

Replace

Replace

Replace

Replace
Clean

Clean

Clean

Remedy

7-48 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

10 Fuel consumption is excessive

Cause
General causes:
● Fuel leaking

Failure of injection pump (excessive injection)

Damage of oil seal in feeder pump (plunger)

● Inappropriate injection condition

Improper adjustment of fuel control lever

● Excessive injection of fuel

Fuel pipe or fuel filter element leaks.

Failure of injection pump plunger
Damage of injection nozzle seat

Fuel leaks inside cylinder head.

Injection timing is incorrect.
Symbols:
○: Possible causes (judged by Symptom and Investigate).
◎: Most possible causes (judged by Symptom and Investigate).

.
△: Long service hours may be a possible cause.

De al
●: Item that determines the Cause.

pt
Confirm records of recent repairs
g n
Service hours
o Long service hours
Is more than other machines of the
◎
△ △

○
△

same type
Symptom

in ti
Fuel consumption Increases gradually ○ ○

Increases suddenly ○ ○
et a

Black ◎ ○ ○ ○
Color of exhaust gas
White ○
n

Seal of injection pump has detached. ◎

rk er

Non-uniform combustion ◎

Cylinder temp is low when feeling exhaust manifold immediately after engine startup ◎ ○
Ma t

The matching marks on the injection pump are not aligned. ◎

Investigate

In

Fuel leaks from the engine. ◎

Level of engine oil rises and the odor of diesel fuel can be smelt. ○ ◎ ◎

Engine speed is high at low idle. ○ ◎

The test of injection pump shows excessiveness of fuel injection. ●

The speed does not change when operation of some cylinders is stopped. ●

The control rack is felt resistant or does not return when pushed. ●
Diagnose

Injection timing is incorrect when tested with outlet valve method. ●

Remove the cylinder head and check for fuel leakage. ●

Remove the feeder pump and check for damage of fuel seal. ●

The engine speed is high at low idle. ●

Replace

Replace

Repair

Repair

Repair
Adjust

Adjust

Adjust

Remedy

Shop Manual - November 2012 7-49

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

11 Coolant contains engine oil, water sprays back or water level drops
General causes:
● Internal leakage of lubrication system Cause

● Internal leakage of cooling system

Damage of cylinder head and cylinder gasket

Damage of oil cooler core and O-ring

Oil cooler of power train is damaged.

Symbols:

Interior cracking of cylinder block

Pitting develops into depression
○: Possible causes (judged by Symptom and Investigate).
◎: Most possible causes (judged by Symptom and Investigate).
△: Long service hours may be a possible cause.

.
●: Item that determines the Cause.

De al
pt
g no
Confirm records of recent repairs
Symptom

Service hours Long service hours △ △

in ti
Rises suddenly ○ ○ ○
Oil level
Rises gradually ○ ○
et a

Use of hard water as coolant ○ ○

n

Engine oil level is already high and engine oil shows turbid white. ◎ ○ ○

There are excessive bubbles in the radiator and the spray comes back. ◎
rk er
Investigate

Hydraulic oil and oil in the hydrodynamic transmission are turbid white. ◎

Water is found in drained hydraulic oil and oil drain from hydrodynamic transmission. ◎
Ma t
In

The airtight test of oil cooler shows the presence of leakage. ● ●

Diagnose

The airtight test of cylinder head shows the presence of leakage. ●

Remove the engine oil pan and check it directly. ● ●
Replace

Replace

Replace

Replace

Replace

Remedy

7-50 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

12 Engine oil pressure alert indicator lights up (oil pressure drops)

General causes:
● Leakage, blocking or wear of lubrication system
● Improper control of oil pressure
● Use of wrong engine oil (inappropriate viscosity)
● Deterioration of engine oil due to overheating
★ Engine oil selection standard

Select as per ambient temperature

Oil type Cause
-30 -20 -10 0 10 20 30 40°C

.
De al Blocking or breaking of oil pipe in oil pan
SAE 30 CD

pt

Oil contaminated by water and/or fuel

SAE10WCD

Plugging of primary filter in oil pan

Hydraulic line leaks or is crushed.

Engine oil SAE10W-30 CD

Insufficient oil in engine oil pan

g n
Breaking of suction pipe braze

Failure of oil pressure sensor

SAE10W-30 CD
Plugging of oil filter element

Wear of bearing or journal

Failure of oil level sensor

Failure of regulator valve
o

Failure of relief valve

Symbols:
in ti

Failure of oil pump

○: Possible causes (judged by Symptom and Investigate).
◎: Most possible causes (judged by Symptom and Investigate).
△: Long service hours may be a possible cause.
et a

●: Item that determines the Cause.

n

Confirm records of recent repairs

Service hours Long service hours △ △ △
rk er

Filter element was not replaced as per Operation and Mainte-

Symptom

◎
nance Manual.
Alert indicator lights up. ◎ ○
Unapproved engine oil has been used all the time. ○ ○
Ma t

Low idle ◎ ○
Conditions for oil pressure indicator Low idle or high idle ◎ ◎ ◎ ◎ ○ ○ ○
In

lighting up Traveling uphill ◎

Sometimes ◎ ◎ ○ ○
Hydraulic line is blocked or leaks (externally). ◎
Engine oil level sensor indicator lights up. ◎ ◎
Investigate

Oil level in engine oil pan is low. ◎

Metal chips are found in engine oil drained. ◎
Metal chips are found attaching to the element of engine oil filter. ◎ ○
Engine oil looks turbid white or gives the smell of diesel fuel. ◎

The engine oil filter element is plugged. ● ●

Proceed with S-13

Remove the engine oil pan and check it directly. ● ● ●

Diagnose

Oil pump rotates heavily; excessive play. ●

Relief valve or regulator valve seized. Spring/valve stem broken. ● ●
Oil level sensor indicator goes off when replacing oil level sensor. ●
The oil pressure measured is out of the standard range. ●
Replace

Replace

Replace
Repair

Repair
Adjust

Adjust
Clean

Clean

Clean

Clean

Remedy
____
Add

Shop Manual - November 2012 7-51

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

13 Higher oil level (engine oil contaminated by water and/or fuel)

★ If the coolant is contaminated by engine oil, proceed with S-11.

General causes:
● Engine oil is contaminated by water (looks turbid white)
● Engine oil is contaminated by fuel (diluted, giving out the smell of diesel fuel).
● Oil flows in from other components.
Cause

Cylinder head/gasket damage (pre-combus-

Fuel leaks in the pipe inside cylinder head.

Seal of pump auxiliary device is damaged.
Surface wear or damage of rear oil seal.
Damage of oil cooler core and O-ring

. Part in injection pump is damaged.

Internal cracks in cylinder block

De al

Depression caused by pitting

Failure of nozzle seat jacket

pt
Symbols:

Failure of thermostat
○: Possible causes (judged by Symptom and Investigate).
g n
◎: Most possible causes (judged by Symptom and Investigate).

tion chamber)
o
△: Long service hours may be a possible cause.
●: Item that determines the Cause..
in ti
Symptom

Confirm records of recent repairs

Service hours Long service hours △ △ △ △
et a

Radiator coolant contaminated by engine oil ◎ ○ ○ ○ ○

n

White exhaust gas ◎ ○ ○

Water drips from muffler when the engine is started. ◎
rk er

Open the radiator cap. When the engine runs at idle speed, abnormal
◎ ○
amount of bubbles appear or water sprays back.
The breather hole of water pump is blocked by sludge.
Ma t

Water comes out of the breather hole of water pump when cleaned.
Oil level in the clutch, hydrodynamic box or buffer cavity drops. ◎
In
Investigate

Oil level in hydraulic tank drops. ◎

Engine oil give out the smell of diesel fuel. ◎ ◎ ◎
Fuel must be often added. ◎ ◎ ◎
Low water temperature ◎

The airtight test of engine oil cooler shows a leakage. ●

The airtight test of cylinder head show a leakage. ●
Compression force is low. ●
Remove the rear seal and check it directly.
Diagnose

●
Seal of the pump auxiliary device is damaged. ●
Remove the cylinder head cover and check it directly. ●
Remove the injection pump and check it directly. ●
Improper contact of thermostat sealing valve ●
Remove and check the engine oil pan. ● ●
Replace

Replace

Replace

Replace

Replace

Replace

Replace
Repair

Repair

Repair

Remedy

7-52 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

14 Higher water temperature (overheated)

General causes:
● Lack of cool air (deformation or damage of fan) Cause

Oil temp. of torque converter over-rises .

● Efficiency of heat dissipation drops.

Damage of cylinder head and gasket

Thermostat error (Actuation failure).
Plugged or crushed fins of radiator
● Failure of cooling system

Blocking or breaking of oil cooler

Failure of coolant thermometer

Depression caused pitting

● Oil temperature of power train rises too high.

Water pump is damaged.

Failure of pressure valve

Plugging of radiator core

Fan belt skids or wears.

Coolant is insufficient.
Symbols:
○: Possible causes (judged by Symptom and Investigate).
◎: Most possible causes (judged by Symptom and Investigate).
△: Long service hours may be a possible cause.

.
●: Item that determines the Cause.

De al
pt
Confirm records of recent repairs
Service hours Long service hours △ △ △ △

g n Sudden overheating ◎ ○ ○
Symptom

Overheating conditions
Overheating tendency ◎ ◎ ○ ○
o
Temperature rises quickly. ◎
Water thermometer
in ti
Stay in the red range. ◎
Water level sensor of radiator lights up. ◎
The lower fan belt produces noise when loaded suddenly. ◎
et a

Turbid white oil floats on the coolant. ◎

Coolant flows out of the overflow hose. ◎
n

There are excessive bubbles in the radiator. Water sprays back. ◎

rk er

Engine oil level is high. The oil looks turbid white. ○ ◎

There is play while the fan belt pulley is rotating. ◎
Investigate

Debris or sludge is full under radiator cover and lower guard. ◎ ◎

Ma t

When the radiator is illuminated with a bulb behind it, there is no

◎
light coming through it.
In

Water leaks due to cracking hose or loose clips. ◎

The belt is found slack when belt tension is checked. ◎
Oil temperature of the power train enters the red range faster than
◎
engine coolant temperature.

Temp difference between top and bottom of reservoir is large. ●

Perform diagnose on the chassis.

Temp difference between top and bottom of reservoir is small. ●

The core is found blocked when checking the filler of water. ●
The thermostat is not activated at the activating temperature during
Diagnose

●
testing.
The temperature of water is normal during testing. ●
The oil cooler is blocked. ●
The set pressure is low when checked with the radiator cap tester. ●
Compression force is low. ●
Remove the oil pan and check it directly. ●
Add Water
Replace

Replace

Replace

Replace

Replace

Replace

Replace
Repair

Repair

Repair

Remedy

Shop Manual - November 2012 7-53

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

15 Abnormal noise

★ Internal noise or external noise is to be

Cause
determined.

Air leaks between turbocharger and cylinder head.

Back clearance of gear drive system is incorrect.
General causes:

Injection pump failure (seized rack and plunger)

Failure of injection pump (excessive injection)

Valve gear breaks (air valve, rocker arm, etc.)

Deformation of fan or interference of fan belt

Improper adjustment of air valve clearance.

Internal failure of muffler (Screen deviates).

● Abnormal noise caused by damage of part

Wear of piston ring and cylinder sleeve

Injection nozzle is blocked or seized.

● Irregular combustion

Turbocharger is seized or interfered.

● Air intake system is abnormal.

Sleeve is missing or seized.

Symbols:
○: Possible causes (judged by Symptom and Investigate).

.
◎: Most possible causes (judged by Symptom and Investigate).

De al
△: Long service hours may be a possible cause.

pt
●: Item that determines the Cause.

g n
Confirm records of recent repairs
Service hours
o Long service hours △
Symptom

Gradual occurrence ○ ○
Conditions for abnormal noise
Sudden occurrence
in ti
○ ○ ○
Unapproved fuel has been used all the time. ○ ○
Engine oil must be added more often. ◎
Blue under light load ◎
et a

Color of exhaust gas

Black ◎ ○ ○
Metal chips are found in engine oil filter element. ◎ ◎
n

Excessive blowby ◎
Interfering noise is heard around the turbocharger.
rk er

◎
Engine acceleration is poor and combustion is abnormal. ◎
Cylinder temp is low when feeling exhaust manifold immediately af-
◎ ○
ter the engine is started.
Investigate

Ma t

Seal of injection pump has detached. ◎

The engine gives high abnormal noise when accelerated. ○ ○ ○ ○ ○ ○
In

Clangs are heard around the cylinder. ◎ ◎

Air leaks between turbocharger and cylinder head. Loose clasp . ◎
Noise of vibration is heard around the muffler. ◎

Compression force is low. ●

The turbocharger is felt resistant when turned with hand. ●
Remove the gear chamber cover and check it directly. ● ●
Speed does not change when operation of some cylinders stops. ●
Diagnose

The control rack is found resistant or hard to return while pushed. ●

Injection amount is found incorrect when testing injection pump. ●
The fan deforms and/or the belt is loose. ●
The air valve clearance is out of standard range. ●
Remove the cylinder head and check it directly. ●
Abnormal noise disappears after the muffler is removed. ●
Replace

Replace

Replace

Replace

Replace

Replace

Replace
Repair

Repair

Repair
Adjust

Adjust

Remedy

7-54 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

16 Violent vibration

★ If abnormal noise is also heard along with vibration, proceed with S-15.
General causes: Cause

Valve gear (air valve, rocker arm and so on) is seized.

Engine mounting bolts are loose. Cushion is damage.

The back clearance of gear drive system is incorrect.

● Damage (abnormal wear or breaking) of part

Engine and power train not aligned by centerline.

● Misalignment

Failure of injection pump (excessive injection)

The part (damper) of output shaft is broken.
● Irregular combustion

The rod and main bearing are worn.

The cam bushing is worn.

Symbols:

.
De al
○: Possible causes (judged by Symptom and Investigate).

pt
◎: Most possible causes (judged by Symptom and Investigate).
△: Long service hours may be a possible cause.

g n
●: Item that determines the Cause.
o
Confirm records of recent repairs
Long service
in ti
Service hours △ △ △
hours
Symptom

Sudden in-
○ ○
crease
Conditions for vibration
Gradual in-
et a

○ ○ ○
crease
n

Unapproved engine oil has been used all the time. ○ ○

Metal chips are found in engine oil filter element. ◎ ◎

rk er

Metal chips are found in engine oil drained. ◎ ◎

Oil pressure is low at low idle. ○ ○

Ma t

Vibration occurs in the range of moderate speed. ○ ○

Investigate

In

Vibration changes with engine speed. ○ ○ ○ ○

Exhaust gas becomes black. ◎ ○

Seal of injection pump has detached. ◎

Remove the oil pan and check it directly. ●

Remove the side cover and check it directly. ●

Check wether the engine mounting bolts are loose and whether the cushion is damaged. ●
Diagnose

Check directly the interior of output shaft (damper). ●

The results of radial runout test and end face runout test are out of the standard ranges. ●

Remove the front cover and check it directly. ●

Remove the cylinder head cover and check it directly. ●

The amount of injection is incorrect when testing the injection pump. ●

Replace

Replace

Replace

Replace

Replace
Repair

Repair

Adjust

Remedy

Shop Manual - November 2012 7-55

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

7-56 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

7.9 Troubleshooting of Hydraulic and Mechanical System

1 Work equipment, swing drive and final drive operate slowly or power is weak ..................... 7-56
2 Engine speed drops sharply or engine stalls ......................................................................... 7-58
3 Work equipment, final drive and swing drive do not work ..................................................... 7-59
4 Abnormal noise occurs (around the pump)............................................................................ 7-59
5 Poor precise control performance or bad sensitivity.............................................................. 7-60
6 Boom moves slowly or power is weak ................................................................................... 7-60
7 Arm moves slowly or power is weak ...................................................................................... 7-62
8 Bucket moves slowly or power is weak ................................................................................. 7-64
10 Excessive hydraulic drift (of boom, arm and bucket) ........................................................... 7-65
10 Response is slow when engine runs at low idle ................................................................... 7-66

.
11 Work equipment with greater load moves slowly during combined operation ..................... 7-66

De al
12 Boom raises slowly during swing + boom RAISE operation................................................ 7-67

pt
13 Travel speed drops considerably during travel + swing operation....................................... 7-67
14 Travel speed drops fast during travel + boom RAISE operation ......................................... 7-67
g n
15 Machine cannot make a straight travel ................................................................................ 7-68
o
16 Excessive travel deviation the beginning............................................................................. 7-70
17 Travel speed is low or power is weak .................................................................................. 7-70
in ti
18 Difficulty in turning operation ............................................................................................... 7-71
19 Travel speed cannot be changed ........................................................................................ 7-72
20 Travel system fails (only at one side) .................................................................................. 7-72
et a

21 Swing operation fails ........................................................................................................... 7-73

n

22 Poor swing acceleration ...................................................................................................... 7-74

rk er

23 Excessive overrunning upon swing stoppage ..................................................................... 7-76

24 Considerable shaking resulted from swing stoppage (in only one direction) ...................... 7-77
25 Abnormally high noise resulted from swing stoppage (in only one direction) ...................... 7-77
Ma t

26 Excessive hydraulic drift of swing (when swing brake is released or applied) .................... 7-78
27 Swing speed is faster than specified ................................................................................... 7-79
In

28 Dozer blade moves slowly or power is weak ....................................................................... 7-79

29 Dozer blade does not work .................................................................................................. 7-80
30 Excessive hydraulic drift of dozer blade .............................................................................. 7-80

Shop Manual - November 2012 7-57

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

1 Work equipment, swing drive and final drive operate slowly or power is weak

★ Make sure that the main pump produces no abnormal noise before troubleshooting.

(Perform troubleshooting described in 4 in case of any abnormal noise.)

.
YES Plunger pump

De al
error

pt
2
g n
YES Is the relief pres-
sure of main valve
regular?
o
● 21.5~22.5MPa 4
in ti
(Rexroth) Main relief valve
26.3MPa (HUSCO) NO error
1 ● Engine at high idle
Is the setting of speed
et a

pilot pressure
correct?
n

※Check and
rk er

measure the
pressure of oil
circuit accord- NO
ing to related
Ma t

sections of
Te s t i n g a n d
Adjusting.
In

7-58 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

Cause Remedy

Plunger pump error Repair or replace

.
De al
pt
g no
Main relief valve failure Replace
in ti
et a

Failure of pressure unit in the pilot oil Repair or replace

n

circuit (see Testing and Adjusting)

rk er
Ma t
In

Shop Manual - November 2012 7-59

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2 Engine speed drops sharply or engine stalls

★ Make sure that the main relief pressure is regular.

Cause Remedy
YES Throttle valve in servo Clean
mechanism blocked
1
Is the throttle
valve of servo
mechanism
blocked?

.
Is the engine Refer to troubleshooting of —

De al
speed regular at engine

pt
NO relief?

g no
in ti
et a
n
rk er
Ma t
In

7-60 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

3 Work equipment, final drive and swing drive do not work

Cause Remedy
Failure of pilot oil pressure Replace
2 YES lockout solenoid valve
YES Is pilot set pres-
sure normal? Failure of control circuit Replace
1
Disconnect pilot ● 35 MPa NO
oil source block {35 kg/cm2}
and check for oil ● Engine at high idle Failure of main pump Repair or replace
leakage. 3 YES

● Start the engine Is PTO spline

with the start normal? Failure of PTO spline Repair or replace
NO

.
motor NO

De al
pt
g no
in ti
4 Abnormal noise occurs (around the pump)
et a
n

Cause Remedy
rk er

3 YES
To part 4
YES Do the bubbles
disappear after
the engine is
Ma t

2 shut down? Bad hydraulic oil Replace hydrau-

NO
lic oil
YES A r e t h e r e
In

bubbles in the
YES
hydraulic tank?
4 Blocked by impurities such Clean
Is oil suction as fibers
1 screen plugged
5 YES
by foreign sub-
Is oil level in the NO stances? Internal failure of pump Repair or re-
Is the oil suction
hydraulic tank place
screen plugged
normal? ※Impurities: fab- by metal impuri-
ric, etc.
NO ties? Are there
metal chips
adhered to the Observe the changes dur- Check again ac-
drain plug? ing short operation. cording to varia-
NO tion of condition.

Insufficiency of hydraulic Refill hydraulic

NO oil oil.

Shop Manual - November 2012 7-61

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

5 Poor precise control performance or bad sensitivity

Cause Remedy

YES
1 Throttle valve in LS oil cir- Clean
Is the throttle valve cuit is blocked.
in the LS oil circuit
blocked? F a i l u r e o f f l o w c o n t r o l Replace
valve or servo plunger
NO

.
De al
pt
g no
6 Boom moves slowly or power is weak
in ti
★ When travel speed and swing speed are normal
et a
n
rk er

6 YES
Is the leakage
YES
of hydraulic cyl-
inder normal?
NO
Ma t

5
Is the LS pres- ● Max. 15 cc/min
4YES
In

sure normal when ● Engine at high idle

Is the pressure the boom raises ● Relief at stroke end
compensation in relief?
YES v a l v e n o r m a l ?
Does the pres- Engine at high idle
NO
3 sure compensa- 26.3 MPa (HUSCO)
Does the con- tion valve moves 21.5~22.5 MPa (Rexroth)
YES trol valve spool
steadily?
2 moves steadily? NO
Is the pilot valve
output pressure
YES
normal? NO
1
● 3~3.5 MPa
Is LS pressure NO
normal? ● Engine at high
idle
26.3
MPa(HUSCO) NO
21.5~22.5 MPa
(Rexroth)

7-62 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

.
De al
pt
g no
in ti
et a

Cause Remedy
n

Failure of regeneration valve Replace

rk er

Damage of hydraulic cylinder gasket Repair or replace

Ma t
In

Failure of oil suction valve Replace

Damage or failure of pressure com- Repair or replace

pensation valve

Failure of control valve spool Repair or replace

Damage of PPC valve Replace

Failure of safety valve and oil suction Replace

valve

Shop Manual - November 2012 7-63

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

7 Arm moves slowly or power is weak

★ When travel speed and swing speed are normal

5 YES
Is the LS pres-
YES s u r e n o r m a l
4 when the oil
Is the pressure circuit of arm in
YES c o m p e n s a t i o n relief? NO
valve normal?
3 Des the pres-
Does the control sure compensa-

.
YES

De al
valve spool move tion valve move NO
2 steadily? steadily?

pt
Is the pilot valve
YES output pressure NO
normal?

normal?
1
Is the LS pressure
g no 3~3.5 MPa
Engine at h i g hNO
idle
in ti
NO
● 26.3 MPa (HUSCO)
21.5~22.5 MPa (Rexroth)
● Engine at high idle
et a
n

Is the leakage 6 YES

A of arm cylinder
rk er

normal?

● Max. 15 cc/min NO
● Engine at high idle
Ma t

● Relief at travel end

In

7-64 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

Cause Remedy

To “A”

Failure of oil suction valve Replace

Damage or failure of pressure com- Repair or replace

pensation valve

.
De al
pt
Failure of control valve spool Repair or replace

g no Damaged pilot valve Replace

Failure of safety valve and oil suction Replace

in ti
valve
et a
n

Failure of regeneration valve Repair or replace

rk er

Damage of arm cylinder plunger gas- Repair or replace

ket
Ma t
In

Shop Manual - November 2012 7-65

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8 Bucket moves slowly or power is weak

★ When travel speed and swing speed are normal

Cause Remedy

3 YES
To“A” Replace
YES Does the control
valve spool move
2 steadily？
Is pilot valve
YES output pressure NO F a i l u r e o f c o n t r o l Repair or re-
normal? valve spool place

.
De al
1 3.0~3.5MPa

pt
Are the LS pres- Damage of PPC valve Replace
NO
sure and the
system pressure
normal?
Rexroth: 24.5 MPa
HUSCO: 26.3 MPa
g no
D a m a g e o f s a f e t y Replace
NO valve
in ti
YES
5
Failure of safety valve Replace
YES Is the leakage of bucket
et a

cylinder normal?
n

4
● Max. 15 cc/min
Is the pressure NO Damage of bucket cyl- Repair or re-
● Engine at high idle
rk er

compensation inder plunger gasket place

From“A” ● Relief at travel end
valve normal? Des
the pressure com-
pensation valve
move steadily?
Ma t

Damage or failure of Repair or re-

NO pressure compensa- place
tion valve
In

7-66 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

10 Excessive hydraulic drift (of boom, arm and bucket)

Since the safety valve and oil suction valve act

together upon the boom, arm and bucket, ex-
cessive hydraulic drift occurring equally in the
boom, arm and bucket indicates damage of
the safety valve.

Cause Remedy
YES Failure of secondary Replace
relief valve
Is everything
normal after the
secondary relief

.
valve has been Damage of oil seal of Replace

De al
Is the leakage
replaced. control valve spool
of hydraulic cyl-

pt
inder normal? NO

Damage of hydraulic Replace

●
g n
See Testing and
Adjusting.
o cylinder plunger gas-
ket
● Engine at high idle
in ti
● Relief at strokel
end
et a
n
rk er
Ma t
In

Shop Manual - November 2012 7-67

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10 Response is slow when engine runs at low idle

★ When work equipment works at a regular

speed

Cause Remedy
Failure of secondary C l e a n o r
relief valve replace

.
De al
pt
g n
11 Work equipment with greater load moves slowly during combined operation
o
★ When engine runs at full speed
in ti

Cause Remedy
et a

Failure of pressure Replace (the pressure compensation valve

compensation valve with less load)
n
rk er

(※Replace the valve group assembly)

Combined operations Side with greater load

Ma t

1 Boom RAISE + Arm IN Boom RAISE

In

2 Boom RAISE + Arm OUT Arm OUT

3 Boom RAISE + Bucket CURL Boom RAISE

4 Arm OUT + Bucket DUMP Arm OUT

5 Boom LOWER + Arm OUT Arm OUT

7-68 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

12 Boom raises slowly during swing + boom RAISE operation

★ When machine works normally and Swing

and Boom RAISE are operated separately

Cause Remedy
1. Pilot pres- Check pressure
sure low
Clean or replace
2. Oil leakage

13 Travel speed drops considerably during travel + swing operation

.
De al
★ When machine works normally and Swing

pt
and Travel are operated separately

g no
Cause Remedy
Failure of pressure R e p a i r o r
in ti
compensation valve replace
and LS check valve
(The pressure com-
pensation valve is
et a

used for travel.)

n
rk er

14 Travel speed drops fast during travel + boom RAISE operation

Ma t
In

★ When machine works normally and Work

Equipment (Boom RAISE) and Travel are
operated separately

Cause Remedy
Excessive travel Replace travel
flow decrease dur- compensation
ing travel+swing valve spool
operation, causing
rapid travel speed
reduction.

Shop Manual - November 2012 7-69

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

15 Machine cannot make a straight travel

★ When work equipment speed and swing speeds are normal

a. Machine deviates at one side during forward travel and reverse travel.

Cause Remedy
YES
3
Repair or
Damage of final drive
YES Are there any replace
metal chips seen
2

.
in the drainage of

De al
Does pressure final drive at the
YES compensation side of deviation? To“A”

pt
valve (at the side NO
of deviation)
1
Is output pressure
difference between
g nomove steadily?
3.0~3.5MPa NO
Damage or failure of
pressure compensa-
tion valve
Repair or
replace
the left and the
in ti
right travel pilot
valves normal? YES
Damage of travel pilot
● Output pressure 4 Replace
valve
difference between Does the control
et a

forward travel and lever of travel

reverse travel: 0.2 NO pilot valve reach
Correct the fault of
n

MPa or lower the stopper?

connecting rod adjuster Adjust
NO
● Engine at high idle of travel control lever
rk er

● Travel relief
YES
Damage of swivel joint R e p a i r o r
gasket replace
Ma t

NO Does the travel motor

drain normally?
In

5 Damage of travel mo- Replace

Does the machine tor internal linkage, the gasket
● Max. 5l/min
deviate toward the NO brake, counterbalance or the as-
other side when the ● Engine at high idle valve or check valve sembly
From“A”
left and right hoses ● Travel relief
between control
valve and swivel
joint are swaped. Damage of control Repair or
YES valve spool replace

7-70 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

b. The side of deviation is different during forward travel and reverse travel.

Cause Remedy

YES
1 Damage of swivel joint R e p a i r o r
Does the control gasket replace
lever of travel
pilot valve reach
the stopper?
Failure of control valve R e p a i r o r
NO spool replace

.
De al
pt
Figure 1 Position of damaged swivel joint seal and direction of travel deviation

g no
in ti
Forward
T1(Discharge)
Only right side Forward
moves forward
A1 (Right forward)
et a

Forward Right forward and

Reverse right reverse
B1 (Right reverse)
n

Right reverse Forward

and left forward Reverse
C1 (Left forward)
Left forward and
rk er

Forward
Reverse left reverse
Only left side
D1 (Left reverse)
reverse Reverse
E1 (Dozer lower)
Ma t

Reverse F1 (Dozer lift)

In

Direction of deviation is the same

Direction of deviation is different in foward travel and reverse.
in forward travel and reverse.
ZX55-1005046

Shop Manual - November 2012 7-71

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

16 Excessive travel deviation the beginning

★ When travel speed is normal

★ (However, deviation can also occur during normal travel. Perform troubleshooting according
15 “Machine Cannot Make a Straight Travel”.

Cause Remedy

YES Replace
2
Failure of control valve the control
Is there the sign of

.
spool valve as-

De al
YES swapping when the
left and right hoses sembly.

pt
1 between the control
Replace
Is there the sign of valve and swivel
joint are swapped? Damage of swivel joint the gasket
swapping when the
left and right hoses
between the swivel
joint and the motor
g no NO gasket or the as-
sembly

are swapped? Damage of travel mo- R e p l a c e

in ti
tor (failure of travel t h e m o t o r
NO
※ See Testing and Ad- counterbalance valve) assembly.
justing
et a
n

17 Travel speed is low or power is weak

rk er

★ When no deviation occurs during travel (In case of travel deviation, first perform troubleshoot-
ing as per 15 “Machine Cannot Make a Straight Travel.” )
Ma t

★ When work equipment operates at normal speed

In

Cause Remedy

YES
Damage or seizure of C l e a n o r
2
When balance valve balance valve spool replace
YES
is cleaned or re-
placed, does it get
1
better?
When travel motor Refer to troubleshoot-
—
is relieved, is the NO ing of engine
relief pressure nor-
mal?
※ See Testing and Damage or inappropri-
Adjusting Adjust or
ate adjustment of main
NO replace
relief valve

7-72 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

18 Difficulty in turning operation

Cause Remedy

2 YES Damage of travel mo-

Repair or
tor servo plunger or
Is the output replace
center swivel joint
YES pressure of travel
Both sides
speed selector
valve normal?
1 Failure of travel speed R e p a i r o r
3.0~3.5MPa NO selector valve replace
Is it difficult to
change toward
both the left
and right sides YES Damage or failure of
Repair or

.
or just one pressure compensa-

De al
replace
side? 3 tion valve

pt
Does the control
One side lever of travel
pilot valve reach YES Failure of oil suction
4 Repair or
g nNO
o the stopper? Does situation
change reversely
after oil suction
NO valves of control
valve of the control
valve
replace
in ti
valve are swapped? Damage of check valve
Replace
NO of the travel motor
(Low or high)
et a
n
rk er
Ma t
In

Shop Manual - November 2012 7-73

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

19 Travel speed cannot be changed

Cause Remedy

YES Failure of travel speed

1 selector servo plunger Replace
Is the output of travel motor
pressure of travel
speed selector
valve normal?
Failure of travel speed R e p a i r o r
NO selector valve replace
● 3~3.5 MPa
● Travel speed selector
at Hi position (high
speed)

.
De al
● Travel switch ON

pt
● Engine at high idle

g n
20 Travel system fails (only at one side)
o
in ti
Cause Remedy
YES
3 Motor damaged Replace
YES Is LS pressure
2
et a

normal
YES Is brake re- Safety valve damaged Replace
leased?
n

NO
Brake damaged or
rk er

1 balance valve not fully Replace

NO
Is pilot pres- open
sure normal?
Ma t

Repair or
Pilot portion error
replace
In

NO

7-74 Shop Manual - November 2012

 SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

21 Swing operation fails

a) Swing operation fails in both left and right
directions.

Cause Remedy

2 YES
YES Swing motor damaged Replace
Is LS pressure
normal
Clean or
Valve spool seized
NO replace
1
Is pilot pres-
sure normal?

.
De al
Oil source solenoid R e p a i r o r

pt
valve damaged replace
NO

g no
in ti

b) Swing operation fails only in one direction.

et a
n

Cause Remedy
rk er

YES
1 To“A”
Is the shuttle
valve of swing
Ma t

pilot circuit nor-

mal?
In

Shuttle valve damaged Replace

NO

YES Damage of swing mo-

3 Replace
tor safety valve
YES Does the control
valve spool move
2 smoothly?
Is the pilot valve D a m a g e o f c o n t r o l Repair or
From“A” output pressure valve spool replace
normal? NO

● 3~3.5 MPa
● Operate the swing con-
trol lever Damage of pilot valve Replace
● Turn the swing lock- NO
out switch to the ON
(locked) position.
● Engine at high idle

Shop Manual - November 2012 7-75

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

22 Poor swing acceleration

2 YES
Does the pres-
YES sure compensa-
Both sides tion valve move
steadily?

NO
3.0~3.5MPa

6
Does situation
YES g e t n o r m a l YES
after left and

.
1 right motor

De al
I s i t d i ff i c u l t safety valves

pt
to turn left or are swapped?
right, or both
NO
sides?
g no
5
Does the
YES
in ti
4 control valve
Is output pressure spool move
YES
of pilot valve (at steadily ？
the side of shuttle
valve body) nor- NO
et a

mal?
NO
n

3
● Condition similar to
Is the pilot item 5
rk er

One side valve output

pressure nor- ● Remove the inlet
NO mal? hose of pilot shuttle
valve. Install a con-
● 3~3.5 MPa nector and plug its
Ma t

● Engine at full speed end.

In

● Swing lockout switch

ON (locked) NO

※ When the oil circuit is not blocked by a connector.

Hoses of the pilot valve can replace the swing hose with the arm (IN and OUT) hose or the boom
(RAISE) hose, and then reverse the operation.

7-76 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

Cause Remedy

Damage of swing mo- R e p a i r o r

tor assembly replace

Damage of pressure Replace

compensation valve

Damage of swing mo-

Replace
tor safety valve

.
De al
Damage of swing mo- Replace
tor oil suction valve

pt
g no
in ti

Failure of control valve R e p a i r o r

spool replace
et a

Failure of pilot shuttle Connect or

valve (used for swing replace
n

operation)
rk er
Ma t
In

Failure of pilot valve Replace

Shop Manual - November 2012 7-77

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

23 Excessive overrunning upon swing stoppage

a) Only one side

Cause Remedy

YES
2 Damage of pilot valve Replace
YES Does the situation
change reversely af-
ter swapping the left
1 and the right output
Damage of swing mo-
Does the control hoses of the pilot Replace
tor safety valve
valve spool move valves. NO
steadily?

.
De al
Damage of control Repair or
NO valve spool replace

pt
g no
in ti

b) Both sides
et a
n

Cause Remedy
Damage of swing mo-
rk er

Repair or replace
tor
Ma t
In

7-78 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

24 Considerable shaking resulted from swing stoppage (in only one direction)

Cause Remedy

YES
1 Damage of pilot valve Replace
Does the
control valve
spool move
steadily? Damage of control Repair or
valve spool replace
NO

.
De al
25 Abnormally high noise resulted from swing stoppage (in only one direction)

pt
g no Cause Remedy

YES
in ti
Damage of swing mo-
Replace
tor safety valve

1
Does the control
et a

YES
valve spool move Damage of swing mo-
Replace
steadily? 2 tor oil suction valve
n

Does the situa-

tion get normal
rk er

after the oil YES

3 D a m a g e o f s w i n g Repair or
NO suction valve is
replaced? mechanism replace
Are there any
debris in the
swing mecha-
Ma t

NO
nism?
Damage of back pres- R e p a i r o r
In

sure valve replace

NO

Shop Manual - November 2012 7-79

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

26 Excessive hydraulic drift of swing (when swing brake is released or applied)

When swing brake is released

Cause Remedy

2 YES Damage of swing mo-

Does the symp- Replace
tor safety valve
YES tom appear
Only one side reversely after
swapping the
left and the right
Damage of swing mo- R e p a i r o r
safety valves?
tor oil suction valve replace
1 NO
Does the control

.
valve spool move

De al
steadily? 3 YES Damage of oil seal of
Replace

pt
control valve spool
Is the amount of
Both sides motor discharge
NO normal?
g no
● 7l/min NO
Damage of swing mo- R e p a i r o r
tor replace
● Engine at high idle
in ti
● When swing is re-
lieved
et a
n

When swing brake is applied

rk er

Cause Remedy

YES
Ma t

Repair or
1 Failure of swing brake
replace
In

Is the output pres-

sure of swing brake
solenoid valve
regular? Failure of swing brake R e p a i r o r
● Engine at high idle NO solenoid valve replace

7-80 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

27 Swing speed is faster than specified

Cause Remedy

Failure of flow control

Replace
valve

.
De al
pt
28 Dozer blade moves slowly or power is weak

g n
★ When work equipment speed, travel speed
and swing speed are normal
o
Cause Remedy
in ti
YES
Failure of dozer blade A d j u s t o r
1
valve (relief valve) replace
Is the amount
et a

of blade cyl-
inder leakage
n

normal? Damage of dozer blade

Replace
cylinder plunger gasket
NO
rk er

● Engine at high
idle

● Released at
stroke end
Ma t
In

Shop Manual - November 2012 7-81

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

29 Dozer blade does not work

★ When the Dozer blade is operated sepa-

rately

Cause Remedy

YES
2 Damage of pilot valve Replace
Does the failure
YES become reversed
1
Does the control after swapping the
valve spool move left and the right Damage of control
Replace
steadily? output hoses of valve
pilot valve? NO

.
De al
pt
Failure of control valve R e p a i r o r
spool replace
NO
g no
in ti
30 Excessive hydraulic drift of dozer blade
et a

Cause Remedy
n

YES Failure of dozer blade

Adjust or
rk er

1 valve (relief valve or

replace
Is the amount safety valve)
of dozer blade
cylinder leak-
age normal?
Ma t

Damage of dozer blade

Replace
cylinder plunger gasket
● Engine at high NO
In

idle
● Released at
stroke end

7-82 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

7.10 Troubleshooting of Machine Monitoring System

Harness of machine monitoring system .................................................................................... 7-82

1 Charging indicator does not light up when start switch is ON ............................................... 7-83
2 Preheat indicator does not light up when start switch is at HEAT position ............................ 7-84
3 Engine coolant temperature reading is abnormal .................................................................. 7-85
4 Engine oil level indication is abnormal................................................................................... 7-86
5 Work lamps do not light up .................................................................................................... 7-87
6 Horn does not sound ............................................................................................................. 7-88

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 7-83

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Harness of machine monitoring system

Oil pressure switch

Throttle control device

Relay group

Safety relay
To access lamp
To engine Preheat controller

To start motor Washer switch

Fuel control dial
Wiper switch

To oil source valve Start switch

.
De al
To oil level gauge

pt
In-cab lamp switch

Fuse box
g no
Battery contactor To wiper, cigar lighter
and in-cab lamp
in ti
Integrated controller

Electric horn
et a

Work lamp
n
rk er

ZX55-1005047
Ma t
In

7-84 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

1 Charging indicator does not light up when start switch is ON

★ Check related connectors for contact problem before troubleshooting.

★ Make sure that the connectors removed are restored before carrying out next step.

Cause Remedy

YES
Damage of start switch Replace

.
De al
Damage of start YES
switch Damage of indicator
Replace

pt
2 light
Are the both
ends of indicator
g no NO light normal?

NO
Harness broken
Check the
harness.
in ti
et a

Related diagram
n

60
Connected to safety relay
rk er

Engine
Indicator Light for
Ma t

Battery Charging
In

L
B
R

Start Switch

E
START ON OFF
B

Br

R1 Fuse
13 14
Acc

R2

C ZX55-1005048

Shop Manual - November 2012 7-85

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2 Preheat indicator does not light up when start switch is at HEAT position

★ Check related connectors for contact problem before troubleshooting.

★ Make sure that the connectors removed are restored before carrying out next step.

Cause Remedy

YES
Damage of start switch Replace

.
1

De al
Damage of start YES

pt
switch 2 Damage of indicator
Replace
Voltage at either light
end of the pre-
g noNO
heat indicator
light is normal.
Harness broken
Check the
harness.
NO
in ti
et a

Related diagram
n

Preheat Controller
rk er

To preheat fuse
Ma t

T-132 T-131
In

17 1 2 16
To preheat plug
68 14 14 66
1 2
3 4 61 0
3 5
Preheat Relay 68 69
4 6
Start Switch CN-134M

START ON OFF 14

B Preheat Indicator Light

Br

R1 Fuse
13 14
Acc
61
R2

C
ZX55-1005049

7-86 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

3 Engine coolant temperature reading is abnormal

★ Check related connectors for contact problem before troubleshooting.

★ Make sure that the connectors removed are restored before carrying out next step.

Cause Remedy

YES Damage of water temp

Replace
sensor

.
1 YES

De al
Repair or
Damage of Trouble of controller
replace

pt
water temp 3
sensor YES
Controller input
normal
g no Check for
bad ground-
2

NO
Tr o u b l e o f h a r n e s s
between controller and
water temp sensor
Check the
harness.

NO ing.
in ti
Bad grounding Reground
NO
et a
n

Related diagram
rk er
Ma t

Integrated controller
In

Temp.sensor T-118 CN-145F CN-226M CN-235M CN-603F CN-601F

510 510 510

ZX55-1005050

Shop Manual - November 2012 7-87

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4 Engine oil level indication is abnormal

★ Check related connectors for contact problem before troubleshooting.

★ Make sure that the connectors removed are restored before carrying out next step.

Cause Remedy

YES
Damage of start switch Replace

.
YES

De al
1
Damage of indicator
Replace

pt
Damage light
of oil level 3
YES
sensor Controller input
g no
Check for
2
normal

NO
Harness broken
Check the
harness.
bad ground-
NO
in ti
ing.

Bad grounding Reground

NO
et a
n
rk er

Related diagram
Ma t

Integrated controller
In

Fuel level sensor

CN-101F CN-145F CN-226M CN-235M CN-603F CN-601F
509
509 509

ZX55-1005051

7-88 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

5 Work lamps do not light up

★ Check related connectors for contact problem before troubleshooting.

★ Make sure that the connectors removed are restored before carrying out next step.

Cause Remedy

YES
Failure of work lamp Replace

.
Is the voltage Breaking or improper

De al
between the YES contact of harness be- Check the
tween work lamp nega- harness.

pt
positive and
negative posts 2 tive post and chassis
of work lamp Is the volt-
regular?
g nNO
o a g e o f
work lamp
positive post
Is the work
3
YES Breaking of harness
between work lamp
and fuse
Check the
harness.
regular?
lamp fuse nor-
in ti
NO mal?
Failure of fuse Replace
NO
et a
n
rk er

Related diagram

24
Ma t

S2

Battery relay
In

21 33
To battery B M Fuse 86 87
K6
85 30
E BR

34

Work lamp

ZX55-1005052

Shop Manual - November 2012 7-89

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6 Horn does not sound

★ Check related connectors for contact problem before troubleshooting.

★ Make sure that the connectors removed are restored before carrying out next step.

Cause Remedy

YES Horn switch harness

Replace
1 broken
Horn button
switch dam-
Replace

.
aged YES

De al
Overcurrent or open the fuse or
2 circuit check the

pt
Does the fuse line
blow out?
NO Replace
g no
NO
Horn damaged or har- t h e h o r n
ness broken and check
the line
in ti

Related diagram
et a
n

Horn

F-103 F-104
rk er

23
4
32 5 3
Ma t

0 1 2 31 23
Battery
In

HA1 0

Fuse

ZX55-1005053

7-90 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Troubleshooting

E.
PgAD nal
Gpt
e
Kin tio
a
ANke rn
t
ar e
BLM Int

Shop Manual - November 2012 7-91

Troubleshooting SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

t.
ADGe al
pE
n
nPg o
i
ti ta
n
ArNk er
eK
Ma t
BL In

7-92 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

Disassembly and Assembly

.
8 Disassembly And Assembly

De al
pt
8.1 Reading Guide ......................................................................................................... 8-7
8.2 Operation Precautions ............................................................................................. 8-8
g n
8.3 Engine and Main Pump Assembly - Remove and Install ....................................... 8-10
o
8.3.1 Remove........................................................................................................ 8-10
in ti
8.3.2 Install............................................................................................................ 8-15
8.4 Radiator Assembly - Remove and Install ............................................................... 8-16
8.4.1 Remove........................................................................................................ 8-16
et a

8.4.2 Installation .................................................................................................... 8-17

n

8.5 Fuel Tank Assembly - Remove and Install ............................................................. 8-18

rk er

8.5.1 Remove........................................................................................................ 8-18

8.5.2 Install............................................................................................................ 8-19
8.6 Center Swivel Joint Assembly - Remove and Install.............................................. 8-20
Ma t

8.6.1 Remove........................................................................................................ 8-20

In

8.6.2 Install............................................................................................................ 8-21

8.7 Center Swivel Joint Assembly - Disassemble and assemble ................................ 8-22
8.7.1 Disassemble ................................................................................................ 8-22
8.7.2 Assemble ..................................................................................................... 8-22
8.8 Sprocket - Remove and Install............................................................................... 8-23
8.8.1 Remove........................................................................................................ 8-23
8.8.2 Install............................................................................................................ 8-24
8.9 Travel Motor Assembly - Remove and Install ........................................................ 8-25
8.9.1 Remove........................................................................................................ 8-25
8.9.2 Install............................................................................................................ 8-26
8.10 Disassembly and Assembly of Travel Motor (GM09VN) ...................................... 8-27
8.10.1 Sectional view of the travel motor assembly .............................................. 8-27
8.10.2 Exploded view of reducer assembly .......................................................... 8-29

Shop Manual - November 2012 8-1

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.10.3 Exploded view of hydraulic motor assembly .............................................. 8-30

8.10.4 Parts catalogue .......................................................................................... 8-31
8.10.5 Tools........................................................................................................... 8-32
8.10.6 Tightening torques ..................................................................................... 8-39
8.10.7 Table of weights ......................................................................................... 8-39
8.10.8 Disassembly............................................................................................... 8-40
8.10.9 Table of maintenance standard ................................................................. 8-66
8.10.10 Assembly.................................................................................................. 8-68
8.10.11 Table of dimensions for clearance adjustable parts ................................. 8-94
8.10.12 Confirmation of performance test............................................................. 8-95
8.11 Swing Motor and Swing Mechanism AS - Removal and Installation.................... 8-96

.
8.11.1 Removal ..................................................................................................... 8-96

De al
pt
8.11.2 Installation .................................................................................................. 8-97
8.12 Swing Motor AS - Disassembly and Assembly .................................................... 8-98
g n
8.12.1 Disassembly............................................................................................... 8-98
o
8.12.2 Assembly.................................................................................................. 8-106
8.13 Swing Mechanism Assembly - Disassemble and Assemble ...............................8-115
in ti
8.13.1 Disassemble .............................................................................................8-115
8.13.2 Assemble ..................................................................................................8-118
et a

8.14 Swing Platform Assembly - Remove and Install ................................................ 8-122

n

8.14.1 Remove.................................................................................................... 8-122

8.14.2 Install........................................................................................................ 8-124
rk er

8.15 Swing Bearing Assembly - Remove and Install ................................................. 8-125

8.15.1 Remove.................................................................................................... 8-125
Ma t

8.15.2 Install........................................................................................................ 8-125

In

8.16 Idler and Tension Spring Assembly - Remove and Install.................................. 8-126
8.16.1 Remove.................................................................................................... 8-126
8.16.2 Install........................................................................................................ 8-127
8.17 Tension Spring Assembly - Disassemble and Assemble ................................... 8-128
8.17.1 Disassemble ............................................................................................ 8-128
8.17.2 Assemble ................................................................................................. 8-132
8.18 Idler Assembly - Disassemble and Assemble .................................................... 8-134
8.18.1 Disassemble ............................................................................................ 8-134
8.18.2 Assemble ................................................................................................. 8-135
8.19 Track Roller Assembly - Remove and Install ..................................................... 8-138
8.19.1 Remove.................................................................................................... 8-138
8.19.2 Install........................................................................................................ 8-138
8.20 Track Roller Assembly - Disassemble and Assemble ........................................ 8-139

8-2 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.20.1 Disassembly............................................................................................. 8-139

8.20.2 Assemble ................................................................................................. 8-141
8.21 Carrier Roller Assembly - Remove and Install ................................................... 8-143
8.21.1 Remove.................................................................................................... 8-143
8.21.2 Install........................................................................................................ 8-143
8.22 Track Shoe Assembly - Remove and Install ...................................................... 8-144
8.22.1 Remove.................................................................................................... 8-144
8.22.2 Install........................................................................................................ 8-144
8.23 Hydraulic Tank Assembly - Remove Install ........................................................ 8-145
8.23.1 Remove.................................................................................................... 8-145
8.23.2 Install........................................................................................................ 8-146

.
8.24 Main Pump Assembly - Remove and Install ...................................................... 8-147

De al
pt
8.24.1 Remove.................................................................................................... 8-147
8.24.2 Install........................................................................................................ 8-148
g n
8.25 Main Pump Input Shaft Oil Seal - Remove and Install....................................... 8-149
o
8.25.1 Remove.................................................................................................... 8-149
8.25.2 Install........................................................................................................ 8-149
in ti
8.26 Control Valve Assembly - Remove and Install ................................................... 8-150
8.26.1 Removal ................................................................................................... 8-150
et a

8.26.2 Installation ................................................................................................ 8-152

n

8.27 Control Valve AS - Disassembly and Assembly ................................................. 8-153

8.27.1 Disassembly............................................................................................. 8-153
rk er

8.27.2 Assembly.................................................................................................. 8-169

8.28 Oil Source Control Valve Assembly - Remove and Install ................................. 8-186
Ma t

8.28.1 Removal ................................................................................................... 8-186

In

8.28.2 Installation ................................................................................................ 8-187

8.29 Left Pilot Valve Assembly - Remove and Install................................................. 8-188
8.29.1 Remove.................................................................................................... 8-188
8.29.2 Install........................................................................................................ 8-188
8.30 Right Pilot Valve Assembly - Remove and Install .............................................. 8-189
8.30.1 Remove.................................................................................................... 8-189
8.30.2 Install........................................................................................................ 8-189
8.31 Work Equipment Pilot Valve Assembly .............................................................. 8-190
8.31.1 Disassemble ............................................................................................ 8-190
8.31.2 Assemble ................................................................................................. 8-190
8.32 Travel Pilot Valve Assembly - Remove and Install ............................................. 8-192
8.32.1 Remove.................................................................................................... 8-192
8.32.2 Install........................................................................................................ 8-193

Shop Manual - November 2012 8-3

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.33 Travel Pilot Valve Assembly - Disassemble and Assemble ............................... 8-194
8.33.1 Assemble ................................................................................................. 8-195
8.34 Boom Cylinder Assembly - Remove and Install ................................................. 8-196
8.34.1 Removal ................................................................................................... 8-196
8.34.2 Install........................................................................................................ 8-197
8.35 Arm Cylinder Assembly - Remove and Install .................................................... 8-198
8.35.1 Remove.................................................................................................... 8-198
8.35.2 Install........................................................................................................ 8-199
8.36 Bucket Cylinder Assembly - Remove and Install .............................................. 8-200
8.36.1 Remove.................................................................................................... 8-200
8.36.2 Install........................................................................................................ 8-201

.
8.37 Blade Cylinder Assembly - Remove and Install ................................................. 8-202

De al
pt
8.37.1 Remove.................................................................................................... 8-202
8.37.2 Install........................................................................................................ 8-203
g n
8.38 Hydraulic Cylinder Assembly - Disassemble and Assemble .............................. 8-204
o
8.38.1 Disassembly............................................................................................. 8-204
8.38.2 Assembly.................................................................................................. 8-207
in ti
8.39 Work Equipment Assembly - Remove and Install .............................................. 8-210
8.38.3 Removal ................................................................................................... 8-210
et a

8.39.1 Install.........................................................................................................8-211
n

8.40 Bucket Assembly - Remove and Install ............................................................. 8-212

8.40.1 Remove.................................................................................................... 8-212
rk er

8.40.2 Install........................................................................................................ 8-213

8.41 Arm Assembly - Remove and Install .................................................................. 8-214
Ma t

8.41.1 Remove.................................................................................................... 8-214

In

8.41.2 Install........................................................................................................ 8-215

8.42 Bucket and Arm Assembly - Remove and Install ............................................... 8-216
8.42.1 Remove.................................................................................................... 8-216
8.42.2 Install........................................................................................................ 8-217
8.43 Boom Assembly - Remove and Install ............................................................... 8-218
8.43.1 Remove.................................................................................................... 8-218
8.43.2 Install........................................................................................................ 8-219
8.44 Dozer Blade Assembly – Remove and Install .................................................... 8-220
8.44.1 Remove.................................................................................................... 8-220
8.44.2 Install........................................................................................................ 8-221
8.45 Cab Assembly – Remove and Install ................................................................. 8-222
8.45.1 Remove.................................................................................................... 8-222
8.45.2 Install........................................................................................................ 8-224

8-4 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.46 Counterweight Assembly - Remove and Install ................................................. 8-225

8.46.1 Removal ................................................................................................... 8-225
8.46.2 Install........................................................................................................ 8-226
8.47 Monitor Assembly - Remove and Install ............................................................ 8-227
8.47.1 Remove.................................................................................................... 8-227
8.47.2 Install........................................................................................................ 8-227

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 8-5

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.

8-6 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8 DISASSEMBLY AND ASSEMBLY

8.1 Reading Guide

1. When a component assembly is removed or installed

1) Of the removal or installation of a component assembly, working sequence and method are
provided for removing operation instead of installing operation.

2) Special method for installation procedure is indicated with . The same mark after related
steps in a removal procedure means that it is also applicable to the installation procedure.

.
De al
Example:

pt
○○○○ Assembly - Installation.................... Title of operation
g n
................................................................. Precautions for safety during operation
o
1. ×××× (1)............................................... Operating steps
★ ..................................................................
in ti
Method or key points for removing a part
.
2. △△△△ (2)............................................... indicates the method used for installation
et a

3. □□□□ assembly (3)

......................................................... See table of lubricant and coolant
n

○○○○ Assembly - Installation Title of operation

rk er

Installation is performed in a reversed order of removal

............................................................ Method used for installation
Ma t

★ .............................................................. Method or key points for installing △△△△ (2)

Adding water or oil.............................. Operating steps
In

★ ............................................................. Key points for adding water or oil

......................................................... Amount of oil or water to be added

2. General precautions and operation precautions are presented together for installation or re-
moval (disassembly or assembly) of a component. These precautions are to be observed dur-
ing operation.

Shop Manual - November 2012 8-7

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.2 Operation Precautions

The following precautions must be observed ● The surrounding area must be cleaned
before removing or installing (disassembling before removing a component. Cover
or assembling) a component. the component after removal in order to
prevent invasion of dirt or dust.
1. Precautions to be observed prior to
removal operation ★ Lines-handling precautions during
disassembling operation
● Dispose of the engine coolant properly
if antifreeze is contained in the engine The lines disassembled must be blinded
coolant. with a plug of proper size during disas-
sembling operation. If a part is not under

.
● After disconnecting a hose or tube, hydraulic pressure, a cork of proper size

De al
wrap or plug the opening in order to can be used.

pt
prevent invasion of dirt or dust.
2. Precautions to be observed prior to
g n
● A suitable container must be prepared
o
to collect drained oil.
installation operation

● Tighten all the screws and nuts (sleeve

in ti
● Notice the matching marks indicat- nuts) to specified torques.
ing the installation positions. Matching
mark must be made at where is neces- ● The hoses installed must be free from
et a

sary before removal in order to avoid distortion or interference.

incorrect reinstallation.
n

● Replace the gaskets, O-rings, cotter

rk er

● Do not pull the wire in order to avoid pins and lockplates.

the wire coming off its contact. To avoid
excessive force imposing on the wire, ● Bend the cotter pin or lockplate secure-
ly.
Ma t

hold the connector when disconnecting

a wire.
In

● Before applying the adhesive, remove

● Tag the wires and the hoses in order to oil and dust from the part. Apply 2 or 3
make sure of their positions for connec- drops of adhesive to the threaded por-
tion. By doing so, mistakes could be tion.
avoided during reinstallation.
● Before applying the sealant to the
● Check the number and thickness of the gasket, remove oil and dust from the
shims, and keep them in a safe place. surface and check it for contamination
or damage. Apply gasket sealant uni-
● When raising or lifting a component, be formly.
sure to use proper lifting equipment of
enough strength. ● Clean all parts, and correct any dam-
age, dents, burrs, or rust.
● When forcing screws are used to re-
move a component, tighten the screws ● Apply engine oil to the moving parts
uniformly in turn. and sliding parts.

8-8 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

● After installing a snap ring, make sure 4. Now, the engine can be run at normal
that the snap ring is mounted properly speed.
in the circular groove.
★ This same procedure is to be performed
● Before connecting the wiring connector, before using your machine for the first
remove oil, dirt or water from the wiring time after repair or long storage.
connector. Make sure that the wiring
connector is connected securely. 3. Precautions after operation

● Before using an eyebolt, check the ● If the engine coolant has been discharged,
eyebolt for deformation or deterioration. tighten the drain valve and add coolant to
Screw on the eyebolt as far as possible the specific level. Run the engine to circu-
and align it to the direction of the hook. late the coolant through the system. And

.
then check the coolant level again.

De al
● Before tightening split flanges, tighten

pt
them uniformly in turn in order to pre- ● If the hydraulic equipment has been re-
vent over-tightening on one side. moved and then reinstalled, add hydraulic
g no
★ After reassembling the hydraulic cylinder,
oil to the specific level. Run the engine to
circulate the hydraulic oil through the sys-
main pump or other hydraulic equipment tem. And then check the oil level again.
in ti
that has been disassembled and repaired,
it is necessary to purge the air from the ● If the lines or hydraulic equipment has been
hydraulic cylinder prior to initial operation removed and repaired, purge the air from
et a

of the cylinder. The purging procedure is the hydraulic system after reassembling.
n

performed as the following: For detailed information, see “Air in Each

Component - Bleed” on page 6-30.
rk er

1. Start the engine and run the engine at

low idle. ● Apply specified amount of grease (MoS2)
to related parts of the work equipment.
Ma t

2. Operate the work equipment control

In

lever in order to cycle the movement of

the hydraulic cylinder 4 or 5 times. Stop
the cylinder at where it is 100 mm from
its stroke end.

3. Go on operating the hydraulic cylinder

3 or 4 times to its stroke end.

Shop Manual - November 2012 8-9

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.3 Engine and Main Pump Assembly - Remove and Install

8.3.1 Remove

Low the work equipment to the ground and

stop the engine. Keep the hydraulic lock-
out control lever at FREE position and
cycle both joysticks 1-2 minutes. After the
pressure of hydraulic circuit has been re-
leased completely, slowly loosen the filler
cap in order to release the internal pres-
sure of hydraulic tank.

.
De al
Loosen the butterfly nut of the breather

pt
valve. Press the button to release internal
pressure.
g n
Disconnect the cable from the negative (-)
o
post of the battery.
in ti
1. Remove the filter screen of hydraulic tank 3 1
and plug the opening with the tool.
et a

★ When the tool is not used, remove the

n

drain plug to drain oil from the hydraulic

tank and the lines.
rk er

Hydraulic tank: approx. 80L 2

4
Ma t

2. Disconnect the following hoses from the

In

ZXT55-1006074
main pump.

● Main pump discharge hose (1)

● LS pressure inlet hose (2)
● Oil suction hose (3)
● Main pump Leakage hose (4)
If oil is blocked by the tool, oil will come
out. A plug must be ready in this case.
12
3. Disconnect two leads from the alternator
(12).

ZXT55-1006075

8-10 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

4. Disconnect the lead (13) of oil pressure

switch.

★ Disconnect the lead clamp (14).

13
5. Remove the mounting bolts of heater relay 14
(15).

★ Move the harnesses of heater relay

and engine aside. ZXT55-1006076

.
De al
6. Disconnect the preheat plug lead connec-

pt
tor (E12) (16).

g n
7. Disconnect the air compressor lead con-
nector (M34) (17).
o
16
in ti
et a

ZXT55-1006077
n
rk er
Ma t
In

17

ZXT55-1006078

Shop Manual - November 2012 8-11

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8. Disconnect the water temperature sensor

lead connector (P7) (18) and radiator up-
per pipe (19).
18
19

ZXT55-1006079

.
De al
pt
9. Disconnect the start motor earth wire (20),
the throttle pull wire (20a) and the engine
g n
shutdown pull wire (20b).
o
23
10. Disconnect the start motor lead (21).
in ti
20b
11. Disconnect the fuel delivery hose (22) and
22 20a
the oil return hose (23).
et a

20
n

21
rk er

★ Fuel will come out if the fuel delivery

ZXT75-1208001
hose is disconnected. Prepare a wood
cork in advance.
Ma t
In

12. Disconnect the air conditioner hot water

pipe (24) and cold water pipe (25).

24

ZXT55-1006082

8-12 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

25

ZXT55-1006081

.
De al
pt
13. Disconnect the radiator lower water pipe
g n
(26) and upper water pipe (19).
o
26
in ti
et a
n
rk er

ZXT55-1006083
Ma t
In

14. Remove the fan guard (28).

28

ZXT55-1006084

Shop Manual - November 2012 8-13

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

15. Remove the air conditioner compressor as-

sembly (optional) from the engine through 32
34
the following steps.

● When the compressor assembly is

removed after drainage of refrigerant 33 31
(R134a):

1) Drain the refrigerant (R134a) complete-

ly.
30
ZXT55-1006085
2) Disconnect the 2 air condition tubes (31)
from the compressor assembly (30).

.
De al
● When the compressor assembly is re-

pt
moved without draining the refrigerant
(R134a):
g no
1) Loosen the air conditioner compressor
tensioning pulley (32) and mounting
in ti
bolt (33) in order to remove the belt (34)
from the air conditioner compressor.
et a

2) Remove the air conditioner compressor

n

assembly (30) with the lines . Secure

them to the engine with a rope.
rk er
Ma t

16. Hoist up the engine and main pump as-

In

sembly temporarily. Remove the engine’s

four (4) mounting bolts (35).

17. Move the engine and main pump assembly

(36) aside.

★ Check whether all leads and lines are

disconnected. The assembly does not 35
interfere with the body and the radiator.
ZXT75-1208001
Engine and main pump AS:

370 kg

8-14 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.3.2 Install

● The installation is performed in a reverse

order of removal.

Fuel hose connector bolt:

29.4±4.9 Nm {3.0±0.5 kgm}

● Adding water

.
De al
Add water through water filler to the spe-

pt
cific level.

g n
Run the engine to circulate water in the
system, and then check the water level
o
36 ZXT75-1006014
again.
in ti

● Adding oil (hydraulic tank)

et a

Add oil through oil filler to the specific level.

n

Run the engine to circulate oil in the sys-

rk er

tem, and then check the oil level again.

Hydraulic tank: approx. 80 L (SAE

Ma t

10W-CD)
In

● Purging air

Press the manual oil pump and purge the

air inside the fuel lines.

● Add refrigerant

Add refrigerant (R134a) to air conditioner

lines with a freon filler.

Shop Manual - November 2012 8-15

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.4 Radiator Assembly - Remove and Install

8.4.1 Remove

Low the work equipment to the ground and

stop the engine. Loosen the oil filler cap 2
slowly to release internal pressure in the
hydraulic tank.

Disconnect the cable from the negative (-)

post of the battery.

.
De al
1. Remove the filter screen of hydraulic tank

pt
and plug the opening with the tool.

g n
★ When the tool is not used, remove the
drain plug to drain oil from the hydraulic
o ZXT75-1006015

tank and the lines.

in ti
Hydraulic tank: approx. 80L
3 5
et a

2. Drain the coolant. 1

n

3. Remove the air prefilter (1).

rk er

4. Remove the rear hood (2).

Ma t

5. Remove the air cleaner (3).

In

6. Remove the top hood (5). ZXT75-1006016

7. Remove the fan guard (6).

★ The clamp of fuel control cable is also

connected with one of the mounting bolts
of the fan guard. 6

8. Remove the fan (7) and then move it to- 7

ward the radiator.

ZXT75-1006017

8-16 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

9. Remove the radiator upper water pipe (8)

and the lower water pipe (9).

10. Remove the air conditioner dryer cylinder

(10). 8

11. Remove the seal plate (11) around the ra- ZXT75-1006018
diator.

.
De al
12. Remove the air conditioner condenser (12)

pt
and move it aside with the dryer cylinder.
9
g n
★ Be careful not to damage the core when
hoisting the radiator and hydraulic oil
o
cooler assembly. Stop the engine and
in ti
remove the fan during removal operation.
et a

8.4.2 Installation
n

ZXT75-1006019
● The installation is performed in a reverse
rk er

order of removal.

● Adding water
Ma t

Add water through water filler to the spe-

In

cific level. 11

10
Run the engine to circulate water in the
system, and then check the water level
again.

● Adding oil (hydraulic tank) 12 ZXT75-1006020

Add oil through oil filler to the specific level.

Run the engine to circulate oil in the sys-

tem, and then check the oil level again.

Hydraulic tank: approx. 80L (SAE

10W-CD)

Shop Manual - November 2012 8-17

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.5 Fuel Tank Assembly - Remove and Install

8.5.1 Remove

Disconnect the cable from the negative (-)

post of the battery.

★ Turn right by 45°and lower the work equip-

ment fully onto the ground.

1. Drain the fuel. 1

2
Fuel tank: approx. 130L (full)

.
De al
pt
2. Remove the handhold (1).

g n
3. Remove the front cover (2).
o
4. Disconnect the lead connector (3) of fuel
ZXT75-1006021
in ti
level sensor.

5. Disconnect the upper return hose (4) of the

et a

fuel tank.
n

6. 6. Disconnect the oil suction hose (5).

rk er

7. Remove the mounting bolts and hoist the 3

fuel tank assembly away.
Ma t
In

Fuel tank AS: 55kg ZXT75-1006022

8-18 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.5.2 Install

● Reverse the removing sequence to install

the assembly.

Fuel tank mounting bolt thread:

4
Thread adhesive: (LT-2)

Mounting bolt:

.
ZX75-1006023
176.5±19.6 Nm {18±2 kgm}

De al
pt
● Refueling (fuel tank)
g n
Fuel tank: approx. 130L (full)
o 5
in ti
et a
n

ZX75-1006024
rk er
Ma t
In

Shop Manual - November 2012 8-19

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.6 Center Swivel Joint Assembly - Remove and Install

8.6.1 Remove

Lower the work equipment fully onto the

ground, stop the engine and keep it ener- 8 1
gized. Leave the hydraulic lockout control 2
3
lever at FREE position and cycle the left
4 5
and right joysticks for 10-20 seconds to
release system pressure. 6
7
★ Tag all pipes during removal in order to
prevent incorrect reinstallation.

.
De al
pt
17
ZXT75-1006025
g n
1. Remove the four oil pipes (1), (2), (3) and
(4) of the left and right travel motors from
the swivel joint.
o
in ti
2. Remove the two oil pipes (5) and (6) of the
blade. 10
14
et a

11 15
3. Disconnect the PS port (7) for both left and
n

right travel motors. 16

rk er

4. Disconnect the swivel joint upper return

hose (8) and the lower return hose (9). Re- 12
13
move all port connectors.
Ma t

ZXT75-1006026
In

5. Remove (10), (11), (12), (13), (14), (15)

and (16).

6. Remove the swivel joint bottom mounting

bolts. Remove the swivel joint fixing bolts.
Hoist up the swivel joint assembly (17) and
move the swivel joint away.

8-20 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.6.2 Install

● Reverse the removing sequence to install

the assembly.

Swivel joint mounting bolt thread:

Thread adhesive: (LT-2)

Mounting bolt: 9

.
De al
110.25±12.26 Nm{11.25±1.25 kgm} ZXT75-1006027

pt
● Adding oil (hydraulic tank)
g n
★ Add oil through oil filler to the specific
o
level. Run the engine to circulate oil in
in ti
the system, and then check the oil level
again.
et a

● Purging air
n

★ Purge the air inside the travel motor.

rk er

For detailed information, see “Air in Each

Component - Bleed” on page 6-30.
Ma t
In

Shop Manual - November 2012 8-21

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.7 Center Swivel Joint Assembly - Disassemble and assemble

8.7.1 Disassemble

1. Remove the bolt (14) and the end cover

(12).

2. Remove the O-ring (11) and the retaining

rings (9) and (10). 12
11
14 13 10
9
3. Use the tool 2 to pull out the housing (8)
from the rotor (3). 8
7
6 5

.
4

De al
4. Remove the oil seal (7), O-ring seal (6) 3

pt
and water seal (4) from the rotor (3). 2
1

g no
in ti
ZX55-1006019

8.7.2 Assemble
et a
n

● Reverse the disassembling sequence to

assemble the assembly.
rk er
Ma t
In

ZX55-1006020

8-22 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.8 Sprocket - Remove and Install

8.8.1 Remove

1. Remove the track assembly.

1

For more information see “Track Shoe

Assembly - Remove and Install” on page 8-144.

2. Swing the work equipment by 90°and raise

the machine with the work equipment.
Place a block 1 between the track frame
and the track.

.
1

De al
pt
3. Remove the mounting bolts and slightly
ZX55-1006021
pull out the sprocket (1).
g no
in ti
4. Install the eyebolt and nut. Hoist the
sprocket (1) away.
et a

Sprocket:
n

SY65C: 17.2kg
rk er

SY75C: 22.5kg
Ma t
In

Shop Manual - November 2012 8-23

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.8.2 Install

● Reverse the removing sequence to install

the assembly.

Sprocket mounting bolt thread:

2x45°
Thread adhesive: (LT-2)
Matching the travel
motor sprocket
Mounting bolt: installation face

.
205.8±19.6 Nm{21±2 kgm}

De al
Schematic Drawing of Partial SY65C3 Sprocket

pt
ZX75-1006031

g n
★ Make sure that the larger chamfer side of
o
installed sprocket matches the installation C1 C3
in ti
face of travel motor sprocket.

Matching the travel

et a

motor sprocket
installation face
n
rk er
Ma t

Schematic Drawing of Partial SY75C3 Sprocket

ZX75-1006032
In

8-24 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.9 Travel Motor Assembly - Remove and Install

8.9.1 Remove

1. Remove the sprocket.

For more information see “Sprocket -

Remove and Install” on page 8-23.

Lower the work equipment fully onto the

ground and stop the engine. Leave the
hydraulic lockout control lever at FREE
position and cycle the left and right con-

.
De al
trol levers for 10-20 seconds to release

pt
system pressure.

g n
2. Remove cover (1).
o
in ti
et a
n
rk er

1
ZXT55-1006087
3. Remove the four hoses (2) of travel motor.
Ma t

Remove the four hose connectors (3).

In

4. Remove the mounting bolts (4) of the trav-

el motor and hoist the motor assembly (5) 3
away.

★ Plug the disconnected hoses.

★ Take care not to damage the connector 2

seals. 5
4 ZXT55-1006088

Travel motor assembly:

SY65C: 80kg
SY75C: 95kg

Shop Manual - November 2012 8-25

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.9.2 Install

● Reverse the removing sequence to install

the assembly.

Cover bolt thread:

Thread adhesive: (LT-2)

Cover bolt:

.
De al
65.7±6.9 Nm{6.7±0.7 kgm}

pt
g no
Travel motor mounting bolt thread:
in ti
Thread adhesive: ((LT-2)

Travel motor mounting bolt:

et a
n

276.85±31.85 Nm {8.25±3.25 kgm}

rk er

★ Purge air from the hydraulic motor

(hydraulic tank).
Ma t

For detailed information, see “Air in Each

In

Component - Bleed” on page 6-30.

● Adding oil (hydraulic tank)

★ Add oil through oil filler to the specific

level. Run the engine to circulate oil in
the system, and then check the oil level
again.

8-26 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.10 Disassembly and Assembly of Travel Motor (GM09VN)

8.10.1 Sectional view of the travel motor assembly

127 130 126 137 121 173 123

136

.
De al
pt
142

g no
128
in ti

125
et a
n

124
rk er
Ma t
In

168

152
174

144

178

B-B

ZX75-1006035

Shop Manual - November 2012 8-27

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

143 139 135 116 115 153 103 31 10 28 21 176 177 11 4 17 5 23 9 12

112
22
165
14
154
25
164

163
20
166 7

.
De al
141
24

pt
101
26

150

119
g no 8
6
in ti
16

154 15
et a

145
19
n

114
33
109
rk er

18
113

29
Ma t

1 3
30 154 179 27 104 151 105 108 2 107 106 149 162 37 161 185 132 102
In

ZX75-1006036

8-28 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.10.2 Exploded view of reducer assembly

21

28

10

31

22

.
De al
2.37 21

pt
5
30
g no
4
in ti

27 1
et a
n

17 12
11 23
18
rk er

9
33
23
12
8
Ma t

29
In

25
7
14
20
22

26
24
6
16
15

19 ZX75-1006037

Shop Manual - November 2012 8-29

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.10.3 Exploded view of hydraulic motor assembly

165 135
164
166 139
163
112
126
137 113
130 109
150
127
121 154 141 115

116
173

.
De al
124
136

pt
128
125 127
142 g n
146
o176
179 130
137
126
in ti
168 101
174
152 146
199 143 123
146
125
et a

132
128
149
n

136
124
102
rk er

177
176
Ma t

103
153
In

105.106

107
185
108
161.162
104

110
114
110
145

151
ZX75-1006038

8-30 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.10.4 Parts catalogue

S/N Part Name Quantity S/N Part Name Quantity

1 Reducer AS 1 Motor, hydraulic 1
Hub 1 Flange GP, rear 1
Rotor GP 1 101 ·Flange, rear 1
·Rotor AS 1 123 ·Spool 1
2 ··Rotor 1 144 ·Plug, hex 3
152 ·Plug 2
3 ··Flange, fixing 1
154 ·Plug, hex 6
19 ·Bolt,hinge 3
174 ·Seal, O-ring 2
37 ·Expander 1 178 ·Orifice 1
RV gear AS 1 179 ·Element, filter 1
·RV gear GP 1 199 ·Nameplate 1

.
4 ··RV gear A 1 1

De al
5 ··RV gear B 1 102 Shaft 1

pt
9 Crankshaft 3 103 Plate, swash 1
12 ·Spacer 6 104 Block, cylinder 1
22 ·Bearing, roller, cone type 6 105 Plunger GP 9
23
g n
·Bearing, needle
o 6 106

107
·Plunger AS
··Plunger
··Slipper
1
1
1
6 Gear, input 1
108 Disc, fixing 1
in ti
Gear GP, spur 1 109 Ball, thrust 1
7 ·Gear, spur 3 110 Disc, timing 2
112 Washer 1
8 Cover 1
et a

Plunger 8
113 Spring 1
n

F Seal GP 1 114 Spring 2

10 ·Separator 1 115 Plate, friction 2
rk er

31 ·Seal, floating 1 116 Gasket 1

121 Plug, screw 2
124 Plug, screw 2
11 Collar 1
125 Seat, spring 2
14 Separator 3
Ma t

126 Plug, screw 2

15 Coupling 1 127 Valve 2
In

16 Shaft 1 128 Spring 2

17 Pin 24 130 Spring 1
18 Ring 1 132 Seal, oil 1
135 Seal, O-ring 2
20 Ring, snap 136 Seal, O-ring 2
t: 1.90 to 1.95 137 Seal, O-ring 1
↓<0.05 clearance> 3 139 Seal, O-ring 2
t: 2.45 to 2.50 141 Pin, parallel 2
142 Pin, parallel 8
21 Bearing, ball 2
143 Bolt, socket head 1
24 Ring, snap, C-type (shaft) 1
145 Ring, snap, THS 1
25 Ring, snap, C-type (shaft) 3 149 Bearing, ball, deep-grooved 1
26 Ball, steel 1 150 Bearing, ball, deep-grooved 3
27 Seal, O-ring 2 151 Roller 1
28 Seal, O-ring 1 153 Plate, thrust 1
29 Seal, O-ring 1 161 Plunger AS 1
30 Seal, O-ring 1 162 ·Plunger 1
33 Plug, hex 3 ·Slipper

Shop Manual - November 2012 8-31

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.10.5 Tools

5. Standard tools
Applicable Parts
(Call-outs in structural/ Name Type/Standard Quantity
exploded view)
126,143,121,152,33 Torque wrench Nominal size: 1800, digital 1
19,124,160 Torque wrench Nominal size: 5600, digital 1
33 Hex wrench Nominal size: 8 1
126 Hex wrench Nominal size: 10 1
152 Hex wrench Nominal size: 6 1
126 Allen wrench Nominal size: 10, insert angle: 12.7 1

.
De al
143 Allen wrench Nominal size: 8, insert angle: 12.7 1

pt
124,160 Socket head Nominal size: 36, insert angle: 12.7 1
19 Socket head Nominal size: 27, insert angle: 12.7 1
124,160
g no
Connector Insert angle: 12.7×19.05 1
124,160 Spanner Powerful circular type 1
in ti
1,165,21,11,132 Hammer Nominal size: 12 1
8,10,102,112 Plastic hammer L= approx. 300 1
24,25 Pliers, snap ring For shaft 1
et a

20,145 Pliers, snap ring For hole —

n

1 Punch, center φ9.5×100 1

rk er

21 Punch, pin φ4×150 1

1,2 used for hoisting product Sling Hook and wire cable 1 set
Cleaning the products and parts Brush, flushing — 1
Ma t

Cleaning the products and parts Brush, wire — 1

In

Used for containing lubricant oil, hy- Barrel for general purpose
Vessel 3
draulic oil or steel balls W450×D300×H120
Used for making matching marks Paint mark White paint 1
17 Basket, steel wire — 2 pcs
11 Gasket, rubber — 1
149 Gloves, leather — 1 pair
Used for hydraulic oil and lubricant
Filling oil Can, oil 2
oil
33 Tape, seal — 1

8-32 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

6. Equipment

Applicable Parts
Name Type/Standard Quantity
(Call-outs in structural/exploded view)
Disassembling and assembling a prod- Workbench for gen-
— 1 set
uct eral purpose
Used for primary and sec-
Cleaning the products and parts Cleaning tank 1 set
ondary cleaning
Pressure work- Pressure: Min. 1.96 kN {200
104, 149 1 set
bench kg}
Heating capacity: Min.
149 Heating box 100°C 1 set

.
Volume: 500×500×500

De al
Portable drill

pt
1 Electric drill 1
(Max. bit diameter: φ10)
1 Drilling bit φ2 1

ucts and parts

g n
161,162,163 used for dry, clean prod-
o
Compressed air
Pressure: 294~490 kPa
{3~5 kg/cm²}
—

3 Lathe — 1 set
in ti

7. Measuring instrument
et a
n

Applicable Parts
Name Type/Standard Quantity
(Call-outs in structural/exploded view)
rk er

Used for adjusting the thickness of snap

Feeler gauge Measuring range: 0.04~0.3 mm 2
ring (20)
Used for adjusting the thickness of snap Micrometer, outer Measuring range: 0~25 mm
Ma t

1
ring (20) diameter Min. scale: 0.01
In

Used for adjusting the preload on ball Integral type Measuring range: 0~25 mm
1
bearing (21) Micrometer, depth Min. scale: 0.01

Shop Manual - November 2012 8-33

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8. Tooling equipment

1) Travel motor workbench

● The workbench is used for disassem-

bling and assembling a travel motor
easily and safely.

ZX75-1006039

.
De al
pt
2) Clamping device

g n
● The clamping device is used to clamp
o
the spindle (2) and the hub (1).
in ti
et a
n

ZX75-1006040
rk er

3) Holder (I)
Ma t
In

● The holder (I) is used for installing the

spring (114), washer (110) and snap
ring (145) into the cylinder block (104).

● The holder (I) is also used for removing

the spring (114) from the cylinder block
(104).

ZX75-1006041

8-34 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

4) Holder (II)

● The holder (II) is used for removing the

deep-grooved ball bearing (149) from
the shaft (102).

ZX75-1006042

.
De al
5) Holder (III)

pt
● The holder (III) is used for press fitting
g n
the oil seal (132) into the spindle (2).
o
in ti

ZX75-1006043
et a
n

6) Holder (IV)
rk er

● The holder (IV) is used for installing the

RV gear assembly securely.
Ma t

● Press the holder (IV) against the outer

In

ring of the cone-roller bearing of the

crankshaft (9) of the RV gear assembly.
Slightly hammer the holder (IV) in order
to install the RV gear assembly.
ZX75-1006044

Shop Manual - November 2012 8-35

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

7) Mold used for adjusting the main bearing

preload

● The mold is used for press fitting the

ball bearing (21) onto the hub (1).

● The mold is also used for measuring

the axial clearance of ball bearing (21)

ZX75-1006045

.
De al
8) Steel rod (I)

pt
● The steel rod (I) is used for removing
g n
the ring (18) from the hub (1).
o
in ti
et a
n

ZX75-1006046
rk er

9) PT eyebolt
Ma t

● The eyebolt is used with wire cable and

crane for removing the cover (8) of the
In

hub (1).

PT 3/8

ZX75-1006047

8-36 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

10) Long eyebolt

● The long eyebolt is used for hoisting

the travel motor, spindle (2) and hub (1).

Location A
Hub M14
Rotor M16 A

Travel motor M14 ZX75-1006048

.
De al
11) Scraper

pt
● The scraper is used for removing the

(101).
g n
timing disc (109) from the rear flange
o
in ti
et a

ZX75-1006049
n
rk er

12) Pin punch

Φ10
Ma t

● The pin punch is used for removing the

outer ring and journal (11) from the ball
In

bearing (21).

150

Φ4

ZX75-1006050

Shop Manual - November 2012 8-37

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

13) Sharp-end punch

● The sharp end punch is used for re-

moving the inner ring (165) of pilot
valve.

ZX75-1006051

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

8-38 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.10.6 Tightening torques

Part/Nut Used Width between Tighten-

Applicable Parts
Opposite Sides ing Torque
(Structural Drawing) Name Nominal size (mm) (Nm {kgm})
19 Bolt, hinge M20 P2.5 27 41.16 {4.2}
33 Plug, socket head PT3/8 8 3.92 {0.4}
124 Plug M30 P1.5 36 35.28 {3.6}
126 Plug M24 P1.5 10 12.74 {1.3}
143 Bolt, socket head M10 P1.5 8 5.78 {0.59}
144 Bolt, socket head PT1/8 5 1.23 {0.125}

.
144 Plug M20 26 5.88 {0.6}

De al
pt
152 Plug PF1/4 6 2.94 {0.3}
154 Bolt, socket head GDL-1/16-S 4 2.94 {0.3}
g no
8.10.7 Table of weights
in ti

Applicable Parts (Structural Drawing) Name Weight (kg)

et a

— Motor AS, travel Approx. 90

n

1 Hub 21.75
2 Rotor 26.65
rk er

101 Flange AS, rear 11.85

Ma t
In

Shop Manual - November 2012 8-39

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.10.8 Disassembly

1. Preparatory work 1) It is necessary to consider the checking

items and the confirmed trouble charac-
● Prepare the following items before dis- teristics before disassembling the travel
assembling the travel motor. motor. And then perform the job as per the
disassembling steps provided.
1) Workbench
2) Be careful when handling the parts as they
● Prepare a workbench used for disas- are very precise. Take care not to let them
sembling the travel motor. collide each other or fall.

● The workbench must be strong enough 3) A securely-installed part may have burrs

.
De al
for disassembling and assembling or be broken if it is hammered or pried for

pt
the internal parts of travel motor. The removal or installation.
workbench must have a surface large
g n
enough for placing the parts in proper
arrangement while the parts would not
o 4) If the travel motor disassembled partially or
completely is left as it is, the parts may rust
be moved or fall. due to moisture and dust. Therefore, if the
in ti
job has to be suspended, measures should
● Cover the workbench with a rubber be taken to prevent rusting or dust inva-
sheet or ethylene sheet. sion.
et a

2) Tools and materials 5) Make a mark on mating surface of the

n

parts during disassembly.

rk er

Prepare the tools and materials men-

tioned above. 6) Store the disassembled parts properly in
order to avoid damage or missing.
Ma t

2. General precautions for disassembling

7) As a rule, all seals must be replaced once
In

★ The internal parts disassembled are the travel motor has been disassembled.
slippery due to application of hydraulic Therefore, prepare all kinds of seals for re-
oil. Take care not to let them fall in placement prior to disassembly.
order to avoid injury.

★ When flammable liquid (such as

kerosene) is used to clean the parts,
it is easy to cause fire or burns. Be
especially careful while doing this job.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

3. Cleaning travel motor

1) Screw on the two eyebolts symmetrically

into the threaded holes on the spindle (2).

2) Hook the wire cable to the eyebolts. Hoist

up the travel motor and send it to the
2
cleaning tank.

3) Clean every part of the travel motor with

a brush. The part between the hub (1)
and the spindle (2) should be cleaned
thoroughly as it (where a floating seal is ZX75-1006052

.
mounted) contains soil and sand.

De al
pt
g no
in ti

2
et a

1
n
rk er

ZX75-1006053
Ma t
In

4. Installing the travel motor

1) Install the travel motor onto the workbench.

Align the line hole of hub (1) with the hole

on the workbench. Take care while install-
ing the travel motor into the mounting
holes of the workbench.
1

ZX75-1006054

Shop Manual - November 2012 8-41

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2) Fix the travel motor to the workbench with

two socket-headed bolts.

ZX75-1006055

.
De al
pt
5. Draining lubricant oil
33
g n
1) Turn the travel motor upside down.
o
2) Loosen the three socket-headed bolts (33).
in ti

If the bolts (33) were removed, oil may

come out when the travel motor is turned
et a

upside down. Therefore, loosen the bolts

until they can just be loosened with hand.
n

ZX75-1006056
rk er
Ma t

3) Turn the travel motor back.

In

4) Remove the three bolts (33) from the cover

(8) and drain the lubricant oil.
8
33
Place a container under the workbench
while draining lubricant oil.

ZX75-1006057

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

6. Removing the cover

8

1) Turn the travel motor upside down.

1
2) Make a matching mark on the mating sur-
face between hub (1) and cover (8).

ZX75-1006058

.
3) Find the closed gap of ring (18). Punch a

De al
hole on the hub externally, where is ap-

pt
proximately 20 mm from the end of ring
18
(18).
g no
in ti
et a

ZX75-1006059
n
rk er
Ma t

Notch Cover Ring

In

Φ2 7mm
20mm

Hub

ZX75-1006060

Shop Manual - November 2012 8-43

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4) Drill a 2 mm bore from the outside of hub (1)

toward the ring (18).

18
Press the drilling bit against the punched 1
hole and drill straightly till the ring is
pushed by the drilling bit and the cover
is raised. Wipe off the metal chips so as
to prevent them from sticking to the parts
disassembled.

ZX75-1006061

.
De al
5) Insert the steel rod into the bore to push

pt
out the ring (18).
g n
Now, the end of ring (18) is pushed out of
the cover (8).
o 18

8
in ti
et a
n

ZX75-1006062
rk er
Ma t

6) Hold the end of ring (18) and push it up-

ward on cover (8) in order to remove the 18
In

8
ring (18) from the circular groove of hub (1).

ZX75-1006063

8-44 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

7) Screw on the two PT eyebolts into the

socket-headed screw plugs (33) of the
cover (8). 8

8) Hook the wire cable to the PT eyebolts and

crane the cover (8) away.
33
29
If it is difficult to remove the cover (8) due
to resistance of the O-ring seal (29), use
a plastic hammer to slightly tap the edges
during hoisting. ZX75-1006064

.
De al
pt
9) Remove the O-ring seal (29) from the cov-
er (8). g no 29

The removed O-ring seal (29) shall not be

in ti
reused.
et a
n

8
rk er

ZX75-1006065
Ma t
In

7. Removing the input gear

24
1) Remove the C-type snap ring (24) from the
shaft (16).

16

ZX75-1006066

Shop Manual - November 2012 8-45

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2) Remove the input gear (6) from the shaft

(16). 6

3) Remove the shaft (16) from the coupling

(15).
16

4) Remove the ball (26) from the shaft (16).

5) Remove the coupling (15) from the shaft

(102).
ZX75-1006067

8. Removing the rear flange

.
De al
1) Overturn the travel motor.

pt
When it is necessary to disassemble the
g n
interior of rear flange, the following job
o
must be carried out in order to remove the 124

screw plug easily. Loosen the bolt until it

in ti
can be screwed off easily with hand.

Do not loosen the bolts if it is unnecessary

et a

to disassemble the interior of rear flange.

n
rk er

ZX75-1006068
Ma t
In

2) Loosen the two screw plugs (124).

126
3) Loosen the two screw plugs (126).

When it is necessary to disassemble the

interior of rear flange, this job aims to re-
move the screw plug easily.

Do not loosen the bolts if it is unnecessary

to disassemble the interior of rear flange.
ZX75-1006069

8-46 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

4) Remove the eight socket-headed bolts

(143). 143

ZX75-1006070

.
De al
pt
5) Remove the rear flange (101) from the 101
spindle (2).
g n
Hold the rear flange with both hands and
o 109

113
carefully lift it off. If the flange is removed
2
in ti
through prying or hammering with greater
force, the timing disc (109) may fall and
be broken.
et a

6) Remove the eight springs (113).

n

ZX75-1006071
rk er
Ma t

7) Remove the parallel pin (142) from the

In

spindle (2). 142

ZX75-1006072

Shop Manual - November 2012 8-47

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8) Remove the O-ring seal (30) from the spin-

dle (2).

The removed O-ring seal (30) shall not be 30

reused. 2

ZX75-1006073

9. Disassembling the rear flange

.
De al
pt
1) Leave the mating surface of spindle (2) of
the rear flange (101) upward.
g n
2) Remove the timing disc (109) from the rear
o
109
flange (101).
in ti

It may be difficult to remove the time disc

because the oil on the disc could make
et a

the disc sticking to the mating surface

of the rear flange. In this case, insert a
n

scraper knife into the groove of the rear 101

rk er

ZX75-1006074
flange mating surface to slightly lift up the
timing disc. Inserting a sharp tool (such
as screwdriver) between the mating sur-
Ma t

faces may damage the mating surfaces

and cause oil leakage. Never use such a
In

tool to perform this job.

3) Remove the parallel pin (141) from the rear

flange (101).
141

101
ZX75-1006075

8-48 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

4) Remove the deep-grooved ball bearing

from the rear flange (101).

150

101

ZX75-1006076

.
De al
10. Disassembling the brake valve of rear

pt
flange
101
g n
1) Remove the two screw plugs (124) from
o
the rear flange (101).
in ti
2) Remove the two spring seats (125) and
the two springs (128) from the rear flange
(101).
et a

124
n

ZX75-1006077
rk er
Ma t

3) Remove the spool (123) from the rear

flange (101). 101
In

Tilting the rear flange (101) to incline the

plug hole downward, the spool (123) will 125
slide down. Hold the end of the spool to
take it out.
128

123
ZX75-1006078

Shop Manual - November 2012 8-49

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4) Remove the two screw plugs (126) from

the rear flange (101).
126

101

ZX75-1006079

.
De al
pt
5) Remove the two springs (130) and the two
valves (127) from the rear flange (101).
g no 127
in ti
et a

101
n

ZX75-1006080
rk er
Ma t

6) Remove the O-ring seal (136) from the

In

screw plug (124).

Do not reuse the removed O-ring seal

(136).
124

136
ZX75-1006081

8-50 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

7) Remove the O-ring seal (137) from the

screw plug (126).

Do not reuse the removed O-ring seal

(137).

126
137
ZX75-1006082

.
De al
pt
11. Disassembling the pilot valve of rear flange

g n
1) Insert the sharp-end punch into notch of
o
ring (165) and hammer the punch to re-
move the ring (165).
in ti
165
2) Hoist up the rear flange (101) when the re-
moved annular hole faces downward. Re-
et a

move the stopper (164), spring (166) and

n

valve (163) from the rear flange.

rk er

ZX75-1006083

The ring (165) is only removed when it is

necessary to replace the pilot valve. The
removal of ring (165) will damage the
Ma t

hole. Therefore, repair the hole carefully

In

after the ring is removed.

Do not reuse the removed ring (165).

101
★ If the parts on the rear flange cannot be
removed when the rear flange is lifted
with its hole facing downward, gradu- 163
ally apply compressed air to the second 166
speed selector port.
164
ZX75-1006084
If the compressed air applied can
cause the parts to eject and result in
personal injury, take care when using
the compressed air.

Shop Manual - November 2012 8-51

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

12. Removing the screw plug

1) The screw plug (152) is only removed

when necessary. If the failure is caused by
dirt, remove the plug and clean the oil port
thoroughly.

Now, be careful not to let the steel balls

(168) fall.

2) Remove the O-ring seal (174) from the

ZX75-1006085
screw plug (152).

.
Do not reuse the removed O-ring seal

De al
(174).

pt
g no
13. Disassembling the parking brake
in ti
★ If compressed air is applied suddenly,
the plunger (112) may come off sud-
139
denly from the spindle (2). Therefore,
et a

place a protective cover on the plunger 112

(112).
n

135
rk er

1) Apply compressed air to the opening of the

parking brake on the spindle (2) in order to
remove the plunger (112) from the spindle
Ma t

ZX75-1006086
(2).
In

2) Remove the O-ring seals (135) and (139)

from the plunger (112).

Do not reuse the removed O-ring seals

(135) and (139).

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

14. Disassembling the hydraulic motor

If the travel motor is placed side down, oil

will come out. Put a container under the
travel motor.

1) Turn the travel motor by 90 degrees. 104

2) Drain the oil from the travel motor.

3) Hold the cylinder block (104) with hands ZX75-1006087

and rotate it by 2-3 turns in both directions
in order to separate the slipper (106) from

.
the thrust plate (153).

De al
pt
★ If the cylinder block (104) is pulled out
without performing the above steps, 104
g n
the slipper (106) will be detained on the
o
swash plate (103). The parts stuck to
116

102
the cylinder (104) will come off and fall
in ti
to the spindle (2).

4) Pull out the cylinder block (104) from the

et a

shaft (102).
n

Now, remove the friction plate (115), gas-

rk er

ket (116) and cylinder block (104) togeth- ZX75-1006088

er.
Ma t
In

5) Remove the friction plate (115) and gasket

(116) from the cylinder block (104).

6) Remove the plunger assembly [plunger

(105), slipper (106) and fixing plate (107)]
from the cylinder block (104). 106

Hold the fixing plate (107) with both hands 107

105
in order to remove it with other parts on it.
104
116 115
The plunger (105) and the slipper (106) ZX75-1006089
are made into one piece by calendering
the spherical part of the plunger. The
plunger (105) and the slipper (106) cannot
be separated without damaging the slipper
(106).

Shop Manual - November 2012 8-53

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

If either or both of them should be re-

placed, replace them (hereunder referred
to as the plunger assembly) together.
Replace nine sets (hereunder referred to
as the plunger kit) at the same time.

7) Pull out the plunger assembly (105) and

(106) (nine assemblies) from the fixing
plate (107). 107
106

105
ZX75-1006090

.
De al
pt
g n
8) Remove the thrust ball (108) from the cyl-
inder block (104).
o
108
in ti
et a
n

104
rk er

ZX75-1006091
Ma t
In

9) Remove the three rollers (151) from the

cylinder block (104). 151

104

ZX75-1006092

8-54 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

15. Removing the spring from the cylinder

block

1) Place the cylinder (104) on press work-

bench.

Align the holder (I) with the washer, when 145

removing the spring, so as to prevent
damaging the cylinder block due to con-
tact. Use an ethylene sheet to wrap the
104
cylinder block in order to protect it. ZX75-1006093

Remove the spring only when replacement

.
is necessary.

De al
pt
2) Place the holder (I) on the washer (110).
Holder (I)
Fix the holder (I) with the press. Use the
g n
snap ring pliers to remove the annular R-
o
type snap ring (145) from the groove of the
Washer Snap ring

cylinder block (104). Spring

in ti
Cylinder
3mm block
3) Gradually release the press till the spring
force comes to zero.
et a
n

★ If the press is released suddenly, the

spring may eject and cause injury.
rk er

ZX75-1006094
Therefore, the press is to be released
slowly.
Ma t
In

4) Remove the R-type snap ring (145),

washer (110), spring (114) and washer 110
(110) from the cylinder block (104).

114

104

ZX75-1006095

Shop Manual - November 2012 8-55

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

16. Pulling out the shaft

1) Remove the swash plate (103) from the 103

shaft (102).

When the swash plate is being removed,

pay attention to the pivot (176), which
102
may stick to the swash plate.

ZX75-1006096

.
De al
2) Pull out the shaft (102) from the spindle (2).

pt
Now, the deep-grooved ball bearing is re-
moved with the shaft.
g no
Tapping the shaft end at the side of reduc-
149
2

er with a plastic hammer can help pull out

in ti
the shaft easily. The shaft may jump out
102
when hammered with greater force.
et a

3) Remove the thrust plate (153) from the

n

swash plate (103).

ZX75-1006097
rk er

It is probably difficult to remove the swash

plate (103) due to oil on the mating sur-
faces. In this case, insert a scraper knife
Ma t

between the swash plate and the thrust

In

plate, lift it up slowly and then remove the

swash plate without difficulty.

8-56 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

4) Remove the two pivots (176) and the two

parallel pins (177) from the spindle (2).

★ Through the following steps, the sec-

ond speed selector plunger assembly
may jump out and cause injury due
to compressed air. Therefore, place a
2
protective cover on the second speed
selector plunger assembly.

5) Blowing compressed air through the chan-

ZX75-1006098
nel of rotation shaft (2) can help remove
the second speed selector plunger assem-

.
bly (plunger and slipper) and the spring

De al
from the rotation shaft (2).

pt
● Plunger (161)
Plunger AS
g no
● Slipper (162)
in ti

Compressed air:
et a

0.29~0.49 MPa {3~5 kg/cm²}

n

The plunger (161) and the slipper (162)

rk er

are made into one piece by calendering

the spherical part of the plunger. The
plunger (161) and the slipper (162) cannot
Ma t

be separated without damaging the slipper

In

(161). If either or both of them should be

replaced, replace them (hereunder referred
to as the plunger assembly) together.

17. Removing the deep-grooved ball bearing

149
Remove the deep-grooved ball bearing
only when required.
102

1) Place the holder (II) on the press work- Holder (II)

bench and put in the shaft (102).

2) Push the shaft end with the press in order

to remove the deep-grooved ball bearing
(149) from the shaft.
ZX75-1006099

Shop Manual - November 2012 8-57

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Never reuse the deep-grooved ball bear-

9
ing.

18. Removing the spur gear

1) Turn the travel motor.

★ Take care that the snap ring may

come off the pliers tip and fly out when
removed. 25

ZX75-1006100
2) Remove the three C-shaped snap rings
(25) from the crankshaft (9).

.
De al
pt
3) Remove the three spur gears (7) from the 7
crankshaft (9).
g no
in ti

9
et a
n

ZX75-1006101
rk er
Ma t

4) Remove the three separators (14) from the

crank shaft (9).
In

14

ZX75-1006102

8-58 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

19. Removing the fixing flange

1) Turn the travel motor.

2

2) Install the clamps (2) to the hub (1) and the

spindle (2) in order to fix them. Install the
clamps symmetrically.

If the fixing flange (3) is removed without

1
installing the clamps, the hub (1) will sep-
arate from the spindle (2) and the spindle
ZX75-1006103
(2) may fall from the workbench.

.
The clamps must be used.

De al
pt
3) Turn the travel motor.

g no
20
in ti

3
et a
n
rk er

ZX75-1006104
Ma t

4) Remove the three snap rings (20) from the

In

fixing flange (3).

20
5) Make matching marks on the snap rings
(20) and the fixing flange (3).

ZX75-1006105

Shop Manual - November 2012 8-59

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

These marks are used to restore the snap

19
rings and the fixing flange to their original
positions.

6) Loosen the three hinge bolts (19).

Adhesive was applied to the threads of

bolt (19). If the hinged part is stuck by ad-
hesive when loosening the bolts, the bolts
could be seized and are difficult to re-
move. Therefore, slowly loosen the hinge ZX75-1006106
bolts. If the bolts are tight, do not loosen
them forcibly. Tighten them first and then

.
loosen them slowly.

De al
pt
The tightening torque of hinge bolt is
411.6±63.7 Nm (42±6.5 kgm). Due to the
g n
presence of adhesive on the threads, a
o
torque greater than 411.6±63.7 Nm (42±6.5
kgm) should be used to loosen the bolts.
in ti
3
7) Remove the fixing flange (3) from the spin-
dle (2).
et a
n

8) Paint matching marks on the fixing flange

(3) and the spindle (2). 2
rk er

Before disassembling, making these

marks can help restore the fixing flange
Ma t

ZX75-1006107
(3) onto the spindle (2). Make a mark on
In

each hole of the three hinge bolts (19).

When the spindle (2) or the fixing flange
(3) is to be replaced, replace them as an
assembly (hereunder referred to as spin-
dle assembly).

20. Removing the clamps

1) Turn the travel motor.

2) Remove the two clamps.

ZX75-1006108

8-60 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

21. Removing the spindle

1) Screw on symmetrically two eyebolts into 2

the threaded bolt holes of the spindle (2).

2) Hook the eyebolt and lift the hub (1) off the
spindle (2) with a crane. 31

1
Meanwhile, remove the floating seal
(31) and the outer ring and oil seal of
the roller bearing (22). ZX75-1006109

.
3) Remove the separator (10) from the hub

De al
(1).

pt
g no 10
in ti

1
et a

ZX75-1006110
n
rk er

4) Remove the O-ring seal (28) from the hub

(1).
Ma t

Never reuse the removed O-ring seal (28). 28

In

ZX75-1006111

Shop Manual - November 2012 8-61

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

22. Removing the ball bearing, RV gear as- 1

sembly and pins

1) Use a punch and hammer to tap the

2
end of pin (17) in order to remove the ball
bearing (21) from the hub (1). 17

Also remove the RV gear assembly [RV

gear A (4), RV gear B (5), crankshaft (9), 21
cone-roller bearing (22), needle bearing
(23) and spacer (12)] and the pin (17) at ZX75-1006112
the same time.

.
When removing the ball bearing (21),

De al
slightly hammer 3-4 locations on the edge

pt
of pin in order to keep the bearing level.

g n
When the outer ring of ball bearing (21) is
o
removed from the hub (1), the ball bearing
(21), the RV gear assembly and pin (17)
in ti
may fall from the hub (1). Therefore, place
a container and a rubber sheet under the
workbench to protect the fallen parts.
et a
n

2) Remove the ball bearing (21), the RV gear

assembly and pin (17). The gear A (4) and
rk er

gear B (5) of the RV gear assembly can be

separated from the crankshaft (9).
Ma t

The cone-roller bearing (22), the needle

In

bearing (23) and the spacer (23) are

removed only when replacement is re-
quired.

23. Removing the ball bearing and retainers

1) Turn the travel motor. 3

2) Tap the end of retainer (11) at the side of

the cover (8) of the hub (1) with a punch 4
and a hammer in order to remove the
ball bearing (21) and the retainer (11).

11

21
ZX75-1006113

8-62 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

If the ball bearing (21) and the retainer (11)

are removed, they may fall from the hub
(1). In this case, place a rubber sheet un-
der the workbench in order to protect the
parts.

24. Removing the parts of spindle

132
1) Remove the oil seal (132) from the spindle
2
(2).

Never reuse the removed oil seal (132).

.
De al
pt
g no ZX75-1006114
in ti
2) Remove the floating seal (31) from the
31
spindle (2).
et a
n
rk er

2
Ma t
In

ZX75-1006115

3) Remove the three outer rings from the

roller bearing (22). 22

It might be difficult to remove the outer

ring of the roller bearing (22) because the
lubricant oil forms a layer of sticky film
on the parts. In this case, tap the center
of the spindle (2) installation hole with an 2
aluminum rod. The oil film can be ruined
and the outer ring can be removed easily.
ZX75-1006116

Shop Manual - November 2012 8-63

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

25. Disassembling the fixing flange

1) Remove the outer ring of the roller bearing

(22) from the fixing flange (3).

22

ZX75-1006117

.
26. Primary cleaning of parts

De al
2 3

pt
1) The parts can be categorized into the hub 101
(1), the spindle (2), the fixing plate (3), the
g n
rear flange (101) and other parts (hereun-
o
der referred to as internal parts) 1
in ti
2) Clean the hub, spindle, cover and rear
flange in a tank.
et a

Clean the parts and completely remove

n

ZX75-1006118
the soil and sand from the parts.
rk er

★ Kerosene is flammable. Take special

care to prevent fire.
Ma t

3) Clean the internal parts with kerosene in a

In

tank for primary cleaning.

If the parts are flushed with water before

they are soaked enough in the kerosene,
the parts would be bruised. Therefore,
keep the parts in the kerosene until the
dirt and grease come off and float up.

8-64 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

27. Secondary cleaning

1) Clean the interior of the parts with kero-

sene in a tank for secondary cleaning.
Slowly turn the parts.

3
2) Wipe off the kerosene from the parts with
clean cloth.

Dry the interior of the hub (1), spindle (2)

and fixing flange (3) with compressed air
ZX75-1006119
in a clean and dry place. Apply hydraulic
oil to the parts after drying. Leave the rear

.
flange (101), the hydraulic motor parts

De al
and the RV gear assembly to dry in a

pt
clean and dry place. Apply hydraulic oil to
the parts after drying.
g no
If the 24 pins (17) are taken carelessly,
2

they may scratch each other and get lost.

in ti
Therefore, handle them carefully.
et a

ZX75-1006120
n
rk er
Ma t
In

Shop Manual - November 2012 8-65

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.10.9 Table of maintenance standard

Disassemble and check the GM motor according to the following standard. Take care when han-
dling its parts. Be especially careful not to damage the moving parts and the sliding parts.

1. Seals

The seals (O-ring seal, oil seal and floating seal) must be replaced once removed, regardless
of damage or not.

2. Maintenance standard of replacement parts

1) Replace all parts that are apparently damaged.

.
De al
2) Replace the parts that show the following failures (symptoms).

pt
Permis-
Part No. Part Name
g no Failure
Standard
Value (Sizes)
sible Value
(Benchmark)
Spindle kit
in ti
(2)
Spindle ● Serious damage of part surface
(3) — —
Fixing flange ● Part surface easily bruised or worn
(19)
et a

Hinge bolt
RV gear AS
n

(4)
RV gear (A)
(5) ● Nonuniform wear of RV gear surface
rk er

RV gear (B)
(9) ● The parts move unstably when crankshaft (9) — —
Crankshaft
(22) rotates.
Roller bearing
(23)
Ma t

Needle bearing
● Cracks in sliding surface
In

10 Separator — —
● Abnormal wear of sliding surface
20 Snap ring ● Abnormal wear of edge or end face — —
● Bruise
21 Ball bearing ● Surface peeling — —
● Nonuniform wear of surface
● Bruise in moving part against the spool (123)
● Big clearance between rear flange and spool

Rear flange kit ● Bruise of surface against valve (127)

(101) Clearance Clearance
Rear flange ● Excessive depression of surface against
(123) 12~18μ 23μ
Spool valve (127)
● Bruise of external surface
● Nonuniform wear of external surface

8-66 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

Permis-
Standard
Part Number Part Name Failure sible Value
Value (Sizes)
(Benchmark)
● Wear of surface against oil seal
Shaft (132)
102 — —
● Wear of spindle
153 Thrust plate ● Thrust plate seized — —
● Wear of spindle
● Apparent wear of cylinder barrel
104 Cylinder block interior
— —
● Bruise or nonuniform wear of slid-
ing surface against timing disc

.
De al
(109)

pt
● Presence of axial clearance be-
Plunger AS tween plunger (105) and slipper
(105)
Plunger Clearance Clearance
(106) g nSlipper
o (106).
● Abnormal wear of slipper
0.05 mm 0.15 mm

● Nonuniform wear of slipper

in ti
● Nonuniform wear of edge and end
107 Fixing plate — —
face
● Nonuniform wear of sliding part
et a

108 Thrust ball — —

against fixing plate (107).
n

● Sliding surface seized or worn

109 Timing disc — —
non-uniformly
rk er

● Nonuniform wear of both end fac-

es Braking torque Braking torque
115 Friction plate
82.38 Nm 82.38 Nm
116 Gasket ● Specified torque not achieved
Ma t

{8.4kgm} {8.4gm}
● Gasket seized
In

127 Valve ● Bruise in seat surface — —

● Bruise
149 Ball bearing
● Surface peeling — —
150 Ball bearing
● Nonuniform wear of surface
163 Valve ● Bruise of external surface — —

Shop Manual - November 2012 8-67

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.10.10 Assembly

● As a rule, disassembling operation is per- 7) Clean hydraulic oil (NAS 9 or above) is to

formed in the reverse order of disassem- be applied to the hydraulic motor parts and
bling. the moving or sliding parts of valve during
assembling.
1. Preparatory work
8) Do not wear cotton gloves during assem-
Like the preparatory work for disas- bling. (Fibers of cotton gloves can cause
sembling, prepare a workbench, tools and failure.)
materials used for disassembling.
9) Tighten all bolts and screw plugs to the
2. General precautions table of tightening torques.

.
De al
1) Abide by the general precautions for disas- 10) Plug all openings after assembling op-

pt
sembling. eration in order to prevent invasion of dust.
g n
2) Before assembling, it is necessary to re-
o
move all metal chips and impurities on
3. Assembling method

the parts and check for burrs and bruises.

in ti
It is necessary to adjust the ball bearing
Remove the burrs and bruises if any with a preload and the snap ring thickness if
whetstone. any part is replaced before assembling.
Check whether the following are replaced
et a

3) Replace the O-ring seals, oil seals and before assembling.

n

floating seals.
1) It is necessary to adjust the replacement
rk er

4) As a rule, the hinge bolt should be re- parts of ball bearing preload, i.e. the hub
placed. The use of the old bolt requires (1), spindle (2), retainer (11), fixing flange
removing any attached substance from the (3) and ball bearing (21).
Ma t

bolt. Remove any bruises with a whetstone

In

on bolt seat. Remove the grease on the 2) It is necessary to adjust the replacement
hinge bolts. parts of snap ring thickness, i.e. The spin-
dle (2), fixing flange (3), crankshaft (9),
5) The hinge bolt (19) and bolt hole of the spacer (12), roller bearing (22) and snap
spindle (2) are to be degreased as adhe- ring (20).
sive will be applied to them during assem-
bling. Use only the adjusted parts if any part
above is replaced before assembling. The
6) Be careful not to damage the O-ring seals, use of unadjusted part may cause failure
oil seals and floating seals during assem- of the travel motor and soon the damage.
bling. (A small amount of greased can be Therefore, this is a rule to be abided by.
applied to the parts in order to ease their
installation.)

8-68 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

4. Reassembling the hub assembly

1) Make sure that the hub (1), spindle (2), fix- 1

ing flange (3), retainer (11) and the two ball
bearings (21) have not been replaced.

Proceed to the next step if the above parts

have not been replaced. Adjust the pre-
load of ball bearing before going to the
next step if any above part has been re-
placed.
ZX75-1006121

2) Screw on the two eyebolts symmetrically

.
into the holes of the hub (1).

De al
pt
3) Hook the wire rope to the eyebolts. Hoist
1
the hub (1) to the workbench with a crane.
g no
Align the hole on the hub (1) to the hole on
the workbench. Carefully place the hub
in ti
into the installation hole of the workbench.

4) Secure the hub (1) to the workbench with

et a

socket-headed bolt.
n

ZX75-1006122
rk er

5) Install the retainer (11) to the hub (1).

Ma t
In

ZX75-1006123

Shop Manual - November 2012 8-69

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6) Install the ball bearing (21) into the hub (1).

Press a punch against the outer ring of

the ball bearing (21), Hammer the punch
21
slightly in order to install the ball bearing 1
properly.

ZX75-1006124

.
De al
7) Apply grease to the O-ring seal (28) and

pt
install it into the O-ring seal groove of the
hub (1).
g no 28

1
in ti
et a
n

ZX75-1006125
rk er

8) Install the separator (10) to the hub (1).

Ma t

If it is difficult to install the separator (10),

tap it with a plastic hammer. Note that
In

10
sudden insertion of the separator may 1
break the O-ring seal (28) and cause oil
leakage.

ZX75-1006126

8-70 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

5. Reassembling the spindle assembly 31

1) Apply grease to the O-ring seal of the float-

ing seal (31). Install the floating seal (31)
into its groove on the spindle (2).

Remove the O-ring seal from the floating 2

seal. Apply a thin layer of grease around
the O-ring seal.

Install the O-ring seal properly into the

ZX75-1006127
groove on the floating seal. Install the float-
ing seal and make it parallel to the groove

.
surface of the spindle.

De al
pt
2) Install the two eyebolts symmetrically into
the spindle (2).
g no
3) Hook the wire cable to the eyebolts. Hoist
2

up the spindle and slowly install it into the

in ti
hub (1).
31
et a

1
n
rk er

ZX75-1006128

4) Secure the hub (1) and the spindle (2) with

Ma t

clamps. The clamps are to be installed

In

symmetrically.

5) Turn the travel motor.

ZX75-1006129

Shop Manual - November 2012 8-71

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6) Install the three outer rings of the roller

bearing (22) into the corresponding holes 22

on the spindle (2).

ZX75-1006130

.
7) Assembling the RV gear assembly

De al
pt
a. Insert RV gear A (4) into the hub (1). 4

g no
1
in ti
et a

ZX75-1006131
n
rk er

b. Install the three crankshafts (9) into the

corresponding holes in the outer ring of
9
the roller bearing (22) in the spindle (2).
Ma t

Now, the roller bearing (22), the needle

In

bearing (23) and the spacer (12) must be

installed to the crankshafts.

ZX75-1006132

8-72 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

c. Insert the RV gear B (5) into the hub (1).

Since the RV gear A (4) and the RV gear B

(5) are matching each other, the punched 4

holes on the gear ends must be aligned.

1

ZX75-1006133

.
De al
8) Insert the 24 pins (17) into the pin gap on

pt
the hub (1) and the back lash of the gear.
17
g n
Apply lubricant oil to the pins (17) before
inserting them.
o
1
in ti
et a
n

ZX75-1006134
rk er

9) Install the ball bearing (21) into the hub (1).

1
2
Ma t

Press a sharp-end punch Against the

In

outer ring of the ball bearing (21). Tap the 21

outer ring with a hammer in order to in-
stall the bearing slowly.

ZX75-1006135

Shop Manual - November 2012 8-73

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6. Assembling the fixing flange 3

1) Install the fixing flange (3) onto the inner

ring of the ball bearing on the hub (1).

Locate the matching marks of the spindle

(2) and the crankshaft (9) to their origi- 9
nal positions before disassembling when
installing the fixing flange (3) on the ball 1
bearing (21).

ZX75-1006136
If the fixing flange (3) cannot be put inside
the inner ring of the ball bearing smoothly,

.
tap it uniformly with a plastic hammer.

De al
pt
g n
7. Tightening the hinge bolts
o
1) Apply lubricant to the hinging part of the
in ti
hinge bolt (19). Apply adhesive to the
threaded section of the hinge bolt.
et a

2) Tighten the three hinge bolts (19) till the

fixing flange (3) is fully pushed against the
n

ball bearing (21). 3

rk er

The hinge bolts (19) should be degreased ZX75-1006137

if they are stuck with oil or grease. Clean
Ma t

the bolts and leave them dry in air for 10

minutes. And then apply adhesive to their
In

threaded section.

3) Tighten the three hinge bolts (19) to the

specified torque.
3
Hinge bolt (19):

19
411.6±63.7 Nm {42±6.5 kgm}

ZX75-1006138

8-74 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

Tighten the three hinge bolts (19) slowly

and uniformly. If one or two hinge bolts
are tightened first, the fixing flange would
tilt; the ball bearing (21) would not be in-
3
stalled precisely into the fixing flange (3);
the hinge bolt (19) would be seized. If the
seats of three hinge bolts (19) cannot be
installed precisely onto the surface of the
fixing flange, check and shoot the cause.
22
4) Turn the travel motor.
ZX75-1006139

5) Remove the two clamps.

.
De al
6) Turn the travel motor..

pt
7) Install the outer ring of the cone-roller bear-
g n
ing (22) to the fixing flange (3).
o
8. Assembling the snap ring
in ti

1) Make sure that the spindle (2), fixing flange

(3), crankshaft (9), cone-roller bearing (22),
et a

spacer (12) and snap ring (20) are not re- 3

n

placed.
20
rk er

Proceed to the next step if the above parts

are not replaced. If any of the above parts
is replaced, adjust the axial clearance of
Ma t

the cone-roller bearing (22) before pro-

22
In

ceeding to the next step.

ZX75-1006140

If only the snap ring (20) is to be replaced,

select one similar to the used snap ring or
a similar one of the 12 types.

2) Install the snap ring (20) into the snap ring

hole on the fixing flange (3).

Install the three snap rings (20) to their po-

sitions before disassembling. Align them 14
with the matching marks on the fixing
flange (3). When a new snap ring (20) is
9
to be used, select one whose thickness
ZX75-1006141
has been used in former process.

Shop Manual - November 2012 8-75

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3) Install the three separator (14) on the

crankshaft (9).

9. Assembling the spur gears

7

1) Install the three spur gears (7) on the

crankshaft (9).

.
ZX75-1006142

De al
pt
The installation of spur gears requires Position the marks
g n
aligning them with the matching marks
o
(punched holes) indicated in the illustra-
(punched holes) of
the spur gears as
indicated.
tion on the right.
in ti

Fixing flange
et a
n
rk er

ZX75-1006143
Ma t

2) Install the three C-type shaft snap ring (25)

to the crankshaft (9). 9
In

25
ZX75-1006417

8-76 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

10. Assembling the oil seal

Holder (III)
1) Turn the travel motor.

2) Apply lithium base grease to the lip of oil

seal. Assembling the oil seal (132) to the
spindle (2) with a hammer and the holder
(III). Spindle
Oil seal

ZX75-1006145

.
De al
11. Assembling the shaft

pt
1) Place the deep-grooved ball bearing
g n
(149) in a heating box and heat it up to
100±10°C In 10 minutes. And then install it
o
to the shaft (102).
in ti
Wear leather gloves while installing the
102
shaft. Take care not to get burned. 149
et a

Insert the ball bearing (149) till it is installed ZX75-1006146

n

to the flange of the shaft (102).

rk er

2) Install the two parallel pins (177) into the

Ma t

pin holes on the spindle (2).

In

3) Apply lithium base grease, as adhesive,

to the two pivots (176). Install them to the 2
parallel pins (177) to the spindle (2). 176

4) Install the plunger assembly [plunger (161)

and slipper (162)] on the spindle (2).
177
5) Turn the travel motor by 90°. ZX75-1006147

Shop Manual - November 2012 8-77

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6) Install the shaft (102) on the spindle (2).

Slowly put the shaft (102) on the spindle

(2). Be careful not to damage the lip of oil
102 2
seal (132) on the spindle (2). Damage of
the lip can cause oil leakage, which would
soon lead to damage of the travel motor.

ZX75-1006148

.
De al
7) Apply molybdenum bisulfide grease to

pt
the thrust plate (153) and install it on the 103
153
swash plate (103).
g no
8) Install the swash plate (103) on the spindle
(2).
in ti
2
Apply grease on the mating surfaces be-
tween the swash plate (103) and the
et a

spindle (2).
n

ZX75-1006149
Align the steel Ball hole with the two steel
rk er

balls (167) on the spindle while installing

the swash plate (103) on the spindle (2).
Ma t

12. Reassembling the cylinder block

In

110
1) Install the washer (110), spring (114),
washer (110) and the annular R-type snap
ring (145) sequentially into the cylinder 114
block (114).

2) Place the cylinder block (104) on the work- 104

bench of the press.
ZX75-1006150

8-78 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

3) Put the holder (I) on the washer (110) and

secure it with the press. Install the annular
R-type snap ring (145) into its groove on
the cylinder block (104) with snap ring pli-
ers.

Wrap the cylinder block (104) with an eth- 145

ylene sheet so as to protect its interface
with the timing disc (109).
104
ZX75-1006151

.
De al
13. Reassembling the parts of hydraulic motor

pt
1) Install the three rolls (151) into the holes
g n
on the cylinder block (104).
o
2) Put the thrust ball (108) on the cylinder
in ti
block (104). 107
106
3) Install the nine plunger assemblies on the
et a

fixing plate (107). 105

n

ZX75-1006152
After installation of the plunger assemblies,
rk er

soak them in hydraulic oil.

Ma t

4) Install the nine plunger assemblies into the

cylinder block (104).
In

Align the spherical part of the thrust ball

(108) with the fixing plate (107).
106

107
105

104
116 115
ZX75-1006153

Shop Manual - November 2012 8-79

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

5) Install the cylinder block (104) on the shaft

(102). 104
116

Align the spline hole of cylinder block (104) 102

with the spline of shaft (102) during instal-
lation. After installing the cylinder block,
turn it with hand to check for play. Re-
check is required in the presence of play.

ZX75-1006154

.
De al
14. Assembling the parking brake assembly

pt
104
1) Install the friction plate (115) and the gas-
g n
ket (116) into the external groove of the
cylinder block (104). Install the friction plate
o
before the gasket.
in ti

Soak the friction plate (115) in hydraulic oil

prior to installation.
et a
n

ZX75-1006155
rk er

2) Install the O-ring seals (135) and (139) in

their groove on the plunger (112). Now, ap- 112
Ma t

2
ply a thin film of grease to the O-ring seals.
In

3) Turn the travel motor by 90°.

ZX75-1006156

8-80 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

4) Install the plunger (112) on the spindle (2).

If the plunger (12) cannot be put into the

spindle (2) smoothly due to resistance of
139
the O-ring seals (135) and (139), tap its
end with a plastic hammer. Take care not 112
to damage the O-ring seals while install-
ing the plunger (112). 135

ZX75-1006157

.
De al
15. Reassembling the brake valve parts of the

pt
rear flange

g n
1) Install the two O-ring seals (137) on the
two screw plugs (126).
o
in ti
Apply grease to the O-ring seals (137).
et a

137 126
n

ZX75-1006158
rk er

2) Install the valve (127) and the spring (130)

on the screw plug (126). Now, using the
126
adhesive performance of grease, apply
Ma t

grease to the spring in order to reduce the

In

force of spring. Connect the valve, spring 127

and screw plug.

3) Install the screw plug (126), mounted with

valve (127) and spring (130), into the rear
flange (101). 101

ZX75-1006159
To install the screw plug (126), place the
flange (101) on the workbench, let the
plug mounting hole face upward, and
align the plug with its hole.

Protect the O-ring seal and prevent the

spring (130) from detaching from the valve
(127) due to contact of rear flange with
valve inner wall.

Shop Manual - November 2012 8-81

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

If the spring (130) separates from the valve

(127), it is unable to install the valve on the
seat of rear flange (101), which can cause
oil leakage.

4) After the two plugs (126) are installed, tem-

porarily screw them in the rear flange (101)
with a hex wrench.
126

.
De al
101

pt
ZX75-1006160
g no
5) Install the spool (123) in the rear flange
in ti
123
(101).

Apply hydraulic oil to the spool prior to in-

et a

101
stallation.
n

★ When installing the spool, align it with

rk er

the hole on the rear flange so as to

protect its surface and the rear flange
inner surface against damage.
Ma t

ZX75-1006161
In

★ If the hole of rear flange and the exter-

nal surface of spool are damaged due
to contact, internal leakage may occur
after assembling. The performance of
travel motor could decrease.

6) Install the O-ring seal (136) on the screw

plug (136).

Apply grease to the O-ring seal (136).

124

136
ZX75-1006162

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

7) Install the spring seat (125) and the spring

(128) on the screw plug (124).
125 101
8) Install the two plugs (124) on the rear
flange (101).

Pay attention to the spring, which should

not deform after the plug is installed on
the rear flange.
124
128
ZX75-1006163

.
9) Temporarily screw on the two plugs (124)

De al
to the rear flange (101).

pt
101

g no
in ti
et a

124
ZX75-1006164
n
rk er

16. Reassembling the rear flange

1) Installing the pilot valve in the rear flange

Ma t
In

a. Place the rear flange with its mating 163

surface (against the spindle (2)) facing
upward.
101
b. Install the valve (163) in the rear flange
(101).
ZX75-1006165

Shop Manual - November 2012 8-83

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

c. Install the spring (166) on the valve

164
(163) and put the stopper (164) on
them.

166

ZX75-1006166

.
d. Bend the new ring (165) a little and

De al
install it into the annular groove of the

pt
165
rear flange from the plug (164).
g n
The ring (165) must be installed into the
o
annular groove of the rear flange (101). 164
Otherwise, the valve (163) cannot work
in ti
regularly. There would be trouble in se-
lecting high speed or low speed. A new
101
ring (165) must be used.
et a

ZX75-1006167
n

2) Apply hydraulic oil to the deep-grooved

ball bearing (150) and install it to the rear
rk er

flange (101).
150
Ma t
In

101

ZX75-1006168

8-84 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

3) Install the two parallel pins (141) into the

pin holes on the rear flange (101).
141

101

ZX75-1006169

.
4) Apply grease to the mating surface of the

De al
timing disc (109) facing the rear flange

pt
(101).
109
g n
5) Using the parallel pin (141) as the guide,
o
install the timing disc (109) on the rear
flange (101).
in ti

Install the timing disc (109) till it is secured 141 101

to the rear flange (101).
et a

ZX75-1006170
n

Installing the timing disc in this way can

prevent it from falling from the rear flange
rk er

while it is being installed to the spindle (2).

Ma t

17. Connecting rear flange with spindle

In

30
1) Install the O-ring seals (30) and (27) in
2
their groove on the spindle (2).

Do not apply grease to the O-ring seals (30)

during installation.

If grease is applied, the operation of

travel motor will cause the grease to leak ZX75-1006171
out from between the rear flange and
the spindle. The leak of grease could be
mistaken as the leak of oil, so do not apply
grease to the O-ring seals (30).

Shop Manual - November 2012 8-85

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2) Install the two parallel pins (142) on the

spindle (2).
142

3) Inject 0.55 l hydraulic oil in the spindle (2).

ZX75-1006172

.
De al
4) Install the rear flange (101) on the spindle

pt
101
(2), making the pin holes align with the two
parallel pins (142) mounted on the spindle
(2). g no
2

Install the eight springs (113) on the rear 113

in ti
flange before installing the rear flange
(101) on the spindle (2).
et a

Now, apply grease to the springs (113) in

order to prevent them from falling off the
n

ZX75-1006173
rear flange.
rk er
Ma t

5) Screw the eight socket-headed bolts (143)

In

on the spindle (2) to the specified torque. 143

Bolt (143): 2

57.82±9.8 Nm (5.9±1.0 kgm)

ZX75-1006174

8-86 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

6) Tighten the screw plug (124) to the speci- 124

fied torque.

Plug (124):

352.8±39.2 Nm (36±4 kgm)

ZX75-1006175

.
7) Tighten the screw plug (126) to the speci-

De al
126
fied torque.

pt
Plug (126):
g no
127.4±14.7 Nm (13±1.5 kgm)
in ti
et a

ZX75-1006176
n
rk er

18. Reassembling the input gear

6

1) Turn the travel motor..

Ma t
In

2) Install the coupling (15) on the shaft (102).

16

3) Install the shaft (16) on the coupling (15).

4) Install the input gear (6) on the shaft (16).

Install the input gear (6) on the shaft (102),

ZX75-1006177
making it gear with the three spur gears
(7). If it fails to gear, check it.

Shop Manual - November 2012 8-87

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

5) Install the C-shaped snap ring (24) in its

circular groove on the shaft (16). 24

6) Install the steel ball (26) in its hole on the

shaft (16).

Apply grease to the steel ball so as to pre-

vent the ball from falling while the cover (8)
is installed.
16

ZX75-1006178

.
De al
19. Reassembling the cover

pt
29
1) Fill 1.7l lubricant oil in the hub (1).
g n
2) Install the O-ring seal (29) in its groove on
o
the cover (8).
in ti
Apply grease to the O-ring seal (29).
et a

8
ZX75-1006179
n
rk er

3) Install the cover (8) on the hub (1).

Ma t

Align the cover (8) with the hub (1) through

the matching marks in order to restore
In

8
them to their original positions. Tap the
edge of the cover (8) with a plastic ham-
mer to install the cover. 1

Installing the cover suddenly with great

force would damage the O-ring seal and
cause leak of lubricant oil.
ZX75-1006180

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

4) Install the ring (18) in its circular groove on

the hub (1).
18

ZX75-1006181

.
De al
5) Wind sealing tape around the two socket-

pt
33
headed screw plugs (33) and screw them
into the cover (8) to the specified torque. 8
g n
Screw plug (33):
o
in ti
39.2±14.7 Nm (4±1.5 kgm)

The plug (33) is to be covered by at least

et a

two layers of sealing tape. Tighten each

plug (33) till the number of threads out-
n

ZX75-1006182
standing from the cover become ±1.
rk er

20. Removing the travel motor

Ma t

1) Turn the travel motor..

In

2) Remove the travel motor mounting bolts

from the workbench.

ZX75-1006183

Shop Manual - November 2012 8-89

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3) Screw the two eyebolts into the bolt holes

on the spindle (2).
2
Install the two eyebolts symmetrically in
the bolt holes on the spindle (2).

4) Hook the wire cable to the eyebolts and

move the travel motor away from the work-
bench with a crane.

ZX75-1006184

.
De al
21. Adjusting the preload of ball bearing

pt
The ball bearing (21) must have appropri-
g n
ate preload in order to ensure its service
o
life. If any part affecting the preload is
replaced, install the part temporarily and
in ti
1
check the preload according to the follow-
ing procedure.
et a

If the GM motor is assembled without

checking the preload, it may fail and be
n

damaged soon. ZX75-1006185

rk er

● Parts affecting the preload of ball bear-

ing:
Ma t

● Hub (1), spindle (2), fixing flange (3),

In

21
6
ball bearing and retainer (11).

● Skip this step and go on with 6.1 if no 2

part is replaced. 1

● The following steps are used to check

and adjust the preload.
ZX75-1006186

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

Ball bearing preload adjusting steps

1) Install the main bearing preload adjusting

clamps on the spindle (2). Tighten the
special nut In order to fit the ball bearing
(21) in the hub (1).

Nut : 39.2 Nm {4 kgm}

2) Use a depth micrometer to measure the

depth “A” through the measurement hole of
ZX75-1006187
the main bearing preload adjusting clamp.

.
3) Since the size “B” of the main bearing

De al
preload adjusting clamp is given, the clear- 6

pt
5
ance “C” can be concluded through the
formula below.
B
g no
A: Measured value
A
C
in ti
“C” = “A” - “B” B: Clamp size
C: Standard size
et a
n

ZX75-1006188
rk er

4) Calculate the size “D” of the fixing flange

D
(3). E面
Ma t
In

5) Adjust the fixing flange (3) as per the mea-

3
surement of the above step 2) through step
4).

Size “C” is the standard size of fixing

flange.

a. When the measured size of fixing ZX75-1006189

flange is more than the standard size,
machine the E side of the fixing flange
into the standard size.

b. When the measured dimension of fixing

flange is within the standard tolerance,
the fixing flange can be used as it is.

Shop Manual - November 2012 8-91

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

c. When the measure dimension D of fix-

ing flange is less than the standard di-
mension, replace the shaft assembly. A
new fixing flange (3) has a tolerance for
adjustment.

Since the fixing flange is used together

with the spindle, they are made into an
assembly. Therefore, instead of replacing
the fixing flange separately, it should be
replaced with the spindle. The assembly
of fixing flange and spindle is called the
spindle assembly.

.
3

De al
● The disassembling and assembling

pt
procedures are to be performed again
when the spindle assembly is replaced.
g no
6) Remove the main bearing preload adjust-
ZX75-1006190

ing clamps From the spindle (2).

in ti

7) Proceed to 6.1 after adjusting the fixing

flange through the above steps a), b) and
et a

c).
n
rk er

22. Adjusting the axial clearance of the cone-

roller bearing
Ma t

If any of the following parts is replaced, the 9

In

thickness of snap ring (20) must be ad-

justed to obtain a suitable axial clearance
of the cone-roller bearing (22). If the GM
motor is assembled without adjusting the
axial clearance of the cone-roller bear-
ing, the motor would fail and be damaged
ZX75-1006191
soon.

● Spindle (2), fixing flange (3), crankshaft

(9), spacer (12), snap ring (20) and
cone-roller bearing (22).

● If none of the above parts is replaced,

you can go to step 8 without adjusting
the thickness of the snap ring.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

● The axial clearance of cone-roller bear-

ing is to be adjusted through the follow- 9
ing steps.
3
1) Tap the outer ring of the cone-roller bear-
ing (22) mounted on the crankshaft (9) with 20
a hammer and the holder (IV).

Install the RV gear assembly securely on

the spindle (2) with this method.
22

2) Install the thinnest snap ring (20) in the ZX75-1006192

groove on the fixing flange (3).

.
De al
3) Tap the edge of the snap ring (20) with a

pt
hammer and the holder (IV).

g n
Check the RV gear assembly to see if it is
o
installed in the spindle (2) securely. 9
in ti
et a
n

ZX75-1006193
rk er

4) Insert feeler gauge between the snap ring

(20) and the cone-roller bearing (22) in or-
Ma t

der to check the clearance.

In

5) Measuring the thickness of snap ring 20

● Adjusting the thickness of snap ring

(max.)
22
Max. = (Feeler gauge thickness) +
(Thickness of mounted snap ring)
ZX75-1006194

● Adjusting the thickness of snap ring

(min.)

Min. = (Feeler gauge thickness) +

(Thickness of mounted snap ring) -
(0.05 mm)

Shop Manual - November 2012 8-93

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6) After the thickness of the snap ring is de-

termined, select one from the 12 types and
install it on the fixing flange.

(See the Table of dimensions for clearance

adjustable parts on the next page.)

7) Proceed to 8.2 after installing the snap ring

of determined thickness.

ZX75-1006195

.
De al
8.10.11 Table of dimensions for clearance adjustable parts

pt
No.
g no
GM Model
GM09VN
Part Name
in ti

Symbol Dimension
et a

A 1.90 -1.95
n

B 1.95 -2.00
54.2

C 2.00 -2.05
rk er

D 2.05 -2.10
E 2.10 -2.15
Ma t

t
1
Mark F 2.15 -2.20
(Categorized symbols)
In

ZX75-1006196 G 2.20 -2.25

H 2.25 -2.30
I 2.30 -2.35
J 2.35 -2.40
K 2.40 -2.45
L 2.45 -2.50

8-94 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.10.12 Confirmation of performance test

Test the performance of the GM motor after maintenance according to the following procedure.

1. Necessary testing apparatus

No. Description Qty

1 Pressure gauge (35 kg/cm2) 2

2 Test the cylinder (5l) 1
3 Stop watch 1

2. Testing procedure

.
De al
pt
Install GM motor to the body (sprocket) and connect the pipes.
GM motor install-
1 Do not install the track as GM motor performance test under
ation and lines
zero load is to be carried out.
g no
Note:
1. Connect the GM motor lines in order to install pressure gauge
in ti
(main oil circuit) and test the displacement of hydraulic motor.
2. Do not install the GM motor with a hammer. Bolt the motor on
carefully.
et a

Rotating Operating
n

GM motor GM motor speed Press.

2 direction time
operation
rk er

1 10 rpm At least one

Zero Left/right minute for
load each test
2 20 rpm
Ma t
In

GM motor perfor-
3 mance confirma-
tion test

Preparatory work prior to testing......................operation, till the temperature rises to:

1 ·Hydraulic oil temperature: 45-55 °C
·Reducer assembly hub outer temperatire:40-80°C

Confirm the testing....................................Testing the following items to check the performance.

GM motor driving pressure - -
2
Max. 16 kg/cm² at 10 rpm
GM motor displacement - -
Max. 0.51 1 L/m at 10 rpm
Judgement standard

OK NO

Install track Disassemble and readjust

Shop Manual - November 2012 8-95

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.11 Swing Motor and Swing Mechanism AS - Removal and Installation

8.11.1 Removal

Lower the work equipment fully on the

ground and stop the engine. Slowly loos-
en the oil filler cap in order to release the
internal pressure of the hydraulic tank.
2

Since no accumulator is equipped, loosen 3

the hose slowly before removing and
check if oil squirts out.

.
De al
1. Disconnect the swing motor suction hose 4

pt
(1).

g n
2. Disconnect the two hoses (2) of the main
ports from the swing motor.
o ZX75-1006197
in ti
3. Disconnect swing motor brake pressure re-
leasing hose (3).
et a

4. Disconnect the two oil-draining hoses (4)

of the swing motor.
n
rk er

5. Disconnect the three hoses (5) between

the control valve and the swivel joint.
5
Ma t

6. Remove the mounting bolts, hoist up the

swing mechanism and swing motor as-
In

sembly (6), and remove it through forcing

screws . 5

ZX75-1006198
★ When removing the swing mechanism
and swing motor assembly, lift it away
slowly and be careful not to damage
the leads or pipelines.

Swing mechanism and swing

motor AS:

80 kg

8-96 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.11.2 Installation

● Installation is performed in a reverse order

of removal.

Mating surface of swing mecha-

nism box:

Gasket sealant (LG-4)

6
Mounting bolt of swing mechanism

.
ZX75-1006199

De al
and swing motor assembly:

pt
276.85±31.85 Nm (28.25±3.25 kgm)
g n
● Adding oil (hydraulic tank).
o
in ti
Refill the tank to the specified level through
the filler opening. Start the engine to circu-
late the oil in the system. And then check
et a

oil level.
n

● Purging the air

rk er

Purge the air from the swing motor.

Ma t

For detailed information, see “Air in Each

Component - Bleed” on page 6-30.
In

Shop Manual - November 2012 8-97

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.12 Swing Motor AS - Disassembly and Assembly

8.12.1 Disassembly

1. Swing motor assembly

3
2
Place the swing motor (1) on the tool.

.
De al
pt
Tool
ZX75-1006200

g no
2. End cap
7 5 4 3
in ti
1) Loosen the screw plug (2). 6
et a

2) Remove the end cap (3).

n

★ The oil distributor could be seized by

rk er

the end cap. Be careful to not let the oil

distributor fall. 2
Ma t

ZX75-1006201
3) Remove the outer ring (4) and the spacer
(5).
In

4) Remove the plug (2), spring (6) and relief 8

valve (7). 9

3. Brake spring

Remove the brake spring (8).

4. Remove the oil distributor (9).

★ Store the oil distributor properly for

reuse. Be careful not to damage its ZX75-1006202

contact surface against cylinder block.

8-98 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

5. Brake plunger
Tool 10
Remove the brake plunger (10) with com-
pressed air supplied from the tool.

★ Air pressure: 0.39 MPa {4 kg/cm²}

Note that the brake plunger could

jump out under excessively high air
pressure.
ZX75-1006203

.
6. Shaft and cylinder block assembly

De al
11

pt
Remove the shaft and cylinder block as-
sembly (11) from the motor housing (12).
g no
in ti
et a

12 ZX75-1006204
n
rk er

7. Plates
Ma t

Remove the plates (13) and (14).

In

13

14 ZX75-1006205

Shop Manual - November 2012 8-99

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8. Auxiliary bearing
1

Remove the auxiliary bear (15) with the

remover .

★ Take care not to apply force to the

bearing retainer.

★ Wrap the surface of cylinder block

contacting oil distributor with packing
paper to avoid damage. 15 ZX75-1006206

.
De al
9. Cylinder block and plunger assembly 17

pt
1) Remove the cylinder block and plunger as-
g n
sembly (16) from the shaft assembly (17).
o
★ The cylinder block and plunger may
in ti
separate. Be careful not to let them fall.
16
et a

ZX75-1006207
n
rk er

2) Disassembling the cylinder block and

plunger assembly 20
Ma t

Pull out the plunger assembly (19) from

In

the cylinder block (18) and remove the

21
positioner guide collar (20) and the
preload pin (21).
19
★ The preload pin could detach or fall 18
when removing the cylinder block and
plunger assembly from the shaft or pull- ZX75-1006208
ing out the plunger assembly from the
cylinder block. Take care not to loose
the preload pin.

8-100 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

3) Disassembling the plunger assembly

Remove the plunger (23) from the pres- 23

sure plate (22).

22
ZX75-1006209

.
De al
4) Disassembling the cylinder block 26 18

pt
Tool
a. Place the tool on the cylinder block (18).
g n
b. Tighten the bolts of tool P3 with a span-
o 24

ner. Tighten the nuts to compress the

in ti
spring in order to remove the snap ring
(24).
25
et a

c. Slowly loosen the tool nuts to release

the spring (25) and then remove the ZX75-1006210
n

tool P3.
rk er

d. Remove the spacer (26), spring (25)

and spacer (26) from the cylinder block
Ma t

(18).
In

28
10. Shaft assembly

1) Remove the thrust plate (27) and spacer 27

(28) from the shaft assembly (17).

17

ZX75-1006211

Shop Manual - November 2012 8-101

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2) Remove the bearing (30) from the shaft (29)

2
with a pusher (2).

30
29

ZX75-1006212

.
11. Plate

De al
12

pt
Remove the plate (13) from the motor
housing (12).
g no
★ The plate can be removed after removal 13
of the shaft and cylinder assembly from
in ti
the motor housing.
et a

ZX75-1006213
n
rk er

12. Oil seal and outer ring

1) Remove the snap ring (31) and then the oil

Ma t

seal (32) from the motor housing (12).

In

2) Remove the outer ring (33).

21
1

ZX75-1006124

8-102 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

13. When only the oil seal is to be replaced

instead of the disassembling operation de-
31
scribed above, replace the oil seal through
the following steps.
7
B
1) Remove the snap ring (31).

2) Use a stick to push out the middle part

of the oil seal (32) (or hammer its end)in A
order to take it out.
32
ZX75-1006215
★ Hammer the center between the outer
and inner of the oil seal and pry two

.
positions that are opposite to each

De al
other, as indicated by A and B on the

pt
right illustration.

g n
★ Do not damage the shaft casing.
o
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 8-103

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Swing motor diagram

18

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

ZX75-1006216

8-104 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

No. Part Name Specification Quantity

1 Body, seat — 1
2 Seal, oil ø30xø50øx11AP1709 1
3 Block, cylinder — 1
4 Shaft — 1
5 Bearing 30305C 1
6 Sleeve, shaft ø30xø25øx20 1
7 Plate, swash — 1
8 Spring — 9
9 Plate, installation — 1
10 Block AS, piston — 9

.
11 Guide, ball — 1

De al
12 Cover, rear — 1

pt
13 Pin — 2
14 Seal, O-ring AS568-252 1
15
16
g no Bearing
Disc, valve
30202
—
1
1
in ti
17 Valve AS, relief — 2
18 Bolt M12x30 4
19 Plug PT 1/2 1
et a

20 Plug — 1
n

21 Seal, O-ring P14 1

22 Gasket ø34xø30x0.5t —
rk er

23 Plug PT 1/4 3
24 Ring, support P26 2
Ma t

25 Seal, O-ring P26 2

26 Plate, friction — 1
In

27 Plate — 1
28 Plunger, brake — 1
29 Seal, O-ring AS568~254 2
30 Spring — 18
31 Valve, delay — 1
32 Bolt M6x75 3
33 Plug — 2
34 Seal, O-ring P11 2
35 Valve — 2
36 Spring — 2
37 Plug — 2
38 Seal, O-ring P18 2
39 Seal, O-ring AS568-118 2
40 Ring, support — 2

Shop Manual - November 2012 8-105

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.12.2 Assembly

Clean all parts and remove their burrs. Ap-

ply oil (EO10-CD) to the sliding surfaces be- Tool
fore installation. The following items must be
checked before installation.

● Contact between cylinder block and oil dis-

tributor (See Contact Checking Procedure)

● Contact between oil distributor and end

cover (See Contact Checking Procedure) 33

.
De al
ZX75-1006217

pt
1. Motor housing g n Tool 12
o
1) Use the tool to fit the outer ring (33).
in ti
2) Place the tool P1 on the motor housing.
et a
n
rk er

ZX75-1006218
2. Shaft assembly
Ma t

1) Install the bearing (30) on the shaft (29)

with the tool in order to form the shaft as-
In

Tool
sembly (17).

★ Use the tool to press the end of bearing

17
inner ring in order to assemble the
bearing on the shaft end. 30

Pressing load: 29

1,834-7,119 N {187-726 kg} ZX75-1006219

Bearing fitting surface:

Lubricant oil (EO10-CD)

8-106 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

2) Install the shaft assembly (17) in the motor

housing (12).
27

3) Install the thrust plate (27) and the spacer

(28). 17

★ After the thrust plate (27) is installed in

motor housing, turn the thrust plate (27)
in both directions to see whether it has 28
been installed precisely. 12

ZX75-1006220

.
3. Cylinder block and plunger assembly

De al
26 18

pt
Tool
1) Assembling the cylinder block
g n
a. Install the spacer (26), spring (25) and
o
spacer (26) in the cylinder block (18).
24
in ti
b. Place the tool on the cylinder block (18).
25
c. Tighten the bolts of the tool with a
et a

spanner. Screw on the nuts to com- ZX75-1006221

n

press the spring. Install the snap ring

(24).
rk er

★ Check the snap ring to see if it has

been mounted securely.
Ma t
In

d. Remove the tool.

2) Assembling the plunger assembly 23

Install the plunger (23) on the pressure

plate (22).

22 ZX75-1006222

Shop Manual - November 2012 8-107

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3) Assembling the cylinder block and plunger

assembly 20

a. Install the three preload pins (21) on

the cylinder block (18).
21

★ Apply grease (G2-LI) to the pins to

prevent them from coming out. 19

18
b. Install the positioner guide collar (20)
on the cylinder block (18) and then in- ZX75-1006223
stall the plunger assembly (19) to form
the cylinder block and plunger assem-

.
bly.

De al
pt
★ Match the cylinder block spline with the
positioner guide collar.
g no
4) Install the cylinder block and plunger as- 16

sembly (16) in the motor housing.

in ti

★ Keep the preload pins from falling.

et a
n

12
rk er

ZX75-1006224
Ma t

4. Plates and plunger

14
In

1) Install the plates (13) and (14).

★ Do not clean the plates with trichloro-

ethylene or denatured alcohol, or blow
it with high-pressure air. 13

Plate surface:

Lubricant oil (EO10-CD) ZX75-1006225

8-108 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

2) Install the O-ring seal and then the brake

plunger (10). 10

ZX75-1006226
5. Adjusting the play of shaft end

1) Place a jack under the bottom end of

.
De al
shaft. Install the auxiliary bearing (15) with

pt
the tool P7 and the remover .
4
g n
★ Press the end of bearing inner ring with
the tool P7 in order to install the bear-
o
Tool
ing on the shaft end.
in ti
15

Pressing load:
et a

1,412-5,237 N {144-534 kg} 3

ZX75-1006227
n

(Probably up to (9.8 kN) 1,000 kg)

rk er

Bearing fitting surface:

Ma t

Lubricant oil (EO10-CD)

In

5 4 9 3
2) Install the spacer (5) and outer ring (4) on
the end cover (3).

★ Install the removed spacers.

3) Install the oil distributor (9) on the end cov-

er (3) and align it with the dowel pin.

★ Make sure the oil distributor does not ZX75-1006228

interfere the bearing and the pins.

★ Keep the oil distributor free from colli-

sion during installation. (Any collision
could damage the sliding surfaces and
result in deformation.)

Shop Manual - November 2012 8-109

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4) Keep the end cover (3) level while install-

3
ing it on the motor housing (12).

★ Keep the oil distributor from falling.

★ Do not install the spring and O-ring

seals of the parking brake.

Mounting bolt:

110.3±12.3 Nm {11.25±1.25 kgm} 12 ZX75-1006229

5) Push the shaft end with the remover in

order to move the shaft toward the end

.
De al
cover.

pt
Pushing load: 5
g n981-1,079 N {100-110 kg}
o
in ti
6) Install the eyebolt on the shaft end and pull
up the shaft. Check the axial clearance
with a dial indicator .
et a

ZX75-1006230
Axial clearance: 0.05-0.25mm
n

7) Make adjustment following the procedure

rk er

below if the axial clearance is out of the

standard range.
Ma t

a. Remove the end cover. 6

In

b. Remove the oil distributor and the outer

ring.

c. Select a proper spacer from the table

below.

Thickness (mm) Spacer ZX75-1006231

1.6 70S-7T-12260
1.7 70S-7T-12270
1.8 70S-7T-12360
1.9 70S-7T-12370
2.0 70S-7T-12380
2.1 70S-7T-12390
2.2 70S-7T-12460

8-110 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

d. Install the selected spacer. Assemble

the parts and check the axial clearance 7
following the step 5-2) through 5-6).
6
e. Remove the end cover after adjustment
of the axial clearance.

6. End cover assembly

1) Install the relief valve (7) and the spring (6) 2

sequentially, followed by installation of the ZX75-1006232

O-ring seals. Tighten the plug (2).

.
2) Install the brake spring (8).

De al
8

pt
g no
in ti

3) Put the O-ring seal in the motor housing.

et a

Install the end cover horizontally and align

ZX75-1006233
it with the pin.
n
rk er

★ Keep the brake spring and the oil

distributor from falling. 3 2
Ma t

★ Make sure the end cover does not

interfere the dowel pin.
In

★ Do not get the O-ring seal seized in the

motor housing and the end cover.

Mating surface of motor hous-

ing:
ZX75-1006234

Gasket sealant [LG-7 or LG-5

(LOCTITE 572/575) ]

Mounting bolt:

110.3±12.3 Nm (1.25±1.25 kgm)

Shop Manual - November 2012 8-111

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4) Tighten the plug (2).

Plug (2):

166.7±19.6 Nm (17±2 kgm)

7. Checking the torque of swing motor as-

sembly

Install the tool P8 on the motor shaft and

disengage the brake. Turn the shaft at a
speed of 3-5 seconds per turn and check
its torque.

.
De al
★ The torque must remain unchanged Tool

pt
ZX75-1006235
when the shaft is turned

g n
Torque change:
o
0-1.96 Nm {0-0.2 kgm}
in ti

Torque:
et a

31
10.8-16.7 Nm {1.1-1.7 kgm} P4
n

Brake disengaging pressure:

rk er

32
2.94±0.29 MPa {30±3 kg/cm²}
Ma t

8. Oil seal
In

1) Check the shaft, which should be free from

ZX75-1006236
burrs and sharp edges.

2) Press to fit the oil seal (32) with the tool

P4.

★ Clean the lip of oil seal.

Oil seal lip:

Lubricant oil (G2-LI-S)

3) Install the snap ring (31).

8-112 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

Checking the contact surfaces of cylinder

block, oil distributor and end cover

1. Checking the contact surfaces between Cylinder block Aligning tool Oil distributor
cylinder block and oil distributor

★ No such check is required when cylinder

block and oil distributor are spare (new).

★ Such check is required when either the cyl-

inder or oil distributor is spare or repaired.

★ Improper contact surfaces can be cor-

.
ZX75-1006237
rected through grinding on a bench.

De al
pt
1) Make an aligner for cylinder block and oil
Seal (a)
distributor.
g no
★ The aligner could be made with soft
materials such as plastic or bakelite.
in ti

2) Degrease the parts to be checked.

et a

★ Never clean the parts with cloth.

n

Oil distributor Cylinder block

3) Properly store the tools and paint checking

rk er

ZX75-1006238
marks on the cylinder block.

★ The paint applied must be as thin as

Ma t

possible.
In

4) Press the oil distributor with a force of 4-5

kilograms against the cylinder block and
turn it by 90°, and then turn it back to its
original position. Repeat this operation 2-3
times.

Seal (a)
Oil distributor Min. 80%
Cylinder block Min. 80%

Shop Manual - November 2012 8-113

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

5) Remove the oil distributor. Print the contact

surface on record paper and check it.
Oil distributor
End cover
★ The standard contact surfaces are
shown below:

2. Oil distributor and end cover

Clearance is required on
1) Completely remove the oil and grease from this surface. Contact area
the parts to be checked. must be over 80 percent.
ZX75-1006239
★ Never use cloth to do such cleaning.

.
2) Paint a checking mark on the end cover

De al
and then place the oil distributor on the

pt
end cover.

g n
★ The paint must be as thin as possible.
o
3) Press the oil distributor with a force of 4-5
in ti
kilograms against the cylinder block and
turn it by 90°, and then turn it back to its
original position. Repeat this operation 2-3
et a

times.
n

4) Remove the oil distributor. Print the contact

rk er

surface on record paper and check it.

★ The contact area between oil distributor

Ma t

and end cover mating surface must

In

be not lower than 80 percent when no

change is made.

★ Improper contact is to be corrected by

grinding on a bench.

8-114 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.13 Swing Mechanism Assembly - Disassemble and Assemble

8.13.1 Disassemble

1. Draining the oil

Remove the hose; loosen the drain plug (a); 1

drain the oil from the swing mechanism.

2. Swing motor assembly

.
De al
Remove the swing motor assembly (1).

pt
a
ZXT75-1006240

g no
in ti
3. No.1 sun gear and No.1 planetary carrier.
2
1) Remove No.1 sun gear (2).
et a

2) Remove No.1 planetary carrier (3).

n
rk er

3
Ma t
In

ZXT75-1006241

3) Disassemble No.1 planetary carrier as per

the following method. 5 4

6 7
a. Remove the snap ring (4), followed by
removal of the thrust washer (5), gear
(6), bearing (7) and thrust washer (8).
8
b. Hammer in the pin (9) and hammer out
ZX75-1006242
the shaft (10).

Shop Manual - November 2012 8-115

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

★ Remove the pin (9) after removal of the

shaft. 12 11 10

c. Remove the thrust washer (11) from the

planetary carrier (12).

4. No.2 sun gear 9

ZX75-1006243
Remove No.2 sun gear (13).

5. No.2 planetary carrier

13

.
1) Remove No.2 planetary carrier assembly

De al
(14).

pt
2) Disassemble No.2 planetary carrier as-
g n
sembly as per the following method.
o
in ti

ZXT75-1006244
et a
n
rk er

14
Ma t
In

ZXT75-1006245

8-116 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

a. Remove snap ring (15). Then, remove

thrust washer (16), gear (17), bearing 17 16 15

(18) and thrust washer (19). 18

23 22
b. Hammer in pin (20) and hammer out
shaft (21).
19
★ Remove pin (20) after removal of shaft.
20

c. Remove thrust washer (22) from plan- 21 ZX75-1006246

etary carrier (23).

6. Retainer

.
De al
pt
1) Place the shaft and the casing onto a A
press. Push bearing (24) with pusher A.
g n
★ Slowly operate the press till the bearing
o 25

is pressed to a position that the open

in ti
retainer can be removed.

2) Remove the open retainer (25).

24
et a

ZX75-1006247
n
rk er
Ma t
In

Shop Manual - November 2012 8-117

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.13.2 Assemble

★ Clean all the parts. Check the parts for

contamination or damage.
5 34
36
1. Oil seal 34

Press the oil seal (33) to fit the casing (34)

with the pusher 5 .

★ A new oil seal should be used for 33 35

replacement.
ZX75-1006248

.
De al
Lip of oil seal: grease (G2-LI)

pt
2. Outer ring of bearing
g no
Press the bearing outer rings (35) and (36) 6
to fit the casing (34) with the pusher.
in ti

29
et a

30
n
rk er

3. Shaft assembly 31

ZX75-1006249
1) Install the retainer (30) on the shaft (31).
Ma t

2) Use the press to fit the bearing (29) with

In

the pusher 6 .

3) Place the casing assembly (37) on the 7

26
shaft assembly (28). 37

4) Operate the press to push the bearing (25) 25

to a position that the open retainer can be
inserted with the pusher 7 .
28
★Pressing force:

ZX75-1006250
Max. 11.76 kN {1200 kg}

★Slow press the bearing while turning

the housing.

8-118 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

5) Install the open retainer (26).

6) Use the pusher 8 and the press to push

the shaft (31) till the open retainer is fixed
in place.

7) Screw the bolts (10 mm, P=1.5 mm) into

the casing. Measure the tangential force in
the direction of rotation with a spring bal-
ance 9 .

★Tangential force: Max. 147N {15 kg}

.
★Tangential force is the maximum force

De al
at the beginning of rotation.

pt
4. Dust seal
g n
Press to fit the dust seal (32) with the
pusher 10 .
o 10

32
in ti
★ A new dust seal is required.

5. No.2 planetary carrier assembly

et a

1) Assemble No.2 planetary carrier assembly

n

as per the following method.

rk er

ZX75-1006251
a. Install the thrust washer (22) on the
planetary carrier (23).
Ma t

b. Align the pin holes of the shaft and the

In

carrier. Use a plastic hammer to install 17 16 15

the shaft (21). 18

c. Insert the pin (20). 23 22

★ Seal the gap at where the pin is 19

inserted on the carrier.
20
★ Make sure that the step difference
between the shaft and the planetary 21 ZX75-1006252
carrier is lower than 0.2 mm.

d. Instal the thrust washer (19), bearing

(18), gear (17) and thrust washer (16),
followed by the snap ring (15).

Shop Manual - November 2012 8-119

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2) Install No.2 planetary carrier assembly (14)

on the shaft and casing assembly. 14

6. No.2 sun gear

Install No.2 sun gear (13).

ZXT75-1006245

.
De al
pt
13

g no
in ti

7. No.1 planetary carrier assembly

et a

1) Install No.1 planetary carrier assembly as

n

ZXT75-1006244
per the following method.
rk er

a. Install the thrust washer (11) on the

planetary carrier (12).
Ma t

12 11 10
b. Align the pin holes of the shaft and the
In

carrier. Use a plastic hammer to install

the shaft (10)..

9
c. Insert the pin (9).
ZX75-1006243
★ Seal the gap at where the pin is
inserted on the carrier.

★ Make sure that the step difference

between the shaft and the planetary
carrier is lower than 0.2 mm.

8-120 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

d. Install the thrust washer (8), shaft (7),

gear (6) and thrust washer (5), followed 5 4
by the snap ring (4).
6 7

ZX75-1006242

2) Install No.1 planetary carrier assembly (3).

3) Install No.1 sun gear (2).

.
De al
2

pt
g no
8. Swing motor assembly
in ti
Install the swing motor assembly (1).
3
et a

Mounting bolt: 66.15±7.35 N·m

ZXT75-1006241
n

Motor mating surface:

rk er

Gasket sealant (LG-4 or LG-6) 1

Ma t

9. Apply oil and grease

In

Tighten the drain plug and add oil through

the filler opening.

Swing mechanism box: approx. 1.5L

(Jesung)

ZXT75-1006258

Shop Manual - November 2012 8-121

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.14 Swing Platform Assembly - Remove and Install

8.14.1 Remove

Disconnect the cable from the negative (-)

post of the battery.

1. Remove the work equipment assembly. 3

For more information see “Work Equipment

4
Assembly - Remove and Install” on page 8-210.
5
2. Remove the counterweight assembly.

.
2

De al
pt
For more information see “Counterweight
Assembly - Remove and Install” on page 8-225.
g n
3. Disconnect the boom cylinder hose (2).
o ZXT75-1006259
in ti
4. Hoist boom cylinder assembly (3), and re-
move fixing plate (4) and pin (5).
et a

5. Remove the boom cylinder assembly (3).

n

Boom cylinder assembly:

rk er

105 kg 6
Ma t

6. Disconnect all the hoses (5) between con-

trol valve, travel speed control hose (6)
In

and oil drain hose (7). 5

7. Remove the swivel joint stop plate (8). 8

ZXT55-1006084

8-122 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8. Place a block 1 between the wire rope and

the machine frame, and then hoist up the
swing platform. Keep the wire rope away
from the engine.
1

ZX55-1006085

.
9. Remove the bolts and hoist away the

De al
swing platform (14).

pt
g no
★ Leave two bolts at both the front and
14

the rear sides. Use adjusting blocks to

in ti
adjust the balance of the swing platform
in all directions. Remove the bolts left
and hoist away the platform.
et a
n

Do not damage the swivel joint while

removing the swing platform.
rk er

ZX75-1006262

Swing platform assembly:

Ma t

2700 kg
In

Shop Manual - November 2012 8-123

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.14.2 Install

● Reverse the removing sequence to install

the assembly.

Swing bearing mating surface:

Gasket sealant (LG-1)

Threads of swing platform mount-

ing bolt:

.
De al
pt
Thread adhesive (LT-2)

g n
Swing platform mounting bolt:
o
277.5±32.4 N·m
in ti
● Adding oil (hydraulic tank)
et a

★ Add oil to the specific level through the

filler opening. Start the engine to circulate
n

oil in the system. Check oil level again.

rk er

● Purging the air

Ma t

★ Purge the air from the swing motor.

In

For detailed information, see “Air in Each

Component - Bleed” on page 6-30.

8-124 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.15 Swing Bearing Assembly - Remove and Install

8.15.1 Remove

1. Remove the swing platform assembly.

For more information see “Swing Platform 3

Assembly - Remove and Install” on page 8-122.
1
2. Remove the 24 mounting bolts (1) of the
swing bearing and 2 dowel pin (2).

3. Hoist the swing bearing assembly (3). 2

.
De al
pt
ZXT75-1006263

g n
Swing bearing assembly: 110kg
o
in ti

8.15.2 Install
et a

● Reverse the removing sequence to install

n

the assembly.
rk er

Before chassis
Ma t

Inner ring gear surface:

In

Grease (G2-LI) s

Mounting bolt: Inner race soft area

Outer race soft area

Thread adhesive (LT-2) ZX75-1006264

Mounting bolt:

279±30 N·m
(Tighten the bolts diagonally.)

Shop Manual - November 2012 8-125

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.16 Idler and Tension Spring Assembly - Remove and Install

8.16.1 Remove
SY65C3

1. Remove the track shoe assembly.

For more information see “Track Shoe

Assembly - Remove and Install” on page 8-144.
1
2. Hoist up the idler (1) and tension spring
yoke (2). Pull them out from the front end.

.
De al
Idler and yoke: 60kg 2

pt
ZX75-1006265

3. Remove the two fixing bolts (3) from the

g n
tension spring cylinder.
o
in ti
3
et a
n
rk er

ZXT75-1006266
Ma t
In

4. Hoist up the tension spring cylinder (4) and

pull it out from the front end.

Tension spring cylinder: 22kg 4

ZX75-1006267

8-126 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

5. Remove the yoke (2) from the idler (1).

2
Idler: 50 kg 1

Yoke: 10 kg

SY75C3, SY75C9 ZXT75-1006268

1. Remove the track shoe assembly.

.
De al
For more information see “Track Shoe

pt
Assembly - Remove and Install” on page 8-144.
1
g n
2. Hoist up the idler and tension spring yoke
o
assembly (1). Pull it out from the front end.
in ti
Idler and tension spring AS: 102 kg

3. Remove the tension spring assembly (3)

et a

from the idler assembly (2).

n

ZX75-1006269
rk er

Idler assembly: 62 kg
Ma t

Tension spring assembly: 40 kg

In

8.16.2 Install

● Reverse the removing sequence to install

the assembly. 2
3

Threads of tension spring assembly

mounting bolt:

Thread adhesive: 1277

ZX75-1006270

Shop Manual - November 2012 8-127

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.17 Tension Spring Assembly - Disassemble and Assemble

8.17.1 Disassemble

SY65C3

11, 12
10
9

.
7

De al
4 5 6

pt
3
2
1

g no
in ti
2
et a

ZX55-1006091
n
rk er

1. Remove the feeder valve (11) and the

grease fitting (12). 2 B
Ma t

2. Remove the yoke (1), piston rod (2) and

In

wear ring (3) from the tensioner assembly.

The wear ring (3) is mounted on the piston
rod (2).

3. Disassembling the tension spring assem-

bly

1) Place the tension spring assembly 1 on ZX55-1006090

the tool B.

The tool must be placed properly since

the tension spring is under higher
installation load. Improper placement of
the tool is dangerous.

8-128 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

★ Spring installation load:

37.24 kN{3800kg}

2) Slowly apply hydraulic pressure to com-

press the spring. Remove the nut (10).

★ Compress the spring till the nut can be

loosened.

★ Slowly release the hydraulic pressure

to release the tension of spring.

.
★ Remove the front support (cylinder) (7)

De al
and the rear support (9) from the spring

pt
(8).

g n
★ Remove the dust ring (4), seal ring (5)
o
and wear ring (6) from the cylinder.
in ti
4. Disassembling the piston rod assembly

Remove the wear ring (3) from the piston

et a

rod.
n
rk er
Ma t
In

Shop Manual - November 2012 8-129

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

SY75C3, SY75C9

11 12
10
9
8
7
6
4 5
2 3
1

.
De al
3

pt
1 g no
ZX75-1006271
in ti
1. Remove the feeder valve group (12).
2 B
et a

2. Remove the piston rod group from the

tensioner assembly .
n
rk er

3. Disassembling the tension spring assem-

bly
Ma t

1) Place the tension spring assembly on

the tool B.
In

The tool must be placed properly since ZX55-1006090

the tension spring is under higher

installation load. Improper placement of
the tool is dangerous.

★ Spring installation load: 47.4 kN

2) Slowly apply hydraulic pressure to com-

press the spring. Remove the nut (11).

★ Compress the spring till the nut can be

loosened.

8-130 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

★ Slowly release the hydraulic pressure

to release the tension of spring.

★ Remove the cylinder group (cylinder

block) (6), O-ring seal (7), pull rod (8)
and spring seat (1) from the spring (9).

★ Remove the O-ring seal (7) and the pull

rod (8) from the cylinder block (6).

4. Disassembling the piston rod assembly

Remove the wear ring (2) from the piston

.
rod .

De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 8-131

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.17.2 Assemble

SY65C3
1. Assembling the piston rod group

Assemble the wear ring (3) on the piston

rod (2).

2. Assemble the tension spring assembly 1 .

1) Install the dust ring (4), seal ring (5), and

Apply grease
wear ring (6) on the cylinder block.

.
2) Install the front support (cylinder (7) and

De al
the rear support (9) on the spring (8). Place

pt
it on the tool B.

g n
3) Slowly apply hydraulic pressure to com-
o
press the spring and tighten the nut (10) in
a

ZX75-1006273
order to achieve the determined installation
in ti
length (a) of the spring.

★Spring installation length (a): 349 mm

et a

Threads of nut:
n
rk er

Thread sealant 1277

4) Remove the tension spring 1 from the tool

Ma t

B.
In

3. Apply at least 40 cc grease to the cylinder.

Inside cylinder block: G2-LI grease

4. Install the piston rod group on the tension

spring assembly 1 .

Wear ring of the piston rod sliding

part: G2-LI grease

5. Install the oil feeder valve (11) and the

grease fitting (12).

★ Install the valve with the grease fitting

facing outward.

8-132 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

SY75C3, SY75C9

1. Assembling the piston rod group

Assemble the wear ring (2) on the piston

rod (1).

2. Assemble the tension spring assembly .

1) Install the dust ring (3), seal ring (4), wear

ring (5) and O-ring seal (7) on the cylinder Apply grease
block (6).

2) Install the pull rod (8) on the cylinder block

.
(6).

De al
pt
a
3) Install the above cylinder block group and
spring seat (10) on the spring (9), and
g n
place it on the tool B.
o ZX75-1006273

4) Slowly apply hydraulic pressure to com-

in ti
press the spring and tighten the nut (11) in
order to achieve the determined installation
length (a) of the spring.
et a

★Spring installation length (a): 323 mm

n

Threads of nut:
rk er

Thread sealant 1277

Ma t

5) Remove the tension spring assembly

In

from the tool B.

3. Apply at least 90 cc grease to the cylinder.

Inside cylinder block: G2-LI grease

4. Install the piston rod group on the tension

spring assembly .

Wear ring of the piston rod sliding

part: G2-LI grease

5. Install the oil feeder valve (12).

★ Install the valve with the grease fitting

facing outward.

Shop Manual - November 2012 8-133

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.18 Idler Assembly - Disassemble and Assemble

8.18.1 Disassemble

1. Remove the dowel pin (1) and bearing (2). 7

8
6
2. Remove the floating seal (3) from the bear- 13
12
ing (2) and the idler (4). 10
5
3. Remove the O-ring (11). Remove the idler
(4) from the shaft (5) and the bearing as-
sembly (7).
9

.
11

De al
★ The idler contains 80 ml oil, which 3
1

pt
should be drained completely before
disassembly. To keep the floor clean,
g n
cover it with cloth.
o
4
in ti
2 ZX55-1006092
et a

4. Remove the other floating seal (6) from the 4

n

6 5
idler (4), shaft (5) and bearing assembly (7).
rk er
Ma t
In

6 7
ZX55-1006093

5. Remove the dowel pin (8) in order to re- 9 10 4 5

move the bearing (7) from the shaft (5).

6. Remove the bushings (9) and (10) from the

idler (4).

7 8
ZX55-1006094

8-134 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.18.2 Assemble

1. Press fit the bushings (9) and (10) on the

idler (4).

9 10 4

.
De al
ZX55-1006095

pt
g n
2. Assemble the O-ring seal. Use the dowel
pin (8) to install the bearing (7) on the shaft
o 9 10 4 5

(5).
in ti
et a
n

7 8
rk er

ZX55-1006094
Ma t

3. Install the floating seal (6) on the idler (4),

shaft (5) and bearing (7) assembly.
In

6
★ Floating seal

Before installing the floating seal, remove

the grease from the contact surfaces (the
dashed area) between the O-ring seal and ZX55-1006096
the floating seal.

Shop Manual - November 2012 8-135

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

★ After the floating seal is installed, check

its inclination which should be less than
1 mm. The projection (a) of the floating
a
seal should be within a range between
5-7 mm.

ZX55-1006097

4. Assemble the shaft (5) and the bearing (7)

7 5
on the idler (4).

.
4

De al
pt
g no
in ti

ZX55-1006098
et a
n

5. Install the floating seal (3) on the idler (4)

rk er

and the bearing (2). 4 3

2 3
★ Apply oil to the floating seal and keep it
Ma t

free from any contaminant or dust.

In

★ Remove any oil or dust from the contact

surfaces between the O-ring seal and
the floating seal. ZX55-1006099

8-136 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

ZX55-1006100

6. Install the O-ring seal. Use the dowel pin (1) 7

to install the bearing (2). 8
6

.
13
12

De al
7. Apply oil and screw on the plug. 10

pt
5

Oil:
g no
Approx. 80 mL
9
11
in ti
(No.18 double-curve gear oil) 3
1

Plug:
et a

205.8±49 N·m
n

4
2 ZX55-1006101
rk er
Ma t
In

Shop Manual - November 2012 8-137

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.19 Track Roller Assembly - Remove and Install

8.19.1 Remove

1. Lower the work equipment on the ground.

Loosen the valve (1) and the grease fitting 1 2
(2) to release track tension.

The track tensioning cylinder is under high

pressure, so do not loosen the grease fit-
ting by more than one turn. If no grease is
seen, move the machine back and forth.
ZX55-1006102

.
De al
2. Remove the mounting bolts of the track

pt
roller. Swing the work equipment by
90°and raise the machine with the work
g n
equipment. Remove the track roller assem-
bly (3) that faces outward.
o 3
in ti
8.19.2 Install
● Reverse the removing sequence to install
et a

the assembly.
n
rk er

★ Adjusting the tension of track shoe. ZXT75-1006286

For more information, see “Track Tension -

Ma t

Check and Adjust” on page 6-28.

In

Threads of track roller AS mounting

bolt: Thread adhesive (LT-2)

★ Place the screw plug on the outside of the

chassis. Install the track roller assembly in
place.

★ Operate the work equipment control lever

to slowly lower the machine. Tighten the
mounting bolts partially.

★ Operate the work equipment control lever

to fully lower the machine on the ground.
Tighten the mounting bolts completely.

8-138 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.20 Track Roller Assembly - Disassemble and Assemble

8.20.1 Disassembly

1. Remove the pin (1) and then the lower end

cover (2). 1 2

2. Remove the floating seals (3) from the end

cover (2) and the track roller (4).

3. Pull out the body (4) from the shaft (5).

★ The body contains lubricant oil, so it

.
De al
is necessary to drain the oil. To keep ZXT75-1006287

pt
the working area clean, cover it with a
sheet of cloth.
g no
in ti
3 4

2
et a

3
n
rk er
Ma t

ZXT75-1006288 ZXT75-1006289
In

5 4 4
6

ZXT75-1006290 ZXT75-1006291

Shop Manual - November 2012 8-139

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. Remove the floating seals (6) (on the op-

posite side) from the track roller (4) and the
shaft (5).
5
5. Remove the bushings (7) and (8) from the
track roller (4).
6

ZXT75-1006293

.
4

De al
7/8

pt
g no
in ti
et a

ZXT75-1006292
n
rk er

1
5
7
Ma t

3
In

ZX75-1006294

8-140 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.20.2 Assemble

1. Use the pusher to press fit the bushings (9)

9
and (10) on the track roller (4). 4

2. Install the end cover (8) on the shaft (5).

Install the pin (7) and the O-ring seal (11).

10

ZX75-1006295

.
De al
pt
3. Install the floating seal (6) on the shaft (5).

g n
★ When installing the floating seal, clean
o
the contact surfaces between the
5
O-ring seal (6c) and the floating seal
in ti
(6a), removing all grease and oil and
make it dry. Make sure that the contact
surfaces are free from contaminants
et a

6a
and dust. 6c
11
n

7
8
rk er

ZX75-1006296
Ma t
In

4. Install the floating seals (6) and (3) on the 4

track roller (4). 3b

★ For more information on the precau- 3d

tions for installing the floating seals (6b),
(6d), (3b) and (3d), see the paragraph
led by a star in step 3.
6b

6d
ZX75-1006297

Shop Manual - November 2012 8-141

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

5. Install the shaft (5) on the track roller (4).

6. Turn the track roller (4) and shaft (5) as-

4
sembly.

7. Inject oil between shaft (5) and track roller

(4).
5

Oil: 160~180mL (SAE30)

ZX75-1006298

.
De al
5

pt
8. Install the floating seal (3) on the end cover
(2).
g no
★ For more information on the precau-
4

tions for installing the floating seals (3a)

in ti
and (3c), see the paragraph led by a
star in step 3.
et a

ZX75-1006299
n

3a
rk er

3c
Ma t
In

ZX75-1006300

9. Install the end cover (2) on the shaft (5).

Install the pin (1) and the plug (12).
5 2 12

1
ZX75-1006301

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.21 Carrier Roller Assembly - Remove and Install

8.21.1 Remove

1. Lower the work equipment on the ground.

Loosen the valve (1) and the grease fitting
2
(2) to release track tension. 1

The track tensioning cylinder is under high

pressure, so do not loosen the grease fit-
ting by more than one turn. If no grease is

.
seen, move the machine back and forth. ZX55-1006102

De al
pt
2. Use a hydraulic jack 1 to push up the track
to a position that the carrier roller assem-
g n
bly could be removed. Remove the carrier
o
roller assembly (3).
in ti

8.21.2 Install
et a
n

● Reverse the removing sequence to install

the assembly.
rk er
Ma t

★ Adjusting the track tension.

In

For more information, see “Track Tension - 1

Check and Adjust” on page 6-28.

3 ZX55-1006116
Threads of carrier roller AS mount-
ing bolt:

Thread adhesive (Tonsan 1277)

Shop Manual - November 2012 8-143

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.22 Track Shoe Assembly - Remove and Install

8.22.1 Remove

1. Lower the work equipment on the ground.

Loosen the valve (1) and the grease fitting 2
1
(2) to release track tension.

The track tensioning cylinder is under high

pressure, so do not loosen the grease fit-
ting by more than one turn. If no grease is
seen, move the machine back and forth. ZX55-1006102

.
De al
pt
2. Move the machine forward so that the main
pin can be positioned in front of the idler.
g n
Chock the track properly with a block 1 .
o
3

3. Pull out the main pin with tool C.

in ti

4. Remove the tool C, take out the pin tem-

et a

porarily, remove the dust seal and back the

n

machine to spread the track (3). C 1

rk er

ZX55-1006181

8.22.2 Install
Ma t

● Reverse the removing sequence to install

In

the assembly.

★ Adjusting the track tension.

For more information, see “Track Tension -

Check and Adjust” on page 6-28. a

★ Press fit the main pin with tool C. The

protrusion (a) at both end of the main pin
ZX55-1006117
should be the same.

★ Apply grease (G2-LI) on the contact

surface of the bushing when installing the
dust seal.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.23 Hydraulic Tank Assembly - Remove Install

8.23.1 Remove

Lower the work equipment fully on the

ground and stop the engine. Move the hy- 1
draulic lockout control to FREE position.
Cycle both joysticks 10-20 seconds to re-
lease system pressure.

1. Drain the oil from the hydraulic tank.

Hydraulic tank: 120L

.
De al
pt
2. Remove the right door and the top right
cover.
g no
in ti

ZXT75-1006306
et a
n

3. Remove the return pipe (1) connecting the

rk er

oil tank with the radiator, and the return

pipe (2) connecting the oil tank with the
swing mechanism.
Ma t
In

ZXT75-1006307

Shop Manual - November 2012 8-145

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. Disconnect the hoses (3), (4), (5), (6) and

(7).

★ Mark the hoses before disconnecting 4

5
them.
6
7

ZXT75-1006308

.
De al
5. Remove the oil suction pipe (8).

pt
6. Hoist away the hydraulic tank assembly (9). 3
g n
Hydraulic tank AS: 70 kg
o
8
in ti

8.23.2 Install
et a

ZXT75-1006309
n

● Reverse the removing sequence to install

the assembly.
rk er
Ma t

Threads of hydraulic tank mounting

In

bolt:

Thread adhesive (Tonsan 1277)

Hydraulic tank mounting bolt:

176.5±19.6N·m

● Adding oil (hydraulic tank)

8
Add oil to the specific level through the
filler opening. Start the engine to circulate
the oil in the system. Check the oil level
again.

Hydraulic tank: 120L

ZXT75-1006310

8-146 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.24 Main Pump Assembly - Remove and Install

8.24.1 Remove

Lower the work equipment fully on the

ground and stop the engine. Move the hy-
draulic lockout control to FREE position. 1
Cycle both joysticks 10-20 seconds to re-
lease system pressure.

1. Remove the filter screen of the hydraulic 2

tank and plug the tank with a tool.

.
De al
★ When the tool is not used, remove

pt
the drain plug to drain the oil from the
hydraulic tank and the system.
g n
Hydraulic tank: 120 L
o
in ti

ZXT75-1006311
et a
n

2. Remove the hood and related covers.

rk er

3. Remove the side cover of engine.

4. Remove the two fixing plates (1) and then

Ma t

the muffler (2).

In

3a
5. Remove the nut (3a). Disconnect the air
intake hose (3). 3

ZXT75-1006312

Shop Manual - November 2012 8-147

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6. Disconnect the following hoses from the

main pump.

● Drain hose (4)

● Suction hose (5)
● Pilot oil hose (6)
● Delivery hose (7)
● Pilot module hose (8) 4

7. Remove the disc (9) connecting the fly-

wheel. ZXT75-1006313

.
8. Remove the coupling (10).

De al
pt
9. Remove the main pump connection bolts 8
7
(11).
g no
in ti

8.24.2 Install 6
5
et a

● Reverse the removing sequence to install

n

the assembly.
rk er

ZXT75-1006314

Pump housing mating surface:

Ma t
In

Gasket sealant (LG-6)

● Adding oil (hydraulic tank)

Add oil to the specific level through the

filler opening. Purge air from the main
pump. Run the engine to circulate oil in the
system. Check the oil level again.

● Purging the air

Purge air from the main pump.

For detailed information, see “Air in Each

Component - Bleed” on page 6-30.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.25 Main Pump Input Shaft Oil Seal - Remove and Install

8.25.1 Remove

1. Remove the main pump assembly.

2 3 4
For more information see “Main Pump
Assembly - Remove and Install” on page 8-147.

2. Remove the snap ring (2) and then the

spacer (3).

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

.
De al
remove the seal.

pt
★ Do not damage the shaft while removing ZX55-1006125
the oil seal.g no
in ti
8.25.2 Install

● Reverse the removing sequence to install

et a

the assembly.
n

Apply a thin coat of grease on the

rk er

oil seal prior to installation.

Ma t
In

Shop Manual - November 2012 8-149

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.26 Control Valve Assembly - Remove and Install

8.26.1 Removal

SY65C3
5
1. Remove the U-bolt (1) and the main con-
trol valve oil inlet tube (2). 2

1 9
2. Remove the swing makeup hose (3) con-
necting the main control valve and the 3
swing drive.

.
3. Remove the 14 main hoses (4) (seven

De al
4
hoses on each side).

pt
4. Remove the 14 pilot hoses (5) (seven hos-
g n
es on each side).
o
ZXT65-1006006
in ti

5. Remove the main return hose (6) connect-

ing the main control valve and the radiator.
et a

6. Remove the LS hose (7) connecting the

n

8
main control valve and the main pump.
rk er

7
7. Remove the pilot hose (8) connecting the
main control valve and the oil source valve.
Ma t

8. Remove the plate (9) supporting the oil in-

In

let tube of the main control valve. 6 ZXT65-1006007

9. Remove the three main control valve

mounting bolts (10).

10. Install the main control valve assembly (11)

with a lifting device. 10

11

ZXT65-1006008

8-150 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

SY75C3, SY75C9

Lower the work equipment fully on the

ground and stop the engine. Slowly loos-
en the filler cap to release internal pres-
sure in the hydraulic tank.
1
The machine is not equipped with an ac-
cumulator. It is important to slowly loosen
the hose connection nut and check if oil
squirts out before disassembling. 2

★ Mark the hoses before disassembling.

.
De al
1. Disconnect the swing makeup hose (1).

pt
3
3
2. Disconnect in order (from top to bottom)
g n
the hoses (2) and (3) between the valve
o
and the actuator.
in ti
★ Disconnect the 14 hoses (2) (seven at ZXT75-1006316

each side) and the 14 hoses (3) (seven

at each side).
et a
n

★ From the top, the hoses are arranged

in such an order: swing, right travel, left
rk er

travel, arm, bucket, blade and boom.

3. Disconnect the main control valve drain

Ma t

hose (4), the pilot tube (5) connecting the

In

main control valve with the oil source con-

trol valve, the LS pipe (6) connecting the
main control valve with the main pump,
4
and the main oil return pipe (7) connecting
the main control valve with the radiator. 5

6
7

ZXT75-1006317

Shop Manual - November 2012 8-151

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. Disconnect the main oil inlet pipe (8) con-

necting the main pump with the main con-
trol valve. Remove the main control valve 8
mounting bolts (9).

5. Remove the main control valve assembly

(10).
9
Control valve AS: 60 kg

10

.
De al
pt
g no ZXT75-1006318

8.26.2 Installation
in ti

● Installation is performed in the reverse or-

der of removal.
et a
n

● Adding oil (hydraulic tank)

rk er

★ Add oil to the specific level through the

filler opening. Start the engine to circulate
the oil in the system. Check the oil level
Ma t

again.
In

● Purging the air

★ Purge the air between the valve and the

hydraulic cylinder.

For detailed information, see “Air in Each

Component - Bleed” on page 6-30.

8-152 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.27 Control Valve AS - Disassembly and Assembly

8.27.1 Disassembly

SY65C3

★ Completely remove any dust or debris from the main control valve. Clean the main control
valve.

★ Place the main control valve on a clean, level workbench. Mark every part before disassem-
bling.

1. Remove the nut (143) and the screw (144) from the main control valve. When removing the

.
De al
valve plates, do not move the O-ring seals (130) be the plates.

pt
g no
141
in ti
et a
n

110

143
rk er

144
119
Ma t
In

130

130 119

ZX65-1006009

Shop Manual - November 2012 8-153

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2. Disassembling the valve plates for the boom, blade, bucket and arm:

1) Take apart the corresponding valve plate and carefully remove (130). Take out (12) and re-
move (h), (13) and (14).

2) Remove (111) and take down (g) and (113).

3) Take out (H+) and remove (i), (m) and (n).

4) Take out (93) and remove (81). Remove (c), (83) and (84). Pull out (16).

84
83
c

.
De al
pt
81
93
g n81
o
c
93

83
in ti
84

19
et a
n

111
g
rk er

17 y

113 18 12 x 130
h
Ma t

13
14
In

18

19

15

16

19

114

i
m
n
124*
ZX65-1006010

8-154 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

3. Disassembling the valve plate for both left and right travel

1) Take apart the corresponding valve plate and carefully remove (130). Take out (12) and re-
move (h), (13) and (14). Remove (111) and take down (g) and (113).

2) Take out (Q) and remove (i), (m) and (n).

3) Take out (93) and remove (81). Remove (c), (83) and (84). Pull out (16).

84
83
c

.
De al
pt
93 81
g no 81
c
93

83
in ti
84

19
et a
n

111
rk er

g
17 y

113 18 12 x 130
h
Ma t

13 A
14
In

18

19

15

16

19

117
i
m Q
n
ZX65-1006011

Shop Manual - November 2012 8-155

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. Disassembling the valve plate for hydraulic breaker

1) Take apart the corresponding valve plate and carefully remove (130). Take out (12) and re-
move (h), (13) and (14). Remove (111) and take down (g) and (113).

2) Take out (Q) and remove (i), (m) and (n). Take out (H+) and remove (i), (m) and (n).

3) Take out (93) and remove (81). Remove (c), (83) and (84). Pull out (16).

84
83
c

.
De al
pt
93g n81
o
c
81
93

83
in ti
84

19
et a
n

111
g
rk er

17 y

113 18 12 x 130
h
13
Ma t

14
In

18

19

15

117
i 16
m Q
n
19

114 114

i
m
n
124*
ZX65-1006012

8-156 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

5. Disassembling the valve plate for swing drive

1) Take apart the corresponding valve plate and carefully remove (130). Take out (12) and re-
move (h), (13) and (14). Remove (111) and take down (g) and (113).

2) Take out (Q) and remove (i), (m) and (n).

3) Remove (87), (d) and (88). Take out (93) and remove (81). Remove (c), (83) and (84). Pull out
(16).

84
83
c

.
De al
pt
g n
88
o d
87
81

93
90 87
in ti
93 d
88
81
90
c
83
et a

84
n

19
rk er

111
g
y
Ma t

17

18
In

113 12 x 130
h
13
14

18

19

15

16

19

117
i
m Q
n
ZX65-1006013

Shop Manual - November 2012 8-157

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

SY75C3, SY75C9

Clean the main control valve of any dust

and debris.

★ Mark every part before disassembling.

1. Place the main control valve on a clean,

level workbench.

2. Remove the nut (13), gasket (12) and

screw (11) from the main control valve. 13 11 12 11 13 1112
10 20 20

.
★ When removing the valve plates, do not 9

De al
move the O-ring seals (21), (22), (25)

pt
8B 8A
and (26) between the plates. 8
7B 7A

1)
g n
Feed valve plate GP
o
7
14
6B 6A
14

2) Boom valve plate GP 5B 5A

6
in ti
3) Blade valve plate GP 15 15
4B 4A
5
4) Bucket valve plate GP 15 15
3B 3A
4
5) Arm valve plate GP 15 15
et a

2B 2A
3
6) Right travel valve plate GP 19
n

1B 1A
7) Left travel valve plate GP 2
15
rk er

8) Auxiliary valve plate GP 15

1 16
9) Swing valve plate
19
10) Delivery valve plate GP
Ma t

ZX75-1006319

11) Setscrew
In

12) Compression washer

13) Nut
14) Relief valve
15) Relief valve
16) Unloading regulator GP
17) Plug GP
18) Cutoff plug GP
19) Check valve GP
20) Cutoff plug GP

8-158 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

24

23

21

.
22

De al
pt
g no 23
ZX75-1006320
in ti
21) O-ring seal (big) 23) O-ring seal (plug)
22) O-ring seal (small) 24) O-ring seal (end cover)
et a
n

28
rk er

28
Ma t
In

27

27 25

26

ZX75-1006321

25) O-ring seal (big) 27) O-ring seal (plug)

26) O-ring seal (small) 28) O-ring seal (end cover)

Shop Manual - November 2012 8-159

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

1. Disassembling the feed valve plate

1) Take down (1) and remove (11), (12), (13) and (14).

2) Take down (8) and (9). Remove (5), (6), (7) and (10).

7
6

.
De al
5

pt
g no
in ti
et a

4
1
n

11 12
rk er
Ma t

2
14
In

10

9
13

ZX75-1006322

8-160 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

2. Disassembling the valve plate for boom

1) Take down (17) and remove (18).

2) Loosen (1) and remove (2). Remove (3), (4) and (5). Pull out (6).

3) Take down (9) and remove (8). Pull out (7) finally.

A B

.
16

De al
13 15

pt
14
18 18
g no 9

8
in ti
12
11
10
et a

17 6 5 4 3 2 1
n
rk er
Ma t
In

7 8 9

ZX75-1006323

Shop Manual - November 2012 8-161

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3. Disassembling the blade

1) Remove the valve body (14) and open the relief valve (15).

2) Loosen the end cover bolt (1). Take down the spool end group (2) and remove spring (3),
spring seat (4) and O-ring seal (5). Pull out the spool (6).

3) Take down the plug group (9) and remove the O-ring seal (8). Pull out the compensator spool
(7) finally.

.
De al
A B

pt
g no
13

15 10 12 15
in ti
11
et a
n
rk er

14 6 5 4 3 2 1
Ma t
In

7 8 9
ZX75-1006324

8-162 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

4. Disassembling the valve plate for bucket

1) Remove the bucket valve body (14) and take apart the relief valve (15).

2) Spool end group: Loosen (1); remove (2), and then (3), (4) and (5); pull out (6).

3) Take apart the plug group (9). Remove the O-ring seal (8). Finally, pull out the compensator
spool group (7).

.
A B

De al
pt
13
g no 10
12
11
in ti
et a

14 6 5 4 3 2 1
n
rk er
Ma t
In

7 8 9
ZX75-1006325

Shop Manual - November 2012 8-163

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

5. Disassembling the valve plate for arm

1) Remove (14) and take apart (15).

2) Loosen (1). Remove (2), and then (3), (4) and (5). Pull out (6).

3) Take apart (9) and remove (8). Pull out (7) finally.

A B

.
De al
13

pt
15 10 15
12

g no 11
in ti

14 6 5 4 3 2 1
et a
n
rk er
Ma t
In

7 8 9 ZX75-1006326

8-164 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

6. Disassembling the valve plate for travel

1) Remove 14) and take apart (15).

2) Loosen (1). Remove (2), and then (3), (4) and (5). Pull out (6).

3) Take apart (9) and remove (8). Pull out (7) finally.

A B

.
De al
pt
13

g no 10

11
12
in ti
14 6 5 4 3 2 1
et a
n
rk er
Ma t
In

7 8 9
ZX75-1006327

Shop Manual - November 2012 8-165

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

7. Disassembling the auxiliary valve plate

1) Remove (14) and take apart (15).

2) Loosen (1). Remove (2), and then (3), (4) and (5). Pull out (6).

3) Take apart (9) and remove (8). Pull out (7) finally.

A B

.
De al
pt
13

15 g no 10

11
12 15
in ti
et a

14 6 5 4 3 2 1
n
rk er
Ma t
In

7 8 9 ZX75-1006328

8-166 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8. Disassembling the valve plate for swivel

1) Remove (16). Take apart (17).

2) Take apart (1) and (2). Loosen (3). Remove (4), and then (5), (6) and (7). Pull out (8).

3) Take apart (11), remove (10) and pull out (9) finally.

A B

.
De al
pt
16

13 15
g no
14
*
*
*
*

in ti
9

8
et a

62025 12
n

KIT-SERVICE
11
rk er

10

6 5 3
Ma t

17 4 2 1
In

7 8 9

ZX75-1006329

Shop Manual - November 2012 8-167

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

9. Disassembling the delivery valve plate

.
De al
pt
g no
in ti
et a
n

ZX75-1006330
rk er

No. Description Quantity Remark

Oil delivery valve block
1 1
Ma t

NSCX183-A4
In

8-168 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.27.2 Assembly

SY65C3

★ Keep the valve plates free from con- 5) Sequentially install the rest valve plates
taminants such as dust and paints. Do for the blade, bucket, arm, left/right travel,
not damage the O-ring seals between the breaker, oil feed, swivel and oil makeup.
plates.
6) After stacking all working valve plates and
1. Assembling the whole main valve feed/delivery valve plates, install and tight-
en the nut on the screw.
1) Install one end of the double-ended screw
(144) in the valve plate for oil return. 7) Place the valve on a level surface before

.
applying the torque, with its installation feet

De al
2) Let the return valve external surface and on the level surface.

pt
the screw face upward.
★ Incorrect torque will cause the spool of
g n
3) Install the O-ring seals in the groove on the
surface of return valve.
o main valve to be seized. Applying the
torque on a non-level surface will also
cause the spool to be seized.
4) Put the boom valve plate on the screw and
in ti
then install the O-ring seals. 8) Install the auxiliary valve and/or oil port
plug on all valve plates.
et a
n
rk er

141
Ma t
In

110

143

144
119

130

130 119

ZX65-1006009

Shop Manual - November 2012 8-169

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2. Assembling the valve plates for boom, blade, bucket and arm

1) Install (14), (13), (h) and (12). Install (113) and (9). Finally install (111).

2) Install (i), (m) and (n), and then install (H+).

3) Install (16), followed by (84), (83), (c) and (81). Finally install (93).

84
83
c

.
De al
pt
93 81
81 93
g no c
83
84
in ti
19
et a

111
g
n

17 y
rk er

113 18 12 x 130
h
13
14
Ma t

18
In

19

15

16

19

114

i
m
n
124*
ZX65-1006010

8-170 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

3. Assembling the valve plates for travel

1) Install (14), (13), (h) and (12). Install (113) and (9). Finally install (111).

2) Install (i), (m) and (n), and then install (Q).

3) Install (16), followed by (84), (83), (c) and (81). Finally install (93).

84
83
c

.
De al
pt
93 81
81 93
g no c
83
84
in ti
19
et a

111
n

g
17 y
rk er

113 18 12 x 130
h
13 A
14
Ma t

18
In

19

15

16

19

117
i
m Q
n
ZX65-1006011

Shop Manual - November 2012 8-171

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. Assembling the valve plates for breaker

1) Install (14), (13), (h) and (12). Install (113) and (9). Finally install (111).

2) Install (i), (m) and (n), and then install (Q).

3) Install (i), (m) and (n), and then install (H+).

4) Install (16), followed by (84), (83), (c) and (81). Finally install (93).

84
83

.
c

De al
pt
g n
93
o
81
81
93
c
in ti
83
84
et a

19
n

111
rk er

g
17 y

113 18 12 x 130
Ma t

h
13
14
In

18

19

15

117
i 16
m Q
n
19

114 114

i
m
n
124*
ZX65-1006012

8-172 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

5. Assembling the valve plates for swivel

1) Install (14), (13), (h) and (12). Install (113) and (9). Finally install (111).

2) Install (i), (m) and (n), and then install (Q).

3) Install (16), followed by (84), (83), (c) and (81). Finally install (93), (87), (d) and (88).

84
83
c

.
De al
pt
88 81
d
87
g no 90
93
93
87
d
88
81
90
in ti
c
83
84
et a

19
n
rk er

111
g
17 y

113 18 12 x 130
Ma t

h
13
14
In

18

19

15

16

19

117
i
m Q
n
ZX65-1006013

Shop Manual - November 2012 8-173

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

SY75C3, SY75C9

★ Keep the valve plates free from contami-

nants such as dust and paints.

★ Do not damage the O-ring seals between

the plates.

Assemble the main valve according to

the following procedure, which can avoid
damaging the seals and make it easy to
check for surface debris.

.
De al
1. Fully screw on the nut (13) on the end of

pt
13 11 12 11 13 1112
screw (11) with less threads.
10 20 20
g n
2. Install the compression gasket (12) on the
o
screw (11). Let the coned surface face the
9

8B 8A

main valve and the screw go through the 8

in ti
7B 7A
hole of the feed valve plate. 14
6B 6A
14
7
★ Let the feed valve plate external sur-
et a

5B 5A
6
face and the screw face upward. 15
4B
15
4A
n

5
15 15
3. Install the O-ring seals (21), (22), (23) and 4
3B 3A
rk er

15 15
(24) in the grooves on surface of the feed 2B 2A
3
valve plate. 19
1B 1A
2
Ma t

15
4. Put the boom valve plate on the screw and 15
1
In

then install the O-ring seals. 16

19
ZX75-1006319

1) Feed valve plate GP 11) Setscrew

2) Boom valve plate GP 12) Compression washer
3) Blade valve plate GP 13) Nut
4) Bucket valve plate GP 14) Relief valve
5) Arm valve plate GP 15) Relief valve
6) Right travel valve plate GP 16) Unloading regulator GP
7) Left travel valve plate GP 17) Plug GP
8) Auxiliary valve plate GP 18) Cutoff plug GP
9) Swing valve plate 19) Check valve GP
10) Delivery valve plate GP 20) Cutoff plug GP

8-174 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

5. Sequentially install the rest valve plates (3), (4), (5), (6), (7), (8), (9) and (10) for the blade,
bucket, arm, right travel, left travel, auxiliaries, swivel and oil delivery.

★ The O-ring seals are only installed on the valve plates for the boom, blade, bucket, arm,
right travel, left travel, auxiliaries and swivel. The valve plate for oil delivery has no O-ring
seals.

6. After stacking all working valve plates, feed valve plates and delivery valve plates, install the
compression washer (20) on the screw (19). Let the coned surface face the surface of valve.

7. Install the nut the on the screw. Tighten the nut to approximate 44 Nm.

Place the valve on a level surface before applying the torque, with its installation feet on the

.
level surface.

De al
pt
★ After the main valve is placed on a level surface, apply a torque of 295±30Nm on the nut (21)
of the screw.
g no
★ Incorrect torque will cause the spool of main valve to be seized.
in ti
★ Install auxiliary valve or oil port plug on all valve plates and apply the torque as specified.
et a
n
rk er
Ma t
In

Shop Manual - November 2012 8-175

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

24

23

21

.
22

De al
pt
g no 23
ZX75-1006320
in ti
21) O-ring seal (big) 23) O-ring seal (plug)
22) O-ring seal (small) 24) O-ring seal (end cover)
et a
n

28
rk er

28
Ma t
In

27

27 25

26

ZX75-1006321

25) O-ring seal, (big) 27) O-ring seal (plug)

26) O-ring seal (small) 28) O-ring seal (end cover)

8-176 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

1. Assembling the plate group of feed valve

1) Install the spool (4) in the valve body (1). Install the spring (5), gasket (6) and O-ring seal (7),
followed by end cover group (8). Install the O-ring seal (10) and then the end cover group (9).

2) Install the check valve group (11), unloading regulator group (12) and cutoff plug group (13).

.
6

De al
pt
5

g no
in ti
et a
n

4
1
11
rk er

12
Ma t

2
In

14

10

9
13

ZX75-1006322

Shop Manual - November 2012 8-177

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2. Assembling the valve plates for boom

1) Install the spool (6) in the valve body (17). Install the spring (3), seat (4) and O-ring seal (5),
followed by spool end group (2) and end cover bolt (1).

2) Install the compensator spool (7) in the valve body (17), followed by the O-ring seal (8) and
the plug group (9).

3) Finally install the relief valve (18).

A B

.
De al
16

pt
13 15

18
g no 14

9
18
in ti
8
12
11
et a

10
n

17 6 5 4 3 2 1
rk er
Ma t
In

7 8 9

ZX75-1006323

8-178 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

3. Assembling the valve plates for blade

1) Install (6) in (14). Install (3), (4) and (5), followed by (2) and (1).

2) Install (7) in (14), followed by (8) and (9).

3) Finally install (15).

A B

.
De al
pt
13

10 12 15
15
g no
11
in ti
et a

14 6 5 4 3 2 1
n
rk er
Ma t
In

7 8 9
ZX75-1006324

Shop Manual - November 2012 8-179

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. Assembling the valve plates for bucket

1) Install (6) in (14). Install (3), (4) and (5), followed by (2) and (1).

2) Install (7) in (14), followed by (8) and (9).

3) Finally install (15).

A B

.
De al
pt
13
10
12
g no 11
in ti

14 6 5 4 3 2 1
et a
n
rk er
Ma t
In

7 8 9
ZX75-1006325

8-180 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

5. Assembling the valve plates for arm

1) Install (6) in (14). Install (3), (4) and (5), followed by (2) and (1).

2) Install (7) in (14) and then install (8) and (9).

3) Finally install (15).

A B

.
De al
13

pt
15 10 15
12
g no 11
in ti

14 6 5 4 3 2 1
et a
n
rk er
Ma t
In

7 8 9 ZX75-1006326

Shop Manual - November 2012 8-181

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

6. Assembling the valve plates for left/right travel

1) Install (6) in (14). Install (3), (4) and (5), followed by (2) and (1).

2) Install (7) in (14), followed by (8) and (9).

A B

.
De al
13

pt
10 12

g no 11
in ti
14 6 5 4 3 2 1
et a
n
rk er
Ma t
In

7 8 9
ZX75-1006327

8-182 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

7. Assembling the auxiliary valve plates

1) Install (6) in (14). Install (3), (4) and (5), followed by (2) and (1).

2) Install (7) in (14), followed by (8) and (9).

3) Finally install (15).

A B

.
De al
pt
13
10
g n
15
o
11
12 15
in ti
et a

14 6 5 4 3 2 1
n
rk er
Ma t
In

7 8 9 ZX75-1006328

Shop Manual - November 2012 8-183

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8. Assembling the valve plates for swivel

1) Install (8) in (16). Install (5), (6) and (7), followed by (4) and (3). And then install (2) and (1).

2) Install (9) in (16), followed by (10) and (11).

3) Finally install (17).

A B

.
De al
16

pt
13 15
g no 14
*
*
*
*

in ti
9

8
et a

62025 12
n

KIT-SERVICE
11
rk er

10

17 6 5 4 3 2 1
Ma t
In

7 8 9

ZX75-1006329

8-184 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

9. Assembling the valve plates for oil delivery

.
De al
pt
g no
in ti
et a
n

ZX75-1006330
rk er
Ma t
In

Shop Manual - November 2012 8-185

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.28 Oil Source Control Valve Assembly - Remove and Install

8.28.1 Removal

Lower the work equipment fully on the

ground and stop the engine. Move the hy-
draulic lockout control to FREE position.
Cycle both joysticks 10-20 seconds to re-
lease system pressure.

Disconnect the cable from the negative (-)

of battery.

.
De al
1. Open the right door.

pt
2. Remove the two solenoid lead connectors
g n
(1) from the clips and disconnect them.
o
3
in ti
★ Note down the lead connection num-
bers and locations. 2
et a

3. Disconnect the five hoses (2). 2

n

★ Tag the location of hose before discon-

rk er

necting it.

4. Unscrew the mounting bolts. Remove the 1

Ma t

oil source control valve assembly (3).

In

★ When removing a solenoid valve ZXT75-1208009

separately, remove the nut before
disassembling the harness of solenoid
valve.

8-186 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.28.2 Installation

● Installation is performed in the reverse or-

der of removal.

Check the connector number prior to con-

nection.

Mounting nut:

.
De al
4.9±0.1 Nm {0.5±0.1 kgm}

pt
Solenoid valve as a separate part:
g no
39.2±9.8 Nm {4±1 kgm}
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 8-187

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.29 Left Pilot Valve Assembly - Remove and Install

8.29.1 Remove

Lower the work equipment onto the ground

and shut down the engine. Relieve sys-
tem pressure.

1. Remove rubber jacket (2) from cover (1)

and pull it upward.
2

★ Check the direction of control lever.

.
De al
2. Open the hoop.

pt
★ Remove the mounting bolts and move
g n
the jacket (2) backward.
o 1
ZX75-1006333

3. Remove the mounting bolts of the pilot

in ti
valve assembly. Lift up the pilot valve as-
sembly and disconnect the six hoses (4).
et a

4
n

4. Remove the pilot valve assembly (5).

rk er
Ma t

8.29.2 Install
In

● Reverse the removing sequence to install

4 5
the assembly.
ZXT75-1006334

Hose connection bolt:

24.5±5.0 Nm {2.5±0.5 kgm}

Adjust the pilot valve if the control lever

plays too much. For more information, see
“Work Equipment and Swing Pilot Valve -
Adjust” on page 6-21.

8-188 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.30 Right Pilot Valve Assembly - Remove and Install

8.30.1 Remove

Lower the work equipment onto the ground

and shut down the engine. Relieve sys-
tem pressure.
3
1. Remove rubber jacket (2) from cover (1)
and pull it upward.

★ Check the direction of control lever.

.
De al
★ Move the cover (1) upward. 2

pt
2. Open the hoop.
g n
3. Remove the mounting bolts of the pilot
o
valve assembly (5). Lift up the pilot valve
in ti
assembly and disconnect the six hoses (4).
1
ZXT75-1006335
et a

4. Remove the pilot valve assembly (5).

n
rk er
Ma t

8.30.2 Install
In

● Reverse the removing sequence to install

the assembly.
4

Hose connection bolt: ZXT75-1006336

24.5±5.0 Nm {2.5±0.5 kgm}

Adjust the pilot valve if the control lever

plays too much. For more information, see
“Work Equipment and Swing Pilot Valve -
Adjust” on page 6-21.

Shop Manual - November 2012 8-189

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.31 Work Equipment Pilot Valve Assembly

8.31.1 Disassemble

1. Remove the nut (1) and then the lower disc 1

(2) and rubber jacket (3).
2
2. Remove the bolt and then the plate (5).
4

★ Do not remove connector (4) unless it

has to be replaced. 3

3. Remove the seal (6) and the retainer (7). 5

.
De al
pt
6
4. Pull out the plunger (8). Remove the posi-
7
tioner (9), springs (10) and (11), and gas-
ket (12). g no 8
9
★ Spring (10) consists of two kinds of 10
in ti
springs with different installation loads.
So check the installation position (oil 11
port) and the tag to avoid making 12
et a

mistake during installation. 13

n

5. Pull out the valve (13) from valve body (14). 14

rk er

ZX75-1006337
Ma t

8.31.2 Assemble
In

1. Install the valve (13) in valve body (14).

2. Install the gasket (12) and the spring (11)

on the valve (13). 5 7mm

★ When installing the spring (11), the end

with small diameter (inner diameter)
shall face the gasket (12).

3. Install the spring (10), positioner (9) and

plunger (8).

★ The number of coils of the spring (10)

ZX75-1006338
for each hydraulic oil port is different.
Be aware of this during installation.

8-190 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

Port Position Free Length of Spring

P1, P2 44.4 mm
P3, P4 42.4 mm

★ The position of each port is marked on

bottom of valve body.

Plunger: grease (G2-LI)

★ When installing the plunger (8), apply

grease to the outer of plunger and to
the bore of valve body.

.
4. Install the O-ring seal on the retainer (7),

De al
which will be installed on valve body (14).

pt
And then install the seal (6).
g n
5. Install the plate (5).
o
Mounting bolt: 24.5±5.0 Nm {2.5±0.5
in ti
kgm}

6. Install the connector (4).

et a

Sliding part of connector:

n

Grease (G2-LI)
rk er

Threads inside valve body:

Ma t

Thread adhesive: (LT-2)

In

★ Apply adhesive to two points on the

inner threads, one drop of Loctite for
each point.

Connector: 24.5±5.0 Nm {2.5±0.5

kgm}

★ The tightening torque of connector

should be ensured.

7. Install the jacket (3) and disc (2). Tighten

the nut (1).

Nut: 112.7±14.7 Nm {11.5±1.5kgm}

★ The tightening torque of connector

should be ensured.

Shop Manual - November 2012 8-191

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.32 Travel Pilot Valve Assembly - Remove and Install

8.32.1 Remove

Lower the work equipment onto the ground

and shut down the engine. Loosen slowly
the oil filler cap to relieve the residual
pressure inside the hydraulic tank.

1. Remove the floor mat.

2. Remove the bottom cover. 1

.
De al
3. Remove the control lever (1).

pt
ZXT75-1006339

g no
in ti
4. Remove the bolts (2).

2
et a
n
rk er

2
Ma t
In

ZXT75-1006340

5. Disconnect the eight pilot hoses (3). Re-

move the pilot valve assembly for travel.

3 3

ZXT55-1006171

8-192 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.32.2 Install

● Reverse the removing sequence to install

the assembly.

★ Adjust the travel control lever.

See “Testing and Adjusting” for more

information on adjustment of travel control
lever.

.
De al
pt
Cover mounting bolt:
g n
19.6±1.96 Nm {2.0±0.2 kgm}
o
in ti

Hose connector mounting bolt (cross

et a

width : 30 mm):
n

39.2±4.9 Nm {4.0±0.5 kgm}

rk er

Hose connector mounting bolt (cross

width : 22 mm):
Ma t

29.4±4.9 Nm {3.0±0.5 kgm}

In

Shop Manual - November 2012 8-193

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.33 Travel Pilot Valve Assembly - Disassemble and Assemble

★ The chapter only discusses the precau-

tions to be observed when reassembling
the travel pilot valve assembly.

Push rod

.
De al
pt
g no
in ti
9 8 7 6 4 3 2 1
5
et a
n
rk er

ZX215T-1006158
Ma t
In

8-194 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.33.1 Assemble

● Reassemble the travel pilot valve assem-

bly.

1. Install the spring (8) in the spool bore of

housing (9). Install the spool (7). Put the
cover (6) on the spool and hold the cover
(6) with a hand.

2. Align the bore and install the plate (4).

Tighten the socket-headed screws (1).

.
De al
Socket head screw:

pt
98~114Nm {10~11.6 kgm}
g n
3. Install the dust ring (3) on the pushrod. In-
o
stall the cams(2). Fix the cam (2) with the
in ti
camshaft (5).

Interface between pushrod and dust

et a

ring (5): grease (No.1 calcium base

grease)
n
rk er
Ma t
In

Shop Manual - November 2012 8-195

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.34 Boom Cylinder Assembly - Remove and Install

8.34.1 Removal

Fully extend the arm and bucket. Lower the

work equipment completely on the ground. 2 3
Place the hydraulic lockout control in the
LOCKED position.
1
1. Lift the boom cylinder assembly (1). Re-
move the locknut (2) and the pin roll (3).

★ Check the number and thickness of ZXT75-1006342

.
De al
shims and store them properly.

pt
g n
2. Start the engine, retract the piston rod and
tie rod with a string to prevent it from com-
o
ing off.
in ti

★ Place a support under the cylinder

assembly. Adjust the position of the
1
et a

cylinder assembly hoisted.

n

3. Disconnect the left hose (4) and the right 7

rk er

hose (5).
5
4
4. Remove the bolt (6) at the side of bottom 6 ZXT75-1006343
Ma t

pin roll. Remove the pin roll (7) and the

boom cylinder assembly (1).
In

★ Check the number and thickness of

shims and store them properly.

Boom cylinder AS: 105 kg

8-196 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.34.2 Install

● Reverse the removing sequence to install

the assembly.

7 8
Apply grease on bushing surface:
EP G2-LI grease

Apply grease after installation of

pin roll: EP G2-LI grease

Do not put your finger in the pinhole while

aligning it.

.
De al
★ Adjust shim thickness so that the clear-

pt
Max.1mm
ance between piston rod (7) and plate (8)
is between 0.5 and 0.8 mm.
g n
★ Std. shim thickness: 0.5 mm, 1.0 mm
o ZX75-1006344
in ti

Apply grease on bushing surface:

EP G2-LI grease
et a

Apply grease after installation of

n

pin roll: EP G2-LI grease

rk er

10
Do not put your finger in the pinhole while
aligning it.
Ma t

★ Adjust shim thickness so that the clearance

between cylinder bottom (9) and plate (10)
In

is between 0.5 and 0.8 mm.

Max 1mm
★ Std. shim thickness: 0.5 mm, 1.0 mm
9
● Purging the air ZX75-1006345

★ Purge the air from oil cylinder.

For detailed information, see “Air in Each

Component - Bleed” on page 6-30.

● Adding oil (hydraulic tank)

★ Add oil to the specific level through the

filler opening.

Start the engine to circulate oil in the

system and then check oil level again.

Shop Manual - November 2012 8-197

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.35 Arm Cylinder Assembly - Remove and Install

8.35.1 Remove

Retract the bucket and the arm. Place

them on blocks. Move the hydraulic lock-
1
out control to the LOCKED position. 5
3
1. Hoist the cylinder assembly.

2. Remove the latch and the pin roll (1) on

the end.

.
De al
pt
★ Check the number and thickness of 4 2
g n
shims and store them properly.
o ZXT75-1006346

3. Start the engine and retract the piston rod.

in ti
Tie the rod with a string to prevent it from
coming off.
et a

4. Disconnect both the left and right hoses (2).

n

5. Disconnect the lubrication line (3).

rk er

6. Lift the arm cylinder assembly. Remove the

latch and then the bottom pin roll (4). Re-
Ma t

move the arm cylinder assembly (5).

In

★ Check the number and thickness of

shims and store them properly.

Arm cylinder assembly: 80 kg

8-198 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.35.2 Install

● Reverse the removing sequence to install

the assembly.

7 8
Apply grease on bushing surface:
EP G2-LI grease
Apply grease after installation of
pin roll: EP G2-LI grease
Do not put your finger in the pinhole while
aligning it.

.
★ Adjust shim thickness so that the clear-

De al
Max.1 mm
ance between piston rod (7) and plate (8)

pt
ZX75-1006347
is between 0.5 and 0.8 mm.
g n
★ Std. shim thickness: 0.5 mm, 1.0 mm
o
in ti
Apply grease on bushing surface:
EP G2-LI grease
et a

Apply grease after installation of

pin roll: EP G2-LI grease
n

Max.1 mm
rk er

Do not put your finger in the pinhole while

aligning it.
10 9
★ Adjust shim thickness so that the clearance
Ma t

ZX75-1006348
between cylinder bottom (9) and plate (10)
In

is between 0.5 and 0.8 mm.

★ Std. shim thickness: 0.5 mm, 1.0 mm

● Purging the air

★ Purge the air from oil cylinder.

For detailed information, see “Air in Each

Component - Bleed” on page 6-30.

● Adding oil (hydraulic tank)

★ Add oil to the specific level through the

filler opening.

Start the engine to circulate oil in the

system and then check oil level again.

Shop Manual - November 2012 8-199

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.36 Bucket Cylinder Assembly - Remove and Install

8.36.1 Remove

Extend the bucket cylinder’s piston rod

approximately 20 mm. Lower the work
equipment fully on the ground. Place the
hydraulic lockout control in the LOCKED
position.

1. Place a block 1 under the end of arm.

2. Place blocks 2 and 3 between the linkage

.
De al
and the arm.

pt
1
ZX75-1006349
3. Lift the bucket cylinder assembly.
g n
4. Remove the lockbolt (1).
o
in ti
5. Remove the latch and then the pin roll (2). 2 1

Tie the piston rod to prevent it from coming

off.
et a
n

2
If the pin roll (2) comes off, the linkage (7)
rk er

would fall. So always keep the block ② in

its position. 7
Ma t

3
★ Check the number and thickness of shims ZX75-1006350
In

and store them properly.

6. Disconnect the left and right hoses (3).

4
7. Disconnect the grease tube (4).
5
8. Hoist up the bucket cylinder assembly. Re-
move the latch and the bottom pin roll (5).
Remove the bucket cylinder (6). 6

★ Check the number and thickness of shims

and store them properly. 3
ZX75-1006351

Bucket cylinder assembly: 60 kg

8-200 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.36.2 Install

● Reverse the removing sequence to install

the assembly.
★ When tightening the locknut, keep a clear-
ance of 0.5-1.5 mm between the plate and
the nut.

Apply grease on bushing surface:

EP G2-LI grease 0.5~1.5mm

Apply grease after installation of ZX75-1006352

pin roll: EP G2-LI grease

.
De al
Do not put your finger in the pinhole while

pt
aligning it.
★ Adjust shim thickness so that the clear- Max. 1mm
g n
ance between piston rod (7) and plate (8)
o
is between 0.5 and 0.8 mm.
in ti
★ Std. shim thickness: 0.5 mm, 1.0 mm
et a

Apply grease on bushing surface:

EP G2-LI grease
n

Apply grease after installation of 8 7 ZX75-1006353

rk er

pin roll: EP G2-LI grease

Do not put your finger in the pinhole while

aligning it.
Ma t

★ Adjust shim thickness so that the clearance

In

between cylinder bottom (9) and plate (10)

is between 0.5 and 0.8 mm. MAX1mm

★ Std. shim thickness: 0.5 mm, 1.0 mm

● Purging the air

★ Purge the air from oil cylinder.
For detailed information, see “Air in Each
Component - Bleed” on page 6-30.
9 10
● Adding oil (hydraulic tank) ZX75-1006354

★ Add oil to the specific level through the

filler opening.
Start the engine to circulate oil in the
system and then check oil level again.

Shop Manual - November 2012 8-201

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.37 Blade Cylinder Assembly - Remove and Install

8.37.1 Remove

Swing the work equipment by 45°. Lower

the work equipment on the ground. Lower
the blade on the ground and stop the
engine. Cycle the blade control lever
2-3 times in order to release the residual
pressure in the hydraulic lines.

Slowly loosen the filler cap to release

the internal pressure of hydraulic tank.

.
De al
Place the hydraulic lockout control in the

pt
LOCKED position.

g n
1. Remove the blade cylinder protective cov-
o
1
er.
in ti
2
2. Hoist the blade cylinder (1). Remove the
pin (2) from the its head.
et a
n
rk er

★ Check the number and thickness of shims

and store them properly. 4
3
Ma t

3. Start the engine, retract the piston rod, and ZXT75-1006355

tie the rod to prevent it from coming off.

In

4. Disconnect the hose (3).

5. Remove the bottom pin (4). Hoist away the

blade cylinder assembly (1).

★ Check the number and thickness of shims

and store them properly.

Blade cylinder assembly: 50 kg

8-202 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.37.2 Install

● Reverse the removing sequence to install

the assembly.

Do not put your finger in the pin hole while

aligning it.

★ Install the shims securely in their origi-

nal positions.

● Purging the air

.
De al
★ Purge the air from oil cylinder.

pt
For detailed information, see “Air in Each
g n
Component - Bleed” on page 6-30.
o
● Adding oil (hydraulic tank)
in ti

★ Add oil to the specific level through the

filler opening.
et a
n

Start the engine to circulate oil in the

system and then check oil level again.
rk er
Ma t
In

Shop Manual - November 2012 8-203

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.38 Hydraulic Cylinder Assembly - Disassemble and Assemble

8.38.1 Disassembly

1. Cylinder assembly

1) Plate the cylinder assembly (1) on the tool E2 2 1

E1.

2) Using a hydraulic pump or a power wrench, E1

loosen the cylinder head assembly (2) with
the tool E2.

.
De al
3) Pull out the rod assembly (3).

pt
ZX75-1006356
★ Place a container under the cylinder to
collect oil. g no
2. Piston rod assembly
in ti
1) Place the rod assembly (3) the on the tool
3
E1.
et a

2) Using a hydraulic pump or a power wrench,

n

loosen the nut (4) with the tool E3.

E1
rk er

● Width of the nut:

Ma t

unit: mm ZX75-1006357
In

Cylinder Boom Arm Bucket Blade

Width of nut 70 65 60 80

4 3

E1

E3

ZX75-1006358

8-204 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

3) Remove the rod assembly (5) and the po-

sitioner (6).

● Positioner (6) is only used for the boom

and arm cylinders.
5
4) Remove the plunger (7). 6
7
● Only for the boom and arm cylinders. 8

5) Remove the retainer (8) and the cylinder 9 ZX75-1006359

head assembly (9).

.
6) Remove the cover (12), pull out the nine

De al
balls (10) and remove the piston (11).

pt
10 12 11

● Only for arm cylinder.

g no
in ti

ZX75-1006360
et a
n

3. Disassembling the piston assembly Boom, arm and bucket cylinders

rk er

1) Remove the wear ring (13).

13
14
Ma t

2) Remove the piston ring (14).

In

13

ZX75-1006361

Blade cylinder

14

13

ZX75-1006362

Shop Manual - November 2012 8-205

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. Disassembling the cylinder head as- Boom, arm and bucket cylinders
sembly 22
15

1) Remove the O-ring sea and the support 21

ring (15).
20 17
2) Remove the O-ring seal (17).
19
3) Remove the snap ring (18) and then the
dust seal (19). 18
ZX75-1006365

4) Remove piston rod seal (20).

Blade cylinder

.
5) Remove the buffer ring (21).

De al
pt
20
6) Remove the bushing (22).
g no 22
in ti
19 18
ZX75-1006363
et a
n
rk er
Ma t
In

8-206 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.38.2 Assembly

★ Do not damage the seals, dust rings and

O-ring seals.
E6
E7
★ Do not install the support ring in a forcible
way. Heat up the ring in (50-60°C) Hot 19
22
water before installation.

1. Assembling the cylinder head assembly

1) Press fit the bushing (22) with the tool E6.

ZX75-1006364

.
2) Install the buffer ring (21).

De al
pt
3) Install the rod seal (20).
Boom, arm and bucket cylinders
g n
4) Use the tool E7 to install the dust ring (19)
o
and secure it with snap ring (18).
22
15

21
in ti
5) Install the support ring (15) and the O-ring
seal. 20 17
et a

6) Install the O-ring seal (17). 19

n

18
ZX75-1006365
rk er
Ma t

2. Assembling the piston assembly

In

1) Expand the piston ring (4) with the tool E4. E4 E5

14
★ Place the piston ring on the tool E4. 14
Cycle the joystick 8-10 times in order to
expand the piston ring.

2) Install the tool E5 in place. Compress the

piston ring (14). ZX75-1006366

3) Install the wear ring (13).

★ Keep the end opening of the ring to a

moderate degree.

Circular groove: grease (G2-LI)

Shop Manual - November 2012 8-207

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3. Piston rod assembly

1) Install plunger (11) on piston rod. Install the

nine balls (10) and secure them with the
cover (12). 10 12 11

★ Make sure that a little clearance is

present on plunger end.

● Only for arm cylinder.

2) Install the cover assembly (9).

ZX75-1006360

.
3) Install the O-ring seal, support ring and re-

De al
tainer (8).

pt
7 8
★ Only for boom cylinder and arm cylin-
der.
g no
4) Install plunger (7).
in ti

★ Only for boom cylinder and arm cylin-

der.
et a

Max.1mm
n

5) Install the retainer. ZX75-1006367

rk er

★ Only for boom cylinder and arm cylin-

der.
Ma t

6) Install piston assembly (5).

In

5
6
7

9 ZX75-1006359

8-208 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

7) Place the piston rod on the tool E1.

4 3
8) Tighten the nut (4) with the tool E3.

Nut: Thread adhesive (LT-2) E1

Nut: E3

Tightening Torque
Cylinder
Nm{kgm}
Boom 2597±259.7 {265±26.5} ZX75-1006358

Arm 2646±264.6 {270±27}

Bucket 2156±215.6 {220±22}

.
De al
Blade 3969±399.9 {405±40.5}

pt
4. Cylinder assembly
g no
1) Place the cylinder on the tool E1. 3
in ti
2) Install the piston rod assembly (3).

★ Push in the piston rod completely.

et a

E1
n

3) Using a hydraulic pump or a power wrench,

tighten the cylinder head assembly (2) with
rk er

the tool E2. ZX75-1006357

Cylinder head AS:

Ma t
In

Cylinder Tightening Torque

E2 2 1
Boom 960.4±96.04 {98±9.8}
Arm 784±78.4 {80±8}
Step 1:Tighten to 1176-1372 {120-140} E1
Step 2: Loosen to 0 {0}
Bucket Step 3: Tighten to 392 {40}
Step 4: Tighten diagonally.
(Turn a length of 3.5-4.5 mm)
Blade 980.0±98.0 {100±10} ZX75-1006356

Shop Manual - November 2012 8-209

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.39 Work Equipment Assembly - Remove and Install

8.38.3 Removal

Fully extend the arm and bucket. Lower

the work equipment completely on the
ground. Place the hydraulic lockout con-
trol in the LOCKED position.

1. Hoist up the boom cylinder assembly (1),

remove the locknut of pin and dismount the 2
pin (2) of cylinder head.
1

.
De al
ZX75-1006373
★ Check the number and thickness of

pt
shims removed and store them in a
safe place. g n 3
o
2. Lower the boom cylinder assembly on a 5
stand.
in ti

3. Disconnect the hoses (3) and (4), and tie

them to the valve.
et a
n

★ Plug the disconnected hoses. 4

ZX75-1006374
rk er

4. Disconnect the wiring connector (5) of the

work lamps.
Ma t

F
5. Hoist up the work equipment assembly and
In

remove the shims. Remove the root pin roll

(6) with the tool F. Remove the work equip-
ment assembly (7).
6

ZX75-1006375

★ Check the number and thickness of

shims removed and store them in a
safe place.
7

Work equipment AS: 1122 kg

ZX75-1006376

8-210 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.39.1 Install

● Reverse the removing sequence to install

the assembly.

Apply grease on bushing surface:

EP G2-LI grease
Apply grease after installation of
pin roll: EP G2-LI grease
Do not put your finger in the pinhole while
aligning it.

.
★ Adjust shim thickness so that the clearance

De al
between piston rod (10) and bracket (11) is

pt
between 0.5 and 0.8 mm.
11
g n
★ Std. shim thickness: 0.5 mm, 1.0 mm
o
in ti
Apply grease on bushing surface:
EP G2-LI grease
et a

Apply grease after installation of

10
pin roll: EP G2-LI grease ZX75-1006377
n
rk er

Do not put your finger in the pinhole while

aligning it.

★ Adjust shim thickness so that the clear-

Ma t

ance between boom (12) and bracket (13)

is between 0.5 and 0.8 mm. 12
In

★ Std. shim thickness: 0.5 mm, 1.0 mm

● Purging the air

★ Purge the air from oil cylinder.

For detailed information, see “Air in Each

13
Component - Bleed” on page 6-30.
ZX75-1006378
● Adding oil (hydraulic tank)

★ Add oil to the specific level through the

filler opening.

Start the engine to circulate oil in the

system and then check oil level again.

Shop Manual - November 2012 8-211

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.40 Bucket Assembly - Remove and Install

8.40.1 Remove

Let the back of bucket face down. Lower

the work equipment completely on the
ground. Place the hydraulic lockout con-
trol in the LOCKED position.
1
1. Loosen the nut (1) and pull out the bolt (2).
3

.
De al
★ Check the number and thickness of

pt
shims removed and store them in a
ZX75-1208002
safe place.
g n
2. Start the engine to retract the piston rod.
o
Tie the rod to prevent it from coming off.
in ti
3. Remove the pin (3) connecting the arm
and the bucket.
et a
n
rk er

★ Check the number and thickness of

shims removed and store them in a
safe place.
Ma t

4
4. Raise the work equipment and swing it to
In

remove the bucket assembly (4). ZX75-1208001

Bucket AS:

SY65C3: 211kg

SY75C3: 227kg

8-212 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.40.2 Install

● Reverse the removing sequence to install

the assembly.

Apply grease on bushing surface:

EP G2-LI grease 9
Apply grease after installation of
pin roll: EP G2-LI grease
Do not put your finger in the pinhole while
aligning it.

.
De al
★ Adjust shim thickness so that the clearance

pt
between bucket end (9) and linkage (10) is
between 0.5 and 0.8 mm. 10
g n
★ Std. shim thickness: 0.5 mm, 1.0 mm
o ZX75-1006381
in ti

Apply grease on bushing surface:

EP G2-LI grease
et a

9
Apply grease after installation of
n

pin roll: EP G2-LI grease

rk er

Do not put your finger in the pinhole while

aligning it.
Ma t

★ Install O-ring (13) securely on the end

surface of the bucket
In

10
★ Adjust number of quick change shim (14) ZX75-1006381
so that the clearance between arm end (11)
and bushing (12) is between 0.5 and 0.8
mm.

★ Std. shim thickness: 0.5 mm, 1.0 mm

Shop Manual - November 2012 8-213

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.41 Arm Assembly - Remove and Install

8.41.1 Remove

1. Remove the bucket assembly. For more in-

formation see “Bucket Assembly - Remove
3
and Install” on page 8-212.
2
2. Secure the front linkage to the arm with a
wire rope.
1
3. Retract the arm and remove the pin of arm
cylinder cap. Lower the arm and bucket
cylinder assembly (1) on the block 1 . 1

.
De al
Place the hydraulic lockout control in the

pt
ZX75-1006383
LOCKED position.

4. Place a block
and the boom.
2g nbetween the arm cylinder
o
5. Remove the latch and then the pin roll (3)
in ti
6
of the arm cylinder cap.
et a

4
★ Check the number and thickness of
n

shims and store them properly.

rk er

6. Start the engine to retract the piston rod.

Tie the rod to keep it from coming off.
Ma t

7. Disconnect the left and right hoses (4). ZX75-1006384

In

★ Plug the disconnected hoses at the

male end.

8. Remove the cotter pin and slotted nut.

Then, remove the pin (6) connecting the
arm and the boom. 1

★ Check the number and thickness of

shims and store them properly.

9. Lift the boom and swing it to remove the

arm and bucket cylinder assembly (1).

Arm, bucket cylinder AS (including ZX75-1006385

linkage): 240 kg

8-214 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.41.2 Install

● Reverse the removing sequence to install

the assembly.

Apply grease on bushing surface:

EP G2-LI grease
7 8
Apply grease after installation of
pin roll: EP G2-LI grease

Do not put your finger in the pinhole while

aligning it.

.
De al
★ Adjust shim thickness so that the clearance

pt
between piston rod (7) and bracket (8) is
between 0.5 and 0.8 mm.
g n
★ Std. shim thickness: 0.5 mm, 1.0 mm
o ZX75-1006386
in ti

Apply grease on bushing surface:

EP G2-LI grease
et a

Apply grease after installation of

n

pin roll: EP G2-LI grease 10 9

rk er

Do not put your finger in the pinhole while

aligning it.
Ma t

★ Adjust shim thickness so that the clearance

between boom end (9) and arm bottom (10)
In

is between 0.5 and 0.8 mm.

★ Std. shim thickness: 0.5 mm, 1.0 mm

● Purging the air

ZX75-1006392
★ Purge the air from oil cylinder.

For detailed information, see “Air in Each

Component - Bleed” on page 6-30.

● Adding oil (hydraulic tank)

★ Add oil to the specific level through the

filler opening.

Start the engine to circulate oil in the

system and then check oil level again.

Shop Manual - November 2012 8-215

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.42 Bucket and Arm Assembly - Remove and Install

8.42.1 Remove

Retract the bucket and arm, lower them on

a block 1 , and then place the hydraulic 2
1
lockout control in the LOCKED position.

Slowly loosen the filler cap to release in-

ternal pressure of hydraulic tank.

1. Place a block 2 between the arm cylinder 1

and the boom.

.
De al
pt
2. Remove the latch and then the pin roll (1) ZX75-1006388
of the arm cylinder cap.
g no
★ Check the number and thickness of
shims and store them properly.
in ti
3
3. Start the engine and retract the piston rod.
Tie the rod to prevent it from coming off.
et a
n

4. Disconnect the left and right hoses (2). 2

rk er

★ Plug the hoses disconnected at the

male end.
Ma t

ZX75-1006389
5. Remove the latch and then the pin (3) con-
In

necting the arm and the boom.

4
6. Lift the boom and swing it in order to re-
move the bucket and arm assembly (4).

★ Check the number and thickness of

shims and store them properly.

Bucket and Arm AS: 470kg

ZX75-1006390

8-216 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.42.2 Install

● Reverse the removing sequence to install

the assembly.

Apply grease on bushing surface: 7 8

EP G2-LI grease

Apply grease after installation of

pin roll: EP G2-LI grease

Do not put your finger in the pinhole while

aligning it.

.
De al
★ Adjust shim thickness so that the clearance

pt
between piston rod (7) and bracket (8) is
between 0.5 and 0.8 mm.
g n
★ Std. shim thickness: 0.5 mm, 1.0 mm
o ZX75-1006391
in ti

Apply grease on bushing surface:

EP G2-LI grease
et a

Apply grease after installation of

n

pin roll: EP G2-LI grease 10 9

rk er

Do not put your finger in the pinhole while

aligning it.
Ma t

★ Adjust shim thickness so that the clear-

ance between boom (9) and bracket (10) is
In

between 0.5 and 0.8 mm.

★ Std. shim thickness: 0.5 mm, 1.0 mm

● Purging the air

ZX75-1006392
★ Purge the air from oil cylinder.

For detailed information, see “Air in Each

Component - Bleed” on page 6-30.

● Adding oil (hydraulic tank)

★ Add oil to the specific level through the

filler opening.

Start the engine to circulate oil in the

system and then check oil level again.

Shop Manual - November 2012 8-217

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.43 Boom Assembly - Remove and Install

8.43.1 Remove

1. Remove the bucket assembly. 1

For more information see “Bucket and Arm

Assembly - Remove and Install” on page 8-216.

2. Lower the boom assembly fully on the

2
ground. Place the hydraulic lockout control
in the LOCKED position.

.
De al
ZX75-1006393
3. Lift the boom assembly (1), remove the

pt
latch and dismount the top pin roll (2).

g n
★ Check the number and thickness of
o
shims and store them properly.
3
5
in ti
4. Lower the boom cylinder assembly onto
the bracket.
et a

5. Disconnect the hoses (3) and (4). Tie them

n

4
to the platform. ZX75-1006394
rk er

★ Plug the disconnected hoses on the

end of male connector. F
Ma t

6. Disconnect the lead connector (5) of work

In

lamp.

7. Lift the boom assembly and remove the

6
press plate. Then, remove the pin roll (6) at
the root of boom with tool F. ZX75-1006395

8. Hoist the boom assembly (7).

★ Check the number and thickness of

shims and store them properly. 7

Boom AS (with arm cylinder):

516 kg
ZX75-1006396

8-218 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.43.2 Install

● Reverse the removing sequence to install

the assembly.

Apply grease on bushing surface:

EP G2-LI grease

Apply grease after installation of

pin roll: EP G2-LI grease
11
Do not put your finger in the pinhole while
aligning it.

.
De al
★ Adjust shim thickness so that the clearance

pt
between piston rod (10) and bracket (11) is
between 0.5 and 0.8 mm.
g n
★ Std. shim thickness: 0.5 mm, 1.0 mm
o
10
in ti
ZX75-1006397

Apply grease on bushing surface:

EP G2-LI grease
et a

Apply grease after installation of

n

pin roll: EP G2-LI grease

rk er

Do not put your finger in the pinhole while

12
aligning it.
Ma t

★ Adjust shim thickness so that the clear-

ance between boom (12) and bracket (13)
In

is between 0.5 and 0.8 mm.

★ Std. shim thickness: 0.5 mm, 1.0 mm

● Purging the air

13
★ Purge the air from oil cylinder. ZX75-1006398

For detailed information, see “Air in Each

Component - Bleed” on page 6-30.

● Adding oil (hydraulic tank)

★ Add oil to the specific level through the

filler opening.

Start the engine to circulate oil in the

system and then check oil level again.

Shop Manual - November 2012 8-219

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.44 Dozer Blade Assembly – Remove and Install

8.44.1 Remove

Swing the work equipment by 45°, and

lower the work equipment onto the
ground. Lower the dozer blade onto the
ground and stop the engine. Cycle the
blade control lever 2-3 times in order to
release the residual pressure in hydraulic
circuit.

Slowly loosen the filler cap to release

.
De al
the internal pressure of hydraulic tank.

pt
Place the hydraulic lockout control in the
LOCKED position.
g no
1. Remove the dozer blade cylinder guard
plate (1). 1
in ti

2. Hoist the dozer blade cylinder assembly (2)

and remove the pin roll (3) at the boom.
et a
n
rk er

★ Start the engine, retract the blade cylin-

der piston rod and put it on a block.
Ma t

ZX75-1006399
★ Check the number and thickness of
In

shims and store them properly.

ZXT75-1006400

8-220 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

3. Lift the blade assembly and remove the left

and right pin rolls (4).

★ Check the number and thickness of

3
shims and store them properly.

4. Remove the blade assembly (5).

Dozer blade assembly: 300 kg

ZXT75-1006401

.
De al
pt
5 4

g no
in ti
et a

ZX75-1006402
n

8.44.2 Install
rk er

● Reverse the removing sequence to install

Ma t

the assembly.
In

Do not put your finger in the pin hole when

aligning it.

★ Install the shims securely.

Do not put your finger in the pin hole when

aligning it.

★ Install the shims securely in their origi-

nal places.

Shop Manual - November 2012 8-221

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8.45 Cab Assembly – Remove and Install

8.45.1 Remove
1
Disconnect the cable from the negative (-)
post of battery.

1. Remove the floor mat

2. Remove the preheat controller harness (1)

and fuse box harness (2).

ZXT75-1006403

.
De al
pt
g no
in ti
et a

2
n
rk er

ZXT75-1006404
Ma t
In

8-222 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

3. Disconnect the grounding wire (3) and the

relay harness (4).

ZXT75-1006405

.
De al
pt
4
g no
in ti

ZXT75-1006408
et a

4. Disconnect the safety relay harness (5),

n

preheat relay harness (6) and cab harness

(7).
rk er

5
Ma t

7
In

ZXT75-1208003

ZXT75-1208004

Shop Manual - November 2012 8-223

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

5. Disconnect washer hose (8).

★ Mark the positive and negative end

of the connector to avoid wrong re-
connection. 8

6. Remove the four mounting bolts of the cab.

★ Check the location of chassis ground-

ing connection.

7. Hoist away the cab assembly (9). ZXT75-1208005

.
Cab AS: 276 kg

De al
pt
9
g no
in ti
et a
n
rk er

ZXT75-1208006

8.45.2 Install
Ma t
In

● Reverse the removing sequence to install

the assembly.

8-224 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.46 Counterweight Assembly - Remove and Install

8.46.1 Removal

1. Remove the left rear cover (1) and the right

rear cover (2).

3
2. Remove the eight bolts (3) connecting the
rear bracket and the counterweight.
3

.
De al
pt
ZXT75-1006412

g no
3
in ti
3
et a
n

2
rk er
Ma t

ZXT75-1006413
In

3. Remove the spray can (4) and relay

mounting plate (5).

ZXT75-1208007

Shop Manual - November 2012 8-225

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. Install the eyebolts on the counterweight.

Hoist up the counterweight.

5. Remove the mounting bolts and hoist away

the counterweight assembly (6).

Counterweight AS: 767 kg

6
ZXT75-1208008

.
De al
pt
8.46.2 Install

the assembly.
g n
● Reverse the removing sequence to install
o
in ti

Threads of counterweight mounting

et a

bolt:
n

Thread adhesive: (LT-2)

rk er

Counterweight mounting bolt:

Ma t

549.2±58.8 N·m
In

★ Installation of counterweight requires

making adjustment so that the left and
right clearances and the step differ-
ences are identical.

8-226 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Disassembly and Assembly

8.47 Monitor Assembly - Remove and Install

8.47.1 Remove

First disconnect the cable from the nega-

tive (-) post of battery.

1. Remove the cover (1). 1

★ Lift the cover to remove it.

2. Remove the three screws and then the 2

.
De al
monitor assembly (2).

pt
ZXT75-1006416
★ Disassemble the monitor lead connec-
g n
tor from the location (2).
o
in ti
et a

8.47.2 Install
n
rk er

● Reverse the removing sequence to install

the assembly.
Ma t
In

Shop Manual - November 2012 8-227

Disassembly and Assembly SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

t.
ADGe al
pE
n
nPg o
i
ti ta
n
ArNk er
eK
Ma t
BL In

8-228 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Maintenance Standard

Maintenance Standard

.
9 Maintenance Standard

De al
pt
9.1 Swing Machinery ..................................................................................................... 9-3
9.2 Swing Bearing.......................................................................................................... 9-4
g n
9.3 Track Frame............................................................................................................. 9-5
o
9.4 Idler .......................................................................................................................... 9-7
in ti
9.5 Track Roller.............................................................................................................. 9-9
9.6 Track Shoe..............................................................................................................9-11
9.7 Control Valve ......................................................................................................... 9-14
et a

9.8 Oil Source Control Valve........................................................................................ 9-18

n

9.9 Work Equipment and Swing Pilot Valve ................................................................. 9-19

rk er

9.10 Travel Pilot Valve ................................................................................................. 9-21

9.11 Work Equipment .................................................................................................. 9-23
9.11.1 Work equipment dimension ........................................................................ 9-25
Ma t

9.12 Hydraulic Cylinder................................................................................................ 9-27

In

Shop Manual - November 2012 9-1

Maintenance Standard SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.

9-2 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Maintenance Standard

9 MAINTENANCE STANDARD

9.1 Swing Machinery

KYB swing mechanism

157±10 Nm

2.45±0.49Nm

.
De al
70±1.0 Nm 373±20 Nm

pt
z-z
g n
z
o
z
in ti
et a
n
rk er

15.7±0.8Nm

177±10 Nm
Ma t

15.7±0.8Nm
In

24.5±4.9Nm

ZX75-1007001

Shop Manual - November 2012 9-3

Maintenance Standard SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

9.2 Swing Bearing

S S
A

.
De al
pt
g no
B
in ti
et a

B A-A
n

1
rk er
Ma t
In

B-B

ZX75-1007002

Unit: mm

No. Check item Criteria Remedy

Standard clearance Clearance limit

1 Bearing axial clearance Replace
0.04-0.20 0.5

9-4 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Maintenance Standard

9.3 Track Frame

SY65C3

177+19Nm

.
De al
pt
g no
in ti
2 177+19Nm
et a
n
rk er
Ma t

1 3
In

ZX65-1007003

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit
Vertical width of Track frame Repair
1 62 66
idler guide
Idler 60 64 Repair or replace
Horizontal width Track frame 161 165 Repair
2
of idler guide Idler 160 156 Repair or replace
Standard size Repair limit
Installation Installation Installation
3 Tension spring Free length Free length Replace
length load load
387 349 37.2KN — —

Shop Manual - November 2012 9-5

Maintenance Standard SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

SY75C3, SY75C9

279+30Nm

.
De al
pt
g no
in ti
2
177+19Nm
et a
n
rk er
Ma t

1 3
ZX75-1007004
In

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit
Vertical width of Track frame Repair
1 75 79
idler guide
Idler 73 69 Repair or replace
Horizontal width Track frame 157 161 Repair
2
of idler guide Idler 156 156 Repair or replace
Standard size Repair limit
Installation Installation Installation
3 Tension spring Free length Free length Replace
length load load
410 323 47.4K±3.79N — —

9-6 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Maintenance Standard

9.4 Idler

SY65C3

.
De al
pt 6
1

g no
in ti
et a

7
n

ZX75-1007005
rk er

Unit: mm

No. Check item Criteria Remedy

Ma t

Standard size Repair limit

In

1 Outside diameter of flange

372 –
2 Outside diameter of tread 340 332
Repair or replace
3 Width of flange 53 47
4 Total width 110 102
5 Width of tread 28.5 32
Standard Tolerance Standard Clearance
Clearance between shaft size Shaft Hole clearance limit
6
and bushing -0.250 +0.062 0.250- Replace bushing
44 1.5
-0.290 0 0.352
7 Idler axial play Repair limit: 1.5

Shop Manual - November 2012 9-7

Maintenance Standard SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

SY75C3, SY75C9

3
5

.
De al
pt 2

1
6
g no
in ti
et a

7
n

ZX75-1007006
rk er

Unit: mm

No. Check item Criteria Remedy

Ma t

Standard size Repair limit

In

1 Outside diameter of flange

460 –
2 Outside diameter of tread 415 407
Repair or replace
3 Width of flange 43 37
4 Total width 100 92
5 Width of tread 28.5 32
Standard Tolerance Standard Clearance
Clearance between shaft size Shaft Hole clearance limit
6
and bushing -0.250 +0.062 0.250- Replace bushing
44 1.5
-0.290 0 0.352
7 Idler axial play Repair limit: 1.5

9-8 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Maintenance Standard

9.5 Track Roller

SY65C3

3 4

1
2

.
5

De al
pt
g no 7
in ti
et a

ZX55-1007006
n

Unit: mm
rk er

No. Check item Criteria Remedy

Outside diameter of flange Standard size Repair limit

1
(outer) 122 —
Ma t

Repair or
2 Outside diameter of tread 95 87
In

replace
3 Width of tread 23.5 26.5
4 Width of flange 26.5 23.5
Standard Tolerance Standard Clearance
Clearance between shaft size Shaft Hole clearance limit
5
and bushing -0.050 +0.180 0.23-
35 1.5
-0.075 +0.320 0.395
Replace
Standard Tolerance Standard Interference
bushing
Interference between roller size Shaft Hole interference limit
6
and bushing +0.160 +0.039 0.081-
39 —
+0.120 0 0.16
Standard clearance Clearance limit
7 Roller side clearance
2.5~3.5 —
Standard size Repair limit Repair or
8 Thickness of tread
25 22 replace

Shop Manual - November 2012 9-9

Maintenance Standard SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

SY75C3, SY75C9

3 4

1
2
5

.
De al
pt
7
g no
in ti
et a

ZX75-1007008
n

Unit: mm
rk er

No. Check item Criteria Remedy

Outside diameter of flange Standard size Repair limit

1
(outer) 138 —
Ma t

Repair or
2 Outside diameter of tread 110 102
In

replace
3 Width of tread 48 51
4 Width of flange 21 18
Standard Tolerance Standard Clearance
Clearance between shaft size Shaft Hole clearance limit
5
and bushing -0.060 +0.3 0.210-
40 1.5
-0.090 +0.15 0.39
Replace
Standard Tolerance Standard Interference
bushing
Interference between roller size Shaft Hole interference limit
6
and bushing +0.14 +0.024 0.020-
44 —
+0.090 -0.016 0.15
Standard clearance Clearance limit
7 Roller side clearance
2.5~3.5 —
Standard size Repair limit Repair or
8 Thickness of tread
33 29 replace

9-10 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Maintenance Standard

9.6 Track Shoe

Triple-grouser track shoe and swamp land track shoe

L
154
154 L 154 L

.
De al
3

pt
1 9

g no
6 5 7
in ti
et a

2
n
rk er
Ma t
In

11

10

ZX55-1007007

Shop Manual - November 2012 9-11

Maintenance Standard SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

SY65C3

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit
1 Link pitch
135 138
Reverse or replace
Outside diameter of
2 35 31
bushing
3 Height of shoe rib 14 7 Weld flange or repair
before reaching repair
4 Link height 67 63 limit
Standard Tolerance Standard Clearance

.
De al
Interference between size Shaft Hole clearance limit
5

pt
bushing and link Shaft 35 +0.05 +0.07 0.18- Replace if interfer-
—
Hole 34.7 -0.05 0 0.35 ence limit is exceeded

6 g n
Interference between
regular pin and link
o Shaft 24 +0.025 +0.06
Hole 22 -0.025 0
0.235-
0.345
—

Replace with one of

Clearance between Shaft 21.92 +0.03 +0.06 0.05-
in ti
7 — larger size if repair
master pin and link Hole 22 0 0 0.11
limit is not reached
Shoe bolt tightening
8 216±20 Nm Tighten
et a

torque
n

Thickness of track Standard clearance Clearance limit

9 Weld flange or repair
shoe 6 —
rk er

Thickness of link
10 (bushing press-fitting 13.2 10 Repair or replace
Ma t

portion)
In

11 Thickness of bushing 6.15 4 Reverse or replace

9-12 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Maintenance Standard

SY75C3, SY75C9

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit
1 Link pitch
154 157
Reverse or replace
Outside diameter of
2 41.2 37.2
bushing
3 Height of shoe rib 20 13 Weld flange or repair
before reaching repair
4 Link height 75 71 limit
Standard Tolerance Standard Clearance

.
De al
Interference between size Shaft Hole clearance limit
5

pt
bushing and link Shaft 41.2 +0.030 +0.06 0.21- Replace if interfer-
—
Hole 40.9 -0.030 0 0.33 ence limit is exceeded

6 g n
Interference between
regular pin and link
o Shaft 24.1
Hole 23.8
+0.025 +0.06
-0.025 0
0.215-
0.325
—

Replace with one of

Clearance between Shaft 23.78 0 +0.06 0.02-
in ti
7 — larger size if repair
master pin and link Hole 23.8 -0.03 0 0.11
limit is not reached
Shoe bolt tightening
8 290±20 Nm Tighten
et a

torque
n

Thickness of track Standard clearance Clearance limit

9 Weld flange or repair
shoe 6 —
rk er

Thickness of link
10 (bushing press-fitting 14.4 12.4 Repair or replace
Ma t

portion)
In

11 Thickness of bushing 8.25 4.75 Reverse or replace

Shop Manual - November 2012 9-13

Maintenance Standard SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

9.7 Control Valve

SY65C3

Ls 溢流阀拧紧力矩：
45±10% Nm
T P LS T1

.
42±10% Nm

De al
pt
g no T3
in ti

P2
et a
n
rk er
Ma t
In

70±10% Nm

M
LS T1

ZX75-1007010

9-14 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Maintenance Standard

SY75C3, SY75C9

91+9.5Nm
28.5±3.1kgf m

.
De al
pt
8B 8A

g no 7B

6B
7A

6A
in ti
5B 5A

4B 4A
et a

3B
n

3A
rk er

2B 2A

1B 1A
Ma t
In

ZX75-1007011

Shop Manual - November 2012 9-15

Maintenance Standard SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

44.7 Nm
33.9 Nm
65+/-6.8 Nm

.
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pt
g no
in ti
et a

ZXT75-1007012
n
rk er
Ma t

65Nm
100.3Nm
In

9.5Nm
ZXT75-1007013

9-16 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Maintenance Standard

65Nm

.
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pt
g no
in ti
ZXT75-1007014
et a
n
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Ma t
In

Shop Manual - November 2012 9-17

Maintenance Standard SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

9.8 Oil Source Control Valve

MA=100±10Nm

1 MA=10±1Nm
e

.
5

De al
а

pt
MA=10±1Nm в

g no r

n MA=100±10Nm
m
3
i
in ti
d
1 c
et a

b 4
a
MA=100±10Nm
n

5
rk er

q
MA=150±15Nm
r
Ma t

MA=10±10Nm MA=30±3Nm
In

8
j
i
10
h
g 2
MA=100±10Nm MA=15 20Nm

ZX75-1007015

9-18 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Maintenance Standard

9.9 Work Equipment and Swing Pilot Valve

SY65C3

P 1

2 T

4
3

.
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In

ZX75-1007017

Installation information:
Flange mounting area: Flatness=0.5mm
Screw head size: R=5mm
Flange fixing screw tightening torque: max=10NM
Return oil port tightening torque: max=30NM

Shop Manual - November 2012 9-19

Maintenance Standard SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

SY75C3, SY75C9

Ls溢流阀拧紧力矩：
44.7± 4.7 Nm

.
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In

ZX75-1007018

9-20 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Maintenance Standard

9.10 Travel Pilot Valve

SY65C3

1 2 1 2 1 2

P
3 4 3 4

.
3 4

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In

View A side

Installation information:
Flange mounting area: Flatness=0.5mm
Screw head size: R=8mm
Flange fixing screw tightening torque: Max.=40Nm
Piping joint tightening torque: Max.=30Nm

ZX75-1007019

Shop Manual - November 2012 9-21

Maintenance Standard SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

SY75C3, SY75C9

.
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pt
T

g no
P
in ti
1 3
et a

36.3±2.0Nm 370±20kg.fcm
n
rk er
Ma t
In

36.3±2.0Nm 370±20kg.fcm
2 1

4 3

ZX75-1007020

9-22 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Maintenance Standard

9.11 Work Equipment

F C

G E B

.
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O

pt
N
H
L
g no
in ti
1 2 5
et a
n

M-M
A-A E-E H-H
rk er

6
Ma t
In

B-B N-N
J-J

F-F

3 7

O-O
C-C G-G K-K

L-L
D-D

ZX75-1007022

Shop Manual - November 2012 9-23

Maintenance Standard SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Unit: mm

Criteria
No. Check item Standard Tolerance Standard Clear- Remedy
size Shaft Hole clearance ance limit
Clearance between pin connect-
-0.03 +0.147 0.130-
1 ing boom and revolving frame and 60 1.0
-0.06 +0.100 0.234
bushing
Clearance between pin connect- -0.03 +0.147 0.130-
2 60 1.0
ing boom and arm and bushing -0.06 +0.100 0.234

Clearance between pin connect- -0.025 +0.142 0.105-

3 50 1.0
ing rock bar and arm and bushing -0.05 +0.08 0.192

.
De al
Clearance between pin connect-
-0.025 +0.142 0.105-

pt
4 ing rock bar and linkage and 50 1.0 Replace
-0.05 +0.08 0.192
bushing

5
g n
Clearance between pin connect-
ing linkage and bucket and bush-
o
50
-0.025
-0.05
+0.142
+0.08
0.105-
0.192
1.0
ing
in ti
Clearance between pin connect- -0.025 +0.142 0.105-
6 50 1.0
ing arm and bucket and bushing -0.05 +0.08 0.192
et a

Clearance between pin connect-

-0.025 +0.142 0.105-
7 ing chassis and dozer blade and 45 1.0
n

-0.05 +0.08 0.192

bushing
rk er
Ma t
In

9-24 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Maintenance Standard

9.11.1 Work equipment dimension

1. Arm

19
A
11
C A
12 5
B B
13 6
10
C 14

.
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8 7

pt
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17 15 4 1
et a
n

3 2
18 16
rk er
Ma t
In

ZX75-1007023

Unit: mm

No. SY65C/SY75C No. SY65C/SY75C

1 φ60 11 417
2 66 12 359
3 212 13 310
4 φ60 14 977
5 178 15 φ50
6 251 16 188
7 452 17 φ50
8 1622 18 200
9 1757 Max. 1120
19
10 255 Max. 1850

Shop Manual - November 2012 9-25

Maintenance Standard SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2. Bucket

2 5

22 21 11 7
18
19
6
16 9 16

4 17
1 3
8

.
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15 9 15

pt
20

12 10
g n
11
o
13
in ti
ZX75-1007024

Unit: mm
et a
n

No. SY65C/SY75C No. SY65C/SY75C

1 294 12 41
rk er

2 97 13 298
3 107 14 φ17
Ma t

4 319 15 φ83
In

5 971 16 φ83
6 108 17 84
7 - 18 76
8 - 19 63
9 φ50 20 63
10 200 21. 225
11 57 22 30

9-26 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Maintenance Standard

9.12 Hydraulic Cylinder

Boom/Arm/Bucket/Dozer blade
686.7+69.7N M Boom/Arm/Bucket/Dozer blade
735.8+73.6N M

.
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pt
g no
ZX75-1007025
in ti

Unit: mm
et a

Criteria
n

No. Check item Standard Tolerance Standard Clear- Remedy

Cylinder
rk er

size Shaft Hole clearance ance limit

Boom 65 – – – –
Clearance bet ween
Arm 60 – – – – Replace
1 piston rod and bush-
Ma t

Bucket 55 – – – – bushing
ing
In

Dozer 50 – – – –
Boom 65 – – – –
Clearance bet ween
Arm 50 – – – –
2 piston rod support pin
Bucket 50 – – – – Replace
and bushing
Dozer 70 – – – – support pin
Clearance bet ween or bushing
3 cylinder bottom sup- Boom 65 – – – –
port pin and bushing

Shop Manual - November 2012 9-27

Maintenance Standard SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

ptE
.
DeG l
Pg Aona
in ti
etK a
n
ArkNer
Ma t
BL In

9-28 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Engine

.
10 Engine

De al
pt
10.1 General ................................................................................................................ 10-5
10.1.1 General maintenance precautions ............................................................. 10-5
g n
10.1.2 Reading guide ............................................................................................ 10-5
o
10.1.3 Technical data and specifications ............................................................ 10-10
in ti
10.1.4 Tightening torque ......................................................................................10-11
10.1.5 Fixing nuts and bolts for key parts ........................................................... 10-13
10.1.6 Engine maintenance and servicing .......................................................... 10-21
et a

10.1.7 Lubricating system ................................................................................... 10-22

n

10.1.8 Fuel system.............................................................................................. 10-23

rk er

10.1.8.1 Fuel filter ......................................................................................... 10-23

10.1.8.2 Water separator (optional) .............................................................. 10-24
10.1.8.3 Air bleeding ..................................................................................... 10-24
Ma t

10.1.8.4 Fuel injector .................................................................................... 10-25

In

10.1.9 Cooling system ........................................................................................ 10-28

10.1.10 Thermostat ............................................................................................. 10-29
10.1.11 Valve clearance – adjust ........................................................................ 10-30
10.1.12 Injection timing ....................................................................................... 10-32
10.1.13 Compression pressure – measure ......................................................... 10-33
10.1.14 Engine repair kit ..................................................................................... 10-35
10.2 Engine Assembly – Disassemble....................................................................... 10-36
10.2.1 General .................................................................................................... 10-36
10.2.2 Disassemble ............................................................................................ 10-37
10.2.3 Rocker shaft and rocker arm.................................................................... 10-51
10.2.4 Cylinder head ........................................................................................... 10-53
10.2.5 Piston and connecting rod ....................................................................... 10-55
10.2.6 Camshaft, camshaft timing gear and thrust plate .................................... 10-58

Shop Manual - November 2012 10-1

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.3 Engine Assembly – Inspect and Repair ............................................................. 10-60

10.3.1 Cylinder head ........................................................................................... 10-60
10.3.2 Valve guide .............................................................................................. 10-62
10.3.3 Valve and valve seat ring ......................................................................... 10-64
10.3.4 Valve spring ............................................................................................. 10-68
10.3.5 Rock shaft and rocker arm ....................................................................... 10-69
10.3.6 Cylinder block .......................................................................................... 10-72
10.3.7 Tappet and push rod ................................................................................ 10-80
10.3.8 Camshaft.................................................................................................. 10-82
10.3.9 Camshaft and camshaft bearing .............................................................. 10-84
10.3.10 Crankshaft and bearing.......................................................................... 10-87

.
10.3.11 Flywheel and ring gear ........................................................................... 10-96

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pt
10.3.12 Piston ..................................................................................................... 10-97
10.3.13 Piston ring .............................................................................................. 10-98
g n
10.3.14 Piston pin ............................................................................................. 10-100
o
10.3.15 Connecting rod..................................................................................... 10-102
10.3.16 Idle gear shaft and idle gear ................................................................ 10-103
in ti
10.4 Engine Assembly – Assemble.......................................................................... 10-105
10.4.1 Rocker shaft and rocker arm.................................................................. 10-105
et a

10.4.2 Cylinder head ......................................................................................... 10-106

n

10.4.3 Piston and connecting rod ..................................................................... 10-109

10.4.4 Camshaft, camshaft timing gear and thrust plate ...................................10-112
rk er

10.4.5 Aluminium casting type timing gear housing PTO – Assemble .............. 10-131
10.5 Lubricating System .......................................................................................... 10-142
Ma t

10.5.1 Technical data and specifications ......................................................... 10-142

In

10.5.2 General .................................................................................................. 10-143

10.5.3 Oil pump................................................................................................. 10-144
10.5.4 Main oil filter ........................................................................................... 10-145
10.5.5 Oil pump – disassemble......................................................................... 10-146
10.5.6 Oil filter with built-in oil cooler – Disassemble ........................................ 10-150
10.5.7 Oil filter with built-in oil cooler – Inspect and repair................................ 10-151
10.5.8 Oil filter with built-in oil cooler – Assemble ............................................. 10-152
10.6 Cooling System ............................................................................................... 10-154
10.6.1 Technical data and specifications .......................................................... 10-154
10.6.2 General .................................................................................................. 10-155
10.6.3 Water pump .......................................................................................... 10-156
10.6.4 Water pump – Inspect and repair .......................................................... 10-157
10.6.5 Water pump – Disassemble ................................................................... 10-158

10-2 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.6.6 Water pump – Assemble ........................................................................ 10-161

10.6.7 Thermostat – inspect and repair ............................................................ 10-164
10.7 Fuel System .................................................................................................... 10-165
10.7.1 Technical data and specifications ......................................................... 10-165
10.7.2 General ................................................................................................. 10-166
10.7.3 Fuel filter and water separator .............................................................. 10-169
10.7.4 Injector – Disassemble........................................................................... 10-170
10.7.5 Injector – inspect and repair .................................................................. 10-172
10.7.6 Injector –Assemble ................................................................................ 10-173
10.7.7 Injector – adjust...................................................................................... 10-175
10.7.8 Dual injection type injector– Disassemble ............................................. 10-176

.
10.7.9 Dual injection type injector – Assemble and adjust ................................ 10-178

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10.7.10 Injection pump calibration data ........................................................... 10-190
10.7.11 Governor adjustment............................................................................ 10-193
g n
10.8 Engine Electrical System ................................................................................. 10-194
o
10.8.1 Starter motor .......................................................................................... 10-194
10.8.2 General .................................................................................................. 10-196
in ti
10.8.3 Electrical system – disassemble ............................................................ 10-197
10.8.4 Electrical system – inspect and repair ................................................... 10-202
et a

10.8.5 Electrical system – assemble................................................................. 10-208

n

10.8.6 Selection of lube oil and tightening torque ............................................. 10-209

10.8.7 Performance testing ............................................................................... 10-210
rk er

10.9 Alternator ..........................................................................................................10-211

10.9.1 General .................................................................................................. 10-212
Ma t

10.9.2 Alternator – Disassemble ....................................................................... 10-213

In

10.9.3 Alternator – Inspect and repair ............................................................... 10-216

10.9.4 Alternator – Assemble ............................................................................ 10-221
10.10 Troubleshooting ............................................................................................. 10-223
10.10.1 Startup failures ..................................................................................... 10-224
10.10.2 Engine unstable at idle ........................................................................ 10-228
10.10.3 Low power............................................................................................ 10-231
10.10.4 Excessive fuel consumption................................................................. 10-235
10.10.5 Excessive oil consumption ................................................................... 10-237
10.10.6 Engine overheating .............................................................................. 10-238
10.10.7 White smoke ........................................................................................ 10-240
10.10.8 Black smoke......................................................................................... 10-241
10.10.9 Low oil pressure ................................................................................... 10-242
10.10.10 Abnormal engine noise ...................................................................... 10-244

Shop Manual - November 2012 10-3

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.11 List of Special Tools ....................................................................................... 10-247

10.12 Repair Standard............................................................................................. 10-249

.
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In

WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.

10-4 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10 ENGINE
10.1 General
10.1.1 General maintenance precautions

1. Remove the grounding wire from the bat- they are inspected or installed. Oil orifices
tery before any engine maintenance is per- and other holes shall be cleaned with
formed in order to prevent the wiring from compressed air to make sure they are not
being damaged or burned due to a short clogged.
circuit.
7. The rotating and sliding potion of all parts
2. Choose proper maintenance tools. Use shall be lubricated with lube oil or grease

.
special tools if specified. before installation.

De al
pt
3. Use genuine Sany spare parts. 8. Apply sealant onto gaskets, if necessary,
to prevent leaks.
g n
4. Do not reuse any cotter pins, gaskets, O-
o
rings, washers and self-locking nuts. Dis- 9. Bolts and nuts shall be tightened to speci-
card non-reusable parts once they have fied torques.
in ti
been removed and replace them with new
parts. 10. Relieve the residual pressure in any ma-
chine-mounted gas containers before dis-
et a

5. Removed parts shall be kept clean and assembling the engine, or disconnecting
n

well grouped to facilitate future installation. pipe lines and hoses. Failure to do so may
Fasteners shall be sorted out in groups result in a hazardous situation.
rk er

since rigidity and design may vary depend-

ing on the location of installation. 11. Always check for a second time the job you
have done. Maintenance is not completed
Ma t

6. All parts shall be rinsed or cleaned before without this procedure.

In

10.1.2 Reading guide

1. Refer to the Table of Contents at the be- 4. Cross-reference is provided when several
ginning of this section to find your desired different parts share the same mainte-
information. nance procedures.

2. General technical features (e.g. mainte- 5. Simple disassembling and assembling pro-
nance items, maintenance requirement cedures are omitted for the sake of conve-
and tightening torques are listed under nience. More complicated procedures are
“General” . explained in detail, however.

3. Each part is divided into such subsections 6. An exploded view is provided at the begin-
as “Disassemble” , “Inspect” , “Mainte- ning of each maintenance subsection. The
nance” and “Assemble” . following is an explanation of some of the
marks used in it.

Shop Manual - November 2012 10-5

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Parts marked with (*) are included in the

Repair Kit

All parts in the same square shall be

treated as a unit during removing and
6 installation.Removing and installation
7 precedures are showns in respective
1 2
8 illustration.

The number indicates maintenance

sequence.
3 13 9
10
12 Do not remove parts not numbered unless
5 they need to be replaced.
11

.
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1617

pt
" Repair Kit" means a repair kit that
can be purchased
14
g no
Parts are listed in specified maintenance
order under "Disassembling sequence"
15 Repair kit
or "Assembling sequence"
in ti

Disassembling Sequence – 2 Removing and installation of parts marked

1.Water bypass hose with a ▲ is very important. Detailed
et a

10.Cylinder head liner

2.Thermostat shell
3.Water pump
▲ 11.Crankshaft damper belt pulley information is provided in the text.
with dust ring
n

▲4.Injector body 12. Timing gear cover

5.Preheat plug and connector 13. Timing gear cover
6.Cylinder head cover 14. Timing gear oil pipe
rk er

▲7.Rocker shaft and rocker arm 15. Idle gear "B" and shaft
8.Push rod ▲ 16. Idle gear "A"
▲9.Cylinder head 17. Idle gear shaft
Ma t
In

10-6 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

7. The following is an example of textual explanation in this section.

This is the illustrated item. Marked with a

▲ on the page of key parts.

4.Camshaft timing gear

1) Install thrust plate .
2) Apply engine oil on bolt thread .
1 3) Install camshaft timing gear with timing mark Refer to the illustration for letters and
facing outside.
Torque of camshaft timing gear bolt
figures in a circle.
2 Kg·m(lb·ft/N·m)
11.0 ± 1.0 (79.5 ± 7.2/107.8 ± 9.8)

13.Crankshaft rear oil seal

Special tools are identified by tool name

.
1) Apply engine oil on the lip and edge of oil

De al
seal. or part No. The illustration shows how to
2) Install the oil seal in the cylinder block with an

pt
oil seal installer. use the special tool.
Oil seal installer: 5-8840-0141-0

g no
14.Flywheel housing
Graphic symbol shows the category of
6 1) Place the liquid seal on the shaded area the repair work or procedure. Meanings
in ti
10
8 5
9
as illustrated. of these symbols are given below.
2) Tighten the bolts a bit at one time to
speficied toruqe in the numbered order.
2 Torque of flywheel housing bolt
kg·m(lb·ft/N·m)
et a

7 1
M10x1.25 (0.40x0.05) bolt 5.6±1.0(40.5±7.2/ 54.9±9.8)
M12x1.25 (0.47x0.05) bolt 10.5±1.0 (76.0±7.2/103.0±9.8) Maintenance data and specifications are
M12x1.75 (0.47x0.07) bolt 9.8±1.0 (71.0±7.2/ 96.0±9.8)
given in the table.
n

4
rk er
Ma t
In

Shop Manual - November 2012 10-7

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8. Graphic symbols in this section indicate the category of a maintenance task or a specific pro-
cedure to be carried out.

---Remove ---Adjust

---Install ---Clean

---Disassemble ! ---Caution

---Assemble ---Tighten to specified torque

.
De al
---Align

pt
---Special tools (ISUZU supply)

g n
---Direction
o ---Proper tools (Market available)
in ti
---Inspect ---Lubricate (oil)

---Measure ---Lubricate (grease)

et a
n

---Apply sealant
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In

10-8 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

9. A measurement will be evaluated accord-

ing to “Standard” and “Limit” . If a mea-
sured value is within the standard range,
the measured part is usable. “Limit” is
seen as an absolute value. If a measured
value exceeds the “Limit” , the measured
part shall be repaired or replaced.

10. All components and parts are in singular

forms in this section.

11. Directions in this section:

.
FRONT——Side of the cooling fan when

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pt
observed from the direction of the flywheel.

g n
RIGHT——Right side when observed in
o
the same direction.
in ti
LEFT——Left side when observed in the
same direction.
et a

REAR——Side of the flywheel.

n
rk er

Cylinders are numbered from the front to

the rear of the engine.
Ma t

The first cylinder from the FRONT is No.

In

1; and the last one has the largest serial

number.

The engine is rotating counterclockwise

when observed from the side of the
flywheel.

Shop Manual - November 2012 10-9

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.1.3 Technical data and specifications

Item Engine Model CC-4JG1

Engine type Water-cooled, 4-cycle, In-line, OHV

Combustion chamber Direct injection
Cylinder liner Dry type
No. of cylinder - bore x stroke mm(in) 4 - 95.4 x 107
Displacement lit.(cid) 3.059 (186.7)
Compression ratio 18.6
Dimension 739 x 625 x 746
Length x Width x Height mm (in) (29.1 x 24.6 x 29.4)

.
De al
Dry weight kg (lb) 248 (547)

pt
Fuel injection sequence 1 – 3– 4 – 2
Injection timing 16 ° BTDC
Fuel
Injection pump
g no Diesel fuel
In-line plunger type, Bosch A type
in ti
Governor Mechanical
-1
Low idle RPM min 1,100
Injector Multi-orifice
et a

2
Injection initiating pressure MPa(kgf/cm /psi) 18.1 (185/2630)
n

Fuel filter type Filter cartridge paper element

rk er

Water separator (if equipped) Sediment/water level indication

Compression pressure MPa(kgf/cm2/psi) 3.04 (31/441)
Valve clearance (Cold state)
Ma t

Intake valve mm(in.) 0.40 (0.0157)

In

Exhaust valve mm(in.) 0.40 (0.0157)

Lubricating method Pressure circulation
Oil pump Rotating line type
Primary oil filter type Full flow, filter cartridge, paper element
Auxiliary oil filter Not installed
Oil capacity lit.(qts) 7.6 – 9.6 (8.0 – 10.1) (only oil pan)
Oil cooler (if equipped) Water-cooler; mounted in oil filter
Cooling method Forced pressure circulation
Coolant capacity lit.(qts) 5.0 (5.3)
Water pump Belt driven impeller
Thermostat Paraffin
Alternator V-A 24 – 30
Starter motor V-kW 24 – 3.2

10-10 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.1.4 Tightening torque

Unless specified otherwise, use a required tightening torque provided in the table below.

Standard bolts
N·m( kgf·m)

ID 4 8 8 9

Dia.×pitch
(mm)
M 6 × 1.0 3.9 – 7.8 {0.4 – 0.8} 4.9 – 9.8 {0.5 – 1.0} --
M 8 × 1.25 7.8 – 17.7 {0.8 – 1.8} 11.8 – 22.6 {1.2 – 2.3} 16.7 – 30.4 {1.7 – 3.1}

.
De al
M10 × 1.25 20.6 – 34.3 {2.1 – 3.5} 27.5 – 46.1 {2.8 – 4.7} 37.3 – 62.8 {3.8 – 6.4}

pt
* M10 × 1.5 19.6 – 33.4 {2.0 – 3.4} 27.5 – 45.1 {2.8 – 4.6} 36.3 – 59.8 {3.7 – 6.1}
M12 × 1.25 49.1 – 73.6 {5.0 – 7.5} 60.8 – 91.2 {6.2 – 9.3} 75.5 – 114.0 {7.7 – 11.6}
* M12 × 1.75
M14 × 1.5
g n45.1 – 68.7 {4.6 – 7.0}
o
76.5 – 115.0 {7.8 – 11.7}
56.9 – 84.4 {5.8 – 8.6}
93.2 – 139.0 {9.5 – 14.2}
71.6 – 107.0{7.3 – 10.9}
114.0 – 171.0{11.6 – 17.4}
in ti
* M14 × 2.0 71.6 – 107.0 {7.3 – 10.9} 88.3 – 131.0 {9.0 – 13.4} 107.0 – 160.0{10.9 – 16.3}
M16 × 1.5 104.0 – 157.0 {10.6 – 16.0} 135.0 – 204.0 {13.8-20.8} 160.0 – 240.0{16.3 – 24.5}
* M16 × 2.0 100.0 – 149.0 {10.2 – 15.2} 129.0 – 194.0 {13.2 – 19.8} 153.0 – 230.0{15.6 – 23.4}
et a

M18 × 1.5 151.0 – 226.0 {15.4 – 23.0} 195.0 – 293.0 {19.9 – 29.9} 230.0 – 345.0{23.4 – 35.2}
n

* M18 × 2.5 151.0 – 226.0 {15.4 – 23.0} 196.0 – 294.0 {20.0 – 30.0} 231.0 – 346.0{23.6 – 35.3}
rk er

M20 × 1.5 206.0 – 310.0 {21.0 – 31.6} 270.0 – 405.0{27.5 – 41.3} 317.0 – 476.0 {32.3 – 48.5}
* M20 × 2.5 190.0 – 286.0 {19.4 – 29.2} 249.0 – 375.0 {25.4 – 38.2} 293.0 – 440.0 {29.9 – 44.9}
M22 × 1.5 251.0 – 414.0 {25.6 – 42.2} 363.0 – 544.0 {37.0 – 55.5} 425.0 – 637.0 {43.3 – 64.9}
Ma t

* M22 × 2.5 218.0 – 328.0 {22.2 – 33.4} 338.0 – 507.0 {34.5 – 51.7} 394.0 – 592.0 {40.2 – 60.4}
In

M24 × 2.0 359.0 – 540.0 {36.6 – 55.0} 431.0 – 711.0 {43.9 – 72.5} 554.0 – 831.0 {56.5 – 84.7}
* M24 × 3.0 338.0 – 507.0 {34.5 – 51.7} 406.0 – 608.0 {41.4 – 62.0} 521.0 – 782.0 {53.1 – 79.7}

Items with an asterisk (*) are bolts used for female thread parts made of soft material (e.g. cast
iron).

Shop Manual - November 2012 10-11

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Unless specified otherwise , use tightening torque in the table below.

Flange bolt

N
N·m(
m( kgf
kgf·m)
m)

ID
4 8 9

Dia.×pitch(mm)
M 6 × 1.0 4.6 – 8.5 {0.5 – 0.9} 6.6 – 12.2 {0.6 – 1.2} ———————————
M 8 × 1.25 10.5 – 19.6 {1.1 – 2.0} 15.3 – 28.4 {1.6 – 2.9} 18.1 – 33.6 {2.1 – 3.4}
M10 × 1.25 23.1 – 38.5 {2.4 – 3.9} 35.4 – 58.9 {3.6 – 6.1} 42.3 – 70.5 {4.3 – 7.2}

.
* M10 × 1.5 22.3 – 37.2 {2.3 – 3.8} 34.5 – 57.5 {3.5 – 5.8} 40.1 – 66.9 {4.1 – 6.8}

De al
pt
M12 × 1.25 54.9 – 82.3 {5.6 – 8.4} 77.7 – 117.0 {7.9 – 11.9} 85.0 – 128.0 {8.7 – 13.0}
* M12 × 1.75 51.0 – 76.5 {5.2 – 7.8} 71.4 – 107.0 {7.3 – 10.9} 79.5 – 119.0 {8.1 – 12.2}
M14 × 1.5
* M14 × 2.0
g n
83.0 – 125.0 {8.5 – 12.7}
o
77.2 – 116.0 {7.9 – 11.8}
115.0 – 172.0 {11.7 – 17.6} 123.0 – 185.0{12.6 – 18.9}
108.0 – 162.0 {11.1 – 16.6} 116.0 – 173.0{11.8 – 17.7}
M16 × 1.5 116.0 – 173.0 {11.8 – 17.7} 171.0 – 257.0 {17.4 – 26.2} 177.0 – 265.0{18.0 – 27.1}
in ti
* M16 × 2.0 109.0 – 164.0 {11.2 – 16.7} 163.0 – 244.0 {16.6 – 24.9} 169.0 – 253.0{17.2 – 25.8}
Items with an asterisk (*) are bolts used for female thread parts made of soft material (e.g. cast
et a

iron).
n
rk er
Ma t
In

10-12 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.1.5 Fixing nuts and bolts for key parts

Cylinder head cover, cylinder head, and rocker shaft bracket

N·m (kgf·m/lb·ft)

8-18
(0.8-1.8/5.8-13)

.
De al
pt
49-59
g no (5.0-6.0/36-43)
in ti
et a

10-20
(1.0-2.0/7.2-14)
n
rk er

第 1步 第 2步 第 3步
4 4 -5 4
6 0 -7 5 6 0 -7 5
（ 4 .5 -5 .5 /3 3 -4 0 ）
Ma t

涂抹机油
In

FD75-1008005

Shop Manual - November 2012 10-13

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Crankshaft bearing cap, connecting rod bearing cap, crankshaft belt pulley, fly-
wheel, and oil pan

N·m (kgf·m/lb·ft)

113-123

.
(11.5-12.5/83-90)

De al
27-31 45-60

pt
(2.8-3.2/20-23)

g n
157-177
o
(16-18/116-130)
in ti

197-240
et a

(20.1-24.5/145-177)
n
rk er
Ma t
In

14-24
(1.4-2.4/10-17)

FD75-1008006

10-14 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Timing gear housing, flywheel housing, camshaft and timing gear

N·m (kgf·m/lb·ft)

M10×1.25 35-45(3.6-4.6/26-33)
M12×1.5 74-91(7.5-9.3/54-67)

.
14-24

De al
(1.4-2.4/10-17)

pt
g no
in ti
et a
n

14-24
(1.4-2.4/10-17)
rk er

14-24
(1.4-2.4/10-17)
Ma t

98-118 14-24
(10-12/72-87) (1.4-2.4/10-17)
In

10-15
(1.0-1.5/7-11)
66-85
(6.7-8.7/48-63)
FD75-1008007

Shop Manual - November 2012 10-15

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Cooling system and lubricating system

N·m (kgf·m/lb·ft)

14-24
(1.4-2.4/10-17)

.
De al
pt
g no
14-24
(1.4-2.4/10-17)
in ti
et a
n

14-24
rk er

(1.4-2.4/10-17)
Ma t
In

14-24
(1.4-2.4/10-17)

14-24
(1.4-2.4/10-17)

FD75-1008008

10-16 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Intake and exhaust manifold

N·m (kgf·m/lb·ft)

.
De al
pt
14-24
g n
(1.4-2.4/10-17)
o 29-39
(3.0-4.0/22-29)
in ti
et a
n
rk er
Ma t
In

14-24
(1.4-2.4/10-17)

FD75-1008009

Shop Manual - November 2012 10-17

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Engine electrical system

N·m (kgf·m/lb·ft)

15-20
14-24 (1.5-2.0/11-14)

.
(1.4-2.4/10-17)

De al
pt
g no 14-24
(1.4-2.4/10-17)
in ti
et a
n
rk er
Ma t
In

66-86
(6.7-8.7/48-63)

FD75-1008010

10-18 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Fuel injection system

N·m (kgf·m/lb·ft)

.
De al
20-39
(2.0-4.0/14-29)

pt
g no
in ti
31-43
(3.2-4.4/23-32) 14-24
(1.4-2.4/10-17)
et a
n

14-24
(1.4-2.4/10-17)
rk er
Ma t
In

14-24
(1.4-2.4/10-17)

14-24
(1.4-2.4/10-17)
14-24
(1.4-2.4/10-17)

FD75-1008011

Shop Manual - November 2012 10-19

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Fuel injection system

N·m (kgf·m/lb·ft)

.
De al
pt
g no
in ti
et a
n
rk er

20-39
(2.0-4.0/14-29)
Ma t
In

14-24
(1.4-2.4/10-17)
14-24
(1.4-2.4/10-17)

FD75-1008012

10-20 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.1.6 Engine maintenance and servicing

Maintenance and servicing means the general

maintenance procedures carried out by pro-
fessional service personnel.

For maintenance schedule such as replace-

ment of fuel filter and oil filter, refer to the Op-
eration and Maintenance Manual.

Engine model identification

FD75-1008013

.
Engine serial No.:

De al
pt
The serial number is located at the left back
side of the engine.
g no
Injection pump identification
in ti
Adjust fuel injection amount according to the
adjusting parameters of the injection pump. A
et a

Injection pump ID number (A) is located on the Pump No. ............................

n

NP-PE .............................................
identification label as shown. (LICENCE BOSCH)
rk er

Note: A Identification number

In-line type FD75-1008014

Be sure to check the ID number prior to repair
Ma t

and maintenance operation.

In

Maintenance data of the injection pump may

differ depending on the ID number. Reference
to wrong maintenance data may reduce en-
gine performance and damage the engine.

ZEXEL (manufacturer) ID. number

ISUZU part No.

MAKER 1
ASS’Y NO.
INJ.PUMP
ASS’Y NO. 2

Distributor type
FD75-1008015

Shop Manual - November 2012 10-21

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.1.7 Lubricating system

Primary oil filter

Replace

1. Loosen the drain plug and discharge

oil.

2. Tighten the drain plug after a few min-

utes.

3. Turn the old oil filter counterclockwise

.
with a filter wrench to remove it.

De al
pt
4. Clean the mounting surface of the oil
cooler.
g no
This facilitates the mounting of a new
FD75-1008016

filter.
in ti

5. Apply a thin coat of engine oil on the O-

ring.
et a
n

6. Install and tighten the new oil filter until

the O-ring contacts the sealing surface.
rk er
Ma t
In

7. Further tighten it by another 1.25 turns.

8. Check oil level and add oil to meet

specified level if necessary.

9. Start the engine and check for oil leak

starting with the primary oil filter.

FD75-1008017

10-22 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.1.8 Fuel system

10.1.8.1 Fuel filter

Replace

1. Turn the oil fuel filter counterclockwise

with a filter wrench to dismount the fil-
ter.

.
De al
pt
g no FD75-1008016
in ti
2. Clean the mounting surface of the top
cover to facilitate the mounting of the
new fuel filter.
et a
n
rk er
Ma t

FD75-1008018
In

3. Apply a thin coat of engine oil on the O-

ring.

4. Fill fuel into the new filter for the fuel

system air bleeding operation.

5. Install and tighten the new fuel filter un-

til the O-ring contacts the sealing sur-
face.

Be careful not to let any fuel spill. FD75-1008019

6. Further tighten the filter by 1/3 to 2/3

turn with a filter wrench.

Shop Manual - November 2012 10-23

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.1.8.2 Water separator (optional)

1. Check the water level inside the water

separator .

2. If water level reaches mark , loosen 2

the drain plug at the bottom of the

water separator to drain the water. 1

3
FD75-1008020

Drain plug tightening torque

.
De al
N·m (kgf·m/lb·ft)

pt
9 – 15 (0.9 – 1.5/7 – 11)

g no
in ti
10.1.8.3 Air bleeding

3
Engine with in-line type injection pump
et a
n

1. Loosen the handle of the fuel feed 2

pump on the injection pump.

rk er

2. Loosen the fuel return bolt on the

fuel filter. 1
Ma t
In

3. Keep operating the fuel feed pump until FD75-1008021

no foam can be observed in the fuel
seeping out of return bolt on the fuel fil-
ter.

4. Tighten the fuel return bolt on the fuel

filter.

5. Loosen the air vent bolt and check if

air is completely released by operating
the fuel feed pump.

6. Operate the fuel feed pump several

times to check for fuel leaks in adjacent
areas of the injection pump and the fuel FD75-1008022
filter.

10-24 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.1.8.4 Fuel injector

Inspection

Inspect the starting pressure of the injector

and the spray pattern using an injector tester.

If the starting pressure is higher or lower than

specified, or if atomizing condition is N/G, re-
place or repair the injector.

Injector starting pressure

MPa (kgf/cm2 /psi)

.
De al
FD75-1008024
18.1 (185/2,630)

pt
g n
Double injection type
o
MPa (kgf/cm2 /psi)
in ti
1st 19.5 (199/2,830)
2nd 26.5 (270/3,840)
et a

Atomizing condition
n
rk er

(1) OK 1 2 3

(2) N/G (clogged nozzle)

Ma t

(3) N/G (dribbling)

In

FD75-1008025

Shop Manual - November 2012 10-25

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Adjusting

1. Clamp the injector with a bench vice.

2. Remove the locknut of the injector with

a wrench.

3. Install the injector tip , push rod ,

spring and shim .

Locknut tightening torque

N·m(kgf·m/lb·ft)

.
39 – 49 (4.0 – 5.0/29 – 36)

De al
FD75-1008026

pt
g n
4. Install the injector on the tester.
o
1
5. Apply pressure on the injector tester
in ti
and check if the injector opens under
specified pressure.
et a

Thickness of shim
n

mm(in.) 3 2
4
rk er

Range 0.1 – 0.59 (0.0039 – 0.023)

FD75-1008027

Warning:
Ma t

Highly pressurized testing liquid in the tes-

In

ter may spurt out. Keep your hands away

from the tester at all times.

10-26 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Adjusting (Double injection type)

● Use special tools shown in the illustration

when adjusting the starting pressure of the Dial indicator

injector.

● Refer to the detailed information in Section

8. Nut

Check nut

Measuring rod

.
De al
pt
Injector casing
g no
in ti
1st spring seat
et a
n
rk er
Ma t
In

FD75-1008028

FD75-1008029

Shop Manual - November 2012 10-27

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.1.9 Cooling system

Cooling fan belt

Adjustment of cooling fan belt is achieved

through moving the alternator.
D
A Crankshaft belt pulley
C

B Alternator belt pulley B

C Cooling fan belt pulley

A

.
D Apply a pressing force of 98 N (10kgf/22

De al
lb·ft) onto the intermediate section of the

pt
belt.
FD75-1008030

Belt deflection g no
mm(in.)
in ti
10.0 (0.39)
et a
n
rk er
Ma t
In

10-28 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.1.10 Thermostat

Test

1. Submerge the thermostat completely in

water.

Keep stirring the water to prevent heat

from being transmitted to the thermo-
stat directly.

2. Heat the water.

.
De al
pt
FD75-1008031
3. Check the temperature when the ther-
g n
mostat starts to open.
o
in ti
First opening temperature 1
°C (°F)
82 (180)
et a

2
n

4. Check the temperature of the thermo-

rk er

stat when it is fully open.

Ma t

3
Fully-opening temperature
In

°C (°F) FD75-1008032

95 (203)

Valve lift at full opening

mm(in.)
8.0 (0.315)

Thermostat

Stirring rod

Wood block

Shop Manual - November 2012 10-29

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.1.11 Valve clearance – adjust

1. Tighten the rocker shaft bolts in the il-

lustrated order.

Rocker shaft bolt tightening torque

N·m (kgf·m/lb·ft) 3 1 2 4
49 – 59 (5 – 6/36 – 43)

FD75-1008033

.
2. Rotate the crankshaft until the TDC

De al
mark on the belt pulley aligns with the

pt
timing pointer so that piston of cylinder
No. 1 or No. 4 is at the top dead center
g n
(TDC) of compression stroke.
o
TDC
in ti
3. Check the rocker shaft of the intake/ex-
haust valve of cylinder No. 1 for clear-
ance.
et a

If clearance is observed, piston of

n

cylinder No. 1 is at TDC of compression

stroke.
rk er

FD75-1008034

If the rocker shaft is pressed down,

piston of cylinder No. 4 is at TDC of
Ma t

compression stroke.
In

Adjust valve clearance when cylinder No. 1

or No. 4 is at TDC of compression stroke.

Valve clearance

mm(in.)
0.40 (0.016)

Loosen the valve clearance adjusting

screw as shown. (The illustration shows FD75-1008035
when cylinder No. 1 is at TDC of compres-
sion stroke)

10-30 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Insert a feeler gauge of proper thickness

between the rocker shaft and valve stem.

4. Turn the valve clearance adjusting

screw until a slight resistance is felt on
the feeler gauge.

5. Tighten the locknut securely.

FD75-1008036

.
Turn the crankshaft by 360°.

De al
pt
Realign the TDC mark on the crankshaft
belt pulley with the timing pointer.
g no
Adjust the valve clearance of other valves
as shown. (The illustration shows when
in ti
cylinder No. 4 is at TDC of compression
stroke)
et a

FD75-1008037
n
rk er
Ma t
In

Shop Manual - November 2012 10-31

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.1.12 Injection timing

Inspection

In-line type injection pump

1) Rotate the crankshaft clockwise until

timing mark “O” of crankshaft gear
aligns with the pointer on the timing
gear housing.

Cylinder No. 1 is at a position close to

injection timing.

.
De al
2) Disconnect the fuel injection pipe of cyl-

pt
inder No. 1. FD75-1008038

g no
3) Remove delivery valve seat , spring 1
in ti
and delivery valve of cylinder No. 1. 2

4) Tighten delivery valve seat to the speci- 3

et a

fied torque.
n

Delivery valve seat tightening torque

rk er

N·m (kgf·m/lb·ft)
39 – 44 (4.0 – 4.5/29 – 33)
Ma t

FD75-1008039
In

5) Operate the fuel feed pump on the in-

jection pump and turn the crankshaft
slowly at the same time until fuel stops
flowing out of delivery valve seat.

6) Check if the mark on crankshaft belt TDC17

pulley aligns with the pointer on the tim-
ing gear housing.

Injection timing (static, BDTC)

16°
FD75-1008040

10-32 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

7) Remove the delivery valve seat.

2
8) Install delivery valve and spring
3 1
and delivery valve seat .

9) Tighten the delivery valve seat to speci-

fied torque.

10) Connect the fuel injection pipe and

tighten it to the specified torque.
FD75-1008041
Fuel injection pipe tightening torque
N·m (kgf·m/lb·ft)

.
De al
20 – 39 (2 – 4/15 – 29)

pt
1) Air bleeding operation.
g no
10.1.13 Compression pressure – measure
in ti

1. Start the engine and run it for several

minutes to warm up.
et a
n

2. Stop the engine and cut off fuel supply.

rk er

3. Remove all preheat plugs.

Pressure gauge: 5-8840-2675-0

Ma t
In

Pressure gauge connector: 5-8840-

9029-0
4. Install the pressure gauge and the con-
nector onto the slot of preheat plug of
cylinder No. 1.

5. Rotate the engine with the starter mo-

tor and note down the pressure gauge
reading.

Compression pressure @ 200 rpm

MPa (kgf/cm2 /psi)
Standard Limit
3.04 (31/441) 2.2 (22/313)

Shop Manual - November 2012 10-33

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Recommended lube oil

Engine model Lube oil

Without turbocharger Engine lube oil ≥ tier CD
With turbocharger Engine lube oil ≥ tier CD

Engine oil viscosity table

.
De al
Viscosity grade -- Ambient temperature

pt
Single grade
g no
SAE 20,20W SAE40
in ti
SAE 10W SAE 30

Ambient temp
-30℃ -15℃ -0℃ 15℃ 25℃ 30℃
et a

（-22°F） （5°F） （32°F） （59°F） （77°F）

（86°F）
n

Multiple grade SAE 10W-30

rk er

SAE 15W-40,20W-40
Ma t

FD75-1008363
In

10-34 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.1.14 Engine repair kit

All the numbered parts listed below are included in the Engine Repair Kit.

Parts marked with (*) are also included in the Overhaul Kit.

3 20
19

2
17
18

.
De al
15 14
5

pt
10
13 19
12 11
g no 1 6

19
in ti
4

7
9
et a
n
rk er
Ma t

8
In

16
FD75-1008045

* 1. Cylinder head gasket 11. Water pump gasket

* 2. Cylinder head cover gasket 12. Water outlet pipe gasket
* 3. Cylinder head cover bolt gasket * 13. Thermostat gasket
4. Water drain plug gasket * 14. Intake manifold gasket
5. Crankshaft rear oil seal * 15. Exhaust manifold gasket
6. Gear housing gasket 16. Crankshaft front oil seal
7. Gear housing cover gasket * 17. Injector O-ring
8. Oil pan oil drain plug gasket * 18. Injector gasket
9. Oil pan gasket 19. Connecting bolt gasket
10. Oil filter gasket 20. Vacuum pump pipe gasket

Shop Manual - November 2012 10-35

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.2 Engine Assembly – Disassemble

10.2.1 General

The illustration blow is based on A-4JG1 en-

gines of the 4J series.

.
De al
pt
g no
in ti
et a
n
rk er

FD75-1008046

● 4J series industrial diesel engines use is very durable. Thanks to this design, the
Ma t

ISUZU concave combustion chamber. This cylinder head bolt needs no further tighten-
unique design improves fuel economy in a ing.
In

wide range of working conditions.

● Tufftride crankshaft has a long service life.
● Temperature auto compensating piston The crankshaft needs no further grinding.
with cast iron bushing reduces thermal ex-
pansion and engine noise under cold state. ● The crankshaft main bearing and connect-
ing rod bearing is aluminium plated. They
● Chrome-plated dry type cylinder liner pro- are very sensitive to foreign objects such
vides excellent durability. as metal chips. Keeping oil holes and other
related part clean and free of foreign ob-
● Stack-up steel plate cylinder head gasket jects is of great importance.

10-36 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.2.2 Disassemble

The following illustration is based on model A-4JG1 engines.

18 17 16 3 78 5 12 11 13 10

.
De al
pt
g no
in ti
et a

15 19 4 2 1 6 9 14 19
n
rk er

FD75-1008047

Disassembling sequence – 1
Ma t

1. Cooling fan and air duct ▲11. Fuel injection pipe with pipe clamp
In

2. Cooling fan belt ▲12. Injection pump

3. Cooling fan belt pulley 13. Intake manifold
4. Alternator and adjustment plate 14. Starter motor
5. Fuel pipe (fuel filter to injection pump) 15. Oil filter
6. Fuel pipe (fuel filter to fuel feed pump) 16. Cooling water hose
7. Fuel pipe (fuel filter return pipe) 17. Cooling water inlet pipe
8. Fuel filter ▲18. Exhaust manifold
9. Oil pipe (injection pump to cylinder block) 19. Mounting bracket (right and left)
10. Oil return pipe
Note:

Disassembling sequence may vary depending on specific engine model.

Shop Manual - November 2012 10-37

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

! Important operation (Disassembling sequence – 1)

11. Fuel injection pipe with pipe clamp

1) Loosen the sleeve nut of the fuel in-

jection pipe at the side of the delivery
valve.

Do not apply excessive force onto the

fuel injection pipe.
FD75-1008048
2) Loosen the clamp of the fuel injection
pipe.

.
De al
pt
3) Remove the fuel injection pipe.

g no
in ti
et a

FD75-1008049
n
rk er

12. Injection pump

1) Remove the six injection pump brack-

Ma t

et bolts from the timing gear housing.

In

2) Remove rear bracket bolt from the

rear bracket of the injection pump.

3) Pull out the injection pump along with FD75-1008050

the timing gear.

Note:

Protect the opening of the delivery valve seat

with tapes or similar material to prevent for-
eign objects from entering.

10-38 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

18. Exhaust manifold

4 8 5 1
Loosen the exhaust manifold bolts in the
illustrated order a bit at one time.

3 7 6 2
FD75-1008052

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-39

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2 7
1

.
De al
pt
3 9
13
g no
10
in ti
12

5
et a

11 4
n
rk er

17
16
Ma t
In

14 Repair kit

15 FD75-1008053

10-40 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Disassembling sequence – 2

1. Cooling water bypass hose 10. Cylinder head gasket

2. Thermostat cover ▲11. Crankshaft belt pulley with dust seal
3. Water pump 12. Timing gear housing cover (optional)
▲4. Injector 13. Timing gear cover
5. Preheat plug and preheat plug connector 14. Timing gear lube oil pipe
6. Cylinder head cover 15. Idle gear “B” and shaft
▲7. Rocker shaft and rocker arm ▲16. Idle gear “A”
8. Push rod 17. Idle gear shaft
▲9. Cylinder head

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-41

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

15 14

13
5
3

10
12

.
De al
pt
11
g no
2a
in ti
8
et a

9
7
n
rk er
Ma t

4
In

1a Repair kit

FD75-1008054

10-42 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Disassembling sequence – 3

1. Oil pan ing

▲2. Flywheel ▲9. Crankshaft bearing cap with lower bear-
2a. Rear flywheel (if equipped) ing
3. Flywheel housing 10. Crankshaft thrust bearing
4. Oil pump with oil piping 11. Crankshaft with timing gear
▲5. Camshaft with timing gear and thrust ▲12. Crankshaft upper bearing
plate ▲13. Tappet
6. Timing gear housing 14. Crankshaft rear oil seal
▲7. Connecting rod cover with lower bearing 15. Cylinder block
▲8. Piston & connecting rod with upper bear-

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-43

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

! Important operation (Disassembling sequence – 2)

4. Injector

1) Remove the bracket nut of the injector.

FD75-1008055

.
De al
pt
2) Remove the fuel injector with bracket

weight.
g n
using an injector remover and a sliding
o
in ti

Injector remover: 5-8840-2034-0

et a

Sliding weight: 5-8840-0019-0

n
rk er

FD75-1008056
Ma t

7. Rocker arm and rocker shaft

In

Loosen the bracket bolt of the rocker

shaft in the illustrated order a bit at one
time.

Note:
1 3 4 2

Failure to loosen the bolt in the illustrated

order a bit at one time may have a nega- FD75-1008057
tive effect on the rocker shaft.

10-44 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

9. Cylinder head

Loosen the cylinder head bolt in the illus- 6 14 15 7

trated order a bit at one time. 10 11
2 3

Note:
17
1 13 16 12 4
5
Failure to loosen the bolt in the illustrated 9
order a bit at one time may have a nega- 8
tive effect on the lower surface of the cylin-
der head. FD75-1008058

.
De al
11. Crankshaft belt pulley with dust ring

pt
1) Choke the flywheel with a wood block
g n
to prevent it from spinning.
o
2) Remove the belt pulley with a belt pul-
in ti
ley remover.

Belt pulley remover:

et a
n

FD75-1008059
rk er

16. Idle gear “A”

Before removing idle gear “A” and shaft,

Ma t

inspect camshaft timing gear clearance,

In

crankshaft timing gear clearance and

idle gear “A” end play.

Shop Manual - November 2012 10-45

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Timing gear clearance – measure

1) Place the dial gauge at the timing gear

to be measured.

Keep the gear to be measured and the

gear around static.

2) Move the gear to be measured to the

left and to the right side as far as you
can.

Record the reading on the dial gauge.

FD75-1008060

.
De al
Replace the timing gear if the measured

pt
value exceeds the specified limit.

Timing gear clearance

g n mm(in.)
o
Gear Standard
in ti
Camshaft gear – Idle gear A 0.032–0.060
Crankshaft gear – Idle gear A 0.032–0.066
et a

Idle gear A– Idle gear B 0-0.035

n

Idle gear B– Injection pump gear 0-0.029

rk er

Idle gear “A” end play – measure

Ma t

Insert a feeler gauge in between the idle

gear and the thrust ring and measure the
In

clearance.

Replace the thrust ring if the measured

value exceeds the limit.

Idle gear end play

mm(in.)
Standard Limit
FD75-1008061
0.08 – 0.18 (0.003–0.007) 0.30 (0.012)

10-46 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

! Important operation (Disassembling sequence – 3)

2. Flywheel

1) Choke the flywheel with a wood block to

prevent if from spinning.
1
5 4
2) Loosen the flywheel bolt in the illustrated
order a bit at one time. 3 6
2

.
De al
FD75-1008062

pt
plate
g n
5. Camshaft with timing gear and thrust
o
in ti
1) Remove the thrust plate bolt.

2) Push the camshaft freely in the direction of

et a

the camshaft timing gear and thrust plate.

n

Note:
rk er

Be careful not to damage the camshaft jour-

nal, cam and camshaft during this process. FD75-1008063
Ma t
In

7. Connecting rod cover with lower bearing

If the connecting rod lower bearing is to be

.1
NO

installed later, attach a tag to each of the

bearings with the corresponding cylinder
number on it.

FD75-1008064

Shop Manual - November 2012 10-47

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

8. Piston and connecting rod with upper

bearing

1) Before removing the piston and the con-

necting rod, remove the carbon deposit on
the top surface of the cylinder with a scrap-
er.

2) Move the piston to the top of the cylinder

and tap the bottom of the connecting rod
with a hammer handle or similar tools to
remove it.
FD75-1008065

.
De al
pt
If the connecting rod upper bearing is to be
installed later, attach a tag to each of the bear-

on it.
g n
ings with the corresponding cylinder number
o
in ti
NO.1
et a
n
rk er

FD75-1008066
Ma t

9. Crankshaft bearing cap with lower bear-

ing
In

1) Measure the crankshaft end play at the

center of crankshaft journal.

This step shall be carried out before the

removal of crankshaft bearing cap.

Replace the crankshaft thrust bearing if the

measured value exceeds the limit.
FD75-1008067

Crankshaft end play

mm(in.)
Standard Limit
0.10 (0.0039) 0.30 (0.0118)

10-48 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

2) Loosen the bolt of crankshaft bearing cap

in the illustrated order a bit at one time.

If the crankshaft bearing is to be installed 3 2

7 10 6
later, attach a tag to each of the bearings
with the corresponding cylinder number on
it.
8 9
4 5 1

FD75-1008068

.
12. Crankshaft upper bearing

De al
pt
If the crankshaft upper bearing is to be
installed later, attach a tag to each of the
g n
bearings with the corresponding cylinder
number on it.
o
in ti
et a

FD75-1008069
n

13. Tappet
rk er

If the tappet is to be installed later, attach

a tag to each of the tappets with the cor-
Ma t

responding cylinder number on it.

In

NO.1

FD75-1008070

Shop Manual - November 2012 10-49

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

14. Crankshaft rear oil seal (axial type)

Remove the flywheel cover.

Since the oil seal is deeply pushed in, it

shall be removed using a special tool as
illustrated.

Oil seal remover: 5-8840-2360-0

FD75-1008071

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

10-50 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.2.3 Rocker shaft and rocker arm

.
De al
pt
2
g no
7
in ti

5
1
et a

4
n

3
rk er

FD75-1008072

Disassembling sequence
Ma t

▲1. Snap ring 5. Spring

In

▲2. Rocker arm 6. Snap ring

▲3. Bracket 7. Rocker shaft
4. Rocker arm

Shop Manual - November 2012 10-51

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

! Important operation

1. Rocker shaft snap ring

2. Rocker arm

3. Rocker shaft bracket

1) Remove the snap ring with a snap ring

pliers.

2) Remove the rocker arm.

.
De al
3) Remove the rocker shaft bracket.

pt
If the rocker arm and rocker shaft bracket
g n
is to be installed later, attach a tag to each
o
of the rocker arms and rocker shaft brack-
ets with the corresponding cylinder number
in ti
on it.
et a
n
rk er
Ma t
In

10-52 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.2.4 Cylinder head

.
De al
6

pt
g no
in ti
et a

7
n
rk er
Ma t
In

FD75-1008073

Disassembling sequence

▲1. Retainer lock 5. Valve stem oil seal

2. Upper seat 6 . Lower seat
3. Spring 7. Cylinder head
▲4. Intake/Exhaust valve

Shop Manual - November 2012 10-53

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

! Important operation

1. Retainer lock

1) Place the cylinder head on a flat wood

board.

2) Remove the retainer lock with a spring

compressor.

Be careful not to allow the valves fall

out of the cylinder head.

.
De al
Spring compressor: 9-8523-1423-0

pt
FD75-1008074

g n
4. Intake/Exhaust valve
o
in ti
If the intake/exhaust valve is to be in-
stalled later, attach a tag to each of the
intake/exhaust valves with the corre-
NO.1 NO.1
sponding cylinder number on it.
et a

EXH I N
n

If a valve is excessively worn or dam-

aged, replace it.
rk er

Refer to “Valve and valve seat ring” on

page 10-64 in “Engine Assembly - Inspect
Ma t

FD75-1008075

and Repair.
In

Note:

If the valve guide is excessively worn or

damaged, replace it.

Refer to “Valve guide – Replace” on page 10-63

in “Engine Assembly - Inspect and Repair.

Valve and valve guide shall be replaced to-

gether. Do not replace valve or valve guide
individually.

FD75-1008076

10-54 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.2.5 Piston and connecting rod

.
4

De al
pt
3
g no
5
in ti
et a
n
rk er

1
Ma t

FD75-1008077
In

Disassembling sequence

▲1. Connecting rod bearing 5. Connecting rod

▲2. Piston ring ▲6. Piston pin snap ring
▲3. Piston pin snap ring ▲7. Piston
▲4. Piston pin

Shop Manual - November 2012 10-55

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

! Important operation

1. Connecting rod bearing

If the connecting rod bearing is to be in-

stalled later, attach a tag to each of the
bearings with the corresponding cylin-
NO.1
der number on it.

FD75-1008078

.
2. Piston ring

De al
pt
1) Clamp the connecting rod with a bench
vice. g no
Be careful not to damage the connect-
ing rod.
in ti

2) Remove the piston ring with a piston

ring remover.
et a
n

Piston ring remover: FD75-1008079

rk er

Do not attempt to remove the piston

ring with other tools. Excessive expan-
sion of the piston ring may reduce its
Ma t

tension.
In

3. Piston pin snap ring

6. Piston pin snap ring

Remove the piston pin snap ring with a

snap ring pliers.

FD75-1008080

10-56 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

4. Piston pin

7. Piston

Strike the piston pin out with a hammer and a

copper bar.

If the piston is to be installed later, attach a tag

to each of the pistons with the corresponding
cylinder number on it. FD75-1008081

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-57

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.2.6 Camshaft, camshaft timing gear and thrust plate

3
1
2

.
De al
pt
g no
in ti
et a
n

FD75-1008082
rk er

Disassembling sequence
Ma t

▲1. Camshaft timing gear 3. Positioning key

In

▲2. Thrust plate 4. Camshaft

10-58 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

! Important operation

1. Camshaft timing gear

2. Thrust plate

1) Clamp the camshaft with a bench vice.

Be careful not to damage the camshaft.

.
De al
pt
g no FD75-1008083
in ti
2) Pull out the camshaft timing gear
with a clamp .
3
et a

2
Clamp: 5-8840-0086-0
n

3) Remove thrust plate .

rk er
Ma t

1
In

FD75-1008084

Shop Manual - November 2012 10-59

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.3 Engine Assembly – Inspect and Repair

If excessive abrasion and damage are ob-

served during inspection, make necessary
adjustment, repair and replacement.

10.3.1 Cylinder head

Deformation on cylinder head bottom

surface

1. Measure the circumference and the di-

.
agonal of the cylinder head bottom sur-

De al
face with a straight edge and a feeler

pt
gauge.
g n
2. If the measured value is larger than the
o
limit, but smaller than the max. grinding
quantity, grind the bottom surface of the
in ti
cylinder head once again.
FD75-1008085

If the measured value exceeds the max.

et a

grinding quantity, replace the cylinder

n

head.
rk er

Deformation of cylinder head bottom

H
mm(in)
Ma t

Max. grinding quan-

Standard Limit
tity
In

0.05(0.002)
0.2(0.008) 0.3(0.012)
or less
A

Cylinder head height (Ref.) E F

C D
B
mm(in)
Standard Limit
FD75-1008086
0.10 (0.0039) 0.30 (0.0118)

Note:

If cylinder head bottom surface is ground,

inspect valve deflection.

10-60 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Deformation of exhaust pipe mounting

surface

Measure the deformation of the exhaust

pipe mounting surface on the cylinder head
with a straight edge and a feeler gauge.

If the measured value is larger than the

limit, but smaller than the max. grinding
quantity, grind the exhaust pipe mounting
surface on the cylinder head once again.
FD75-1008087

If the measured value exceeds the max.

.
grinding quantity, replace the cylinder

De al
head.

pt
Deformation of exhaust pipe mounting sur-
face g no
mm (in)
Max. grinding quan-
in ti
Standard Limit
tity
0.05(0.002)
0.2(0.008) 0.4 (0.016)
or less
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-61

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.3.2 Valve guide

Clearance between valve stem and valve guide

Measuring method – 1

1. Insert the stem into the valve guide

and set the pointer of the dial gauge to
zero.

2. Move the valve head from one side to

another.

.
De al
Read the value on the dial gauge.

pt
Record the maximum value. FD75-1008088
g n
● If the measured value exceeds the limit,
o
replace the valve and the valve guide
in ti
together.

Valve stem clearance

et a

mm(in)
n

Standard Limit
rk er

Intake 0.039–0.069
0.020(0.008)
valve (0.0015–0.0027)
Exhaust 0.064–0.096
0.025(0.0098)
Ma t

valve (0.0025–0.0038)
In

Measuring method – 2

1. Measure the outer diameter (O.D.) of

the valve stem.

Refer to “Valve stem outer diameter” on

page 10-64.

2. Measure the inner diameter (I.D.) of the

valve guide with an inside callipers mi-
crometer or an optical gauge.

FD75-1008089

10-62 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Valve guide – Replace

Removal

Remove the valve guide from the bottom

surface of the cylinder head with a hammer
and a valve guide tool.

Valve guide tool: 9-8523-1212-0

FD75-1008090

.
De al
Installation

pt
1. Apply engine oil onto the outside of the
valve guide.
g no
2. Place the tool on the valve guide.
in ti
3. Strike the valve guide into place from
the top surface of the cylinder head
with a hammer.
et a
n

Valve guide tool: 9-8523-1212-0 FD75-1008091

rk er
Ma t
In

4. Measure the distance between valve

guide top end and cylinder head top
surface.

Valve guide top end height (H) (Ref.)

H
mm(in)
13.0 (0.512)

Note: FD75-1008092

If the valve guide is removed, replace the

valve and the valve guide together.

Shop Manual - November 2012 10-63

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.3.3 Valve and valve seat ring

Measure the diameter of the valve stem at

3 points as illustrated.

If the measured value is less than the limit,

replace the valve and valve guide together.

Valve stem outer diameter

mm(in)

.
De al
FD75-1008093
Standard Limit

pt
Intake 7.949–7.961
7.88(0.3102)
valve (0.3129–0.3134)
Exhaust
valve
g n
7.921–7.936
o
(0.3118–0.3124)
7.88(0.3102)
in ti
Valve thickness – measure

If the measured value is less than the limit,

et a

replace the valve and the valve guide to-

n

gether.
rk er

Intake/exhaust valve thickness

Ma t

mm(in)
In

Standard Limit
Intake FD75-1008094
1.79 (0.070) 1.1 (0.043)
valve
Exhaust
1.39 (0.055) 1.1 (0.043)
valve

10-64 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Valve depth

1. Install valve on the cylinder head .

2
2. Measure valve depth from the bottom
surface of cylinder head with a depth
gauge or a straight edge and a steel
ruler.

If the measured value exceeds the limit,

replace the valve seat ring.
1
Valve depth

.
De al
mm(in) FD75-1008095

pt
Standard Limit
Intake
valve
Exhaust
g n
0.65 (0.026)
o
1.10 (0.043)
1.28 (0.050)

1.60 (0.063)
valve
in ti
Width of valve contact surface
et a

1. Check the coarseness and flatness of

the contact surface of the valve.
n
rk er

Keep the contact surface smooth.

2. Measure width of the contact surface.

Ma t

If the measured value exceeds the limit,

In

replace the valve seat ring.

FD75-1008096

Valve contact surface width

mm(in)
Standard Limit
Intake
1.7 (0.067) 2.2 (0.087)
valve
Exhaust
2.0 (0.079) 2.5 (0.098)
valve

Shop Manual - November 2012 10-65

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Valve seat ring – replace

Removal

1. Heat the interior circumference of

2
valve seat ring with electrical arc. 3

2. Wait for the valve seat ring to cool

down. This will make it easier to re-
4
move the valve seat ring when it con-
tracts.

3. Pry the valve seat ring with a screw

.
driver . Be careful not to damage the 1

De al
cylinder head .

pt
FD75-1008097

4. Remove the carbon deposit and other

g n
foreign objects from the mounting hole
o
on the cylinder head.
in ti
Installation
et a

1. Set attachment (its O.D. is smaller

than that of the valve seat ring) onto
n

3
valve seat ring .
rk er

1
Note:
Ma t

The smooth surface of the attachment 2

must contact the valve seat ring.
In

2. Apply pressure slowly onto the attach-

ment with a bench press and press
the valve seat ring into place. FD75-1008098

Note:

Do not use excessive pressure, otherwise,

the valve seat ring may get damaged.

10-66 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Modification

1. Remove the carbon deposit on the sur- 150°

face of the valve seat ring. 90°
30°
2. Use a valve reamer (15°, 30°or 75°)
to strike off the scratches and coarse
parts. This helps the width of the con-
tact surface return to the standard val-
ue at 90°.

● Only strike off the scratches and coarse

areas. Do not strike too much. Be care- FD75-1008099

.
ful not to strike off smooth areas on the

De al
valve seat ring.

pt
Valve seat ring angle 45°

Note:
g no
in ti
Use adjustable valve cutter handle. Do
not allow the handle of the valve cutter to
shake inside the valve guide.
et a
n
rk er

3. Apply grinding paste on the surface of

valve seat ring.
Ma t

4. Insert the valve into valve guide.

In

5. Keep turning the vale when tapping the

valve into contact with the valve seat
ring.

6. Check if the width of valve contact sur-

FD75-1008100
face is correct.

Check if the surface of valve seat ring

is in close contact with the circumfer-
ence of the valve.

Shop Manual - November 2012 10-67

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.3.4 Valve spring

Free length

Measure the free length of valve spring

with a vernier caliper. If the measured
length is less than the limit, replace the
valve spring.
Valve spring free length
mm(in)
Standard Limit
FD75-1008101
49.7 (1.96) 48.2 (1.90)

.
De al
pt
Deflection

g n
Measure the deflection of the valve spring
with a flat board and a square.
o
in ti

If the measured value exceeds the limit,

et a

replace the valve spring.

n

Valve spring deflection

rk er

mm(in) Square

Standard Limit FD75-1008102

Ma t

1.5 (0.06) or less 2.5 (0.098)

In

Tension

Measure valve spring tension with a spring

tester. If the measured value is less than
the limit, replace the valve spring.

Valve spring tension

N(kgf/lb)
Compressed height Standard Limit
FD75-1008103
38.9 mm (1.53 in) 254(25.9/57) 225 (23/51)

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.3.5 Rock shaft and rocker arm

Eccentricity

1. Place the rocker shaft on the V-seat as

illustrated.

2. Measure the eccentricity at the interme-

diate section with a dial gauge.

● If the eccentricity is small, correct it with FD75-1008104

a bench press. The rocker shaft shall
be cold when being corrected.

.
De al
● If the eccentricity exceeds the limit, re-

pt
place the rocker shaft.
g no
Rocker shaft eccentricity
mm(in)
in ti
Standard Limit
0.2 (0.008) 0.6 (0.024)
et a
n

Outer diameter
rk er

Measure the O.D. of the rocker shaft at the

point where rocker arm is to be installed.
Ma t

If the measured value is less than the limit,

In

replace the rocker shaft.

Rocker shaft O.D.

mm(in) FD75-1008105

Standard Limit
18.98 – 19.00 (0.747 – 0.748) 18.85 (0.742)

Shop Manual - November 2012 10-69

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Clearance between rocker shaft and

rocker arm

1. Measure the inner diameter of rocker

arm bushing with a vernier calliper or a
dial gauge.

Rocker arm bushing I.D.

mm(in)
Standard Limit FD75-1008106

19.01 – 19.03 (0.748 – 0.749) 19.05 (0.750)

.
De al
pt
2. Measure the O.D. of rocker shaft.

g n
If the measured value exceeds the limit,
replace the rocker arm or the rocker shaft.
o
in ti

Rocker arm – rocker shaft clearance

et a

mm(in)
n

Standard Limit
0.01–0.05 (0.0004–0.002) 0.2 (0.008)
rk er

3. Check if the rocker arm oil hole is

Ma t

clogged.
In

Clean the oil hole with compressed air

is necessary.

FD75-1008107

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Rocker arm modification

2
● Check the contact area of the rocker
arm and valve stem for wear and
scratches .
1

● If minor wear or scratch is observed on

the contact surface, use a oil stone to
grind it.

● If serious wear or scratch is observed,

replace the rocker arm.
FD75-1008108

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-71

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.3.6 Cylinder block

Cylinder liner bore – measure

X

Measure cylinder bore at measuring point

Y Y
in the longitudinal and lateral direction
with a bore dial indicator. X

Measuring point : Max. wear point

1
[11 – 15 mm (0.43 – 0.59 in)]

If the measured value exceeds the limit,

.
replace cylinder liner.

De al
pt
FD75-1008109
Cylinder liner bore
mm(in)
Standard
g no Limit
95.421–95.460
95.5 (3.7598)
in ti
(3.7567–3.7583)

Note:
et a

Interior surface of dry type cylinder liner

n

is chrome plated and can not be bored or

rk er

ground.

Replace the cylinder liner if the interior sur-

Ma t

face is scratched or scorched.

Cylinder liner projection – inspect
In

1. Place a straight edge on top of the 1

cylinder liner to be measured.

2. Measure each cylinder liner projection

with a feeler gauge .
Cylinder liner projection
mm(in) 2

Standard
0–0.10 (0–0.0039) FD75-1008110

Projection difference between any two

adjoining cylinder liners shall not exceed
0.03mm (0.0012in).

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Cylinder liner – replace

Removal

1. Remove the positioning pin of the cylin-

der block.

2. Mount the cylinder liner remover on the

cylinder liner.

3. Check if the plate of cylinder liner is

securely clamped by the ankle of the
remover.

.
De al
4. Rotate the remover counterclockwise

pt
slowly to pull out the cylinder liner.
FD75-1008111

0
g n
Cylinder liner puller plate: 5-8840-9058-
o
in ti
Cylinder liner puller: 5-8840-9038-0
Note:
et a

Be careful not to damage the top surface

n

of the cylinder block when removing the

cylinder liner.
rk er

Deformation of cylinder block top surface

1
Ma t

1. Remove the positioning pin.

In

2. Remove the cylinder liner.

3. Measure the 4 sides and diagonal line

of the cylinder block top surface with a 2
straight edge and a feeler gauge .

Cylinder block top surface deformation

mm(in)
FD75-1008112
Standard Limit
0.05 (0.002) or less 0.2 (0.008)

If the measured value exceeds the limit,

replace the cylinder block.

Shop Manual - November 2012 10-73

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Cylinder block height (Ref.)

mm(in) H

Standard
272.945 – 273.105 (10.746 – 10.752)

4. Install the cylinder liner. A

E F
Refer to “Cylinder block bore – mea- C D
B
sure” on page 10-75.

5. Install the cylinder block positioning pin. FD75-1008113

.
De al
pt
Selection of cylinder liner class

Measure cylinder bore and choose proper

cylinder liner class. g no
in ti

Standard interference (Ref.)

mm(in)
et a

0.001 – 0.019 (0.00004 – 0.00075)

n
rk er

FD75-1008114
● Small cylinder liner interference affects
the cooling effect of the engine.
Ma t

● Large cylinder liner interference makes

In

it difficult to put cylinder liner into cylin-

der block.

● Cylinder liner class (1, 2, 3 and 4) is

marked on the top surface of the cylin-
der block with permanent ink when it is
produced to indicate the right liner size
that matches each cylinder.

● Measure cylinder block bore is the

class mark is wrong.

FD75-1008115

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Cylinder block bore – measure

1. Measure cylinder bore at point in four 1

directions W-W, X-X, Y-Y, Z-Z as illus-
trated.

Measuring point : 98 mm (3.86 in)

2. Calculate the average of 4 measure-

ments and determine the right cylinder FD75-1008116
liner class that matches the cylinder.

.
De al
X
Cylinder liner class

pt
W Z

Nominal Cylinder liner

Cylinder block bore
size g n
97.001 – 97.010
o class
1
Y Y

97.011 – 97.020 2 Z
W
in ti
φ97
97.021 – 97.030 3 X

97.031 – 97.040 4
FD75-1008117
et a
n

Installation
rk er

1. Install cylinder liner with special tools.

Ma t

1) Rinse cylinder liner and cylinder bore 1

In

surface with clear kerosene or diesel.

2

2) Dry the cylinder liner and cylinder bore

with compressed air.

Note:

Clean the cylinder liner and cylinder bore FD75-1008118

prior to installation.

Shop Manual - November 2012 10-75

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3) Insert cylinder liner into cylinder

block from top of cylinder block.

4) Place the cylinder liner installer on

top of cylinder liner.

Cylinder liner installer: 5-8840-2313-0

5) Position the cylinder block properly so

that the center line of cylinder liner in-
4
staller is right below the axis of the 3
press .

Note:

.
De al
Check if cylinder liner is positioned vertical

pt
to the press and check if the cylinder liner
moves. g no
6) Apply a initial pressing force of 500 kgf
(1,102.5 lb/4,900 N) onto the cylinder
in ti
liner with the press. FD75-1008119

7) Press the cylinder liner into place with a

et a

force of 2,500 kgf (5,512.5 lb/24,500 N).

n

8) Measure cylinder liner projection after

rk er

installation.

Refer to “Cylinder liner projection -

Ma t

inspect” on page 10-72.

In

2. Install cylinder liner with dry ice

● If cylinder liner is chrome-plated, dry

ice is recommended for installation.

● Cool the cylinder liner with dry ice for it

to contract to make installation easier.

Note:
Insert cylinder liner into cylinder block while
it is cold.

Warning:
Be careful when handling dry ice. Improper
handling may cause severe frostbite.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Selection of piston

Choose piston of the same class as cylin-

der liner.

Cylinder liner
Piston class Match
bore class
AX AX OK
CX CX OK
AX CX N/G
CX AX N/G

Selection of piston class

.
De al
Measure cylinder liner bore. Choose piston

pt
X
of proper class for the installed cylinder W Z
liner. Y Y
g no
1. Cylinder liner bore – measure
Z
X
W
in ti
1
Measuring point and

Measure cylinder liner bore at two measur- 2

et a

ing points in 4 directions W-W, X-X, Y-Y

and Z-Z .
n
rk er

FD75-1008120
Calculate the average of the 8 measure-
ments and determine the correct cylinder
liner bore.
Ma t

Measuring point : 20 mm (0.79 in)

In

: 160 mm (6.30 in)

Cylinder liner bore

mm(in)
Standard Limit
95.421–95.460
95.5 (3.7598)
(3.7567–3.7583)

Shop Manual - November 2012 10-77

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Relation between cylinder liner bore and

piston class

mm(in)
Cylinder liner bore Piston class
95.421 – 95.440
AX
(3.7567 – 3.7575)
95.441 – 95.460
CX
(3.7575 – 3.7583)

Note:

Always use piston of correct class. Use of

.
De al
wrong piston class may result in engine

pt
failure.

g n
2. Piston outer diameter – measure
o
Measuring point : 71 mm (2.79 in)
in ti
A,DD-4JG1 Piston O.D
mm(in)
et a

Piston O.D. Piston class

n

95.365 – 95.384
AX
(3.7545 – 3.7553)
rk er

95.385 – 95.404 1
CX
(3.7553 – 3.7561)
FD75-1008121
Ma t

Cylinder liner – piston clearance

In

mm(in)
0.037 – 0.075 (0.0015 – 0.0030)

Note:

Clearance between cylinder liner and pis-

ton assembly is pre-set. However, installa-
tion may reduce cylinder liner bore. Always
measure cylinder liner bore clearance to
keep this value is within specified range.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Piston O.D. (other than A, DD-4JG1)

mm(in)
Piston O.D. Piston class
95.369 – 95.384
AX
(3.7547 – 3.7553)
95.385 – 95.400
CX
(3.7553 – 3.7559)

Cylinder liner-piston clearance

mm(in)
0.051 – 0.081 (0.0020 – 0.0032)

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-79

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.3.7 Tappet and push rod

Check for spots, cracks and other abnor-

malities on the contact surface of the tap-
pet and the camshaft. Replace the tappet
when such conditions are observed.

Refer to the illustration on the right.

1. Spots 1 2 3
2. Cracks
3. Correct contact

.
De al
4. Irregular contact

pt
5. Irregular contact
4 5

Note: g no FD75-1008122

The tappet has a spherical surface. Do not

in ti
attempt to modify the tappet by grinding it
with an oil stone or similar tools. Replace
the tappet when it is damaged.
et a
n

Tappet outer diameter

rk er

Measure tappet O.D. with a micrometer. If

the measured value is less than the limit,
replace the tappet.
Ma t
In

Tappet O.D.
mm(in)
FD75-1008123
Standard Limit
12.97–12.99 (0.5106–0.5114) 12.95 (0.5098)

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Clearance between tappet and cylinder blo

ck
mm(in)
Standard Limit
0.03 (0.0012) 0.1 (0.0039)

.
FD75-1008124

De al
pt
Push rod deflection
g no
1. Place the push rod on a flat surface.
in ti
2. Roll the push rod on the flat surface
and measure the curvature with a feeler
gauge.
et a
n

● If the measured value exceeds the limit,

rk er

replace the push rod.

FD75-1008125
Ma t

Push rod curvature

In

mm(in)
Limit
0.3 (0.012)

3. Check the two ends of the push rod for

excessive wear and damage. Replace
the it if such condition is evident.

Shop Manual - November 2012 10-81

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.3.8 Camshaft

Check journal, cam, oil pump driving gear

and camshaft bearing for excessive wear X
and damage. Replace the camshaft and
camshaft bearing if such condition is evi- Y Y
dent.
X
Measure each journal diameter in two di-
rections X-X and Y-Y with a micrometer. If
the measured value is less than the limit,
replace the camshaft.

.
De al
FD75-1008126

Camshaft journal diameter

pt
mm(in)
Standard g no Limit
49.945–49.975(1.9663–1.9675) 49.60 (1.953)
in ti
Cam height
et a

Measure cam height (H) with a dial indica-

tor. If the measured value is less than the
n

limit, replace the camshaft.

rk er

Cam height (H)

Ma t

mm(in)
In

Standard Limit FD75-1008127

42.02 (1.65) 41.65 (1.64)

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Camshaft deflection

1. Position the camshaft on two V-blocks.

2. Measure camshaft deflection with a dial

indicator.

If the measured value exceeds the limit,

replace the camshaft.

Camshaft deflection
FD75-1008128
mm(in)

.
De al
Standard Limit

pt
0.02 (0.0008) 0.10 (0.004)

g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-83

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.3.9 Camshaft and camshaft bearing

Measure camshaft bearing inner diameter

with an inside dial indicator.

Camshaft bearing inner diameter

mm(in)
Standard Limit
50.0–50.03 (1.9685–1.9697) 50.08 (1.9716)

If the clearance between camshaft bearing FD75-1008129

and camshaft journal exceeds the limit, re-

.
De al
place camshaft bearing.

pt
g n
Camshaft bearing clearance
o
mm(in)
in ti
Standard Limit
0.025–0.085 (0.0010–0.033) 0.12 (0.005)
et a

Camshaft bearing – replace

n
rk er

Removal

1. Remove cylinder block plug.

Ma t

2. Remove camshaft bearing with a cam-

In

shaft bearing changer.

Bearing changer: 5-8840-2038-0

FD75-1008130

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Installation

1. Align bearing oil hole with cylinder

block oil hole.

2. Install camshaft bearing with a cam-

shaft bearing changer.

Bearing changer: 5-8840-2038-0

.
De al
FD75-1008131

pt
g n
Camshaft end play
o
1. Before removing the camshaft gear
in ti
, push thrust plate towards the cam- 1
shaft journal as far as you can.
et a

2. Measure the clearance between thrust

plate and camshaft gear with a feeler
n

gauge.
rk er

3
If the measured value exceeds the 2
limit, replace the thrust plate.
Ma t

FD75-1008132
In

Camshaft end play

mm(in)
Standard Limit
0.050–0.114 (0.002–0.0045) 0.2 (0.008)

Shop Manual - November 2012 10-85

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Thrust plate – replace

Removal 3 2

1. Remove camshaft timing gear with a

clamp .

Clamp: 5-8840-0086-0

2. Remove thrust plate .

1

.
FD75-1008133

De al
pt
Installation
g n
1. Install thrust plate.
o
in ti
2. Apply engine oil on the mounting sur-
face and thread of the bolt.
et a

3. Install camshaft gear.

n
rk er

Camshaft gear tightening torque FD75-1008134

N·m(kgf·m/lb·ft)
Ma t

98 – 118 (10 – 12/72 – 87)

In

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.3.10 Crankshaft and bearing

● Check the surface of crankshaft journal

and crank pin for excessive wear and
damage.

● Check the mounting surface of oil seal

for excessive wear and damage.

● Check if the oil hole is clogged.

Note:
The crankshaft is nitridized to improve its
rigidity. Therefore, it needs no further grind-

.
De al
ing.

pt
Crankshaft nitridation inspection Keep tested part horizontal
to prevent testing solution

g n
1. Rinse the crankshaft with organic de-
o
tergent and make sure the surface to
from flowing.

Main journal or crank

Keep oil hole adjacent area
free of testing solution.

be inspected is free of grease and oil. pin work surface

in ti
Approx.10mm
2. Prepare 5-10% copper amidochloride
solution (solved in distilled water)
et a

FD75-1008135
n

3. Apply the solution on the surface with

an injector.
rk er

Keep the inspected surface horizontal

to prevent the solution from flowing.
Ma t

Note:
In

Do not allow the solution to come into con-

tact with the oil hole and surrounding ar-
eas.
Judge

1. Wait 30 - 40 seconds.

If the color does not change within 30-

40 seconds, the crankshaft is usable.

If the color changes (the inspected

surface turns purple bronze), replace
the crankshaft.

2. Rinse the surface of the crankshaft with

clean water when testing is finished.

Shop Manual - November 2012 10-87

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Note:

Copper mercury amidochloride is highly

corrosive. Rinse the tested surface imme-
diately after the testing is over.

Crankshaft end play

Place the dial indicator as illustrated, and

measure crankshaft end play.

If the end play is larger than the limit, re-

place the thrust bearing in groups.

.
De al
Crankshaft end play

pt
mm(in)
Standard
0.10 (0.0039)
g no Limit
0.30 (0.0118)
FD75-1008136
in ti

Crankshaft eccentricity
et a

1. Position the dial indicator on the inter-

n

mediate section of crankshaft journal.

rk er

2. Rotate the crankshaft gently in normal

engine rotating direction.
Ma t

Observe the reading on the indicator

while rotating the crankshaft.
In

If the measured value exceeds the limit,

FD75-1008137
replace the crankshaft.

Crankshaft eccentricity
mm(in)
Standard Limit
0.05 (0.002) or less 0.08 (0.0031)

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Crankshaft bearing tension

Check crankshaft bearing tension. When

installing the crankshaft bearing with your
fingers, much effort shall be required.

FD75-1008138

Crankshaft journal and crank pin diam-

eter

.
De al
1 3 4

pt
1. Measure crankshaft journal diameter
2 2
with a micrometer in two directions 1-1
and 2-2. g no
1

2. Measure at point and .

in ti

3. Measure crank pin diameter in the

same manner.
et a

FD75-1008139
If the measured value is less than the
n

limit, replace the crankshaft.

rk er

Crankshaft journal diameter

mm(in)
Ma t

Standard Limit
In

69.917–69.932
69.910 (2.7524)
(2.7526–2.7531)

Crank pin diameter

mm(in)
Standard Limit
69.917–69.932
69.910 (2.7524)
(2.7526–2.7531)

Crankshaft journal & crank pin uneven

wear
mm(in)
Standard Limit
0.05 (0.002) or less 0.08 (0.0031)

Shop Manual - November 2012 10-89

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Crankshaft journal-bearing clearance

If the clearance between crankshaft bear-

ing outer diameter and crankshaft journal
diameter exceeds the limit, replace the
bearing and/or the crankshaft.

Crankshaft bearing cap bolt tightening

torque
N·m(kgf·m/lb·ft)
157–177 (16–18/116–130)

.
De al
pt
Crankshaft journal–bearing clearance
mm(in)
Standard
g no Limit FD75-1008140

0.031–0.063 (0.0012–0.0025) 0.11 (0.0043)

in ti

Connecting rod bearing inner diameter

et a

1. Place the bearing into the large end.

n
rk er

2. Tighten bearing cap to specified torque.

Conrod bearing cap bolt tightening torque

Ma t
In

N·m(kgf·m/lb·ft)
27–31 (2.8–3.2/20–23)→45°–60°

FD75-1008141
3. Measure connecting rod bearing I.D.
with an inside dial indicator.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Clearance between crank pin and bear-

ing

If the clearance between bearing O.D. and

crank pin diameter exceeds the limit, re-
place bearing or crankshaft.
Crank pin–bearing clearance
mm(in)
Standard Limit
0.029–0.066 (0.0011–0.0026) 0.10 (0.0039)

Clearance measurement (use plasti-

.
gauge)

De al
pt
Crankshaft journal–bearing clearance

g n
1. Clean cylinder block, journal & bearing
o
mating surface, bearing cap and bear-
ing.
in ti

2. Install bearing onto cylinder block.

et a

3. Install crankshaft on bearing carefully.

n

4. Rotate the crankshaft by about 30°to

rk er

set bearing into place. FD75-1008142

5. Place the plastigauge across the full

Ma t

width of the bearing and on the journal

In

as illustrated.

6. Install bearing cap together with bear-

ing.

7. Tighten bearing cap to specified torque.

Crankshaft bearing cap bolt tightening

torque

N·m(kgf·m/lb·ft)
157–177 (16–18/116–130)
FD75-1008143

Keep the crankshaft still when installing

and tightening bearing cap.

8. Remove bearing cap.

Shop Manual - November 2012 10-91

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

9. Compare the width of the plastigauge

adhered on crankshaft or bearing with
the mark on the plastigauge box.

If the measured value exceeds the limit,

proceed with the following procedure.

1) Measure crankshaft O.D. with a mi-

crometer.

2) Measure bearing I.D. with an inside dial

indicator. FD75-1008144

If the clearance between crankshaft

journal and bearing exceeds the limit,

.
De al
replace crankshaft and/or bearing.

pt
Crankshaft journal & bearing clearance

Standard
g no
Limit
mm(in)

0.031–0.063 0.0012–0.0025) 0.11 (0.0043)

in ti

Crank pin–bearing clearance

et a

1. Clean crankshaft, connecting rod, bear-

ing cap and bearing.
n
rk er

Install bearing inside connecting rod

and bearing cap.

2. Keep crankshaft still when installing

Ma t

bearing cap.
In

3. Prevent connecting rod from moving.

4. Adhere the plastigauge on crank pin.

Apply engine oil on the plastigauge to

prevent it from falling off.

5. Install bearing cap and tighten it to

specified torque.

Do not allow connecting rod to move

when installing and tightening bearing
cap.
Conrod bearing cap bolt tightening torque
N·m(kgf·m/lb·ft)
27–31 (2.8–3.2/20–23)→45°–60°

10-92 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

6. Remove bearing cap.

NO.3
NO.2 NO.4
7. Compare the width of the plastigauge NO.5
NO.1
adhered on crankshaft or bearing with
the mark on the plastigauge box.

If the measured value exceeds the limit,

proceed with the following procedure.

1) Measure crank pin O.D. with a microm-

1 2 1 1 2
eter.
FD75-1008145
2) Measure bearing I.D. with an inside dial

.
indicator.

De al
pt
If the clearance between crank pin
and bearing exceeds the limit, replace
g n
crankshaft and/or bearing.
o
Crank pin–bearing clearance
in ti
mm(in)
Standard Limit
0.029–0.066 (0.0011–0.0026) 0.10 (0.0039)
et a
n
rk er

Crankshaft bearing – select

Ma t

NO.1 NO.2 NO.5

Refer to the table below when installing a
In

new crankshaft bearing or replacing an old

bearing.

When selecting and installing a new crank-

shaft bearing, pay attention to cylinder
block journal hole diameter size mark and
crankshaft journal diameter size mark. NO.3 NO.4

FD75-1008146

Shop Manual - November 2012 10-93

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Main bearing bore mm(in) Crankshaft main journal dia. mm(in) Crankshaft bear- Oil clearance
Size mark I.D. Size mark O.D. ing size mark mm(in)
69.927~69.932 0.035~0.061
1 or - Black
(2.7530~2.7532) (0.0014~0.0024)
73.987~74.000 69.922~69.927 0.032~0.058
1 2 or --
(2.9129~2.9134) (2.7528~2.7530) (0.0013~0.0023)
Blue
69.917~69.922 0.037~0.063
3 or ---
(2.7526~2.7528) (0.0015~0.0025)
69.927~69.932 0.031~0.056
1 or -
(2.7530~2.7532) (0.0012~0.0022)
Green
73.975~73.987 69.922~69.927 0.036~0.048
2 2 or --
(2.9124~2.9129) (2.7528~2.7530) (0.0014~0.0019)

.
69.917~69.922 0.033~0.058

De al
3 or --- Black
(2.7526~2.7528) (0.0013~0.0023)

pt
g n
Crankshaft timing gear – Replace
o
1
Removal
in ti
1. Remove crankshaft gear with a
crankshaft gear remover .
et a

2. Remove crankshaft positioning pin.

n

2
rk er

Crankshaft gear remover: 9-8840-

2057-0
FD75-1008147
Ma t
In

Installation

● Install crankshaft gear with a crank-

shaft gear installer .

● Keep crankshaft gear timing mark (X-X)

facing outside.
1
Crankshaft gear installer: 9-8522-0020-
0
2

FD75-1008148

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Crankshaft guide bearing

Check crankshaft guide bearing for exces-

sive wear and damage, and replace it if
necessary.

Crankshaft guide bearing – replace

Removal

Remove crankshaft guide bearing with a

guide bearing remover. FD75-1008149

.
Guide bearing remover: 5-8840-2000-0

De al
pt
Sliding weight: 5-8840-0019-0
g no
Installation
in ti

1. Position crankshaft guide bearing on

the crankshaft bearing mounting hole
et a

horizontally.
n
rk er

2. Use a copper hammer to hit the bear-

ing along the edge of the outer groove
Ma t

FD75-1008150
of the guide bearing and strike it into
the mounting hole.
In

Guide bearing installer: 5-8522-0024-0

Note:

Do not strike the inner groove of the guide

groove. Otherwise, the bearing may be
damaged and its service life reduced.

Shop Manual - November 2012 10-95

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.3.11 Flywheel and ring gear

Flywheel

1. Check the friction surface of the fly-

1
wheel for excessive wear and heat
cracking.

2. Measure the abrasion (depth) of the

friction surface.

In reality, the friction area (shaded area)

between flywheel and clutch driven
disc is smaller than original machined

.
De al
surface.

pt
FD75-1008151
A “ridge” exists on the flywheel surface.
g n
Make sure surface abrasion is mea-
o
sured in the area surrounded by the
“ridge” .
in ti

If the measured value exceeds the limit,

replace the flywheel.
et a

Flywheel friction surface depth

n

mm(in)
rk er

Standard
1.0 (0.04) or more
Note:
Ma t

A bulging area exists on the friction surface

In

of the flywheel as shown. Do not measure

wear beyond this area. Be sure to measure
on the shaded area.
Ring gear

Inspect the ring gear.

If damage or excessive wear in evident on

ring gear teeth, replace the ring gear.

Ring gear – replace

Removal
FD75-1008152

Remove the ring gear by striking at the

edge with a hammer and a chisel.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Installation

1. Heat the ring gear evenly with a gas

burner for it to expand.

Temperature of the gas burner shall

not exceed 200°C (390°F).

2. Install the ring gear when it has been

sufficiently heated.

Install the ring gear with the chamfered FD75-1008153

side facing the clutch.

.
De al
Note:

pt
Another way to heat the ring gear is to
g n
wrap the edge of the ring gear with a die-
o
sel-soaked cloth and burn the cloth.
in ti
10.3.12 Piston
et a

Piston class selection and cylinder liner

bore measurement.
n
rk er

For information regarding piston class

selection and cylinder liner bore measure-
ment, refer to “Cylinder liner bore - mea-
Ma t

sure” on page 10-72.

In

FD75-1008154

Shop Manual - November 2012 10-97

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.3.13 Piston ring

Piston ring gap clearance 2

1
1. Insert the piston ring into the cylinder
liner horizontally.

2. Push the piston ring into the cylinder

liner with an upside-down piston until
the ring reaches measuring point or
.
FD75-1008155
Cylinder liner diameter at these two

.
points is minimal.

De al
pt
Do not allow the piston ring to tilt. It
must be positioned horizontally.
g no
3. Measure piston ring gap clearance with
a feeler gauge.
in ti

Measuring point : 10 mm (0.39 in)

et a

Measuring point : 120 mm (4.72 in)

n

If piston ring gap clearance exceeds

rk er

the limit, replace piston ring.

Ma t

Piston ring gap clearance

In

mm(in)
Standard Limit
0.2–0.35
1st compression ring
(0.008–0.014)
0.37–0.52 1.5
2nd compression ring
(0.015–0.020) (0.059)
0.2–0.4
Oil ring
(0.008–0.016)

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Clearance between piston ring and pis-

ton ring groove

Measure clearance between piston ring

and piston ring groove with a feeler gauge
at several points around the piston.

If the clearance exceeds the limit, replace

piston ring.

FD75-1008156

Clearance between piston ring and piston

.
De al
ring groove

pt
mm(in)
Standard Limit
g no
1st compression ring
0.09–0.130
(0.0035–0.0051)
in ti
0.05–0.090 0.15
2nd compression ring
(0.002–0.0035) (0.006)
0.03–0.07
Oil ring
(0.0012–0.0028)
et a

Replace piston if piston ring groove is

n

damaged or deformed.
rk er
Ma t
In

Shop Manual - November 2012 10-99

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.3.14 Piston pin

Piston pin diameter

Measure piston pin outer diameter at more

than one point with a micrometer.

If the measured value is less than the limit,

replace piston pin.

Piston pin diameter

mm(in)
FD75-1008157
Standard Limit

.
De al
33.995–34.000
33.97 (1.3374)

pt
(1.3384–1.3386)

g n
Clearance between piston pin and pis-
o
ton
in ti
Measure the piston pin hole on the piston
with an inside dial indicator.
et a

Piston pin hole

n

mm(in)
rk er

Standard
34.004 – 34.012 (1.3387 – 1.3391)
Ma t
In

Piston clearance
mm(in) FD75-1008158
0.004 – 0.017 (0.0002 – 0.0007)

Clearance between piston pin and con-

necting rod small end bushing

Measure the clearance between piston pin

and connecting rod small end bushing with
a micrometer and an inside dial indicator.

If the clearance exceeds the limit, replace

piston pin and/or connecting rod bushing.

FD75-1008159

10-100 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Clearance between piston pin and con-

necting rod small end bushing
mm(in)
Standard Limit
0.008–0.020 (0.0003–0.0008) 0.05 (0.002)

Connecting rod bushing – replace

Removal

1. Clamp the connecting rod on a bench

.
De al
vice.

pt
1. Remove connecting rod bushing with a
g n
conrod bushing remover.
o
in ti
Installation FD75-1008160
et a

1. Clamp the connecting rod with a bench

vice.
n
rk er

2. Install connecting rod bushing with a

conrod bushing installer.
Ma t
In

3. Expand the piston pin hole with a pis-

ton hole grinder that has a reamer.

1
Conrod small end bushing inner diameter
mm(in)
Standard
34.008 – 34.015 (1.3389 – 1.3392)

FD75-1008161

Shop Manual - November 2012 10-101

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.3.15 Connecting rod

Connecting rod – align

Measure the parallelism and distortion of

the large and small end of the connecting
rod with an aligner.

If distortion or parallelism exceeds the limit,

replace the connecting rod.

Connecting rod aligning

per 100mm(3.94in)

.
De al
mm(in)

pt
FD75-1008162
Standard Limit
Distortion
Parallelism
g n
0.05(0.002)
o
or less
0.20 (0.008)
0.15 (0.006)
in ti

Connecting rod side clearance

et a

1. Install the connecting rod on the crank

n

pin.
rk er

2. Measure the clearance between conrod

large end side surface and crank pin
Ma t

side surface with a feeler gauge.

In

If the measured value exceeds the limit,

replace connecting rod.

Conrod and crank pin side clearance

FD75-1008163
mm(in)
Standard Limit
0.175–0.290 (0.0069–0.0114) 0.35 (0.014)

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.3.16 Idle gear shaft and idle gear

Idle gear shaft outer diameter

Measure idle gear shaft O.D. with a mi-

crometer.

If the measured value is less than the limit,

replace idle gear shaft.

Idle gear shaft O.D.

mm(in)
Standard Limit FD75-1008164

.
De al
44.95–44.98 (1.770–1.771) 44.90 (1.767)

pt
g n
Idle gear “A” inner diameter
o
Measure the idle gear with a dial indicator.
in ti

Idle gear I.D.

mm(in)
et a

Standard Limit
n

0.175–0.290 (0.0069–0.0114) 0.35 (0.014)

rk er

If the clearance between idle gear shaft

and idle gear exceeds the limit, replace FD75-1008165
Ma t

idle gear.
In

Clearance between idle gear shaft and idle

gear
mm(in)
Standard Limit
0.025–0.085 (0.0010–0.0033) 0.2 (0.008)

Shop Manual - November 2012 10-103

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Idle gear “B”

Bearing – replace
1
Use a proper rod and a bench press or a 2
hammer.

Bearing projection shall be within specified

height.
FD75-1008166
mm(in)
Projection 0.4–0.6 (0.016–0.024)
Height 23.7–24.0 (0.933–0.945)

.
De al
pt
Timing gear housing
g n
If excessive wear or damage is evident on
o
the crankshaft front oil seal, replace it.
in ti
Crankshaft front oil seal – replace
et a

Removal
n

Remove the oil seal from the gear housing FD75-1008167

rk er

by hit the edge of it with a plastic hammer

and a screw driver.
Ma t

Be careful not to damage the mounting

surface of the oil seal.
In

Installation
1. Apply engine oil around the oil seal.

2. Place the oil seal 1mm (0.039in) in

front of the timing gear housing with an
oil seal installer and a clamp.

Oil seal installer: 5-8840-2061-0

FD75-1008168

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.4 Engine Assembly – Assemble

10.4.1 Rocker shaft and rocker arm

3 2

.
De al
4
5

pt
6

g no 1

7
in ti
FD75-1008169
et a

Assembling sequence
n

▲1. Rocker shaft 5. Rocker arm

rk er

2. Rocker shaft snap ring 6. Rocker shaft spring

3. Rocker arm 7. Rocker shaft snap ring
Ma t

4. Rocker shaft bracket

In

! Important operation

1. Rocker shaft

1) Position the rocker shaft with the large oil

hole (Dia. 4 mm (0.175in)) facing the front
of engine.

2) Install rocker shaft, rocker arm, rocker

shaft bracket and spring together.

FD75-1008170

Shop Manual - November 2012 10-105

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.4.2 Cylinder head

.
De al
2

pt
g no
1
in ti
et a
n

4
rk er
Ma t

FD75-1008171
In

Assembling sequence
1. Cylinder head ▲5. Valve spring
2. Valve spring lower seat 6. Valve spring upper seat
▲3. Valve stem oil seal ▲7. Retainer lock
▲4. Intake/Exhaust valve

10-106 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

! Important operation

3. Valve stem oil seal

1) Apply a thin coat of engine oil to the in-

terior surface of the oil seal.

2) Install the oil seal onto the valve guide

with an oil seal installer.

Oil seal installer: 5-8840-2033-0

FD75-1008172

.
De al
4. Intake/Exhaust valve

pt
1) Apply a coat of engine oil on the valve
stem. g no
2) Install intake/exhaust valve.
in ti

3) Face the cylinder head upward to in-

stall valve spring.
et a

Be careful not to drop valves that have

n

been installed.
rk er

5. Valve spring
Ma t

1) Face the cylinder head upward and in-

In

stall valve spring.

2) Install the valve spring with the short-

pitched end (shaded) facing downward.

Be careful not to drop the valves that

have been installed.

FD75-1008173

Shop Manual - November 2012 10-107

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

7. Retainer lock

1) Press valve spring into place with a

spring compressor.

Spring compressor: 9-8523-1423-0

2) Install the retainer lock onto the valve

stem.

3) Hit the periphery of the retainer lock so

with a rubber hammer so that is well
positioned. FD75-1008174

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

10-108 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.4.3 Piston and connecting rod

.
De al
4

pt
5
g no
3
in ti
et a
n
rk er

7
Ma t

FD75-1008175
In

Assembling sequence

▲1. Piston 5. Piston pin snap ring

▲2. Piston pin snap ring ▲6. Piston ring
▲3. Connecting rod ▲7. Connecting rod bearing
▲4. Piston pin

Shop Manual - November 2012 10-109

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

! Important operation

1. Piston

2. Piston pin snap ring

3. Connecting rod

1) Clamp the connecting rod with a bench

vice.

Be careful not to damage the connect-

.
ing rod.

De al
FD75-1008176

pt
2) Install the snap ring with a snap ring pli-
ers.
g no
3) Install the piston onto the connecting 1
rod.
in ti

Front mark on piston head and

"ISUZU" mark on the connecting rod
et a

shall be in the same side. 2

n
rk er

FD75-1008177
Ma t

4. Piston pin
In

1) Apply a coat of engine oil on the piston

pin and the piston pin hole.

2) Push the piston pin into the pin hole

with your thumb. The piston pin shall
touch the snap ring.

FD75-1008178

10-110 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

3) Install the snap ring into the snap ring

groove with your fingers.

4) Check if the connecting rod can move

freely along the piston pin.

FD75-1008179
6. Piston ring

.
1) Install 3 piston rings with a piston ring

De al
changer.

pt
3

Piston ring changer:

g n
Install piston ring in the following order:
o
2
Oil seal (Spiral spring type)
in ti

2nd compression ring (Conical 1

undercut type)
et a

1st compression ring (Barrel type)

n

FD75-1008180
rk er

Note:
Install compression ring with the marked
side facing upward.
Ma t

Before installing the oil ring, put the spiral

In

spring into the oil seal groove and both

sides of the spiral spring shall be without
clearance.

2) Apply engine oil on piston ring surface.

3) Check if the piston rings can move

freely in the grooves.

7. Connecting rod bearing

● Clean the grease and any other foreign

matters on the rear side surface and
mounting surface of the connecting rod FD75-1008181
bearing.

Shop Manual - November 2012 10-111

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.4.4 Camshaft, camshaft timing gear and thrust plate

2
3

.
4

De al
pt
g no
in ti
et a
n
rk er

FD75-1008182

Assembling sequence
Ma t
In

1. Camshaft 3. Thrust plate

2. Positioning pin ▲4. Camshaft timing gear

10-112 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

! Important operation

4. Camshaft timing gear

1) Install thrust plate and bolt .

2) Apply engine oil on bolt thread.

2
3) Install camshaft timing gear with the
timing mark facing outside.

.
Camshaft timing gear bolt tightening torque

De al
FD75-1008183

pt
N·m(kgf·m/lb·ft)

g n
98–118 (10–12/72–87)
o
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-113

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Assembling

1 -12

2
8 13

14

.
5

De al
3

pt
g no
4
14a
in ti
9
et a

6
10
n
rk er

11
Ma t

15
In

Repair kit

FD75-1008184

10-114 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Assembling sequence – 1

▲ 1. Cylinder block ▲ 9. Piston and connecting rod with upper

▲ 2. Tappet bearing
▲ 3. Crankshaft upper bearing ▲10. Connecting cap with lower bearing
▲ 4. Crankshaft with crankshaft timing gear ▲11. Oil pump with oil piping
▲ 5. Crankshaft thrust bearing ▲12. Crankshaft real oil seal
▲ 6. Crankshaft bearing cap with lower bearing ▲13. Flywheel housing
▲7. Timing gear housing ▲14. Flywheel
▲ 8. Camshaft with camshaft timing gear and 14a. Rear flywheel (if equipped)
thrust plate ▲15. Oil pan

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-115

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

17

13 11
14

10

.
De al
pt
12 9
5
g no
8
in ti
6

15
7 16
et a
n

1
2
rk er
Ma t
In

Repair kit
3
FD75-1008185

10-116 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Assembling sequence – 2

▲1. Idle gear shaft 10. Push rod

▲2. Idle gear "A" ▲11. Rocker shaft and rocker arm
▲3. Idle gear "B" ▲12. Water pump
4. Timing gear oil pipe ▲13. Thermostat housing
▲5. Timing gear cover 14. Water bypass hose
6. Timing gear case cover (optional) ▲15. Preheat plug and wiring
▲7. Crankshaft belt pulley with dust ring ▲16. Injector
▲8. Cylinder head gasket 17. Cylinder head cover
▲9. Cylinder head

.
De al
pt
! g n
Important operation (Assembling sequence –1)
o
in ti
1. Cylinder block

Clean the interior and outside surface of

et a

cylinder block, oil hole and water jacket

with compressed air.
n
rk er
Ma t

FD75-1008186
In

2. Tappet

1) Apply engine oil on the tappet and

around the tappet mounting hole on
cylinder block.
1
2) Check the location tag attached during
disassembling. (If the tappet is reus-
able)

Note: 2
FD75-1008187

The tappet must be installed before instal-

lation of the camshaft.

Shop Manual - November 2012 10-117

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3. Crankshaft upper bearing

The upper bearing has oil hole and groove

on it; while the lower bearing does not.

1) Remove the foreign matters on the

mounting surface of the upper and low-
er crankshaft bearing if any.

2) Check the location tag attached during

disassembling if the upper bearing is
FD75-1008188
reusable.

.
4. Crankshaft with crankshaft timing

De al
gear

pt
Apply a thick coat of engine oil on the sur-
g n
face of crankshaft journal and crankshaft
o
bearing before crankshaft installation.
in ti
Note:

Do not apply engine oil on the back of

et a

bearing or bearing mounting surface on

n

cylinder block.
rk er

5. Crankshaft thrust bearing

1) Apply a thick coat of engine oil on

Ma t

crankshaft thrust bearing.

In

2) Install crankshaft thrust bearing onto

the central journal. Oil groove of the
thrust bearing shall face the sliding sur- FD75-1008189

face.

6. Crankshaft bearing cap with lower

bearing

1) Apply TB-1207B or equivalent sealant

on the mounting surface of bearing cap
No. 5 on cylinder block.

FD75-1008190

10-118 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Note:
Make sure the mounting surface of the
bearing cap is free of oil and grease before
applying silicon sealant.

Do not clog the threaded hole on the cylin-

der and bearing with silicon sealant.

2) Install bearing cap.

The arrow mark on cylinder head shall

point to front of the engine.

The journal number as shown shall

.
De al
match the journal where bearing cap is

pt
to be mounted.

Note: g no
The fourth bearing cap does not have a
1 2 3 Nile 5
FD75-1008191
in ti
number mark.

3) Apply engine oil on bearing cap bolt.

et a

4) Tighten crankshaft bearing cap bolt in

n

the illustrated order a bit at one time as

rk er

per specified torque.

Crankshaft bearing cap bolt tightening 8

4 1
5
9

torque
Ma t
In

N·m(kgf·m/lb·ft) 3 2
7 6 10
157–177 (16–18/116–130)
FD75-1008192

5) Check if the crankshaft can be rotated

freely by hand.

7. Timing gear housing

1) Tighten the timing gear housing with

gasket to specified torque.

Timing gear housing bolt tightening bolt

N·m(kgf·m/lb·ft)
14–24 (1.4–2.4/10–17) FD75-1008193

Shop Manual - November 2012 10-119

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2) Remove the surplus section of the tim-

ing gear housing gasket.

8. Camshaft with timing gear and thrust

plate

1) Apply engine oil on camshaft and cam-

shaft bearing.

2) Install the camshaft on cylinder block.

Be careful not to damage the camshaft

bearing.

.
De al
pt
FD75-1008194
3) Tighten thrust plate bolt to specified
torque.
g n
Thrust plate bolt tightening torque
o
N·m(kgf·m/lb·ft)
in ti
14–24 (1.4–2.4/10–17)
et a

4) Check if the camshaft can be rotated

slightly by hand.
n
rk er

9. Piston and connecting rod with upper

bearing
Ma t

10. Connecting rod bearing cap with 3

lower bearing
In

1) Apply engine oil on all the piston rings

2
and around the piston .

FD75-1008195

10-120 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

2) Position the end gaps of the piston

2
rings as illustrated.

1st compression ring

2nd compression ring

Oil ring

3) Apply MoS2 grease on the skirt of pis- 1

3
ton.
FD75-1008196

This procedure helps the engine to

.
enter into smooth running state after

De al
initial startup after assembling.

pt
4) Apply engine oil on the surface of up-
per bearing.
g no
Note:
in ti

Do not apply engine oil on the back of

bearing or the mounting surface of con-
et a

necting rod bearing.

n

FD75-1008197
5) Coat the cylinder wall with engine oil.
rk er

6) Position the piston with the front mark

on piston head facing the front of cylin-
Ma t

der block.
In

7) Press the piston rings with a piston ring

compressor.

8) Push the piston in with a hammer han-

dle until the connecting rod contacts
the crank pin.

At the same time, rotate the crankshaft FD75-1008198

until the crank pin reaches lower dead
center.

Shop Manual - November 2012 10-121

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

9) Install connecting rod bearing cap.

Front mark on the bearing cap shall

face the front of engine.

Number of the bearing and number of

the connecting rod shall be the same.

Note:

Installation direction of the bearing cap is FD75-1008199

very important. Incorrect installation may
result in serious engine damage.

.
De al
pt
10) Apply engine oil on the thread and
mounting surface of each connecting
rod cap bolt.
g no
11) Tighten connecting rod cap bolt to
in ti
specified torque.

Connecting rod cap bolt tightening torque

et a
n

N·m(kgf·m/lb·ft)
rk er

27–31 (2.8–3.2/20–23)→45°–60° FD75-1008200

Ma t

11. Oil pump with oil piping

In

Install the oil pump with oil pumping and

tighten oil pump bolt to specified torque.

Oil pump bolt tightening torque

N·m(kgf·m/lb·ft)
14–24 (1.4–2.4/10–17)

Note:
FD75-1008201
Do not damage the O-ring when tightening
oil pump bolt.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

12. Crankshaft read oil seal (axial type)

12.5±0.3
1) Fix the adapter onto the end of crank-
shaft.

2) Install the oil seal on the circumference

of the adapter.

3) Set the sleeve in the adapter and tight-

en it with a bolt (M12 x 1.75L = 70) until
the face of the adapter contacts the FD75-1008202
sleeve.

4) Remove the adapter and the sleeve.

.
De al
5) Check the sectional dimension of the

pt
oil seal after it is pressed in place.

0.012 in)
g n
Std. dimension =12.5 ±0.3 mm (0.492 ±
o
in ti
6
Oil seal installer: 5-8840-9057-0 8 10
5
9
13. Flywheel housing 3
et a

1) Apply sealant on the shaded area as il- 2

n

lustrated.
1
rk er

2) Tighten flywheel housing blot a bit at

one time to specified torque in the illus-
trated order. 4 FD75-1008203
Ma t
In

Flywheel housing bolt tightening torque

N·m(kgf·m/lb·ft)
M10 x 1.25 35 – 45 (3.6 – 4.6/26 – 33)
M12 x 1.5 74 – 91 (7.5 – 9.3/54 – 67)

14. Flywheel

1) Chock the flywheel with a wood block 1

7 6
to prevent it from rotating.
3 4
2) Apply engine oil on the thread of fly- 5 8
2
wheel bolt.

3) Tighten flywheel bolt to specified torque

in the illustrated order. FD75-1008204

Shop Manual - November 2012 10-123

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Flywheel bolt tightening torque

N·m(kgf·m/lb·ft)
113 – 123 (11.5 – 12.5/83 – 90)

15. Oil pan

1) Apply TB-1207B or equivalent sealant

on the round surface of bearing cap
No. 5, bearing groove and the round
surface of timing gear housing.

.
De al
pt
FD75-1008205
g no
2) Install the gasket into the bearing
in ti
groove of bearing cap No. 5.
et a
n
rk er
Ma t

FD75-1008206
In

3) Tighten oil pan bolt a bit at one time to

specified torque in the illustrated order. 5

Oil pan bolt tightening torque 1 6

8

N·m(kgf·m/lb·ft)
4
14 – 24 (1.4 – 2.4/10 – 17)
2
7

FD75-1008207

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

! Important operation (Assembling sequence –2)

1. Idle gear shaft

Oil hole on the idle gear shaft shall face

upward.

.
De al
2. Idle gear "A"

pt
FD75-1008208

1) Apply engine oil on idle gear and idle

gear shaft .
g no
2) Keep mounting mark "X" and "Y" on the
in ti
1 2
idle gear facing the front of engine.
et a
n
rk er

FD75-1008209
Ma t

3) Align mounting mark "X" on idle gear

In

“Y”
with mounting mark "X-X" on crankshaft
timing gear . 1
4
4) Align mounting mark "Y" on idle gear
with mounting mark "Y-Y" on crankshaft
timing gear .

5) Tighten idle gear bolt to specified

torque “X”
3
FD75-1008210
Idle gear "A" bolt tightening torque

N·m(kgf·m/lb·ft)
21–30 (2.1– 3.1/15 – 22)

Shop Manual - November 2012 10-125

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3. Idle gear "B"

1) Apply engine oil on idle gear and idle

gear shaft.

2) Align mounting mark "Z" on idle gear

with mark "Z" on idle gear .

Idle gear "B" bolt tightening torque

N·m(kgf·m/lb·ft)
FD75-1008211
93 – 113 (9.5 – 11.5/69 – 83)

.
5. Timing gear cover

De al
pt
1) Before installing timing gear cover, ap-
1
ply a coat of sealant (3mm x 5 mm (0.12
g n
in x 0.20 in)) at the arrow-pointed loca-
tion as illustrated.
o 5
in ti
2) Check if the O-ring of timing gear hous-
ing cover has been inserted into timing
gear housing groove. “Z”
et a

3) Tighten timing gear housing cover bolt

n

to specified torque. FD75-1008212

rk er

Timing gear housing cover bolt tightening

torque
Ma t

N·m(kgf·m/lb·ft)
In

M 8 x 1.25 14 – 24 (1.4 – 2.4/10 – 17)

M12 x 1.25 65 – 85 (6.7 – 8.7/48 – 63)

7. Crankshaft belt pulley with dust ring

1) Chock the flywheel ring gear with a

wood block to prevent it from rotating.

2) Tighten crankshaft belt pulley bolt to

specified torque

Crankshaft belt pulley bolt tightening

torque
N·m(kgf·m/lb·ft)
FD75-1008213
197 – 240(20.1 – 24.5/145 – 177)

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Be careful not to damage the hub of crank-

shaft belt pulley.

8. Cylinder head gasket

1) Remove the carbon deposit and gasket

residue on piston top surface and cylin-

.
De al
der block upper surface.

pt
g no
in ti
FD75-1008214

2) Check the piston head projection at

et a

measuring point and on piston

head and point and on cylinder
n

block with a dial indicator. Each cylin- 1 2

rk er

der shall be measured.

3) Record the maximal measured value. 4

3
Ma t

Thickness of cylinder head gasket is

In

determined by this value.

Piston head projection FD75-1008215

mm(in)
0.758 – 0.913 (0.0298 – 0.0359)

Piston head projection shall be within the

range in the table above.

Shop Manual - November 2012 10-127

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4) Select cylinder head gasket of proper

thickness FRONT
TOP

Average piston head projection

mm(in)
Average piston Gasket thick-
Class mark
head projection ness (Ref.)
0.758–0.812
A 1.60
(0.0298–0.0320)
0.813–0.858 Class mark
B 1.65
(0.0320–0.0338)
0.859–0.914 FD75-1008216
C 1.70
(0.0338–0.0360)

.
De al
pt
5) The "TOP" mark on cylinder head gas-
ket shall face upward.
g no
9. Cylinder head
in ti
1) Align cylinder block positioning pin with
cylinder head positioning pin. Position
et a

13 5 4 12
cylinder head onto cylinder head gas-
1
ket.
n

17 9 8 16
rk er

2) Apply engine oil on the thread and

2
mounting surface of cylinder head bolt. 18 14 7 15
10
6 3 11
Ma t
In

FD75-1008217
3) Tighten cylinder head bolt in three
steps to specified torque in the illus-
trated order.

Cylinder head bolt tightening torque

N·m(kgf·m/lb·ft)
Step 1 Step 2 Step 3
44–54 (4.5–5.5/33–40) 60 – 75° 60 – 75°

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

11. Rocker shaft and rocker arm

Tighten rocker shaft bracket bolt to speci-

fied torque in the illustrated order.

Rocker shaft bracket bolt tightening torque

N·m(kgf·m/lb·ft)
49 – 59 (5.0 – 6.0/36 – 43)

FD75-1008218
12. Water pump

1) Temporarily tighten the arrow-pointed

.
De al
water pump bolt.

pt
This bolt will be tightened to specified
g n
torque after the installation of alternator
adjustment plate.
o
in ti
2) Tighten other water pump bolts to spec-
ified torque.
et a

FD75-1008219
n

Water pump bolt tightening torque

rk er

N·m(kgf·m/lb·ft)
14 – 24 (1.4 – 2.4/10 – 17)
Ma t
In

13. Thermostat housing

1) Install thermostat housing.

2) Tighten thermostat housing bolt to

specified torque.

Thermostat housing bolt tightening torque

N·m(kgf·m/lb·ft)
14 – 24 (1.4 – 2.4/10 – 17)
FD75-1008220

Shop Manual - November 2012 10-129

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

15. Preheat plug and preheat plug con-

nector

1) Tighten preheat plug to specified

torque.

Preheat plug tightening torque

N·m(kgf·m/lb·ft)
15 – 20 (1.5 – 2.0/11 – 14)

2) Install preheat plug connector.

.
De al
16. Injector

pt
3
1) Install gasket and O-ring
g n onto the 5
injector .
o
4

2) Install injector and injector bracket

in ti
onto cylinder head.
2
3) Tighten injector nut and washer to
et a

1
specified torque.
n

Injector nut tightening torque

rk er

FD75-1008221

N·m(kgf·m/lb·ft)
Ma t

31 – 43 (3.2 – 4.4/23 – 32)

In

FD75-1008222

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.4.5 Aluminium casting type timing gear housing PTO – Assemble

Timing gear housing PTO and related parts

1
2

7 4

.
De al
5

pt
16

g no
in ti
6
10
9
et a

12
14
n
rk er

11
Ma t
In

13

15

FD75-1008223

Shop Manual - November 2012 10-131

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Assembling sequence – 2B Timing gear housing PTO

1. Positioning pin ▲9. Idle gear B

▲2. Idle gear shaft ▲10. Idle gear C
3. Gasket ▲11. PTO gear
▲4. Gear housing ▲12. Gearing housing cover
5. Positioning pin 13. Oil supply pipe
6. Stud 14. Gasket
▲7. Idle gear A ▲15. Oil pan
8. Oil pipe 16. Cover

.
Important operation

De al
pt
2. Rocker shaft
g n
1) Install the rocker shaft on cylinder block
o
with oil hole facing upward.
in ti
2) Install the positioning pin onto cylinder
block.
et a

Note:
n

Location of the gear housing is determined

rk er

FD75-1008365
by positioning pin and idle shaft A.

4. Gear housing
Ma t
In

1) Install the gear housing onto cylinder

block using a new gasket, and tighten
the bolt to specified torque.

Gear housing bolt tightening torque

N·m(kgf·m/lb·ft)
14 – 24 (1.4 – 2.4/10 – 17)
FD75-1008366

2) Install positioning pin on gear housing

3) Install stud on gear housing.

● Apply Loctite 262 or equivalent sealant

on the stud.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

7. Idle gear A

1) Install camshaft along with gear.

2) Install the idle gear and the thrust plate

on idle gear shaft.

● Apply engine oil on idle gear shaft.

● Install the thrust plate with the con-

cave side facing the gear. FD75-1008367

● Tighten the bolt to specified torque.

.
Bolt tightening torque

De al
pt
N·m(kgf·m/lb·ft)
21 – 30 (2.1 – 3.1/15 –22)
g no
3) Install oil piping (gear housing to idle
gear shaft)
in ti

● Tighten bolt to specified torque.

et a

Bolt tightening torque

n

N·m(kgf·m/lb·ft)
rk er

10 – 15 (1.0 – 1.5/7.2 –11)

9. Idle gear B
Ma t

FRONT REAR
1) Press the bearing into idle gear until
In

the gear contacts bearing. Timing mark

● Use a spacer bush (2) as a seat.

● Press only the outside edge of the

bearing when pressing it.
3
2) Install idle gear shaft (3) onto idle gear.
1 2 FD75-1008368

3) Install idle gear onto gear housing.

4) Tighten the bolt to specified torque.

Bolt tightening torque

N·m(kgf·m/lb·ft)
93– 113 (9.5 – 11.5/69 –83)

Shop Manual - November 2012 10-133

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

“O”
“O”
Timing gear mark
“V”

Align timing mark X, Y and Z.

“Y” “Z”
“X” FD75-1008369

.
De al
10. Idle gear C FRONT REAR

pt
Narrow
Install bearing component onto gear.
g no
● Press only the outside edge of the
bearing when pressing it.
in ti
et a

FD75-1008370
n
rk er

11. PTO gear FRONT REAR

Ma t

Install bearing component onto gear.

In

● Press only the outside edge of the

bearing when pressing it.

FD75-1008371

10-134 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

PTO gear housing “O”

“O”

Install idle gear C and PTO gear in gear “V”

housing.

“Y” PTO gear

“Z”
“X” PTO idle gear
FD75-1008372
12. Gear housing cover

.
1) Apply sealant onto gear housing.

De al
pt
2) Install gear housing cover onto gear
housing.
g no
3) Tighten the bolt to specified torque.
in ti
Bolt tightening torque
N·m(kgf·m/lb·ft)
et a

M8 14-24(1.4-2.4/10-17) FD75-1008373
n

M12 75-91(9.6-9.3/55-67)
rk er

4) Install oil piping onto gear housing

cover.
Ma t

15. Oil pan

In

1) Apply TB1207B or equivalent sealant

onto bearing cap No. 5, bearing cap
groove and timing gear housing.

FD75-1008374

Shop Manual - November 2012 10-135

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

2) Install the rear projected part of the

gasket into the groove of bearing cap
No. 5.

Make sure the projected part is in the

groove.

FD75-1008375

.
3) Tighten the bolt and nut of the oil pan in

De al
5
several steps to specified torque in the

pt
illustrated order. 1 6
8
g n
Oil pan bolt and nut tightening torque
o
4
2
in ti
N·m(kgf·m/lb·ft)
7
14 – 24 (1.4 – 2.4/10 –17)
3
et a

FD75-1008376
n
rk er
Ma t
In

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

11 13 17 6 9 8 7 2 1 21 3 15

.
De al
pt
g n
23 16 20
o
12 14 18 19 8 22 5 10 20 FD75-1008377
in ti

Assembling sequence – 3
et a

▲ 1. Intake pipe 13. Cooling water hose

n

▲ 2. Injection pump ▲14. Alternator and adjustment plate

rk er

▲ 3. Fuel injection pipe with clamp ▲15. Oil filter

4. Oil return pipe 16. Oil pressure switch
5. Oil pipe (injection pump to cylinder block) 17. Cooling fan belt pulley
Ma t

6. Fuel filter 18. Cooling fan belt

In

7. Fuel pipe (fuel filter to fuel drain pipe) 19. Cooling fan and air guide
8. Fuel pipe (fuel filter to fuel feed pump) 20. Mounting bracket (right and left)
9. Fuel pipe (fuel filter to injection pump) 21. Air breather hose
▲10. Starter motor 22. Vent plug
▲11. Exhaust pipe 23. Oil strainer
12. Cooling water inlet pipe

Shop Manual - November 2012 10-137

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

! Important operation (Assembling sequence – 3)

1. Intake pipe

Install the intake pipe gasket and the side

with a square corner shall face the front of
engine.

.
De al
FD75-1008378

pt
2. Injection pump
g n
1) Rotate the crankshaft clockwise slowly
o
until the crankshaft timing pointer
1
in ti
aligns with crankshaft timing gear mark
"O" .
et a
n

2
rk er

FD75-1008379
Ma t
In

2) Install the injection pump onto the tim-

ing gear housing.
3
Align injection pump timing pointer
with timing gear mark "O" .

3) Temporarily tighten bolt of injection

pump bracket.
4
This bolt will be further tightened after
rear bracket bolt has been tightened.
FD75-1008380

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

4) Tighten bolt of injection pump rear

bracket to specified torque.

Injection pump rear bracket bolt tightening

torque

N·m(kgf·m/lb·ft) 6
14 – 24 (1.4 – 2.4/10 – 17)

5) Tighten bolt of injection pump brack- 6

5 FD75-1008381
et to specified torque.

Injection pump bracket bolt tightening

.
De al
torque

pt
N·m(kgf·m/lb·ft)
g n
14 – 24 (1.4 – 2.4/10 – 17)
o
in ti
et a
n

FD75-1008382
rk er
Ma t

3. Fuel injection pipe with clamp

In

1) Temporarily tighten the sleeve nut of

fuel injection pipe.

2) Install pipe clamps at specified loca-

tions.

Note:

Make sure the clamps are installed to the FD75-1008383

correct location.

Improper positioning of the clamps may

cause rupture of fuel injection pipe and im-
pulse noise of fuel.

Shop Manual - November 2012 10-139

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3) Tighten the sleeve nut of fuel injection

pipe to specified torque.

Fuel injection pipe sleeve nut tightening

torque

N·m(kgf·m/lb·ft)

20 – 39 (2.0 – 4.0/14 – 29)

10. Starter motor

Tighten bolt of starter motor to specified

.
De al
torque.

pt
FD75-1008384

Starter motor bolt tightening bolt

g no N·m(kgf·m/lb·ft)
in ti
66 – 85 (6.7 – 8.7/48 – 63)

11. Exhaust pipe

et a
n

Tighten bolt of exhaust pipe a bit at one

5 1 4 8
time to specified torque.
rk er
Ma t

6 2 3 7
Exhaust pipe bolt tightening torque
In

N·m(kgf·m/lb·ft) FD75-1008385

14 – 24 (1.4 – 2.4/10 – 17)

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

14. Alternator and adjustment plate

Tighten bolt of alternator and adjustment

plate to specified torque.

Alternator bolt tightening torque

N·m(kgf·m/lb·ft)
14 – 24 (1.4 – 2.4/10 – 17)

Tighten the bolt of adjustment bolt to speci-

fied torque after installation of cooling fan
belt.

.
De al
pt
Adjustment plate bolt tightening torque

g no N·m(kgf·m/lb·ft)
14 – 24 (1.4 – 2.4/10 – 17)
in ti
15. Oil filter and oil cooler
et a

Tighten the bolt of oil filter to specified

torque.
n
rk er

Oil filter bolt tightening torque

N·m(kgf·m/lb·ft)
Ma t

14 – 24 (1.4 – 2.4/10 – 17)

In

Connect water pipe to oil cooler (if

equipped) and clamp the water pipe.

Shop Manual - November 2012 10-141

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.5 Lubricating System

10.5.1 Technical data and specifications

Item 4JG1
Oil pump type Spiral line type
Flow rate Lit(qts)/min. 17.5 (18.4)
-1
Rotating speed min 1000
2
Oil supply pressure kPa(kgf/cm /psi) 392 (4.0/57)
Oil temperature °C(°F) 47 – 53 (116.6 – 127.4)
Oil SAE 30

.
Oil filter type Full flow, paper element, filter cartridge

De al
2
Reducing valve actuation pressure kPa(kgf/cm /psi) 420 – 460 (4.3 – 4.7/61 – 67)

pt
2
Relief valve opening pressure kPa(kgf/cm /psi) 79 – 118 (0.8 – 1.2/11 – 17)
Oil cooler type g no
Safety valve actuation pressure kPa(kgf/cm /psi) 2
Water-cooler
225 – 265 (2.3 – 2.7/33 – 38)
in ti
et a
n
rk er
Ma t
In

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.5.2 General

Lube oil flow

● The following diagram is based on 4J se- ● Lube oil flow may vary depending on en-
ries engines equipped with oil cooler (op- gine specifications.
tional).

Battery
Alarm lamp

.
De al
Oil pressure switch

pt
Cylinder block main oil passage

g no
Oil filter Idle gear shaft

Filter drum
in ti
Crankshaft Camshaft Vacuum pump
Main oil filter bearing bearing
Oil pipe
et a

Rocker shaft
n

Relief valve Conrod

bearing
rk er

Rocker arm
Timing gear
Ma t

Oil pump Pressure

regulating
In

valve

Strainer

Oil pan

FD75-1008386

● Lubricating system of 4J series engines is and oil filter. Then, it is supplied to each
completely forced circulation type. of the key components of the engine from
cylinder block oil passage.
● Lube oil is introduced to cylinder block oil
passage from oil pump through oil cooler

Shop Manual - November 2012 10-143

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.5.3 Oil pump

.
De al
pt
g no
in ti
et a
n
rk er
Ma t

FD75-1008387
In

● 4J series engines use rotor type oil pump.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.5.4 Main oil filter

.
De al
pt
g no
in ti

FD75-1008388
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-145

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.5.5 Oil pump – disassemble

.
De al
pt
g no
in ti
et a

4
n
rk er
Ma t

3
In

FD75-1008390

Disassembling sequence

1. Oil pipe 4. Vane

2. Strainer chamber ▲5. Pump casing with rotor and pinion
3. Pump cover

10-146 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Oil pump – inspect and repair

Make necessary adjustment, repair and re-

placement if excessive wear and damage
is observed during inspection.

Clearance between vane, rotor and

pump cover

Measure the clearance between vane, ro-

tor and pump cover with a feeler gauge.

If the measured value exceeds the limit,

.
De al
replace pin, shaft, rotor and vane together.

pt
Clearance between vane, rotor and pump
cover g no FD75-1008391

mm(in)
in ti
Standard Limit
0.02 – 0.07 (0.0008 – 0.0028) 0.15 (0.006)
et a

Clearance between rotor and vane

n

Measure the clearance between rotor and

rk er

vane with a feeler gauge.

If the clearance exceeds the limit, replace

Ma t

shaft, rotor and vane together.

In

Clearance between rotor and vane

mm(in)
FD75-1008392

Standard Limit
0.14 (0.006) or less 0.20 (0.008)

Shop Manual - November 2012 10-147

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Clearance between vane and pump cas-

ing

Measure the clearance between vane and

pump casing with a feeler gauge.

If the clearance exceeds the limit, replace

the oil pump assembly.

Clearance between vane and pump casing

FD75-1008393
mm(in)

.
Standard Limit

De al
pt
0.20 – 0.27 (0.008 – 0.011) 0.40 (0.016)

g no
in ti
et a
n
rk er
Ma t
In

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Oil pump – Assemble

.
De al
pt
g no
in ti

2
et a
n
rk er

3
Ma t
In

FD75-1008394

Assembling sequence

1. Pump casing with rotor and pinion 4. Strainer chamber

2. Vane 5. Oil pipe
3. Pump cove

Shop Manual - November 2012 10-149

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.5.6 Oil filter with built-in oil cooler – Disassemble

.
De al
pt
5
g no
in ti
4
et a
n
rk er

7
Ma t

1
In

FD75-1008395

Disassembling sequence

1. Oil drain plug 5. Safety valve

2. Filter cartridge type oil filter 6. Relief valve
3. Oil cooler 7. Oil filter body
4. O-ring

10-150 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.5.7 Oil filter with built-in oil cooler – Inspect and repair

Make necessary adjustment, repair and re-

placement if excessive wear and damage is
observed during inspection.

Pressure reducing valve

1. Connect an oil pressure gauge in the oil

passage around the oil filter.

2. Start the engine to check the opening pres-

.
De al
sure of the reducing valve.

pt
Reducing valve opening pressure
g no
kPa(kgf/cm2 /psi) FD75-1008396
in ti
420 – 460 (4.3 – 4.7/61 – 67)
et a

Oil cooler
n

Water leakage of water pipe

rk er

1. Block one end of the oil cooler water pipe.

Ma t

2. Submerge the oil cooler into water.

In

3. Blow compressed air (200 kPa (kgf/cm2/28 FD75-1008397

psi)) in from the other end of the water

pipe.

If bubbles are observed, water leakage exists.

Shop Manual - November 2012 10-151

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.5.8 Oil filter with built-in oil cooler – Assemble

2
6

.
De al
pt
10

g no
8
9
in ti
5

4
et a

3
6
n

6
rk er
Ma t

FD75-1008398
In

Assembling sequence

▲1. Oil filter element 6. Bolt

2. Oil filter element seat 7. Oil filter assembly
3. Return oil pipe 8. Bracket
4. Oil inlet pipe 9. O-ring
5. Cover ▲10. Oil drain plug

10-152 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

! Important operation

1. Oil filter element

1) Apply engine oil on the O-ring.

2) Mount the oil filter element until its

mounting surface contacts the O-ring.

3) Further tighten the oil filter element by

1.25 turn.

.
De al
pt
10. Oil drain plug
g no
Tighten the oil drain plug to specified
torque.
in ti

Oil drain plug tightening torque

et a

N·m(kgf·m/lb·ft)
n
rk er

20 – 30 (2.0 – 3.0/14 – 22)

Ma t
In

Shop Manual - November 2012 10-153

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.6 Cooling System

10.6.1 Technical data and specifications

Item
Main pump type Impeller centrifugal
Transmission ratio 1.1
Flow amount Lit(qts)/min 100 (105.5)
Total hydraulic head @ 3000 rpm 30°C (86°F) kPa 60
Pump bearing type Double row bearing

.
Thermostat type Paraffin

De al
Initial opening temperature °C(°F) 82 (180)

pt
Complete opening temperature °C(°F) 95 (203)

g n
Valve lift at complete opening
o mm(in.) 8.0 (0.31)
in ti
et a
n
rk er
Ma t
In

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.6.2 General

Cooling water flow

.
De al
pt
g no
in ti
et a
n

FD75-1008224
rk er

● Cooling system of the engine includes the ● When temperature of cooling liquid reach-
radiator, the water pump, the cooling fan es 82°C (180°F), the thermostat starts
and the thermostat. to open and the amount of cooling liquid
Ma t

passing the radiator increases gradually.

In

● Cooling liquid passes water pump and

thermostat and returns to cylinder block ● When temperature of cooling liquid
via bypass pipe so that the temperature of reaches 95°C (203°F), the thermostat is
cold cooling liquid can rise quickly and the completely open, and all cooling liquid cir-
engine can work smoothly. Cooling liquid culates via the radiator to achieve efficient
does not pass the radiator. engine radiation.

Shop Manual - November 2012 10-155

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.6.3 Water pump

.
De al
pt
g no
in ti
et a

FD75-1008225
n
rk er

The centrifugal water pump forces the cooling

water to circulate in the whole cooling system.
Ma t
In

10-156 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.6.4 Water pump – Inspect and repair

1. Press the fan center and rotate the

shaft.

Check for float or other abnormalities.

2. Move the fan center back and forth and

measure axial play (pushing direction).

Axial play

mm( in)

.
De al
Limit

pt
0.2(0.0079) FD75-1008226

g n
If axial play exceeds the limit, replace fan
o
center and/or shaft.
in ti
The water pump (without PTO) shall not be
disassembled for repair.
et a

If the water pump is damaged, replace the

n

assembly.
rk er
Ma t
In

Shop Manual - November 2012 10-157

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.6.5 Water pump – Disassemble

4 3

.
De al
pt
7
g n
8
o9
in ti
6
et a
n

FD75-1008227
rk er

Disassembling sequence

1. Screw ▲ 6. Fan center

Ma t

2. Cover 7. Bearing body

In

3. Gasket 8. Oil thrower

▲ 4. Check screw 9. Sealing member
▲ 5. Vane

10-158 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

! Important operation

4. Check screw

Remove the check screw.

.
FD75-1008228
5. Vane and sealing member

De al
pt
Remove the vane and sealing member
with a press and a copper bar.
g no
Note:
in ti
Do not remove the vane using a hammer
to avoid damage to the vane.
et a
n

FD75-1008229
rk er

6. Fan center
Ma t
In

Remove the fan center with a press and a

copper bar.

FD75-1008230

Shop Manual - November 2012 10-159

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Water pump – Inspect and repair

Make necessary adjustment, repair and re-

placement if excessive wear and damage
is observed during inspection.

Bearing body

Check the bearing for noise, damage or

other abnormalities.

FD75-1008231

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

10-160 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.6.6 Water pump – Assemble

4
6

.
De al
pt
1

3
g no2
in ti
9
et a
n

FD75-1008232
rk er

Assembling sequence
Ma t

▲ 1. Seal ▲ 6. Gasket
In

2. Ring 7. Cover
▲ 3. Bearing body 8. Screw
▲ 4. Check screw ▲ 9. Fan center
▲ 5. Vane

Shop Manual - November 2012 10-161

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

! Important operation

1. Seal

1) Apply a thick coat of sealant (1) on the

surface of the sealing member.

2) Install the sealing member.

1

FD75-1008233

.
De al
pt
3. Bearing body (1)

4. Check screw (2)

g no 2
in ti
1) Align the screw hole on the pump casing
with the check screw mounting hole.
1

2) Install the bearing body.

et a
n

3) Tighten the check screw.

FD75-1008234
rk er

5. Vane (1)
Ma t

1
In

Press the vane in slowly with a press.

Check the distance between vane and
pump casing.

Vane - pump casing distance

mm( in)

0.6-0.8( 0.0024-0.031) FD75-1008235

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

FD75-1008236

.
9. Fan center

De al
pt
Press the fan center onto water pump shaft
slowly with a press. Check the pressed-in
distance. g no
Pressed -in distance
in ti
mm( in)

107-108(4.236-4.260)
et a

FD75-1008237
n
rk er
Ma t
In

Shop Manual - November 2012 10-163

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.6.7 Thermostat – inspect and repair

Make necessary adjustment, repair and re-

placement if excessive wear and damage
is observed during inspection.

Testing

1. Submerge the thermostat into water.

2. Heat the water.

Keep stirring the water to prevent heat

.
De al
from being transferred directly to the ther-

pt
mostat.

g no FD75-1008031
in ti

3. Check the initial opening temperature

1
of the thermostat.
et a

2
Thermostat initial opening temperature
n

°C(°F)
rk er

82 (180)

4. Check the complete opening tempera-

Ma t

ture of the thermostat. 3

In

Thermostat complete opening temperature FD75-1008032

°C(°F)

95 (203)

Valve lift at complete opening

mm(in.)
8.0 (0.315)

Thermostat

Stirring rod

Wood block

10-164 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.7 Fuel System

10.7.1 Technical data and specifications

Item
Injection pump type Japan Bosch A type
Plunger outer diameter mm(in) 9.0 (0.35)
Governor type RSV mechanical type
Oil delivery pump type Single acting type
Injector type Multi-orifice

.
No. of orifice 5

De al
Orifice diameter mm(in) 1.0 (0.039)

pt
2
Actuation pressure MPa(kgf/cm /psi) 18.1 (185/2,630)

g n
Main fuel filter type
o Filter cartridge paper element
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-165

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.7.2 General

Fuel flow

Fuel filter
Injector

.
De al
pt
g nWater separator
o
in ti

Injection pump
et a

Fuel tank
n
rk er

FD75-1008240

● The fuel system includes: fuel tank, water ● Fuel supplied from the plunger of the injec-
Ma t

separator (if equipped), fuel filter, injection tion pump feeds the injector at the optimal
pump and injector. moment to achieve best engine perfor-
In

mance.
● Fuel from the tank passes the water sepa-
rator and the filter, and moisture and other
foreign matters are removed from the fuel.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Injector

.
De al
Injector casing

pt
g no Adjustment plate
in ti
Spring
Spring seat
et a

Injection nozzle Lock nut

n
rk er
Ma t

FD75-1008241
In

● This engine uses a multi-orifice (5 orifices) ● Pressurized fuel from the injection pump is
injector. The injector is composed of the injected into the combustion chamber via
injector casing and the pintle valve assem- the injection orifice on the injector casing.
bly.

Shop Manual - November 2012 10-167

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Fuel filter and water separator

.
De al
pt
Drain mark

g no
in ti
et a
n
rk er

FD75-1008242
Ma t
In

● This engine uses a cartridge type fuel filter ● There is a float inside the water separator.
and a water separator. Drain the water in the separator when the
float reaches the drain mark.
● Since the interior of the injection pump is
lubricated by the fuel that it pumps, the fuel
must be very clean. Fuel filter and water
separator removes the water and other for-
eign matters from the fuel before it reaches
the injection pump.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.7.3 Fuel filter and water separator

Filter cartridge – replace

1. Apply a thin coat of engine oil on the

O-ring of filter cartridge and install the
O-ring.

2. Install a new filter cartridge and tight-

en it to specified torque with a filter
wrench.

Filter cartridge torque

.
FD75-1008243

De al
N·m(kgf·m/lb·ft)

pt
15-21(1.5-2.1/11-15)
g n
3. Release the air in the fuel system with
o
the manual fuel pump.
in ti
Filter cartridge with water separator –
replace
et a

1. Apply a thin coat of engine oil on the

n

O-ring of filter cartridge and install the

O-ring.
rk er

2. Install a new filter cartridge and tight-

en it to specified torque with a filter
Ma t

wrench.
In

Filter cartridge torque FD75-1008244

N·m(kgf·m/lb·ft)
12-14(1.2-1.4/8.7-10)

3. Install the sensor on the filter cartridge

and tighten it to specified torque.

Sensor tightening torque

N·m(kgf·m/lb·ft)
12-14(1.2-1.4/8.7-10)

4. Release the air in the fuel system with

the manual fuel pump.

Shop Manual - November 2012 10-169

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.7.4 Injector – Disassemble

.
De al
pt
4 7

3
g no
in ti
2
et a
n

1
rk er

FD75-1008245
Ma t

Disassembling sequence
In

1. Check nut 5. Spring

▲ 2. Injection nozzle 6. Adjustment gasket
3. Separator 7. Injector casing
4. Spring seat

10-170 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

! Important operation

Conduct the following test prior to disas-

sembling of injector.

1) Install the injector onto the tester.

2) Feed pressurized fuel (18.1 MPa (185

kgf/cm2/2,630psi)) into the injector with
the tester.

3) Check the area around the injection

.
De al
nozzle for fuel leaks. If fuel leakage is

pt
observed, replace the injection nozzle
FD75-1008246
and the injector casing together.
g n
2. Injection nozzle
o
in ti
1) Remove the injection nozzle from the
injector casing.
et a

The pintle valve and injection nozzle

group shall not be interchanged.
n
rk er

2) Submerge the injection nozzle into

clean diesel fuel to keep dust away.
Ma t

FD75-1008247
In

Shop Manual - November 2012 10-171

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.7.5 Injector – inspect and repair

Make necessary adjustment, repair and re-

placement if excessive wear and damage
is observed during inspection.

Pintle valve – inspect

1. Remove the pintle valve from the injec-

tion nozzle.

2. Rinse the pintle valve and the nozzle

with clear diesel fuel.

.
De al
3. Check if the pintle valve can move free-

pt
ly inside the injection nozzle.
g n
If the pintle can not move freely, repair
o
it. (Refer to “Injection nozzle – Grind”
FD75-1008248

below.
in ti

Injection nozzle – grind

3
et a

1. Apply chrome oxide and animal oil mix-

n

ture on the pintle valve and grind it

inside the injection nozzle .
rk er

Note:
Ma t

Do not apply excessive mixture of chrome

1
oxide and animal oil on the valve seat. 2
In

FD75-1008249

2. Rinse the pintle valve and injection

nozzle in clear diesel fuel after grinding.

Injection nozzle and pintle valve – in-

spect

● Check the injection nozzle and the pin-

tle valve for damage and deformation.

● If damage and deformation is observed,

replace injection nozzle and pintle
valve.

FD75-1008250

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.7.6 Injector –Assemble

.
De al
4 1

pt
5

6
g no
in ti
et a

7
n

FD75-1008251
rk er

Assembling sequence
Ma t

1. Injector casing 5. Separator

▲ 2. Adjustment gasket 6. Injection nozzle
In

3. Spring ▲7. Check nut

4. Spring seat

Shop Manual - November 2012 10-173

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

! Important operation

2. Adjustment gasket

If the opening pressure of the injection noz-

zle is wrong, disassemble the adjustment
gasket to adjust the opening pressure.

T
Note:
ΦD1

● Measure the thickness of the gasket ΦD2

with a micrometer.

.
FD75-1008252

De al
Adjustment gasket

pt
Part No. Thickness mm(in)
897116—0290
897116—0320
g no 0.10(0.0039)
0.20(0.0079)
897116—0330 0.30(0.0118)
in ti
897116—0340 0.40(0.0157)
897116—0350 0.50(0.0197)
897116—0360 0.51(0.0201)
et a

897116—0370 0.52(0.0205)
n

897116—0380 0.53(0.0209)
897116—0390 0.54(0.0213)
rk er

897116—0400 0.55(0.0217)
897116—0410 0.56(0.0220)
897116—0420 0.57(0.0224)
Ma t

897116—0430 0.58(0.0228)
In

897116—0440 0.59(0.0232)
D1: ø3.6 D2: ø7.2
Note:
Every 0.01mm in thickness of the adjust-
ment gasket can adjust a pressure of 147
kPa (approx. 1.5kgf/cm2/21.3psi)

7. Lock nut

Tighten the lock nut to specified torque. FD75-1008253

Lock nut tightening torque

N·m(kgf·m/lb·ft)
29 – 39 (3 – 4/22 – 29)

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.7.7 Injector – adjust

1. Fix the injector on the tester.

2. Apply pressure on the tester and check the

injector can open at specified pressure. If
not, increase or reduce the number of ad-
justment gaskets.

Warning:
FD75-1008254

Testing fluid in the tester may spurt out under

high pressure, which may easily penetrate hu-

.
man skin. Always keep your hands away from

De al
the tester.

pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-175

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.7.8 Dual injection type injector– Disassemble

9
16

15 8

.
14

De al
pt
6

5
g no 4

3
13
in ti

12
2
et a

11
n

10
rk er

1
Ma t

FD75-1008255
In

Disassembling sequence

1. Lock nut 9. Push rod

2. Injection nozzle 10. Connector
3. Spacer bush 11. Spring seat
4. Pin 12. 1st spring
5. Lifting block 13. Gasket(for 1st injection pressure adjusting)
6. Spring seat 14. Injector casing
7. Gasket (for 2nd injection pressure adjust- 15. Gasket
ing) 16. Hollow bolt
8. 2nd spring

10-176 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

1. Remove carbon deposit on the injection

nozzle and the injector casing with a brush
prior to disassembling of the injector.

Note:

Do not use the brush to touch the orifice when

removing carbon deposit.

2. Disassemble the injector in the illustrated

order.

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-177

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.7.9 Dual injection type injector – Assemble and adjust

7
16

15 6

1 8

.
De al
pt
9

11
g no 10

12
2
in ti

3
13
et a

4
n

5
rk er

14
Ma t

FD75-1008256
In

Assembling sequence

1. Injector casing 9. Spring seat

2. Gasket(for 1st injection pressure adjusting) 10. Pin
3. 1st spring 11. Lifting block
4. Spring seat 12. Spacer bush
5. Connector 13. Injection nozzle
6. 2nd spring 14. Lock nut
7. Push rod 15. Gasket
8. Gasket (for 2nd injection pressure adjust- 16. Hollow bolt
ing)

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Adjusting sequence

● Adjustment of injector follows the assem-

bling sequence.

● Adjustment of injector is achieved in two

steps. Since the injector is a precision
component, adjustment shall be conducted
very carefully. Always keep the injector
clean and free of dusts.

Adjust 1st opening pressure with the adjust- 1 1st opening pressure adjustment
ment gasket.

.
De al
Confirm the full lift of the pintle valve and con-
2 Pintle valve full lift confirmation

pt
firm pintle valve closing using the same meth-
od.
g no
Confirm preliminary lift as well as closing. 3 Preliminary lift
in ti

Note:
If preliminary lift is not correct, replace injec-
et a

tion nozzle, lifting block, pin, spacer and injec-

n

tor repair kit.

rk er

4 2nd opening pressure confirmation

Confirm 2nd opening pressure; and confirm
closing using the same method.
Ma t

Adjust 2nd opening pressure with the adjust- 2nd opening pressure adjustment
In

5
ment gasket.

Check atomization and injector assembly.

6 Final check

Adjustment data

Pintle valve full lift 0.25 mm(0.0098in)

Pintle valve preliminary lift 0.04 mm(0.0016)
1st 19.5Mpa(199kgf/cm2/ 2830psi )
Injector opening pressure
2nd 27.5 – 28.5Mpa(280 – 290 kg/fcm2/ 3.980 – 4.120psi)

Shop Manual - November 2012 10-179

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

First opening pressure – adjust

1. Hold the injector casing with a clamp.

FD75-1008257

.
2. Install gasket (1) and seat (3) of 1st 3

De al
spring (2).

pt
2
1

g no
in ti
FD75-1008258
et a

3. Install connector (1), 2nd spring (2),

n

gasket (3), spring seat (4) and push rod 3

5
(5).
rk er

2
1

4
Ma t
In

FD75-1008259

10-180 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

4. Install pin (1), lifting block (2) and spac- 3

er bush (3).
2
1

FD75-1008260

5. Install injection nozzle.

1

.
De al
2

pt
g no
in ti
FD75-1008261
et a

6. Tighten locknut (1) by hand and install

a new gasket (2).
n

1 3
rk er

Check nut (1): 157892—5100

2

(Special tool)
Ma t

Gasket (2): 026508—1140

In

FD75-1008262

Shop Manual - November 2012 10-181

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

7. Tighten locknut (1) to specified torque. 2

Check nut torque

N·m(kgf·m/lb·ft) 1

29-39(3.0-4.0/22-29)

Check nut (1): Special tool

Torque wrench (2)

FD75-1008263
8. Fix the injector on the tester.

9. Operate the tester and measure the 1st

.
De al
opening pressure of the injector.

pt
10. If the 1st opening pressure is wrong,
g n
disassemble the injector and replace
the adjustment gasket until correct
o
opening pressure is achieved.
in ti
Note:
et a

● Measure the thickness of adjustment

gasket with a micrometer.
n

FD75-1008264
rk er

● Use different gasket combination to ad-

just opening pressure.
Ma t

Thickness of 1st opening pressure adjust-

ment.
In

Part No. Thickness mm(in)

15349-0440 0.52(0.0205)
115349-0450 0.54(0.0213)
T

115349-0460 0.56(0.0220)
115349-0470 0.58(0.0228)
ΦD1
115349-0480 0.60(0.0236)
115349-0490 0.70(0.0276) ΦD2
115349-0040 1.20(0.0472)
FD75-1008265
D1: ø2.6 D2: ø6.2

Note:

Every 0.01mm in thickness of the adjust-

ment gasket can adjust a pressure of 147
kPa (approx. 1.5kgf/cm2/21.3psi)

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Pintle valve full lift – confirm

2
1. Install gasket (1) and bolt (2) onto the
locknut.
1 1
Gasket: 026508—1140

894227—6020

Plunger: 157892—1600
FD75-1008266

586777—1410

.
2. Fix the injector with the nozzle down.

De al
Install dial indicator connector onto the

pt
injector. 1

g n
Dial indicator connector: 157829—4400
o
in ti
et a
n

FD75-1008267
rk er
Ma t

3. Install nut (1) onto the dial indicator

In

connector. 1

Nut (1):157892—1000 2

FD75-1008268

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Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. Mount the measuring rod (1) onto the

dial indicator (2). 2 1

Note:

Length of the measuring rod does not in-

clude the threaded section.

Measuring rod (L=75mm): 157892—7000

FD75-1008269
Dial indicator (2): 157894—3801

.
De al
5. Tighten the nut so that the measuring

pt
rod of the dial indicator contacts the
head of 1st spring seat. Dial indicator

Note:
g no
Nut
in ti
● Check that the dial indicator contact
Lock nut
2mm( 0.0787in) height for easy read- Measuring rod
ing.
et a

● Do not over tighten the nut of dial in-

n

dicator to prevent it from being stuck

rk er

(make sure the shaft can move freely). Injector

1st spring seat

Ma t
In

FD75-1008270

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

6. Fix the injector onto the tester and set

the reading on the indicator to zero.

7. Operate the tester and release air at

the lock nut. Check for fuel leaks.

FD75-1008271

8. Operate the tester until pressure

.
rises to 34.1-44.1Mpa (350-450kgf/

De al
cm 2 /4977-6399 psi) and the pintle

pt
Pintle valve lift
valve is at full lift.

g n
Record full lift “L” (dial indicator reading)
o
Injector assembly: 115300—3722
in ti
0 34.3~44.1MPa
First opening pressure
{350~450kgf/cm2

Injector full lift Injection pressure

et a

FD75-1008272

mm(in)
n

0.23-0.27(0.0091-0.0106)
rk er

Note:
Ma t

This operation is to check the injection

nozzle and the injector assembly for dam-
In

ages or other malfunction.

Preliminary lift – confirm

1. Relieve injection pressure slowly when

the pintle valve is at full lift.

Note:

Pintle valve lift (dial indicator reading)also

declines a little as injection pressure drops. Pressure gauge FD75-1008273

Shop Manual - November 2012 10-185

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Pintle valve lift

Injection pressure
FD75-1008274

2. Observe the valve lift value on the dial

.
L

De al
indicator (when pintle valve starts fall- Pre-lift measuring point

pt
ing and the 2nd spring stops acting).
Pintle valve lift

“L”.
g n
Refer to preliminary lift measuring point
o
I
in ti
Preliminary lift measuring point:
O
Record dial indicator reading at 1st open- First opening pressure
et a

FD75-1008275
ing.
n
rk er

Preliminary lift 2nd spring

Push rod
Pressure
Lift mm( in) Adjusting plate
Mpa (kgf/cm2/psi) Spring
Ma t

19.5( 199/2.830) 0.04( 0.0016)

In

Spacer

Note:
Lift block

This point can be found when injection Pintle valve

pressure drops gradually. FD75-1008276

3. Check if preliminary lift “L” is correct.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

4. If preliminary lift is wrong, replace pin,

lifting block, spacer bush and injector
assembly repair kit. 1
3
2

FD75-1008277

Second opening – Confirm

.
1. Operate the tester until pressure ris-

De al
es to 34.1- 44.1Mpa (350 - 450kgf/

pt
cm2/4977 - 6399 psi) and pintle valve
reaches full lift.
g no
in ti
et a

FD75-1008278
n
rk er

2. Adjust injection pressure for it to de-

L
cline gradually.
Pintle valve lift (mm
Ma t

Note:
In

5
Pintle valve lift (dial indicator reading)also
declines a little as injection pressure drops.
0
34.3-44.1MPa
Second opening pressure 350-450kg/cm2

FD75-1008279

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Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3. Record the reading on pressure gauge

When pintle vale is at
(2nd opening pressure). Dial indicator
90 L+0.05mm
reading is the pintle valve lift. 10
80
(General preliminary lift L +0.05mm 20
(0.002in) 70
30 Pintel valve full lift
Second opening pressure (when being re-
60
paired) 40
50

Lift mm( in) Pressure Mpa(kgf/cm2/psi) Dial indicator FD75-1008280

0.09 17.5-28.5
(0.0035) (280-290/3980-4120)

.
De al
pt
g n
Second opening pressure – adjust
o 3
5

If opening pressure of the injector is wrong, 2

in ti
disassemble the injector and replace ad- 1

justment gasket until correct opening pres- 4

sure is achieved.
et a
n

Note:
rk er

● Second opening pressure also changes

FD75-1008281
as first opening pressure changes.
When first opening pressure has been
Ma t

adjusted, second opening pressure

In

shall also be adjusted.

● Adjust pressure using different gasket

combination.
T

● Measure the thickness of adjustment

ΦD1
gasket with a micrometer.
ΦD2

FD75-1008282

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Second opening pressure adjustment gas-

ket

Part No. Thickness mm (in)

897116—0340 0.40(0.0157)
897116—0350 0.50(0.0197)
897116—0360 0.51(0.0201)
897116—0370 0.52(0.0205)
897116—0390 0.54(0.0213)
897116—0410 0.56 ( 0.0220)
897116—0430 0.58 ( 0.0228)
897116--0440 0.59 (0.0232)

.
D1:ø3.6 D2:ø7.2

De al
pt
Note:

g n
Every 0.01mm in thickness of the adjust-
o
ment gasket can adjust a pressure of 147
kPa (approx. 1.5kgf/cm2/21.3psi)
in ti

Final check
et a

1. Remove dial indicator (1), nut(2), and

n

dial indicator locknut (3).

rk er

2. Remove adjustment locknut (1) and 2

gasket.
Ma t

3. Install locknut and check that the pin is

In

inside the injection nozzle. Tighten the

locknut by hand and tighten the original FD75-1008283
locknut to specified torque.

Check nut torque 2

N·m(kgf·m/lb·ft)
29-39( 3.0-4.0/22-29)

FD75-1008284

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Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. Set the injector onto the tester and check

the atomization of the first opening, tight-
ening torque and for fuel leaks.

5. If injection nozzle shall be replaced, re-

place injection nozzle, lifting block, pin,
spacer bush and injector assembly repair
kit.

Note: FD75-1008285

If preliminary lift is wrong, only replace the in-

jection nozzle.

.
De al
10.7.10 Injection pump calibration data

pt
Name plate and serial number
g no
1. Adjustment and repair of the injection
ZEXE L

pump shall be conducted at the service

in ti
center approved by ZEXEL.
A

2. Before conducting adjustment and repair pump No

et a

work at the service center, refer to the NP-PE

name plate and serial number for technical
n

(LICENCE BOSCH)
specifications provided by the manufac-
rk er

turer. A Identification number

FD75-1008286

The service center will not be able to ad-

Ma t

just and repair the injection pump properly

without these data.
In

If the data can not be found, contact

ISUZU Motors through your engine dis-
tributor.

3. Do not remove the name plate and serial

number from the injection pump.

Always keep the name plate and serial

number clean and legible.

Note:

Testing conditions and calibration data are as

follows.

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Injection amount adjustment testing condition

Injection nozzle ZEXEL No.:105780-0000

Injector casing ZEXEL No.:105780-2080
2
Injection starting pressure MPa(kgf/cm ) 17.2 (175)
Injection line dimension mm(in)
Inner diameter 2.0 (0.079)
Outer diameter 6.0 (0.236)
Length 600.0 (23.6)
2
Oil feed pump pressure MPa(kgf/cm ) 1.6 (22.75)
Testing diesel fuel IS04113 or SAE std.testing fuel (SAEJ967D)

.
De al
Working temperature ° C(° F) 40-45(104-113)

pt
Pump rotation direction Clockwise(seen from driving side)

g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-191

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Injection pump calibration data

Assembly No.: 000000–0000
Engine model: CC-4JG1 Date:
Company: ISUZU
Part No.: 0–00000–000–0

Injection pump: PES4A Governor: EP/RSV Timing device:

000000–0000 000000–0000
1. Testing condition

Rotation Direction: Clockwise (Seen from the driving side)

Injection nozzle: 000000–0000 Injector casing: 000000–0000
Injection nozzle opening pressure: 175 kgf/cm2
Oil feed pump pressure: 1.6 kgf/cm2

.
De al
Fuel injection pipe: I.D. 2 mm – Length 600mm

pt
Testing fuel: ISO4113 or SAE Std. testing fuel (SAE J967d) Fuel temperature: 40+5 °C
Overflow valve opening pressure: 1.3 kgf/cm2
2. Injection timing
g no
Pre stroke: Plunger No. 1 3.3 ±0.05 mm Note: Adjust control lever position mm
in ti
Injection sequence: 1——3 ——4 ——2
90°±30’ 180°±30’ 270°±30’
(Interval: °±30’)
et a

Number the plunger from the driving side.

n

Tappet clearance: Bolt adjusting type: Each cylinder more than 0.3mm
Gasket adjusting type: Rotate the camshaft by hand 2-3 times and make sure it rotates smoothly.
rk er

4. Injection amount:

Control lever Rotation

Ma t

Adjusting Injection amount Max. deviation

position speed Positioning Remark
point (cm3/1000 cycle) (%)
In

(mm) (rpm)
A 8.3 1,500 64 – 65 ±2.5 Lever
Basic
C about 6.6 500 9.5 – 13.5 ±15 Rack
D above 14.0 100 (70 – 85) – Lever

5. Timing advance specifications:

Injection pump speed (rpm)

Advance angle (°)

ZEXEL CORPORATION 3-4-1 Kitano, Niiza-shi, Saitama-ken, 352Japan

Service Department Tel. {048}470-1559·Fax.{048}474-9856

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10.7.11 Governor adjustment

Complete adjustment

Above 14.0
Idling spring setting
13.0

Governor spring setting

9.3
9.1±0.1
Rack position (mm)

A
8.3
7.8±0.1

.
500

De al
6.3
C

pt
4.3±0.4

g no
in ti

0 160±30 250 500 610 1535 1545 1610

et a

Injection pump speed(rpm)

n

FD75-1008287
rk er

Speed lever angle

Ma t
In

35°±3° 12°±6°

stop

25°±5°

FD75-1008288

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Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.8 Engine Electrical System

10.8.1 Starter motor

Identification MITSUBISHI
ELECTRIC CORP,JAPAN 24V

MITSUBISHI starter motor is identified by the TYPE

1
NO
name plate on the yoke block as shown.
2
Manufacturer type no.
3

ISUZU part number

FD75-1008293

.
De al
Bar code

pt
Note:
g n
Check the identification number prior to repair-
o
ing operation.
in ti
Repair data may vary depending on different
identification number.
et a

Use of wrong repair data may cause damage

n

to the starter motor.

rk er
Ma t
In

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Technical data and specifications

Rated voltage V 24
Rated power output kW 3.2
Testing time Sec. 30
Rotating direction (seen from pinion side) Clockwise
Clutch type Roller
Terminal voltage (no load) V 23
Min. current (no load) A 80
Min. operating speed rpm 3750
Pinion

.
De al
Module 2.75

pt
Number of teeth 11
Outer diameter mm(in.) 38.5 (1.52)

Brush length
g n
Yoke block outer diameter
o mm(in.) 81.6 (3.21)
in ti
Standard value mm(in.) 18 (0.71)
Limit mm(in.) 11 (0.43)
Brush spring standard mounting load N(kgf) 26.7–36.1(2.7–3.7)
et a

Rectifier outer diameter

n

Standard value mm(in.) 32 (1.26)

rk er

Limit mm(in.) 31.4 (1.24)

Mica plate groove depth
Standard value mm(in.) 0.5 (0.02)
Ma t

Limit mm(in.) 0.2 (0.008)

In

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Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.8.2 General

Magnetic switch Shaft spring

Shaft
Rear bracket One-way clutch
Clutch shaft
Brush Front bracket

Bearing
Oil seal

.
De al
pt
Pinion
g no
Ball Gear shaft Bearing
Armature Yoke block
Inner gear
in ti
assembly

Planetary gear
FD75-1008294
et a
n
rk er
Ma t
In

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10.8.3 Electrical system – disassemble

3 13 15

4 1
1 19

11
4

.
9

De al
pt
7

6
g no
in ti
5
10
20
12
et a

8 14 16 17 21 18
n

FD75-1008364
rk er

Disassembling sequence

1. Nut: Terminal M 14. Plate and casing

Ma t

2. Screw 15. Lever assembly

3. Magnetic switch (1) Lever
In

4. Pinion (2) Casing (not shown)

5. Bolt (3) Plate (not shown)
6. Screw (4) Lever spring
7. Rear bracket 16. Planetary gear
8. Yoke block assembly 17. Gear shaft
9. Brush spring 18. Clutch
10. Brush 19. Front bracket
11. Brush holder assembly 20. Inner gear
12. Armature assembly 21. Gasket
13. Ball

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Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

When disassembling the starter motor, make Magnetic switch

match marks on the magnetic switch and the Nut
yoke block to facilitate later assembling.

1. Nut (Terminal M)

Remove the nut of magnetic switch termi-

nal M and the wring.

Yoke block
FD75-1008295

.
De al
2. Screw

pt
Remove the screw.
3. Magnetic switch g no Screw

Remove magnetic switch and plunger.

in ti
et a

4. Pinion FD75-1008296
n

Simple tools are needed to remove the

rk er

Connector
pinion. The tools include a bolt, a nut and
Snap ring
a tin-plated steel plate.
Stop ring
Ma t

These tools are not needed for assembling Pinion

of the pinion. It is installed using a clamp. Pinion spring

In

● Pull the lever (not the plunger) with the

bolt to a position where the pinion can
move forward. Fix the bolt on the steel
FD75-1008297
plate in order to fix the lever and the pin-
ion.

● Set the adjustable socket onto the stop

ring. Strike the socket with a hammer
to remove the stop ring and expose the
snap ring. Then, remove snap ring, stop
ring, pinion and pinion snap ring.

● The snap ring is not reusable.

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5. Bolt Screw

6. Screw and brush holder

Remove bolt and screw.

7. Rear bracket

Remove rear bracket.

Rear bracket
FD75-1008298

.
8. Yoke block assembly

De al
pt
Set the socket (large dia. 32mm) on the
commutator of the armature and slide the
g n
brush on the socket. Remove the yoke
block assembly.
o
in ti
● Removing the yoke assembly in such a
manner will make assembling easier. To
inspect brush rotation, simply remove Yoke block assembly
et a

the brush from the socket. FD75-1008299

n
rk er

9. Brush spring
Ma t

10. Brush
In

Pull up the brush spring and remove the

brush.

11. Brush holder

Brush holder
Brush
Remove the brush holder after removal of FD75-1008300
the brush.

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Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

12. Armature assembly

Bearing

Pull the armature out of the planetary gear

and remove the bearing with a clamp.

Armature

FD75-1008301

.
De al
13. Ball

pt
Lever sleeve

Be careful not to lose the ball.

14. Plate
g no
Disc
in ti
Remove the plate and the casing. Lever spring

15. Shifting fork assembly

et a

Shift fork
FD75-1008302
Remove the shifting fork casing, plate and
n

two lever spring.

rk er

16. Planetary gear

Ma t

Remove four casings, the plate and two

In

lever spring. Gear shaft

17. Gear shaft

Planetary gear

FD75-1008303

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18. One-way clutch

19. Front bracket

Remove gear shaft, one-way clutch and

lever together from the front bracket.
One-way clutch
FD75-1008304

20. Inner gear

.
21. Gasket

De al
pt
When the two E shaped gaskets are
removed, it is disassembled into one-way
g n
clutch, inner gear, gasket and gear shaft.
o
Inner gear
FD75-1008305
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-201

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.8.4 Electrical system – inspect and repair

Make necessary adjustment, repair and re-

placement if excessive wear or damage is
observed during inspection.

Armature 2

Armature short circuit test

1. Set the armature on the growler . 1

.
2. Press a hacksaw blade against the ar-

De al
mature core and rotate the armature.

pt
If the armature is short-circuited, the
g n
blade will vibrate and be attracted to
the armature core.
o FD75-1008403
in ti
Replace the armature if it is short-
circuited.
et a

Armature coil grounding test

n

Check the connectivity of the circuit

rk er

between the rectifier plate and the core.

If the circuit is connected, the armature

Ma t

is grounded due to insulation failure

and must be replaced.
In

FD75-1008404

Armature coil connectivity test

Check the circuit connectivity of commuta-

tor plate.

If the circuit is not connected, the armature

coil is broken and shall be replaced.

FD75-1008405

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Commutator eccentricity

Measure commutator eccentricity with a

dial indicator and a V-block.

If the measured value exceeds the limit,

replace the commutator.

Commutator eccentricity
mm(in) FD75-1008406

Standard value Limit

0.02 (0.0008) 0.05 (0.002)

.
De al
pt
Commutator outer diameter – measure

caliper.
g n
Measure commutator O.D. with a vernier
o
in ti
If the measured value exceeds the limit,
replace the armature.
et a

Commutator outer diameter

n

mm(in) FD75-1008407
rk er

Standard value Limit

32 (1.26) 31.4 (1.24)
Ma t
In

Mica plate depth – measure

Measure mica plate depth with a depth

gauge.

If the measured value exceeds the limit,

cut the mica plate.

Mica plate depth

mm(in) FD75-1008408

Standard value Limit

0.5 (0.02) 0.2 (0.008)

Shop Manual - November 2012 10-203

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Bearing – inspect

Inspect the bearing.

If the bearing is worn or damaged, replace

it.

FD75-1008409

Yoke block

.
De al
Field coil grounding test

pt
Measure the grounding of field coil with a
circuit tester. g no
1. Hole a probe against the field coil of the
in ti
brush.

2. Hold the other probe on the exposed

surface of the yoke block.
et a

FD75-1008410
n

The circuit shall be open.

rk er

If the circuit is connected, the field coil

is grounded and shall be repaired or
replaced.
Ma t
In

Field coil connectivity test

Check the connectivity of the field coil with

a circuit tester.

1. Hold a probe against the field coil.

2. Hold the other probe on the brush.

The circuit shall be connected. FD75-1008411

If the circuit is not connected, the field

coil is open and shall be repaired or
replaced.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Brush and brush holder

Brush length – measure

Measure the length of the brush with a ver-

nier caliper.

If the measured value exceeds the limit,

replace the brush and/or the yoke block.

Brush length
mm(in)
FD75-1008412
Standard value Limit

.
De al
18 (0.71) 11 (0.43)

pt
g n
Brush spring – inspect
o
Check the spring for loss of elasticity and
in ti
corrosion. If such condition is observed, re-
place brush spring.
et a

Measure spring tension with a spring scale.

n

If the measured value exceeds the limit,

rk er

replace the brush spring. FD75-1008413

Ma t

Brush holder insulation test

In

Check the insulation of the brush holder

with a circuit tester.

1. Hold one probe on the lead wire of field

coil.

2. Hold the other probe against the brush r.

FD75-1008414
The circuit shall be open.

If the circuit is connected, repair or replace

the brush holder.

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Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Magnetic switch

Check the connectivity between terminal S

of magnetic switch and coil casing. If the
circuit is not connected, the shunt coil is
broken and must be replaced.

FD75-1008415

Check the connectivity between terminal

.
De al
S of magnetic switch and terminal M. If the

pt
circuit is not connected, the series coil is
broken and must be replaced.
g no
in ti

One-way clutch and pinion FD75-1008416

et a

Fix the one-way clutch casing and rotate

n

the pinion with your hand. If slight resis-

rk er

tance can be felt when it rotates in one

direction but not in the other, everything is
normal.
Ma t

Otherwise, replace the one-way clutch. If

In

the pinion is found worn or damaged, re-

place it.

● Lube oil is filled inside the one-way

clutch. If the clutch is cleaned with
engine oil or diesel fuel, lube oil may
splash.

Front bracket

If oil spill or damage is observed when in-

specting bearing and oil seal, replace front
bracket assembly (including bearing and
oil seal).

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Inner gear and planetary gear

If wear and damage is observed when in-

specting the gears, replace inner gear and
planetary gear.

Shifting fork
Push the head portion
one-way clutch
Check both ends of the shifting fork (where
it contacts the overdrive clutch) for wear.
Worn shifting fork may cause poor engage-
ment and pinion failure.

.
De al
If pinion projection exceeds the reference

pt
value and can not be adjusted, replace the Moving range
shifting fork.
g n
Pinion projection
o
mm(in)
FD75-1008306

0.5 – 2.0
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-207

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.8.5 Electrical system – assemble

Though the assembling sequence is the re-

verse of the disassembling sequence, several
points need to be explained.

1. Selection of lube oil and tightening

torque

Refer to the details on the following page.

● Lube oil recommended:

.
De al
MUL TEMP#6129(Kyodo Yushi), Molykote

pt
RAG-650(Dow Corning) or equivalent.

2. Tightening torqueg no
Refer to the details on the following page.
in ti
3. Pinion projection – inspect
Switch
S
et a

When the cranking motor has been

installed, inspect pinion projection.
n

Battery
Pinion projection
rk er

Starter motor
mm(in)
0.5 – 2.0
Ma t

FD75-1008307
Measuring method
In

Connect the starter motor with the battery as

illustrated.

Push the head portion

● When the switch is ON, the pinion will over drive clutch
move forward to the rotating position.
Since the armature will also rotate at this
time, be very careful.

● Push the overdrive clutch slightly with your

hand, and measure the displacement when
it returns. Moving range

If the displacement is within 0.5-2.0, it is FD75-1008308

OK. If it exceeds the limit, replace the liver.

10-208 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.8.6 Selection of lube oil and tightening torque

4.9~8.8N·m
{0.5~0.9kgf·m} g

8.8~13N·m{0.9~1.3kgf·m}

.
h

De al
pt
g no
in ti

i
et a

2.4~4.4N·m
{1.25~0.45kgf·m} f b a e d
n

7.8~13N·m{0.8~1.3kgf·m}
rk er

FD75-1008309
Ma t

Lube oil selection Name

In

a Slide bearing and ball Molycoat R AG-650

b Slide bearing Molycoat R AG-650
c Overdrive clutch and bearing Molycoat R AG-650
d Gear shaft spline Molycoat R AG-650
e Sliding member between lever and overdrive clutch MULTEMP #6129
f Armature shaft gear, inner gear and planetary gear Molycoat R AG-650
g Plunger surface MULTEMP #6129
h Armature bearing interior and outside surface MULTEMP #6129
i Oil seal MULTEMP #6129

Shop Manual - November 2012 10-209

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.8.7 Performance testing

Starter motor performance can be easily af-

fected by battery capacity. Use battery of
specified capacity for the testing.

Because current is very high, the test must be

finished very quickly.

Zero-load testing
A
Measure rated speed, voltage and current at

.
zero load. Switch

De al
pt
Zero load features (Standard) Ammeter B
V S
Voltage 23V
Current
g no Max. 80A
Battery
Voltmeter
Starter
motor
Speed Min. 3,750rpm
in ti

FD75-1008310
et a
n
rk er
Ma t
In

10-210 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.9 Alternator

HITACHI and MITSUBISHI alternators are

identified by the name plate on the rear cover HITACHI
as illustrated.
1

ISUZU part number 2

Manufacturer code 3
IG
L HITACHI
Rated voltage

.
De al
pt
FD75-1008311

g n
ISUZU part number
o
Manufacturer’s name
in ti
MITSUBISHI

Rated voltage 1

2
et a

Bar code 3
n

4
Note:
rk er

Check the identification number before repair FD95-1008311

work starts.
Ma t
In

Applicable repair data may vary depending on

different ID number. Use of wrong repair data
may cause damage to your alternator.

Shop Manual - November 2012 10-211

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.9.1 General

.
De al
pt
g no
in ti
et a
n
rk er

Based on LR240
Ma t

FD75-1008315
In

● This alternator is composed of front cover, ● This small-sized and light-weight alterna-
rotor, stator, built-in IC rectifier (some en- tor offers excellent reliability. Its simple
gines use Tirrell alternator with separated structure makes maintenance much easier.
rectifier) and rear cover. Built-in IC rectifier reduces wiring.

10-212 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.9.2 Alternator – Disassemble

Disassembling sequence below is based on

alternator with built-in IC rectifier.

5
6
3 7
8

.
De al
pt
g no 4

12
in ti
11

1
et a
n
rk er
Ma t

10
In

9
FD75-1008316

Disassembling sequence

1. Through bolt 7. Ball bearing

2. Rear cover and stator 8. Front cover
▲3. Belt pulley and fan ▲9. Stator
▲4. Air guide collar ▲10. Rectifier with brush holder
5. Rotor with bearing 11. IC rectifier
6. Bearing fixer 12. Rear cover

Shop Manual - November 2012 10-213

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

! Important operation

3. Belt pulley and fan

1) Clamp the rotor shaft with a bench vice

with soft clamp.
1

2) Loosen the locknut of belt pulley.

3) Remove belt pulley together with air

2
guide collar.

.
De al
FD75-1008313

pt
4. Rotor and bearing g no
1) Remove the rotor from front cover with a
1
plastic hammer or a press .
in ti

2) Remove air guide collar.

et a

2
n
rk er

FD75-1008314
Ma t

8. Front cover
In

Remove front cover from stator with a

screwdriver.

Note:

Do not attempt to pry the coil from the stator.

FD75-1008317

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

9. Stator

10. Rectifier with brush holder

Remove the rectifier with solder iron and

2
plier .
1

Note:

Clamp the lead wire between the rectifier and FD75-1008318

solder iron with the piler. This can prevent the
rectifier from being heated.

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-215

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.9.3 Alternator – Inspect and repair

Make necessary adjustment, repair and

replacement if excessive wear or damage
are observed during inspection.

Rotor and bearing

Check the slip ring surface for stain and

roughness. If the surface is rough, grind it
with #500-600 sand paper. If the surface is
stained, clean it with ethanol soaked cloth.

.
De al
Ball bearing

pt
Check if the ball bearing can rotate
smoothly. g no
If noise can be heard when it is rotating,
FD75-1008319
in ti
replace the bearing.

Measure the outer diameter of the slip ring

with a vernier caliper.
et a

Slip ring outer diameter

n

mm(in)
rk er

Standard value Limit

31.6 (1.24) 30.6 (1.20)
Ma t

Rotor coil connectivity test

In

FD75-1008320

Check the connectivity of the rotor coil with

a circuit tester.

1. Connect both probes of the testers with

the slip rings of rotor coil.

2. Watch the reading on the tester.

The tester reading shall be close to 9

ohm.

3. If the tester shows the circuit is broken,

FD75-1008321
connection of lead wire and slip ring
shall be inspected.

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SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

If open circuit is observed, repair it and re-

peat the test.

If the rotor coil circuit is still broken, replace

the rotor.
Rotor coil grounding test

Test the grounding of the rotor coil with a

circuit tester.

1. Connect one probe of the tester with

rotor shaft.

2. Connect the other probe with one slip

.
De al
ring.

pt
3. Watch the tester reading.

ring.
g n
4. Connect the probe with the other slip
o FD75-1008322
in ti
5. Watch tester reading.

The tester shall read infinite for both test-

et a

ing (pointer does not move).

n

If the tester does not read infinite for both

rk er

testing (the pointer moves), the rotor is

grounded and must be replaced.

Stator coil
Ma t
In

Stator coil connectivity test

Test the connectivity of stator coil with a

circuit tester.
1Ω
1. Connect the probes of the tester with
two exposed wires of the stator.

2. Watch tester reading.

3. Connect one of the probes with a third

FD75-1008323
stator wire.

4. Watch tester reading.

If two test readings are the same, the

stator coil is connected.

Shop Manual - November 2012 10-217

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

If not, the stator coil is not connected.

5. Check if the neutral connection (as il-

lustrated) is open.

If so, repair it and repeat the test. If not,

replace the stator.
Stator coil grounding test

Test the grounding of the stator coil with a

circuit tester.

1. Connect one probe of the tester with OHMS

.
exposed metal surface on the stator.

De al
pt
2. Connect the other probe with exposed
wire on the stator.
g n
3. Watch tester reading.
o
The tester shall read infinite (pointer
in ti
FD75-1008324
does not move).

If the tester does not read infinite

et a

(pointer moves), the stator is grounded

n

and must be replaced.

rk er

Rectifier

Rectifier (positive diode) connectivity

test
Ma t
In

Test the connectivity of the rectifier with a

circuit tester.

1. Connect the positive probe of the tester N/G OK

with the rectifier seat. 0

Ω
2. Connect the negative probe with the
lug of each of the diodes.

3. Watch tester reading for each connec-

tion.
FD75-1008325
All diodes shall show connected.

If any one of the diodes does not show

connected, the circuit is broken and the
rectifier assembly must be replaced.

10-218 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

7. Connect the negative probe of the tes-

ter with rectifier seat.
OK N/G

8. Connect the positive probe with the lug 0

of each of the diodes one by one. Ω

9. Watch tester readings for all connec-

tions.

All diodes shall not show connected.

FD75-1008326

If any diode shows connected, the

circuit is short-circuited and the rectifier
assembly must be replaced.

.
De al
Rectifier (negative diode) connectivity

pt
test

g n
Test rectifier connectivity with a circuit tes-
ter.
o
N/G OK

1. Connect the negative probe of the tes- 0

in ti
ter with rectifier seat. Ω

2. Connect the positive probe with each of

et a

the diode one by one.

n

3. Watch tester readings for all the con-

rk er

nections. FD75-1008327

All the diodes shall show connected.

Ma t

If any diode does not show connected,

In

its circuit is open and the rectifier as-

sembly must be replaced.

4. Connect the positive probe with rectifier

seat.
OK N/G
5. Connect the negative probe with each
of the diodes one by one. 0
Ω
6. Watch tester readings for all connec-
tions.

All diodes shall not show connected.

FD75-1008328
If any diode shows connected, it is
short-circuited and the rectifier assem-
bly must be replaced.

Shop Manual - November 2012 10-219

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Rectifier assembly – replace

1
Follow the procedure blow to replace the
rectifier assembly with rectifier repair kit.

1. Connect 3 interior lead wires with termi-

nal N .

2. Connect 3 exterior lead wires with

external terminal.
2
FD75-1008417
3. Coil stator wire around rectifier wire (in-
cluded in the repair kit) and weld it.

.
De al
Note:

pt
1. Cut stator wire to proper length before
g n
connecting it with rectifier wiring.
o
Length of stator wire
in ti
mm(in.)
33.5 (1.32)
et a

2. Be careful not to damage the pain sur- FD75-1008418

n

face of the rectifier.

rk er

Brush
Ma t

Measure the brush with a vernier caliper.

In

If the measured value exceeds the limit,

replace the brush.

Brush length
mm(in.)
Limit Standard
FD75-1008419
897201-2810 22 (0.86) 6 (0.24)
897023-2631 25 (0.98) 6 (0.24)

The limit is shown on the brush.

10-220 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.9.4 Alternator – Assemble

8
11 7
6

.
De al
10

pt
1
g no 2

12
in ti
et a
n
rk er

3
5
Ma t

4
In

FD75-1008329

Assembling sequence

1. Rear cover ▲7. Ball bearing

2. IC regulator 8. Bearing fixer
▲3. Rectifier with brush holder 9. Rotor with bearing
▲4. Stator 10. Air guide collar
5. Rear cover and stator ▲11. Belt pulley and fan
6. Front cover 12. Through bolt

Shop Manual - November 2012 10-221

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

! Important operation

3. Rectifier with brush seat

4. Stator

When welding stator coil wire with diode

wire, use pliers, and finish the procedure
as quickly as possible to prevent head
from being transmitted to the diode.

.
De al
FD75-1008330

pt
g n
11. Belt pulley and fan
o
Tighten belt pulley and fan to specified
in ti
torque.

Belt pulley and fan nut tightening torque

et a

N·m(kgf·m/lb·ft)
n

49 – 64 (5.0 – 6.5/36 – 47)

rk er

FD75-1008331
Ma t
In

10-222 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.10 Troubleshooting

Diagnose and correct engine faults as per troubleshooting procedures described in this part.

Each troubleshooting procedure is described in 3 steps:

(1) Checkpoint

(2) Cause

(3) Remedy

This part is divided into:

.
De al
pt
1. Engine startup failures

g n
1) Stater motor does not work
o
2) Starter motor works but engine will not crank
in ti
3) Engine cranks but will not start
et a

2. Engine unstable at idle

n

3. Engine low power

rk er

4. Excessive fuel consumption

Ma t

5. Excessive oil consumption

In

6. Engine overheating

7. White smoke

8. Black smoke

9. Oil temperature does not rise

10. Abnormal engine noise

Shop Manual - November 2012 10-223

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.10.1 Startup failures

1. Starter motor does not work

Checkpoint Cause Remedy

Intermediate switch (if NG NG Replace intermediate

Intermediate switch fault
equipped) switch

OK
NG Battery terminal loosened
NG Clean and/or tighten battery
Battery

.
terminal

De al
Bad contact due to corro-

pt
sion

g no NG Battery uncharged or un- NG

Charge or replace battery
der-charged
in ti
et a

NG NG
Fan belt slack or broken Adjust or replace fan belt
n
rk er

OK

NG NG
Fuse Fuse short circuit Replace fuse
Ma t
In

OK
NG Start switch or start relay NG Replace start switch or start
Start switch
fault relay

OK

NG Magnetic switch or start NG Repair or replace magnetic

Starter motor
relay fault switch

OK

NG NG Repair or replace starter

Starter motor Starter motor fault
motor

10-224 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

2. Starter motor works but engine will not crank

Checkpoint Cause Remedy

Battery terminal loosened

NG NG Clean and/or tighten battery
Battery
Bad contact due to corro- terminal
sion

NG Battery uncharged or un- NG

Charge or replace battery
der-charged

.
De al
pt
g n NG NG
Fan belt slack or broken Adjust or replace fan belt
o
in ti
OK

NG NG
Pinion damage Replace pinion
et a

Starter motor
n
rk er

NG NG Repair or replace magnetic

Magnetic switch fault
switch
Ma t
In

Brush wear
NG NG Replace brush and/or brush
spring
Slack brush spring

OK

NG Piston, crankshaft bearing NG Repair or replace related

Engine parts
seizure or other damage

Shop Manual - November 2012 10-225

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

3. Engine cranks but will not start

Checkpoint Cause Remedy

Shutdown mechanism fault Replace engine shutdown

NG NG
Shutdown mechanism Misadjustment of control mechanism; Adjust control
wiring (in line pump) wiring

Fuel cutoff solenoid valve

NG NG Replace fuel cutoff solenoid
failure (Distribution type
valve
pump)

.
De al
Fuel not fed to injection pump

pt
Fuel
g no NG
Fuel tank empty
NG
Add fuel to tank
in ti

OK
Repair or replace fuel line
et a

NG Fuel lines clogged or dam- NG

Fuel line system
aged; Fuel line joint loose
Tighten fuel line joint
n
rk er

OK

NG Fuel filter overflow valve NG Repair or replace fuel filter

Fuel filter
Ma t

does not close overflow valve

In

NG NG Replace fuel filter element

Fuel filter element clogged
or filter cartridge

OK

NG NG Release air from fuel sys-

Fuel system Air inside fuel system
tem

To be continued

10-226 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Fuel fed to injection pump

Checkpoint Cause Remedy

Continued
OK
Injection actuation pres-
NG NG
Fuel injector sure too low; Poor injection Adjust or replace injector
condition

OK

.
NG Fuel dribbling after injection NG

De al
Injection pump Replace delivery valve
due to injector fault

pt
g no
NG Injection pump control rack NG Repair or replace injection
malfunction pump control rack
in ti
et a

NG Injection pump plunger NG Replace injection pump

n

wear or adherence plunger assembly

rk er

OK
Ma t

Injection pump (Distribution NG Injection pump drive shaft NG Replace injection pump
In

pump) seizure or other damate drive shaft

NG Injection pump governor NG Replace injection pump

spring seizure governor spring

Shop Manual - November 2012 10-227

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.10.2 Engine unstable at idle

Checkpoint Cause Remedy

NG NG
Idle system Mis-adjustment of idling Adjust idling

OK

High idle control mecha- NG High idle control mecha- NG Repair or replace high idle
nism nism fault control mechanism

.
De al
pt
OK

g n NG Mis-adjustment of accelera- NG Adjust accelerator control

Accelerator control system
tor control system system
o
in ti
OK

NG Leaking or clogged fuel NG Repair or replace fuel sys-

Fuel system
et a

system tem
n
rk er

NG NG
Air inside fuel system Release air in fuel system
Ma t
In

NG NG
Moisture in fuel system Replace fuel

OK

NG NG Replace fuel filter element

Fuel filter Fuel filter element clogged
or filter cartridge

To be continued

10-228 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Checkpoint Cause Remedy

Continued
OK

NG NG Repair or replace governor

Injection pump Governor lever fault
lever

Mis-adjustment of pressure
NG NG Adjust or replace pressure
regulating valve (Distribu-
regulating valve
tion type pump)

.
De al
pt
NG NG
g no Plunger spring broken Replace plunger spring
in ti

NG NG
Plunger wear Replace plunger assembly
et a
n
rk er

NG Camshaft wear(In line NG

Replace camshaft
pump)
Ma t
In

NG Roller tappet NG Replace roller tappet

wear(Distribution pump)

NG Cam disc wear(Distribution NG Replace cam disc

pump)

To be continued

Shop Manual - November 2012 10-229

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Checkpoint Cause Remedy

Continued
OK

NG Mis-adjustment of valve NG
Valve clearance Adjust valve clearance
clearance

OK

NG Cylinder head gasket leak; NG

Compression pressure Replace related parts
Cylinder liner wear; Piston

.
ring adherence or broken;

De al
Valve and valve seat mis-

pt
placement

g no
in ti
et a
n
rk er
Ma t
In

10-230 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.10.3 Low power

Checkpoint Cause Remedy

NG NG Clean or replace air filter

Air filter Air filter element clogged
element

OK

NG NG
Fuel Moisture in fuel Replace fuel

.
De al
pt
OK
Replace fuel filter element
g n
Fuel filter
o NG
Fuel filter element clogged
NG

or filter cartridge
in ti
OK

NG NG Repair or replace fuel feed

et a

Fuel feed pump Fuel feed pump fault

pump
n
rk er

OK

NG NG
Injector Injector adherence Replace injector
Ma t
In

Injection actuation pressure

NG NG
very low; Poor spray condi- Adjust or replace injector
tion

OK

NG Injection line damaged or NG

Fuel injection line Replace injection line
clogged

To be continued

Shop Manual - November 2012 10-231

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Checkpoint Cause Remedy

Continued
OK

NG Regulating valve damaged NG Repair or replace regulating

Injection pump
(Distribution pump) valve

NG NG
Delivery valve damaged Replace delivery valve

.
De al
pt
NG NG
Timer fault Repair or replace timer
g no
in ti

NG Cam disc wear (Distribution NG

Replace cam disc
pump)
et a
n
rk er

NG NG Adjust or replace control

Control lever malfunction
lever
Ma t
In

Adjust injection timing;

NG NG
Injection timing fault Repair or replace injection
timer

NG Reduce governor spring NG Replace governor spring

elasticity

To be continued

10-232 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Checkpoint Cause Remedy

Continued
OK

NG NG
Injection pump Plunger wear Replace plunger assembly

NG Camshaft wear (In-line NG

Replace camshaft
pump)

.
De al
pt
NG Roller tappet wear(In-line NG
g n Replace roller tappet
pump)
o
in ti

NG Cam disc wear(Distribution NG

Replace cam disc
pump)
et a
n

OK
rk er

Cylinder head gasket leak;

NG NG
Compression pressure Cylinder liner wear; Piston ring Replace related parts
adherence or broken; Valve
Ma t

and valve seat misplacement

In

OK
NG Mis-adjustment of valve NG
Valve clearance Adjust valve clearance
clearance

OK

NG Slack or broken valve NG

Valve spring Replace valve spring
spring

To be continued

Shop Manual - November 2012 10-233

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Checkpoint Cause Remedy

Continued
OK

NG NG
Exhaust system Exhaust pipe clogged Clean exhaust pipe

OK
Adjusting screw sealing
Full loaded adjusting screw NG NG Adjust or re-seal adjusting
member open and mis-
sealing member screw
placement

.
De al
pt
OK
NG Thrust unit compensation NG Replace thrust unit com-
Turbochargerg no pipe damage or cracking pensation pipe
in ti

NG Air leak in exhaust system NG Repair or replace related

Air leak in intake system parts
et a
n
rk er

NG Turbocharger assembly NG Replace turbocharger as-

fault sembly
Ma t
In

10-234 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.10.4 Excessive fuel consumption

Checkpoint Cause Remedy

NG NG Repair or replace related

Fuel system Fuel leakage
parts in fuel system

OK

NG NG Clean or replace air filter

Air filter Air filter element clogged
element

.
De al
pt
OK

g n
Low idle speed
o NG
Mis-adjustment of low idling
NG
Adjust low idle speed
in ti
OK
Injection actuation pressure
NG NG
et a

Injector very low; Poor spray condi- Adjust or replace injector

tion
n
rk er

OK

NG Injection timing mis-adjust- NG

Injection timing Adjust injection timing
Ma t

ment
In

OK
Fuel dribbling after injection
NG NG
Injection pump Replace delivery valve
due to delivery valve fault

OK

NG Mis-adjustment of valve NG
Valve clearance Adjust valve clearance
clearance

To be continued

Shop Manual - November 2012 10-235

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Checkpoint Cause Remedy

Continued
OK

NG Cylinder head gasket leak;

NG
Compression pressure Cylinder liner wear; Piston ring Replace related parts
adherence or broken; Valve
and valve seat misplacement
OK
NG Slack or broken valve NG
Valve spring Replace valve spring
spring

.
De al
pt
OK
NG Thrust unit compensation NG Replace thrust unit com-
Turbocharger g no pipe damage or cracking pensation pipe
in ti

NG Air leak in exhaust system NG Repair or replace related

parts
et a

Air leak in intake system

n
rk er

NG Turbocharger assembly NG Replace turbocharger as-

fault sembly
Ma t
In

10-236 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.10.5 Excessive oil consumption

Checkpoint Cause Remedy

Replace engine oil Replace engine oil

NG NG
Engine oil
Oil capacity too much Adjust oil capacity

OK

NG Oil leaks at oil seal or gas- NG

Oil seal and gasket Replace oil seal or gasket
ket

.
De al
pt
OK

g n
Breather
o NG
Breather clogged
NG
Clean breather
in ti
OK

Intake/Exhaust valve oil NG Valve oil seal fault; Valve NG Replace valve oil seal,
et a

seal stem and valve guide wear valve and valve guide
n
rk er

OK

NG Worn, broken or misplaced NG Replace piston ring or in-

Piston ring
stall properly
Ma t

piston ring
In

OK

NG Scratched or damaged cyl- NG

Cylinder liner Replace cylinder liner
inder liner

Shop Manual - November 2012 10-237

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.10.6 Engine overheating

Checkpoint Cause Remedy

NG NG
Cooling water Inadequate cooling water Add cooling water

OK

NG NG
Fan connector (if equipped) Oil leak at fan connector Replace fan connector

.
De al
pt
OK

Fan belt g no NG Belt sliding due to slack or

cracked fan belt
NG
Replace fan belt
in ti
OK

NG Radiator cap damaged or NG Replace radiator cap or

et a

Radiator
radiator core clogged clean radiator core
n
rk er

OK

NG NG Repair or replace water

Water pump Water pump damaged
pump
Ma t
In

OK

Cylinder head and cylinder NG Cooling water leak due to NG Replace seal cover
block seal cover seal cover damage

OK

NG NG Replace thermostat
Thermostat Thermostat damage

To be continued

10-238 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Checkpoint Cause Remedy

Continued
OK

NG Cooling system clogged by NG Remove foreign objects

Cooling system
foreign objects from cooling system

OK
NG Fuel injection timing mis- NG
Fuel injection timing Adjust fuel injection timing
adjustment

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-239

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.10.7 White smoke

Checkpoint Cause Remedy

NG NG
Fuel Moisture in fuel Replace fuel

OK

NG NG
Fuel injection timing Injection timing delay Adjust injection timing

.
De al
pt
OK
Cylinder head gasket leak;
g n NG NG
Compression pressure Cylinder liner wear; Piston ring Replace related parts
o
adherence or broken; Valve
and valve seat misplacement
in ti
OK

Intake/exhaust valve oil NG Valve oil seal fault; Valve NG Replace valve oil seal,
et a

seal stem and valve guide wear valve and valve guide
n
rk er

OK

NG Worn, broken or misplaced NG Replace or install piston

Piston ring
piston ring ring properly
Ma t
In

OK

NG Cylinder liner scratch or NG

Cylinder liner Replace cylinder liner
wear

OK

NG NG Replace turbocharger
Turbocharger Turbocharger fault

10-240 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.10.8 Black smoke

Checkpoint Cause Remedy

NG NG Clean or replace air filter

Air filter Air filter element clogged
element

OK
Injection actuation pressure
NG NG
Injector very low; Poor spray condi- Adjust or replace injector

.
tion

De al
pt
OK

g n
Injection timing
o NG Mis-adjustment of fuel in-
jection timing
NG
Adjust injection timing
in ti
OK

NG Delivery valve fault causes NG

et a

Injection pump Replace delivery valve

fuel dribbling after injection
n
rk er

NG NG
Excessive injection Adjust injection amount
Ma t
In

Shop Manual - November 2012 10-241

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.10.9 Low oil pressure

Checkpoint Cause Remedy

NG Wrong oil viscosity; Engine NG Replace engine oil; Adjust

Engine oil
oil capacity excessive engine oil capacity

OK
Oil pressure gauge or as- NG Oil pressure gauge or as- NG Repair or replace oil pres-
sembly; Oil pressure indica- sembly damaged; Oil pres- sure gauge or assembly;
tor sure indicator damaged Replace oil pressure indica-

.
De al
tor

pt
OK

Oil filterg no NG
Oil filter element clogged
NG Replace oil filter element or
filter cartridge
in ti
OK
Reducing valve adherence
Reducing valve and bypass NG NG Replace reducing valve
et a

and/or slack bypass valve

valve and/or bypass valve spring
spring
n
rk er

OK

NG NG
Oil pump Oil pump strainer clogged Clean oil pump strainer
Ma t
In

NG NG Replace oil pump related

Oil pump related parts wear
parts

OK

NG Rocker shaft bushing wear NG Replace rocker shaft bush-

Rocker shaft ing

To be continued

10-242 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Checkpoint Cause Remedy

Continued
OK

NG Crankshaft and camshaft NG Replace camshaft or cam-

Camshaft
bearing wear shaft bearing

OK
NG Crankshaft and bearing NG Replace crankshaft and/or
Crankshaft and bearing bearing
wear

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

Shop Manual - November 2012 10-243

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

10.10.10 Abnormal engine noise

1. Engine knock

Checkpoint Cause Remedy

Check that the engine has been preheated

well before troubleshooting.

Fuel Wrong fuel Replace fuel

.
De al
OK

pt
NG Mis-adjustment of injection NG
Fuel injection timing
g n Adjust injection timing
timing
o
in ti
OK
Incorrect actuation pres-
NG NG
Injector sure and poor spray condi- Adjust or repair injector
et a

tion
n

OK
rk er

NG Cylinder head gasket leak- NG Replace cylinder head gas-

Compression pressure
age; piston ring broken ket or piston ring
Ma t
In

2. Air leak noise

Tighten pipe joint

NG Loose joint or broken ex- NG
Exhaust pipe
haust pipe
Replace exhaust pipe

OK

Injection and/or preheat NG Injector and/or preheat plug NG Replace gasket, tighten
plug loosened injector and/or preheat plug

To be continued

10-244 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

Checkpoint Cause Remedy

Continued
OK

NG Camshaft and camshaft NG Replace camshaft and

Camshaft
bearing wear camshaft bearing

OK
NG Crankshaft and bearing NG Replace crankshaft and/or
Crankshaft and bearing bearing
wear

.
De al
pt
3. Continuous noise
g n
Checkpoint
o
Cause Remedy
in ti

NG NG
Fan belt Loose fan belt Adjust fan belt tension
et a
n

OK
rk er

NG NG
Cooling fan Loosened cooling fan Tighten cooling fan
Ma t

OK
In

NG Worn or damaged water NG Replace water pump bear-

Water pump bearing
pump bearing ing

OK
Repair or replace alternator
NG Alternator or vacuum pump NG
Alternator or vacuum pump
damage
or vacuum pump

OK

NG Mis-adjustment of valve NG
Valve clearance Adjust valve clearance
clearance

Shop Manual - November 2012 10-245

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

4. Slamming noise

Checkpoint Cause Remedy

NG Misadjustment of valve NG
Valve clearance Adjust valve clearance
clearance

OK

NG NG
Rocker arm Rocker arm damaged Replace rocker arm

.
De al
OK

pt
NG NG
Flywheel g no Flywheel bolt loosened Tighten flywheel bolt
in ti
OK

Crankshaft and thrust bear- NG Worn or damaged crank- NG Replace crankshaft or

thrust bearing
et a

ing shaft or thrust bearing

n

OK
rk er

Worn or damaged crank-

Crankshaft and connecting NG NG Replace crankshaft or con-
shaft or connecting rod
rod bearing necting rod bearing
bearing
Ma t
In

OK
Connecting rod bushing
Connecting rod bushing NG NG Replace connecting rod
and piston pin wear or
and piston pin bushing and/or piston pin
damage

OK
Piston and cylinder liner
NG NG Replace piston and cylinder
Piston and cylinder liner wear or damage; Foreign
liner
objects inside cylinder

10-246 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.11 List of Special Tools

No. Tool shape Part No. Tool name Remark

1 5-8840-0145-0 Measuring instrument

2 5-8840-2675-0 Pressure gauge

.
De al
pt
3 5-8840-9029-0 Pressure gauge connector

g no
4 5-8840-0019-0 Sliding weight
in ti
et a

5 5-8840-2034-0 Injector remover

n
rk er

6 9-8523-1423-0 Valve spring compressor

Ma t
In

Camshaft timing gear uni-

7 5-8840-0086-0
versal clamp

8 9-8523-1212-0 Valve guide tool

9 5-8840-2313-0 Cylinder liner installer

10 5-8840-2038-0 Camshaft bearing changer

Shop Manual - November 2012 10-247

Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

No. Tool shape Part No. Tool name Remark

Crankshaft timing gear

11 9-8840-2057-0
remover

12 9-8522-0020-0 Crankshaft timing installer

Crankshaft guide bearing

13 5-8840-2000-0
remover

.
De al
Crankshaft guide bearing
14 5-8522-0024-0

pt
installer

15
g no
5-8840-2061-0
Crankshaft front oil seal
installer
in ti

Valve stem oil seal install-

16 5-8840-2033-0
er
et a
n

Cylinder liner remover

17 5-8840-9058-0
rk er

plate
Ma t

18 5-8840-9038-0 Cylinder liner remover

In

19 5-8840-2360-0 Rear oil seal remover

Oil seal installer (axial

20 5-8840-9057-0
type)

10-248 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator Engine

10.12 Repair Standard

General

1. Tables in this section provide the repair 5) Unless specified otherwise , unit in the
standard of CC-4JG1 diesel engines. tables below is mm(in).

2. Repair standard includes: Check items, 3. Terms

Nominal size, Assembling standard value,
Limit value and Maintenance routine. 1) Wear dimension is the difference be-
tween the size of a unworn part (or
1) Nominal size is the standard manufac- unworn nominal size) and the size of
turing dimension. a part with maximum wear (size of a

.
De al
unusable part).

pt
2) Assembling standard value is stan-
dard value for assembling when repair 2) Unstable wear means wear value is
g n
work is finished. It may differ slightly
from the assembling dimension of new
o between the maximum and minimum
value.
engines.
in ti
4. When the engine needs to be repaired,
3) Limit value is the measured value of a perform a table testing first to determine
part that is not usable any more due to which part(s) of the engine shall be re-
et a

excessive wear. A part becomes unus- paired. Then, proceed with a minimal dis-
able and must be repaired or replaced assembling of the engine repair it. When
n

once the limit is exceeded. specified part of engine needs to be re-

rk er

paired, refer to relevant items listed in the

4) Maintenance routine is the common repair standard table.
maintaining procedures.
Ma t
In

Shop Manual - November 2012 10-249

 Cate- Part Assembling
Check item Nominal size Limit value Maintenance routine Remark
gory name standard value

10-250
Engine

Cylinder compression pres-

3.04 2.2
sure Warm-up
(31/441) (22/313)
MPa (kgf/cm2/psi) Engine speed 200rpm
(adjust as per eleva-
Disassemble and repair
Fuel consumption L/h 100% 140% tion)
the engine

repair
In
Engine oil consumption Supposed new engine
100% 200%
L/h
Ma t
efficiency 100%

Engine disassembling and

Cylinder liner wear A-A
measurement
rk er
n (Ref.)
20.0
In case of top surface Clearance between cyl-
Dia. Dia. 95.5 wear, repair or replace inder block and cylinder
A A
et a
95.4(3.756) (3.760) with a cylinder liner of liner
std. size 0.017 – 0.055
(0.0007 – 0.0022)
in ti
o
Cylinder liner projection
g n

Shop Manual - November 2012

Projection difference
0-0.10 Projection must be between two adjoin-

Engine body
Cylinder block
(0-0.0039) available ing cylinders: less than
De al
0.02
pt
Cylinder block top surface 0.05(0.002) 0.20 Do not repair it. Re-
deformation . or less (0.008) place it.

Pressure test: 3 Min. 490 Repair or replace in

kPa (kgf/cm2/psi) (5/71) case of leakage
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator
 Cate- Part Nominal Assembling
Check item Limit value Maintenance routine Remark
gory name size standard value
Valve depth: B
(incl. intake and exhaust valve)
Intake valve 1.28
0.65(0.029) (0.050)
In
（Insert) INT valve seat
angle 30°
A Replace seat insert
(Cylinder EXH valve seat
head) (Valve)
Ma t
B angle 45°
Same for Exhaust valve
45°
in let & exhaust 1.6(0.063)
Bottom
Must not protrude from 1.1(0.043)
surface
lower surface of cylinder head
rk er
to cylinder
n
Intake valve Exhaust valve
et a
1.7(0.067) 2.0(0.079)
Grind the con-
Repair with valve seat
Width of contact with valve seat: A tact surface after
scrapper
in ti
o repair
2.2(0.087) 2.5(0.098)

Engine body
Cylinder block
g n

Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Deformation and flatness of cylinder

0.5(0.002) Allowable max. cutting
head bottom surface (mounting sur- 0.2(0.008)
or less quantity 0.3(0.012)
De al
face)
pt
Deformation of manifold mounting 0.5(0.002)
0.2(0.008) Repair
surface . or less

Water pressure test 3 min. Repair or replace in

490(5/71)
kPa (kgf/cm2/psi) case of leakage
Engine

10-251
10-252
Cate- Part Nominal Assembling standard
Engine

Check item Limit value Maintenance routine Remark

gory name size value

Position 7 0 mm (2.76 in) to top Clearance with long axis

surface and cylinder block clear- 0.037–0.075
ance: (0.0015–0.0030)
In
Clearance between piston pin and 0.004-0.017 Replace piston or pis-

Piston
piston pin hole (0.0002-0.0007) ton pin
Ma t
Dia. 33.995-34.000 Dia. 33.97
Piston pin Replace piston pin
34.0(1.34) (1.3384-1.3386) (1.3374)
1st compression 0.20-0.35
rk er
ring (0.008-0.014)
n
Piston ring gap 2nd compression 0.37-0.52 Replace piston ring or
1.5(0.059)
clearance ring (0.015-0.020) piston
et a
0.20-0.40
Oil ring
(0.008-0.016)
1st compression 15.7-23.5
in ti
ring g no (1.6-2.4)
Replace

Shop Manual - November 2012

Elastic force 2nd compression 11.0-16.5
N(kgf) ring (1.1-1.7)

Key moving components

Install expander and
Oil ring 41-56 (4.2-5.8) Replace

Piston ring
measure
De al
1st compression 0.090-0.130 Install compression
0.15(0.006)
ring (0.0035-0.0051) rings with mark facing
Clearance be-
0.050-0.090 upward. Reverse in-
pt
tween piston ring 2nd compression 0.15(0.006) Replace piston ring or stallation causes more
and piston ring ring . (0.002-0.003) piston
oil consumption. Oil
groove 0.030-0.070
Oil ring 0.15(0.006) seal can be installed
(0.0012-0.0028) either way.
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Piston ring gap direction 120°space in between

 Cate- Part Nominal Assembling
Check item Limit value Maintenance routine Remark
gory name size standard value
Uneven Do not attempt to
Dia. 70 0.09
wear Main journal grind. Replace with
(2.756) (0.0035)
between new parts.
Replace
main jour-
Dia. 53 0.094
In
nal and Crank pin
(2.087) (0.0037)
crank pin
Use one with projection
Ma t
Journal and bearing arc development and proper arc; note
back contact
rk er
n
Clearance between journal and bearing
et a 0.031-0.063
(0.0012-0.0025)
0.11
(0.0043)
Replace bearing

Measure on thrust
Do not use bearing that

Crank-shaft
Journal bearing undersized surface of No. 1
is too small
bearing
in ti
Crankshaft end play
o 0.10 (0.0039)
0.30
Replace thrust bearing
(0.0118)
g n

Key moving components

Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

0.05 (0.002) 0.08

Crankshaft radial runout Replace crankshaft
or less (0.0031)
De al
Grind gear. Replace in
Ring gear
case of series damage
pt
. Use one with projection
Connecting rod bearing deflection and proper arc; note
back contact

Clearance between connecting rod bear- 0.029-0.066 0.10

Replace bearing

Connecting rod
ing and crank pin (0.0011-0.0026) (0.0039)
Engine

10-253
 Cate- Part Nominal Assembling Maintenance rou-
Check item Limit value Remark
gory name size standard value tine

10-254
Engine

Replace parts with Pay special attention to

Contact between connecting rod bearing
poor contact and crank pin surface preci-
and crank pin
wear sion
Leave enough clearance
Clearance between small end bushing 0.008-0.020 Replace bushing for smooth rotation after
0.5(0.002)
In
and piston pin (0.003-0.008) or piston pin installation of connecting
rod cap
Ma t
Dia. Do not grind crankshaft
Connecting rod bearing undersized
53(2.087) to reduce journal size
rk er
n
Connecting rod and crank pin axial 0.175-0.290
0.35(0.0138)
Replace connect-

Connecting rod
clearance (0.007-0.0114) ing rod
et a
Large-small end hole deflection (every 0. 05(0.002)
0.20(0.008) Repair or replace
100mm) or less
in ti
o
Large-small end hole parallelism (every 0.05(0.002)

Key moving components

g n

Shop Manual - November 2012

0.15(0.006) Repair or replace
100mm) or less

Dia.
Journal uneven wear 0.05(0.002) Replace camshaft
De al
50(1.969)

0.025-0.085
pt
Clearance between journal and bearing 0.12(0.0047) Replace bearing
(0.001-0.0033)

Camshaft
.
Dia. 49.945-49.975 Dia.
Journal wear Replace camshaft
50(1.969) (1.9663-1.9675) 49.60(1.953)
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator
 Cate- Part Assembling Maintenance rou-
Check item Nominal size Limit value Remark
gory name standard value tine
Cam height:

Repair minor wear on

In
42.02(1.65) 41.65(1.64) Replace camshaft
Ma t cam

rk er
n
0.02(0.0008)
Camshaft radial runout 0.10(0.004) Replace camshaft
et a
or less

Camshaft

Key moving components

in ti
g no

Shop Manual - November 2012

0.05-0.114 Replace thrust
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

Camshaft end play 0.20(0.008)

(0.002-0.0045) plate
De al
pt
.
Engine

10-255
 Cate- Part Assembling Maintenance rou-
Check item Nominal size Limit value Remark
gory name standard value tine

10-256
Engine

Dia. 7.949-7.961
Intake valve stem wear
Dia. (0.3129-0.3234) Dia.
Replace valve
8(0.315) Dia. 7.921-7.936 7.88(0.3102)
Exhaust valve stem wear
(0.3118-0.3124)
Clearance between intake valve stem and 0.039-0.069 Replace valve and M e a s u r e v a l v e
0.2(0.008)
valve guide (0.0015-0.0027) valve guide stem at 3 points
In
Clearance between exhaust valve stem 0.064-0.096 Apply oil on valve
0.25(0.0098)
and valve guide (0.0025-0.0038) guide and press in
Ma t
Mating interference between valve guide Replace valve and
0.02(0.0008)
and cylinder head valve guide
Valve thickness
rk er
n Intake valve 1.79 (0.070)
1.1 (0.043) Reference value
et a
Exhaust valve 1.39 (0.055)

Valve guide projection above cylinder

head
in ti
g no 13.0(0.512)

Shop Manual - November 2012

Elastic force N (kgf/lb)
(Compressed to mounting length) 254(25.9/57) 225(23/51)
De al
38.9 mm (1.53 in)
Valve
spring Free length 49.7(1.96) 48.2(1.90)
pt
. 1.5(0.06)
Tilting 2.5(0.098)
or less

Cold state valve clearance 0.40(0.016) Adjust

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator
 Cate- Part Assembling Maintenance rou-
Check item Nominal size Limit value Remark
gory name standard value tine

Clearance between rocker shaft 0.01-0.05 Replace rocker

0.2(0.008)
and bushing (0.0004-0.002) shaft or bushing
In

Valve
Ma t
Dia. 18.98-19.00 Dia. Replace rocker
Rocker shaft wear
rk er (0.747-0.748) 18.85(0.742) shaft

Valve system
Clearance between tappet and cyl-
0.03(0.0012) 0.10(0.0039) Replace tappet
et a
inder block

Tappet
in ti
Tappet wear
o
Outer diameter
g n 12.97-12.99 12.95
Replace tappet
(0.5106-0.5114) (0.5098)

Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

De al
Producer special
Air filter element condition

tem
requirement

Air filter

Air intake sys-

pt
.
Engine

10-257
 Cate- Part Nominal Assembling
Check item Limit value Maintenance routine Remark
gory name size standard value

10-258
Engine

Lube oil pressure (1400rpm) 29-64

196(2/28)
kPa (kgf/cm2/psi) (3-4.5/43-64)

Oil pressure
0.02-0.07 Replace vane, rotor or
In
Vane, rotor and pump cover clearance 0.15(0.006)
(0.0008-0.0026) pump cover
Ma t
0.14(0.006)
Rotor and vane clearance 0.20(0.008) Replace rotor group
or less
rk er
n
0.20-0.2
et a
Pump casing and vane clearance 0.40(0.016) Repair or replace
(0.008-0.011)
in ti
Oil pumping rate L/min
o

Lubricating system
(1000 rpm, SAE #30, pumping pressure
g n

Shop Manual - November 2012

13
390kPa(4kgf/cm2/57psi), Oil tempera-
ture 50°C (122°F))

Oil filter, oil pump and safety valve

De al
Oil filter clogged or damaged Replace
pt
.
Main oil filter safety valve regulating 420-460
pressure kPa (kgf/cm2/psi) 4.3-4.7/61-67)
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator
 Cate- Part Nominal Assembling stan- Limit
Check item Maintenance routine Remark
gory name size dard value value

Water pump ball bearing noise (Radial 0.2

Replace
direction) (0.0079)

Pumping rate L/min

In
(Pump speed 3000 rpm, Water tem-
100
perature 30°C(86°F),
Total hydraulic no less than 60kPa)
Ma t
Repair or replace if vane
Clearance between vane and pump 0.3-1.3
interferes with pump
casing 0.0118-0.0512)
casing
rk er
n
Fan belt deflection
Press with fingers
et a
(Ref. )

Water pump
8-12(0.31-0.47) Adjust

Cooling system
10 kgf (22.0 lb/98N)
in ti
o

A
g n
Replace thermostat
Thermostat initial opening pressure (at 82°C 80-84°C

Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

in case of abnormal
sea level) (180°F) (176-183°F)
opening
De al
Temperature when ther-
Thermostat full opening pressure (at
95°C(203°F) mostat valve lift is at
sea level)
8mm(0.315in) or more
pt
Clogged, broken, loosened fuel pipe,
fuel injection lines, injector casing, Repair or replace
defective sealing member
.
Fuel filter element clogged or dam-

Fuel pipes

Fuel system
Replace Filter cartridge type
aged
Engine

10-259
 Cate- Part Nominal Assembling
Check item Limit value Maintenance routine Remark
gory name size standard value

10-260
Engine

Inspect electrical system

if indicator lights up when
engine is running

Repair

Discharge wire
Charge/ Lead
In
0.1 or less Replace shaft
Ma t
Rotor Bearing abnormal noise Replace bearing Rotate it by hand,
it shall rotate
smoothly
rk er
Thrust side abnormal noise
n 0.3 Repair

Slip ring diameter 27 26 Repair

Alternator 24V,30A
et a
Carbon
Length 22 6
brush
in ti
o

Electrical system
Bolt loosened Repair
g n

Shop Manual - November 2012

Carbon brush length 18 11 Repair

Series coil resis-

De al
tance (Ω) Replace switch in
Magnetic switch case of abnormal
Shunt coil resis- resistance
pt
tance (Ω)
.

Starter motor 24V,3.2KW

Outer diameter Dia. 32 31.4 Replace armature
Commutator
Abrasion 0.5 0.2 Repair
SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator
 Part Nominal Assembling
Category Check item Limit value Maintenance routine Remark
name size standard value

Electrical Pre- Repair in case of short

Preheat plug
system heat In circuit or open circuit

Engine running 30 min. or more Warm-up

Ma t
2.9—3.0
Cylinder pressure @ 200 rpm 2.2/22 Inspect Warm-up
(30—31)
rk er
n
Pressure difference between dif-
5% or less Inspect Warm-up
et a
ferent cylinders

1400 rpm Oil tem-

294—441/3—4.
Oil pressure Inspect perature
in ti

Final inspection
5
g no 80 deg.

Power output 90% or more Inspect

Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

100% for new engine

De al
Fuel consumption pt 110% or less

.
Engine

10-261
Engine SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

ptE
.
DeG l
Pg Aona
in ti
etK a
n
ArkNer
Ma t
BLIn

10-262 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator System Schematics

System Schematics

.
11 System Schematics

De al
pt
11.1 Hydraulic Line Layout ...........................................................................................11-3
11.2 Hydraulic Circuit Diagram .....................................................................................11-4
11.3
g n
Overall System Diagram (1/5)...............................................................................11-6
o
11.4 Overall System Diagram (2/5)...............................................................................11-7
in ti
11.5 Overall System Diagram (3/5)...............................................................................11-8
11.6 Overall System Diagram (4/5)...............................................................................11-9
11.7 Overall System Diagram (5/5).............................................................................11-10
et a

11.8 Electrical Circuit Diagram....................................................................................11-11

n
rk er
Ma t
In

Shop Manual - November 2012 11-1

System Schematics SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.

11-2 Shop Manual - November 2012

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator System Schematics

11.1 Hydraulic Line Layout

11

.
2 3 4 5 6 7

pt
8

De
n g
ti
1

e
rk
Ma
l
na
io
at
rn
te
In

13 12 12 10 9 ZX75-1009001

Shop Manual - November 2012 11-3

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator System Schematics
11.2 Hydraulic Circuit Diagram
SY65C3
Left travel motor Right travel motor

2 Breaking
R/G R/G
Swing motor

.
Hi/Lo speed
shifting valve

pt
SH

2 Dozer Lower1
Hammer pilot valve (optional) PG
Dr Dozer blade cylinder Arm cylinder Bucket cylinder Boom cylinder

De
Dozer Lift 1

GA GB
Right travel

Dozer blade pilot valve A MU B

Reverse

g
4
Forward

n
3
T

Swivel joint PA PB PA PB

ti
Reverse
P

2
Forward
Left travel

e
Travel pilot valve

rk
Arm In Arm Out Left swing Right swing

Shuttle valve
Swing

Main valve
Main safety valve
T

b9 B9 A9

Ma
P2 b7 B7 A7 b6 B6 A6 b5 B5 A5 b4 B4 A4 b3 B3 A3 b2 B2 A2 b8 B8 A8 b1 B1 A1 P Sensor
LS
3
P

Swing Hammer Standby Left travel Right travel Arm Bucket Dozer Boom
Arm

Left pilot joystick blade

1

Bucket Dump

LS safety valve
Bucket

LS flushing valve
4

l
Flushing valve
T
Bucket Curl
T

M
2

na
Boom Lower

Swing speed regulator

3
P

a9 a7 a6 a5 a4 a3 a2 a8 a1 T3
Arm overload valve Back pressure measuring port
Boom deflection overload valve (optional)） Bucket overload valve
Boom

Boom Raise

Boom overload valve Boom pressure compensation valve

Dozer blade overload valve
1

Right pilot joystick

io
Boom main valve spool
at

Pilot filter
Check valve
Regulate power with overflow valve
Check valve
X1
rn

Pressure control valve

ΔP regulating Bv Pr Pv P1 Oil source control valve
Oil cooler
12 V DC

Main pump Flow control valve

B
te

Travel hi/lo speed

12 V DC

sonenoid valve
M Reducing valve
PS

Safety valve
In

Pilot solenoid valve

T P2 P3

ZX75-1009002

Shop Manual - November 2012 11-4

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator System Schematics

SY75C3, SY75C9
Right travel motor Left travel motor

REG
Swing motor

.
Boom cylinder Bucket cylinder Arm cylinder Dozer blade cylinder

pt
De

Dozer lift
Reverse Forward Reverse Forward Dozer lower
Center swivel joint

g
Dozer blade pilot valve

Right travel
n
ti

T
e

P
rk
Main valve 1A 1B 2A 2B 3A 3B 4A 4B 5A 5B 6A 6B 7A 7B 8A 8B

Left travel
Travel pilot valve
LS overflow valve

Ma

out in swing swing

Swing

Arm Arm Right Left

T
LS measure point

P
Flush valve

l
Arm Left pilot joystick
Boom Dozer blade Bucket Arm Right travel Left travel Standby Swing

na

Boom Boom Bucket Bucket

Bucket

lower raise dump curl

T
io

P
Right pilot joystick
Boom
at

Check valve
Check valve
rn

Breath valve

Radiator Travel hi/lo speed control valve Oil source control valve
Torque limit valve
te

Main pump K3VL80

In

Pilot filter ǻP regulating

Pressure cutoff valve M

Pilot solenoid valve

Return oil filter
ZX75-1009003

Shop Manual - November 2012 11-5

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator System Schematics

11.3 Overall System Diagram (1/5)

When all control valves are neutralized

.
pt
7 6 80
8A

De
8

8B 8C

90

g
9A

n
22
9

ti
3 9B 9C

100

e
4 10A
10 23

rk
21

10B 10C

Ma
26
11A
11
2
25
11B 24
11C

l
27

28
na
12
12A
io
To pilot valve 12B 12C

13A
at

13

13B 13C
rn

17
19
14
te

16 15
18
20
In

1
ZX55-1009003

Shop Manual - November 2012 11-6

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator System Schematics

11.4 Overall System Diagram (2/5)

When swing is operated individually

.
pt
7 6 80

De
8A
8

8B 8C

g
90
9A

n
5 22

ti
9

3 9B 9C

e
100
4 10A

rk
10 23
21

Ma
10B 10C

26
11A
11
2

l
25
11B 24
11C
27

28
na
12
12A
io
To pilot valve 12B 12C
at

13A
13
rn

13B 13C
17
19
te

14

16 15
18
In

20

1
ZX55-1009004

Shop Manual - November 2012 11-7

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator System Schematics

11.5 Overall System Diagram (3/5)

When left and right travel are operated simultaneously

.
7 6 80

pt
8A
8

De
8B 8C

90
9A

g
5 22
9

n
3

ti
9B 9C

100
4 10A

e
10 23

rk
21

10B 10C

Ma
26
11A
11
2
25
11B 24

l
11C
27

28
na
12
12A
io
To pilot valve
12B 12C
at

13A
13
rn

13B 13C
17
19
te

14

16 15
18
In

20

1
ZX55-1009005

Shop Manual - November 2012 11-8

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator System Schematics
11.6 Overall System Diagram (4/5)
When boom and arm are operated simultaneously

.
pt
7 6 80
8A
8

De
8B 8C

90
9A

n g
5 22
9

ti
3 9B 9C

100

e
4 10A

rk
10 23
21

10B 10C

Ma
26
11A
11
2

l
25
11B 24
11C
27

na
12
12A
io
28

To pilot valve 12B 12C

at

13A
rn

13B 13C
te

17
19
14

16
In

15
18

20

1
ZX55-1009006

Shop Manual - November 2012 11-9

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator System Schematics

11.7 Overall System Diagram (5/5)

When boom raise and swing are operated simultaneously

.
7 6

pt
80
8A
8

De
8B 8C

90
9A

g
5 22

n
9

ti
3 9B 9C

100

e
4 10A

10 23

rk
21

10B 10C

Ma
26
11A
11
2
25
24

l
11B 11C
27

28
na
12
12A
io
To pilot valve 12B 12C
at

13A
13
rn

13B 13C
17
te

19
14

16 15
18
In

20

1 ZX55-1009007

Shop Manual - November 2012 11-10

SY65C3, SY75C3, SY75C9 Crawler Hydraulic Excavator System Schematics

11.8 Electrical Circuit Diagram Starter

24V-3.2KW Safety relay Preheat fuse
5 12 C
50R 21 C Preheat controller
5 B
M
+ - T-103 21 16 T-109
Battery relay
5 5

.
B R S E
21 60 70 0
T-132 T-131

pt
1.25
1.25
1.25
50B 20 21 21 5 171 2 16 5

5
- + 50R B M 5 5 0.8568 140.85 0.85 14 66 0.85
0 15
3 4 0.85 61 1 2 0 0.85
E BR 3 5
5B 2 Charge indicator Preheat relay 0.85 68 69 0.85
4 6

De
Preheat plug
5B 0 21 L 14 0.85 T-106 CN-134M
B V5 14
1.25B 0 5 R 14
0.85B 0 0.85 Preheat indicator
1.25
E
6 63

g
64 3 5 65
Alternator 24V-30A 14 62 1
0
2

n
Start switch
2
21
启动 ON OFF
Park relay

ti
22 2 5
B
Br 62
5W

R1
13
Acc Throttle control
61

e
R2 mechanism
11
C CN-139F

rk
00 3
507
4 2
50
70 5 3 11
1 M
Shutdown relay

Ma
4 Start relay 1 2 602 701
Horn 23 V3 4
15 5 3 21 601 3
F-103 F-104 0.85 009
1 2 603 2
Integrated monitor 010
1.25
1.25

1.25
1.25

1.25

1.25

1.25
1.25

4 1
5
2

32 5 3 Wire Terminal Terminal

20 13 20 21 21 21 20 21 20 21
Air cleanor
0 1 2 31 23 43 34 1 CAN-L
clogging alarm

l
0.85 0 1 2 3 4 5 6 7 8 9 10 Lighter 000 33 2
Fuse box

p
CAN-H
HA1 103 CN-105M
20 15 10 10 10 15 10 15 15 10 CN-225M 32 3 108b

Cab lamp
23
A A A A A A A A A A

22 14 23 24 25 38 43 42 100
100 0
na Fuel control dial
506
509
506
31
30
4
5
11
13
105 Pilot s/w CN-205F
1.25R

0.85 0 50 511 29 6 Pilot oil pressure

1.25
1.25

1.25

1.25
1.25

1.25
5
2

CN-501M
io
Check lamp 00 603 28 7 CN-117F
511
T-203 T-204 602 27 8 00 50
23 607 26 9 50 00
0.85 43 801 43 25 10
at

CN-701 00 24 11 010 108 CN-125F

24
S2 Sol valve, travel 510 23 12 103
CN-108M 607 22 13 105 Hi temp alarm s/w
106
rn

4 507 21 14 106 T-115

25 57 3 5 38 601 20 15 508 508 Oil press s/w
K6 33 56 2 1 701 19 16 009
86 87 S3 SB2 Sol valve, pilot 509 T-119
25 0 0 57 606 18 17 42
te

34 CN-107M Fuel level sensor

Electromagnetic

85 30 56 55 0.85 606
CN-101F
A/C compressor
clutch

35 36 37 51 52 A/C
34 510
0.85
0.85

0.85
0.85
0.85

Temp sensorT-118
In

L R
M M3 M C.P

M2 Washer Speaker CN-206F A/C panel

Wiper
Work lamp ZX75-1211001

Shop Manual - November 2012 11-11